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Suzuki 2005-2010 Grand Vitara Owner's Manual

Manual is about: GRAND VITARA

Summary of 2005-2010 Grand Vitara

  • Page 1

    Important warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the words , and note have special meanings. Pay special attention to the messages high- lighted by these signal words. The circle with a slash in this manual means “don’t d...

  • Page 3: Foreword

    Foreword this manual (volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (service) and for disassembly and assembly of major components (unit repair-overhaul). Volume 1 contains general information, engine, suspension, dr...

  • Page 4

    Recommendaton of genuine suzuki parts and accessories use suzuki strongly recommends the use of genuine suzuki parts* and accessories. Genuine suzuki parts and accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's exact specifications. A wid...

  • Page 5: Table of Contents

    00 0 1 2 3 4 5 6 7 8 9 10 11 volume 1 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ...........

  • Page 7: Section 00

    Table of contents 00- i 00 section 00 contents precautions precautions ...............................................00-1 precautions........................................................... 00-1 precautions for vehicles equipped with a supplemental restraint (air bag) system ..... 00-1 general p...

  • Page 8: Precautions

    00-1 precautions: precautions precautions precautions for vehicles equipped with a supplemental restraint (air bag) system s5jb0a0000001 warning ! • the configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be s...

  • Page 9

    Precautions: 00-2 diagnosis • when troubleshooting air bag system, be sure to follow “air bag diagnostic system check: in section 8b”. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. • never use electrical test equipment other ...

  • Page 10

    00-3 precautions: • never dispose of live (undeployed) air bag (inflator) modules (driver, passenger, side and curtain). If disposal is necessary, be sure to deploy them according to deployment procedures described in “air bag (inflator) module and seat belt pretensioner disposal: in section 8b”. • ...

  • Page 11

    Precautions: 00-4 caution ! • even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “repair and inspection required after accident: in section 8b”. • when servicing parts other than air bag s...

  • Page 12

    00-5 precautions: caution ! • before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.G. Buttons) may cause damage to the vehicle’s finish. • when performing service to electrical pa...

  • Page 13

    Precautions: 00-6 • whenever you use oil seals, gaskets, packing, o-rings, locking washers, split pins, self-locking nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new gaskets, packing, etc., be sure to remove any residual material from the mating surfac...

  • Page 14

    00-7 precautions: • use care not to expose connectors and electrical parts to water which will be a cause of a trouble. • always be careful not to handle electrical parts (computer, relay, etc.) in a rough manner or drop them. Precaution in servicing full-time 4wd vehicle s5jb0a0000018 warning ! Thi...

  • Page 15

    Precautions: 00-8 • when testing with 2-wheel brake tester, be sure to observe the following instructions. Otherwise, drive train damage and personal injury may result. – shift transmission to n (neutral) position. – shift transfer to n (neutral) position if transfer position is selectable. – run en...

  • Page 16

    00-9 precautions: precaution for can communication system s5jb0a0000005 • 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 lines discrimination. Excessively-loosed lines may be influe...

  • Page 17

    Precautions: 00-10 • when installing vehicle parts, be careful so that the wiring harness is not interfered with or caught by any other part. • to avoid damage to the harness, protect its part which may contact against a part forming a sharp angle by winding tape or the like around it. • be careful ...

  • Page 18

    00-11 precautions: precautions for installing mobile communication equipment s5jb0a0000004 when installing mobile communication equipment such as cb (citizens-band)-radio or cellular-telephone, be sure to observe the following precautions. Failure to follow cautions may adversely affect electronic c...

  • Page 19

    Precautions: 00-12 suspension caution s5jb0a0000010 caution ! • all suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an ...

  • Page 20

    00-13 precautions: when checking system circuits including an electronic control unit such as ecm, tcm, abs control module, etc., it is important to perform careful check, starting with items which are easier to check. 1) disconnect negative cable from battery 2) check each connector at both ends of...

  • Page 21

    Precautions: 00-14 b) also, if measured values were as listed in the following, it means that there is a resistance (abnormality) of such level that corresponds to the voltage drop in the circuit between terminals “a-1” and “b-1”. Voltage between “c-1” and body ground: approx. 5 v “b-1” and body gro...

  • Page 22

    00-15 precautions: intermittent and poor connection inspection s5jb0a0006002 most intermittent are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits ...

  • Page 23: Section 0

    Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 abbreviations ...................................................... 0a-1 symbols .............................

  • Page 24: General Information

    0a-1 general information: general information general description abbreviations s5jb0a0101001 a: abdc: after bottom dead center abs: anti-lock brake system ac: alternating current a/c: air conditioning a-elr: automatic-emergency locking retractor a/f: air fuel mixture ratio alr: automatic locking re...

  • Page 25

    General information: 0a-2 s: sae: society of automotive engineers sdm: sensing and diagnostic module (air bag controller, air bag control module) sfi: sequential multiport fuel injection sohc: single over head camshaft t: tbi: throttle body fuel injection (single-point fuel injection, spi) tcc: torq...

  • Page 26

    0a-3 general information: wire color symbols s5jb0a0101004 there are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. As the color symbol, the single-colored wire uses only one, three or five alphabets (i.E. “g” or “grn”); the d...

  • Page 27

    General information: 0a-4 standard tightening torque each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener o...

  • Page 28

    0a-5 general information: vehicle lifting points s5jb0a0101006 warning ! • before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending of what part to be removed. • before lifting up the vehicle, check to be sur...

  • Page 29

    General information: 0a-6 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. It is extremely dangerous to do any work on the ...

  • Page 30

    0a-7 general information: engine supporting points s5jb0a0101010 warning ! When using engine supporting device (1), be sure to observe the followings. Otherwise, not only deformation of vehicle body and/or engine hook but also personal injury may result. • apply supporting device at the specified po...

  • Page 31

    General information: 0a-8 component location warning, caution and information label location s5jb0a0103001 the figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to warning / caution instructions printed on labels. If any warn...

  • Page 32

    0a-9 general information: 1 2 3 4 7 7 6 8 5 i5jb0a010009-03 1. Air bag label on driver air bag (inflator) module 4. Air bag label on passenger air bag (inflator) module 7. Air bag label on side air bag module 2. Air bag label on contact coil assembly 5. Air bag label on sdm 8. Air bag label on curta...

  • Page 33: Maintenance and Lubrication

    Maintenance and lubrication: 0b-1 maintenance and lubrication precautions precautions for maintenance and lubrication s5jb0a0200001 air bag warning refer to “air bag warning: in section 00”. Scheduled maintenance maintenance schedule under normal driving conditions s5jb0a0205001 note • this interval...

  • Page 34

    0b-2 maintenance and lubrication: note • “r”: replace or change • “i”: inspect and correct, replace or lubricate if necessary • for sweden, items with asterisk (*) should be performed by odometer reading only. • for spark plugs, replace every 50,000 km if the local law requires. • nickel spark plug:...

  • Page 35

    Maintenance and lubrication: 0b-3 note • “i”: inspect and correct or replace if necessary. • “r”: replace or change. • “t”: tighten to specified torque. • *1: inspect more frequently if the vehicle is used under dusty conditions. • *2: clean more frequently if the air flow from air conditioning decr...

  • Page 36

    0b-4 maintenance and lubrication: repair instructions engine accessory drive belt inspection s5jb0a0206001 warning ! All inspection and replacement are to be performed with engine not running. Water pump and generator drive belt inspect belt for cracks, cuts, deformation, wear cleanliness and tensio...

  • Page 37

    Maintenance and lubrication: 0b-5 engine oil and filter change s5jb0a0206003 warning ! • new and used engine oil can be hazardous. Be sure to read “general precautions: in section 00” and observe what in written there. • steps 1) – 7) must be performed with engine not running. For step 8), be sure t...

  • Page 38

    0b-6 maintenance and lubrication: 7) replenish oil until oil level is brought to full level mark on dipstick. (oil pan and oil filter capacity). The filler inlet is at the top of the cylinder head cover. Use only engine oil of sg, sh, sj, sl or sm grade. Select the appropriate oil viscosity accordin...

  • Page 39

    Maintenance and lubrication: 0b-7 exhaust system inspection s5jb0a0206006 warning ! To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance, or the vehicle is raised f...

  • Page 40

    0b-8 maintenance and lubrication: fuel evaporative emission control system inspection s5jb0a0206047 1) visually inspect hoses for cracks, damage, or excessive bends. Inspect all clamps for damage and proper position. 2) check evap canister for operation and clog, referring to “evap canister inspecti...

  • Page 41

    Maintenance and lubrication: 0b-9 parking brake lever and cable inspection s5jb0a0206024 1) inspect brake cable for damage and smooth movement. Replace cable if it is in deteriorated condition. 2) check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever...

  • Page 42

    0b-10 maintenance and lubrication: wheel discs inspection s5jb0a0206026 inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Wheel bearing inspection s5jb0a0206027 1) check front wheel bearing for wear, damage, abnormal noise or rattles. For d...

  • Page 43

    Maintenance and lubrication: 0b-11 5) check boots of steering linkage for damage (leaks, detachment, tear, dent, etc.). If damage is found, replace it with new one. If any dent is found on steering rack boots, correct it to original shape by turning steering wheel to the right or left as far as it s...

  • Page 44

    0b-12 maintenance and lubrication: automatic transmission fluid change s5jb0a0206033 1) inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) make sure that vehicle is placed level. 3) change fluid referring to “a/t fluid change: in section 5a”. Automatic transmissi...

  • Page 45

    Maintenance and lubrication: 0b-13 power steering (p/s) system inspection s5jb0a0206038 1) visually check power steering system for fluid leakage and hose for damage and deterioration. Repair or replace defective parts, if any. 2) check fluid level with engine stopped. If it is lower than lower leve...

  • Page 46

    0b-14 maintenance and lubrication: engine start check engine start for readiness. Warning ! Before performing the following check, be sure to have enough room around the vehicle. Then, firmly apply both the parking brake and the regular brakes. Do not use the accelerator pedal. If the engine starts,...

  • Page 47

    Maintenance and lubrication: 0b-15 specifications tightening torque specifications s5jb0a0207001 reference: for the tightening torque of fastener not specified in this section, refer to “fastener information: in section 0a”. Special tools and equipment recommended fluids and lubricants s5jb0a0208001...

  • Page 48

    0b-16 maintenance and lubrication:.

  • Page 49: Section 1

    Table of contents 1- i 1 section 1 contents engine precautions .................................................1-1 precautions............................................................. 1-1 precautions for engine.......................................... 1-1 engine general information and diagnos...

  • Page 50

    1-ii table of contents dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2) .....................................................1a-107 dtc p0140: o2 sensor (ho2s) circuit no activity detected (sensor-2) .........................1a-110 dtc p0171 / p0172 / p2195 / p2196: ...

  • Page 51

    Table of contents 1-iii vacuum hose and purge valve chamber inspection.......................................................... 1b-3 evap canister purge valve inspection .............. 1b-3 evap canister inspection................................... 1b-4 egr valve removal and installation ............

  • Page 52

    1-iv table of contents pistons, piston rings, connecting rods and cylinders disassembly and assembly .....1d-44 cylinders, pistons and piston rings inspection........................................................1d-45 piston pins and connecting rods inspection.........................................

  • Page 53

    Table of contents 1-v general description ........................................... 1e-11 engine lubrication description .........................1e-11 diagnostic information and procedures.......... 1e-13 oil pressure check ........................................... 1e-13 repair instructions ......

  • Page 54

    1-vi table of contents ignition spark test ..............................................1h-6 repair instructions ..............................................1h-7 high-tension cord removal and installation (for m16 engine) ..............................................1h-7 high-tension cord inspec...

  • Page 55: Precautions

    Precautions: 1-1 precautions precautions precautions for engine s5jb0a1000001 air bag warning refer to “air bag warning: in section 00”. Precautions on engine service refer to “precautions on engine service: in section 1a”. Precautions in diagnosing trouble refer to “precautions in diagnosing troubl...

  • Page 56

    1a-1 engine general information and diagnosis: engine general information and diagnosis precautions precautions on engine service s5jb0a1100001 caution ! The following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reliable en...

  • Page 57

    Engine general information and diagnosis: 1a-2 precautions for dtc troubleshooting s5jb0a1100005 • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special ...

  • Page 58

    1a-3 engine general information and diagnosis: engine diagnosis general description s5jb0a1101002 this vehicle is equipped with an engine and emission control system which are under control of ecm. The engine and emission control system in this vehicle are controlled by ecm. Ecm has an on-board diag...

  • Page 59

    Engine general information and diagnosis: 1a-4 • if the above areas of engine and emission control system is free from any trouble after the engine start (while engine is running), malfunction indicator lamp (1) turns off. • when ecm detects a trouble which has occurred in the above areas, it makes ...

  • Page 60

    1a-5 engine general information and diagnosis: priority of freeze frame data: ecm has 4 frames where the freeze frame data can be stored. The first frame stores the freeze frame data of the malfunction which was detected first. However, the freeze frame data stored in this frame is updated according...

  • Page 61

    Engine general information and diagnosis: 1a-6 engine and emission control system description s5jb0a1101004 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 in...

  • Page 62

    1a-7 engine general information and diagnosis: ecm transmission data note in communication between ecm and combination meter, between ecm and keyless start control module (if equipped) and between ecm and 4wd control module (for j20 engine), data is transmitted only from ecm to combination meter, ke...

  • Page 63

    Engine general information and diagnosis: 1a-8 ecm reception data tcm (for a/t model) bcm data ecm receive torque reduction request slip control signal transmission malfunction indication on transmission emissions related malfunction active transmission gear selector position daytime running light a...

  • Page 64

    1a-9 engine general information and diagnosis: air intake system description s5jb0a1101006 the main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “description of electric throttle body system: ”.), intake m...

  • Page 65

    Engine general information and diagnosis: 1a-10 description of electric throttle body system s5jb0a1101009 the electric throttle body system consists of electric throttle body assembly, accelerator pedal position (app) sensor assembly, ecm and throttle actuator control relay. Among them, assembly co...

  • Page 66

    1a-11 engine general information and diagnosis: description of electric throttle body system calibration s5jb0a1101010 ecm calculates controlled opening of the throttle valve on the basis of the completely closed throttle valve position of the electric throttle body system. The completely closed pos...

  • Page 67

    Engine general information and diagnosis: 1a-12 a/f sensor description s5jb0a1101012 a/f sensor (1), in place of the conventional heated oxygen sensor-1, is installed in the center of the exhaust manifold joining section and it consists of a zirconia element (2) which causes the output current to va...

  • Page 68

    1a-13 engine general information and diagnosis: electronic control system description s5jb0a1101007 the electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ecm which controls various devices according to the signals from the sensors an...

  • Page 69

    Engine general information and diagnosis: 1a-14 engine and emission control system flow diagram fuel t ank fuel level sensor fuel pump egr va lv e map sensor int a ke manifold exha ust manifold v a cuum exha ust gas air fuel va p o r three w a y ca t a lyst exha ust pipe ev ap canister ev ap caniste...

  • Page 70

    1a-15 engine general information and diagnosis: ecm input / output circuit diagram for j20 engine 26 26-1 37 38 39 40 41 +b 60 ig1 +bb ig2 ig2 64 : 74 : 75 pnk pnk/blk pnk/grn pnk/blu grn/blk blk/wht wht blu blu/blk blu/blk 70 : 5v : 12v 42 43 yel yel/grn yel/blk 73 61 yel/red ig1 e23-29 e23-2 c37-5...

  • Page 71

    Engine general information and diagnosis: 1a-16 1. Accelerator pedal position (app) sensor assembly 26-1. Sub fuel level sensor 52. A/c compressor (if equipped with a/c) 2. Shield wire 27. Stop lamp switch 53. “cprsr” fuse 3. Cmp sensor 28. Stop lamp 54. Ignition coil assembly (for no.1 spark plug) ...

  • Page 72

    1a-17 engine general information and diagnosis: for m16 engine 32 33 34 35 36 +b 52 ig1 st ig2 ig2 56 : 64 : 65 pnk pnk/blk pnk/grn pnk/blu grn/blk blk/wht wht blu blu/blk blu/blk 61 : 5v : 12v 37 yel yel/grn yel/blk 63 53 yel/red ig1 e23-29 e23-2 c37-58 e23-1 e23-16 c37-15 c37-30 c37-29 46 e23-60 c...

  • Page 73

    Engine general information and diagnosis: 1a-18 terminal arrangement of ecm coupler (viewed from harness side) connector: c37 1. Accelerator pedal position (app) sensor assembly 22. Stop lamp switch 44. Radiator cooling fan motor no.1 2. Shield wire 23. Stop lamp 45. Radiator cooling fan motor no.2 ...

  • Page 74

    1a-19 engine general information and diagnosis: connector: e23 9 blu electric load current sensor signal (for j20 engine) 39 — — 10 grn/wht co adjusting resistor signal (if equipped) 40 red throttle position sensor (sub) signal 11 red oxygen signal of heated oxygen sensor-2 41 grn ground for throttl...

