Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 2 When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
Page 4 Table of Contents GENERAL INFORMATION Engine and Emission Control System (G10 Engine) General Information Maintenance and Lubrication Engine and Emission Control System (M13 Engine) HEATING AND AIR CONDITIONING Heater and Ventilation Ignition System (G10 Engine) Air Conditioning (Optional) Ignition System (M13 Engine) STEERING, SUSPENSION, WHEELS Cranking System (0.9 kw Reduction AND TIRES...
Page 6: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS How to Use This Manual.........0A-2 Intermittent and Poor Connection ....0A-17 Precautions............0A-3 Identification Information......0A-19 Precaution for Vehicles Equipped with a Vehicle Identification Number ..... 0A-19 Supplemental Restraint (Air Bag) System..0A-3 Engine Identification Number...... 0A-19 Diagnosis...........0A-4 Transmission Identification Number....
Page 7: How To Use This Manual
0A-2 GENERAL INFORMATION How to Use This Manual 1) There is a “Table of Contents” on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a “Contents” on the first page of each section, where the main items in that section are listed.
Page 8: Precautions
• If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
Page 9: Diagnosis
0A-4 GENERAL INFORMATION Diagnosis • When troubleshooting air bag system, be sure to follow “Diagnosis” in Section 10B. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. • Never use electrical test equipment other than that specified in this manual.
Page 10: Servicing And Handling
GENERAL INFORMATION 0A-5 Servicing and handling WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger and side Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise.
Page 11 0A-6 GENERAL INFORMATION WARNING: • For handling and storage of a SDM, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise. • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM.
Page 12: Brakes
GENERAL INFORMATION 0A-7 • WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to fol- low the instructions. • After vehicle is completely repaired, perform “Air Bag Diagnostic System Check” in Section 10B. General Precautions The WARNING and CAUTION below describe some general precautions that you should observe when servic- ing a vehicle.
Page 13 0A-8 GENERAL INFORMATION • When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. •...
Page 14 GENERAL INFORMATION 0A-9 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly. • After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks.
Page 15: Precaution For Can Communication System
0A-10 GENERAL INFORMATION Precaution for CAN Communication System • The loose (1) in the wire harnesses twist of the CAN lines except around the connector (3) should be within 100 mm (3.9 in.) Refer to the wiring diagram for the CAN line discrim- ination.
Page 16: Precaution In Servicing Full-Time 4Wd Vehicle
GENERAL INFORMATION 0A-11 Precaution in Servicing Full-Time 4WD Vehicle This full-time 4WD vehicle can not be converted to 2WD manually. Observe the following caution in servicing. Otherwise, front wheels drive rear wheels or vise-versa and vehicle accidents, drivetrain damage and personal injury may result. •...
Page 17: Precautions For Electrical Circuit Service
0A-12 GENERAL INFORMATION Precautions for Electrical Circuit Service • When replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire. •...
Page 18 GENERAL INFORMATION 0A-13 • When installing the wiring harness, fix it with clamps so that no slack is left. • When installing vehicle parts, be careful so that the wir- ing harness is not interfered with or caught by any other part.
Page 19 0A-14 GENERAL INFORMATION • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe (2) from the wire harness side (backside) of the connector (1). • When connecting meter probe (2) from terminal side of coupler (1) because it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its female terminal open for connection.
Page 20: Electrical Circuit Inspection Procedure
GENERAL INFORMATION 0A-15 Electrical Circuit Inspection Procedure While there are various electrical circuit inspection methods, described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. Open circuit check Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully.
Page 21: Continuity Check
0A-16 GENERAL INFORMATION Continuity check 1) Measure resistance between connector terminals at both ends of the circuit being checked (between A-1 and C-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals A-1 and C-1.
Page 22: Short Circuit Check (Wire Harness To Ground)
GENERAL INFORMATION 0A-17 Short circuit check (wire harness to ground) 1) Disconnect negative (–) cable at battery. 2) Disconnect connectors at both ends of the circuit to be checked. NOTE: If the circuit to be checked is connected to other parts (1), disconnect all connectors of those parts.
Page 23 0A-18 GENERAL INFORMATION • Improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal. If contact tension is not enough, reform it to increase contact tension or replace. 1.
Page 24: Identification Information
GENERAL INFORMATION 0A-19 Identification Information Vehicle Identification Number The number is punched on front dash panel in engine room and it is also on the left side of instrument panel depending on the vehi- cle specification. Engine Identification Number The number is punched on cylinder block. 1.
Page 25: Warning, Caution And Information Labels
0A-20 GENERAL INFORMATION Warning, Caution and Information Labels The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. 1.
Page 26: Vehicle Lifting Points
GENERAL INFORMATION 0A-21 Vehicle Lifting Points WARNING: • Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 27: When Using Floor Jack
0A-22 GENERAL INFORMATION When using floor jack WARNING: If the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands.
Page 28: Abbreviations And Symbols May Be Used In This Manual
GENERAL INFORMATION 0A-23 Abbreviations and Symbols May be Used in This Manual Abbreviations Anti-lock Brake System EFE Heater Early Fuel Evaporation Heater (Positive Temperature Coeffi- ATDC After Top Dead Center cient, PTC Heater) American Petroleum Institute Automatic Transmission Fluid Electronic Power Steering Automatic Locking Retractor EVAP Evaporative Emission...
Page 29 0A-24 GENERAL INFORMATION PSP Switch Power Steering Pressure Switch (P/S Pressure Switch) Powertrain Control Module Positive Crankcase Ventilation R RH Right Hand Society of Automotive Engineers Sensing and Diagnostic Module (Air bag controller, Air bag control module) Sequential Multiport Fuel Injection SOHC Single Over Head Camshaft Throttle Body Fuel Injection (Sin-...
Page 30: Symbols
GENERAL INFORMATION 0A-25 Symbols SYMBOL DEFINITION SYMBOL DEFINITION Tightening torque Apply SEALANT 1216B 99000-31230 Apply oil (engine, transmission, trans- Apply SILICONE SEALANT fer, differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E automatic transmission fluid) 99000-31090 Apply GREASE A 99000-25010 Apply GREASE C 99000-25030 Apply THREAD LOCK 1322 99000-32110...
Page 31: Fastener Information
0A-26 GENERAL INFORMATION Fastener Information Metric Fasteners Information Most of the fasteners used for this vehicle are JIS-defined and ISO-defined metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diame- ter, thread pitch and strength. CAUTION: Even when the nominal diameter (1) of thread is the same, the thread pitch (2) or the width across flats (3)
Page 32: Fastener Strength Identification
GENERAL INFORMATION 0A-27 Fastener Strength Identification Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark strength identification on the nut face.
Page 33 0A-28 GENERAL INFORMATION Tightening torque chart: Thread Diameter (Nominal Diameter) (mm) A equivalent of 4T strength N·m fastener kg-m 0.15 0.30 0.55 10.5 lb-ft 21.0 32.5 47.0 76.0 116.0 A equivalent of 6.8 strength N·m fastener without flange kg-m 0.24 0.47 0.84 12.5 19.3 lb-ft 14.5 30.5 58.0 90.5 139.5 202.5...
Page 34 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View and Connec- tors” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 35 0B-2 MAINTENANCE AND LUBRICATION Transfer Oil (4WD) and Rear Differential Doors ............0B-20 Oil (4WD) Inspection........0B-19 Engine hood..........0B-20 Transfer Oil (4WD) and Rear Differential Ventilator Air Filter (If Equipped)....0B-20 Oil (4WD) Replacement ......0B-20 Final Inspection ..........0B-21 All Latches, Hinges and Locks Recommended Fluids and Lubricants ..
Page 36: Maintenance Schedule
MAINTENANCE AND LUBRICATION 0B-3 Maintenance Schedule Maintenance Schedule Under Normal Driving Conditions NOTE: • This interval should be judged by odometer reading or months, whichever comes first. • This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively.
Page 37 0B-4 MAINTENANCE AND LUBRICATION Km (x 1,000) Interval Miles (x 1,000) Months BRAKE Brake discs and pads (thickness, wear, damage) Brake drums and shoes (wear, damage) – – – Brake hoses and pipes (leakage, damage, clamp) – – – Brake fluid –...
Page 38 MAINTENANCE AND LUBRICATION 0B-5 Maintenance Recommended Under Severe Driving Conditions If the vehicle is usually used under the conditions corresponding to any severe condition code given below, IT IS RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the following table.
Page 39 0B-6 MAINTENANCE AND LUBRICATION Maintenance Service Drive Belt Inspection (M13 Engine) WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Water pump and generator drive belt inspection 1) Disconnect negative (–) cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness.
Page 40 MAINTENANCE AND LUBRICATION 0B-7 Drive Belt Inspection (G10 Engine) WARNING: Disconnect negative cable at battery before checking and replacing belt. A/C compressor drive belt inspection (If equipped) 1) Hoist vehicle and remove engine under cover of right side from vehicle body. 2) Inspect belt for wear, deterioration and tension.
Page 41 0B-8 MAINTENANCE AND LUBRICATION Camshaft Timing Belt Replacement (G10 Engine) Replace belt with new one. Refer to Section 6A for replacement procedure. CAUTION: • Do not bend or twist timing belt. • Do not allow timing belt to come into contact with oil, water, etc.
Page 42 MAINTENANCE AND LUBRICATION 0B-9 Engine Oil and Oil Filter Replacement WARNING: • New and used engine oil can be hazardous. Be sure to read “WARNING” in General Precaution in Section 0A and observe what in written there. • Step 1) – 7) outlined below must be performed with ENGINE NOT RUNNING.
Page 43 0B-10 MAINTENANCE AND LUBRICATION 5) Tighten the filter (1) 3/4 turn from the point of contact with the mounting surface using an oil filter wrench (2). Tightening torque Oil filter (b): 14 N·m (1.4 kg-m, 10.5 lb-ft) (for reference) 6) Replenish oil until oil level is brought to FULL level mark on dipstick.
Page 44: Exhaust System Inspection
MAINTENANCE AND LUBRICATION 0B-11 Engine Coolant Replacement WARNING: To help avoid danger of being burned, do not remove radiator 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. CAUTION: When changing engine coolant, use mixture of 50% spec- ified water and 50% ANTIFREEZE / ANTICORROSION...
Page 45 0B-12 MAINTENANCE AND LUBRICATION Distributor Cap and Rotor Inspection (G10 Engine) • Check distributor cap and rubber caps for cracks. • Clean dusty and stained parts using a dry, soft cloth. • Check center electrode and terminals for wear. • Check rotor for cracks and its electrode for wear. Repair or replace any component which is found to be in malcondition.
Page 46 MAINTENANCE AND LUBRICATION 0B-13 Fuel Tank Inspection Check fuel tank damage, cracks, fuel leakage, corrosion and tank bolts looseness. If a problem is found, repair or replace. PCV Valve Inspection Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog.
Page 47 0B-14 MAINTENANCE AND LUBRICATION Brake Drums and Shoes (Rear) Inspection 1) Remove wheel and brake drum. 2) Check rear brake drums and brake linings for excessive wear and damage, while wheels and drums are removed. At the same time, check wheel cylinders for leaks. Replace these parts as necessary.
Page 48 MAINTENANCE AND LUBRICATION 0B-15 2) Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever. 3) Check parking brake lever for proper operation and stroke, and adjust it if necessary. For checking and adjusting procedures, refer to “Parking Brake Inspection and Adjustment”...
Page 49 0B-16 MAINTENANCE AND LUBRICATION Wheel Discs Inspection Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Wheel Bearing Inspection 1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to “Wheel Disc, Nut and Bearing Check”...
Page 50 MAINTENANCE AND LUBRICATION 0B-17 3) Check steering linkage for looseness and damage. Repair or replace defective parts, if any. 4) Check boots (1) and (2) of steering linkage and steering gear case for damage (leak, detachment, tear, etc.). If damage is found, replace defective boot with new one.
Page 51 0B-18 MAINTENANCE AND LUBRICATION Manual Transmission Oil Inspection 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove oil filler/level plug (1) of transmission. 4) Check oil level.
Page 52 MAINTENANCE AND LUBRICATION 0B-19 Automatic Transmission Fluid Replacement 1) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) Make sure that vehicle is placed level for fluid level check. 3) Change fluid. For its procedure, refer to “Fluid Change” in Section 7B.
Page 53 0B-20 MAINTENANCE AND LUBRICATION Transfer Oil (4WD) and Rear Differential Oil (4WD) Replacement Change transfer oil and differential oil with new specified oil refer- ring to “Transfer Oil Change” in Section 7D or “Rear Differential Oil Change” in Section 7F. All Latches, Hinges and Locks Inspection Doors Check that each door of front, rear and back doors opens and...
Page 54 MAINTENANCE AND LUBRICATION 0B-21 Final Inspection WARNING: When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to prevent any accident. SEATS Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front seat back allows it to be locked at any angle.
Page 55 0B-22 MAINTENANCE AND LUBRICATION FOOT BRAKE Check the followings: • that brake pedal has proper travel, • that brake works properly, • that it is free from noise, • that vehicle does not pull to one side when brake is applied. •...
Page 56: Recommended Fluids And Lubricants
MAINTENANCE AND LUBRICATION 0B-23 Recommended Fluids and Lubricants SG, SH, SJ or SL grade (Refer to “Engine Oil and Oil Filter Replace- Engine oil ment” in this section for engine oil viscosity.) Engine coolant “Antifreeze / Anticorrosion coolant” (Ethylene glycol base coolant) Brake fluid DOT 4 or SAE J1704 Manual transmission oil...
Page 57 0B-24 MAINTENANCE AND LUBRICATION...
Page 58 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 59 1B-2 AIR CONDITIONING (OPTIONAL) Diagnosis Wiring Circuit (M13 Engine Model) 1. Main fuse box 7. A/C switch 13. A/C evaporator thermistor 2. Main relay 8. Dual pressure switch 14. ECT sensor 3. Radiator (and condenser) cooling fan motor relay 9. Blower fan motor relay 15.
Page 60 AIR CONDITIONING (OPTIONAL) 1B-3 A/C System Inspection of ECM and Its cir- cuits (M13 Engine Model) ECM and its circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from it.
Page 61 1B-4 AIR CONDITIONING (OPTIONAL) b. To “HEATER” fuse (25A) in circuit fuse box 2. Dual pressure switch 7. A/C evaporator thermistor 12. Radiator (and condenser) cooling fan motor relay c. To “IG COIL” fuse (15A) in circuit fuse box 3. Blower fan motor relay 8.
Page 62 AIR CONDITIONING (OPTIONAL) 1B-5 Termi- Wire Circuit Measurement Normal value Condition ground E21-30 A/C switch Ground to 0 – 1 V A/C switch ON with ignition switch GRN/ input engine (Fig B) 10 – 14 V A/C switch OFF with ignition switch E22-16 YEL/ Engine coolant...
Page 63 1B-6 AIR CONDITIONING (OPTIONAL) 4) Install new compressor drive belt. 5) Adjust belt tension referring to above procedure. On-Vehicle Service Dual Pressure Switch Inspection Check dual pressure switch (1) for continuity at normal tempera- º º ture (approx. 25 C (77 F)) when A/C system has a proper charge of refrigerant and when A/C system (compressor) is under operation.
Page 64 AIR CONDITIONING (OPTIONAL) 1B-7 4) Check that there is continuity between terminals “A” and “B” when battery is connected to terminals “C” and “D”. If found defective, replace. Compressor (M13 Engine Model) Removal 1) Run engine at idle speed with air conditioning ON for 10 min- utes.
Page 65 1B-8 AIR CONDITIONING (OPTIONAL)
Page 66: Front Wheel Alignment
FRONT WHEEL ALIGNMENT 3A-1 SECTION 3A FRONT WHEEL ALIGNMENT WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.
Page 67 3A-2 FRONT WHEEL ALIGNMENT General Description Front Wheel Alignment Specifications Item Front Wheel Toe (total) 0 ± 1 mm Camber –0 ° 20’ ± 1 ° Caster 3 ° 40’ ± 1 ° Side Slip Limit mm/m 0 – IN 3 mm/m Steering Angle Inside 35 °...
Page 68 • 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 69 3B-2 MANUAL RACK AND PINION On-Vehicle Service Tie Rod End Installation 1) Install tie rod end lock nut (1) and tie rod end (2) to tie rod (3). Align lock nut with mark (4) on tie rod thread. 2) Connect tie rod end to knuckle. Tighten new tie rod end nut (1) to specified torque.
Page 70 MANUAL RACK AND PINION 3B-3 Manual Rack and Pinion Assembly (Steering Gear Case) Installation 1) Apply grease to inside of pinion packing and install pinion packing onto pinion. Mount steering gear case (1) to body and tighten gear case mount bolts (2) and nuts (3) to speci- fied torque.
Page 71 3B-4 MANUAL RACK AND PINION 7) Reinstall cover (1) removed previously to steering shaft joint. 8) Put back floor mat as it was. 9) Install both wheels and tighten wheel bolts to specified torque. Tightening torque Wheel bolt: 95 N·m (9.5 kg-m, 69.0 lb-ft) 10) Lower hoist.
Page 72 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 73: Wiring Diagram
3B1-2 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) General Description Wiring Diagram 1. Main fuse box Speedometer 15. Motor assembly (with clutch incorporated) 2. “EPS” fuse (30 A) 9. “EPS” warning lamp 16. Torque sensor 3. Ignition switch 10. To vehicle speed sensor (VSS) for G10 engine model, 17.
Page 74 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-3 Diagnosis “EPS” Warning Lamp Circuit Check Flow Table for M13 Engine Model CAUTION: Be sure to perform “System Check Flow Table” before starting diagnosis according to flow table. Step Action 1) Make sure that battery voltage is about 11 V Go to Step 2.
Page 75 3B1-4 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) Table-B “EPS” Warning Lamp Remains ON Step Action Was “System Check Flow Table” performed? Go to Step 2. Go to “System Check Flow Table” in this section. 1) With ignition switch OFF, disconnect 8 pin Go to step 3.
Page 76: Front Suspension
FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.
Page 77 3D-2 FRONT SUSPENSION General Description The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehi- cle body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also installed a little lower to the rubber mount.
Page 78 FRONT SUSPENSION 3D-3 Diagnosis Wheel Disc, Bolt & Bearing Check 1) Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. 2) Check wheel bolts for tightness and retighten them to specifi- cation as necessary.
Page 79 3D-4 FRONT SUSPENSION On-Vehicle Service Stabilizer Bar and/or Bushings Components 1. Split pin 4. Stabilizer bar bushing 7. Mount bushing 10. Paint mark Tightening torque 2. Castle nut 5. Suspension control arm 8. Mount bush bracket 11. Paint mark (RH side) Do not reuse.
Page 80 FRONT SUSPENSION 3D-5 • Install mounting bracket (1) so that its oblong hole side (2) comes to the rear. • Tighten stabilizer bar bracket bolts to specified torque. Tightening torque · Stabilizer bar bracket bolt: 45 N m (4.5 kg-m, 32.5 lb-ft) •...
Page 81: Tightening Torque
3D-6 FRONT SUSPENSION • Install wheel and tighten wheel bolts to specified torque. Tightening torque · Wheel bolt (a) 95 N m (9.5 kg-m, 69.0 lb-ft) • Confirm front end (wheel) alignment, referring to Section 3A. Steering Knuckle / Bearing Components Wheel hub 5.
Page 82 FRONT SUSPENSION 3D-7 Removal 1) Hoist vehicle and remove wheel. 2) Uncaulk drive shaft nut (1). 3) Depress foot brake pedal and hold it there. Remove drive shaft nut. 4) Remove caliper carrier bolts. 5) Remove caliper with carrier. NOTE: Hang removed caliper with a wire hook of the like so as to prevent brake hose from bending and twisting exces- sively or being pulled.
Page 83 3D-8 FRONT SUSPENSION 9) Remove tie-rod end nut and disconnect tie-rod end (2) from knuckle (1) with puller. CAUTION: • Never reuse tie-rod end nut. • Reused nut will not be locked securely. 10) Remove wheel speed sensor (1) from knuckle (if equipped). 11) Remove strut bracket bolts (1) from strut bracket and then control arm ball stud bolt (2).
Page 84 FRONT SUSPENSION 3D-9 2) Remove circlip (1). Special tool (A): 09900-06108 3) Remove wheel bearing using special tool and hydraulic press. Special tool (A): 09913-75810 (for gasoline engine model) (A): 09913-85210 (for diesel engine model) CAUTION: • Never reuse wheel bearing. •...
Page 85 3D-10 FRONT SUSPENSION 2) Install circlip (1). Special tool (A): 09900-06108 3) Drive in dust cover (1) so that dimensions “a” and “b” become equal as shown. CAUTION: When drive in dust cover, be careful not to deform it. 4) Caulk with a punch. Installation 1) Using special tools and hydraulic press (1), drive wheel hub (2) into wheel bearing (3) as shown.
Page 86 FRONT SUSPENSION 3D-11 • Apply grease lightly to contact part (1) of wheel bearing and drive shaft. “A”: Grease 99000-25050 2) Install knuckle (2) to ball stud (3) on suspension control arm (4) and strut bracket (1). Installing direction of each bolt is as shown.
Page 87 3D-12 FRONT SUSPENSION 6) Install brake disc. 7) Tighten brake disc screws. Tightening torque Brake disc screw (a): 9 Nm (0.9 kg-m, 6.5 lb-ft) 8) Install brake caliper/caliper carrier. 9) Tighten caliper carrier bolts to specified torque. Tightening torque · Brake caliper carrier bolt (b): 95 N m (9.5 kg-m, 69.0 lb-ft) 10) Depress foot brake pedal and hold it there.
Page 88 FRONT SUSPENSION 3D-13 7) Remove bushing. Place suspension control arm onto flat surface side of spe- cial tool and push out bushing with special tool and oil hydraulic press as shown. Special tool (A): 09943-77910 Installation 1) Place suspension control arm onto flat surface side of spe- cial tool and install new bushing with special tool and oil hydraulic press as shown.
Page 89 3D-14 FRONT SUSPENSION 3) Install ball stud (2) to knuckle (1). Align ball stud groove with knuckle bolt hole as shown. Then install ball stud bolt from the direction as shown. Tighten control arm ball stud bolt to specified torque. Tightening torque Control arm ball stud bolt ·...
Page 90 FRONT SUSPENSION 3D-15 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium Grease SUZUKI SUPER GREASE (E) • Wheel bearing (Should be applicable for –40 C° – 130 °C or –40 (99000-25050) °F – 266 °F) Special Tool 09943-17912...
Page 91 3D-16 FRONT SUSPENSION...
Page 92: Rear Suspension
REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.
Page 93 3E-2 REAR SUSPENSION General Description 2WD model 63 N·m(6.3 kg-m) 175 N·m (17.5 kg-m) 63 N·m(6.3 kg-m) 95 N·m(9.5 kg-m) 100 N·m (10.0 kg-m) 50 N·m(5.0 kg-m) 90 N·m(9.0 kg-m) 80 N·m(8.0 kg-m) 80 N·m(8.0 kg-m) 1. Rear coil spring 4.
Page 94 REAR SUSPENSION 3E-3 4WD model A: With ABS 4. Rear shock absorber 9. Brake drum 14. Wheel bearing retainer ring or rear wheel sensor ring (if equipped with ABS) B: Without ABS 5. Lateral rod 10. Rear axle shaft 15. Spacer 1.
Page 95 3E-4 REAR SUSPENSION Diagnosis Wheel Disc, Bolt and Bearing Check • Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. • Check wheel bolts for tightness and, as necessary, retighten to specification. Tightening torque ·...
Page 96 REAR SUSPENSION 3E-5 On-Vehicle Service 2WD model “A”: Body outside 7. Lateral rod outer washer 14. LSPV bracket 21. Trailing arm rear bolt: (only vehicle with LSPV) Insert from vehicle inside. 1. Rear coil spring 8. Rear axle 15. Brake back plate: 22.
Page 97 3E-6 REAR SUSPENSION 4WD model "A" “A”: Body outside 11. Oil seal 22. Brake back plate bolt 1. Rear coil spring 12. Spacer: 23. Bearing retainer ring (without ABS) The tapered side of spacer inner diameter directed toward outside (brake drum side). 2.
Page 98 REAR SUSPENSION 3E-7 Lateral Rod Installation 1) Install lateral rod (1) or (2) to rear axle (or axle housing) (3) and vehicle body (4) referring to figure for proper installing direction of bolt (5) and washer (6). Tighten nuts (7) temporarily at this step. NOTE: •...
Page 99 3E-8 REAR SUSPENSION Coil Spring Installation 1) Install coil springs (1) (right & left) on spring seat (2) of rear axle as shown in figure and then raise rear axle. NOTE: When seating coil spring (1), mate spring end with stepped part (3) of rear axle spring seat as shown.
Page 100 REAR SUSPENSION 3E-9 8) Lower hoist and vehicle in non-loaded condition, tighten absorber lower bolt (1) and lateral rod body side nut (2) to specified torque. Tightening torque Rear shock absorber lower bolt (a): 63 N·m (6.3 kg-m, 45.5 lb-ft) Lateral rod nut (body side) (b): 100 N·m (10.0 kg-m, 72.5 lb-ft) 9) If equipped with LSPV, check and adjust LSPV spring refer-...
Page 101 3E-10 REAR SUSPENSION 2) Install wheel speed sensor lead wire clamp, if equipped. 3) Install parking brake cable clamp (1). 4) Install shock absorber (1) to rear axle (2). 5) Tighten shock absorber lower bolt (3) temporarily by hand. 6) Remove floor jack from rear axle. 7) Install wheel and tighten wheel bolts to specified torque.
Page 102 REAR SUSPENSION 3E-11 Rear Axle (for 2WD Model) Installation Install removed parts in reverse order of removal, noting the fol- lowing points. 1) Place rear axle on floor jack. Then install lateral rod to rear axle and tighten nut temporarily by hand. 2) Install trailing arm rear bolts (1) (right &...
Page 103 3E-12 REAR SUSPENSION 7) Install brake back plates (1) and tighten back plate bolts (2) to specified torque. Tightening torque · Brake back plate bolt (a): 23 N m (2.3kg-m, 16.5 lb-ft) 8) Connect wheel speed sensor and lead wire clamps (right & left) (if equipped).
Page 104 REAR SUSPENSION 3E-13 12) Install brake drums (right & left). For details, refer to steps 3) to 8) of “Brake Drum Installation” in Section 5C. 13) Fill reservoir with brake fluid and bleed brake system. (For bleeding operation, refer to Section 5.) 14) Install wheel and tighten wheel bolts to specified torque.
Page 105 3E-14 REAR SUSPENSION 2) Remove circlip (1). Special tool (A): 09900-06108 3) Remove wheel bearing by using special tool and hydraulic press. Special tool (A): 09913-76010 CAUTION: • Never reuse wheel bearing. • Reused bearing should have excessive play. Installation 1) Install new wheel bearing (1) by using special tool and hydraulic press.
Page 106 REAR SUSPENSION 3E-15 Rear Axle Shaft and Wheel Bearing (for 4WD Model) Removal 1) Hoist vehicle and remove rear wheels. 2) Remove brake drum screw and rear brake drum by using 8 mm bolts. For details referring to Section 5C. 1.
Page 107 3E-16 REAR SUSPENSION 10) In order to remove the retainer ring (1) from the axle shaft (2), grind (3) with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin. CAUTION: Be careful not to go so far as to grind the shaft. [A]: Without ABS [B]: With ABS 11) Break with a chisel the thin ground retainer ring, and it can...
Page 108 REAR SUSPENSION 3E-17 Installation Install removed parts in reverse order of removal, noting the fol- lowing points. 1) Install wheel bearing spacer (1) with the tapered side of its inner diameter directed toward outside, or brake drum side. 2) Press in a new bearing (2) and retainer ring (3) in order by using an hydraulic press (4).
Page 109 3E-18 REAR SUSPENSION 6) Install rear axle shaft to rear axle housing and tighten brake back plate bolts to specified torque. NOTE: When installing rear axle shaft, be careful not to cause damage to oil seal lip in axle housing. Tightening torque Brake back plate bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 7) Connect brake pipe to wheel cylinder and tighten brake pipe...
Page 110 REAR SUSPENSION 3E-19 Rear Axle Housing (for 4WD Model) Removal 1) Hoist vehicle and remove rear wheels referring to “Wheel Removal and Installation” in Section 3F. 2) Remove rear axle shafts (right & left) referring to Steps 2) – 9) of “Rear Axle Shaft and Wheel Bearing (for 4WD Model)” in this section.
Page 111 3E-20 REAR SUSPENSION 11) Loosen trailing arm rear mounting nuts (3) (right & left) from axle housing, but don’t remove bolts. 12) Remove shock absorber lower mounting bolts (1). 13) Lower floor jack until tension of suspension coil spring becomes a little loose and remove trailing arm rear mounting bolts (2) (right &...