  • Page 75

    Engine general information and diagnosis: 1a-20 4 wht/red can (high) communication line (active high signal) to abs hydraulic unit / control module assembly 34 — — 5 ppl/wht 12 v serial communication line of data link connector 35 — — 6 blk/wht cruise control main switch signal (if equipped with cru...

  • Page 76

    1a-21 engine general information and diagnosis: engine and emission control input / output table s5jb0a1101008 input output electric control device fuel level sensor for detecting fuel level barometric pressure sensor stop lamp switch start switch ignition switch a/c refrigerant pressure sensor (if ...

  • Page 77

    Engine general information and diagnosis: 1a-22 schematic and routing diagram engine and emission control system diagram s5jb0a1102001 48 37 25 42 35 33 34 24 43 18 26 10 9 7 8 14 13 23 11 15 12 2 6 1 3 30 29 38 16 17 36 31 22 21 40 27 41 32 4 28 44 5 45 20 19 46 47 39 49 i5jb0a110015-04.

  • Page 78

    1a-23 engine general information and diagnosis: component location electronic control system components location s5jb0a1103001 for j20 engine note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 1. Air cleaner 18. Radia...

  • Page 79

    Engine general information and diagnosis: 1a-24 for m16 engine note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. Information sensors control devices others 1. Maf and iat sensor a: fuel injector a: ecm 2. Electric th...

  • Page 80

    1a-25 engine general information and diagnosis: diagnostic information and procedures engine and emission control system check s5jb0a1104001 refer to the following items for the details of each step. Information sensors control devices others 1. Maf and iat sensor a: fuel injector a: ecm 2. Electric...

  • Page 81

    Engine general information and diagnosis: 1a-26 step 1: customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for p...

  • Page 82

    1a-27 engine general information and diagnosis: customer problem inspection form (example) note this form is a standard sample. It should be modified according to conditions characteristic of each market. I2rh01110010-01.

  • Page 83

    Engine general information and diagnosis: 1a-28 step 2: dtc / freeze frame data check, record and clearance first, check dtc (including pending dtc), referring to “dtc check: ”. If dtc is indicated, print it and freeze frame data or write them down and then clear them by referring to “dtc clearance:...

  • Page 84

    1a-29 engine general information and diagnosis: using scan tool 1) prepare suzuki scan tool or obd generic scan tool (vehicle not equipped with diagnosis connector). 2) with ignition switch turned off, connect it to data link connector (dlc) (1) located on underside of instrument panel at driver’s s...

  • Page 85

    Engine general information and diagnosis: 1a-30 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 battery cable, removing fuse or disconnecting ecm co...

  • Page 86

    1a-31 engine general information and diagnosis: ) *p0102 mass air flow circuit low input output voltage of maf sensor is less than specification. 1 driving cycle ) *p0103 mass air flow circuit high input output voltage of maf sensor is more than specification. 1 driving cycle ) u*p0106 manifold abso...

  • Page 87

    Engine general information and diagnosis: 1a-32 ) *p0223 throttle position sensor (sub) circuit high output voltage of throttle position sensor (sub) is higher than specification. 1 driving cycle ) u*p0300 random misfire detected misfire of such level as to cause damage to three way catalyst. *2 dri...

  • Page 88

    1a-33 engine general information and diagnosis: ) p0620 generator control circuit battery voltage is higher than specification even through generator control is maximum regulation, or battery voltage is lower than specification even through generator control is minimum regulation and electric load i...

  • Page 89

    Engine general information and diagnosis: 1a-34 ) *p2135 throttle position sensor (main / sub) voltage correlation difference between the opening angle based on throttle position sensor (main) and the opening angle based on throttle position sensor (sub) is more than specification. 1 driving cycle )...

  • Page 90

    1a-35 engine general information and diagnosis: for vehicle equipped with a/t when using obd generic scan tool, not only the previous star (*) marked ecm dtc(s) but also the following dtc(s) is displayed on obd generic scan tool simultaneously. Dtc no. Detecting item detecting condition (dtc will se...

  • Page 91

    Engine general information and diagnosis: 1a-36 fail-safe table s5jb0a1104006 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. Detected item fail-safe operat...

  • Page 92

    1a-37 engine general information and diagnosis: scan tool data s5jb0a1104007 as the data values 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 condition, there may...

  • Page 93

    Engine general information and diagnosis: 1a-38 ) fuel tank level ignition switch on 0 – 100% ) battery voltage ignition switch on / engine at stop 10 – 14 v ) battery current (for j20 engine) at 2000 r/min. With no load after warming up 10.0 – 16.0 v at 2000 r/min. With headlight on and blower moto...

  • Page 94

    1a-39 engine general information and diagnosis: ) a/c pressure (a/c refrigerant absolute pressure) engine running a/c on (a/c is operating) at ambient temperature: 30 °c (86 °f) and humidity: 50% 1300 – 1480 kpa (for j20 engine), 1150 – 1280 kpa (for m16 engine) for more details, refer to pressure o...

  • Page 95

    Engine general information and diagnosis: 1a-40 scan tool data definitions coolant temp (engine coolant temperature, °c, °f) it is detected by engine coolant temp. Sensor. Intake air temp. ( °c, °f) it is detected by intake air temp. Sensor. Engine speed (rpm) it is computed by reference pulses from...

  • Page 96

    1a-41 engine general information and diagnosis: brake sw (on/off) this parameter indicates the state of the brake switch. Intake tuning sol (intake manifold tuning valve, on/off): on: command for intake manifold tuning valve being output. Off: command for intake manifold tuning valve not being outpu...

  • Page 97

    Engine general information and diagnosis: 1a-42 a/c switch (on/off) on: command for a/c operation being output from ecm to hvac. Off: command for a/c operation not being output. A/c comp relay (a/c compressor relay, on/ off) this parameter indicates the state of the a/c switch. Blower fan (on/off) t...

  • Page 98

    1a-43 engine general information and diagnosis: visual inspection s5jb0a1104008 visually check the following parts and systems. Inspection item reference section • engine oil – level, leakage “engine oil and filter change: in section 0b” • engine coolant – level, leakage “coolant level check: in sec...

  • Page 99

    Engine general information and diagnosis: 1a-44 engine basic inspection s5jb0a1104009 this check is very important for troubleshooting when ecm has detected no dtc and no abnormality has been found in “visual inspection: ”. Follow the flow carefully. Step action yes no 1 was “engine and emission con...

  • Page 100

    1a-45 engine general information and diagnosis: 8 check ignition timing 1) using suzuki scan tool, select “misc test” mode on suzuki scan tool and fix ignition timing to initial one. 2) using timing light (1), check initial ignition timing. Special tool (a): 09930–76420 for j20 engine for m16 engine...

  • Page 101

    Engine general information and diagnosis: 1a-46 10 check fuel supply 1) check to make sure that enough fuel is filled in fuel tank. 2) turn on ignition switch for 2 seconds and then off. 3) repeat step 2) a few times. Is fuel pressure felt from fuel feed hose when ignition switch is turned on? For j...

  • Page 102

    1a-47 engine general information and diagnosis: 13 check fuel injector for operation 1) install spark plugs and connect injector connectors. 2) using sound scope (1), check operating sound of each injector (2) when cranking engine. Was injector operating sound heard from all injectors? Go to “engine...

  • Page 103

    Engine general information and diagnosis: 1a-48 engine symptom diagnosis s5jb0a1104010 perform troubleshooting referring to the followings when ecm has detected no dtc and no abnormality has been found in “visual inspection: ” and “engine basic inspection: ”. Condition possible cause correction / re...

  • Page 104

    1a-49 engine general information and diagnosis: low oil pressure improper oil viscosity “engine oil and filter change: in section 0b” malfunctioning oil pressure switch “oil pressure switch inspection: in section 9c” clogged oil strainer “oil pan and oil pump strainer cleaning: for j20 engine in sec...

  • Page 105

    Engine general information and diagnosis: 1a-50 engine noise – connecting rod noise note before checking mechanical noise, make sure that: • specified spark plug is used. • specified fuel is used. Worn piston, ring and cylinder bore “pistons, piston rings, connecting rods and cylinders inspection an...

  • Page 106

    1a-51 engine general information and diagnosis: engine overheating inoperative thermostat “thermostat inspection: in section 1f” poor water pump performance “water pump inspection: in section 1f” clogged or leaky radiator “radiator on-vehicle inspection and cleaning: in section 1f” improper engine o...

  • Page 107

    Engine general information and diagnosis: 1a-52 excessive engine oil consumption – oil leakage blown cylinder head gasket “cylinder head inspection: for j20 engine in section 1d” or “cylinder head inspection: for m16a engine with vvt in section 1d” leaky camshaft oil seals “camshaft, tappet and shim...

  • Page 108

    1a-53 engine general information and diagnosis: surge – engine power variation under steady throttle or cruise. Feels like vehicle speeds up and down with no change in accelerator pedal leaky or loosely connected high-tension cord (for m16 engine) “high-tension cord removal and installation (for m16...

  • Page 109

    Engine general information and diagnosis: 1a-54 engine has no power faulty spark plug “spark plug inspection: in section 1h” faulty ignition coil with ignitor “ignition coil assembly (including ignitor) inspection: in section 1h” leaks, loose connection or disconnection of high-tension cord (for m16...

  • Page 110

    1a-55 engine general information and diagnosis: improper engine idling or engine fails to idle faulty spark plug “spark plug inspection: in section 1h” leaky or disconnected high-tension cord (for m16 engine) “high-tension cord removal and installation (for m16 engine): in section 1h” faulty ignitio...

  • Page 111

    Engine general information and diagnosis: 1a-56 excessive hydrocarbon (hc) emission or carbon monoxide (co) faulty spark plug “spark plug inspection: in section 1h” leaky or disconnected high-tension cord (for m16 engine) “high-tension cord removal and installation (for m16 engine): in section 1h” f...

  • Page 112

    1a-57 engine general information and diagnosis: malfunction indicator lamp does not come on with ignition switch on and engine stop (but engine can be started) s5jb0a1104011 wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn on (close the cont...

  • Page 113

    Engine general information and diagnosis: 1a-58 troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm co...

  • Page 114

    1a-59 engine general information and diagnosis: malfunction indicator lamp remains on after engine starts s5jb0a1104012 wiring diagram refer to “malfunction indicator lamp does not come on with ignition switch on and engine stop (but engine can be started): ”. Circuit description when the ignition s...

  • Page 115

    Engine general information and diagnosis: 1a-60 dtc p0010: camshaft position actuator circuit (for m16 engine) s5jb0a1104013 system and wiring diagram circuit description actual valve timing fails to become close to target advance level of each function although advance control function or retarded ...

  • Page 116

    1a-61 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to ...

  • Page 117

    Engine general information and diagnosis: 1a-62 dtc p0011 / p0012: camshaft position - timing over-advanced or system performance / -retarded (for m16 engine) s5jb0a1104014 system description actual value of advanced valve timing does not reach target value. Valve timing is advanced although ecm com...

  • Page 118

    1a-63 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 is dtc p0010 detected together? Go to “dtc p0010: camshaft posit...

  • Page 119

    Engine general information and diagnosis: 1a-64 dtc p0030: ho2s heater control circuit (sensor-1) s5jb0a1104088 wiring diagram a/f sensor description refer to “a/f sensor description: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect s...

  • Page 120

    1a-65 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Dtc p0031 / p0032: ho2s heater control circuit low / high (sensor-1) s5jb0a1104015 wi...

  • Page 121

    Engine general information and diagnosis: 1a-66 dtc confirmation procedure 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) run engine at idle speed for 1 min. Or more. 5) ...

  • Page 122

    1a-67 engine general information and diagnosis: 4 a/f sensor and ho2s heater resistance check 1) disconnect connector from ho2s-2 with ignition switch turned off. 2) check heater resistance of a/f sensor and ho2s referring to “air fuel ratio (a/f) sensor on-vehicle inspection: in section 1c” and “he...

  • Page 123

    Engine general information and diagnosis: 1a-68 8 ho2s heater relay circuit check 1) measure wire resistance between coil ground terminal of relay connector and vehicle body ground. Is measured resistance lower than 1 Ω ? Output wire of relay connector is open or short to ground. Repair or replace d...

  • Page 124

    1a-69 engine general information and diagnosis: dtc p0037 / p0038: ho2s heater control circuit low / high (sensor-2) s5jb0a1104016 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and ...

  • Page 125

    Engine general information and diagnosis: 1a-70 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to ...

  • Page 126

    1a-71 engine general information and diagnosis: 5 ho2s heater relay power circuit check 1) remove integration relay no.2 (for j20 engine) (1) or ho2s heater relay (for m16 engine) (2) with ignition switch turned off. 2) check for proper connection to relay connector. 3) if connection are ok, measure...

  • Page 127

    Engine general information and diagnosis: 1a-72 dtc p0101: mass air flow circuit range / performance s5jb0a1104017 wiring diagram 10 ho2s heater control circuit check 1) disconnect connector from ecm with ignition switch turned off. 2) check for proper connection of ho2s-2 heater circuit terminal to...

  • Page 128

    1a-73 engine general information and diagnosis: dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an acci...

  • Page 129

    Engine general information and diagnosis: 1a-74 3 maf sensor and its circuit check 1) with ignition switch turned off, connect scan tool to dlc. 2) start engine and warm up to normal operation temperature. 3) check maf value using scan tool. (refer to “scan tool data: ” for normal value.) is each va...

  • Page 130

    1a-75 engine general information and diagnosis: dtc p0102: mass air flow circuit low input s5jb0a1104018 wiring diagram refer to “dtc p0101: mass air flow circuit range / performance: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect s...

  • Page 131

    Engine general information and diagnosis: 1a-76 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to ...

  • Page 132

    1a-77 engine general information and diagnosis: dtc p0103: mass air flow circuit high input s5jb0a1104019 wiring diagram refer to “dtc p0101: mass air flow circuit range / performance: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect ...

  • Page 133

    Engine general information and diagnosis: 1a-78 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to ...

  • Page 134

    1a-79 engine general information and diagnosis: dtc p0106: manifold absolute pressure range / performance s5jb0a1104020 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure note check to make sure that the following conditions are satisfied when using this “dtc confirma...

  • Page 135

    Engine general information and diagnosis: 1a-80 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Dtc p0107: manifold absolute pressure circuit low input s5jb0a1104021 wiring diagram ...

  • Page 136

    1a-81 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to ...

  • Page 137

    Engine general information and diagnosis: 1a-82 dtc p0108: manifold absolute pressure circuit high input s5jb0a1104022 wiring diagram refer to “dtc p0106: manifold absolute pressure range / performance: ”. Dtc detecting condition and trouble area note when dtc p0113, p0118 and p0533 are indicated to...

  • Page 138

    1a-83 engine general information and diagnosis: 3 map sensor power supply voltage check 1) disconnect connector from map sensor with ignition switch turned off. 2) check for proper connection of map sensor at “gry/ red”, “red/wht” and “gry/grn” wire terminals. 3) turn on ignition switch, measure vol...

  • Page 139

    Engine general information and diagnosis: 1a-84 dtc p0111: intake air temperature circuit range / performance s5jb0a1104023 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure note check to make sure that following conditions are satisfied when using this “dtc confirma...

  • Page 140

    1a-85 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to ...

  • Page 141

    Engine general information and diagnosis: 1a-86 5 wire circuit check 1) disconnect connectors from ecm with ignition switch turned off. 2) measure resistance between “lt grn” wire terminal of maf and iat sensor connector and vehicle body ground. Is resistance infinity? Go to step 6. “lt grn” wire is...

  • Page 142

    1a-87 engine general information and diagnosis: dtc p0112: intake air temperature sensor circuit low s5jb0a1104024 wiring diagram refer to “dtc p0111: intake air temperature circuit range / performance: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch tu...

  • Page 143

    Engine general information and diagnosis: 1a-88 3 ecm voltage check 1) disconnect connector from maf and iat sensor with ignition switch turned off. 2) check for proper connection to maf and iat sensor at “lt grn” and “gry/grn” wire terminals. 3) if ok, then turn on ignition switch, measure voltage ...

  • Page 144

    1a-89 engine general information and diagnosis: dtc p0113: intake air temperature sensor circuit high s5jb0a1104025 wiring diagram refer to “dtc p0111: intake air temperature circuit range / performance: ”. Dtc detecting condition and trouble area note when dtc p0108, p0118 and p0533 are indicated t...

  • Page 145

    Engine general information and diagnosis: 1a-90 3 iat sensor voltage check 1) disconnect connector from maf and iat sensor with ignition switch turned off. 2) check for proper connection to maf and iat sensor at “lt grn” and “gry/grn” wire terminals. 3) if ok, then turn on ignition switch, measure v...

  • Page 146

    1a-91 engine general information and diagnosis: dtc p0116: engine coolant temperature circuit range / performance s5jb0a1104026 wiring diagram dtc detecting condition and trouble area 8 ground circuit check 1) remove ecm from its bracket with ecm connectors connected. 2) measure resistance between “...

  • Page 147

    Engine general information and diagnosis: 1a-92 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out b...

  • Page 148

    1a-93 engine general information and diagnosis: 5 wire harness check 1) disconnect ect sensor connector with ignition switch turned off. 2) check for proper connection to ect sensor connector at “ppl/yel” and “gry/grn” wire terminals. 3) if ok, then with ignition switch on, measure voltage between “...

  • Page 149

    Engine general information and diagnosis: 1a-94 dtc p0117: engine coolant temperature circuit low s5jb0a1104027 wiring diagram refer to “dtc p0116: engine coolant temperature circuit range / performance: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch t...

  • Page 150

    1a-95 engine general information and diagnosis: dtc p0118: engine coolant temperature circuit high s5jb0a1104028 wiring diagram refer to “dtc p0116: engine coolant temperature circuit range / performance: ”. Dtc detecting condition and trouble area note when dtc p0108, p0113 and p0533 are indicated ...

  • Page 151

    Engine general information and diagnosis: 1a-96 dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and run it for 10 sec. Or more. 4) check dtc and pending dtc. Dtc troubleshooting note before th...

  • Page 152

    1a-97 engine general information and diagnosis: 5 ect sensor harness voltage check 1) disconnect connectors from ecm with ignition switch turned off. 2) turn on ignition switch. 3) measure voltage between “ppl/yel” wire terminal of ect sensor connector and vehicle body ground. Is voltage about 0 v? ...

  • Page 153

    Engine general information and diagnosis: 1a-98 dtc p0122: throttle position sensor (main) circuit low s5jb0a1104073 wiring diagram dtc detecting condition and trouble area note when dtc p0122 and p0222 are indicated together, it is possible that “wht” wire open circuit. E23 c37 3 4 18 19 5 6 7 10 1...

  • Page 154

    1a-99 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed p...

  • Page 155

    Engine general information and diagnosis: 1a-100 4 ecm voltage check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) check for proper connection of ecm connector at “c37- 53” terminal. 4) if ok, measure voltage between “c37-53” terminal of ecm connector ...

  • Page 156

    1a-101 engine general information and diagnosis: dtc p0123: throttle position sensor (main) circuit high s5jb0a1104074 wiring diagram refer to “dtc p0122: throttle position sensor (main) circuit low: ”. Dtc detecting condition and trouble area note when dtc p0123 and p0223 are indicated together, it...

  • Page 157

    Engine general information and diagnosis: 1a-102 3 ecm voltage check 1) disconnect connector from electric throttle body assembly with ignition switch turned off. 2) check for proper connection to electric throttle body assembly at “wht”, “grn” and “blk” wire terminals. For j20 engine for m16 engine...

  • Page 158

    1a-103 engine general information and diagnosis: 7 wire harness check 1) disconnect connectors from ecm with ignition switch turned off. 2) measure resistance between “blk” and “wht” wire terminals of electric throttle body assembly connector. Is resistance infinity? Go to step 8. “blk” wire is shor...

  • Page 159

    Engine general information and diagnosis: 1a-104 dtc p0131 / p0132 / p0134: o2 sensor (ho2s) circuit low voltage / high voltage / no activity detected (sensor-1) s5jb0a1104032 wiring diagram a/f sensor description refer to “a/f sensor description: ”. Dtc detecting condition and trouble area e23 c37 ...

  • Page 160

    1a-105 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and warm up to normal operating temperature. 4) run engine at idle speed for 1 min. Or more. 5)...

  • Page 161

    Engine general information and diagnosis: 1a-106 a/f sensor description refer to “a/f sensor description: ”. Dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and ...

  • Page 162

    1a-107 engine general information and diagnosis: dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2) s5jb0a1104035 wiring diagram dtc detecting condition and trouble area e23 c37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2...

  • Page 163

    Engine general information and diagnosis: 1a-108 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out ...

  • Page 164

    1a-109 engine general information and diagnosis: 4 ho2s-2 ground check 1) disconnect connector from ho2s-2 with ignition switch turned off. 2) check for proper connection to ho2s-2 connector at “blk/red”, “red”, “grn” and “pnk” wire terminals. 3) if connections are ok, measure resistance between “gr...

  • Page 165

    Engine general information and diagnosis: 1a-110 dtc p0140: o2 sensor (ho2s) circuit no activity detected (sensor-2) s5jb0a1104036 wiring diagram refer to “dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2): ”. Dtc detecting condition and trouble area dtc confirmation ...

  • Page 166

    1a-111 engine general information and diagnosis: dtc p0171 / p0172 / p2195 / p2196: fuel system too lean / rich / stuck lean / stuck rich s5jb0a1104037 wiring diagram a/f sensor description refer to “a/f sensor description: ”. 4 ho2s-2 signal circuit check 1) turn on ignition switch. 2) measure volt...

  • Page 167

    Engine general information and diagnosis: 1a-112 dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an acc...

  • Page 168

    1a-113 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 169

    Engine general information and diagnosis: 1a-114 9 a/f sensor adjusting resistor power /ground circuit check 1) disconnect connector from a/f sensor with ignition switch turned off. 2) check for proper connection to a/f sensor connector. 3) if connections are ok, check a/f sensor adjusting resistor ...

  • Page 170

    1a-115 engine general information and diagnosis: dtc p0222: throttle position sensor (sub) circuit low s5jb0a1104075 wiring diagram dtc detecting condition and trouble area note when dtc p0122 and p0222 are indicated together, it is possible that “wht” wire open circuit. E23 c37 3 4 18 19 5 6 7 10 1...

  • Page 171

    Engine general information and diagnosis: 1a-116 dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed ...

  • Page 172

    1a-117 engine general information and diagnosis: 4 ecm voltage check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) check for proper connection of ecm connector at “c37- 53” terminal. 4) if ok, measure voltage between “c37-53” terminal of ecm connector ...

  • Page 173

    Engine general information and diagnosis: 1a-118 dtc p0223: throttle position sensor (sub) circuit high s5jb0a1104076 wiring diagram refer to “dtc p0222: throttle position sensor (sub) circuit low: ”. Dtc detecting condition and trouble area note when dtc p0123 and p0223 are indicated together, it i...

  • Page 174

    1a-119 engine general information and diagnosis: 3 ecm voltage check 1) disconnect connector from electric throttle body assembly with ignition switch turned off. 2) check for proper connection to electric throttle body assembly at “red”, “wht” and “grn” wire terminals. For j20 engine for m16 engine...

  • Page 175

    Engine general information and diagnosis: 1a-120 7 wire harness check 1) disconnect connectors from ecm with ignition switch turned off. 2) measure resistance between “wht” and “red” wire terminals of electric throttle body assembly connector. Is resistance infinity? Go to step 8. “red” wire is shor...

  • Page 176

    1a-121 engine general information and diagnosis: dtc p0300 / p0301 / p0302 / p0303 / p0304: random misfire detected / cylinder 1 / cylinder 2 / cylinder 3 / cylinder 4 misfire detected s5jb0a1104038 system description ecm measures the angle of the crankshaft based on the pulse signal from the ckp se...

  • Page 177

    Engine general information and diagnosis: 1a-122 2 does fuel level meter indicate “e” level (empty)? Add fuel and recheck. Go to step 3. 3 fuel quality check 1) check that there is fuel of good quality in the fuel tank. Is it ok? Go to step 4. Clean in fuel system circuit and change fuel. 4 ignition...

  • Page 178

    1a-123 engine general information and diagnosis: dtc p0327 / p0328: knock sensor circuit low / high s5jb0a1104039 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc, ...

  • Page 179

    Engine general information and diagnosis: 1a-124 step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check: ”. 2 knock sensor circuit check 1) remove ecm from its bracket with ecm connectors connected. 2) measure volt...

  • Page 180

    1a-125 engine general information and diagnosis: dtc p0335: crankshaft position (ckp) sensor circuit (for j20 engine) s5jb0a1104089 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and...

  • Page 181

    Engine general information and diagnosis: 1a-126 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 182

    1a-127 engine general information and diagnosis: dtc p0335: crankshaft position (ckp) sensor circuit (for m16 engine) s5jb0a1104040 wiring diagram dtc detecting condition and trouble area e23 c37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 ...

  • Page 183

    Engine general information and diagnosis: 1a-128 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. Dtc troubleshooting note before this trouble shoot...

  • Page 184

    1a-129 engine general information and diagnosis: 5 ground circuit check 1) turn ignition switch to off position. 2) measure resistance between “blk/yel” wire terminal of ckp sensor connector and engine ground. Is measured resistance value less than 3 Ω ? Go to step 6. “blk/yel” wire is open or high ...

  • Page 185

    Engine general information and diagnosis: 1a-130 dtc p0340: camshaft position (cmp) sensor circuit s5jb0a1104041 wiring diagram system description the cmp sensor located on the transmission side of cylinder head (for m16 engine) or cylinder head cover (for j20 engine) consists of the signal generato...

  • Page 186

    1a-131 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 187

    Engine general information and diagnosis: 1a-132 4 was terminal “vout” voltage in step 3 within specification? Go to step 5. “wht/red” wire is open or shorted to ground / power supply circuit. If wire and connection are ok, substitute a known-good ecm and recheck. 5 ground circuit check 1) turn igni...

  • Page 188

    1a-133 engine general information and diagnosis: dtc p0401 / p0402: exhaust gas recirculation flow insufficient detected / excessive detected s5jb0a1104042 system and wiring diagram i5jb0a110051-01 1. Egr valve 4. Sensed information 7. “ig coil” fuse 10. Main relay 2. Intake manifold 5. Fresh air 8....

  • Page 189

    Engine general information and diagnosis: 1a-134 dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an acc...

  • Page 190

    1a-135 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 191

    Engine general information and diagnosis: 1a-136 dtc p0403: exhaust gas recirculation control circuit s5jb0a1104043 wiring diagram refer to “dtc p0401 / p0402: exhaust gas recirculation flow insufficient detected / excessive detected: ”. Dtc detecting condition and trouble area dtc confirmation proc...

  • Page 192

    1a-137 engine general information and diagnosis: 4 wire circuit check 1) with ignition switch turned off, measure resistance between engine ground and each “yel/blk”, “yel/ red”, “yel/grn”, “yel” wire terminals of egr valve connector. Is resistance infinity? Go to step 5. Faulty wire(s) are shorted ...

  • Page 193

    Engine general information and diagnosis: 1a-138 dtc p0420: catalyst system efficiency below threshold s5jb0a1104044 system and wiring diagram circuit description ecm monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by ho2s-2. When the catal...

  • Page 194

    1a-139 engine general information and diagnosis: dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out ...

  • Page 195

    Engine general information and diagnosis: 1a-140 dtc p0443: evaporative emission system purge control valve circuit s5jb0a1104045 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or po...

  • Page 196

    1a-141 engine general information and diagnosis: dtc 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 water heater. Note before this trouble shooting is performed, read the p...

  • Page 197

    Engine general information and diagnosis: 1a-142 dtc p0462: fuel level sensor circuit low s5jb0a1104047 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. ...

  • Page 198

    1a-143 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 199

    Engine general information and diagnosis: 1a-144 dtc p0463: fuel level sensor circuit high s5jb0a1104095 wiring diagram refer to “dtc p0462: fuel level sensor circuit low: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2)...

  • Page 200

    1a-145 engine general information and diagnosis: 7 short circuit check for fuel level sensor output signal circuit 1) turn on ignition switch and measure voltage between “e23-24” terminal of ecm connector and vehicle body ground. Is voltage 0 v? Go to step 8. “yel/red” wire shorted to other circuit....

  • Page 201

    Engine general information and diagnosis: 1a-146 dtc p0480: fan 1 (radiator cooling fan) control circuit s5jb0a1104048 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) turn off ignition switch. 2) clear dtc with ignition switch turned on. 3) run engine at idle sp...

  • Page 202

    1a-147 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 203

    Engine general information and diagnosis: 1a-148 6 wire circuit check 1) measure voltage between “red/blk” wire terminal of radiator cooling fan relay no.1 connector and vehicle body ground with ignition switch turned on. Is voltage 0 v? Go to step 7. “red/blk” wire is shorted to other circuit. 7 wi...

  • Page 204

    1a-149 engine general information and diagnosis: 12 wire circuit check 1) measure voltage between “red” wire terminal of radiator cooling fan relay no.2 connector and vehicle body ground with ignition switch turned on. Is voltage 0 v? Go to step 13. “red” wire is shorted to other circuit. 13 wire ci...

  • Page 205

    Engine general information and diagnosis: 1a-150 dtc p0500: vehicle speed sensor (vss) malfunction s5jb0a1104049 wiring diagram dtc detecting condition and trouble area 18 wire circuit check 1) measure voltage between “red/yel” wire terminal of radiator cooling fan relay no.3 connector and vehicle b...

  • Page 206

    1a-151 engine general information and diagnosis: dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out ...

  • Page 207

    Engine general information and diagnosis: 1a-152 dtc p0504: brake switch “a”/“b” correlation (for j20 engine) s5jb0a1104096 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool to dlc. 2) turn on ignition switch and ...

  • Page 208

    1a-153 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 209

    Engine general information and diagnosis: 1a-154 dtc p0532: a/c refrigerant pressure sensor circuit low s5jb0a1104051 wiring diagram dtc detecting condition and trouble area note when dtc p0107 and p1501 are indicated together, it is possible that “gry/red” wire circuit open. Dtc confirmation proced...

  • Page 210

    1a-155 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 211

    Engine general information and diagnosis: 1a-156 dtc p0533: a/c refrigerant pressure sensor circuit high s5jb0a1104052 wiring diagram refer to “dtc p0532: a/c refrigerant pressure sensor circuit low: ”. Dtc detecting condition and trouble area note when dtc p0108, p0113 and p0118 are indicated toget...

  • Page 212

    1a-157 engine general information and diagnosis: dtc p0601 / p0602 / p0607: internal control module memory check sum error / control module programming error / control module performance s5jb0a1104053 system description internal control module is installed in ecm. Dtc detecting condition and trouble...

  • Page 213

    Engine general information and diagnosis: 1a-158 dtc p0616: starter relay circuit low s5jb0a1104054 wiring diagram dtc detecting condition and trouble area step action yes no 1 dtc recheck 1) clear dtc referring to “dtc clearance: ”. 2) turn off ignition switch. 3) turn on ignition switch and check ...

  • Page 214

    1a-159 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine. 4) check dtc and pending dtc. Dtc troubleshooting note before this trouble shooting is perform...

  • Page 215

    Engine general information and diagnosis: 1a-160 dtc p0617: starter relay circuit high s5jb0a1104055 wiring diagram refer to “dtc p0616: starter relay circuit low: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on...

  • Page 216

    1a-161 engine general information and diagnosis: dtc p0620: generator control circuit s5jb0a1104090 system and wiring diagram generator control system description refer to “generator control system description: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition s...

  • Page 217

    Engine general information and diagnosis: 1a-162 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 218

    1a-163 engine general information and diagnosis: dtc p0625 / p0626: generator field terminal circuit low / high s5jb0a1104091 system and wiring diagram refer to “dtc p0620: generator control circuit: ”. Generator control system description refer to “generator control system description: ”. Dtc detec...

  • Page 219

    Engine general information and diagnosis: 1a-164 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 220

    1a-165 engine general information and diagnosis: dtc p0660: intake manifold tuning valve control circuit / open (for j20 engine) s5jb0a1104092 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch off, connect scan tool to dlc. 2) turn on ignition...

  • Page 221

    Engine general information and diagnosis: 1a-166 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 222

    1a-167 engine general information and diagnosis: dtc p1501 / p1502: electric load current sensor circuit low / high s5jb0a1104093 system and wiring diagram electric load current sensor description refer to “generator control system description: ”. Dtc detecting condition and trouble area note when d...

  • Page 223

    Engine general information and diagnosis: 1a-168 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 224

    1a-169 engine general information and diagnosis: dtc p1510: ecm back-up power supply malfunction s5jb0a1104056 wiring diagram circuit description battery voltage is supplied so that dtc memory, values for engine control learned by ecm, etc. Are kept in ecm even when the ignition switch is turned off...

  • Page 225

    Engine general information and diagnosis: 1a-170 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Dtc p1603: tcm trouble code detected (for j20 engine) s5jb0a1104057 wiring diagram d...

  • Page 226

    1a-171 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Dtc p1674: can communication (bus off error) s5jb0a1104058 wiring diagram step actio...

  • Page 227

    Engine general information and diagnosis: 1a-172 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 1 min. Or more. 4) check dtc. ...

  • Page 228

    1a-173 engine general information and diagnosis: 3 ecm, tcm (for a/t model), bcm, abs hydraulic unit / control module assembly, 4wd control module (for j20 engine), combination meter and keyless start control module (if equipped) connectors check 1) check for proper connection at each ecm, tcm (for ...