Page 112 REAR SUSPENSION 3E-21 Installation Install removed parts in reverse order of removal, noting the fol- lowing. 1) Place rear axle housing on floor jack. Then install rear trail- ing arm bolts (1) (right & left) in proper direction as shown. Then tighten nuts (2) temporarily by hand.
Page 113 3E-22 REAR SUSPENSION 5) Clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side. “A”: Sealant 99000-31110 6) Install differential carrier assembly to axle housing and tighten carrier bolts to specified torque. Tightening torque Rear differential carrier bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 7) Install propeller shaft to joint flange aligning match marks (2)
Page 114 REAR SUSPENSION 3E-23 15) Install rear axle shaft (right & left) to rear axle housing. 16) Tighten brake back plate bolts to specified torque. Tightening torque Brake back plate bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 17) Connect brake pipes (3) to wheel cylinders (1) (right & left) and tighten brake pipe flare nuts (2) to specified torque.
Page 115 3E-24 REAR SUSPENSION 26) Tighten right and left trailing arm nuts (1) and shock absorber lower bolts (2) to specified torque. Tighten lateral rod nuts (3) to specified torque. NOTE: When tightening these bolts and nuts, be sure that vehi- cle is off hoist and in non loaded condition.
Page 116 REAR SUSPENSION 3E-25 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE (A) • Axle shaft oil seal (99000-25010)···(for 4WD Model) Sealant SUZUKI BOND NO. 1215 • Joint seam of differential carrier and axle housing (99000-31110)···(for 4WD Model)
Page 117 3E-26 REAR SUSPENSION Special Tool 09913-75810 09913-76010 09927-18411 09900-06108 Bearing installer Rear wheel bearing Universal puller Snap ring pliers (for 2WD Model) installer (for 4WD Model) (for 2WD Model) (for 2WD Model) 09942-15511 09943-17912 09921-57810 09913-50121 Sliding hammer Brake drum remover Bearing remover Oil seal remover (for 4WD Model)
Page 118: Wheels And Tires
WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: • All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 119: Tire Rotation
3F-2 WHEELS AND TIRES General Description Tires This vehicle is equipped with the following tire. Tire specification 165/60R14 75T ········ Gasoline engine model 165/60R14 79T ····························· Diesel engine model The tire is of tubeless type. The tire is designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressures.
Page 120 WHEELS AND TIRES 3F-3 On-Vehicle Service Service Operations Wheel Bolts All models use metric lug wheel bolts. Metric lug bolt size (1): M12 x 1.5 Wheel Removal WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts.
Page 121 3F-4 WHEELS AND TIRES Tightening order “A” – “B” – “C” – “D”: Tightening torque · Wheel bolt (a): 95 N m (9.5 kg-m, 69.0 lb-ft) Tightening Torque Specifications Tightening torque Fastening part N•m kg-m lb-ft Wheel bolt 69.0...
Page 122 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-1 SECTION 4A FRONT DRIVE SHAFT (G10/M13 ENGINES) CONTENTS General Description........4A-1 Front Drive Shaft Disassembly and Assembly ............. 4A-7 Diagnosis............4A-1 Front Drive Shaft Inspection ...... 4A-16 On-Vehicle Service......... 4A-2 Center Shaft and Center Bearing Support Front Drive Shaft Assembly Construction ..
Page 123 4A-2 FRONT DRIVE SHAFT (G10/M13 ENGINES) On-Vehicle Service Front Drive Shaft Assembly Construction 1. Transaxle 7. Oil filler/level plug 13. Drive shaft washer : Apply sealant 99000-31260 to plug thread 2. Drive shaft assembly 8. Oil drain plug 14. Center bearing support : Apply sealant 99000-31260 to plug thread 3.
Page 124 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-3 Front Drive Shaft Assembly Removal and Installation Removal CAUTION: To prevent the breakage of boots, be careful not to dam- age the boots when removing drive shaft assembly. 1) Undo caulking (1) and remove drive shaft nut (2). 2) Loosen wheel bolts.
Page 125 4A-4 FRONT DRIVE SHAFT (G10/M13 ENGINES) 9) Pull out drive shaft joint (2) as follows. • For left side of all model and right side of G10 engine model Using tire lever (1), pull out drive shaft joint (2) so as to release snap ring fitting of joint spline at differential side.
Page 126 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-5 Installation CAUTION: • Be careful not to damage oil seals and boots when installing drive shafts. • Do not hit joint boot with hammer. Inserting joint only by hands is allowed. • Make sure that differential side joint is inserted fully and its snap ring is seated as it was.
Page 127 4A-6 FRONT DRIVE SHAFT (G10/M13 ENGINES) Front Drive Shaft Components [A]: Tripod joint type 6. Wheel side joint (Constant velocity ball joint) 14. Circlip : Apply Black grease included in spare part to joint. [B]: DOJ type 7. Boot (Wheel side) 15.
Page 128 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-7 Front Drive Shaft Disassembly and Assembly Disassembly For DOJ type CAUTION: Disassembly of wheel side joint is not allowed. If any abnormality is found, replace it as assembly. 1) Remove differential side boot big band (1) as follows. •...
Page 129 4A-8 FRONT DRIVE SHAFT (G10/M13 ENGINES) c) Remove cage (1) with retaining ring (2) from housing (3) if necessary. 3) Remove differential side boot small band, and then pull out differential side boot from shaft. 4) Pull out damper through shaft. 5) Remove wheel side boot big band (1) as follows.
Page 130 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-9 1) Remove differential side boot big band (1) as follows. • For boot big band without joint Remove boot big band by tapping boot and band with plastic hammer. If it is hard to remove boot big band, cut it using a nipper or a iron saw with care not to damage tripod joint housing.
Page 131 4A-10 FRONT DRIVE SHAFT (G10/M13 ENGINES) 7) Remove wheel side boot big band (1) as follows. • For boot big band without joint Cut boot big band using a iron saw or a nipper with care not to damage wheel side joint housing. •...
Page 132 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-11 3) Install new wheel side boot on shaft temporarily. 4) Apply grease in the supplied parts to the inside of joint hous- ing. Grease color: Black Grease amount: Approx. 70 g (2.5 oz) 5) Fit wheel side boot onto grooves of housing and shaft. 6) Place new wheel side boot big band onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
Page 133 4A-12 FRONT DRIVE SHAFT (G10/M13 ENGINES) 10) Install damper (1) on left side drive shaft according to dimen- sion specified below. Damper installation position For M/T model with M13 engine “a”: 134 – 140 mm (5.28 – 5.51 in.) For A/T model with M13 engine “a”: 157 –...
Page 134 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-13 15) Install boot on joint housing. • For right side When fixing boot (1) to joint housing (2) with differential side boot big band (3), adjust so that measurements become as indicated below. • For left side Fit boot to grooves of shaft and housing and adjust length “b”...
Page 135 4A-14 FRONT DRIVE SHAFT (G10/M13 ENGINES) For Tripod Joint Type CAUTION: • Do not wash boots in degrease, such as gasoline or kerosene, etc. Washing in degrease causes deteriora- tion of boots. • To ensure full performance of joint as designed, be sure to distinguish two types of grease in spare part and apply the specified amount of grease to each joint.
Page 136 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-15 5) Place new wheel side boot small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure. 6) Install wheel side boot small band (1), putting its lower edge against projected end (4) of boot (3) so that clearance “a”...
Page 137 4A-16 FRONT DRIVE SHAFT (G10/M13 ENGINES) 11) Apply grease to inside of joint housing (1), then install hous- ing, joint it with boot and fit boot to joint housing. After fitting boot, insert screwdriver into boot on joint housing side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
Page 138 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-17 Center Shaft and Center Bearing Support Dis- assembly and Assembly (2WD Model with M13 Engine) Disassembly 1) For M/T model, go to the next step. For A/T model, remove wheel side oil seal and circlip from center bearing support bracket (3).
Page 139 4A-18 FRONT DRIVE SHAFT (G10/M13 ENGINES) • When installing left oil seal (1) and right oil seal (2) to center bearing support bracket (3) by using special tools, use care so that the oil seals installed in proper direction and position as shown figure.
Page 140 FRONT DRIVE SHAFT (G10/M13 ENGINES) 4A-19 RequirPed Service Material Recommended SUZUKI product Material (Part Number) SUZUKI SUPER GREASE A • Oil seal lip Lithium grease (99000-25010) SUZUKI BOND NO. 1217G • Oil drain and filler/level plugs for manual Sealant (99000-31260)
Page 141 4A-20 FRONT DRIVE SHAFT (G10/M13 ENGINES)
Page 142: Propeller Shafts
PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in “FOREWORD” of this manual. CONTENTS On-Vehicle Service..........4B-2 Tightening Torque Specification....4B-6...
Page 143 4B-2 PROPELLER SHAFTS On-Vehicle Service [A]: Forward. 4. Propeller shaft No.2 bolt 8. Center support bolt : Apply thread lock 99000-32110 to thread. 1. Propeller shaft No.1 with center support 5. Dynamic damper Tightening torque 2. Viscous coupling with center support 6.
Page 144 PROPELLER SHAFTS 4B-3 REMOVAL 1) Hoist vehicle. 2) Before removing propeller shafts, give match marks (1) on propeller shaft No.2 (4) and companion flange (2) of rear dif- ferential as shown. Also give match marks (1) on propeller shaft No.2 yoke (5), dynamic damper (3), viscous coupling with center support (6), yoke (7) of propeller shaft No.1 with center support (8) and transfer output flange (9).
Page 145 4B-4 PROPELLER SHAFTS 4) If disassembling propeller shaft assembly is necessary, loosen propeller shaft No.2 bolts (1) and viscous coupling nuts (2) to facilitate subsequent disassembling, but keeping each connection provisionally. 5) Loosen center support bolts (1), then remove propeller shaft No.1 with center support (2), propeller shaft No.2 (3), dynamic damper (5) and viscous coupling with center sup- port (4) all together.
Page 146 PROPELLER SHAFTS 4B-5 INSTALLATION Reverse removal procedure to install propeller shafts noting the following points. • When installing propeller shafts, dynamic damper and vis- cous coupling with center support, align the match marks (1). Otherwise, vibration may occur during driving. •...
Page 147 4B-6 PROPELLER SHAFTS Tightening Torque Specification Tightening torque Fastening portion N•m kg-m lb-ft Propeller shaft bolt 17.0 Propeller shaft No.2 bolt 17.0 Center support bolt 40.0 Viscous coupling nut 17.0...
Page 148 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 149 5-2 BRAKES General Description When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis- tons (two in front and four in rear). The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two independent circuits.
Page 150 BRAKES 5-3 Check and Adjustment Bleeding Brakes CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. NOTE: For vehicle equipped with ABS, make sure that ignition switch is turned off.
Page 151 5-4 BRAKES 3) Depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one-third to one half turn. 4) When fluid pressure in the cylinder is almost depleted, retighten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hydraulic line.
Page 152 BRAKES 5-5 Brake Shoe Check Inspection should be carried out on the following points after brake pedal travel “c” (pedal to silencer clearance) check as described on previous page of this section, even when it is more than specification. Amount of brake shoe wear can be checked as follows. 1) Hoist vehicle.
Page 153 5-6 BRAKES...
Page 154 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 155 5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER On-Vehicle Service Rear Brake Hose/Pipe CAUTION: • Do not use lubricated shop air on brake parts as damage to rubber components may result. • If any hydraulic component is removed or brake line disconnected, bleed the brake system. •...
Page 156 BRAKES PIPE/HOSE/MASTER CYLINDER 5A-3 26 N·m (2.6 kg-m) View A Detail B View C 20 N·m (2.0 kg-m) 9 N·m (0.9 kg-m) [A]: with ABS vehicle 1. Rear brake hose 4. Top side 7. Right side [B]: without ABS vehi- 2.
Page 157 5A-4 BRAKES PIPE/HOSE/MASTER CYLINDER [C]: without ABS vehicle (4WD) 3. Rear brake hose 7. From master cylinder (Secondary) 11. Front side a – g: Clamp 4. To left rear wheel cylinder 8. Top side 12. E–ring (Insert delection) 1. E–ring 5.
Page 158: Front Brake
FRONT BRAKE 5B-1 SECTION 5B FRONT BRAKE WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.
Page 159 5B-2 FRONT BRAKE On-Vehicle Service CAUTION: Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber com- ponents may result. If any component is removed or line disconnected, bleed the brake system. Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners. 1.
Page 160: Front Disc Brake Caliper
FRONT BRAKE 5B-3 2) Install caliper (1) and tighten caliper pin bolts (2) to specifica- tion. NOTE: Make sure that boots (3) are fit into groove securely. Tightening torque Caliper pin bolt (a): 30 N·m (3.0 kg-m, 22.0 lb-ft) 3) Tighten front wheel bolts to specification. Tightening torque Wheel bolt (b): 95 N·m (9.5 kg-m, 69.0 lb-ft) 4) Upon completion of installation, perform brake test.
Page 161: Front Brake Disc
5B-4 FRONT BRAKE 4) Torque wheel bolts to specification. Tightening torque · Wheel bolt (c): 95 N m (9.5 kg-m, 69.0 lb-ft) 5) After completing installation, fill reservoir with brake fluid and bleed brake system. Perform brake test and check each installed part for oil leakage.
Page 162 FRONT BRAKE 5B-5 3) Torque caliper carrier bolts (1) to specification. Tightening torque · Caliper carrier bolt (a): 95 N m (9.5 kg-m, 69.0 lb-ft) 4) Torque front wheel bolts to specifications. Tightening torque · Wheel bolt (b): 95 N m (9.5 kg-m, 69.0 lb-ft) 5) Upon completion of installation, perform brake test.
Page 163 5B-6 FRONT BRAKE...
Page 164 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 165 5C-2 PARKING AND REAR BRAKE On-Vehicle Service CAUTION: • Replace all components included in repair kits to service this drum brake. Lubricate parts as speci- fied. • If any hydraulic component is removed or brake line disconnected, bleed the brake system. •...
Page 166 PARKING AND REAR BRAKE 5C-3 175 N·m (17.5 kg-m) 9 N·m (0.9 kg-m) 1. Brake back plate: 9. Piston assembly 17. Parking brake cable Clean back plate and apply thin coat of Bentonite base brake grease (anti-squeal agent) to six surfaces on which shoe rims rest. 2.
Page 167 5C-4 PARKING AND REAR BRAKE Parking Brake Cable Component Location 1. Parking brake lever assembly 4. Parking cable bracket 7. Parking brake cable bolt 2. Equalizer 5. Parking brake cable: 8. Parking brake lever bolt Apply water tight sealant 99000-31090 to plate and cable contact. 3.
Page 168 PARKING AND REAR BRAKE 5C-5 Brake Drum (for 2WD Model) Removal 1) Hoist vehicle and remove wheel referring to “Wheel” Removal in Section 3F. 2) Remove spindle cap (1) as shown (by hammering lightly at 3 locations around it so as not to deform or cause damage to seating part of cap).
Page 169 5C-6 PARKING AND REAR BRAKE e) Pull brake drum (1) off by hand. If it is hard to remove, use special tools. NOTE: When drum is removed, visually inspect wheel cylinder for brake fluid leakage. Correct leaky point if any. Special tool (A): 09942-15511 (B): 09943-17912...
Page 170 PARKING AND REAR BRAKE 5C-7 3) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil. 4) Install new spindle nut (1). 5) Tighten spindle nut (1) to specified torque. Tightening torque Spindle nut (a): 175 N·m (17.5 kg-m, 126.5 lb-ft) 6) Calk spindle nut (1).
Page 171 5C-8 PARKING AND REAR BRAKE 2) Remove brake drum screw (1) and release parking brake lever. 3) Remove brake drum. If brake drum can not be removed easily, increase clearance between brake shoes and drum, referring to step a) – d) in “Brake Drum (for 2WD Model)”.
Page 172 PARKING AND REAR BRAKE 5C-9 6) Install wheel and tighten wheel bolts to specified torque. Tightening torque Wheel bolt (b): 95 N·m (9.5 kg-m, 69.0 lb-ft) 7) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and perform brake test (foot brake and parking brake).
Page 173 5C-10 PARKING AND REAR BRAKE Installation 1) Apply water tight sealant to mating surfaces of brake back plate and rear axle. “A”: Sealant 366E, 99000-31090 NOTE: In case of vehicle equipped with ABS, do not apply seal- ant around hole for wheel speed sensor. 2) Install brake back plate and tighten back plate bolts to speci- fied torque.
Page 174 69.0 Required Service Material Recommended SUZUKI product Material (Part Number) Water tight SUZUKI SEALING COMPOUND 366E • To apply to mating surfaces of brake back sealant (99000-31090) plate and rear axle • To apply to mating surfaces of brake back...
Page 175 5C-12 PARKING AND REAR BRAKE Special Tools 09942-15511 09943-17912 09913-75520 Sliding hammer Brake drum remover Bearing installer (for 2WD Snap-on Part (Front wheel hub model) NO. B3404B or equivalent remover) 09913-65135 09926-68310 09950-78230 Bearing puller (for 2WD Bearing installer (for 2WD Flare nut wrench (10 –...
Page 176 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 177 6-2-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0113 Intake Air Temperature DTC P0401 Exhaust Gas Recirculation Sensor Circuit High ........6-2-73 Flow Insufficient Detected......6-2-120 DTC P0117 Engine Coolant DTC P0402 Exhaust Gas Recirculation Temperature Circuit Low......6-2-76 Flow Excessive Detected......6-2-120 DTC P0118 Engine Coolant DTC P0420 Catalyst System Efficiency Temperature Circuit High......
Page 178: General Information
ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-3 General Information Statement on 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 an inch).
Page 179 6-2-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Precaution Precaution on engine service THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELI- ABLE ENGINE PERFORMANCE. • When raising or supporting engine for any reason, do not use a jack under oil pan.
Page 180 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-5 • Fuel or fuel vapor hose connection varies with each type of pipe. When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to the figure Hose Connection.
Page 181 6-2-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 3) Disconnect fuel pump relay (1) from relay box (2). 4) Remove fuel filter cap to release fuel vapor pressure in fuel tank and then reinstall it. 5) Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2-3 times for about 3 seconds each time to dissipate fuel pressure in lines.
Page 182 ECM memory as freeze frame data. (For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (2) but also OBD generic scan tool. (Diagnostic informa- tion can be accessed by using a scan tool.)
Page 183 6-2-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Driving Cycle A “Driving Cycle” consists of engine startup and engine shutoff. 2 Driving Cycle Detection Logic The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC) but the malfunction indicator lamp does not light at this time.
Page 184 DLC (1) is in compliance with SAE J1962 in the shape of connec- tor and pin assignment. OBD serial data line (3) (K line of ISO 9141) is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module and ABS control module.
Page 185 ECM memory. • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool or OBD generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good under- standing as to what functions are available and how to use it.
Page 186 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-11 Engine and Emission Control System Check Refer to the following items for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to complaint analysis.
Page 187 6-2-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Final Confirmation Test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test” in followings. Is there any problem symptom, DTC or abnormal condi- tion? 1.
Page 188 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-13 Customer Problem Inspection Form (Example) NOTE: The above form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 189 5) After completing the check, turn ignition switch off and dis- connect scan tool from data link connector. Diagnostic Trouble Code (DTC) Clearance 1) Connect OBD generic scan tool or SUZUKI scan tool to data link connector in the same manner as when making this con- nection for DTC check.
Page 190 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-15 NOTE: DTC and freeze frame data stored in ECM memory are also cleared in the following cases. Be careful not to clear them before keeping their record. • When power to ECM is cut off (by disconnecting bat- tery cable, removing fuse or disconnecting ECM con- nectors).
Page 191 6-2-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Table DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) P0010 Camshaft position actuator Actual valve timing fails to become close to target 1 driving circuit advance level of each function although advance control cycle function or retarding control function is at work.
Page 192 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-17 DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) P0134 O2 sensor (HO2S) circuit no Output voltage of HO2S–1 fails to go above specifica- 2 driving activity detected (Sensor–1) tion. cycles (or HO2S–1 circuit open or short) P0136 O2 sensor (HO2S) circuit Maximum output voltage of HO2S–2 is lower than speci- 2 driving...
Page 193 6-2-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) P1601 CAN communication error Transmitting or receiving error detected to ECM for 1 driving specified time continuously. cycle P1603 TCM trouble code detected When ECM receives a trouble code from TCM, which 1 driving indicates that some problem occurred in sensor circuits...
Page 194 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-19 Fail-Safe Table When any of the following DTCs is detected, ECM 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 195 6-2-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Visual Inspection Visually check the following parts and systems. INSPECTION ITEM REFERRING SECTION • Engine oil – level, leakage “Engine Oil and Oil Filter” in Section 0B. • Engine coolant – level, leakage “Engine Coolant”...
Page 196 Is it 650 – 750 r/min? Check ignition timing as follows: Go to “Engine Symp- Check ignition control 1) Using SUZUKI scan tool, select “MISC” mode on tom Diagnosis” in this related parts referring SUZUKI scan tool and fix ignition timing to initial section.
Page 197 6-2-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check ignition spark as follows: Go to Step 12. Go to “Ignition Spark 1) Disconnect injector couplers. Test” in Section 6F2. 2) Remove spark plugs and connect them to high-ten- sion cords or ignition coils.
Page 198 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-23 Engine Symptom Diagnosis Perform troubleshooting referring to following table when ECM 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 Faulty spark plug...
Page 199 6-2-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Low oil pressure Improper oil viscosity “Engine Oil and Oil Filter Replacement” in Section 0B. Malfunctioning oil pressure switch “Oil Pressure Switch Inspection” in Sec- tion 8C. Clogged oil strainer “Oil Pan and Oil Pump Strainer”...
Page 200 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-25 Condition Possible Cause Reference Item Overheating Inoperative thermostat “Thermostat Inspection” in Section 6B2. Poor water pump performance “Water Pump Inspection” in Section 6B2. Clogged or leaky radiator “Radiator Inspection” in Section 6B2. Improper engine oil grade “Engine Oil and Oil Filter Replacement”...
Page 201 6-2-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Excessive engine Blown cylinder head gasket “Valves and Cylinder Head Inspection” oil consumption in Section 6A2. Leaky camshaft oil seals “Camshaft, Tappet and Shim” in Sec- tion 6A2. Sticky piston ring “Pistons, Piston rings, Connecting Rods and Cylinders Inspection”...
Page 202 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-27 Condition Possible Cause Reference Item Surge Leaky or loosely connected high-tension cord “High-tension Cords Inspection” in Sec- (Engine power vari- tion 6F2. ation under steady Faulty spark plug (excess carbon deposits, “Spark Plugs Inspection” in Section throttle or cruise.
Page 203 6-2-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Engine has no Faulty spark plug “Spark Plugs Inspection” in Section power 6F2. Faulty ignition coil with ignitor “Ignition Coil Assembly (Including Igni- tor) Inspection” in Section 6F2. Leaks, loose connection or disconnection of “High-tension Cords Inspection”...
Page 204 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-29 Condition Possible Cause Reference Item Improper engine Faulty spark plug “Spark Plugs Inspection” in Section idling or engine fails 6F2. to idle Leaky or disconnected high-tension cord “High-tension Cords Inspection” in Sec- tion 6F2.
Page 205 6-2-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Excessive hydrocar- Faulty spark plug “Spark Plugs Inspection” in Section bon (HC) emission 6F2. or carbon monox- Leaky or disconnected high-tension cord “High-tension Cords Inspection” in Sec- ide (CO) tion 6F2.
Page 206 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-31 Scan Tool Data As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condi- tion, there may be cases where the checked value does not fall within each specified data range.
Page 207 6-2-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) SCAN TOOL DATA VEHICLE CONDITION NORMAL CONDITION/ REFERENCE VALUES ✱ At specified idle speed with no load after warm- 1.0 – 4.0 g/s (MASS AIR FLOW RATE) ing up 0.14 – 0.52 lb/min At 2500 r/min with no load after warming up 4.0 –...
Page 208 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-33 SCAN TOOL DATA VEHICLE CONDITION NORMAL CONDITION/ REFERENCE VALUES RADIATOR FAN Ignition switch ON Engine coolant temp.: (RADIATOR FAN CON- Lower than 92.5°C TROL RELAY) (198.5°F) Engine coolant temp.: 97.5°C (208°F) or higher BLOWER FAN Ignition switch ON Blower fan switch: 2nd speed position or more...
Page 209 6-2-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) LONG FT B1 (LONG TERM FUEL TRIM, %) Long term fuel trim value represents long term corrections to the air/fuel mixture computation. A value of 0 indi- cates no correction, a value greater than 0 means an enrichment correction, and a value less than 0 means an enrichment correction, and a value less than 0 implies an enleanment correction.
Page 210 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-35 IGNITION ADVANCE (IGNITION TIMING ADVANCE FOR NO.1 CYLINDER, °) Ignition timing of NO.1 cylinder is commanded by ECM. The actual ignition timing should be checked by using the timing light. BATTERY VOLTAGE (V) This parameter indicates battery positive voltage inputted from main relay to ECM.
Page 211 6-2-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Inspection of ECM and Its Circuits ECM and its circuits can be checked at ECM wiring couplers by measuring voltage, pulse signal and resistance. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with coupler disconnected from it.
Page 212 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-37 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE E23-1 BLK/YEL Ground for ECM Below 0.3 V Ignition switch turned ON E23-2 BLK/YEL Ground for ECM Below 0.3 V Ignition switch turned ON 10 –...
Page 213 6-2-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 10 – 14 V Ignition switch is turned ON *0 – 2 V Ignition switch is turned to ST (cranking) ↑↓ EGR valve (stepper position.
Page 214 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-39 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 10 – 14 V Ignition switch turned ON *0 – 2 V Ignition switch is turned to ST (cranking) ↑↓ EGR valve (stepper position. E23-34 GRN/BLK motor coil 2) output...
Page 215 6-2-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE *2 – 3 V Ignition switch turned ON (Reference wave- E22-9 Knock sensor signal Engine running at idling with after warm- form No.15 and ing up No.16) Engine running at idling with after warm-...
Page 216 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-41 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE E22-21 – – – – E22-22 – – – – E22-23 – – – – E22-24 – – – – E22-25 – – – –...
Page 217 6-2-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON, stop lamp not 0 – 1 V Electric load signal for lighted up E21-9 GRN/WHT stop lamp Ignition switch turned ON, stop lamp 10 –...
Page 218 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-43 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON, blower fan 10 – 14 V selector selected OFF position or A/C (High input) switch turned OFF or A/C evaporator LT GRN/ A/C request signal (if temp.
Page 219 6-2-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 1. Reference waveform No.1 Heated oxygen sensor–2 heater signal at engine idling Measurement CH1: E22-33 to E23-1 terminal CH2: E23-3 to E23-1 Oscilloscope CH1: 500 mV/DIV, CH2: 10 V/DIV setting TIME: 200 ms/DIV Measurement •...
Page 220 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-45 4. Reference waveform No.4 IAC valve signal Measurement CH1: E23-8 to E23-1 terminal Oscilloscope CH1: 5 V/DIV setting TIME: 4 ms/DIV Measurement • After warmed up to normal operating condition temperature • Engine at specified idle speed 5.
Page 221 6-2-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 7. Reference waveform No.7 Ignition coil No.1 and No.4 signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E23-32 to E23-1 Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 40 ms/DIV Measurement •...
Page 222 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-47 10. Reference waveform No.10 Fuel injector signal at engine racing Measurement CH1: E22-10 to E23-1 terminal CH2: E22-6 to E23-1 Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV setting TIME: 1 ms/DIV Measurement •...
Page 223 6-2-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 13. Reference waveform No.13 No.2 fuel injector signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E22-6 to E23-1 Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV setting TIME: 40 ms/DIV Measurement •...
Page 224 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-49 17. Reference waveform No.17 CMP sensor signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E22-30 to E23-1 Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 20 ms/DIV Measurement •...
Page 225 6-2-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 20. Reference waveform No.20 Manifold absolute pressure sensor signal at engine racing Measurement CH1: E22-15 to E22-28 terminal CH2: E22-34 to E22-28 Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 200 ms/DIV Measurement •...
Page 226 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-51 23. Reference waveform No.23 Ignition pulse (engine revolution) signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E21-12 to E23-1 Oscilloscope CH1: 5 V/DIV, CH2: 5 V/DIV setting TIME: 10 ms/DIV Measurement •...
Page 227 6-2-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Resistance Check 1) Disconnect ECM couplers (1) from ECM with ignition switch OFF. CAUTION: Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Check resistance between each pair of terminals of discon- nected couplers as listed in the following table.
Page 228: Component Location
ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-53 Component Location INFORMATION SENSORS CONTROL DEVICES OTHERS 1. MAF and IAT sensor a: Fuel injector A: ECM 2. TP sensor b: EVAP canister purge valve B: Combination meter 3. Stop lamp switch c: Fuel pump relay C: EVAP canister 4.