  • Page 229

    Engine general information and diagnosis: 1a-174 9 dtc check in ecm 1) disconnect connector from keyless start control module (if equipped) with ignition switch turned off. 2) check ecm for dtc. Is there dtc p1674? Go to step 10. “g44-19” or “g44-18” circuit wire between keyless start control module...

  • Page 230

    1a-175 engine general information and diagnosis: 15 can communication line circuit continuity check 1) measure resistance at following connector terminals. • between “e23-4” terminal of ecm connector and “e03-10” terminal of abs hydraulic unit / control module connector • between “e23-19” terminal o...

  • Page 231

    Engine general information and diagnosis: 1a-176 dtc p1676: can communication (reception error for tcm (for a/t model)) s5jb0a1104060 wiring diagram refer to “dtc p1674: can communication (bus off error): ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to ...

  • Page 232

    1a-177 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 233

    Engine general information and diagnosis: 1a-178 8 dtc check in ecm 1) disconnect connectors from tcm (for a/t model) with ignition switch turned off. 2) check ecm for dtc. Is there dtc p1676? Go to step 9. “e92-17” or “e92-7” circuit wire between tcm and can circuit junction connector is open or hi...

  • Page 234

    1a-179 engine general information and diagnosis: 13 can communication line circuit continuity check 1) disconnect connectors from all control modules communicating by can with ignition switch turned off. 2) measure resistance at following connector terminals. • between “e23-4” terminal of ecm connec...

  • Page 235

    Engine general information and diagnosis: 1a-180 dtc p1678: can communication (reception error for bcm) s5jb0a1104061 wiring diagram refer to “dtc p1674: can communication (bus off error): ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignitio...

  • Page 236

    1a-181 engine general information and diagnosis: 4 ecm, abs hydraulic unit / control module and bcm connector check 1) check for proper connection at each ecm, abs hydraulic unit / control module and bcm connector terminals with ignition switch turned off. 2) if connections are ok, recheck ecm for d...

  • Page 237

    Engine general information and diagnosis: 1a-182 11 dtc check in ecm 1) disconnect connector from 4wd control module (for j20 engine) with ignition switch turned off. 2) check ecm for dtc. Is there dtc p1678? Go to step 12. “e91-22” or “e91-23” circuit wire between 4wd control module and can circuit...

  • Page 238

    1a-183 engine general information and diagnosis: 15 can communication line circuit ground short check 1) measure resistance at following connector terminals. • between “e23-4” terminal of ecm connector and vehicle body ground • between “e23-19” terminal of ecm connector and vehicle body ground • bet...

  • Page 239

    Engine general information and diagnosis: 1a-184 dtc p1685: can communication (reception error for abs control module) s5jb0a1104094 wiring diagram refer to “dtc p1674: can communication (bus off error): ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to d...

  • Page 240

    1a-185 engine general information and diagnosis: 5 ecm power and ground circuit check 1) check ecm power and ground circuits referring to “ecm power and ground circuit check: ”. Are they in good condition? Go to step 6. Repair ecm power and/ or ground circuits. 6 dtc check in abs hydraulic unit / co...

  • Page 241

    Engine general information and diagnosis: 1a-186 11 dtc check in ecm 1) disconnect connector from 4wd control module (for j20 engine) with ignition switch turned off. 2) check ecm for dtc. Is there dtc p1685? Go to step 12. “e91-22” or “e91-23” circuit wire between 4wd control module and can circuit...

  • Page 242

    1a-187 engine general information and diagnosis: dtc p2101: throttle actuator control motor circuit range / performance s5jb0a1104077 wiring diagram 17 abs warning lamp check 1) connect connectors to all control modules communicating by can. 2) turn ignition switch on. Is abs warning lamp light up? ...

  • Page 243

    Engine general information and diagnosis: 1a-188 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep ...

  • Page 244

    1a-189 engine general information and diagnosis: dtc p2102: throttle actuator control motor circuit low s5jb0a1104078 wiring diagram refer to “dtc p2101: throttle actuator control motor circuit range / performance: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with igniti...

  • Page 245

    Engine general information and diagnosis: 1a-190 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 246

    1a-191 engine general information and diagnosis: dtc p2103: throttle actuator control motor circuit high s5jb0a1104079 wiring diagram refer to “dtc p2101: throttle actuator control motor circuit range / performance: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignit...

  • Page 247

    Engine general information and diagnosis: 1a-192 dtc p2111: throttle actuator control system - stuck open s5jb0a1104080 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool....

  • Page 248

    1a-193 engine general information and diagnosis: dtc p2119: throttle actuator control throttle body range / performance s5jb0a1104081 wiring diagram refer to “dtc p2101: throttle actuator control motor circuit range / performance: ”. Dtc detecting condition and trouble area dtc confirmation procedur...

  • Page 249

    Engine general information and diagnosis: 1a-194 3 throttle actuator circuit check 1) disconnect connector from electric throttle body assembly with ignition switch turned off. 2) check for proper connection to electric throttle body assembly at “blu/yel” and “blu/red” wire terminals. For j20 engine...

  • Page 250

    1a-195 engine general information and diagnosis: dtc p2122: pedal position sensor (main) circuit low input s5jb0a1104082 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc ...

  • Page 251

    Engine general information and diagnosis: 1a-196 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 252

    1a-197 engine general information and diagnosis: 6 wire harness check 1) disconnect connectors from ecm with ignition switch turned off. 2) measure resistance between “e23-56” terminal of ecm connector and engine ground. Is resistance infinity? Substitute a known- good ecm and recheck. “wht” wire is...

  • Page 253

    Engine general information and diagnosis: 1a-198 dtc p2123: pedal position sensor (main) circuit high input s5jb0a1104083 wiring diagram refer to “dtc p2122: pedal position sensor (main) circuit low input: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch...

  • Page 254

    1a-199 engine general information and diagnosis: 4 ecm voltage check 1) disconnect connector from accelerator pedal position (app) sensor assembly with ignition switch turned off. 2) check for proper connection to accelerator pedal position (app) sensor assembly at “wht”, “wht/blu” and “orn” wire te...

  • Page 255

    Engine general information and diagnosis: 1a-200 dtc p2127: pedal position sensor (sub) circuit low input s5jb0a1104084 wiring diagram refer to “dtc p2122: pedal position sensor (main) circuit low input: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch t...

  • Page 256

    1a-201 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 257

    Engine general information and diagnosis: 1a-202 dtc p2128: pedal position sensor (sub) circuit high input s5jb0a1104085 wiring diagram refer to “dtc p2122: pedal position sensor (main) circuit low input: ”. Dtc detecting condition and trouble area 6 wire harness check 1) disconnect connectors from ...

  • Page 258

    1a-203 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed ...

  • Page 259

    Engine general information and diagnosis: 1a-204 5 wire harness check 1) disconnect connectors from ecm with ignition switch turned off. 2) check for proper connection of ecm connector at “e23- 53” terminal. 3) if ok, measure voltage between “e23-53” terminal of ecm connector and engine ground with ...

  • Page 260

    1a-205 engine general information and diagnosis: dtc p2135: throttle position sensor (main / sub) voltage correlation s5jb0a1104086 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and...

  • Page 261

    Engine general information and diagnosis: 1a-206 dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 262

    1a-207 engine general information and diagnosis: 5 wire harness check 1) measure voltage between “c37-53” terminal of ecm connector and engine ground with ignition switch turned on. Is voltage 0 v? Substitute a known- good ecm and recheck. “wht” wire is shorted to other circuit. 6 wire harness check...

  • Page 263

    Engine general information and diagnosis: 1a-208 dtc p2138: pedal position sensor (main / sub) voltage correlation s5jb0a1104087 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and cl...

  • Page 264

    1a-209 engine general information and diagnosis: dtc troubleshooting note before this trouble shooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting: ”. Step action yes no 1 was “engine and emission control system check” performed? Go to...

  • Page 265

    Engine general information and diagnosis: 1a-210 dtc p2227 / p2228 / p2229: barometric pressure circuit malfunction s5jb0a1104062 dtc p2227: barometric pressure circuit range / performance dtc p2228: barometric pressure circuit low dtc p2229: barometric pressure circuit high system description barom...

  • Page 266

    1a-211 engine general information and diagnosis: dtc confirmation procedure dtc p2227: warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be c...

  • Page 267

    Engine general information and diagnosis: 1a-212 inspection of ecm and its circuits s5jb0a1104063 ecm and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. Caution ! Ecm cannot be checked by itself. It is strictly prohibited to connect voltmet...

  • Page 268

    1a-213 engine general information and diagnosis: terminal no. Wire color circuit normal voltage condition remarks c37-1 pnk fuel injector no.1 10 – 14 v ignition switch turned on. — *0 – 0.6 v ↑↓ 10 – 14 v (“reference waveform no.1: ”, “reference waveform no.2: ” and “reference waveform no.31: ”) en...

  • Page 269

    Engine general information and diagnosis: 1a-214 c37-9 blu electric load current sensor signal (for j20 engine) 0.5 – 1.0 v ignition switch turned on. — 1.3 – 1.7 v run engine at 2000 rpm, headlight switch turned on. 1.8 – 2.4 v run engine at 2000 rpm, headlight switch on and blower selector at hi p...

  • Page 270

    1a-215 engine general information and diagnosis: c37-16 pnk/ grn fuel injector no.3 10 – 14 v ignition switch turned on. — *0 – 0.6 v ↑↓ 10 – 14 v (“reference waveform no.1: ” and “reference waveform no.10: ”) engine running at idle after warmed up engine. Output signal is active low pulse. Pulse fr...

  • Page 271

    Engine general information and diagnosis: 1a-216 c37-24 ppl/ yel engine coolant temp. (ect) sensor signal 3.3 – 3.8 v ignition switch turned on, ect at 0 °c, 32 °f. — 1.38 – 1.72 v ignition switch turned on, ect at 50 °c, 122 °f. 0.40 – 0.53 v ignition switch turned on, ect at 100 °c, 212 °f. C37-25...

  • Page 272

    1a-217 engine general information and diagnosis: c37-37 blk a/f sensor signal (–) 2.6 – 2.8 v (“reference waveform no.18: ”) engine running at idle after warmed up engine. — c37-38 wht a/f sensor signal (+) 3.0 – 3.2 v (“reference waveform no.18: ”) engine running at idle after warmed up engine. — c...

  • Page 273

    Engine general information and diagnosis: 1a-218 c37-51 wht/ blu ckp sensor signal (for m16 engine) 0 – 1 v or 4 – 5 v ignition switch turned on. — *4 – 5 v ↑↓ 0 – 0.6 v (“reference waveform no.20: ” and “reference waveform no.21: ”) engine running at idle after warmed up engine. Sensor signal is pu...

  • Page 274

    1a-219 engine general information and diagnosis: c37-60 brn/ wht oil control valve output (for m16 engine) *0 – 0.6 v ↑↓ 10 – 14 v (“reference waveform no.28: ” and “reference waveform no.29: ”) at the moment of ignition switch turned on. Output signal is active high pulse. Duty ratio varies dependi...

  • Page 275

    Engine general information and diagnosis: 1a-220 e23-15 wht/ grn fuel pump relay output 0 – 2.5 v for 2 sec. From the time ignition switch is turned on or while engine is running. — 10 – 14 v on and after 2 sec. From the time ignition switch is turned on or while engine is at stop. E23-16 blu/ blk m...

  • Page 276

    1a-221 engine general information and diagnosis: e23-40 — — — — — e23-41 — — — — — e23-42 — — — — — e23-43 — — — — — e23-44 — — — — — e23-45 — — — — — e23-46 red/ blk radiator cooling fan relay no.1 output 10 – 14 v ignition switch turned on, engine coolant temp.: below 95 °c (203 °f), or a/c refrig...

  • Page 277

    Engine general information and diagnosis: 1a-222 e23-50 blu/ orn throttle actuator control relay output 0 – 1 v ignition switch turned on. — e23-51 blu/ yel ground for accelerator pedal position (app) sensor (sub) below 0.3 v ignition switch turned on. — e23-52 blu/ grn accelerator pedal position (a...

  • Page 278

    1a-223 engine general information and diagnosis: reference waveform no.1 fuel injector signal (1) with engine idling reference waveform no.2 no.1 fuel injector signal (2) with engine idling reference waveform no.3 no.2 fuel injector signal (2) with engine idling reference waveform no.4 egr valve sig...

  • Page 279

    Engine general information and diagnosis: 1a-224 reference waveform no.5 generator field coil monitor signal (1) at engine idling reference waveform no.6 generator field coil monitor signal (1) at engine idling reference waveform no.7 heated oxygen sensor-2 signal (1) with engine idling reference wa...

  • Page 280

    1a-225 engine general information and diagnosis: reference waveform no.9 evap canister purge valve signal reference waveform no.10 no.3 fuel injector signal (2) with engine idling reference waveform no.11 no.4 fuel injector signal (2) with engine idling measurement terminal ch1: “c37-13” to “c37-58”...

  • Page 281

    Engine general information and diagnosis: 1a-226 reference waveform no.12 ignition coil signal (1) with engine idling reference waveform no.13 ignition coil no.4 signal (2) with engine idling (for j20 engine) reference waveform no.14 ignition coil no.3 signal (2) with engine idling (for j20 engine) ...

  • Page 282

    1a-227 engine general information and diagnosis: reference waveform no.15 • ignition coil no.2 signal (1) with engine idling (for j20 engine) • ignition coil no.2 and no.3 signal (2) with engine idling (for m16 engine) reference waveform no.16 • ignition coil no.1 signal (1) with engine idling (for ...

  • Page 283

    Engine general information and diagnosis: 1a-228 reference waveform no.17 mass air flow sensor signal (1) with engine racing reference waveform no.18 a/f sensor signal with engine idling reference waveform no.19 intake manifold tuning vacuum solenoid valve signal with engine racing (for j20 engine) ...

  • Page 284

    1a-229 engine general information and diagnosis: reference waveform no.20 cmp sensor signal with engine idling reference waveform no.21 cmp sensor signal with engine idling measurement terminal ch1: “c37-52” to “c37-58” ch2: “c37-51” to “c37-36” (for j20 engine), “c37-58” (for m16 engine) oscillosco...

  • Page 285

    Engine general information and diagnosis: 1a-230 reference waveform no.22 throttle actuator output signal with ignition switch turned on reference waveform no.23 throttle actuator output signal with ignition switch turned on reference waveform no.24 manifold absolute pressure sensor signal (1) with ...

  • Page 286

    1a-231 engine general information and diagnosis: reference waveform no.25 manifold absolute pressure sensor signal (1) with engine racing reference waveform no.26 knock sensor signal at engine speed 4000 r/min. Reference waveform no.27 knock sensor signal at engine speed 4000 r/min. Reference wavefo...

  • Page 287

    Engine general information and diagnosis: 1a-232 reference waveform no.29 oil control valve signal with engine racing (for m16 engine) reference waveform no.30 can communication line signal with ignition switch turned on reference waveform no.31 ignition coil signal and fuel injector signal with eng...

  • Page 288

    1a-233 engine general information and diagnosis: resistance check 1) remove ecm from its bracket referring to “engine control module (ecm) removal and installation: in section 1c”. Caution ! Never touch terminals of ecm itself or connect voltmeter or ohmmeter (2). 2) connect special tool to ecm conn...

  • Page 289

    Engine general information and diagnosis: 1a-234 ecm power and ground circuit check s5jb0a1104064 wiring diagram e23 c37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 1...

  • Page 290

    1a-235 engine general information and diagnosis: circuit description when the ignition switch is turned on, the main relay turns on (the contact point closes) and the main power is supplied to ecm. And then ecm supplies 5 v power to each sensor (electric load current sensor (for j20 engine), map sen...

  • Page 291

    Engine general information and diagnosis: 1a-236 4 main relay circuit check 1) turn ignition switch to off position. 2) check “fi” fuse (1) (20 a) in fuse box no.2 for blowing. For j20 engine for m16 engine 3) if ok, measure voltage between “e23-60” terminal of ecm connector and body ground. Is volt...

  • Page 292

    1a-237 engine general information and diagnosis: 8 main relay circuit check 1) remove main relay (1) from fuse box no.2. For j20 engine for m16 engine 2) check for proper connection to main relay connector at “blu/yel” and “blk/red” wire terminals. 3) if ok, measure resistance between each “e23-1” a...

  • Page 293

    Engine general information and diagnosis: 1a-238 fuel injector circuit check s5jb0a1104065 wiring diagram 12 sensor 5 v power source circuit check 1) disconnect connectors from ecm, tp sensor, map sensor, a/c refrigerant pressure sensor (if equipped with a/c), electric load current sensor (for j20 e...

  • Page 294

    1a-239 engine general information and diagnosis: troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm c...