Page 229 6-2-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” with Ignition Switch ON (But Engine Stops) Wiring Diagram BLU/BLK BLK/RED PPL/WHT E21-1 BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL...
Page 230 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-55 Step Action MIL Power Supply Check Go to Step 4. “BLU/BLK” wire circuit open or 1) Disconnect ignition switch connector. poor connection. 2) Remove “METER” fuse. 3) Measure resistance between “BLU/BLK” wire terminal of ignition switch connector and “BLU/BLK”...
Page 231 6-2-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table A-2 Malfunction Indicator Lamp Circuit Check-lamp Remains “ON” after Engine Starts Wiring Diagram BLU/BLK BLK/RED PPL/WHT E21-1 BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL...
Page 232 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-57 Step Action MIL Circuit Check Go to Step 3. “PPL/WHT” wire cir- 1) Turn ignition switch to OFF position. cuit shorted to 2) Remove combination meter referring to “Combination ground. Meter Removal and Installation” in Section8. 3) Disconnect connectors from ECM.
Page 233 6-2-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table A-3 ECM Power and Ground Circuit Check-MIL Doesn’t Light with Igni- tion Switch ON and Engine Doesn’t Start Though It Is Cranked Up Wiring Diagram BLU/BLK BLK/RED PPL/WHT E21-1 BLK/WHT E21-28 BLU/BLK E22-1 E23-2...
Page 234 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-59 Step Action Main Relay Circuit Check Go to Step 4. Go to Step 8. 1) Turn ignition switch to OFF position. 2) Check for fuse blow at FI fuse (20 A). (See Fig. 1.) 3) If OK, measure voltage between “E23-15”...
Page 235 6-2-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Main Relay Check “BLU/BLK” wire Replace main 1) Measure resistance between each two terminals of main open circuit or relay. relay. (See Fig. 3). high resistance cir- Between main relay terminals cuit.
Page 236 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-61 DTC P0010 Camshaft Position Actuator Circuit Wiring Diagram BLK/YEL BLK/YEL E22-3 E22-1 BRN/YEL E22-2 E23-2 BLK/YEL E23-1 BLK/YEL [A]: [A]: Oil flow 3. Camshaft timing sprocket 6. Oil pan 1. Oil control valve 4.
Page 237 6-2-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Confirmation Procedure 1) Clear DTC. Refer to “DTC Clearance”. 2) Start engine and keep it at idle for 10 seconds. 3) Check DTC. Refer “DTC Check”. Troubleshooting Step Action Was “Engine and Emission Control System Check” per- Go to Step 2.
Page 238 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-63 Step Action Check wire circuit. Go to Step 9. “BLK/YEL” wire 1) Disconnect connectors from ECM with ignition switch open or high resis- turned OFF. tance circuit. 2) Measure resistance between “E22-3” terminal of ECM con- nector and “BLK/YEL”...
Page 239 2) Start engine and warm up to normal operating tempera- Chain Tensioner ture. Removal and 3) Select menu to DATA LIST. Installation” in 4) Check that the VVT GAP displayed on SUZUKI scan tool is Section 6A1. 0 – 5°. If OK, go to Step Is it OK?
Page 240 • Vehicle speed at 80 km/h (50 mile/h). and recheck. • Gear position at 5th or D range. 2) Check that the VVT GAP displayed on SUZUKI scan tool is 0 – 5°. Is it OK? Oil Control Circuit Visual Inspection Go to Step 6.
Page 241 6-2-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0102 Mass Air Flow Circuit Low Input Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED E21-5 BLK/RED E22-14 E22-32 LT GRN...
Page 242 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-67 Troubleshooting Step Action Was “Engine and Emission Control System Check” per- Go to Step 2. Go to “Engine and formed? Emission Control System Check” in this section. MAF Sensor Check. Intermittent trouble. Go to Step 3.
Page 243 6-2-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check MAF sensor output signal. Substitute a known- Faulty MAF and IAT 1) Connect connectors to MAF sensor and ECM with good ECM and sensor. ignition switch turned OFF. recheck. 2) Check voltage between “E22-14”...
Page 244 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-69 DTC P0103 Mass Air Flow Circuit High Input Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED E21-5 BLK/RED E22-14 E22-32 LT GRN...
Page 245 6-2-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Check” per- Go to Step 2. Go to “Engine and formed? Emission Control System Check” in this section. MAF sensor check. Intermittent trouble. Go to Step 3.
Page 246 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-71 DTC P0112 Intake Air Temperature Sensor Circuit Low Wiring Diagram BLK/RED E22-14 E22-32 LT GRN E22-17 BRN/WHT BRN/WHT E22-28 1. MAF and IAT sensor 3. To other sensor 2. ECM 4. From main relay DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 247 6-2-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. IAT sensor and its circuit check. Go to Step 3.
Page 248 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-73 DTC P0113 Intake Air Temperature Sensor Circuit High Wiring Diagram BLK/RED E22-14 E22-32 LT GRN E22-17 BRN/WHT BRN/WHT E22-28 1. MAF and IAT sensor 3. To other sensor 2. ECM 4. From main relay DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 249 6-2-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action IAT sensor and its circuit check. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch turned OFF. referring to “Intermittent 2) Turn ON ignition switch. and Poor Connection 3) Check intake air temp.
Page 250 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-75 Step Action Check ground circuit. Go to Step 9. Go to Step 8. 1) Connect connectors to ECM. 2) Check for proper connection of IAT sensor connector at “BRN/WHT” wire terminal. 3) Measure resistance between “BRN/WHT” wire terminal of IAT sensor connector and body ground.
Page 251 6-2-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0117 Engine Coolant Temperature Circuit Low Wiring Diagram YEL/GRN E22-16 E22-28 BRN/WHT BRN/WHT 1. ECT sensor 2. ECM 3. To other sensors DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are •...
Page 252 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-77 Step Action Check ECM voltage. Got to Step 6. Go to Step 4. 1) Disconnect connector from ECT sensor with ignition switch turned OFF. 2) Check for proper connection to ECT sensor at “YEL/GRN”...
Page 253 6-2-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0118 Engine Coolant Temperature Circuit High Wiring Diagram YEL/GRN E22-16 E22-28 BRN/WHT BRN/WHT 1. ECT sensor 2. ECM 3. To other sensors DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are •...
Page 254 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-79 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. ECT sensor and its circuit check. Go to Step 3.
Page 255 6-2-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check ECT sensor ground circuit. Go to Step 9. Go to Step 8. 1) Connect connectors to ECM. 2) Check for proper connection of ECT sensor connector at “BRN/WHT” wire terminal. 3) Measure resistance between “BRN/WHT”...
Page 256 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-81 DTC P0121 Throttle Position Sensor Circuit Range/Performance Wiring Diagram E22-8 WHT/GRN WHT/GRN E22-34 E22-28 BRN/WHT BRN/WHT 1. TP sensor 3. To other sensors 2. To MAP sensor 4. ECM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Difference between actual throttle opening (detected from TP...
Page 257 Check TP sensor and its circuit. Go to Step 11. Go to Step 3. 1) Turn OFF ignition switch and connect SUZUKI scan tool to DLC. 2) Turn ON ignition switch and check TP sensor output voltage when throttle valve is at idle position and fully opened.
Page 258 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-83 Step Action Check wire circuit. Go to Step 6. “WHT/GRN” and/or 1) Disconnect connectors from ECM with ignition “GRY” wire shorted switch turned OFF. to ground circuit. 2) Measure resistance between “WHT/GRN” wire ter- If wire are OK, sub- minal of ECM connector and body ground and stitute a known-...
Page 259 6-2-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check MAF sensor and its circuit. Go to Step 12. Repair or replace it. 1) Check MAF sensor and its circuit, referring to “DTC P0102 Mass Air Flow Circuit Low Input” and “DTC P0103 Mass Air Flow Circuit High Input”...
Page 260 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-85 DTC P0122 Throttle Position Sensor Circuit Low Wiring Diagram E22-8 WHT/GRN WHT/GRN E22-34 E22-28 BRN/WHT BRN/WHT 1. TP sensor 2. To MAP sensor 3. To other sensors 4. ECM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are...
Page 261 6-2-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check TP sensor and its circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch turned OFF and then turn ON ignition referring to “Intermittent switch.
Page 262 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-87 Step Action Check TP sensor. Substitute a known-good Replace TP sensor. 1) Check resistance between terminals of TP ECM and recheck. sensor. See Fig. 2. TP sensor resistance Ω Between 1 and 3: 4.0 – 6.0 k Ω...
Page 263 6-2-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0123 Throttle Position Circuit High Input Wiring Diagram E22-8 WHT/GRN WHT/GRN E22-34 E22-28 BRN/WHT BRN/WHT 1. TP sensor 3. To other sensors 2. To MAP sensor 4. ECM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are...
Page 264 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-89 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check TP sensor and its circuit. Go to Step 3.
Page 265 6-2-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check wire circuit. Go to Step 8. “GRY” wire open circuit or 1) Measure resistance between “E22-34” wire high resistance circuit. terminal of ECM connector and “GRY” wire terminal of TP sensor connector with igni- tion switch turned OFF.
Page 266 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-91 DTC P0131 O2 Sensor (HO2S) Circuit Low Voltage (Sensor-1) DTC P0132 O2 Sensor (HO2S) Circuit High Voltage (Sensor-1) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT E23-4 WHT/BLU BLK/WHT E22-11 BRN/WHT BRN/WHT E22-28 1.
Page 267 6-2-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) NOTE: Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE. • Intake air temp.: –7°C, 19.4°F or higher • Engine coolant temp.: 70°C, 158°F or higher •...
Page 268 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-93 Step Action Check HO2S–1 sensor ground. Go to Step 6. “BRN/WHT” wire high 1) With ignition switch turned ON, check volt- resistance circuit. age between “BRN/WHT” wire terminal of Poor “E22-28” terminal HO2S–1 sensor connector and engine connection.
Page 269 6-2-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0133 O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT E23-4 WHT/BLU BLK/WHT E22-11 BRN/WHT BRN/WHT E22-28 1. Relay box 4. Circuit fuse box 7. Heater 10.
Page 270 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-95 1) Perform step 1) to 6) of DTC P0131/P0132 confirmation procedure. 2) Check if DTC and pending DTC exists by using scan tool. If not, check if oxygen sensor monitoring test has completed by using scan tool.
Page 271 6-2-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Maximum HO2S voltage is lower than 0.45 V. • HO2S–1 (2 driving cycle detection logic) • HO2S–1 circuit • Fuel system •...
Page 272 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-97 Step Action Check wire circuit. Go to Step 6. “RED” wire high resis- 1) Disconnect connectors from ECM with igni- tance circuit or open cir- tion switch turned OFF. cuit. 2) Remove ECM from vehicle body and con- Poor “E22-11”...
Page 273 6-2-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0031 HO2S Heater Control Circuit Low (Sensor-1) DTC P0032 HO2S Heater Control Circuit High (Sensor-1) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT E23-4 WHT/BLU BLK/WHT E22-11 BRN/WHT BRN/WHT E22-28 1. Relay box 4.
Page 274 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-99 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check HO2S–1 heater power circuit. Go to Step 3.
Page 275 6-2-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check HO2S–1 heater power circuit. HO2S–1 heater circuit are “BLK/WHT” and “YEL” 1) Disconnect connector from ECM with igni- wire high resistance cir- tion switch turned OFF. Substitute a known-good cuit.
Page 276 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-101 DTC P0136 O2 Sensor (HO2S) Circuit (Sensor-2) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT E23-3 WHT/BLU BLK/WHT BLU/RED E22-33 BRN/WHT BRN/WHT E22-28 1. Relay box 3. Ignition switch 5. “IG COIL” fuse 7.
Page 277 6-2-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Increase vehicle speed to 60 – 80 km/h (37 – 50 mile/h) at 5th gear or D range. 5) Release accelerator pedal and with engine brake applied, keep vehicle coasting (with fuel cut for 4 sec.
Page 278 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-103 Step Action Check wire circuit. Go to Step 7. “BLU” wire high resis- 1) Disconnect connectors from ECM with igni- tance circuit or open cir- tion switch turned OFF. cuit. 2) Remove ECM from vehicle body and con- Poor “E22-33”...
Page 279 6-2-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0037 HO2S Heater Control Circuit Low (Sensor-2) DTC P0038 HO2S Heater Control Circuit High (Sensor-2) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT WHT/BLU BLK/WHT BLU/RED E23-3 E22-33 BRN/WHT BRN/WHT E22-28 1. Relay box 4.
Page 280 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-105 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check HO2S–2 heater power circuit. Go to Step 3.
Page 281 6-2-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check HO2S–2 heater power circuit. HO2S–2 heater circuit are “BLU/RED” wire high 1) Disconnect connectors from ECM with igni- resistance circuit. tion switch turned OFF. Substitute a known-good 2) Connect connector to HO2S–2 with ignition ECM and recheck.
Page 282 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-107 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Is there DTC(s) other than “P0171” and “P0172”? Go to applicable DTC Go to Step 3.
Page 283 6-2-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0300 Random Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected SYSTEM DESCRIPTION ECM measure the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 284 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-109 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Drive vehicle under freeze frame data condition as noted for 1 min. or more. 4) Stop vehicle and check DTC and pending DTC.
Page 285 6-2-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Engine mechanical systems check. Check wire harness Repair or replace. Check engine mechanical parts or system which can and connection of cause engine rough idle or poor performance. ECM ground, ignition –...
Page 286 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-111 DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool. 3) Start engine and run it for 10 sec.
Page 287 6-2-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) [A]: Fig. for Step 3 DTC P0335 Crankshaft Position (CKP) Sensor Circuit Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E22-35 BLK/YEL E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED...
Page 288 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-113 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 3 – 5 sec. 4) Check DTC and pending DTC. Troubleshooting Step Action...
Page 289 6-2-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check CKP Sensor. Go to Step 8. Replace CKP sensor. 1) Remove CKP sensor referring to “CKP Sensor Removal and Installation” in Section 6E2. 2) Remove metal particles on end face of CKP sensor, if any.
Page 290 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-115 [A]: Fig. 1 for Step 3 [B]: Fig. 3 for Step 8 [C]: Fig. 2 for Step 7...
Page 291 6-2-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0340 Camshaft Position Sensor Circuit Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E22-35 BLK/YEL E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED E21-5 BLK/RED E22-10 1.
Page 292 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-117 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 5 sec. 4) Check DTC and pending DTC. Troubleshooting Step Action...
Page 293 6-2-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check CMP Sensor. Go to Step 8. Replace CMP sen- 1) Remove CMP sensor referring to “CMP Sensor sor. Removal and Installation” in Section 6E2. 2) Remove metal particles on end face of CMP sen- sor, if any.
Page 294 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-119 [A]: Fig. 1 for Step 3 [B]: Fig. 3 for Step 8 [C]: Fig. 2 for Step 7...
Page 295 6-2-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected System/Wiring Diagram 1. EGR value 4. Sensed information 7. “IG COIL” fuse 10. Main relay 2. Intake manifold 5.
Page 296 Go to Step 5. EGR valve operation check. Go to Step 4. Go to Step 10. 1) With ignition switch turned OFF, install SUZUKI scan tool. 2) Check EGR system referring to “EGR System Inspection” in Section 6E2. Is it in good condition?
Page 297 6-2-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action MAP sensor check. Intermittent trouble or Repair or replace. 1) Check MAP sensor for performance referring to faulty ECM “MAP Sensor Individual Check” in “DTC P0108” Check for intermittent Diag. Flow Table. referring to “Intermit- Is check result satisfactory? tent and Poor Connec-...
Page 298 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-123 DTC P0420 Catalyst System Efficiency Below Threshold System/Wiring Diagram E22-11 E22-28 BRN/WHT BRN/WHT E22-33 Circuit Description ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by HO2S–2 (2).
Page 299 6-2-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • While vehicle running at constant speed under other than • Exhaust gas leak high load. • Three way catalytic converter malfunction •...
Page 300 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-125 DTC P0443 Evaporative Emission System Purge Control Valve Circuit Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED BLK/RED E21-5 RED/BLK E23-13...
Page 301 6-2-126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting WARNING: In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas hot water. Step Action Was “Engine and Emission Control System...
Page 302 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-127 DTC P0480 Fan 1 (Radiator Cooling Fan) Control Circuit Wiring Diagram BLK/YEL BLK/YEL BLU/BLK E23-15 E22-1 BLK/RED BLK/RED E21-6 BLK/YEL E23-2 BLK/YEL BLK/RED BLK/RED E21-5 E23-1 BLK/YEL E21-4 BLK/YEL BLU/RED 20A 30A E22-16 YEL/GRN E22-28...
Page 303 6-2-128 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check Relay Circuit Go to Step 3. “BLK/RED”...
Page 304 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-129 Step Action Check Relay Circuit Go to Step 8. “BLU” wire in open or high 1) Turn ignition switch to OFF position. resistance circuit. 2) Disconnect connectors from ECM. 3) Remove radiator fan relay from relay box. 4) Check for proper connection to “E21-4”...
Page 305 6-2-130 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0500 Vehicle Speed Sensor (VSS) Malfunction Wiring Diagram BLK/RED E22-19 1. VSS 3. ECM 2. To main relay 4. To TCM (if equipped) DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area •...
Page 306 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-131 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Check vehicle speed signal. Intermittent trouble or Go to Step 3. Is vehicle speed displayed on scan tool in step faulty ECM.
Page 307 6-2-132 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check vehicle speed sensor signal. Go to Step 12. Go to Step 10. 1) Remove VSS referring to “Vehicle Speed Sensor (VSS)” in Section 7A2 or “Output Shaft Speed Sensor (VSS)” in Section 7B1. 2) Remove metal particles on end face of VSS, if any.
Page 308 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-133 [A]: Fig. 1 for Step 5 [B]: Fig. 2 for Step 9...
Page 309 6-2-134 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0505 Idle Air Control System System/Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED BLK/RED E21-5 E23-8 BLK/RED GRN/YEL 1.
Page 310 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-135 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Idle Speed Check Go to Step 3. Go to Step 4.
Page 311 6-2-136 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1500 Starter Signal Circuit Malfunction Wiring Diagram WHT/BLU BLK/YEL BLK/YEL E22-35 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLK/RED E22-35 BLK/YEL [A]: M/T Vehicle 1. ECM 3. Ignition switch 5. Instrument panel harness/engine harness connector [B]: A/T Vehicle 2.
Page 312 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-137 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Signal circuit check Poor “E22-35” connection “BLK/YEL” wire or “BLK/ 1) Disconnect connectors from ECM with igni- or intermittent trouble.
Page 313 6-2-138 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0107 Manifold Absolute Pressure Low Input Wiring Diagram E22-8 WHT/GRN WHT/GRN LT GRN/RED E22-15 E23-2 BLK/YEL E23-1 BLK/YEL E22-28 BRN/WHT BRN/WHT 1. Manifold absolute pressure sensor 2. To TP sensor 3. To other sensors 4.
Page 314 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-139 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Check MAP sensor and its circuit. Go to Step 3. Intermittent trouble.
Page 315 6-2-140 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check MAP sensor signal circuit. Go to Step 11. Go to Step 9. 1) Turn ON ignition switch. 2) Measure voltage between “LT GRN/RED” wire terminal in MAP sensor harness con- nector and engine ground.
Page 316 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-141 DTC P0108 Manifold Absolute Pressure High Input Wiring Diagram E22-8 WHT/GRN WHT/GRN LT GRN/RED E22-15 E23-2 BLK/YEL E23-1 BLK/YEL E22-28 BRN/WHT BRN/WHT 1. Manifold absolute pressure sensor 3. To other sensors 2. To TP sensor 4.
Page 317 6-2-142 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Check MAP sensor and its circuit. Go to Step 3. Intermittent trouble.
Page 318 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-143 Step Action Check MAP sensor signal circuit. Go to Step 8. “LT GRN/RED” wire 1) Disconnect connectors from ECM with igni- shorted to power supply tion switch turn OFF. or other circuit. 2) Turn ON ignition switch.
Page 319 6-2-144 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1510 ECM Back-up Power Supply Malfunction Wiring Diagram WHT/BLU E21-16 1. ECM 2. “DOME RADIO” fuse 3. Relay box Circuit Description Battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ECM, etc.
Page 320 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-145 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Battery voltage supply circuit check Poor “E21-16” connection “DOME RADIO”...
Page 321 6-2-146 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1601 Can Communication Error Wiring Diagram E13-17 E21-8 E13-7 E21-7 1. ECM 2. TCM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Transmission or reception error of communication data •...
Page 322 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-147 Step Action Circuit Check Go to Step 4. “WHT” wire circuit open or 1) Turn ignition switch to OFF position. high resistance. 2) Disconnect connectors from ECM and TCM. 3) Check for proper connection to “E21-7” ter- minal of ECM connector and “E13-7”...
Page 323 6-2-148 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1603 TCM Trouble Code Detected DTC Detecting Condition When ECM receives a trouble code from TCM, which indicates that some problem occurred in sensor circuits and its calculated values used for operations such as idle speed control, engine power control, and so on by TCM, ECM sets DTC P1603.
Page 324 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-149 DTC P2227 Barometric Pressure Circuit Range/Performance DTC P2228 Barometric Pressure Circuit Low DTC P2229 Barometric Pressure Circuit High System Description Barometric pressure sensor is installed in ECM (PCM). DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC P2227:...
Page 325 6-2-150 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Is DTC P2227 set? Go to Step 3. Substitute a known-good ECM and recheck.
Page 326 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-151 Troubleshooting Step Action Check each injector for operating sound at Fuel injector circuit is in Go to Step 2. engine cranking using sound scope. good condition. Do all 4 injector make operating sound? Check fuel injector resistance.
Page 327 6-2-152 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-2 Fuel Pump and Its Circuit Check BLU/BLK BLK/WHT BLK/WHT E21-28 BLK/WHT E23-14 WHT/BLU BLK/YEL E21-1 BLK/RED E23-2 BLK/YEL 60A 20A E23-1 BLK/YEL BLK/RED E21-6 BLK/YEL BLK/RED BLK/RED E21-5 BLU/BLK E23-15 BLK/YEL 1.
Page 328 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-153 Step Action Check fuel pump relay. Go to Step 5. Faulty relay. 1) Check fuel pump relay, referring to “Main Relay, Fuel Pump Relay and Radiator Fan Relay Inspection” in Section 6E2. Is relay in good condition? Check fuel pump relay drive signal.
Page 329 6-2-154 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-3 Fuel Pressure Check 1. Injector 3. Fuel filter and fuel pump B: Hose 2. Delivery pipe A: Gauge C: 3-way joint Troubleshooting NOTE: Before using the following 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 con- dition.
Page 330 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-155 Step Action Fuel Line Check Faulty fuel pressure reg- Repair or replace. 1) Check fuel pipe, fuel hose and joint for damage or ulator. deform. Are they in good condition? Was fuel pressure higher than specification in Step 1? Go to Step 6. Go to Step 7.
Page 331 6-2-156 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-4 Idle Air Control System Check BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED BLK/RED E21-5 E23-8 BLK/RED GRN/YEL 1.
Page 332 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-157 Step Action Check A/C (input) signal circuit referring to Step Go to Step 6. Repair or replace A/C sig- 1 of “Table B-5 A/C Signal Circuit Check”, if nal circuit or A/C system. equipped.
Page 333 6-2-158 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-5 A/C Signal Circuits Check (Vehicle with A/C) PNK/BLU E21-13 BLU/YEL BLU/BLK BLK/WHT BLK/WHT BLK/WHT GRN/ORN BLU/YEL LT GRN/RED E21-30 GRN/ORN YEL/GRN E21-16 GRN/RED E21-15 BRN/WHT E22-28 E23-11 BLU/WHT BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK...
Page 334 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-159 Troubleshooting Step Action Check Evaporator Temp. Sensor Go to Step 2. Faulty A/C evaporator 1) Disconnect connectors from ECM with igni- temperature sensor or its tion switch turned OFF. circuit. 2) Check for proper connection to “E21-15” and “E22-28”...
Page 335 6-2-160 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check A/C Compressor Relay Circuit Go to Step 9. Go to Step 10. 1) Check voltage between “E23-11” wire termi- nal of ECM connector and vehicle body ground under the following condition. While engine running and A/C switch OFF: 10 –...
Page 336 Go to Step 2. Go to Step 3. Check electric load signal circuit. Electric load signal circuit “PNK/BLU” and/or 1) Connect SUZUKI scan tool to DLC with ignition is in good condition. “RED/YEL” circuit open switch OFF. or short, electric load 2) Start engine and select “DATA LIST”...
Page 337 6-2-162 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-7 Radiator Fan Control System Check BLK/YEL BLK/YEL BLU/BLK E23-15 E22-1 BLK/RED BLK/RED E21-6 BLK/YEL E23-2 BLK/YEL BLK/RED BLK/RED E21-5 E23-1 BLK/YEL E21-4 BLK/YEL BLU/RED 20A 30A E22-16 YEL/GRN E22-28 BRN/WHT 1.
Page 338 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-163 Step Action Check Radiator Fan Relay Go to Step 6. Replace radiator fan relay. 1) Check radiator fan relay referring to “Main Relay, Fuel Pump Relay and Radiator Fan Relay Inspection” in Section 6E2. Is it in good condition? Radiator Fan Control Circuit Check Go to Step 7.
Page 339 6-2-164 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Special Tool Tech 2 kit (SUZUKI scan tool) (See NOTE “C”.) NOTE: “C”: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 340 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 341 6A2-2 ENGINE MECHANICAL (M13 ENGINE) Timing Chain and Chain Tensioner Pistons, Piston Rings, Connecting Rods Components..........6A2-44 and Cylinders Removal and Installation ... 6A2-68 Timing Chain and Chain Tensioner Pistons, Piston Rings, Connecting Rods Removal and Installation......6A2-44 and Cylinders Disassembly and Timing Chain and Timing Chain Assembly ..........
Page 342 ENGINE MECHANICAL (M13 ENGINE) 6A2-3 General Description Engine Construction Description The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 343 6A2-4 ENGINE MECHANICAL (M13 ENGINE) Engine Lubrication Description The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into 2 paths in cylinder block. In one path, oil reaches the crankshaft journal bearings.
Page 344 ENGINE MECHANICAL (M13 ENGINE) 6A2-5 Variable Valve Timing (VVT) System Description System description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power gen- eration and lower fuel consumption can be attained in the whole engine speed range from low to high.
Page 345 6A2-6 ENGINE MECHANICAL (M13 ENGINE) Oil control valve The oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ECM. By this operation, the intake valve timing is varied continuously.
Page 346 ENGINE MECHANICAL (M13 ENGINE) 6A2-7 Timing retarding When the duty ratio of the signal output from the ECM is light, the spool valve of the oil control valve moves to the right (head for the coil). By this spool valve movement, the pressurized oil is led into the chambers for timing retarding and the oil in the chambers for timing advancing is drained.
Page 347: Compression Check
6A2-8 ENGINE MECHANICAL (M13 ENGINE) Diagnosis Diagnosis Table Refer to “Engine and Emission Control System Check” in Section 6-2. Compression Check Check compression pressure on all 4 cylinders as follows: 1) Warm up engine to normal operating temperature. 2) Stop engine after warming up. NOTE: After warming up engine, place transaxle gear shift lever in “Neutral”...
Page 348 ENGINE MECHANICAL (M13 ENGINE) 6A2-9 NOTE: • For measuring compression pressure, crank engine at least 250 rpm by using fully charged battery. • If measured compression pressure is lower than limit value, check installation condition of special tool. If it is properly installed, possibility is compression pres- sure leakage from where piston ring or valve contact.
Page 349 6A2-10 ENGINE MECHANICAL (M13 ENGINE) 3) Remove air cleaner case (1) and resonator (2). 4) Remove PCV hose (1) from PCV valve (2). 5) Connect special tool (Vacuum gauge) to PCV hose (1). Special tool (A): 09915-67311 6) Blind PCV valve (2) using tape (3) or the like. 7) Install air cleaner case and resonator.
Page 350: Oil Pressure Check
ENGINE MECHANICAL (M13 ENGINE) 6A2-11 Oil Pressure Check NOTE: Prior to checking oil pressure, check the following items. • Oil level in oil pan If oil level is low, add oil up to Full level mark (hole) on oil level gauge. •...
Page 351 6A2-12 ENGINE MECHANICAL (M13 ENGINE) 6) After warming up, raise engine speed to 4,000 rpm and mea- sure oil pressure. Oil pressure specification More than 270 kPa (2.7 kg/cm , 39.8 psi) at 4,000 rpm 7) Stop engine and remove oil pressure gauge and attachment. 8) Before reinstalling oil pressure switch (2), be sure to wrap its screw threads with sealing tape (1) and tighten switch to specified torque.