  • Page 295

    Engine general information and diagnosis: 1a-240 fuel pump and its circuit check s5jb0a1104066 wiring diagram e23-1 e23-60 e23-15 blu blu/blk blk/red blk/red blu/blk e23-29 blk/wht wht/grn blk/wht blk/wht pnk blk wht/grn blk/yel 7 6 4 3 2 5 e23 c37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52...

  • Page 296

    1a-241 engine general information and diagnosis: troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm c...

  • Page 297

    Engine general information and diagnosis: 1a-242 6 fuel pump relay drive signal check 1) measure voltage within 2 second after ignition switch is turned on. Is voltage 0 – 1 v? Go to step 7. Substitute a known- good ecm and recheck. 7 wire circuit check 1) turn off ignition switch. 2) detach fuel ta...

  • Page 298

    1a-243 engine general information and diagnosis: fuel pressure check s5jb0a1104067 system diagram special tool (a): 09912–58442 (b): 09912–58432 (c): 09912–58490 4 (c) (b) (a) 1 2 3 i2rh01110133-01 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter and fuel pump.

  • Page 299

    Engine general information and diagnosis: 1a-244 troubleshooting note before using following flow, check to make sure that battery voltage is higher than 11 v. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition. Step action yes no 1 ...

  • Page 300

    1a-245 engine general information and diagnosis: a/c system circuits check s5jb0a1104069 wiring diagram e23 c37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 1...

  • Page 301

    Engine general information and diagnosis: 1a-246 troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm c...

  • Page 302

    1a-247 engine general information and diagnosis: 9 a/c refrigerant pressure sensor voltage check 1) check a/c refrigerant pressure sensor voltage referring to “inspection of ecm and its circuits: ”. Is voltage within specified value? Go to step 10. Check amount of refrigerant. If ok, replace a/c ref...

  • Page 303

    Engine general information and diagnosis: 1a-248 electric load signal circuit check s5jb0a1104070 wiring diagram wht/blu blu/orn wht/red e23 c37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 ...

  • Page 304

    1a-249 engine general information and diagnosis: troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm c...

  • Page 305

    Engine general information and diagnosis: 1a-250 radiator cooling fan low speed control system check s5jb0a1104071 wiring diagram troubleshooting warning ! Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or no...

  • Page 306

    1a-251 engine general information and diagnosis: step action yes no 1 is there dtc(s) of ect sensor circuit (dtc p0116 / p0117 / p0118) and/or radiator cooling fan circuit (dtc p0480)? Go to corresponding dtc flow. Go to step 2. 2 low speed radiator cooling fan control circuit check 1) connect scan ...

  • Page 307

    Engine general information and diagnosis: 1a-252 7 wire circuit check 1) disconnect radiator cooling fan motor no.1 connector with ignition switch turned off. 2) measure resistance between “blu/yel” wire terminal of radiator cooling fan relay no.2 connector and vehicle body ground. Is resistance inf...

  • Page 308

    1a-253 engine general information and diagnosis: radiator cooling fan high speed control system check s5jb0a1104072 wiring diagram refer to “radiator cooling fan low speed control system check: ”. Troubleshooting warning ! Keep hands, tools, and clothing away from engine cooling fan to help prevent ...

  • Page 309

    Engine general information and diagnosis: 1a-254 4 wire circuit check 1) disconnect radiator cooling fan relay no.3 from relay box with ignition switch turned off. 2) turn on ignition switch. 3) measure voltage between “blu/blk” wire terminal of radiator cooling fan relay no.3 connector and vehicle ...

  • Page 310

    1a-255 engine general information and diagnosis: repair instructions idle speed and iac throttle valve opening inspection s5jb0a1106001 before idle speed check, make sure of the following. • lead wires and hoses of electronic fuel injection and engine and emission control systems are connected secur...

  • Page 311

    Engine general information and diagnosis: 1a-256 special tools and equipment special tool s5jb0a1108001 09912–58432 09912–58442 fuel pressure gauge hose fuel pressure gauge this tool is included in fuel pressure gauge set (09912- 58413). ) this tool is included in fuel pressure gauge set (09912- 584...

  • Page 312

    1b-1 aux. Emission control devices: aux. Emission control devices diagnostic information and procedures egr system inspection s5jb0a1204001 1) connect suzuki scan tool to data link connector (dlc) with ignition switch turned off. 2) turn on ignition switch and erase dtc using “clear dtc” in “trouble...

  • Page 313

    Aux. Emission control devices: 1b-2 evap canister purge valve and its circuit inspection s5jb0a1206002 warning ! Do not apply vacuum by mouth; otherwise harmful fuel vapor can be breathed in. Caution ! Do not apply vacuum more than –86 kpa (– 12.47 psi); otherwise evap canister purge valve could be ...

  • Page 314

    1b-3 aux. Emission control devices: vacuum hose and purge valve chamber inspection s5jb0a1206004 check hoses and purge valve chamber for connection, leakage, clog and deterioration. Replace as necessary. Evap canister purge valve inspection s5jb0a1206005 warning ! Do not apply vacuum by mouth; other...

  • Page 315

    Aux. Emission control devices: 1b-4 evap canister inspection s5jb0a1206006 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 is no restriction of f...

  • Page 316

    1b-5 aux. Emission control devices: pcv valve removal and installation s5jb0a1206011 removal 1) disconnect pcv hose from pcv valve. 2) remove pcv valve from cylinder head cover. Installation reverse removal procedure noting the following. • for j20 engine, apply sealant to thread part of pcv valve (...

  • Page 317

    Aux. Emission control devices: 1b-6 specifications tightening torque specifications s5jb0a1207001 reference: for the tightening torque of fastener not specified in this section, refer to “fastener information: in section 0a”. Special tools and equipment recommended service material s5jb0a1208001 spe...

  • Page 318: Engine Electrical Devices

    1c-1 engine electrical devices: engine electrical devices repair instructions engine control module (ecm) removal and installation s5jb0a1306004 caution ! As ecm consists of precision parts, be careful not to expose it to excessive shock. Removal 1) disconnect negative cable at battery. 2) remove ec...

  • Page 319

    Engine electrical devices: 1c-2 4) install map sensor securely. 5) connect map sensor connector securely. Electric throttle body assembly on-vehicle inspection s5jb0a1306022 warning ! Never touch throttle valve with finger while ignition switch is turned on and accelerator pedal is depressed. Otherw...

  • Page 320

    1c-3 engine electrical devices: electric throttle body assembly operation check 1) remove air cleaner outlet hose (for j20 engine) or air intake pipe (for m16 engine). 2) turn on ignition switch. 3) depress accelerator pedal gradually and check that throttle valve moves smoothly until it opens fully...

  • Page 321

    Engine electrical devices: 1c-4 c) measure output voltage variation while throttle valve is opened and closed as following specification. If sensor voltage is out of specified value and linear variation as the following graph, replace electric throttle body assembly. Throttle position sensor output ...

  • Page 322

    1c-5 engine electrical devices: accelerator pedal position (app) sensor assembly on-vehicle inspection s5jb0a1306024 1) check that accelerator pedal position (app) sensor assembly has been mounted to vehicle body properly (no pinched floor carpet, etc). If mounting is not properly, reinstall acceler...

  • Page 323

    Engine electrical devices: 1c-6 accelerator pedal position (app) sensor assembly inspection s5jb0a1306026 check accelerator pedal position (app) sensor (main and sub) output voltage as following steps. 1) for accelerator pedal position (app) sensor (main), arrange 3 new 1.5 v batteries (1) in series...

  • Page 324

    1c-7 engine electrical devices: installation reverse removal procedure noting the following. • clean mating surfaces of ect sensor and water outlet cap. • check o-ring for damage and replace, if necessary. • tighten ect sensor (1) to specified torque. Tightening torque ect sensor (a): 12.5 n·m (1.25...

  • Page 325

    Engine electrical devices: 1c-8 heated oxygen sensor (ho2s-2) heater on- vehicle inspection s5jb0a1306010 1) disconnect sensor connector. 2) using ohmmeter, measure resistance of sensor heater between terminals “v b ” and “gnd” at sensor connector. If found faulty, replace oxygen sensor. Note temper...

  • Page 326

    1c-9 engine electrical devices: 2) connect connector to cmp sensor securely. 3) connect negative cable to battery. Camshaft position (cmp) sensor inspection s5jb0a1306012 visual check • check that o-ring is free from damage. • check that end face of sensor and signal rotor tooth are free from any me...

  • Page 327

    Engine electrical devices: 1c-10 installation reverse removal procedure noting the following. • apply engine oil to o-ring of sensor. • tighten ckp sensor bolt to specified torque. Tightening torque ckp sensor bolt (a): 11 n·m (1.1 kgf-m, 8.0 lb-ft) • connect connector and fix wire harness with clam...

  • Page 328

    1c-11 engine electrical devices: resistance check measure resistance between “1” and “2” terminals of ckp sensor. Ckp sensor resistance 480 – 660 Ω at 20 °c, 68 °f if measured resistance is out of specified value, replace ckp sensor. For m16 engine visual check • check that o-ring is free from damag...

  • Page 329

    Engine electrical devices: 1c-12 control relay inspection s5jb0a1306018 control relay 1) disconnect negative cable at battery. 2) remove main relay (1), fuel pump relay (3), starting motor control relay (2), throttle actuator control relay (4) and ho2s heater relay (5) (for m16 engine) from fuse box...

  • Page 330

    1c-13 engine electrical devices: mass air flow (maf) and intake air temperature (iat) sensor on-vehicle inspection s5jb0a1306019 note before performed this inspection, be sure to read the “precautions of ecm circuit inspection: in section 1a”. 1) disconnect maf and iat sensor connector. 2) connect v...

  • Page 331

    Engine electrical devices: 1c-14 installation reverse removal procedure noting the followings. • tighten maf and iat sensor screws to specified torque. Tightening torque maf and iat sensor screw (a): 1.5 n·m (0.15 kgf- m, 1.1 lb-ft) • connect maf and iat sensor connector securely. Mass air flow (maf...

  • Page 332

    1c-15 engine electrical devices: 2) check resistance of intake manifold tuning vacuum solenoid valve. If resistance is as specified, proceed to next operation check. If not, replace intake manifold tuning vacuum solenoid valve. Resistance of intake manifold tuning vacuum solenoid valve between two t...

  • Page 333

    Engine electrical devices: 1c-16 electric load current sensor on-vehicle inspection (for j20 engine) s5jb0a1306031 using suzuki scan tool 1) connect scan tool to dlc with ignition switch turned off. 2) check “battery current” displayed on scan tool at following condition. Battery current ignition sw...

  • Page 334

    1c-17 engine electrical devices: specifications tightening torque specifications s5jb0a1307001 reference: for the tightening torque of fastener not specified in this section, refer to “fastener information: in section 0a”. Fastening part tightening torque note n ⋅m kgf-m lb-ft accelerator pedal posi...

  • Page 335: Engine Mechanical

    Engine mechanical: for m16a engine with vvt 1d-1 engine mechanical for m16a engine with vvt general description engine construction description s5jb0a1411001 the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arrange...

  • Page 336

    1d-2 engine mechanical: for m16a engine with vvt camshaft position control (vvt variable valve timing) system description s5jb0a1411002 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 c...

  • Page 337

    Engine mechanical: for m16a engine with vvt 1d-3 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...

  • Page 338

    1d-4 engine mechanical: for m16a engine with vvt targeted timing varying operation diagnostic information and procedures compression check s5jb0a1414001 check compression pressure on all 4 cylinders as follows: 1) warm up engine to normal operating temperature. 2) stop engine after warming up. Note ...

  • Page 339

    Engine mechanical: for m16a engine with vvt 1d-5 8) disengage clutch (to lighten starting load on engine) for m/t vehicle, and depress accelerator pedal (1) all the way to make throttle fully open. 9) crank engine with fully charged battery, and read the highest pressure on compression gauge. Note •...

  • Page 340

    1d-6 engine mechanical: for m16a engine with vvt 6) run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification. Vacuum specification (at sea level) 59 – 73 kpa (45 – 55 cmhg, 17.7 – 21.6 in.Hg) at specified idle speed 7) after checking, disconnect special tool (v...

  • Page 341

    Engine mechanical: for m16a engine with vvt 1d-7 special tool selection table c) hold down the tappet so as not to contact the shim by installing special tool on camshaft housing with housing bolt (1) tighten housing bolts to specified torque. Special tool (a): 09916–67020 (a): 09916–67021 tightenin...

  • Page 342

    1d-8 engine mechanical: for m16a engine with vvt 6) select new shim no. (1) with a thickness as close as possible to calculated value. Available new shims no. 7) install new shim facing shim no. Side with tappet. 8) lift valve by turning crankshaft counterclockwise (in opposite direction against abo...

  • Page 343

    Engine mechanical: for m16a engine with vvt 1d-9 air cleaner filter inspection and cleaning s5jb0a1416002 inspection check air cleaner filter for dirt. Replace excessive dirty filter. Cleaning blow off dust by compressed air from air outlet side of element. Cylinder head cover removal and installati...

  • Page 344

    1d-10 engine mechanical: for m16a engine with vvt 2) remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning, apply sealant “a” to the following point. • cylinder head cover gasket (1) sealing surface area (2) as shown. “a”: water tight sealant 99000–31250 ...

  • Page 345

    Engine mechanical: for m16a engine with vvt 1d-11 throttle body and intake manifold components s5jb0a1416009 throttle body on-vehicle inspection s5jb0a1416005 check electric throttle body assembly referring to “throttle valve operation check” and “electric throttle body assembly operation check” und...

  • Page 346

    1d-12 engine mechanical: for m16a engine with vvt electric throttle body assembly removal and installation s5jb0a1416045 removal 1) disconnect negative cable at battery. 2) drain coolant referring to “cooling system draining: in section 1f”. 3) detach breather union (1) from air intake pipe (2). 4) ...

  • Page 347

    Engine mechanical: for m16a engine with vvt 1d-13 intake manifold removal and installation s5jb0a1416010 removal 1) relieve fuel pressure in fuel feed line referring to “fuel pressure relief procedure: in section 1g”. 2) remove throttle body referring to “electric throttle body assembly removal and ...

  • Page 348

    1d-14 engine mechanical: for m16a engine with vvt engine mountings components s5jb0a1416012 engine assembly removal and installation s5jb0a1416013 removal 1) relieve fuel pressure according to “fuel pressure relief procedure: in section 1g”. 2) disconnect negative cable at battery. 3) drain engine o...

  • Page 349

    Engine mechanical: for m16a engine with vvt 1d-15 7) disconnect maf sensor connector (1). 8) remove air cleaner case (2). 9) disconnect radiator inlet hose (1). 10) remove p/s pump belt referring to “p/s pump and a/c compressor (if equipped) drive belt removal and installation for m16 engine model: ...

  • Page 350

    1d-16 engine mechanical: for m16a engine with vvt 17) with hose connected, detach a/c compressor from its bracket (if equipped) referring to “compressor assembly removal and installation for m16 engine model: in section 7b”. Caution ! Suspend removed a/c compressor at a place where no damage will be...

  • Page 351

    Engine mechanical: for m16a engine with vvt 1d-17 7) remove engine jack. 8) install front and rear propeller shafts referring to “propeller shaft removal and installation: in section 3d”. 9) install exhaust no.1, no.2 and center pipes referring to “exhaust system components: in section 1k”. 10) inst...

  • Page 352

    1d-18 engine mechanical: for m16a engine with vvt timing chain cover components s5jb0a1416014 i5jb0a141020-01 1. Crankshaft pulley bolt 9. Oil gallery pipe no.1 17. Oil control valve 2. Crankshaft pulley 10. Copper washer : 11 n ⋅m (1.1 kgf-m, 8.0 lb-ft) 3. Oil seal : apply engine oil to oil seal li...

  • Page 353

    Engine mechanical: for m16a engine with vvt 1d-19 timing chain cover removal and installation s5jb0a1416015 caution ! • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to damage them. • do not expose removed parts to dust. Keep them ...

  • Page 354

    1d-20 engine mechanical: for m16a engine with vvt installation 1) clean sealing surface on timing chain cover, cylinder block and cylinder head. Remove oil, old sealant and dust from sealing surface. 2) install oil seal (1) to timing chain cover, if removed. Note when installing new oil seal, press ...

  • Page 355

    Engine mechanical: for m16a engine with vvt 1d-21 9) install oil gallery pipes no.2 and no.3 to cylinder head (4) and timing chain cover (5). Tighten bolts to specified torque. Tightening torque oil gallery pipe no.2 and no.3 bolt (a): 11 n·m ( 1.1 kgf-m, 8.0 lb-ft) 10) install water pump pulley. 11...

  • Page 356

    1d-22 engine mechanical: for m16a engine with vvt installation 1) install new o-ring (4) to oil control valve. 2) install oil control valve to timing chain cover. Tighten nuts to specification. Tightening torque oil control valve mounting nut (a): 11 n·m (1.1 kgf-m, 8.0 lb-ft) 3) install oil gallery...