Page 352 ENGINE MECHANICAL (M13 ENGINE) 6A2-13 Valve Lash (Clearance) Inspection 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation” in this section. 3) Remove right side engine under cover, if necessary. 4) Using 17 mm wrench, turn crankshaft pulley (1) clockwise until cam lobes (2) become perpendicular to shim faces (3) at valves “1”...
Page 353 6A2-14 ENGINE MECHANICAL (M13 ENGINE) b) Check housing No. and select special tool corresponding to housing No. referring to the following table. Special tool selection table No. on camshaft Embossed mark housing on special tool I3, I4, I5 IN345 E3, E4, E5 EX345 A: I: Intake side or E: Exhaust side B: Position from timing chain side...
Page 354 ENGINE MECHANICAL (M13 ENGINE) 6A2-15 5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by cal- culating the thickness of new shim with the following formula and table. Intake side: A = B + C – 0.200 mm (0.0078 in.) Exhaust side: A = B + C –...
Page 355 6A2-16 ENGINE MECHANICAL (M13 ENGINE) 8) Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4) and remove special tool. Special tool (A): 09916-67020 or 09916-67021 1. Tappet 2. Camshaft 9) Install camshaft housing (1) and tighten bolts to specified torque.
Page 356 ENGINE MECHANICAL (M13 ENGINE) 6A2-17 Air Cleaner Element Inspection and Cleaning • Check air cleaner element for dirt. Replace excessively dirty element. • Blow off dust by compressed air from air outlet side of ele- ment. Knock Sensor Removal and Installation Refer to “Knock Sensor Removal and Installation”...
Page 357 6A2-18 ENGINE MECHANICAL (M13 ENGINE) 9) Remove oil level gauge (1). 10) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head cover. 11) Remove cylinder head cover mounting bolts in such order as indicated in figure.
Page 358 ENGINE MECHANICAL (M13 ENGINE) 6A2-19 • Timing chain cover (1) and cylinder head (2) mating surface as shown. “A”: Sealant 99000-31250 3) Install cylinder head cover to cylinder head. NOTE: When installing cylinder head cover, use care so that cyl- inder head cover gasket or spark plug hole gaskets will not get out of place or fall off.
Page 359 6A2-20 ENGINE MECHANICAL (M13 ENGINE) Throttle Body and Intake Manifold Components 2.5 N·m (0.25 kg-m) 25 N·m (2.5 kg-m) 5 N·m (0.5 kg-m) 25 N·m (2.5 kg-m) 1. Intake manifold 9. Gasket 17. Throttle body mounting bolt 25. To brake booster 2.
Page 360 ENGINE MECHANICAL (M13 ENGINE) 6A2-21 Throttle Body Removal and Installation Removal 1) Relieve fuel pressure referring to “Fuel pressure Relief Pro- cedure” in Section 6-2. 2) Disconnect negative cable at battery. 3) Drain coolant by loosening drain plug (1). WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot.
Page 361 6A2-22 ENGINE MECHANICAL (M13 ENGINE) Intake Manifold Removal and Installation Removal 1) Remove throttle body referring to “Throttle Body Removal and Installation” in this section. 2) Disconnect MAP sensor coupler (1). 3) Disconnect the following hoses: • Brake booster hose (2) from cylinder head cover •...
Page 362 ENGINE MECHANICAL (M13 ENGINE) 6A2-23 Exhaust Manifold Components 45 N·m (4.5 kg-m) 50 N·m (5.0 kg-m) 50 N·m (5.0 kg-m) 43 N·m (4.3 kg-m) 45 N·m (4.5 kg-m) 50 N·m (5.0 kg-m) 50 N·m (5.0 kg-m) 1. Exhaust manifold gasket 6.
Page 363 6A2-24 ENGINE MECHANICAL (M13 ENGINE) Exhaust Manifold Removal and Installation WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. Removal 1) Disconnect negative cable at battery. 2) Remove front bumper with front grille referring to “Front Bumper and Rear Bumper”...
Page 364 ENGINE MECHANICAL (M13 ENGINE) 6A2-25 Installation 1) Install new gasket to cylinder head. 2,(a) 1,(a) Then install exhaust manifold. Tighten manifold bolts (1) and nuts (2) to specified torque. Tightening torque Exhaust manifold bolt and nut (a): 50 N·m (5.0 kg-m, 36.5 lb-ft) NOTE: The figure on the left varies with specification.
Page 365 6A2-26 ENGINE MECHANICAL (M13 ENGINE) Oil Pan and Oil Pump Strainer Components [A]: Sealant application amount 3. O-ring 8. Oil pan bolt and nut “a”: 3 mm (0.12 in.) 4. Gasket Tightening torque “b”: 2 mm (0.08 in.) 5. Oil pan drain plug bolt Do not reuse.
Page 366 ENGINE MECHANICAL (M13 ENGINE) 6A2-27 6) Remove oil pan and then oil pump strainer (1) from cylinder block. Installation 1) Clean oil pump strainer screen (1). 2) Clean sealing surface on oil pan and cylinder block. Remove oil, old sealant and dust from sealing surface. 3) Apply sealant continuously to oil pan mating surface as shown in figure.
Page 367 6A2-28 ENGINE MECHANICAL (M13 ENGINE) 4) Install new O-rings (2) in the position as shown in figure and install oil pump strainer (1). Tighten strainer bolt (3) first and then bracket bolt (4) to specified torque. Tightening torque Oil pump strainer bolt (a): 11 N·m (1.1 kg-m, 8.0 lb-ft) Oil pump strainer bracket bolt (b): 11 N·m (1.1 kg-m, 8.0 lb-ft) 5) After fitting oil pan to cylinder block, run in securing bolts and...
Page 368 ENGINE MECHANICAL (M13 ENGINE) 6A2-29 Engine Mountings Components 55 N·m (5.5 kg-m) 65 N·m (6.5 kg-m) 25 N·m (2.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m)
Page 369 6A2-30 ENGINE MECHANICAL (M13 ENGINE) Unit Repair Overhaul Engine Assembly Removal and Installation Removal 1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro- cedure” in Section 6-2. 2) Disconnect negative and positive cables at battery. 3) Remove engine hood after disconnecting windshield washer hose.
Page 370 ENGINE MECHANICAL (M13 ENGINE) 6A2-31 14) Disconnect the following electric lead wires: • TP sensor (1) • MAP sensor (2) • ECT sensor (3) • EGR valve (4) • CMP sensor (5) • IAC valve (6) • Ignition coil assembly (7) •...
Page 371 6A2-32 ENGINE MECHANICAL (M13 ENGINE) 21) Install lifting device. 22) Remove engine rear mounting bolts (1), engine left mounting bracket nuts (2) and engine right mounting nuts (3). 23) Before removing engine with transaxle from body, recheck to make sure all hoses, electric wires and cables are discon- nected from engine and transaxle.
Page 372 ENGINE MECHANICAL (M13 ENGINE) 6A2-33 3) Lift engine with transaxle into engine compartment, but do not remove lifting device. 4) Install engine rear mounting bolts (1), engine left mounting bracket nuts (2) and engine right mounting nuts (3). 1, (a) Tighten these bolts and nuts to specified torque.
Page 373 6A2-34 ENGINE MECHANICAL (M13 ENGINE) Timing Chain Cover Components [A]: Sealant application amount 8. Oil pan mounting bolt and nut 18. Oil control valve “a”: 3 mm (0.12 in.) 9. Cylinder head cover 19. Oil control valve mounting nut : Apply sealant 99000-31250 to the sealing point for timing chain cover mating surface and cylinder head gasket sealing point referring to...
Page 374 ENGINE MECHANICAL (M13 ENGINE) 6A2-35 Timing Chain Cover Removal and Installation Removal CAUTION: • Keep working table, tools and hands clean while over- hauling. • Use special care to handle aluminum parts so as not to damage them. • Do not expose removed parts to dust. Keep them always clean.
Page 375 6A2-36 ENGINE MECHANICAL (M13 ENGINE) 8) Remove water outlet cap (1) from timing chain cover (2). 9) Remove timing chain cover. 10) Remove oil gallery pipe No.1 (1) and oil control valve (2) from timing chain cover (3). Installation 1) Clean sealing surface on timing chain cover, cylinder block and cylinder head.
Page 376 ENGINE MECHANICAL (M13 ENGINE) 6A2-37 5) Apply sealant “A” to mating surface of cylinder and cylinder head and “B” to mating surface of timing chain cover as shown in figure. “A”: Sealant 99000-31140 “B”: Sealant 99000-31250 Sealant amount for timing chain cover Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.) 6) Apply engine oil to oil seal lip, then install timing chain cover...
Page 377 6A2-38 ENGINE MECHANICAL (M13 ENGINE) 11) Install water pump pulley. 12) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation” in this section. 13) Install oil pan referring to “Oil Pan and Oil Pump Strainer Removal and Installation” in this section. 14) Install crankshaft pulley (1).
Page 378 ENGINE MECHANICAL (M13 ENGINE) 6A2-39 Oil control valve Inspect strainer (1) and mating surface (2) of oil control valve. Clean oil control valve. Oil gallery pipe Inspect oil gallery pipes No.1 (1), No.2 (2) and No.3 (3). Replace if crack, deformation or clog exists. Oil Pump Components...
Page 379 6A2-40 ENGINE MECHANICAL (M13 ENGINE) [A]: Sealant application amount 4. Inner rotor 10. Circlip “a”: 3 mm (0.12 in.) 5. Timing chain cover Tightening torque : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head. : Apply sealant 99000-31250 to mating surface of timing chain cover referring to the figure of Step 4) of “Installation”...
Page 380 ENGINE MECHANICAL (M13 ENGINE) 6A2-41 3) Remove relief valve (1), spring (2) and retainer (3) by remov- ing circlip (4). Assembly 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case and plate.
Page 381 6A2-42 ENGINE MECHANICAL (M13 ENGINE) Oil Pump Inspection Oil seal • Check oil seal lip for fault or other damage. Replace as nec- essary. NOTE: When installing new oil seal (1), press-fit it to oil pump case (2) by using special tool as shown in the figure. Special tool (A): 09913-75810 Drive in dimension...
Page 382 ENGINE MECHANICAL (M13 ENGINE) 6A2-43 Radial clearance Check radial clearance between outer rotor (1) and case (2), using thickness gauge (3). If clearance exceeds its limit, replace oil pump assembly. Limit on radial clearance between outer rotor and case for oil pump : 0.310 mm (0.0122 in.) Side clearance Using straight edge (1) and thickness gauge (2), measure side...
Page 383 6A2-44 ENGINE MECHANICAL (M13 ENGINE) Timing Chain and Chain Tensioner Components 1. Crankshaft timing sprocket 4. Timing chain tensioner 7. Timing chain tensioner bolt : Apply engine oil to sliding surface. 2. Timing chain 5. Timing chain tensioner adjuster assembly 8.
Page 384 ENGINE MECHANICAL (M13 ENGINE) 6A2-45 2) By turing crankshaft, align both intake and exhaust camshaft timing sprocket marks (1) with notches (2) of cylinder head respectively and align crank shaft sprocket key (3) with notch of cylinder block (4). 3) Remove timing chain tensioner adjuster assembly (5). 4) Remove timing chain tensioner (6).
Page 385 6A2-46 ENGINE MECHANICAL (M13 ENGINE) 3) Install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft timing sprocket as shown in figure. 4) Fit crankshaft timing sprocket to timing chain by aligning gold plate (3) of timing chain and circle mark (4) on crankshaft timing sprocket.
Page 386 ENGINE MECHANICAL (M13 ENGINE) 6A2-47 7) Check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with marking of timing chain (2) and match mark on crankshaft timing sprocket (3) are in with marking of timing chain (4). [A]: View A “a”: Approx.
Page 387 6A2-48 ENGINE MECHANICAL (M13 ENGINE) 10) Apply engine oil to timing chain and then turn crankshaft clockwise by 2 revolutions and check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is in match with notch (4) on cylinder block as shown in figure.
Page 388 ENGINE MECHANICAL (M13 ENGINE) 6A2-49 Timing chain • Check timing chain for wear or damage. Timing chain tensioner adjuster • Check that tooth surface (1) are free from damage. Timing chain No.1 guide • Check timing chain No.1 guide (1) for wear or damage.
Page 389 6A2-50 ENGINE MECHANICAL (M13 ENGINE) Camshaft, Tappet and Shim Components 1. Intake camshaft 5. Shim 9. Upper camshaft bearing : Shim No. on it faces tappet side. : Install a bearing half with some holes to upper side of intake camshaft No.1 bearing. 2.
Page 390 ENGINE MECHANICAL (M13 ENGINE) 6A2-51 3) With hexagonal section (1) of intake camshaft (2) held sta- tionary with spanner or the like, loosen mounting bolt of intake cam timing sprocket assembly (3) and remove it. “a” CAUTION: Never attempt to loosen mounting bolt with intake cam timing sprocket assembly held stationary.
Page 391 6A2-52 ENGINE MECHANICAL (M13 ENGINE) Installation 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to cylinder head. NOTE: When installing shim, make sure to direct shim No. side toward tappet. 2) Install camshaft bearing (1) to cylinder head. CAUTION: Do not apply engine oil to camshaft bearing back.
Page 392 ENGINE MECHANICAL (M13 ENGINE) 6A2-53 6) Check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install hous- ings as indicated by these marks. A. I: Intake side or E: Exhaust side B.
Page 393 6A2-54 ENGINE MECHANICAL (M13 ENGINE) Cam wear Using a micrometer, measure cam height “a”. If measured height underruns its limit, replace camshaft. Cam height “a” of camshaft Standard Limit Intake cam 44.929 – 45.089 mm 44.80 mm (1.769 – 1.775 in.) (1.764 in.) Exhaust cam 44.399 –...
Page 394 ENGINE MECHANICAL (M13 ENGINE) 6A2-55 7) Remove housing, and using scale (2) on gaging plastic (1) envelop, measure gaging plastic width at its widest point. Camshaft journal clearance Standard Limit Intake side 0.020 – 0.072 mm 0.10 mm No.1 housing (0.0008 –...
Page 395 6A2-56 ENGINE MECHANICAL (M13 ENGINE) Measure cylinder head bore and tappet outside diameter to deter- mine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head. Cylinder head to tappet clearance Standard: 0.025 – 0.066 mm (0.0010 – 0.0025 in.) Limit: 0.15 mm (0.0059 in.) Tappet outside diameter [A] Standard: 30.959 –...
Page 396 ENGINE MECHANICAL (M13 ENGINE) 6A2-57 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2. Valve spring retainer 8. Valve guide Tightening torque 3.
Page 397 6A2-58 ENGINE MECHANICAL (M13 ENGINE) Installation 1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface. 2) Install knock pins (1) to cylinder block. 3) Install new cylinder head gasket (2) to cylinder block. “TOP”...
Page 398 ENGINE MECHANICAL (M13 ENGINE) 6A2-59 NOTE: If they are reused, check thread diameters of cylinder head bolt (1) for deformation according to the follows and “A” “B” replace them with new ones if thread diameter difference exceeds limit. “a” Measure each thread diameter of cylinder head bolt (1) at “b”...
Page 399 6A2-60 ENGINE MECHANICAL (M13 ENGINE) Valves and Cylinder Head Disassembly and Assembly Disassembly 1) For ease in servicing cylinder head, remove intake manifold, injectors and exhaust manifold from cylinder head. 2) Using special tools (valve lifter), compress valve spring and then remove valve cotters (1) by using special tool (forceps).
Page 400 ENGINE MECHANICAL (M13 ENGINE) 6A2-61 Assembly 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as to remove burrs and make it truly round. Special tool (A): 09916-34542 (B): 09916-37320 2) Install valve guide to cylinder head. Heat cylinder head uniformly to a temperature of 80 to 100 °C (176 to 212 °F) so that head will not be distorted, and drive new valve guide into hole with special tools.
Page 401 6A2-62 ENGINE MECHANICAL (M13 ENGINE) 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
Page 402 ENGINE MECHANICAL (M13 ENGINE) 6A2-63 9) Install intake manifold referring to “Intake Manifold Removal and Installation” in this section. 10) Install fuel injectors referring to “Fuel Injector Removal and Installation” in Section 6E2. 11) Install exhaust manifold referring to “Exhaust Manifold Removal and Installation”...
Page 403 6A2-64 ENGINE MECHANICAL (M13 ENGINE) • Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not too much to grind off its chamber. When it is worn out too much that its chamber is gone, replace valve.
Page 404 ENGINE MECHANICAL (M13 ENGINE) 6A2-65 Valve seat repair A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 405 6A2-66 ENGINE MECHANICAL (M13 ENGINE) • Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using a straightedge and thickness gauge, check flatness of gasketed surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place abrasive paper on and...
Page 406 ENGINE MECHANICAL (M13 ENGINE) 6A2-67 Spring squareness Use a square and surface plate to check each spring for square- ness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit given below must be replaced.
Page 407 6A2-68 ENGINE MECHANICAL (M13 ENGINE) Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation” in this section. 2) Remove cylinder head referring to “Valves and Cylinder Head Removal and Installation”.
Page 408 ENGINE MECHANICAL (M13 ENGINE) 6A2-69 4) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft. Using a hammer handle, tap piston head to install piston into bore.
Page 409 6A2-70 ENGINE MECHANICAL (M13 ENGINE) b) Force piston pin out. Assembly 1) Decarbonize piston head and ring grooves using a suitable tool. 2) Install piston pin to piston (1) and connecting rod (2): a) After applying engine oil to piston pin and piston pin holes in piston and connecting rod.
Page 410 ENGINE MECHANICAL (M13 ENGINE) 6A2-71 Pistons, Piston Rings, Connecting Rods and Cylinders Inspection Cylinder Visual inspection Inspect cylinder walls for scratches, roughness or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched or ridged, rebore cylinder and use oversize piston. Cylinder bore diameter, taper and out-of-round Using a cylinder gauge (1), measure cylinder bore in thrust and axial directions at two positions (“a”...
Page 411 6A2-72 ENGINE MECHANICAL (M13 ENGINE) Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance Standard: 0.032 –...
Page 412 ENGINE MECHANICAL (M13 ENGINE) 6A2-73 Piston pin clearance Check piston pin clearance in small end and piston. Replace con- necting rod and/or piston if its small end is badly worn or dam- aged or if measured clearance exceeds limit. Piston pin clearance in connecting rod small end Standard: 0.003 –...
Page 413 6A2-74 ENGINE MECHANICAL (M13 ENGINE) Connecting rod Big-end side clearance Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod. Big-end side clearance Standard: 0.25 –...
Page 414 ENGINE MECHANICAL (M13 ENGINE) 6A2-75 Crank pin and connecting rod bearings Crank pin diameter Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged or out-of round or taper is out of limit, replace crankshaft or regrind crank pin to undersize and use undersize bearing.
Page 415 6A2-76 ENGINE MECHANICAL (M13 ENGINE) 4) Install rod bearing cap (1) to connecting rod. When installing cap, be sure to point arrow mark (2) on cap to crankshaft pulley side, as shown in figure. After applying engine oil to rod bolts and tighten cap nuts (3) gradually as follows.
Page 416 ENGINE MECHANICAL (M13 ENGINE) 6A2-77 1) Check stamped numbers on connecting rod and its cap as shown. Three kinds of numbers (“1”, “2” and “3”) represent the fol- lowing connecting rod big end inside diameters. For example, stamped number “1” indicates that correspond- ing connecting rod big end inside diameter is 45.0000 –...
Page 417 6A2-78 ENGINE MECHANICAL (M13 ENGINE) 3) There are five kinds of standard bearings differing in thick- ness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing.
Page 418 ENGINE MECHANICAL (M13 ENGINE) 6A2-79 Main Bearings, Crankshaft and Cylinder Block Components...
Page 419 6A2-80 ENGINE MECHANICAL (M13 ENGINE) [A]: Sealant application amount 5. Main bearing 15. Flywheel mounting bolt : Upper half of bearing has an oil groove Tightening torque 6. Sensor plate 16. Rear oil seal housing bolt Do not reuse. 7. Crankshaft timing sprocket key 17.
Page 420 ENGINE MECHANICAL (M13 ENGINE) 6A2-81 5) Loosen main bearing cap No.1 and No.2 bolts in such order as indicated in figure and remove them. 6) Remove crankshaft from cylinder block. Installation CAUTION: • Use new bearing cap No.1 bolts. They are deformed once they are used because they are plastic deforma- tion tightening bolts.
Page 421 6A2-82 ENGINE MECHANICAL (M13 ENGINE) 3) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs. 4) Confirm that dowel pins (3) are installed to intake side of each journal. 5) Install crankshaft to cylinder block.
Page 422 ENGINE MECHANICAL (M13 ENGINE) 6A2-83 8) Apply sealant to mating surface of rear oil seal housing (1). “A”: Sealant 99000-31250 Sealant amount for rear oil seal housing Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.) 9) Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool.
Page 423 6A2-84 ENGINE MECHANICAL (M13 ENGINE) Main Bearings, Crankshaft and Cylinder Block Inspection Main bearing cap No.1 bolt Measure each thread diameter main bearing cap No.1 bolts (1) at “A” “B” “A” on 60mm(2.36in.) from seat side of flange bolt and “B” on 90mm(3.54in.) from seat side of flange bolt by using a micrometer (2).
Page 424 ENGINE MECHANICAL (M13 ENGINE) 6A2-85 2) Tighten main bearing cap No.1 bolts (1) – (10) and main bearing cap No.2 bolts (11) – (20) gradually as follows. a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft) according to numerical order in figure.
Page 425 6A2-86 ENGINE MECHANICAL (M13 ENGINE) • Upper half of bearing (1) has an oil groove (2) as shown in figure. Install this half with oil groove to cylinder block. • Lower half of bearing does not have an oil groove. Visual inspection Check bearings for pitting, scratches, wear or damage.
Page 426 ENGINE MECHANICAL (M13 ENGINE) 6A2-87 5) Remove bearing caps and using scale (1) on gaging plastic (2) envelop, measure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
Page 427 6A2-88 ENGINE MECHANICAL (M13 ENGINE) 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) or numbers (“1”, “2” and “3”) represent the following cap bore diameters. Stamped alphabets or numbers on cylinder block represent bearing cap bore diameter marked with an arrow in figure respectively.
Page 428 ENGINE MECHANICAL (M13 ENGINE) 6A2-89 Specification of new standard crankshaft main bearing size Number stamped on crank web No.2 (Journal diameter) Alphabet A (1) Pink Purple Brown stamped on B (2) Purple Brown Green cylinder block C (3) Brown Green Black (Cap bore dia.) New standard bearing to be...
Page 429 6A2-90 ENGINE MECHANICAL (M13 ENGINE) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicu- lar to each other in order to check for out-of-round. 3) Using journal diameter measured above and alphabets stamped on cylinder block, select an undersize bearing by referring to table given below.
Page 430 ENGINE MECHANICAL (M13 ENGINE) 6A2-91 Sensor plate Check sensor plate for crack or damage. If malcondition is found, replace it. Cylinder block Distortion of gasketed surface Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct it. Cylinder block flatness Limit: 0.03 mm (0.0012 in.) Honing or reboring cylinders...
Page 431 Required Service Material Recommended SUZUKI product Material (Part Number) Sealant SUZUKI BOND NO. 1207F • To apply to mating surfaces of cylinder block and oil (99000-31250) pan. • To apply to mating surfaces of cylinder block and timing chain cover.
Page 432 ENGINE MECHANICAL (M13 ENGINE) 6A2-93 Tightening torque Fastening part N•m kg-m lb-ft Cylinder head bolt for M10 Tighten 20 N·m (2.0 kg-m, 14.5 lb-ft), 40 N·m (4.0 kg-m, 29.0 lb-ft), 60° and 60° by the specified procedure. Bearing cap nut Tighten 15 N·m (1.5 kg-m, 11.0 lb-ft), 45°...
Page 433 6A2-94 ENGINE MECHANICAL (M13 ENGINE) Special Tool 09911-97720 09911-97820 09913-75810 09915-64512 Oil seal guide Oil seal installer Bearing installer Compression gauge 09915-64530 09915-67010 09915-67311 09915-77310 Hose Attachment Vacuum gauge Oil pressure gauge 09915-78211 09916-14510 09916-14521 09916-34542 Oil pressure gauge attach- Valve lifer Valve lifer attachment Reamer handle...
Page 434 ENGINE MECHANICAL (M13 ENGINE) 6A2-95 09916-58210 09916-67020 09916-67021 09916-77310 Valve guide installer handle Tappet holder Tappet holder Piston ring compressor See NOTE below 09916-84511 09917-68221 09917-98221 09924-17810 Forceps Camshaft lock holder Valve stem seal installer Flywheel holder 09926-58010 09944-36011 Bearing puller attachment Steering wheel remover NOTE: [A] and [B] tools in the above table are interchangeable.
Page 435 6A2-96 ENGINE MECHANICAL (M13 ENGINE)
Page 436 ENGINE COOLING (M13 ENGINE) 6B2-1 SECTION 6B2 ENGINE COOLING (M13 ENGINE) CONTENTS General Description........6B2-2 Thermostat Inspection ......6B2-11 Radiator Removal and Installation .... 6B2-12 Cooling System Circulation ......6B2-2 Radiator Inspection ........6B2-13 Coolant............6B2-3 Radiator Cleaning ........6B2-13 Diagnosis............6B2-4 Radiator Cooling Fan Relay Inspection ..6B2-13 Diagnosis Table ..........6B2-4 Radiator Cooling Fan Removal and System Circuit Inspection......6B2-4...
Page 437 6B2-2 ENGINE COOLING (M13 ENGINE) General Description The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is tube-and-fin type one. Cooling System Circulation While the engine is warmed up (thermostat closed), coolant circulates as follows. 1.
Page 438 ENGINE COOLING (M13 ENGINE) 6B2-3 Coolant The coolant recovery system is standard. The coolant in the radiator expands with heat, and the coolant is over- flowed to the reservoir. When the system cools down, the coolant is drawn back into the radiator. The cooling system has been filled with a quality coolant that is a 50/50 mixture of water and ethylene glycol antifreeze.
Page 439 6B2-4 ENGINE COOLING (M13 ENGINE) Diagnosis Diagnosis Table Condition Possible Cause Correction Engine overheats Loose or broken water pump belt Adjust or replace. (It is in case that radia- Not enough coolant Check coolant level and add as tor fan operates) necessary.
Page 440: Coolant Level Check
ENGINE COOLING (M13 ENGINE) 6B2-5 Maintenance WARNING: • Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir. Coolant should be added only to reservoir as necessary. • As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil.
Page 441 6B2-6 ENGINE COOLING (M13 ENGINE) Engine Cooling System Inspection and Ser- vice WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pres- sure if cap is taken off too soon.
Page 442 ENGINE COOLING (M13 ENGINE) 6B2-7 2) With radiator cap removed, run engine until upper radiator hose is hot (this shows that thermostat is open and coolant is flowing through system). 3) Stop engine and drain coolant from radiator drain plug (1). 4) Close radiator drain plug (1).
Page 443 6B2-8 ENGINE COOLING (M13 ENGINE) Water Pump/Generator Drive Belt Tension Inspection and Adjustment WARNING: • Disconnect negative cable at battery before checking and adjusting belt tension. • To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot.
Page 444 ENGINE COOLING (M13 ENGINE) 6B2-9 On-Vehicle Service WARNING: • Check to make sure that engine coolant temperature is cold before removing any part of cooling system. • Also be sure to disconnect negative cord from battery terminal before removing any part. Cooling System Components 1.
Page 445 6B2-10 ENGINE COOLING (M13 ENGINE) Cooling System Draining 1) Remove radiator cap. 2) Drain coolant from radiator drain plug (1). 3) After draining coolant, be sure to tighten drain plug (1) securely. Cooling System Refill Refer to step 7) to 22) of “Cooling System Flush and Refill” in this section.
Page 446 ENGINE COOLING (M13 ENGINE) 6B2-11 Thermostat Removal and Installation Removal 1) Drain coolant referring to “Cooling System Draining” in this section. 2) Remove intake manifold referring to “Intake Manifold Removal and Installation” in Section 6A2. 3) Remove generator referring to “Generator Dismounting and Remounting”...
Page 447 6B2-12 ENGINE COOLING (M13 ENGINE) • Check thermostatic movement of wax pellet as follows: a) Immerse thermostat (1) in water, and heat water gradually as shown. b) Check that valve starts to open at specific temperature. Temperature at which valve begins to open : 80 –...
Page 448 ENGINE COOLING (M13 ENGINE) 6B2-13 Radiator Inspection Check radiator for leakage or damage. Straighten bent fins, if any. Radiator Cleaning Clean frontal area of radiator cores. Radiator Cooling Fan Relay Inspection Refer to “Main Relay, Fuel Pump Relay and Radiator Fan Relay” in Section 6E2.
Page 449 6B2-14 ENGINE COOLING (M13 ENGINE) Radiator Cooling Fan Inspection For M/T vehicle 1) Check continuity between terminals. If there is no continuity, replace radiator fan motor. 2) Connect battery to radiator fan motor coupler as shown in figure, then check that the radiator fan motor operates smoothly.
Page 450 ENGINE COOLING (M13 ENGINE) 6B2-15 Water Pump/Generator Drive Belt Removal and Installation Removal 1) Disconnect negative cable at battery. 2) If vehicle equipped with A/C, remove compressor drive belt (4) before removing water pump belt (1). Refer to “Compressor Drive Belt Removal and Installation” in Section 1B.
Page 451 6B2-16 ENGINE COOLING (M13 ENGINE) Water Pump Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Drain coolant referring to “Cooling System Draining” in this section. 3) Remove water pump/generator drive belt referring to “Water Pump/Generator Drive Belt Removal and Installation” in this section.
Page 452 (Part Number) Ethylene glycol base Additive to engine cooling system for improving coolant (Anti-freeze/ — cooling efficiency and for protection against Anti-corrosion coolant) rusting. SUZUKI BOND NO. 1207F Water tight sealant To apply to mating surface of water pump (99000-31250)
Page 453 6B2-18 ENGINE COOLING (M13 ENGINE) Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft ETC sensor 11.0 Air ventilation bolt 0.45 Thermostat cap bolt Thermostat case bolt 18.0 Generator adjusting bolt 17.0 Generator pivot bolt 36.5 Water pump bolt and Nut 16.0...
Page 454 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 455 6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Camshaft position sensor Fuel cut operation inspection....6E2-37 (CMP sensor) and its circuit Radiator fan control system inspection..........6E2-33 inspection..........6E2-38 Camshaft position sensor Mass air flow (MAF) and intake (CMP sensor) removal and air temperature (IAT) sensor installation ..........
Page 456 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-3 General Description Engine and Emission Control System Construction The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, IAC valve and intake manifold.
Page 457 6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Engine and Emission Control System Flow Diagram...
Page 458 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-5 Engine and Emission Control System Diagram...
Page 459 6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 1. Air Cleaner 14. Knock sensor 27. Stop lamp 2. EVAP canister purge valve 15. ECT sensor 28. Stop lamp switch 3. MAF and IAT sensor 16. CMP sensor 29. ECM 4. TP sensor 17.
Page 460 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-7 Fuel Delivery System Description The fuel system consists of fuel tank (1), fuel pump (2) (with built-in fuel filter (3) and fuel pressure regulator (4)), delivery pipe (5), injectors (6) and fuel feed line (7). The fuel (8) in the fuel tank (1) is pumped up by the fuel pump (2), sent into delivery pipe (5) and injected by the injectors (6).
Page 461 6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Electronic Control System Description The electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 462 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-9 Electronic Control System Component Location INFORMATION SENSORS CONTROL DEVICES OTHERS 1. MAF and IAT sensor a: Fuel injector A: ECM 2. TP sensor b: EVAP canister purge valve B: Combination meter 3. Stop lamp switch c: Fuel pump relay C: EVAP canister 4.
Page 463 6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Engine and Emission Control Input/output Table ELECTRIC CONTROL DEVICE OUTPUT INPUT For detecting fuel level FUEL LEVEL SENSOR BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH LIGHTING SWITCH BLOWER SWITCH A/C SWITCH A/C EVAP OUTLET AIR TEMP.
Page 464 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-11 ECM Input/output Circuit Diagram E22-7 BLU/WHT E22-10 E22-6 BLU/YEL BLU/RED E22-5 E22-30 BLU/ORN E22-4 RED/BLK E23-13 E22-14 E22-32 E23-17 GRN/YEL GRN/BLK E23-34 LT GRN E22-17 BLK/RED E23-16 E23-33 GRN/ORN WHT/GRN E22-8 E22-34 E23-8 GRN/YEL BLK/RED...
Page 465 6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 1. CKP sensor 20. Immobilizer control module 39. Stop lamp 2. CMP sensor 21. Data link connector 40. Lighting switch 3. VSS 22. Injector No.1 41. Position lamp 4. MAP sensor 23. Injector No.2 42.
Page 466 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-13 ECM Terminal Arrangement Table CON- TERMI- CON- TERMI- WIRE COLOR CIRCUIT WIRE COLOR CIRCUIT NECTOR NECTOR BLK/YEL Ground for ECM – – BLK/YEL Ground for ECM – – BLU/RED Heater output of heated oxygen sensor–2 –...
Page 467 6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) [A]: Terminal arrangement of ECM coupler (viewed from harness side) NOTE: For abbreviation of wire color, refer to “Abbreviations and Symbols May be Used in This Manual” in Section 0A.
Page 468 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-15 On-Vehicle Service Accelerator cable adjustment With accelerator pedal depressed fully (1), check clearance between throttle lever (2) and lever stopper (3) of throttle body. If measured value is out of specification, adjust it to specification with cable adjusting nut (4).
Page 469 6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 1) Connect scan tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool 2) Warm up engine to normal operating temperature. 3) Check engine idle speed and “IAC duty” by using “Data List”...
Page 470: Air Intake System
ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-17 Air Intake System Throttle body Components 2.5 N·m (0.25 kg-m) 3.5 N·m (0.35 kg-m) 1. Throttle body 4. Gasket 7. TP sensor screws 2. Throttle body gasket 5. Idle air control valve Tightening torque 3.
Page 471 6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 5) Disconnect connectors from TP sensor (1) and IAC valve (2). 6) Disconnect engine coolant hoses (3) and breather hose (4) from throttle body. 7) Remove throttle body from intake manifold. 8) Remove TP sensor and IAC valve from throttle body. NOTE: While disassembling and assembling throttle body, use special care not to deform levers on throttle valve shaft...
Page 472 A chemical reaction will cause these parts to swell, harden or get distorted. Idle air control (IAC) valve operation check Using Suzuki Scan Tool 1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool 2) Warm up engine to normal operating temperature.
Page 473 6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Installation 1) Install new gasket (2) to throttle body (1). 2) Install IAC valve (3) to throttle body (1). Tighten IAC valve screws to specified torque. Tightening torque IAC valve screw (a): 3.5 N·m (0.35 kg-m, 2.5 lb-ft) 3) Install throttle body referring to “Throttle Body Removel and Installation”...
Page 474 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-21 Oil control valve removal and installation Removal Remove oil gallery pipe No.1 (1) and oil control valve (2) from tim- ing chain cover (3). Installation 1) Install new O-ring (4) to oil control valve. 2) Install oil control valve to timing chain cover.
Page 475 6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Fuel Delivery System Fuel pressure inspection WARNING: Be sure to perform work in a well-ventilated area and away from any open flames, or there is a risk of a fire breaking out. 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres- sure Relief Procedure”...
Page 476 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-23 8) After checking fuel pressure, remove fuel pressure gauge. CAUTION: As fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to following pro- cedures. • Place fuel container under joint. •...
Page 477 6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Fuel pump with pressure regulator removal and installation Removal Remove fuel tank from body according to procedure described in “Fuel Tank Removal and Installation” of Section 6C and remove fuel pump from fuel tank. Installation 1) Install fuel pump to its bracket.
Page 478 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-25 Fuel injector removal and installation Removal CAUTION: A small amount of fuel may come out after removal of fuel injectors, cover them with shop cloth. 1) Relieve fuel pressure according to procedure described in “Fuel Pressure Relief Procedure”...
Page 479 6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Fuel injector inspection WARNING: As fuel is injected in this inspection, perform in a well ventilated area and away from open flames. Use special care to prevent sparking when connecting and disconnecting test lead to and from battery. 1) Install injector to special tool (injector checking tool).
Page 480 ECM, wire harness, etc. iii) Turn ignition switch ON. [A]: When using SUZUKI scan tool [B]: When not using SUZUKI scan tool 7) Apply battery voltage (3) to injector (2) for 15 seconds and measure injected fuel volume with graduated cylinder.
Page 481 6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Electronic Control System Engine control module (ECM) removal and installa- tion CAUTION: As ECM consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect battery negative cable at battery. 2) Disable air bag system, refer to “Disabling Air Bag System”...
Page 482 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-29 Manifold absolute pressure sensor (MAP sensor) inspection 1) Disconnect connector from MAP sensor (1). 2) Remove MAP sensor (1). 3) Arrange 3 new 1.5 V batteries (2) in series (check that total voltage is 4.5 –...
Page 483 6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Throttle position sensor (TP sensor) on-vehicle inspection 1) Disconnect negative cable at battery. 2) Detach purge valve chamber, and remove air cleaner outlet hose. 3) Disconnect TP sensor connector. 4) Using ohmmeter, check resistance between terminals under each condition given in table below.
Page 484 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-31 Engine coolant temperature sensor (ECT sensor) removal and installation Removal 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to “Cooling System Draining” in Sec- tion 6B2. WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot.
Page 485 6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Engine coolant temperature sensor (ECT sensor) inspection Immerse temperature sensing part of ECT sensor (1) in water (or ice) and measure resistance between terminals while heating water gradually. If measured resistance does not show such characteristic as shown in the graph, replace ECT sensor (1).
Page 486 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-33 Heated oxygen sensor (HO2S-1 and HO2S-2) removal and installation Removal WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative cable at battery.
Page 487 6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Camshaft position sensor (CMP sensor) removal and installation Removal 1) Disconnect negative cable at battery. 2) Disconnect connector from camshaft position sensor. 3) Remove camshaft position sensor from cylinder head. Installation 1) Check that O-ring is free from damage. 2) Check that camshaft position sensor and signal rotor teeth are free from any metal particles and damage.
Page 488 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-35 Crankshaft position sensor (CKP sensor) removal and installation Removal 1) Disconnect negative cable at battery. 2) Remove generator drive belt, loosen pivot bolt (2) and move generator rearward. 3) Disconnect connector from crankshaft position sensor. 4) Remove crankshaft position sensor (1) from cylinder block.
Page 489 6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Vehicle speed sensor (VSS) and its circuit inspection 1) Confirm that terminal voltage and ground circuit continuity at VSS connector terminals are in good condition referring to Step 3 to 5 of “DTC P0500 Diag. Flow” in Section 6-2. If not, repair VSS circuit.
Page 490 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-37 Main relay, fuel pump relay and radiator fan relay inspection 1) Disconnect negative cable at battery. 2) Remove main relay (1), fuel pump relay (2) and radiator fan relay (3) from relay box. 3) Check that there is no continuity between terminal “C”...
Page 491 6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Radiator fan control system inspection System Inspection WARNING: Keep hands, tools, and clothing away from engine cool- ing 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 492 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-39 Mass air flow (MAF) and intake air temperature (IAT) sensor removal and installation CAUTION: • Do not disassemble MAF and IAT sensor. • Do not expose MAF and IAT sensor to any shock. •...
Page 493 6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Mass air flow (MAF) and intake air temperature (IAT) sensor inspection CAUTION: Do not heat up the MAF and IAT sensor more than 100°C (212°F). Otherwise, the MAF and IAT sensor is damaged. •...
Page 494: Emission Control System
ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-41 Emission Control System EGR system inspection 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turn OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC”...
Page 495 1) Prepare to operate EVAP canister purge valve as follows. a) When using SUZUKI scan tool: i) Connect SUZUKI scan tool to DLC with ignition switch OFF and disconnect purge valve vacuum hoses from intake manifold and purge valve chamber.
Page 496 “A” “B” 2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire. If check result is not described, check vacuum hoses, EVAP canister purge valve, wire harness and connections.
Page 497 6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Vacuum Hose Check hoses for connection, leakage, clog and deterioration. Replace as necessary. EVAP Canister Purge Valve 1) With ignition switch OFF, disconnect coupler from canister purge valve. 2) Remove EVAP canister purge valve from air cleaner assem- bly.
Page 498 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-45 EVAP Canister WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful. 1) Check outside of EVAP canister visually. 2) Disconnect vacuum hoses from EVAP canister. 3) Check that there should be no restriction of flow through purge pipe (1) and air pipe (2) when air is blown (4) into tank pipe (3).
Page 499 6E2-46 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6) After checking vacuum, stop engine and remove PCV valve. Shake valve and listen for the rattle of check needle inside the valve. If valve does not the rattle, replace valve. 7) After checking, remove plug and install PCV valve. 8) Install air cleaner assembly securely.
Page 500 09917-47911 09930-88530 Checking tool plate Vacuum pump gauge Injector test lead Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.) NOTE: • “A”: This kit includes the following items. 1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose & clamp, 6.
Page 501 6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft TP sensor mounting screw 0.25 IAC valve screw 0.35 ECT sensor 11.5 Heated oxygen sensor 32.5 Camshaft position sensor Knock sensor 16.0 Oil control valve mounting nut Oil gallery pipe No.1 bolt 21.5...
Page 502: Ignition System
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 503 6F2-2 IGNITION SYSTEM (M13 ENGINE) General Description Ignition System Construction The ignition system is an electronic (distributorless) ignition system. Its consists of the parts as described below. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suit- able ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 504 IGNITION SYSTEM (M13 ENGINE) 6F2-3 Ignition System Wiring Circuit Diagram BLK/WHT RED/BLU E23-31 YEL/BLU E23-32 BLK/WHT E21-28 BLU/BLK BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL BLK/RED E21-5 BLK/RED E22-1 WHT/BLU E22-10 E23-2 BLK/YEL 60A 15A E23-1 BLK/YEL E22-30 1. Ignition switch 7.
Page 505 6F2-4 IGNITION SYSTEM (M13 ENGINE) Diagnosis Ignition System Symptom Diagnosis Condition Possible Cause Correction Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to Loose connection or disconnection of lead wire Connect securely. start (No spark) or high-tension cord(s) Faulty high-tension cord(s) Replace.
Page 506 IGNITION SYSTEM (M13 ENGINE) 6F2-5 Reference Waveform Oscilloscope waveforms of CMP sensor and No.1/No.4 ignition trigger signal are as shown in figure when connecting oscillo- scope between terminals E22-10 of ECM connectors connected to ECM and ground, and between terminal E23-32 and ground. Measurement condition for waveform [A] Measurement CH1: E22-10 to E23-1...
Page 507 6F2-6 IGNITION SYSTEM (M13 ENGINE) Step Action Electrical Connection Check Go to Step 5. Connect securely. 1) Check ignition coil assemblies and high-tension cords for electrical connection. Are they connected securely? High-tension Cords Check Go to Step 6. Replace high-tension 1) Check high-tension cord for resistance referring to cord(s).
Page 508 IGNITION SYSTEM (M13 ENGINE) 6F2-7 On-Vehicle Service Ignition Spark Test 1) Remove air cleaner assembly with air intake pipe. 2) Disconnect all injector couplers from injectors. WARNING: Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.
Page 509 6F2-8 IGNITION SYSTEM (M13 ENGINE) Installation 1) Install No.1 cylinder (2) and No.3 cylinder (3) high-tension cords to spark plugs and ignition coil assemblies (1) while gripping each cap. CAUTION: • Never attempt to use metal conductor high-tension cords as replacing parts. •...
Page 510 IGNITION SYSTEM (M13 ENGINE) 6F2-9 Installation 1) Install spark plugs and torque them to specification. Tightening torque Spark plug: 25 N·m (2.5 kg-m, 18.0 lb-ft) 2) Install ignition coil assemblies referring to “Ignition Coil Assembly (Including Ignitor) Removal and Installation” in this section.
Page 511 6F2-10 IGNITION SYSTEM (M13 ENGINE) Ignition Coil Assembly (Including Ignitor) Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Remove air cleaner assembly with air intake pipe and cylin- der head upper cover. 3) Disconnect ignition coil coupler. 4) Disconnect high-tension cord (3) from ignition coil assembly (2).
Page 512: Ignition Timing Inspection
A/T model), and set parking brake. 1) Connect scan tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool 2) Start engine and warm it up to normal operating tempera- ture. 3) Make sure that all of electrical loads except ignition are switched off.
Page 513 18.0 Ignition coil bolt Special Tool 09930-76420 Timing light (Dry cell type) Tech 2 kit (SUZUKI scan tool) (See NOTE.) NOTE: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 514 CRANKING SYSTEM (0.9 KW REDUCTION TYPE) 6G-1 SECTION 6G CRANKING SYSTEM (0.9 KW REDUCTION TYPE) NOTE: • Starting motor vary depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. •...
Page 515 6G-2 CRANKING SYSTEM (0.9 KW REDUCTION TYPE) Specifications Voltage 12 volts Output 0.9 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length 12.3 mm (0.44 in.) Number of pinion teeth Performance Condition Guarantee 90 A maximum No load characteristic 11.0 V 2,800 rpm minimum...
Page 516: Charging System
CHARGING SYSTEM (G10/M13 ENGINES) 6H-1 SECTION 6H CHARGING SYSTEM (G10/M13 ENGINES) NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual. CONTENTS Generator ............6H-2 Removal and installation......6H-3 Diagnosis ............6H-2 Specifications..........6H-3 Undercharged battery........6H-2...
Page 517 6H-2 CHARGING SYSTEM (G10/M13 ENGINES) Generator Diagnosis Undercharged battery This condition, as evidenced by slow cranking or indicator clear with red dot can be caused by one or more of the following condi- tions even though indicator lamp may be operating normal. The following procedure also applies to cars with voltmeter and ammeter.
Page 518 CHARGING SYSTEM (G10/M13 ENGINES) 6H-3 Load Check 1) Run engine at 2,000 rpm and turn on head light and heater motor. 2) Measure current and if it is less than 20 A repair or replace generator. Unit Repair Overhaul Removal and installation For G10 Engine Refer to “Unit Repair Overhaul”...
Page 519 6H-4 CHARGING SYSTEM (G10/M13 ENGINES)
Page 520 EXHAUST SYSTEM (M13 ENGINE) 6K2-1 SECTION 6K2 EXHAUST SYSTEM (M13 ENGINE) CONTENTS General Description........6K2-2 Exhaust Manifold Removal and Installation........... 6K2-4 Maintenance ..........6K2-2 Exhaust Manifold Inspection ....... 6K2-4 On-Vehicle Service........6K2-3 Exhaust Pipe Removal and Installation ..6K2-4 Exhaust System Components.....6K2-3 Tightening Torque Specification....6K2-4...
Page 521 6K2-2 EXHAUST SYSTEM (M13 ENGINE) General Description The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 522 EXHAUST SYSTEM (M13 ENGINE) 6K2-3 On-Vehicle Service Exhaust System Components WARNING: To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. 1.
Page 523 6K2-4 EXHAUST SYSTEM (M13 ENGINE) Exhaust Manifold Removal and Installation Removal and installation Refer to “Exhaust Manifold Removal and Installation” in Section 6A2. Exhaust Manifold Inspection Check gasket and seal for deterioration or damage. Replace them as necessary. Exhaust Pipe Removal and Installation Removal and installation For replacement of exhaust pipe, be sure to hoist vehicle and observe “Warning”...
Page 524 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 525 7A2-2 MANUAL TRANSAXLE (M13 ENGINE) General Description Manual Transaxle Construction and Servicing The transaxle provides five forward speeds and one reverse speed by means of three synchronizers and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 526 MANUAL TRANSAXLE (M13 ENGINE) 7A2-3 Transaxle for 2wd Model 1. 5th speed sleeve & hub 8. Reverse idler gear 15. Countershaft 3rd gear 2. Input shaft 5th gear 9. Input shaft 16. Countershaft 2nd gear 3. Input shaft 4th gear 10.
Page 527 7A2-4 MANUAL TRANSAXLE (M13 ENGINE) Transaxle for 4wd Model 1. 5th speed sleeve & hub 7. Reverse gear shaft 13. Countershaft 4th gear 19. Final gear 2. Input shaft 5th gear 8. Reverse idler gear 14. Countershaft 20. Differential case 3.
Page 528 MANUAL TRANSAXLE (M13 ENGINE) 7A2-5 Diagnosis Manual Transaxle Symptom Diagnosis Condition Possible Cause Correction Gears slipping out of Maladjusted gear shift/select control cables Adjust. mesh Worn shift fork shaft Replace. Worn shift fork or synchronizer sleeve Replace. Weak or damaged locating springs Replace.
Page 529 7A2-6 MANUAL TRANSAXLE (M13 ENGINE) On-Vehicle Service CAUTION: Do not reuse circlip, spring pin, E-ring, oil seal, gasket, self locking nut and specified parts. Reuse of it can result in trouble. Manual Transaxle Oil Change 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
Page 530 MANUAL TRANSAXLE (M13 ENGINE) 7A2-7 4) Remove oil seal (1) and install a new one until it becomes flush with case surface using special tool and hammer. NOTE: When installing oil seal, face its spring side inward. Special tool (A): 09913-75510 (2WD and LH of 4WD) (A): 09951-46010 (RH of 4WD) 5) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make sure of its smooth-...
Page 531 7A2-8 MANUAL TRANSAXLE (M13 ENGINE) Gear Shift Control Lever and Cable Components 1. Gear shift control lever knob 5. Gear select control cable 9. Cable mounting bolt 2. Lever boot holder 6. Gear shift control lever assembly mounting 10. Cable bracket bolt 3.
Page 532 MANUAL TRANSAXLE (M13 ENGINE) 7A2-9 Gear Shift Control Lever and Cable Removal and Installation Removal 1) Remove console box. 2) Disconnect gear shift and select control cables (1) from gear shift control lever assembly (2). a) Disconnect cable end from pivot (7) while pushing cable end bush (4).
Page 533 7A2-10 MANUAL TRANSAXLE (M13 ENGINE) Gear Shift Control Lever and Cable Adjust- ment • Adjustment of shift cable: a) With shift control lever in “NEUTRAL” position, adjust shift cable adjusting nut (3) so that distance “a” between edge of instrument panel (1) and center of shift knob (2) measured as specified value.
Page 534 MANUAL TRANSAXLE (M13 ENGINE) 7A2-11 Vehicle Speed Sensor (VSS) Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Disconnect VSS coupler (1). 3) Remove VSS (2). Installation 1) Apply oil to new O-ring (1) and then install VSS to transaxle. 2) Connect VSS coupler (1).
Page 535 7A2-12 MANUAL TRANSAXLE (M13 ENGINE) Back Up Lamp Switch Removal and Installa- tion Removal 1) Disconnect negative cable at battery. 2) Disconnect back up lamp switch coupler. 3) Remove back up lamp switch (1). 2. Clutch cable 3. Gear shift and select shaft assembly Installation 1) Apply oil to new O-ring (1) and tighten back up lamp switch (2) to specified torque.
Page 536 MANUAL TRANSAXLE (M13 ENGINE) 7A2-13 Unit Repair Overhaul Transaxle Unit Components [A]: Forward 8. Clutch cable 16. Engine rear mounting bolt 1. Engine 9. Backup lamp switch connector 17. Engine rear mounting 2. Transaxle 10. VSS connector 18. Engine rear mounting No.2 bracket bolts 3.
Page 537 7A2-14 MANUAL TRANSAXLE (M13 ENGINE) Transaxle Unit Dismounting and Remounting Dismounting Under hood 1) Disconnect negative cable at battery. 2) Undo wiring harness clamps, disconnect backup lamp switch coupler, VSS coupler and ground cable. 3) Disconnect clutch cable from clutch release lever and bracket.
Page 538 MANUAL TRANSAXLE (M13 ENGINE) 7A2-15 Remounting CAUTION: Care should be taken not to scratch oil seal lip with drive shaft while raising transaxle. Do not hit drive shaft joint with hammer when installing it into differential gear. Reverse dismounting procedure for remounting noting the follow- ing.
Page 539 7A2-16 MANUAL TRANSAXLE (M13 ENGINE) Transaxle Case Components...
Page 540 MANUAL TRANSAXLE (M13 ENGINE) 7A2-17 1. Transaxle right case 11. VSS 2. Transaxle left case 12. Oil gutter bolt : Apply sealant 99000-31260 to mating surface of left case and : Apply thread lock 99000-32110 to all around thread part of bolt. right case.
Page 541 7A2-18 MANUAL TRANSAXLE (M13 ENGINE) Gear Shift and Select Shaft Assembly Removal and Installation Removal 1) Remove gear shift interlock bolt (1) and 5th to reverse inter- lock guide bolt (2) from transaxle case. 2) Remove gear shift and select shaft assembly (3). Installation 1) Apply grease to select lever shaft bush and select lever boss, and install gear shift and select shaft assembly with new...
Page 542 MANUAL TRANSAXLE (M13 ENGINE) 7A2-19 Gear Shift and Select Shaft Disassembly and Assembly 1) Push spring pins out using specified spring pin removers as shown bellow. Special tool (A): 09922-85811 (4.5 mm) (B): 09925-78210 (6.0 mm) (C): 2.8 – 3.0 mm (0.11 – 0.12 in.) Commercially available spring pin remover 2) Inspect component parts for wear, distortion or damage.
Page 543 7A2-20 MANUAL TRANSAXLE (M13 ENGINE) 2) Using special tool, remove circlip (1) and then remove hub plate (2). Special tool (A): 09900-06107 3) Drive out spring pin using special tool and hammer. Special tool (A): 09922-85811 4) Remove gear shift fork (2), sleeve & hub assembly (3), syn- chronizer ring spring, synchronizer ring and 5th gear all together.
Page 544 MANUAL TRANSAXLE (M13 ENGINE) 7A2-21 Assembly 1) Install seat countershaft left bearing outer race (1) to bearing cone, tap cup using special tool and plastic hammer (2). Special tool (A): 09913-84510 2) With putting a shim (2) on bearing outer race (3), place straight edge (1) over it and compress it by hand through straight edge, and then measure clearance “a”...
Page 545 7A2-22 MANUAL TRANSAXLE (M13 ENGINE) CAUTION: Do not reuse left case plate screw (1) and bolts (7). Be sure to use new adhesive pre-coated screw and bolts. Otherwise, screw and bolts may loosen. 4) Place left case plate (2) inserting its end in groove of shift guide shaft (4) and tighten new adhesive pre-coated screw (1) and bolts (7) temporarily with less than specified toque.
Page 546 MANUAL TRANSAXLE (M13 ENGINE) 7A2-23 8) Install needle bearing of separated steel cage type to input shaft, apply oil then install 5th gear (1) and special tool to stop shaft rotation. Special tool (B): 09927-76010 9) Install new countershaft nut (2) and tighten it to specification. Tightening torque Countershaft nut (b): 70 N·m (7.0 kg-m, 51.0 lb-ft) 10) Remove special tool, then caulk countershaft nut (4) at C...
Page 547 7A2-24 MANUAL TRANSAXLE (M13 ENGINE) 15) Clean mating surface of both left case (2) and side cover (1), apply sealant to side cover (1) as shown in figure by such amount that its section is 1.5mm (0.059 in.) in diameter, mate it with left case and then tighten bolts.
Page 548 MANUAL TRANSAXLE (M13 ENGINE) 7A2-25 6) Remove reverse shaft bolt (1) with washer. 7) Remove case bolts (2) from outside and another bolts from clutch housing side. 8) Tapping left case (3) flanges with plastic hammer, remove left case. 9) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3).
Page 549 7A2-26 MANUAL TRANSAXLE (M13 ENGINE) 3) Join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft (3) assemblies all together, then install them into right case (1). CAUTION: Take care not to damage oil seal lip by input shaft, or oil leakage may take place.
Page 550 MANUAL TRANSAXLE (M13 ENGINE) 7A2-27 7) Clean mating surfaces of both right and left cases, apply sealant to right case (2) as shown in figure by such amount that its section is 1.5mm (0.059 in.) in diameter then mate it with left case (1).
Page 551 7A2-28 MANUAL TRANSAXLE (M13 ENGINE) 14) Clean mating surface of guide case. 15) Install fifth gear referring to “Fifth Gear Disassembly and Assembly” in this section. 16) Install gear shift and select shaft assembly referring to “Gear Shift and Select Shaft Assembly Removal and Installation” in this section.
Page 552 MANUAL TRANSAXLE (M13 ENGINE) 7A2-29 Assembly NOTE: Before installation, wash each part and apply specified transaxle oil to sliding faces of bearing and gear. 1) If input shaft oil seal (1) has been removed, install it with its spring side facing upward. Use special tool and hammer for installation and apply grease to oil seal lip.
Page 553 7A2-30 MANUAL TRANSAXLE (M13 ENGINE) Input & Counter Shaft Components...
Page 554 MANUAL TRANSAXLE (M13 ENGINE) 7A2-31 1. Input shaft 18. 5th synchronizer spring 35. Needle bearing (separated steel cage type) 2. Oil seal 19. 5th speed sleeve & hub 36. Countershaft 2nd gear : Apply grease 99000-25010 to oil seal lip 3.