  • Page 357

    Engine mechanical: for m16a engine with vvt 1d-23 timing chain and chain tensioner components s5jb0a1416017 timing chain and chain tensioner removal and installation s5jb0a1416018 removal caution ! After timing chain is removed, never turn crankshaft and camshafts independently more than its allowab...

  • Page 358

    1d-24 engine mechanical: for m16a engine with vvt installation caution ! After timing chain is removed, never turn crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown in the figure. If turned, interference may occur between piston and valves and valves themselves, and...

  • Page 359

    Engine mechanical: for m16a engine with vvt 1d-25 6) apply engine oil to sliding surface of chain tensioner (1) and install chain tensioner and spacer. Tighten tensioner bolt to specified torque. Tightening torque timing chain tensioner bolt (a): 25 n·m (2.5 kgf- m, 18.0 lb-ft) 7) check that match m...

  • Page 360

    1d-26 engine mechanical: for m16a engine with vvt 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 ...

  • Page 361

    Engine mechanical: for m16a engine with vvt 1d-27 camshaft, tappet and shim components s5jb0a1416020 camshaft, tappet and shim removal and installation s5jb0a1416021 caution ! • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to dama...

  • Page 362

    1d-28 engine mechanical: for m16a engine with vvt 4) loosen camshaft housing bolts in such order as indicated in the figure and remove them. 5) remove camshaft housings. 6) remove intake and exhaust camshafts. 7) remove camshaft bearing (1). 8) remove tappets (2) with shims (1). Installation 1) inst...

  • Page 363

    Engine mechanical: for m16a engine with vvt 1d-29 4) apply engine oil to sliding surface of each camshaft and camshaft journal then install them as shown in the figure. 5) install camshaft housing pins (1) as shown in the figure. 6) check position of camshaft housings. Embossed marks are provided on...

  • Page 364

    1d-30 engine mechanical: for m16a engine with vvt camshaft, tappet and shim inspection s5jb0a1416022 intake cam timing sprocket assembly fit intake cam timing sprocket assembly to camshaft (2) and hold hexagonal section of camshaft by using spanner or the like. Check if sprocket (1) is not turned by...

  • Page 365

    Engine mechanical: for m16a engine with vvt 1d-31 6) tighten camshaft housing bolts in such order as indicated in the figure a little at a time till they are tightened to specified torque. Note do not rotate camshaft while gauging plastic is installed. Tightening torque camshaft housing bolt (a): 11...

  • Page 366

    1d-32 engine mechanical: for m16a engine with vvt wear of tappet and shim check tappet and shim for pitting, scratches, or damage. If any malcondition is found, replace. Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit,...

  • Page 367

    Engine mechanical: for m16a engine with vvt 1d-33 valves and cylinder head components s5jb0a1416023 i4rs0a140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (m8) : be sure to tighten cylinder head bolt (m8) after securing the other cylinder head bolt (m10). 2. Valve spring retainer 8...

  • Page 368

    1d-34 engine mechanical: for m16a engine with vvt valves and cylinder head removal and installation s5jb0a1416024 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation: for m16a engine with vvt”. 2) remove oil pan referring to “oil pan and oil pump str...

  • Page 369

    Engine mechanical: for m16a engine with vvt 1d-35 d) repeat step c). E) tighten bolt “a” to specified torque. Note be sure to tighten m8 bolt “a” after securing the other bolts. Tightening torque cylinder head bolt for m8 (a): 25 n·m (2.5 kgf-m, 18.0 lb-ft) cylinder head bolt for m10 (b): 20 n ⋅m (2...

  • Page 370

    1d-36 engine mechanical: for m16a engine with vvt 6) using special tool (valve guide remover), drive valve guide out from combustion chamber side to valve spring side. Special tool (a): 09916–44910 note do not reuse valve guide once disassembled. Be sure to use new valve guide (oversize) when assemb...

  • Page 371

    Engine mechanical: for m16a engine with vvt 1d-37 4) install valve spring seat to cylinder head. 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 gu...

  • Page 372

    1d-38 engine mechanical: for m16a engine with vvt valves and valve guides inspection s5jb0a1416026 valve guide valve stem-to-guide clearance using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to- guide clearance. Be sure to take reading at more than one...

  • Page 373

    Engine mechanical: for m16a engine with vvt 1d-39 valve head radial runout check each valve for radial runout with a dial gauge and “v” block. To check runout, rotate valve slowly. If runout exceeds its limit, replace valve. Valve head radial runout limit: 0.08 mm (0.003 in.) seating contact width c...

  • Page 374

    1d-40 engine mechanical: for m16a engine with vvt cylinder head inspection s5jb0a1416027 • remove all carbon deposits from combustion chambers. Note do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to v...

  • Page 375

    Engine mechanical: for m16a engine with vvt 1d-41 cylinder head bolt measure each thread diameter of cylinder head bolt (1) at “a” on 83.5 mm (2.81 in.) from seat side of flange bolt and “b” on 115 mm (4.53 in.) from seat side of flange bolt by using a micrometer (2). Then calculate difference in di...

  • Page 376

    1d-42 engine mechanical: for m16a engine with vvt pistons, piston rings, connecting rods and cylinders components s5jb0a1416029 pistons, piston rings, connecting rods and cylinders removal and installation s5jb0a1416030 removal 1) remove engine assembly from vehicle referring to “engine assembly rem...

  • Page 377

    Engine mechanical: for m16a engine with vvt 1d-43 installation 1) apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. Note do not apply oil between connecting rod and bearing or between bearing cap and bearing. 2) install guide hoses (1) over connecting rod bo...

  • Page 378

    1d-44 engine mechanical: for m16a engine with vvt pistons, piston rings, connecting rods and cylinders disassembly and assembly s5jb0a1416031 disassembly 1) using piston ring expander, remove two compression rings (top and 2nd) and oil ring from piston. 2) remove piston pin from connecting rod as fo...

  • Page 379

    Engine mechanical: for m16a engine with vvt 1d-45 4) after installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure. Cylinders, pistons and piston rings inspection s5jb0a1416032 cylinder visual inspection inspect cylinder walls for scratches, roughness or rid...

  • Page 380

    1d-46 engine mechanical: for m16a engine with vvt piston clearance measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston...

  • Page 381

    Engine mechanical: for m16a engine with vvt 1d-47 piston pins and connecting rods inspection s5jb0a1416033 piston pin visual inspection check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular attention to condition of small end bore bush. If pin, connect...

  • Page 382

    1d-48 engine mechanical: for m16a engine with vvt connecting rod bolt deformation (plastic deformation tightening bolt) measure each thread diameter of connecting rod bolt (2) at “a” on 32 mm (1.25 in.) from bolt mounting surface and “b” on 40 mm (1.57 in.) from bolt mounting surface by using a micr...

  • Page 383

    Engine mechanical: for m16a engine with vvt 1d-49 connecting rod bearing general information service connecting rod bearings are available in standard size and 0.25 mm (0.0098 in.) undersize bearing, and standard size bearing has 5 kinds of bearings differing in tolerance. For identification of unde...

  • Page 384

    1d-50 engine mechanical: for m16a engine with vvt selection of connecting rod bearings note • if bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. • when replacing crankshaft or connecting rod ...

  • Page 385

    Engine mechanical: for m16a engine with vvt 1d-51 3) there are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in the figure. Each color indicated the following thickness at the center of bearing. Stan...

  • Page 386

    1d-52 engine mechanical: for m16a engine with vvt main bearings, crankshaft and cylinder block components s5jb0a1416035 i5jb0a141026-02.

  • Page 387

    Engine mechanical: for m16a engine with vvt 1d-53 main bearings, crankshaft and cylinder block removal and installation s5jb0a1416036 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation: for m16a engine with vvt”. 2) remove clutch cover, clutch disc ...

  • Page 388

    1d-54 engine mechanical: for m16a engine with vvt installation note • all parts to be installed must be perfectly clean. • be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores. • journal bearings, bearing ...

  • Page 389

    Engine mechanical: for m16a engine with vvt 1d-55 7) if necessary, press-fit rear oil seal (1) to oil seal housing (2) by using special tool as shown in the figure. Special tool (a): 09911–97821 crank rear oil seal installing position (dimension) “a”: 2 mm (0.08 in.) 8) apply sealant to mating surfa...

  • Page 390

    1d-56 engine mechanical: for m16a engine with vvt crankshaft inspection s5jb0a1416037 crankshaft runout using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft. Crankshaft runout limit: 0.02 mm (0.0008 in.) crankshaft thrust pla...

  • Page 391

    Engine mechanical: for m16a engine with vvt 1d-57 note after checking the thrust play, make sure that thread deformation of each bearing cap no.1 bolt referring to “main bearing cap no.1 bolt” in “main bearings inspection: for m16a engine with vvt”. Out-of-round and taper (uneven wear) of journals a...

  • Page 392

    1d-58 engine mechanical: for m16a engine with vvt 4) tighten main bearing cap no.1 bolts (1) – (10) and main bearing cap no.2 bolts (11) – (20) gradually as follows. Note if main bearing cap no.1 bolt is reused, make sure to check main bearing cap no.1 bolt for deformation referring to “main bearing...

  • Page 393

    Engine mechanical: for m16a engine with vvt 1d-59 2) next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in the figure. Three kinds of alphabets (“a”, “b” and “c”) or numbers (“1”, “2” and “3”) represent the following cap bo...

  • Page 394

    1d-60 engine mechanical: for m16a engine with vvt undersize bearing (0.25 mm (0.0098 in.)) • 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure. Each...

  • Page 395

    Engine mechanical: for m16a engine with vvt 1d-61 new undersize crankshaft main bearing specification main bearing cap no.1 bolt measure each thread diameter main bearing cap no.1 bolts (1) at “a” on 60 mm (2.36 in.) from seat side of flange bolt and “b” on 90 mm (3.54 in.) from seat side of flange ...

  • Page 396

    1d-62 engine mechanical: for m16a engine with vvt flywheel inspection s5jb0a1416041 visual inspection • if ring gear is damaged, cracked or worn, replace flywheel. • if the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. Flywheel face runout check flywheel face runo...

  • Page 397

    Engine mechanical: for m16a engine with vvt 1d-63 specifications tightening torque specifications s5jb0a1417001 note the specified tightening torque is also described in the following. “throttle body and intake manifold components: for m16a engine with vvt” “engine mountings components: for m16a eng...

  • Page 398

    1d-64 engine mechanical: for m16a engine with vvt special tools and equipment recommended service material s5jb0a1418001 note required service material is also described in the following. “timing chain cover components: for m16a engine with vvt” “timing chain and chain tensioner components: for m16a...

  • Page 399

    Engine mechanical: for m16a engine with vvt 1d-65 09916–34550 09916–37320 reamer handle valve guide outer reamer (10.5 mm) ) ) 09916–44910 09916–56011 valve guide installer & remover valve guide installer attachment (protrusion: 11.5 mm) ) ) 09916–58210 09916–67020 valve guide installer handle tappe...

  • Page 400: For J20 Engine

    1d-66 engine mechanical: for j20 engine for j20 engine general description engine construction description s5jb0a1421001 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 co...

  • Page 401

    Engine mechanical: for j20 engine 1d-67 i5jb0a142069-02.

  • Page 402

    1d-68 engine mechanical: for j20 engine air cleaner element introduction s5jb0a1421002 this air cleaner element is dry type. Remember that it needs cleaning according to “air cleaner filter inspection and cleaning: for j20 engine”. Imt (intake manifold tuning) system s5jb0a1421003 description imt (i...

  • Page 403

    Engine mechanical: for j20 engine 1d-69 imt (intake manifold tuning) system varies effective length of intake pipe by opening and closing imt valve in order to improve air volumetric efficiency. As intake valve in cylinder head is opened and closed repeatedly, intake air pulsation always exists. If ...

  • Page 404

    1d-70 engine mechanical: for j20 engine system operation imt vacuum solenoid valve open: when imt vacuum solenoid valve is off, the actuator side of imt vacuum solenoid valve is lead to relief port. Under this condition, the negative pressure is not applied to imt valve actuator. The imt valve, ther...

  • Page 405

    Engine mechanical: for j20 engine 1d-71 10) crank engine with fully charged battery, and read the highest pressure on compression gauge. Note • for measuring compression pressure, crank engine at least 250 rpm by using fully charged battery. • if measuring compression pressure is lower than limit va...

  • Page 406

    1d-72 engine mechanical: for j20 engine valve lash (clearance) inspection s5jb0a1424003 1) remove negative cable at battery. 2) remove cylinder head cover referring to “cylinder head cover removal and installation: for j20 engine”. 3) using 17 mm wrench, turn crankshaft pulley (1) clockwise until in...

  • Page 407

    Engine mechanical: for j20 engine 1d-73 replacement of shim 1) close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut section (1) faces inside as shown in the figure. 2) lift down the valve by turning crankshaft to 360 °. 3) hold tappet at that posi...

  • Page 408

    1d-74 engine mechanical: for j20 engine 5) using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table. Shim thickness specification intake side: a = b + c – 0.20 mm (0.008 in.) ex...

  • Page 409

    Engine mechanical: for j20 engine 1d-75 repair instructions air cleaner assembly removal and installation s5jb0a1426044 removal 1) disconnect breather hose (1) from air cleaner outlet hose (2). 2) remove air cleaner outlet hose (2). 3) disconnect maf sensor connector (3). 4) remove air cleaner case ...

  • Page 410

    1d-76 engine mechanical: for j20 engine throttle body and intake manifold components s5jb0a1426007 throttle body on-vehicle inspection s5jb0a1426045 check electric throttle body assembly referring to “throttle valve operation check” and “electric throttle body assembly operation check” under “electr...

  • Page 411

    Engine mechanical: for j20 engine 1d-77 6) disconnect connector (3) from electric throttle body assembly. 7) remove electric throttle body assembly from intake manifold. Installation 1) clean mating surfaces, and install new throttle body gasket to intake manifold. 2) install electric throttle body ...

  • Page 412

    1d-78 engine mechanical: for j20 engine 9) remove evap canister purge valve bracket (10) form intake manifold. 10) remove water pump and generator drive belt referring to “water pump and generator drive belt removal and installation (for j20 engine): in section 1j”. 11) with hose connected, detach p...

  • Page 413

    Engine mechanical: for j20 engine 1d-79 installation 1) install pcv valve to cylinder head cover referring to “egr valve removal and installation: in section 1b”. 2) remove oil, old sealant and dust from sealing surfaces on cylinder head and cover. 3) install new cylinder head side seals (1) to cyli...

  • Page 414

    1d-80 engine mechanical: for j20 engine engine mountings components s5jb0a1426043 (a) 9 (a) 7 (a) 7 (a) (a) 9 (a) 1 2 1 3 5 6 (a) (a) (a) 8 (a) 8 4 i5jb0a142016-01 1. Engine front mounting 6. Engine splash cover 2. Engine front mounting right bracket 7. Engine front mounting nut 3. Engine front moun...

  • Page 415

    Engine mechanical: for j20 engine 1d-81 engine assembly removal and installation s5jb0a1426019 removal 1) relieve fuel pressure according to “fuel pressure relief procedure: in section 1g”. 2) disconnect negative cable at battery. 3) drain engine oil referring to “engine oil and filter change: in se...

  • Page 416

    1d-82 engine mechanical: for j20 engine 12) for m/t model, remove shift control lever referring to “transmission shift control lever removal and installation: in section 5b”. 13) remove exhaust no.1, no.2 and center pipes referring to “exhaust system components: in section 1k”. 14) remove front and ...

  • Page 417

    Engine mechanical: for j20 engine 1d-83 installation 1) install clutch cover and clutch disk referring to “clutch cover, clutch disc and flywheel removal and installation: in section 5c”, if removed. 2) install engine with engine front mounting bracket to engine front mounting. For tightening torque...

  • Page 418

    1d-84 engine mechanical: for j20 engine timing chain cover components s5jb0a1426020 timing chain cover removal and installation s5jb0a1426021 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation: for j20 engine”. 2) remove oil pan referring to “oil pa...

  • Page 419

    Engine mechanical: for j20 engine 1d-85 5) remove crankshaft pulley (1). To remove crankshaft pulley, use special tools (steering wheel remover, bearing puller attachment) with it as shown in figure. Special tool (a): 09944–36011 (b): 09926–58010 6) remove idler pulley (1), water pump pulley (2) and...

  • Page 420

    1d-86 engine mechanical: for j20 engine 3) apply sealant “a” and “b” to specific area as shown in figure. “a”: water tight sealant 99000–31250 (suzuki bond no.1207f) “b”: water tight sealant 99000–31140 (suzuki bond no.1207b) sealant amount for timing chain cover “a”: 3 mm (0.12 in.) “b”: 2 mm (0.08...