Page 555 7A2-32 MANUAL TRANSAXLE (M13 ENGINE) 4) Using special tool, remove circlip (1). Special tool (A): 09900-06107 5) Drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) from input shaft (1) using puller (4) and press. CAUTION: Make sure to use flat side of puller to avoid causing dam- age to 3rd gear tooth.
Page 556 MANUAL TRANSAXLE (M13 ENGINE) 7A2-33 4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure. NOTE: • No specific direction is assigned to each key but it is assigned as sleeve &...
Page 557 7A2-34 MANUAL TRANSAXLE (M13 ENGINE) 8) Install circlip (1) and confirm that circlip is installed in groove securely. Install needle bearing (2) of steel cage type, apply oil to bearing and then install synchronizer ring (3) and 4th gear (4). 9) Press-fit left bearing (2) using special tool and hammer.
Page 558 MANUAL TRANSAXLE (M13 ENGINE) 7A2-35 4) Using special tool, remove circlip (1). Special tool (A): 09900-06107 5) Apply puller (3) to 1st gear (2) and drive out low speed syn- chronizer sleeve & hub assembly (1) with 1st gear (1) using press.
Page 559 7A2-36 MANUAL TRANSAXLE (M13 ENGINE) 3) Put the synchronizer outer ring (1), inner ring (3) and the cone (2) together and then measure the step difference between the outer ring and the inner ring. And also check each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary.
Page 560 MANUAL TRANSAXLE (M13 ENGINE) 7A2-37 8) Drive in low speed sleeve & hub assembly (1) using special tools and hammer, facing “B” side of sleeve to 1st gear. NOTE: • Support shaft with special tool as shown in figure so that retainer of bearing cone (4) will be free from com- pression.
Page 561 7A2-38 MANUAL TRANSAXLE (M13 ENGINE) 11) Press-fit 4th gear (2) using the same procedure as step 10). 12) Install left bearing cone (1) using special tools and hammer. NOTE: For protection of right bearing cone (3), always support shaft with special tool as illustrated. Special tool (A): 09923-78210 (E): 09925-98221...
Page 562 MANUAL TRANSAXLE (M13 ENGINE) 7A2-39 High Speed and Low Speed Gear Shift Shafts Inspection 1) Using feeler gauge, check clearance between fork (1) and sleeve (2) and replace those parts if it exceeds limit below. NOTE: For correct judgement of parts replacement, carefully inspect contact portion of fork and sleeve.
Page 563 7A2-40 MANUAL TRANSAXLE (M13 ENGINE) Differential Components 1. Differential pinion washer 9. Final gear 2. Differential side pinion gear 10. Final gear bolt : Apply thread lock 99000-32110 to all around thread part of bolt 3. Differential side gear 11. Differential pinion shaft 4.
Page 564 MANUAL TRANSAXLE (M13 ENGINE) 7A2-41 Differential Disassembly and Assembly Disassembly 1) Using special tools, remove right bearing (1) and sensor rotor (2). Special tool (A): 09913-60910 (B): 09925-88210 2) Remove left bearing in the same manner at step 1). 3) Support differential case with soft jawed vise and remove final gear bolts then take out final gear.
Page 565 7A2-42 MANUAL TRANSAXLE (M13 ENGINE) 5) Hold differential assembly with soft jawed vise (3), install final gear (2) as shown in figure and then tighten bolts (1) with thread lock cement applied to specified torque. NOTE: Make sure to install final gear in correct installing direc- tion.
Page 566 MANUAL TRANSAXLE (M13 ENGINE) 7A2-43 • For right side a) Using similar procedure to the above, set dial gauge tip to gear (1) shoulder. b) Move gear up and down by hand and read dial gauge. Special tool (A): 09900-20606 (B): 09900-20701 2) If thrust play is out of specification, select suitable thrust washer from among the following available size, install it and...
Page 567 7A2-44 MANUAL TRANSAXLE (M13 ENGINE) Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Transaxle oil level/filler and drain plugs 15.5 Oil gutter bolt Final gear bolt 65.0 Reverse gear shift lever bolt 17.0 Transaxle case bolt 14.0 Reverse shaft bolt 17.0 Gear shift locating bolt Left case plate screw and bolt...
Page 568 MANUAL TRANSAXLE (M13 ENGINE) 7A2-45 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Oil seal lip (99000-25010) • Select lever boss • Select lever shaft bush Sealant SUZUKI BOND NO.1217G • Oil drain plug and filler/level plug (99000-31260) •...
Page 569 7A2-46 MANUAL TRANSAXLE (M13 ENGINE) 09923-74510 09923-78210 09924-74510 09925-18011 Bearing remover Bearing installer Installer attachment Bearing installer 09925-68210 09925-78210 09925-88210 09925-98221 Bearing outer race Spring pin remover 6 mm Bearing puller attachment Bearing installer installer (0.24 in.) 09927-76010 09930-30104 09940-53111 09940-54910 Gear holder Sliding shaft...
Page 570 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View” under “Gen- eral Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 571 7B1-2 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0713 Transmission Fluid Select Cable ..........7B1-95 Temperature Sensor Circuit High ..... 7B1-58 Transmission Range Sensor DTC P0717 Input/Turbine Speed (Shift Switch)..........7B1-97 Sensor Circuit Malfunction ......7B1-60 Output Shaft Speed Sensor (VSS) ... 7B1-98 DTC P0722 Output Speed Sensor Input Shaft Speed Sensor......
Page 572 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-3 General Description This automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up mechanism.
Page 573 7B1-4 AUTOMATIC TRANSAXLE (M13 ENGINE) 20 21 22 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23. Short planet pinion 4.
Page 574 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-5 Specifications Item Specifications Torque Type 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism) converter Stall torque ratio 1.9 – 2.1 Type Internal involute gear type oil pump (non crescent type) Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type “P”...
Page 575 7B1-6 AUTOMATIC TRANSAXLE (M13 ENGINE) Clutch/Brake/Planetary Gear 1. Input shaft and intermediate shaft 8. Reduction driven gear B1: O/D and 2nd coast brake 2. Reduction drive gear 9. Front sun gear B2: 2nd brake 3. Planet carrier 10. Ring gear B3: 1st and reverse brake 4.
Page 576 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-7 Table of Component Operation...
Page 577 7B1-8 AUTOMATIC TRANSAXLE (M13 ENGINE) Electronic Shift Control System...
Page 578 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-9 1. Engine 9. Pressure control solenoid valve 17. Transmission range sensor coupler 2. Transaxle 10. Shift solenoid valve-B (No.2) 18. Solenoid valve coupler 3. “O/D OFF” lamp 11. Shift solenoid valve-A (No.1) 19. Output shaft speed sensor (VSS) 4.
Page 579 7B1-10 AUTOMATIC TRANSAXLE (M13 ENGINE) Transmission Control Module (TCM) E13-11 E12-6 E12-16 E13-12 BLU/RED 2.5V E13-16 E12-25 E13-15 BLK/YEL E13-14 WHT/RED E13-5 WHT/BLU E13-7 E13-4 BRN/YEL E13-17 E13-2 LT GRN/RED E12-11 BLU/YEL E12-9 BLU/RED E13-24 WHT/BLU E12-20 IG11 E12-1 BLU/YEL E12-8 WHT/RED E13-6...
Page 580 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-11 Operation of shift solenoid valves, timing solenoid valve and TCC solenoid valve Valve status Turn power ON Turn power OFF Shift solenoid valve-A (No.1) Close Open Shift solenoid valve-B (No.2) Close Open Timing solenoid Open Close TCC (lock-up) solenoid Close...
Page 581 7B1-12 AUTOMATIC TRANSAXLE (M13 ENGINE) Automatic gear shift diagram Automatic shift schedule as a result of shift control is shown below. In case that selector lever is shifted to “L” range at a higher than 44 km/h (27 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower than that.
Page 582 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-13 Diagnosis General Description This vehicle is equipped with an electronic transaxle control system, which controls the automatic shift up and shift down timing, TCC operation, etc. suitably to vehicle driving conditions. TCM has an On-Board Diagnosis System which detects a malfunction in this system. When diagnosing a trouble in transaxle including this system, be sure to have full understanding of the outline of “On-Board Diagnostic System”...
Page 583 7B1-14 AUTOMATIC TRANSAXLE (M13 ENGINE) On-board Diagnostic System For automatic transaxle control system, TCM has following func- tions. • When ignition switch is turned ON with O/D off switch turned OFF and no malfunction in A/T control system is detected, “O/D OFF”...
Page 584 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-15 Precaution in Diagnosing Trouble • Don’t disconnect couplers from TCM, battery cable from battery, TCM ground wire harness from engine or main fuse before checking the diagnosis information stored in TCM memory. Such disconnection will clear memorized information in TCM memory. •...
Page 585 7B1-16 AUTOMATIC TRANSAXLE (M13 ENGINE) Automatic Transaxle Diagnostic Flow Table Refer to the following items for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer com- 1) Perform customer complaint analysis. plaint analysis. Was customer complaint analysis performed according to instruction? Diagnostic Trouble Code (DTC)/Freeze Frame...
Page 586 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-17 Step Action Final Confirmation Test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to the followings. Is there any problem symptom, DTC or abnor- mal condition? 1. Customer Complaint Analysis (See Customer Problem Inspection Form) Record details of the problem (failure, complaint) and how it occurred as described by the customer.
Page 587 7B1-18 AUTOMATIC TRANSAXLE (M13 ENGINE) 11. Final Confirmation Test Confirm that the problem symptom has gone and the vehicle is free from any abnormal conditions. If what has been repaired is related to the malfunction DTC, clear the DTC once and check to ensure that no malfunction DTC is indicated.
Page 588 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-19 Customer Problem Inspection Form (Example) NOTE: The above form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 589 7B1-20 AUTOMATIC TRANSAXLE (M13 ENGINE) “O/D OFF” Lamp Check 1) Turn ignition switch ON. 2) Check that “O/D OFF” lamp (1) lights for about 2 sec. and then goes OFF. If anything faulty is found, advance to “Diagnostic Flow Table A-3”...
Page 590 After repair or replace malfunction part(s), clear all DTCs by per- forming the following procedure. 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check.
Page 591 7B1-22 AUTOMATIC TRANSAXLE (M13 ENGINE) Diagnostic Trouble Code (DTC) Table Detecting condition Driving cycle Detecting item (DTC will set when detecting) when MIL lighted Transmission Range Sensor Cir- P0705 Multiple signals are inputted simultaneously. 1driving cycle cuit Malfunction (PRNDL Input) Transmission Range Sensor Cir- P0707 No sensor signal is inputted.
Page 592 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-23 Detecting condition Driving cycle Detecting item (DTC will set when detecting) when MIL lighted Voltage of shift solenoid terminal is high Shift Solenoid “B” Control Circuit P0977 although TCM is commanding shift solenoid 1driving cycle High to turn OFF.
Page 593 7B1-24 AUTOMATIC TRANSAXLE (M13 ENGINE) Fail Safe Table This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The table below shows the fail safe function for each fail condition of solenoid, solenoid or its circuit. Trouble Area Fail Safe Operation •...
Page 594 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-25 Trouble Area Fail Safe Operation • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. • After 15 minutes pass from detecting malfunction, engine coolant temperature is assumed to be 90°C (194°F).
Page 595 7B1-26 AUTOMATIC TRANSAXLE (M13 ENGINE) Visual Inspection Visually check the following parts and systems. INSPECTION ITEM REFERRING SECTION • A/T fluid ----- level, leakage, color Section 0B • A/T fluid hoses ----- disconnection, looseness, deterioration Section 7B1 • Throttle cable ----- play (under warm engine), installation Section 6E2 •...
Page 596 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-27 Automatic Transaxle Basic Check This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in visual inspection. Follow the flow table carefully. Step Action Was “Automatic Transaxle Diagnostic Flow Go to Step 2.
Page 597 7B1-28 AUTOMATIC TRANSAXLE (M13 ENGINE) Trouble Diagnosis Table Trouble diagnosis table-1 Electrical Repair Condition Possible Cause Correction Shift solenoid valve-A and/or-B circuit faulty Pressure control solenoid valve circuit faulty → ↔ (Only when N D or 3 O/D shifting) Timing solenoid valve circuit faulty Inspect circuit for open, short and intermit- Output shaft speed sensor (VSS) circuit faulty tent.
Page 598 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-29 Condition Possible Cause Correction Shift solenoid valve-B circuit faulty Pressure control solenoid valve circuit faulty Timing solenoid valve circuit faulty Output shaft speed sensor (VSS) circuit faulty Inspect circuit for open, short and intermit- Input shaft speed sensor circuit faulty tent.
Page 599 7B1-30 AUTOMATIC TRANSAXLE (M13 ENGINE) Condition Possible Cause Correction Output shaft speed sensor (VSS) circuit faulty Pressure control solenoid valve circuit faulty Inspect circuit for open, short and intermit- tent. If NG, repair. CAN communication circuit faulty Incorrect gear Pressure control solenoid valve circuit faulty shift point Inspect circuit for open, short and intermit- Throttle position sensor circuit faulty...
Page 600 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-31 Trouble diagnosis table-2 On-vehicle Repair Condition Possible Cause Correction Unable to run in all Faulty valve body component Replace valve body assembly range Engine abnormal condition Inspect and repair engine Malfunction of shift solenoid valve-A and/or-B Malfunction of output shaft speed sensor (VSS) Malfunction of input shaft speed sensor Malfunction of transmission range sensor...
Page 601 7B1-32 AUTOMATIC TRANSAXLE (M13 ENGINE) Condition Possible Cause Correction Malfunction of shift solenoid valve-B Malfunction of timing solenoid valve Malfunction of output shaft speed sensor (VSS) Inspect. If NG, replace. Malfunction of input shaft speed sensor Malfunction of O/D off switch →...
Page 602 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-33 Trouble diagnosis table-3 Off-vehicle Repair Condition Possible Cause Correction Faulty oil pump Seized or broken planetary gear Faulty one-way No.2 clutch Damaged drive plate Inspect. If NG, replace. Unable to run in all range Faulty forward clutch Faulty reverse clutch Faulty 1st and reverse brake Faulty torque converter...
Page 603: Road Test
7B1-34 AUTOMATIC TRANSAXLE (M13 ENGINE) Road Test This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a level road. WARNING: • Carry out test in very little traffic area to prevent an accident. •...
Page 604 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-35 Condition Possible Cause Correction Malfunction of shift solenoid valve-B Malfunction of O/D off switch Malfunction of engine coolant temperature sen- Malfunction of output shaft speed sensor (VSS) Malfunction of input shaft speed sensor Inspect. If NG, replace. Malfunction of throttle position sensor →...
Page 605 7B1-36 AUTOMATIC TRANSAXLE (M13 ENGINE) Condition Possible Cause Correction Malfunction of TCC solenoid valve Malfunction of shift solenoid valve-A and/or-B Malfunction of brake light switch Malfunction of engine coolant temperature sen- Malfunction of output shaft speed sensor (VSS) Inspect. If NG, replace. Malfunction of input shaft speed sensor TCC (lock-up) function Malfunction of throttle position sensor...
Page 606 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-37 Manual Road Test This test checks the gears 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) With select lever in “P”, start engine and warm it up.
Page 607 7B1-38 AUTOMATIC TRANSAXLE (M13 ENGINE) 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 608 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-39 Stall Test This test is to check overall performance of automatic transaxle and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is between FULL and LOW marks.
Page 609: Time Lag Test
7B1-40 AUTOMATIC TRANSAXLE (M13 ENGINE) Time Lag Test This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since selector 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. 2) Start engine.
Page 610: Line Pressure Test
AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-41 Line Pressure Test Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following conditions. • Automatic fluid is at normal operating temperature (70 – 80°C /158 –...
Page 611 7B1-42 AUTOMATIC TRANSAXLE (M13 ENGINE) Troubleshooting Condition Possible Cause Correction Higher than standard Malfunction of pressure control solenoid valve Inspect. If NG, replace valve body level in each range (Low line pressure) assembly. Faulty valve body component Replace valve body assembly. Malfunction of pressure control solenoid valve Inspect.
Page 612 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-43 Diagnostic Flow 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. • O/D OFF switch is turned ON (“O/D OFF” lamp lights). •...
Page 613 7B1-44 AUTOMATIC TRANSAXLE (M13 ENGINE) Diagnostic Flow Table A-2: No Lock-Up Occurs System Description TCM turns TCC solenoid OFF under any of the following conditions. • Brake light switch is turned ON. (Brake pedal is depressed) • Engine coolant temperature is less than 60°C (140°F). •...
Page 614 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-45 Diagnostic Flow Table A-3: “O/D OFF” Lamp Circuit Check (“O/D OFF” Lamp Lights Steadily) Wiring Diagram BLU/YEL E12-11 BLU/RED E12-9 1. TCM 4. O/D off switch 2. “O/D OFF” lamp [A]: Terminal arrangement of TCM connector (viewed from harness side) 3.
Page 615 7B1-46 AUTOMATIC TRANSAXLE (M13 ENGINE) Step Action Check O/D off switch for operation. “BLU/RED” circuit shorted Replace O/D off switch. 1) Disconnect O/D off switch coupler. to ground. 2) Check continuity between terminals under each condition below. (See fig.) O/D off switch under being released: No conti- nuity O/D off switch under being pressed: Continuity Is check result satisfactory?
Page 616 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-47 Diagnostic Flow Table A-4: “O/D OFF” Lamp Circuit Check (“O/D OFF” Lamp Does Not Light Anytime) Wiring Diagram BLU/YEL E12-11 BLU/RED E12-9 1. TCM 4. O/D off switch 2. “O/D OFF” lamp [A]: Terminal arrangement of TCM connector (viewed from harness side) 3.
Page 617 7B1-48 AUTOMATIC TRANSAXLE (M13 ENGINE) Diagnostic Flow Table A-5: TCM Power and Ground Circuit Check Wiring Diagram E13-24 WHT/BLU WHT/RED E13-6 BLK/WHT E13-1 E13-23 24 23 1. TCM 3. Ignition switch 2. A/T relay [A]: Terminal arrangement of TCM connector (viewed from harness side) Troubleshooting Step Action...
Page 618 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-49 Step Action Check TCM Ground Circuit. TCM power and ground “BLK” circuit for TCM 1) Turn ignition switch OFF. circuits are in good condi- ground open. 2) With TCM connectors disconnected, check tion. for proper connection to TCM at “E13-1”/ “E13-23”...
Page 619 7B1-50 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0705 Transmission Range Sensor Circuit Malfunction Wiring Diagram E12-20 IG11 E12-1 E12-8 BLU/YEL E12-7 GRN/RED E12-19 E12-18 GRN/BKL 20 19 1. TCM 3. Backup lamp 2. Transmission range sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA...
Page 620 Go to Step 5. for operation. Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition and Poor Connection” in switch OFF. Section 0A. 2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 2 or L) on display when shifting select lever to each range.
Page 621 7B1-52 AUTOMATIC TRANSAXLE (M13 ENGINE) Table for Step 4 Terminal E12-20 E12-1 E12-8 E12-7 E12-19 E12-18 Select lever 8 – 14 V position 8 – 14 V 8 – 14 V 8 – 14 V 8 – 14 V 8 – 14 V...
Page 622 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-53 DTC P0707 Transmission Range Sensor Circuit Low Wiring Diagram E12-20 IG11 E12-1 E12-8 BRU/YEL E12-7 GRN/RED E12-19 E12-18 GRN/BKL 20 19 1. TCM 3. Backup lamp 2. Transmission range sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA...
Page 623 Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with igni- and Poor Connection” in tion switch OFF. Section 0A. 2) Turn ignition switch ON and check transmis-...
Page 624 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-55 Table for Step 4 Terminal E12-20 E12-1 E12-8 E12-7 E12-19 E12-18 Select lever 8 – 14 V position 8 – 14 V 8 – 14 V 8 – 14 V 8 – 14 V 8 – 14 V...
Page 625 7B1-56 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Wiring Diagram E13-11 E13-12 BLU/RED 12 11 1. TCM 3. A/T 2. Transmission fluid temperature sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA Transmission temperature sensor terminal voltage is less...
Page 626 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-57 Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Go to Step 2. Go to “Automatic Tran- Table” performed? saxle Diagnostic Flow Table” in this section. Check Transmission Fluid Temperature Circuit “GRN” circuit shorted to Go to Step 3. for Ground Short.
Page 627 7B1-58 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0713 Transmission Fluid Temperature Sensor Circuit High Wiring Diagram E13-11 E13-12 BLU/RED 12 11 1. TCM 3. A/T [A]: Terminal arrangement of TCM connector (viewed from harness side) 2. Transmission fluid temperature sensor 4. Valve body connector DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA...
Page 628 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-59 Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Go to Step 2. Go to “Automatic Tran- Table” performed? saxle Diagnostic Flow Table” in this section. Check Transmission Fluid Temperature Circuit Go to Step 3. “BLU/RED” or “GRN/ for Open.
Page 629 7B1-60 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0717 Input/Turbine Speed Sensor Circuit Malfunction Wiring Diagram E12-6 E12-16 2.5V 1. TCM 2. Input shaft speed sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA No input shaft speed sensor signal is detected although...
Page 630 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-61 Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check” in this section. Check Input Shaft Speed Sensor Circuit. Go to Step 4. Go to Step 3. 1) Disconnect TCM connectors with ignition switch OFF.
Page 631 7B1-62 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0722 Output Speed Sensor (VSS) Circuit No Signal Wiring Diagram BLK/RED E12-25 1. TCM 2. Output shaft speed sensor (VSS) 3. To ECM [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA No output shaft speed sensor signal is detected although...
Page 632 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-63 Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Go to Step 2. Go to “Automatic Tran- Table” in this section performed? saxle Diagnostic Flow Table” in this section. Check Output Shaft Speed Sensor (VSS) Go to Step 3. “BLK/RED”...
Page 633 7B1-64 AUTOMATIC TRANSAXLE (M13 ENGINE) Step Action Check Output Shaft Speed Sensor (VSS) Intermittent trouble or Replace drive gear and/or Gears Visually. Faulty TCM. driven gear of output shaft Check output shaft speed sensor gears for the Check for intermittent speed sensor.
Page 634 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-65 DTC P0741/P0742 TCC Circuit Performance or Stuck OFF/TCC Circuit Stuck DTC Detecting Condition and Trouble Area [DTC P0741] DTC DETECTING CONDITION TROUBLE AREA When driving vehicle with 3rd or 4th gear in “D” range, dif- •...
Page 635 7B1-66 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0751/P0752/P0756/P0757 Shift Solenoid-A (No.1) Performance or Stuck OFF/Shift Solenoid-A (No.1) Stuck ON/Shift Solenoid-B (No.2) Performance or Stuck OFF/Shift Solenoid-B (No.2) Stuck ON DTC Detecting Condition and Trouble Area [DTC P0751] DTC DETECTING CONDITION TROUBLE AREA 3rd gear ratio is detected although TCM command is for •...
Page 636 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-67 1) Connect scan tool to DLC with ignition switch OFF, if available. 2) Clear DTC in TCM memory. 3) Start engine and warm it up to normal operating temperature. 4) Shift select lever to “N” and “D” range for each 10 seconds. 5) Start vehicle and increase vehicle speed to 65 km/h (40 mile/h) with throttle position 10% or more.
Page 637 7B1-68 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0785 Timing Solenoid Wiring Diagram E13-14 WHT/RED 1. TCM 3. A/T 2. Timing solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA •...
Page 638 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-69 Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check” in this section. Check Timing Solenoid Valve Circuit for IG Go to Step 3. “WHT/RED” circuit Short or Open. shorted to power circuit or 1) Turn ignition switch ON and measure volt- open.
Page 639 7B1-70 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0962 Pressure Control Solenoid Control Circuit Low Wiring Diagram E13-4 BRN/YEL E13-2 LT GRN/RED 1. TCM 3. A/T 2. Pressure control solenoid valve [A]: Terminal arrangement of TCM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA Pressure control solenoid valve output voltage is too low...
Page 640 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-71 Step Action Check pressure control solenoid valve resistance Go to Step 3. Replace pressure control 1) Turn ignition switch OFF solenoid valve or valve 2) Disconnect valve body harness connector on body harness. automatic transmission. 3) Check for proper connection to solenoid at “BRN/YEL”...
Page 641 7B1-72 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0963 Pressure Control Solenoid Control Circuit High Wiring Diagram E13-4 BRN/YEL E13-2 LT GRN/RED 1. TCM 3. A/T 2. Pressure control solenoid valve [A]: Terminal arrangement of TCM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA Pressure control solenoid valve output voltage is too high...
Page 642 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-73 Step Action Check pressure control solenoid valve resistance Intermittent trouble or Replace pressure control 1) Turn ignition switch OFF faulty TCM. Check for solenoid valve or valve 2) Disconnect valve body harness connector on intermittent referring to body harness.
Page 643 7B1-74 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P0974/P0977 Shift Solenoid-A (No.1) Control Circuit High/Shift Solenoid- B (No.2) Control Circuit High Wiring Diagram E13-16 BLK/YEL E13-15 16 15 1. TCM 3. Shift solenoid valve-B (No.2) [A]: Terminal arrangement of TCM connector (Viewed from harness side) 2.
Page 644 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-75 Step Action Check shift solenoid valve circuit for IG short Go to Step 3. DTC P0974: “BRN” cir- 1) Connect valve body harness connector. cuit shorted to power cir- 2) Disconnect TCM connectors. cuit. 3) Check for proper connection to TCM at termi- DTC P0977: “BLK/YEL”...
Page 645 7B1-76 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P1701 CAN Communication Error Wiring Diagram E13-7 E21-7 E13-17 E21-8 1. ECM [A]: Terminal arrangement of TCM connector (Viewed from harness side) 2. TCM [B]: Terminal arrangement of ECM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA...
Page 646 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-77 Step Action Check CAN communication circuit for open. Go to Step 3. “RED” wire circuit open or 1) Turn ignition switch to OFF position. high resistance. 2) Disconnect connectors from ECM and TCM. 3) Check for proper connection to “E21-7” termi- nal of ECM connector and “E13-7”...
Page 647 7B1-78 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC P1702 Internal Control Module Memory Check Sum Error DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA Calculation of current data stored in TCM is not correct comparing with pre-stored checking data in TCM. DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.
Page 648 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-79 DTC P2769 Torque Converter Clutch (TCC) Circuit Low Wiring Diagram E13-5 WHT/BLU 1. TCC solenoid valve 2. TCM 3. A/T [A]: Terminal arrangement of TCM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA Voltage of TCC solenoid valve TCM terminal is low...
Page 649 7B1-80 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Go to Step 2. Go to “Automatic Tran- Table” performed? saxle Diagnostic Flow Table” in this section. Check TCC solenoid valve resistance Go to Step 3. Replace TCC solenoid 1) Turn ignition switch OFF valve or lead wire.
Page 650 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-81 DTC P2770 Torque Converter Clutch (TCC) Circuit High Wiring Diagram E13-5 WHT/BLU 1. TCC solenoid valve 2. TCM 3. A/T [A]: Terminal arrangement of TCM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC DETECTING CONDITION TROUBLE AREA Voltage of TCC solenoid valve TCM terminal is high...
Page 651 7B1-82 AUTOMATIC TRANSAXLE (M13 ENGINE) DTC Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Go to Step 2. Go to “Automatic Tran- Table” performed? saxle Diagnostic Flow Table” in this section. Check TCC solenoid valve circuit for IG short Go to Step3. “WHT/BLU”...
Page 652 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-83 Scan Tool Data As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condi- tion, there may be cases where the checked value does not fall within each specified data range.
Page 653 7B1-84 AUTOMATIC TRANSAXLE (M13 ENGINE) NORMAL CONDITION/REFER- SCAN TOOL DATA VEHICLE CONDITION ENCE VALUES TIMING SOLE- Ignition switch ON and selector lever is in “N” range NOID MONITOR For about 0.5 sec. while on gear shifting between 3rd and 4th or gear shifting N to D TCC SOLENOID At 5 km/h (3 mile/h) constant speed, O/D off switch COMMAND...
Page 654 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-85 SCAN TOOL DATA DEFINITIONS: GEAR POSITION Current gear position computed by throttle position coming from ECM and vehicle speed. ENGINE SPEED (RPM) Engine speed computed by reference pulses from crankshaft position sensor. INPUT SHAFT REVOLUTION (RPM) Input shaft revolution computed by reference pulses coming from input shaft speed sensor on transaxle case.
Page 655 7B1-86 AUTOMATIC TRANSAXLE (M13 ENGINE) O/D OFF SWITCH Inputted signal from O/D off switch on selector knob. ON: O/D off switch ON OFF: O/D off switch OFF TRANSAXLE RANGE Transaxle range detected by signal fed from transmission range sensor. D RANGE SIGNAL ON: Signal which TCM require ECM to increase idle speed OFF: Signal which TCM does not require ECM to increase idle speed THROTTLE POSITION (%)
Page 656 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-87 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 disconnected from it.