  • Page 421

    Engine mechanical: for j20 engine 1d-87 note be sure to use the following bolts instead of pins in order to fix crank pulley by special tool. Bolt size: m8, p1.25 l = 25 mm (0.98 in.) strength: 7t tightening torque crankshaft pulley bolt (a): 150 n·m (15.0 kgf-m, 108.5 lb-ft) 11) install engine asse...

  • Page 422

    1d-88 engine mechanical: for j20 engine 2nd timing chain and chain tensioner removal and installation s5jb0a1426024 caution ! After 2nd timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may oc...

  • Page 423

    Engine mechanical: for j20 engine 1d-89 7) remove intake and exhaust camshaft timing sprocket bolts (1). To remove them, fit a spanner (4) to hexagonal part (3) at the center of camshaft to hold it stationary. 8) remove camshaft timing sprockets and 2nd timing chain (2). Installation 1) check that m...

  • Page 424

    1d-90 engine mechanical: for j20 engine 6) tighten intake and exhaust camshaft timing sprocket bolts (1) to specified torque. To tighten it, fit a spanner (2) to hexagonal part (3) at the center of camshaft to hold it stationary. Tightening torque camshaft timing sprocket bolt (a): 80 n·m (8.0 kgf-m...

  • Page 425

    Engine mechanical: for j20 engine 1d-91 camshaft sprocket check teeth of sprocket for wear or damage. Timing chain check timing chain for wear or damage. Tensioner adjuster no.2 check shoe (1) for wear or damage and latch functions properly. 1st timing chain and chain tensioner components s5jb0a1426...

  • Page 426

    1d-92 engine mechanical: for j20 engine 1st timing chain and chain tensioner removal and installation s5jb0a1426027 caution ! After timing chain is removed, never turn crankshaft and camshafts independently more than its allowable turning range described referring to “2nd timing chain and chain tens...

  • Page 427

    Engine mechanical: for j20 engine 1d-93 8) with latch of tensioner adjuster no.1 returned and plunger (1) pushed back into body, insert stopper (4) into latch (2) and body (3). After inserting it, check to make sure that plunger will not come out. 9) install timing chain tensioner (2) adjuster no.1 ...

  • Page 428

    1d-94 engine mechanical: for j20 engine 1st timing chain and chain tensioner inspection s5jb0a1426028 timing chain guide no.1 check shoe for wear or damage. Timing chain tensioner check shoe (1) for wear or damage. Crankshaft timing sprocket check teeth of sprocket for wear or damage. Idler sprocket...

  • Page 429

    Engine mechanical: for j20 engine 1d-95 camshafts, tappet and shim components s5jb0a1426029 camshafts, tappet and shim removal and installation s5jb0a1426030 caution ! • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to damage them....

  • Page 430

    1d-96 engine mechanical: for j20 engine 2) match match mark (1) on crank timing sprocket and mating surface of cylinder block and lower crankcase (2). 3) install camshafts. Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks on cylinder head a...

  • Page 431

    Engine mechanical: for j20 engine 1d-97 9) install timing chain cover. Refer to “timing chain cover removal and installation: for j20 engine” for installation. 10) install cylinder head cover. Refer to “cylinder head cover removal and installation: for j20 engine” for installation. 11) install oil p...

  • Page 432

    1d-98 engine mechanical: for j20 engine 6) remove housing, and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point. Journal clearance if measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft jo...

  • Page 433

    Engine mechanical: for j20 engine 1d-99 valves and cylinder head components s5jb0a1426032 valves and cylinder head removal and installation s5jb0a1426033 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation: for j20 engine”. 2) remove oil pan referrin...

  • Page 434

    1d-100 engine mechanical: for j20 engine 7) loosen cylinder head bolts (m10) in such order as numbered in figure and remove them. Note don’t forget to remove cylinder head bolt (m6) (3) as shown in figure. 8) check all around cylinder head for any other parts required to be removed or disconnected a...

  • Page 435

    Engine mechanical: for j20 engine 1d-101 d) tighten cylinder head bolts (m10) to 52 n ⋅m (5.2 kgf-m, 38.0 lb-ft) according to numerical order in figure. E) in the same manner as in step b), retighten cylinder head bolts (m10) to 103 n ⋅m (10.3 kgf- m, 74.5 lb-ft). F) tighten cylinder head bolt (m6) ...

  • Page 436

    1d-102 engine mechanical: for j20 engine 3) release special tool, and remove spring retainers and valve springs. 4) remove valve from combustion chamber side. 5) remove valve stem seal (1) from valve guide, and then valve spring seat (2). Note do not reuse seal once disassembled. Be sure to use new ...

  • Page 437

    Engine mechanical: for j20 engine 1d-103 3) ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore. Special tool (a): 09916–34542 (b): 09916–37810 4) install valve spring seat to cylinder head. 5) install new valve stem seal (1) to valve guide. After applying engine oil t...

  • Page 438

    1d-104 engine mechanical: for j20 engine 9) install intake manifold referring to “intake manifold removal and installation: for j20 engine”. 10) install exhaust manifold referring to “exhaust manifold removal and installation (for j20 engine model): in section 1k”. 11) install injectors referring to...

  • Page 439

    Engine mechanical: for j20 engine 1d-105 valve visual inspection • remove all carbon from valves. • inspect each valve for wear, burn or distortion at its face and stem end, as necessary, replace it. • inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem en...

  • Page 440

    1d-106 engine mechanical: for j20 engine 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. 1) exhaust valve seat: use va...

  • Page 441

    Engine mechanical: for j20 engine 1d-107 • distortion of manifold seating faces: check seating faces of cylinder head for manifolds, using a straightedge and thickness gauge, in order to determine whether these faces should be corrected or cylinder head replaced. Distortion for cylinder head surface...

  • Page 442

    1d-108 engine mechanical: for j20 engine pistons, piston rings, connecting rods and cylinders components s5jb0a1426036 pistons, piston rings, connecting rods and cylinders removal and installation s5jb0a1426037 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and ...

  • Page 443

    Engine mechanical: for j20 engine 1d-109 3) 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. Hold ring compres...

  • Page 444

    1d-110 engine mechanical: for j20 engine assembly note two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. 1) each piston (1) has stamped number ...

  • Page 445

    Engine mechanical: for j20 engine 1d-111 4) install piston pin to piston (1) and connecting rod (3): after applying engine oil to piston pin and piston pin holes in piston and connecting rod, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and inst...

  • Page 446

    1d-112 engine mechanical: for j20 engine pistons, piston rings, connecting rods and cylinders inspection and cleaning s5jb0a1426039 inspection cylinder • inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or r...

  • Page 447

    Engine mechanical: for j20 engine 1d-113 piston pin • check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly worn or damaged, replace pin, conne...

  • Page 448

    1d-114 engine mechanical: for j20 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 clearanc...

  • Page 449

    Engine mechanical: for j20 engine 1d-115 • connecting rod bearing clearance: a. Before checking bearing clearance, clean bearing and crank pin. B. Install bearing in connecting rod and bearing cap. C. Place a piece of gauging plastic (1) to full width of crank pin as contacted by bearing (parallel t...

  • Page 450

    1d-116 engine mechanical: for j20 engine • selection of connecting rod bearings: note • if bearing is in malcondition or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. • when replacing crankshaft or connecting rod and its...

  • Page 451

    Engine mechanical: for j20 engine 1d-117 d. From number stamped on connecting rod and its cap and alphabet stamped on crank web no. 3 cylinder, determine new standard bearing to be installed to connecting rod big-end inside, by referring to the table. For example, if number stamped on connecting rod...

  • Page 452

    1d-118 engine mechanical: for j20 engine main bearings, crankshaft and cylinder block components s5jb0a1426040 i5jb0a142056-02.

  • Page 453

    Engine mechanical: for j20 engine 1d-119 main bearings, crankshaft and cylinder block removal and installation s5jb0a1426041 removal 1) remove engine assembly from vehicle. Refer to “engine assembly removal and installation: for j20 engine”. 2) remove clutch and flywheel (drive plate for a/t) by usi...

  • Page 454

    1d-120 engine mechanical: for j20 engine 7) loosen crankcase bolts, in sequence shown in figure and remove them. 8) remove crankshaft from cylinder block. Installation note • all parts to be installed must be perfectly clean. • be sure to oil crankshaft journals, journal bearings, thrust bearings, c...

  • Page 455

    Engine mechanical: for j20 engine 1d-121 8) install lower crankcase (1) to cylinder block. After applying engine oil to all crankcase bolts ((1) – (22)), tighten them gradually as follows. A) tighten bolts ((1) – (10)) to 30 n ⋅m (3.0 kgf-m, 21.5 lb-ft) according to numerical order as shown. B) tigh...

  • Page 456

    1d-122 engine mechanical: for j20 engine 12) install flywheel (drive plate for a/t). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) applied with sealant to specification. Special tool (a): 09924–17810 tightening torque flywheel bolt (a): 70 n·m (7.0 k...

  • Page 457

    Engine mechanical: for j20 engine 1d-123 crankshaft thrust play measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and lower crankcase installed. Tighten crankcase bolts referring to “main bearings, crankshaft and cylinder block removal and ins...

  • Page 458

    1d-124 engine mechanical: for j20 engine main bearing clearance check clearance by using gauging plastic according to the following procedure. 1) remove lower crankcase. 2) clean bearings and main journals. 3) place a piece of gauging plastic (1) to full width of bearing (parallel to crankshaft) on ...

  • Page 459

    Engine mechanical: for j20 engine 1d-125 2) next, check journal bore diameter. On lower crankcase five alphabets are stamped as shown in figure. Three kinds of alphabets (“a”, “b” and “c”) represent the following journal bore diameters. Journal bore diameter stamped alphabets on lower crankcase repr...

  • Page 460

    1d-126 engine mechanical: for j20 engine 4) from number stamped on crank web no.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal by referring to table shown. For example, if number stamped on crank web no.2 is “5” and alphabet stamped on lower cra...

  • Page 461

    Engine mechanical: for j20 engine 1d-127 • if necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. A. Regrind journal to the following finished diameter. Finished journal diameter 57.7380 – 57.7560 mm (2.27315 – 2.27385 in.) b. Using micrometer, measure regr...

  • Page 462

    1d-128 engine mechanical: for j20 engine oil pump chain check oil pump chain for wear or damage. Flywheel • if ring gear is damaged, cracked or worn, replace flywheel. • if the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. • check flywheel for face runout with a d...

  • Page 463

    Engine mechanical: for j20 engine 1d-129 specifications tightening torque specifications s5jb0a1427001 note the specified tightening torque is also described in the following. “engine mountings components: for j20 engine” “timing chain cover components: for j20 engine” “2nd timing chain and chain te...

  • Page 464

    1d-130 engine mechanical: for j20 engine special tools and equipment recommended service material s5jb0a1428001 note required service material is also described in the following. “timing chain cover components: for j20 engine” “2nd timing chain and chain tensioner components: for j20 engine” “1st ti...

  • Page 465

    Engine mechanical: for j20 engine 1d-131 09916–16510 09916–34542 valve lifter attachment reamer handle ) / ) ) / ) 09916–37810 09916–38210 valve guide reamer (6 mm) valve guide reamer (11 mm) ) ) 09916–46020 09916–57340 valve guide remover valve guide installer attachment ) ) 09916–57350 09916–66510...

  • Page 466

    1d-132 engine mechanical: for j20 engine 09944–36011 steering wheel remover ).

  • Page 467: Engine Lubrication System

    Engine lubrication system: for m16a engine with vvt 1e-1 engine lubrication system for m16a engine with vvt general description engine lubrication description s5jb0a1511001 the oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed thr...

  • Page 468

    1e-2 engine lubrication system: for m16a engine with vvt i3rh0b150001-01.

  • Page 469

    Engine lubrication system: for m16a engine with vvt 1e-3 diagnostic information and procedures oil pressure check s5jb0a1514001 note prior to checking oil pressure, check the following. • oil level in oil pan if oil level is low, add oil up to full level mark (hole) (1) on oil level gauge referring ...

  • Page 470

    1e-4 engine lubrication system: for m16a engine with vvt 8) start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) connect oil pressure switch coupler (1). Repair instructions oil pan and oil pump strainer components s5jb0a1516001 1 i5jb0a151003-01 i5jb0a1...

  • Page 471

    Engine lubrication system: for m16a engine with vvt 1e-5 oil pan and oil pump strainer removal and installation s5jb0a1516002 removal 1) remove oil level gauge. 2) drain engine oil by removing drain plug. 3) remove front suspension frame referring to “front suspension frame, stabilizer bar and/or bu...

  • Page 472

    1e-6 engine lubrication system: for m16a engine with vvt 4) install oil pan to cylinder block temporarily. 5) insert knock pin (1) in hole (2) of oil pan in order to locate oil pan precisely. Note knock pin is available as a spare part (part number: 04211–13189). 6) after fitting oil pan to cylinder...

  • Page 473

    Engine lubrication system: for m16a engine with vvt 1e-7 oil pump components s5jb0a1516004 oil pump removal and installation s5jb0a1516005 oil pump is incorporated with timing chain cover. For removal and installation, refer to “timing chain cover removal and installation: for m16a engine with vvt i...

  • Page 474

    1e-8 engine lubrication system: for m16a engine with vvt reassembly 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. 3) install outer (1) and inner rotors (2) to oil pump ...

  • Page 475

    Engine lubrication system: for m16a engine with vvt 1e-9 radial clearance check radial clearance between outer rotor (1) and case (2) using thickness gauge (3). If clearance exceeds its limit, replace outer rotor or case. Radial clearance between outer rotor and case for oil pump limit: 0.310 mm (0....

  • Page 476

    1e-10 engine lubrication system: for m16a engine with vvt specifications tightening torque specifications s5jb0a1517001 note the specified tightening torque is also described in the following. “oil pan and oil pump strainer components: for m16a engine with vvt” “oil pump components: for m16a engine ...

  • Page 477: For J20 Engine

    Engine lubrication system: for j20 engine 1e-11 for j20 engine general description engine lubrication description s5jb0a1521001 the oil pump is trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered o...

  • Page 478

    1e-12 engine lubrication system: for j20 engine i5jb0a151013-01.

  • Page 479

    Engine lubrication system: for j20 engine 1e-13 diagnostic information and procedures oil pressure check s5jb0a1524001 warning ! To avoid danger of being burned, do not touch exhaust manifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has cooled down. Note...

  • Page 480

    1e-14 engine lubrication system: for j20 engine repair instructions oil pan and oil pump strainer components s5jb0a1526001 1217g 3 8 (a) (a) (a) (a) (b) (c) (d) 9 1 7 5 2 6 4 (a) 4 i5jb0a152004-02 1. Oil pan : apply sealant 99000-31260 to mating surface. 8. Gasket 2. Oil pump strainer 9. Baffle plat...

  • Page 481

    Engine lubrication system: for j20 engine 1e-15 oil pan and oil pump strainer removal and installation s5jb0a1526002 removal 1) remove oil level gauge. 2) raise vehicle. 3) remove engine under cover (1). 4) drain engine oil by removing drain plug (2). 5) remove front suspension frame referring to “f...

  • Page 482

    1e-16 engine lubrication system: for j20 engine 4) install new gasket and drain plug (2) to oil pan after applying engine oil. Tighten drain plug to specified torque. Tightening torque oil drain plug (c): 35 n·m (3.5 kgf-m, 25.5 lb-ft) 5) install front suspension frame referring to “front suspension...

  • Page 483

    Engine lubrication system: for j20 engine 1e-17 oil pump removal and installation s5jb0a1526005 caution ! Don’t remove sprocket and inner rotor from oil pump, otherwise damage of oil pump center shaft and abnormal operation of oil pump could result. Removal 1) disconnect negative cable at battery. 2...

  • Page 484

    1e-18 engine lubrication system: for j20 engine 5) install oil pump case pins (5) to oil pump case no.2. 6) assemble oil pump. After assembling oil pump, check to be sure that rotor turns smoothly by hand. Tightening torque oil pump case bolt (a): 12 n·m (1.2 kgf-m, 9.0 lb- ft) oil pump inspection s...

  • Page 485

    Engine lubrication system: for j20 engine 1e-19 side clearance using straightedge (5) and thickness gauge (4), measure side clearance. If side clearance exceeds its limit, replace oil pump assembly. Limit on side clearance 0.11 mm (0.0043 in.) specifications tightening torque specifications s5jb0a15...

  • Page 486

    1e-20 engine lubrication system: for j20 engine special tools and equipment recommended service material s5jb0a1528001 note required service material is also described in the following. “oil pan and oil pump strainer components: for j20 engine” special tool s5jb0a1528002 material suzuki recommended ...

  • Page 487: Engine Cooling System

    Engine cooling system: 1f-1 engine cooling system general description cooling system description s5jb0a1601001 the cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. Coolant description s5jb0a...

  • Page 488

    1f-2 engine cooling system: schematic and routing diagram coolant circulation s5jb0a1602001 while the engine is warmed up (thermostat closed), coolant circulates as follows. When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be coole...