Page 657 7B1-88 AUTOMATIC TRANSAXLE (M13 ENGINE) Con- Terminal Normal Wire color Circuit Condition nector number Voltage Ignition switch turned ON, engine 2 – 3 V stops. While engine running. Input shaft speed sensor (Output signal is waveform. Wave- (Reference form frequency varies depending on waveform output shaft speed.
Page 658 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-89 Con- Terminal Normal Wire color Circuit Condition nector number Voltage Ground 0 – 1 V Ignition switch ON Pressure control solenoid LT GRN/RED 0.6 – 1.0 V Ignition switch ON valve (–) – – – –...
Page 659 7B1-90 AUTOMATIC TRANSAXLE (M13 ENGINE) 1. Reference waveform No.1 Input shaft speed sensor signal at engine idling. Measurement CH1: E12-6 to E13-1 terminal Oscilloscope CH1: 2 V/DIV setting TIME: 10 ms/DIV Measurement • After warmed up to normal operating tem- condition perature •...
Page 660 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-91 On-Vehicle Service Maintenance Service Fluid level check at normal operating (hot) tempera- ture (Hot check) Inspection 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 operat- ing temperature (70 –...
Page 661 7B1-92 AUTOMATIC TRANSAXLE (M13 ENGINE) Fluid level check at room (cold) temperature (Cold check) Inspection Fluid level can be checked temporarily at room (cold) temperature which correspond to 20 – 30°C (68 – 86°F). This level check is considered to be preparation before performing level check under normal operating (hot) temperature.
Page 662 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-93 5) Check fluid level referring to “Fluid Level Check at Room (Cold) Temperature (Cold Check)” and “Fluid Level Check at Normal Operating (Hot) Temperature (Hot Check)” in this section. Automatic transaxle fluid ® An equivalent of DEXRON -III Automatic transaxle fluid capacity When draining from drain plug hole:...
Page 663: Selector Lever
7B1-94 AUTOMATIC TRANSAXLE (M13 ENGINE) Selector Lever 1. Selector lever assembly 4. Indicator assembly 2. Knob assembly 5. Illumination lamp assembly 3. Screw 6. Connector Inspection Check selector lever for smooth and clear-cut movement and position indicator for correct indication. For operation of select lever, refer to the figure.
Page 664 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-95 Select Cable 1. Selector lever assembly 6. Clip 2. Select cable 7. Select cable retainer bolt 3. Select cable retainer 8. Manual select lever pin : Apply lithium grease 99000-25010 to all around pin (0.15 g) 4.
Page 665 7B1-96 AUTOMATIC TRANSAXLE (M13 ENGINE) Adjustment 1) Shift manual shift lever to “N” range (transmission range sen- “R” “N” “D” “P” “2” sor “N” range). “L” 2) Remove adjuster (cable end) from selector lever pin of selec- tor lever assembly. 3) Release lock plate (1) which restrict moving of cable end holder (2).
Page 666 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-97 Transmission Range Sensor (Shift Switch) Adjustment and Inspection 1) Shift manual select lever (4) to “N” range. 2) Check that needle direction shaped on lock washer (2) and “N” reference line (1) on transmission range sensor are aligned.
Page 667 7B1-98 AUTOMATIC TRANSAXLE (M13 ENGINE) Output Shaft Speed Sensor (VSS) Inspection 1) Connect positive cable of 12 volt battery to “A” terminal of sensor and ground cable to “C” terminal. Then using voltme- ter, check voltage between “B” terminal and “C” terminal with output shaft speed sensor (VSS) driven gear rotated.
Page 668: Throttle Position Sensor
AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-99 Input Shaft Speed Sensor Inspection 1) Disconnect negative cable at battery. 2) Disconnect input shaft speed sensor connector (2). 3) Check resistance between input shaft speed sensor termi- nals. Input shaft speed sensor resistance Ω Standard: 560 –...
Page 669: Engine Coolant Temperature Sensor
7B1-100 AUTOMATIC TRANSAXLE (M13 ENGINE) Engine Coolant Temperature Sensor Inspection Check engine coolant temperature sensor referring to “Engine Coolant Temperature Sensor” in Section 6E1. O/D Off Switch Inspection 1) Remove console box. 2) Disconnect O/D off switch connector (1). 3) Check continuity between O/D off switch terminals. O/D off switch Pushing Free...
Page 670 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-101 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Timing Solenoid Valve) Removal 1) Disconnect negative cable at battery. 2) Lift up vehicle. 3) Remove drain plug and drain A/T fluid. 4) Install drain plug. Tightening torque A/T fluid drain plug: 17 N·m (1.7 kg-m, 12.5 lb-ft) 5) Remove A/T oil pan (1) and oil pan gasket (2).
Page 671 7B1-102 AUTOMATIC TRANSAXLE (M13 ENGINE) 9) Remove TCC solenoid valve (1), shift solenoid valve-A (No.1) (2), shift solenoid valve-B (No.2) (3) and timing sole- noid valve (4) by removing bolts. Inspection Resistance Check Shift solenoid valves, Timing solenoid valve and TCC solenoid valve resistance Ω...
Page 672 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-103 Operation Check Shift solenoid valve-A (No.1), -B (No.2) and TCC solenoid valve CAUTION: Do not insert air gun against strainer installed on inlet of solenoid valve too deeply, when blowing air into solenoid valve. If not, the strainer will be damaged. •...
Page 673 7B1-104 AUTOMATIC TRANSAXLE (M13 ENGINE) Timing solenoid valve CAUTION: Do not insert air gun against strainer installed on inlet of solenoid valve too deeply, when blowing air into solenoid valve. If not, the strainer will be damaged. • Check that solenoid valve (1) actuate with click sound when battery voltage is conducted.
Page 674 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-105 Installation 1) Install shift solenoid valve-A (No.1) (1), shift solenoid valve-B (No.2) (2), TCC solenoid valve (3) and timing solenoid valve (4). Tightening torque Solenoid valve bolt (a): 11 N·m (1.1 kg-m, 8.0 lb-ft) 2) Connect solenoid connectors identifying their installing posi- tions by wire color.
Page 675 7B1-106 AUTOMATIC TRANSAXLE (M13 ENGINE) Pressure Control Solenoid Valve Removal 1) Disconnect negative cable at battery. 2) Lift up vehicle. 3) Remove drain plug and drain A/T fluid. 4) Install drain plug. Tightening torque A/T fluid drain plug: 17 N·m (1.7 kg-m, 12.5 lb-ft) 5) Remove A/T oil pan (1) and oil pan gasket (2).
Page 676 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-107 Inspection Resistance Check Measure resistance between pressure control solenoid valve (1) terminals. Pressure control solenoid valve resistance Ω Standard: 5.0 – 5.6 (at 20°C (68°F)) Operation Check Check pressure control solenoid valve operation in the either manner of the followings.
Page 677 7B1-108 AUTOMATIC TRANSAXLE (M13 ENGINE) [Not using regulated DC power supply] 1) Connect pressure control solenoid valve (1) to battery (2) setting the 8 – 10 W bulb (4) on the way as shown in the fig- ure. 2) Check for movement of valve (3) in the direction of arrow “A”. 3) Disconnect pressure control solenoid valve (1) from battery (2) and check for movement of valve (3) in the direction of arrow “B”...
Page 678 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-109 Transmission Control Module (TCM) CAUTION: • TCM and ECM consists of highly precise parts, there- fore when handling it, be careful not to expose to excessive shock. • When replacing TCM with used one, all learned con- tents, which have been stored in TCM memory by exe- cuting learning control, should be initialized after replacement.
Page 679 7B1-110 AUTOMATIC TRANSAXLE (M13 ENGINE) A/T Relay Inspection 1) Disconnect negative cable at battery. 2) Remove glove box. 3) Remove A/T relay (1) from instrument panel wire harness. 4) Check that there is no continuity between terminal “C” and “D”. If continuity is indicated, replace A/T relay.
Page 680 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-111 Transmission Fluid Temperature Sensor Inspection 1) Disconnect negative cable at battery. 2) Lift up vehicle. 3) With engine is cool, remove drain plug and drain A/T fluid. 4) Install drain plug. (Refer to “Fluid Change” in this section.) 5) Remove A/T oil pan.
Page 681 7B1-112 AUTOMATIC TRANSAXLE (M13 ENGINE) Installation Reverse removal procedure to install solenoid wire harness and valve body assembly noting the following points. • For details of valve body assembly and their connectors installation, refer to “Unit Assembly” in this section. •...
Page 682 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-113 Differential Side Oil Seal Replacement 1) Lift up vehicle and drain automatic transaxle fluid. 2) Remove drive shaft joints from differential gear of transaxle. Refer to “Drive Shaft Assembly” in Section 4A for procedure to disconnect drive shaft joints. For differential side oil seal removal, it is not necessary to remove drive shafts from steering knuckle.
Page 683 7B1-114 AUTOMATIC TRANSAXLE (M13 ENGINE) 5) Install new differential side oil seals (1) by using special tool. Special tool (C): 09944-88220 (D): 09924-74510 Differential side oil seal installing depth Right side “a”: 2.6 – 3.6 mm (0.10 – 0.14 in) Left side “b”: 3.8 –...
Page 684 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-115 Automatic Transaxle Assembly Components 1. Drive plate 5. Lower stiffener 2. Drive plate bolt 6. Transaxle and engine fastening bolt : Apply sealant 99000-31230 to thread. 3. Drive plate to torque converter bolt 7. Transaxle and engine fastening nut 4.
Page 685 7B1-116 AUTOMATIC TRANSAXLE (M13 ENGINE) Dismounting 1) Take down transaxle with engine. For its procedure, refer to “Engine Assembly” in Section 6A2. 2) Remove lower stiffener (1). 3) Remove drive plate to torque converter bolts. To lock drive plate (1), engage flat head rod or the like (2) with drive plate ring gear.
Page 686 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-117 Remounting 1) Make sure that torque converter is installed correctly to tran- saxle. Refer to “Unit Assembly” in this section. WARNING: Be sure to keep transaxle with torque converter horizon- tal or facing up throughout the work. Should it be tilted with torque converter down, converter may fall off and cause personal injury.
Page 687 7B1-118 AUTOMATIC TRANSAXLE (M13 ENGINE) Unit Repair When repairing automatic transaxle, it is necessary to conduct the on-vehicle test to investigate where the cause of the trouble lies first. Then whether overhaul should be done or not is determined. If the transaxle is disassembled without such pre- liminary procedure, not only the cause of the trouble would be unknown, but also a secondary trouble may occur and often time would be wasted.
Page 688 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-119 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 689 7B1-120 AUTOMATIC TRANSAXLE (M13 ENGINE) Unit Disassembly CAUTION: • Thoroughly clean transaxle exterior before overhauling • Keep working table, tools and hands clean while over- hauling. • Use special care to handle aluminum parts so as not to damage them. •...
Page 690 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-121...
Page 691 7B1-122 AUTOMATIC TRANSAXLE (M13 ENGINE) 1. Torque converter 33. Oil pan 65. 2nd brake retaining plate 2. Torque converter housing 34. A/T fluid drain plug 66. 2nd brake disc : Apply sealant 99000-31230 to mating surface to transaxle case. 3. Oil strainer assembly 35.
Page 692 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-123 Disassembly CAUTION: Remove torque converter as much straight as possible. Leaning it may cause to damage oil seal lip. 1) Remove torque converter (1). 2) Remove engine mounting LH bracket (1). 3) Remove manual select lever (1). 4) Uncaulk lock washer (1), then remove lock nut (2) and lock washer (1).
Page 693 7B1-124 AUTOMATIC TRANSAXLE (M13 ENGINE) 5) Remove transmission range sensor (1). 6) Remove input shaft speed sensor (1) and output shaft speed sensor (VSS) (2). 7) Remove harness bracket (3) and select cable clamp (4). 8) Remove fluid cooler pipes (1) and pipe union (2). 9) Remove fluid level gauge (3) and fluid filler tube (4).
Page 694 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-125 11) Remove oil strainer assembly (1). 12) Disconnect connectors from solenoid valves, and transmis- sion fluid temperature sensor (1). 13) Remove valve body assembly bolts. CAUTION: Be careful not to let manual valve fall off when removing valve body assembly.
Page 695 7B1-126 AUTOMATIC TRANSAXLE (M13 ENGINE) 15) Remove valve body harness (1). CAUTION: When pulling valve body harness (1) out of transaxle case, take care not to damage transmission fluid temper- ature sensor (2) at narrow exit of case. Careless sensor treatment might cause sensor malfunc- tion.
Page 696 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-127 18) Remove accumulator pistons and springs. To remove C2 (1), C1 (2) and B1 (3) accumulator pistons and springs, position rag on pistons to catch each piston. To remove pistons, force low-pressure compressed air (1 kg/ , 15 psi, 100 kPa, max) into hole (4) as shown in figure, and pop each piston into rag.
Page 697 7B1-128 AUTOMATIC TRANSAXLE (M13 ENGINE) 22) Remove breather hose (1). 23) Remove breather union (2). 24) Measure input shaft thrust play. Apply dial gauge onto input shaft end (1) and measure thrust play of input shaft. When input shaft thrust play is out of specification, select input shaft front thrust bearing with proper thickness from among the list below and replace it.
Page 698 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-129 27) Remove input shaft front thrust bearing (1). NOTE: If input shaft front thrust bearing is not found, it may have been taken out with oil pump assembly. 28) Remove input shaft rear thrust bearing (1) and thrust bearing race (2).
Page 699 7B1-130 AUTOMATIC TRANSAXLE (M13 ENGINE) 32) Remove fluid reservoir LH plate (1). 33) Turn over transaxle and remove rear cover assembly (1). 34) Remove reverse clutch drum thrust bearing (1). NOTE: If reverse clutch drum thrust bearing is not found, it may have been taken out with rear cover assembly.
Page 700 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-131 36) Measure O/D and 2nd coast brake piston stroke. • Measure dimension “a” from mating surface of transaxle case to O/D and 2nd coast brake rear plate (1) using straightedge and micrometer caliper. • Measure dimension “b” from O/D and 2nd coast brake piston (2) to rear cover assembly mating surface using straightedge and micrometer caliper.
Page 701 7B1-132 AUTOMATIC TRANSAXLE (M13 ENGINE) 39) Remove O/D and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4). 40) Remove forward clutch hub (1). 41) Remove rear sun gear thrust bearing (1) from forward clutch hub (2).
Page 702 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-133 44) Remove planetary gear thrust bearing (1). NOTE: If planetary gear thrust bearing is not found on one-way clutch No.1 assembly, it may have been left in trasaxle. 45) Remove one-way clutch No.1 assembly (2) from rear plane- tary sun gear subassembly (3).
Page 703 7B1-134 AUTOMATIC TRANSAXLE (M13 ENGINE) 50) Before disassembling 2nd brake piston assembly (4), check 2nd brake piston stroke by measuring clearance between 2nd brake separator plate (1) and piston (2) with feeler gauge (3). If clearance (piston stroke) is out of specification, replace brake discs and plates with new ones.
Page 704 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-135 54) Remove 2nd brake separator plates (1) discs (2) and retain- ing plate (3). 55) Remove brake drum gasket (1). 56) Remove one-way clutch outer race retainer (1). 57) Check one-way clutch No.2 as follows. •...
Page 705 7B1-136 AUTOMATIC TRANSAXLE (M13 ENGINE) 59) Remove planetary gear assembly (1). 60) Measure 1st and reverse brake piston stroke • Using special tool, measure 1st and reserve brake piston stroke when compressed air (400 – 800 kPa, 4 – 8 kg/cm 57 –...
Page 706 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-137 64) Turn over transaxle and uncaulk reduction drive gear nut (1). 65) Secure reduction drive gear (1) with parking lock pawl, then remove reduction drive gear nut. CAUTION: • It is recommended that this operation should be car- ried out on rubber mat to prevent damaging transaxle case.
Page 707 7B1-138 AUTOMATIC TRANSAXLE (M13 ENGINE) 68) Screwing 3 bolts (1), remove reduction drive gear (2). Bolt Length 30 mm (1.20 in.) CAUTION: Screw 3 bolts into reduction drive gear uniformly, or reduction drive gear, bearing and transaxle case may be damaged.
Page 708 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-139 72) Using spring pin remover with 3 mm (0.12 in.) in diameter and hammer, drive out manual valve lever pin (1). 73) Remove manual shift shaft (2). 74) Remove parking lock pawl rod (2) from manual valve lever (1).
Page 709 7B1-140 AUTOMATIC TRANSAXLE (M13 ENGINE) Inspection Brake Discs Dry and inspect them for pitting, burn flaking, significant wear, glazing, cracking, charring and chips or metal particles imbedded in lining. If discs show any of the above conditions, replacement is required. NOTE: •...
Page 710 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-141 One-way Clutch No.1 Assembly 1) Install one-way clutch No.1 assembly (2) to rear planetary sun gear subassembly (1). 2) Securing rear planetary sun gear subassembly, ensure that one-way clutch No.1 assembly rotates only in one direction. If the one-way clutch rotates in both directions or it does not rotate in either direction, replace it with new one.
Page 711 7B1-142 AUTOMATIC TRANSAXLE (M13 ENGINE) Oil pump assembly 1. Oil seal 7. Oil pump subassembly bolts : Apply grease 99000-25030 to oil seal lip. 2. O-ring Apply automatic transaxle fluid. 3. Oil pump body Tightening torque 4. Oil pump driven gear Do not reuse.
Page 712 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-143 3) Remove oil seal (1) using special tool. Special tool (A): 09913-50121 2. Oil pump body Inspection 1) Check body clearance of driven gear. Push driven gear to one side of body Using feeler gauge, measure clearance between driven gear and body.
Page 713 7B1-144 AUTOMATIC TRANSAXLE (M13 ENGINE) 4) Using special tool, measure stator shaft bush bore. If measured stator shaft bush bore is out of specifications, replace oil pump assembly with new one. Special tool (A): 09900-20605 Stator shaft bush bore Standard: 18.424 – 18.450 mm (0.7254 – 0.7264 in.) 1.
Page 714 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-145 3) Install stator shaft assembly to oil pump body and tighten 8 pump subassembly bolts (1) to specification. Tightening torque Oil pump subassembly bolt (a): 10 N·m (1.0 kg-m, 7.5 lb-ft) 4) After applying A/T fluid to new O-ring, install it to oil pump body.
Page 715 7B1-146 AUTOMATIC TRANSAXLE (M13 ENGINE) Direct clutch assembly 1. Input shaft front thrust bearing 8. Shaft snap ring 2. Input shaft seal ring 9. Direct clutch separator plate 3. Input shaft subassembly 10. Direct clutch disc 4. Inner O-ring 11. Direct clutch retaining plate 5.
Page 716 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-147 Preliminary Check 1) Install direct clutch assembly (1) to oil pump assembly (2), blow in air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) through oil hole (3) of oil pump assembly with special tool attached on upper surface of direct clutch piston, and mea- sure piston stroke of direct clutch.
Page 717 7B1-148 AUTOMATIC TRANSAXLE (M13 ENGINE) 5) Remove outer O-ring (1). 2. Direct clutch piston 6) Remove inner O-ring (2). 1. Input shaft subassembly 7) Remove input shaft seal rings (1). Inspection Clutch Discs, Plates and Retaining Plate Check that sliding surfaces of discs, separator plates and retain- ing plate are not worn hard or burnt.
Page 718 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-149 Direct Clutch Return Spring Subassembly Measure free length of direct clutch return spring. Free length of direct clutch return spring “a”: 36.04 mm (1.419 in.) NOTE: • Do not apply excessive force when measuring spring free length.
Page 719 7B1-150 AUTOMATIC TRANSAXLE (M13 ENGINE) • Install plate snap ring so that its both ends would be posi- tioned in correct locations as shown in figure. [A] Correct [B] Incorrect • After assembly, measure direct clutch piston stroke. Special tool (A): 09900-20607 (B): 09900-20701 Direct clutch piston stroke: 0.4 –...
Page 720 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-151 Forward and reverse clutch assembly 1. Forward clutch balancer 11. Reverse clutch separator plate 2. Forward clutch return spring subassembly 12. Reverse clutch disc 3. Forward clutch piston 13. Reverse clutch cushion plate 4. Forward clutch piston O-ring 14.
Page 721 7B1-152 AUTOMATIC TRANSAXLE (M13 ENGINE) Preliminary Check 1) Install forward and reverse clutch assembly (1) to transaxle rear cover (2), blow in compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) through oil hole (4) of transaxle rear cover with the special tool attached on the upper surface of reverse clutch retaining plate (3), and measure reverse clutch piston stroke.
Page 722 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-153 3) Remove balancer snap ring by using special tool and hydraulic press. CAUTION: Do not press forward clutch return spring subassembly in over 1.5 mm (0.059 in.). Excessive compression may cause damage to return spring subassembly and/or balancer. Special tool (A): 09926-97610 4) Remove forward clutch balancer (1).
Page 723 7B1-154 AUTOMATIC TRANSAXLE (M13 ENGINE) 8) Remove forward clutch piston O-ring (1) from intermediate shaft subassembly (2). 9) Remove forward clutch drum O-ring (1) from forward clutch drum (2). 10) Remove intermediate shaft seal ring (1) from intermediate shaft subassembly (2). Inspection Clutch Discs, Separator Plates and Retaining Plate Check that sliding surfaces of discs, separator plates and retain-...
Page 724 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-155 Forward Clutch Return Spring Subassembly Measure free length of forward clutch return spring. Free length of forward clutch return spring: 24.04 mm (0.946 in.) NOTE: • Do not apply excessive force when measuring spring free length. •...
Page 725 7B1-156 AUTOMATIC TRANSAXLE (M13 ENGINE) • Do not damage forward clutch return spring subassembly and balancer by pressing in forward clutch return spring sub- assembly passing through its original installing position over 1.5 mm (0.059 in.). Special tool (A): 09926-97610 •...
Page 726 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-157 • Measure forward clutch piston stroke in the same manner as “Preliminary Check”. Special tool (A): 09900-20607 (B): 09900-20701 (C): 09952-06020 Forward clutch piston stroke: 1.30 – 1.50 mm (0.051 – 0.059 in.) When piston stroke is out of specification, select forward clutch retaining plate with proper thickness from among the list below and replace it.
Page 727 7B1-158 AUTOMATIC TRANSAXLE (M13 ENGINE) • Install reverse clutch plate snap ring so that its both ends would be positioned in correct locations as shown in figure. [A]: Correct [B]: Incorrect • Measure reverse clutch piston stroke in the same manner as “Preliminary Check”.
Page 728 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-159 2nd brake piston assembly 1. 2nd brake cylinder 4. Outer O-ring 2. 2nd brake piston Apply automatic transaxle fluid. 3. Inner O-ring Do not reuse. Disassembly 1) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 –...
Page 729 7B1-160 AUTOMATIC TRANSAXLE (M13 ENGINE) Assembly Reverse disassembly procedure for assembly, noting the following points. • Use new O-rings. Apply A/T fluid to the O-rings, before installation. • Install 2nd brake piston (1) to which A/T fluid is applied to 2nd brake cylinder (2).
Page 730 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-161 Transaxle rear cover assembly (O/D and 2nd coast brake piston) 1. Snap ring 7. Transaxle rear cover 2. O/D and 2nd coast brake return spring subassembly 8. Rear cover plug 3. O/D and 2nd coast brake piston front O-ring 9.
Page 731 7B1-162 AUTOMATIC TRANSAXLE (M13 ENGINE) 3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) to oil hole (2) of transaxle rear cover (1) to remove O/D and 2nd coast brake piston. 4) Remove O/D and 2nd coast brake piston front O-ring (1) and rear O-ring (2).
Page 732 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-163 Inspection O/D and 2nd Coast Blake Return Spring Subassembly Measure free length of O/D and 2nd coast blake return spring. Free length of O/D and 2nd coast blake return spring “a”: 18.99 mm (0.748 in.) NOTE: •...
Page 733 7B1-164 AUTOMATIC TRANSAXLE (M13 ENGINE) • Do not damage O/D and 2nd coast brake return spring sub- assembly and piston by pressing in O/D and 2nd coast brake return spring subassembly passing through its original installing position over 1.0 mm (0.039 in.). Special tool (A): 09926-96030 (B): 09946-06710...
Page 734 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-165 Disassembly 1) Remove final gear bolts (1), and then final gear (2). 2) Remove differential side RH bearing by using special tools. Special tool (A): 09926-37610 (B): 09926-37610-001 (C): 09926-37610-003 (D): 09926-47610-002 3) Remove output shaft speed sensor (VSS) drive gear (1). 2.
Page 735 7B1-166 AUTOMATIC TRANSAXLE (M13 ENGINE) Inspection 1) Hold differential case subassembly with soft jawed vice and set special tools as shown. Special tool (A): 09900-20607 (B): 09900-20701 2) Measure differential gear thrust play. Differential gear thrust play: 0.05 – 0.20 mm (0.002 – 0.008 in.) 3) If thrust play is out of specification, replace differential case subassembly.
Page 736 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-167 3) Tighten final gear bolts (1) to specified torque. Tightening torque Final gear bolt (a): 78 N·m (7.8 kg-m, 56.5 lb-ft) 2. Final driven gear NOTE: • To avoid rust, apply A/T fluid to final driven gear after installation.
Page 737 7B1-168 AUTOMATIC TRANSAXLE (M13 ENGINE) Countershaft assembly 1. Countershaft RH bearing 5. Bearing cap 2. Countershaft 6. Countershaft bearing shim 3. Countershaft LH bearing Apply automatic transaxle fluid. 4. Reduction driven gear Do not reuse. Disassembly 1) Remove countershaft LH bearing (1) and reduction driven gear (2) at once by using special tool and hydraulic press.
Page 738 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-169 Assembly 1) Install new countershaft RH bearing (1) by using special tool and hydraulic press. Special tool (A): 09913-84510 NOTE: Replace countershaft RH bearing together with bearing cup as a set. 2) Install reduction driven gear (1) with special tools and hydraulic press.
Page 739 7B1-170 AUTOMATIC TRANSAXLE (M13 ENGINE) Valve body assembly 1. Pressure control solenoid valve 8. Manual valve 2. Shift solenoid valve-A (No.1) 9. Solenoid lock plate 3. Shift solenoid valve-B (No.2) 10. O-ring 4. TCC (Lock-up) solenoid valve Apply automatic transaxle fluid. 5.
Page 740 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-171 2) Remove pressure control solenoid valve (1). 2. Solenoid lock plate 3) Remove TCC (Lock-up) solenoid valve (1). 4) Remove shift solenoid valve-A (1). 5) Remove shift solenoid valve-B (1). 6) Remove timing solenoid valve (1).
Page 741 7B1-172 AUTOMATIC TRANSAXLE (M13 ENGINE) 7) Remove temperature sensor clamp (1). Assembly Reverse disassembly procedure for assembly, noting following points. • Shift solenoid valve-A and -B are identical • After applying A/T fluid to new O-rings, fit them to solenoid valves, then install solenoid valves to valve body.
Page 742 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-173 2) Remove lubrication LH tube (1) and RH tube (2). NOTE: Do not bend lubrication tube with excessive force. 3) Remove differential side oil seal (1). 4) Remove countershaft RH bearing cup by using special tools. Special tool (A): 09944-96011 (B): 09942-15511...
Page 743 7B1-174 AUTOMATIC TRANSAXLE (M13 ENGINE) Assembly 1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque converter housing. Tightening torque Torque converter housing plug (a): 7.5 N·m (0.75 kg-m, 5.5 lb-ft) 2) Using special tools, assemble differential side RH bearing cup.
Page 744 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-175 5) Install lubrication LH tube (1) and RH tube (2). 6) Install fluid reservoir RH plate (1) and lubrication tube clamp (2). Tightening torque Lubrication tube clamp bolt (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) Fluid reservoir RH plate bolt (b): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) Transaxle case...
Page 745 7B1-176 AUTOMATIC TRANSAXLE (M13 ENGINE) 3) Remove differential side LH bearing cup and shim with spe- cial tools. Special tool (A): 09944-96011 (B): 09942-15511 Assembly 1) Using special tools, assemble shim and differential side LH bearing cup. Special tool (A): 09924-74510 (B): 09944-88220 NOTE: Use shim with same thickness as the removed one.
Page 746 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-177 Adjustment before unit assembly Differential Side Bearing Preload 1) After applying A/T fluid to differential assembly, fit it to tran- saxle case. 2) Install torque converter housing to transaxle case, then tighten bolts (1) to specified torque. Tightening torque Torque converter housing bolt (a): 33 N·m (3.3 kg-m, 24.0 lb-ft)
Page 747 7B1-178 AUTOMATIC TRANSAXLE (M13 ENGINE) Available shim thickness Thickness Identification mark 1.80 mm (0.070 in.) 1.85 mm (0.072 in.) 1.90 mm (0.074 in.) 1.95 mm (0.076 in.) 2.00 mm (0.078 in.) 2.05 mm (0.080 in.) 2.08 mm (0.081 in.) 2.11 mm (0.083 in.) 2.14 mm (0.084 in.) 2.17 mm (0.085 in.) 2.20 mm (0.087 in.)
Page 748 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-179 3) Measure bearing preload (b) by using special tool. Special tool (A): 09928-06050 Counter shaft bearing preload = (b) – Differential side bearing preload (a) Counter shaft bearing preload (Starting torque) In the case of new bearing 0.33 –...
Page 749 • Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before assembly. • Use Suzuki Super Grease “C” to retain parts in place. • Be sure to install thrust bearings and races in correct direction and position.
Page 750 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-181 4) After applying A/T fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3) and manual valve lever to transaxle case. 5) After installing manual valve lever pin (2) by using spring pin remover with 3 mm (0.12 in.) in diameter (5) and hammer, turn spacer to set the position as shown in the figure.
Page 751 7B1-182 AUTOMATIC TRANSAXLE (M13 ENGINE) 9) Install 1st and reverse brake return spring subassembly (1) to transaxle case (2). 10) Apply A/T fluid to 1st and reverse brake discs (2) separator plates (3) and retaining plate (1), then install them to tran- saxle case.
Page 752 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-183 12) Install 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations as shown in figure. [A] Correct [B] Incorrect 13) Using special tools, measure 1st and reverse brake piston stroke when compressed air (400 –...
Page 753 7B1-184 AUTOMATIC TRANSAXLE (M13 ENGINE) 15) Install parking lock pawl (1) and spring (2). Apply A/T fluid to parking lock pawl shaft, then insert it into transaxle case. 16) Install new planetary ring gear subassembly (1) to reduction drive gear (3) by using special tools and hydraulic press. CAUTION: •...
Page 754 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-185 18) Caulk reduction drive gear nut (1). 19) Apply A/T fluid to planetary gear assembly (1), then fit it to planetary ring gear assembly. 20) Check for correct installation of planetary gear assembly as follows. Measure the distance “a”...
Page 755 7B1-186 AUTOMATIC TRANSAXLE (M13 ENGINE) 21) Apply A/T fluid to one-way clutch No.2 assembly (1), then install it to planetary gear assembly. After that, ensure that planetary carrier rotates only in counterclockwise direction “A”, not in clockwise direction “B”. 22) Install one-way clutch outer race retainer (1). 23) Apply A/T fluid to new brake drum gasket (1), then install it to transaxle case.
Page 756 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-187 26) Apply A/T fluid to 2nd brake piston assembly (1), and align the projection of 2nd brake piston assembly with the groove of transaxle case, then put together. 27) Install 2nd brake piston snap ring (1) by using special tool and hydraulic press.
Page 757 7B1-188 AUTOMATIC TRANSAXLE (M13 ENGINE) 30) Apply A/T fluid to front planetary sun gear (1) and install it to planetary gear assembly (2). 31) Install O/D and 2nd coast brake retaining plate snap ring (1). CAUTION: Be sure to install O/D and 2nd coast brake retaining plate snap ring correctly in groove of transaxle case.
Page 758 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-189 36) After applying A/T fluid to rear sun gear thrust bearing race (1), install it to rear planetary sun gear (2). 37) After applying A/T fluid to rear sun gear thrust bearing (1), install it to forward clutch hub (2). 38) After applying A/T fluid to forward clutch hub (1), install it in transaxle case (2).
Page 759 7B1-190 AUTOMATIC TRANSAXLE (M13 ENGINE) 41) Check for correct installation of forward and reverse clutch assembly as follows. Measure distance “a” by using micrometer caliper (1) and “a” straightedge (2). If out of specification, remove forward and reverse clutch assembly, forward clutch hub, rear planetary sun gear subassembly and one-way clutch No.1 assembly, and reinstall them properly.
Page 760 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-191 43) Measure O/D and 2nd coast brake piston stroke. • Measure dimension “a” from end face of transaxle case to O/ D and 2nd coast brake rear plate (1) using straightedge and micrometer caliper. • Measure dimension “b” from O/D and 2nd coast brake piston (2) to rear cover assembly mating surface using straightedge and micrometer caliper.
Page 761 7B1-192 AUTOMATIC TRANSAXLE (M13 ENGINE) 46) Remove sealant attached to mating surface of transaxle rear cover (1) completely. 47) Apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter.
Page 762 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-193 54) After applying A/T fluid to direct clutch hub (1), install it to planetary gear assembly. 55) After applying A/T fluid to input shaft rear thrust bearing (1) and thrust bearing race (2), install them into direct clutch hub (3).
Page 763 7B1-194 AUTOMATIC TRANSAXLE (M13 ENGINE) 58) Check for correct installation of direct clutch assembly as fol- lows. Measure distance “a” by using micrometer caliper (1) and “a” straightedge (2). If out of specification, remove direct clutch assembly, direct clutch hub and reinstall them properly. Distance between direct clutch assembly and mating sur- face of transaxle case “a”: 10.5 –...
Page 764 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-195 61) Measure input shaft thrust play. Apply dial gauge onto input shaft end (1) and measure thrust play of input shaft. Special tool (A): 09900-20607 (B): 09900-20701 Input shaft thrust play: 0.3 – 0.9 mm (0.012 – 0.035 in.) 62) After applying A/T fluid to new O-ring, fit it to breather union (2).
Page 765 7B1-196 AUTOMATIC TRANSAXLE (M13 ENGINE) 67) After applying A/T fluid to new O-ring, fit it to transaxle case plug (1). Then install the transaxle case plug to transaxle case (2). Tightening torque Transaxle case plug (a): 7.5 N·m (0.75 kg-m, 5.5 lb-ft) 68) Install new O-rings to each accumulator piston and apply A/T fluid to them.
Page 766 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-197 70) After applying A/T fluid to cooler check valve (1) and spring (2), install them to transaxle case (3). 71) After applying A/T fluid to new governor apply No.1 gasket (1), install it to transaxle case. 72) After applying A/T fluid to new O-ring, fit it to valve body har- ness connector (3), then install valve body harness to tran- saxle case.
Page 767 7B1-198 AUTOMATIC TRANSAXLE (M13 ENGINE) 74) Tighten valve body bolts to specified torque. Tightening torque Valve body bolt 11 N·m (1.1 kg-m, 8.0 lb-ft) Valve body bolt length Bolt Length “a” Pieces 20 mm (0.79 in.) 28 mm (1.10 in.) 49 mm (1.93 in.) 36 mm (1.42 in.) 40 mm (1.58 in.)
Page 768 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-199 77) Install oil cleaner magnets (1) in oil pan (2). NOTE: If metal particles are attached to the magnets, clean them before installing. 78) Install new oil pan gasket (1) between transaxle case and oil pan (2).
Page 769 7B1-200 AUTOMATIC TRANSAXLE (M13 ENGINE) 82) Apply A/T fluid to O-rings of each sensor and install input shaft speed sensor (1) and output shaft speed sensor (VSS) (2). Tightening torque Input shaft speed sensor bolt (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) Output shaft speed sensor (VSS) bolt (b): 13 N·m (1.3 kg-m, 9.5 lb-ft) 83) Install harness bracket (3) and select cable clamp (4).
Page 770 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-201 91) Bend dents of lock washer (1) in order to prevent displace- ment of lock washer. 92) Install manual select lever (1). Tightening torque Manual select lever nut (a): 13 N·m (1.3 kg-m, 9.5 lb-ft) 93) Install engine mounting LH bracket (1).
Page 771 7B1-202 AUTOMATIC TRANSAXLE (M13 ENGINE) CAUTION: • Before installing converter, make sure that its pump hub portion is free from nicks, burrs or damage which may cause oil seal to leak. • Be very careful not to drop converter on oil pump gear. Damage in gear, should it occur, may cause a critical trouble.
Page 772 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-203 Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft A/T fluid drain plug 12.5 Output shaft speed sensor bolt Input shaft speed sensor bolt 0.55 Transaxle case plug 0.75 Solenoid valve bolt Rear cover plug 0.75 Transaxle and engine fastening bolt and nut 61.5...
Page 773 7B1-204 AUTOMATIC TRANSAXLE (M13 ENGINE) Special Tool 09900-20605 09900-20607 09900-20701 09913-50121 Dial caliper gauge Dial gauge Magnetic stand Oil seal remover 09913-61510 09913-70123 09913-84510 09913-85210 Bearing puller Bearing installer Bearing installer Bearing installer 09923-78210 09924-74510 09925-37811-001 09925-88210 Bearing installer Bearing installer handle Oil pressure gauge Bearing puller attachment 09925-98210...
Page 774 AUTOMATIC TRANSAXLE (M13 ENGINE) 7B1-205 09926-37610-002 09926-37610-003 09926-58010 09926-96030 Bearing puller attachment Bearing remover attach- Bearing remover attach- Clutch spring compressor See NOTE 2. ment ment See NOTE 2. 09926-96050 09926-97610 09926-97620 09926-98310 Brake piston compressor Spring compressor Spring compressor Clutch spring compressor 09928-06050 09942-15511...
Page 775 • Automatic transaxle An equivalent of DEXRON -III • Parts lubrication when installing • O-rings Sealant SUZUKI BOND No. 1216B • Mating surface of torque converter (99000-31230) housing • Mating surface of rear cover assem- • Torque converter housing bolts •...
Page 776 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 777: Clutch Cable
7C-2 CLUTCH (G10/M13 ENGINES) On-Vehicle Service Clutch Cable [A]: For RH vehicle 5. Clutch release lever nut 11. Adjust bolt [B]: For LH vehicle 6. Clutch release lever bolt 12. Clutch cable outer bolt 1. Clutch cable 7. Clutch pedal 13.
Page 778 CLUTCH (G10/M13 ENGINES) 7C-3 REMOVAL 1) Disconnect negative cable at battery. 2) Remove clutch cable joint nut (1). 3) Remove joint pin (2) from clutch release lever (3). 4) Remove clutch cable outer bolts (1) from dash panel (2) in engine room.
Page 779 7C-4 CLUTCH (G10/M13 ENGINES) INSTALLATION 1) Apply grease to cable end hook (1) and also joint pin (2) before installing cable. “A”: Grease 99000-25010 2) Hook cable end with pedal using screwdriver or long nose pliers from cabin inside, then join inner cable joint pin in release lever.
Page 780 CLUTCH (G10/M13 ENGINES) 7C-5 Clutch Pedal and Clutch Pedal Bracket 1. Clutch pedal bracket 9. Adjust bolt 2. Pedal bracket bolt 10. Packing (in cabin) 3. Pedal bracket nut 11. Pedal return cushion 4. Pedal shaft 12. Clutch pedal 5. Pedal bush 13.
Page 781 7C-6 CLUTCH (G10/M13 ENGINES) Clutch Cover, Clutch Disc and Flywheel [A]: M13 engine 7. Clutch release shaft No.1 bush : Apply grease 99000-25010 to bush inside. (0.3 g (0.01 oz)) [B]: G10 engine 8. Release bearing : Apply grease 99000-25010 to joint of bearing and release shaft and also bearing inside.
Page 782 CLUTCH (G10/M13 ENGINES) 7C-7 3) Pull out input shaft bearing (1) using the special tools, if bearing removal is necessary. Special tool (A): 09921-26020 (B): 09930-30104 (C): 09917-58010 [A]: M13 engine 2. Flywheel [B]: G10 engine 3. Wrench 4) Loosen flywheel bolt while holding flywheel with special tool and removal flywheel from crank shaft.
Page 783 7C-8 CLUTCH (G10/M13 ENGINES) Clutch cover 1) Check diaphragm spring (1) for abnormal wear or damage. 2) Inspect pressure plate (2) for wear or heat spots. 3) If abnormality is found, replace clutch cover. Do not disas- semble it into diaphragm spring and pressure plate. Flywheel Check surface contacting clutch disc for abnormal wear or heat spots.
Page 784 CLUTCH (G10/M13 ENGINES) 7C-9 3) Aligning clutch disc to flywheel center using special tool, install clutch cover (1) and bolts (2). Then tighten bolts to specification. NOTE: • While tightening clutch cover bolts, compress clutch disc with special tool (C) by hand so that disc cen- tered.
Page 785 7C-10 CLUTCH (G10/M13 ENGINES) 6) Install tap (M16 X 1.5) (1) to clutch release shaft No.1 bush. 7) Pull out No.1 bush using tap (1) and special tools. Special tool (B): 09923-46020 (C): 09930-30104 INSPECTION Clutch release bearing Check clutch release bearing for smooth rotation. If abnormality is found, replace it.
Page 786 CLUTCH (G10/M13 ENGINES) 7C-11 INSTALLATION 1) Drive in a new No.1 bush using special tools, and then apply grease to bush inside. Special tool (A): 09930-30104 (B): 09923-46030 “A”: Grease 99000-25010 2) Install release shaft with return spring. 3) Apply grease to No.2 bush (1) inside and press-fit it using the same special tool as in removal.
Page 787 16.5 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Cable end hook and joint pin. (99000-25010) • Release shaft bushes and seal. • Release shaft. • Release bearing inside. • Pedal spring.
Page 788 CLUTCH (G10/M13 ENGINES) 7C-13 Special Tool 09917-58010 09921-26020 09922-46010 09923-36320 Bearing remover Bearing remover Bush remover Clutch center guide 09923-36330 09923-46020 09923-46030 09924-17810 Clutch center guide Joint pipe Joint pipe Flywheel holder 09925-98210 09925-98221 09930-30104 Input shaft bearing Bearing installer Sliding shaft installer...
Page 789 7C-14 CLUTCH (G10/M13 ENGINES)
Page 790 • For the descriptions (items) not found in this section, refer to the same section of the Service Man- ual mentioned in “FOREWORD” of this manual. • The sealant SUZUKI BOND NO.1215B (99000-31110) is changed to SUZUKI BOND NO.1217G (99000- 31260). In the service manual mentioned in “FOREWORD” of this manual, it is instructed that the sealant SUZUKI BOND No.1215B (99000-31110) should be used for the servicing of transfer.
Page 791 7D-2 TRANSFER Unit Repair Overhaul 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 50 N·m (5.0 kg-m) 55 N·m (5.5 kg-m) 23 N·m (2.3 kg-m) 55 N·m (5.5 kg-m) 50 N·m (5.0 kg-m) 1. Transfer assy 6. Transfer to engine stiffener 11.
Page 792 18. Snap ring Do not reuse. 9. Reduction drive gear oil seal 19. Circlip Tightening torque : Apply SUZUKI SUPER GREASE A 99000-25010 to oil seal lip. 10. Pinion shaft bearing 20. Bevel gear nut Apply transfer oil. : After tightening nut to specified...
Page 793 7D-4 TRANSFER DISMOUNTING 1) Disconnect negative cable at battery. 2) Hoist vehicle and remove wheels. 3) Drain transaxle oil referring to “Manual Transaxle Oil Change” in Section 7A2. 4) Drain transfer oil referring to “Oil Change” in Section 7D of the Service Manual mentioned in the “FOREWORD”...
Page 794 TRANSFER 7D-5 12) Remove transfer rear mounting bracket (2) with transfer rear mounting (1) from transfer assembly. MOUNTING Reverse dismounting procedure for installation noting the follow- ing. 1) Tighten transfer mounting bolts (3) to specified torque. Tightening torque Transfer mounting bolt (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) 1.
Page 795 7D-6 TRANSFER 4) Tighten transfer to engine stiffener bolts to specified torque. Tightening torque Transfer to engine stiffener No.1 bolt (a): 50 N·m (5.0 kg-m, 36.5 lb-ft) Transfer to engine stiffener No.2 bolt (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) 5) Tighten transfer to transaxle stiffener bolts (1) to specified torque.
Page 796 TRANSFER 7D-7 Required Service Material Recommended SUZUKI products Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Oil seal lips (99000-25010) • O-ring Sealant SUZUKI BOND NO. 1217G • Oil drain plug (99000-31260) • Oil level plug • Mating surface of transfer case...
Page 797 7D-8 TRANSFER...
Page 798 REAR DIFFERENTIAL 7F-1 SECTION 7F REAR DIFFERENTIAL NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in “FOREWORD” of this manual. CONTENTS General Description........7F-2 Differential carrier and drive bevel pinion............
Page 799 7F-2 REAR DIFFERENTIAL General Description The rear differential assembly for 4WD model uses a hypoid bevel pinion and gear. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Page 800 REAR DIFFERENTIAL 7F-3 3) Remove brake drum and disconnect parking brake cable from brake back plate referring to “Parking Brake Lever Cable Removal and Installation” in Section 5C. 4) Remove axle shafts referring to “Rear Axle Shaft and Wheel Bearing Remove and Installation (for 4WD Model)” in Sec- tion 3E.
Page 801 7F-4 REAR DIFFERENTIAL REMOUNTING Reverse removal procedure for installation, noting the following. • Clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side. “A”: Sealant 99000-31260 • Apply sealant to carrier bolts (2) and tighten carrier bolts to specified torque.
Page 802 REAR DIFFERENTIAL 7F-5 Unit Repair Overhaul 1. Drive bevel pinion nut 10. Drive bevel pinion rear taper roller 19. Differential pinion : After tightening nut so as rotational torque bearing of drive bevel pinion to be in specified torque, caulk nut securely. 2.
Page 803 7F-6 REAR DIFFERENTIAL DISASSEMBLY 1) Put match marks (4) on differential side bearing caps (3) and differential carrier (1). 2) Take off differential side bearing caps by removing their bolts and remove differential gear assembly (2) with shims. NOTE: Check number of shims and thickness of each shim in advance.
Page 804 REAR DIFFERENTIAL 7F-7 9) Hold companion flange (1) with special tool and then remove drive bevel pinion nut. Special tool (A): 09930-40113 10) Remove companion flange from drive bevel pinion. Use special tool if it is hard to remove. Special tool (B): 09913-65135 11) Remove drive bevel pinion with rear bearing, and spacer from differential carrier.
Page 805 7F-8 REAR DIFFERENTIAL 15) Drive out drive bevel pinion bearing outer races (1) by using metallic stick (2). INSPECTION • Check companion flange for wear of damage. • Check bearings for wear or discoloration. • Check differential carrier for cracks. •...
Page 806 REAR DIFFERENTIAL 7F-9 Drive bevel pinion bearing outer race For press-fitting bevel pinion bearing outer races, use special tools as shown. CAUTION: Perform press-fitting carefully so as not to tilt outer race. Special tool (A): 09925-98210 (B): 09941-34513-004 (C): 09924-74510 (D): 09951-16090 Differential case assembly 1) Assemble differential case assembly noting installing posi-...
Page 807 7F-10 REAR DIFFERENTIAL 2) Measure thrust play of differential gear (2) as follows. Special tool (A): 09900-20607 (B): 09900-20701 Differential gear thrust play 0 – 0.37 mm (0 – 0.014 in.) [A]: Right side [B]: Left side Right side • Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surface of gear (2).
Page 808 REAR DIFFERENTIAL 7F-11 7) Press-fit differential side bearings (3) to differential case (1) by using special tools. Special tool (A): 09951-76010 (B): 09951-16060 2. Drive bevel gear Differential carrier and drive bevel pinion A: Dummy height of pinion form dummy (= 40 mm/1.575 in.) F: Shim thickness for mounting distance adjustment (= D) 6.
Page 809 7F-12 REAR DIFFERENTIAL 1) Assemble bearing form dummy with dummy shaft using spe- cial tools. Special tool (A): 09922-76120 (B): 09922-76230 2) Install dial gauge (1) to bearing form dummy with dummy shaft as shown in figure. Special tool set distance (reference) “c”: 2 –...
Page 810 REAR DIFFERENTIAL 7F-13 6) Tighten bevel pinion nut (special tool) (1) so that specified bearing preload is obtained. NOTE: Before taking measurement, check for rotation by hand more than 15 revolutions. Drive bevel pinion bearing preload (at 50 rpm) 0.5 – 1.3 N·m (5.0 – 13.0 kg-cm, 0.35 – 0.90 lb-ft) 7) Set dial gauge to bearing form dummy with dummy shaft and make 0 (zero) adjustment on surface plate.
Page 811 7F-14 REAR DIFFERENTIAL 11) Select adjusting shim(s) (1) closest to calculated value from among following available sizes and put it in place and then press-fit rear bearing. Special tool (A): 09940-51710 Available shim thickness “a”: 0.30, 1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21, 1.24, 1.27, and 1.30 mm (0.012, 0.039, 0.041, 0.042, 0.043, 0.044, 0.045, 0.046, 0.048, 0.049, 0.050 and 0.051 in.) 12) With new pinion spacer (3) inserted as shown, install front...
Page 812 REAR DIFFERENTIAL 7F-15 15) Install companion flange (3) to drive bevel pinion and tighten drive bevel pinion nut gradually with special tool, set preload of bearing to specification. NOTE: • Before taking measurement, check for smooth rotation by hand. • Drive bevel pinion bearing preload is adjusted by tight- ening drive bevel pinon nut to deform spacer.
Page 813 7F-16 REAR DIFFERENTIAL 2) Divide selected shim(s) between both sides (right and left) and install them to differential carrier. Then install differential side bearing caps. NOTE: • Align match marks (1) on caps and carrier. • Apply differential gear oil to bearings. Tightening torque Differential side bearing cap bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
Page 814 REAR DIFFERENTIAL 7F-17 5) After completing of gear tooth contact check, caulk drive bevel pinion nut (2) with caulking tool (1) and hammer. 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.
Page 815 Material (Part Number) Thread lock cement THREAD LOCK CEMENT 1322 Drive bevel gear bolts (99000-32110) Lithium grease SUZUKI SUPER GREASE A Oil seal lips (99000-25010) Sealant SUZUKI BOND NO. 1217G • Thread part of differential carrier bolt (99000-31260) • Mating surface of differential carrier...
Page 816 REAR DIFFERENTIAL 7F-19 Special Tool 09900-20607 09900-20701 09913-50121 09913-60910 Dial gauge Magnetic stand Oil seal remover Bearing puller 09913-65135 09913-75810 09922-76120 09922-76140 Bearing puller Bearing installer Dummy shaft Bevel pinion shaft 09922-76150 09922-76230 09922-76320 09922-76340 Bevel pinion nut Bevel gear dummy Rear collar Rear collar 09922-76410...
Page 817 7F-20 REAR DIFFERENTIAL 09925-88210 09925-98210 09930-40113 09940-51710 Bearing puller attachment Bearing installer Flange holder Bearing installer 09941-34513-004 09951-16060 09951-16090 09951-76010 Bearing installer Lower arm bush remover Oil seal installer Bearing installer...
Page 818: Lighting System
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 819: Rear Fog Light
8B-2 LIGHTING SYSTEM Diagnosis Rear Fog Light Condition Possible Cause Correction Rear fog light does not • Main fuse and/or fuses blown Replace main fuse and/or fuses to come on when head- check for short lights and front fog lights •...
Page 820 LIGHTING SYSTEM 8B-3 On-Vehicle Service Rear Fog Light Rear fog light circuit Inspection 1) Check headlights and front fog lights (if equipped) come on. If headlight and/or fog light does not come on, check for light controller circuit as follows. 2) Disconnect negative cable at battery.
Page 821 8B-4 LIGHTING SYSTEM...
Page 822 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 823: Combination Meter
8C-2 INSTRUMENTATION/DRIVER INFORMATION General Description Combination Meter A27 A11 A18 A19 A15 A9 A8 A23 A25 A12 A10 A7 A24 A3 A11 A12 A13 A14 A15 A16 A9 A10 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 [A]: Terminal arrangement of coupler viewed from harness side 3.
Page 824 INSTRUMENTATION/DRIVER INFORMATION 8C-3 Diagnosis Low Engine Oil Level Warning Light Symptom Diagnosis for Z13DT Engine Condition Possible Cause Correction Low engine oil level Fuse blown Replace fuse to circuit for short. warning light does not Wiring or grounding faulty Repair circuit. light up when low Engine oil level switch faulty Check engine oil level switch refer-...
Page 825 8C-4 INSTRUMENTATION/DRIVER INFORMATION On-Vehicle Service Low Fuel Warning System Operation This light comes ON for 4 seconds after ignition switch is turned to ON position, and goes out. However, in insufficient fuel level, this light indicates low fuel level by the following operation. Low fuel warning light operation Low fuel warning Fuel level in fuel tank...
Page 826 INSTRUMENTATION/DRIVER INFORMATION 8C-5 7) After 4 seconds, check for low fuel warning lamp operation under the following each float position (1) of fuel pump (2). If faulty condition is found, replace combination meter. Low fuel warning light operation for G10/M13 engine Float position Low fuel warning light operation...
Page 827 8C-6 INSTRUMENTATION/DRIVER INFORMATION...
Page 828: Immobilizer Control System
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 829 8G-2 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) General Description Components The immobilizer control system designed to prevent vehicle burglar and it consists of following components. • Engine control module (ECM) • Immobilizer control module (with coil antenna) • Ignition key (with built-in transponder) Operations 1) Each ignition key has its own FIX CODE (FC) stored in memory.
Page 830 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) 8G-3 On-board Diagnostic System for M13 Engine Model ECM and immobilizer control module diagnose troubles which may occur in the area including the following parts when the igni- tion switch is turned to ON position. Immobilizer control module •...
Page 831 8G-4 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) Diagnosis Diagnostic Flow Table for M13 Engine Model Step Action Turn ignition switch to start engine. Go to step 5. Go to step 2. Does engine run? W-line circuit check W-line circuit is in good W-line circuit open or Measure terminal voltage of immobilizer control condition.
Page 832 SUZUKI scan tool. If communication between scan tool and immobilizer control module can not be established, check if SUZUKI scan tool is communicable by connecting it to immobilizer control system another vehicle. If communication is possible in this case, SUZUKI scan tool is in good condition.
Page 833 8G-6 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) Inspection of Immobilizer Control Module and Its Circuits for M13 Engine Model Voltage Inspection Immobilizer control module can be checked at wiring connectors by measuring voltage. CAUTION: Immobilizer control module can not be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to immobilizer control module with coupler disconnected from it.
Page 834 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) 8G-7 DTC B3040 W-line Communication Fail for M13 Engine Model Wiring Circuit Refer to “Wiring Circuit for M13 Engine Model” on page 8G-2. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area No response from ECM while immobilizer control mod- W-line circuit ule requests signal ECM power circuit...
Page 835 8G-8 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) DTC B3042 W-line CKT Malf (Short to Ground) for M13 Engine Model Wiring Circuit Refer to “Wiring Circuit for M13 Engine Model” on page 8G-2. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area W-line circuit voltage is low.
Page 836 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) 8G-9 DTC B3043 W-line CKT Malf (Short to Battery) for M13 Engine Model Wiring Circuit Refer to “Wiring Circuit for M13 Engine Model” on page 8G-2. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area W-line circuit voltage is high.
Page 837 8G-10 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) DTC B3059 No Request from ECM for M13 Engine Model Wiring Circuit Refer to “Wiring Circuit for M13 Engine Model” on page 8G-2. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area No request from ECM via MIL circuit Ignition switch is MIL circuit faulty not reset correctly.
Page 838 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES) 8G-11 Special Tools 09931-76011 Tech-1A kit (SUZUKI scan Tech-2 kit (SUZUKI scan tool) tool) (See NOTE “A”.) (See NOTE “B”.) NOTE: • “A”: This kit includes the following items. 1. Storage case, 2. Operator's manual, 3. Tech-1A, 4. DLC cable, 5. Test lead/probe, 6. Power source cable, 7.
Page 839 8G-12 IMMOBILIZER CONTROL SYSTEM (G10/M13 ENGINES)
Page 840 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 841: Body Structure
9-2 BODY SERVICE Body Structure Front Fender Removal 1) Remove front bumper. 2) Disconnect connector of side turn signal lamp. 3) Remove front fender lining (1). 4) Remove front fender (2). Installation Reverse removal procedure for installation. NOTE: If paint on fender bolt is peeled off, be sure to apply paint again.
Page 842 BODY SERVICE 9-3 Front Bumper and Rear Bumper NOTE: Fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 843 9-4 BODY SERVICE Exterior and Interior Trim Back Door Emblem Back door emblem dimension Dimension Dimension Position Position 22.36 1.57 2.99 0.08 2.72 0.35 22.6 0.35 74.5 2.93 0.35 2.91...
Page 844 BODY SERVICE 9-5 Panel Clearance Panel to panel clearance Dimension Dimension Position Position 4.1 – 6.1 0.161 – 0.24 6 – 8 0.236 – 0.315 5 – 7 0.197 – 0.276 4.8 – 7.8 0.189 – 0.307 5 – 7 0.197 –...
Page 845 9-6 BODY SERVICE...
Page 846 Prepared by 1st Ed. August, 2003 Printed in Japan...

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