  • Page 489

    Engine cooling system: 1f-3 diagnostic information and procedures engine cooling symptom diagnosis s5jb0a1604001 condition possible cause correction / reference item engine overheats (radiator fan operates) loose or broken water pump belt adjust or replace. Not enough coolant check coolant level and...

  • Page 490

    1f-4 engine cooling system: repair instructions cooling system components s5jb0a1606001 i5jb0a161003-03.

  • Page 491

    Engine cooling system: 1f-5 [b] 8 (a) 21 25 24 15 7 11 6 16 5 33 3 16 14 31 34 29 30 29 32 32 1 4 36 35 37 38 26 2 39 22 23 10 10 9 9 i5jb0a161004-03 [a]: m16 engine model 14. Thermostat 29. To cylinder head [b]: j20 engine model 15. Thermostat cap 30. To water pump 1. Radiator 16. Radiator inlet no...

  • Page 492

    1f-6 engine cooling system: coolant level check s5jb0a1606002 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 pressure if radiator cap is taken off too soon. To check level, lift hood ...

  • Page 493

    Engine cooling system: 1f-7 cooling system draining s5jb0a1606019 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 flush and refill s5jb0a1606004 warning ! To help avoid danger of being burned...

  • Page 494

    1f-8 engine cooling system: cooling water pipes or hoses removal and installation s5jb0a1606005 removal 1) drain coolant referring to “cooling system draining: ”. 2) to remove these pipes or hoses, loosen clamp on each hose and pull hose end off. Installation install removed parts in reverse order o...

  • Page 495

    Engine cooling system: 1f-9 thermostat removal and installation (for j20 engine model) s5jb0a1606022 removal 1) drain coolant referring to “cooling system draining: ”. 2) disconnect radiator outlet hose from thermostat cap (1). 3) remove thermostat cap (1) from water pump (2). 4) remove thermostat f...

  • Page 496

    1f-10 engine cooling system: radiator cooling fan motor on-vehicle inspection s5jb0a1606010 1) check main and/or sub fan operation of radiator cooling fan as follows. A) connect battery to main fan motor coupler (coupler color: black) or sub fan motor coupler (coupler color: gray) as shown in figure...

  • Page 497

    Engine cooling system: 1f-11 radiator cooling fan assembly removal and installation s5jb0a1606021 removal 1) disconnect negative (–) cable at battery. 2) disconnect connectors (1) of cooling fan motors. 3) with hose connected, detach p/s fluid reservoir with reservoir bracket. 4) remove air cleaner ...

  • Page 498

    1f-12 engine cooling system: radiator removal and installation s5jb0a1606014 removal 1) disconnect negative cable at battery. 2) for a/t, drain a/t fluid referring to “a/t fluid change: in section 5a”. 3) drain coolant. 4) remove cooling fan assembly referring to “radiator cooling fan assembly remov...

  • Page 499

    Engine cooling system: 1f-13 2) install water pump assembly (1) to cylinder block and tighten bolts and nut to specified torque. Tightening torque water pump bolt and nut (a): 25 n·m (2.5 kgf-m, 18.0 lb-ft) 3) install water pump pulley. 4) install water pump and generator drive belt referring to “wa...

  • Page 500

    1f-14 engine cooling system: water pump inspection s5jb0a1606018 caution ! Do not disassemble water pump. If any repair is required on pump, replace it as assembly. Rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, replace it. Specific...

  • Page 501: Fuel System

    Fuel system: 1g-1 fuel system precautions precautions on fuel system service s5jb0a1700001 warning ! Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. • disconnect negative cable at battery. • do not...

  • Page 502

    1g-2 fuel system: fuel pump description s5jb0a1701003 the fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) included and a fuel level gauge (3) attached. Also, the jet pump (4) installed in the fuel pump sucks up the fuel from the sub fuel level...

  • Page 503

    Fuel system: 1g-3 diagnostic information and procedures fuel pressure inspection s5jb0a1704001 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. 1) relieve fuel pressure in fuel feed l...

  • Page 504

    1g-4 fuel system: 6) after checking fuel pressure, remove fuel pressure gauge. Warning ! As fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to the following procedures. • place fuel container under joint. • cover joint with rag and loosen joint nut slow...

  • Page 505

    Fuel system: 1g-5 repair instructions fuel system components s5jb0a1706001 i5jb0a170001-03.

  • Page 506

    1g-6 fuel system: 5 2 26 1 11 3 4 8 14 (b) 13 (a) 12 (b) 23 (c) 16 25 27 21 10 9 10 20 15 18 17 19 29 28 21 6 7 [b] 22 30 i5jb0a170002-03.

  • Page 507

    Fuel system: 1g-7 [a]: for m16 engine model 11. Fuel pump gasket 24. To fuel tank [b]: for j20 engine model 12. Fuel tank bolt 25. To evap canister purge valve [c]: view a 13. Fuel pump bolt 26. Sub fuel level sensor 1. Fuel tank 14. Fuel filler neck 27. Main fuel level sensor 2. Fuel pump assembly ...

  • Page 508

    1g-8 fuel system: fuel hose disconnecting and reconnecting s5jb0a1706023 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in ...

  • Page 509

    Fuel system: 1g-9 the other than fuel tank system for quick joint (other than fuel vapor line) disconnecting 1) remove mud, dust and/or foreign material between pipe (1) and quick joint (2) by blowing compressed air. 2) unlock joint lock by inserting special tool between pipe and quick joint. Specia...

  • Page 510

    1g-10 fuel system: for quick joint (fuel vapor line) disconnecting 1) remove mud, dust and/or foreign material between pipe (1) and quick joint (fuel vapor line) (2) by blowing compressed air. 2) release lock plate (3) completely in arrow direction, and then remove quick joint (fuel vapor line) (2) ...

  • Page 511

    Fuel system: 1g-11 fuel lines on-vehicle inspection s5jb0a1706004 caution ! Due to the fact that fuel feed line (1) is under high pressure, use special care when servicing it. Visually inspect fuel lines for evidence of fuel leakage, hose crack and deterioration or damage. Make sure all clamps are s...

  • Page 512

    1g-12 fuel system: fuel injector removal and installation s5jb0a1706007 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Removal 1) relieve fuel pressure according to “fuel pressure r...

  • Page 513

    Fuel system: 1g-13 • after installation, with engine off and ignition switch on, check for fuel leaks around fuel line connection. Fuel injector inspection s5jb0a1706008 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce th...

  • Page 514

    1g-14 fuel system: 5) install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting. 6) put graduated cylinder under injector. 7) operate fuel pump and apply fuel pressure to injector as follows: a) when using scan tool: i) connect scan tool to dlc with ignition ...

  • Page 515

    Fuel system: 1g-15 fuel pressure regulator removal and installation s5jb0a1706024 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ”in order to reduce the risk or fire and personal injury. Removal 1) relieve fuel pressure according to “fuel p...

  • Page 516

    1g-16 fuel system: fuel filler cap inspection s5jb0a1706011 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Remove cap (1), and check gasket for even filler neck imprint, and deterio...

  • Page 517

    Fuel system: 1g-17 fuel tank inlet valve inspection s5jb0a1706016 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Check fuel tank inlet valve for the following. If any damage or malf...

  • Page 518

    1g-18 fuel system: 12) support fuel tank (1) with jack (2) and remove its mounting bolts. 13) for m16 engine, lower fuel tank a little as to disconnect connectors (1) of fuel pump (2) and sub fuel level gauge (3), then remove fuel tank. Installation caution ! • when connecting joint, clean outside s...

  • Page 519

    Fuel system: 1g-19 7) install parking brake cable clamp to fuel tank cover referring to “parking brake cable location: in section 4d” 8) install rear propeller shaft referring to “propeller shaft removal and installation: in section 3d” 9) install exhaust center pipe referring to “exhaust system com...

  • Page 520

    1g-20 fuel system: fuel pump assembly removal and installation s5jb0a1706019 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Removal 1) remove fuel tank from vehicle refer to “fuel t...

  • Page 521

    Fuel system: 1g-21 main fuel level sensor removal and installation s5jb0a1706022 caution ! • do not touch resister plate (1) and deform arm (2). It may cause main fuel level sensor to fail. • be very careful not to cause damage to fuel tube installed section (sealed section in bore). If it be damage...

  • Page 522

    1g-22 fuel system: removal 1) remove fuel tank from vehicle referring to “fuel tank removal and installation: ” 2) disconnect sub fuel level sensor connector (1). 3) remove sub fuel level sensor (2). Installation reverse removal procedure for installation noting the following. • replace o-ring with ...

  • Page 523

    Fuel system: 1g-23 special tools and equipment recommended service material s5jb0a1708001 note required service material is also described in the following. “fuel system components: ” special tool s5jb0a1708002 material suzuki recommended product or specification note oil suzuki di o ring oil(500cc)...

  • Page 524: Ignition System

    1h-1 ignition system: ignition system general description ignition system construction s5jb0a1801001 the ignition system is an electronic (distributor less) ignition system. Especially a direct ignition system is adopted for j20 engine. They consists of the parts as described below. • ecm it detects...

  • Page 525

    Ignition system: 1h-2 schematic and routing diagram ignition system wiring circuit diagram s5jb0a1802001 e23 c37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 ...

  • Page 526

    1h-3 ignition system: component location ignition system components location s5jb0a1803001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 2. Main relay 10. No.4 spark plug 18. Ignition coil assembly for no.1 3. Ig...

  • Page 527

    Ignition system: 1h-4 diagnostic information and procedures ignition system symptom diagnosis s5jb0a1804001 reference waveform of ignition system s5jb0a1804002 refer to “reference waveform no.12 to 16” and “reference waveform no.20 and 21” under “inspection of ecm and its circuits: in section 1a” fo...

  • Page 528

    1h-5 ignition system: 3 dtc check 1) perform dtc check referring to “dtc check: in section 1a”. Is dtc stored in ecm? Go to applicable dtc diag. Flow. Go to step 4. 4 electrical connection check 1) check ignition coil assemblies and high-tension cords (for m16 engine) for electrical connection. Are ...

  • Page 529

    Ignition system: 1h-6 ignition spark test s5jb0a1804004 1) remove engine cover. 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. 3) remove ...

  • Page 530

    1h-7 ignition system: repair instructions high-tension cord removal and installation (for m16 engine) s5jb0a1806001 removal 1) remove engine cover. 2) disconnect no.1 cylinder (2) and no.3 cylinder (3) high-tension cords from ignition coil assemblies (1) while gripping each cap. 3) pull out high-ten...

  • Page 531

    Ignition system: 1h-8 spark plug inspection s5jb0a1806004 caution ! • when servicing the iridium / platinum spark plugs (slender center electrode type plugs), do not touch the center electrode to avoid damage to it. The electrode is not strong enough against mechanical force as it is slender and its...

  • Page 532

    1h-9 ignition system: installation 1) install ignition coil assembly (2). 2) tighten ignition coil bolts (1) to specified torque, and then connect ignition coil coupler. Tightening torque ignition coil bolt for m16 engine (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) ignition coil bolt for j20 engine (b): 6.5 ...

  • Page 533

    Ignition system: 1h-10 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 temperature. 3) make sure that all of electrical loads except ignition are switched off. 4) check to be sure that idle speed is withi...

  • Page 534

    1h-11 ignition system: specifications tightening torque specifications s5jb0a1807001 reference: for the tightening torque of fastener not specified in this section, refer to “fastener information: in section 0a”. Special tools and equipment special tool s5jb0a1808001 fastening part tightening torque...

  • Page 535: Starting System

    Starting system: 1i-1 starting system precautions cranking system note s5jb0a1900001 note starting motor varies depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. General description cranking circuit introductio...

  • Page 536

    1i-2 starting system: diagnostic information and procedures cranking system symptom diagnosis s5jb0a1904001 possible symptoms due to starting system trouble would be as follows: • starting motor does not run (or runs slowly) • starting motor runs but fails to crank engine • abnormal noise is heard p...

  • Page 537

    Starting system: 1i-3 starting motor performance test s5jb0a1904002 caution ! Each test must be performed within 3 – 5 seconds to avoid coil from burning. Pull-in test 1) connect battery to magnetic switch as shown. 2) check that plunger and pinion move outward. If plunger and pinion don’t move, rep...

  • Page 538

    1i-4 starting system: hold-in test 1) while connected as above with plunger out, disconnect negative lead (2) from terminal “m” (1). 2) check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch. Plunger and pinion return test 1) disconnect negative lead (...

  • Page 539

    Starting system: 1i-5 repair instructions starting motor dismounting and remounting s5jb0a1906001 dismounting 1) disconnect negative (–) battery lead at battery. 2) hoist vehicle 3) disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 4) remove starting motor...

  • Page 540

    1i-6 starting system: starting motor components s5jb0a1906005 the starting motor consists of parts shown in below and has permanent magnets mounted in starting motor yoke (frame). The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected...

  • Page 541

    Starting system: 1i-7 starting motor inspection s5jb0a1906004 plunger inspect plunger for wear. Replace if necessary. Magnetic switch push in plunger and release it. The plunger should return quickly to its original position. Replace if necessary. Pull-in coil open circuit test check for continuity ...

  • Page 542

    1i-8 starting system: brush holder • check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for contamination. Clean or correct as necessary. • check for continuity across insulated brush (positive side) and gro...

  • Page 543

    Starting system: 1i-9 ground test check the commutator and armature core. If there is continuity, armature is grounded and must be replaced. Open circuit test check for continuity between segments. If there is no continuity at any test point, there is an open circuit and the armature must be replace...

  • Page 544

    1i-10 starting system: specifications starting motor specifications s5jb0a1907001 1.2 kw type [1.4 kw type] tightening torque specifications s5jb0a1907002 note the specified tightening torque is also described in the following. “starting motor dismounting and remounting: ” “starting motor components...

  • Page 545: Charging System

    Charging system: 1j-1 charging system general description battery description s5jb0a1a01001 the battery has three major functions in the electrical system. • it is a source of electrical energy for cranking the engine. • it acts as a voltage stabilizer for the electrical system. • it can, for a limi...

  • Page 546

    1j-2 charging system: • green dot: battery is sufficiently charged for testing. • dark: battery must be charged before testing. If there is a cranking complaint, battery should be tested as described in “battery inspection: ”. Charging and electrical systems should also be checked at this time. • cl...

  • Page 547

    Charging system: 1j-3 charging system circuit the generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage is bei...

  • Page 548

    1j-4 charging system: generator symptom diagnosis s5jb0a1a04001 a charging circuit wiring diagram for generator connection is shown in “generator description: ”. To avoid damage, always follow these precautions: caution ! • do not mistake polarities of “ig” terminal and “l” terminal. • do not create...

  • Page 549

    Charging system: 1j-5 no-load check 1) run engine from idling up to 2000 rpm and read meters. Note turn off switches of all accessories (wiper, heater etc.). Specification for undercharged battery (no-load check) current: 10 a voltage: 14.2 – 14.8 v (at 20 °c, 68 °f) note consideration should be tak...

  • Page 550

    1j-6 charging system: repair instructions jump starting in case of emergency s5jb0a1a06004 with auxiliary (booster) battery caution ! If vehicle is manual transmission model and has a catalytic converter, do not push or tow it to start. Damage to its emission system and/or to other parts may result....

  • Page 551

    Charging system: 1j-7 battery dismounting and remounting s5jb0a1a06005 warning ! When handling battery, following safety precautions should be followed: • hydrogen gas is produced by battery. A flame or spark near battery may cause the gas to ignite. • battery fluid is highly acidic. Avoid spilling ...

  • Page 552

    1j-8 charging system: water pump and generator drive belt tension inspection and adjustment (for m16 engine) s5jb0a1a06012 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 ...

  • Page 553

    Charging system: 1j-9 water pump and generator drive belt on-vehicle inspection (for j20 engine) s5jb0a1a06013 [type a] 1) disconnect negative cable at battery. 2) inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found, replace belt, referring to “wate...

  • Page 554

    1j-10 charging system: water pump and generator drive belt removal and installation (for j20 engine) s5jb0a1a06014 removal warning ! Disconnect negative (–) cable at battery before removing and installing generator belt. 1) loosen tensioner by turning the tensioner pulley (2) clockwise. 2) while hol...

  • Page 555

    Charging system: 1j-11 generator dismounting and remounting s5jb0a1a06006 [a] [b] (a) (b) (c) (b) (c) 7 1 8 2 9 6 4 8 (a) 3 1 7 2 9 6 5 3 (c) (c) i5jb0a1a0003-02 [a]: for m16 engine 4. Generator adjusting bolt (for m16 engine) 9. Generator [b]: for j20 engine 5. Generator mounting bolt (for j20 engi...

  • Page 556

    1j-12 charging system: dismounting 1) disconnect negative (–) cable at battery. 2) disconnect maf sensor coupler (for j20 engine). 3) remove air cleaner case and air cleaner outlet hose (for j20 engine). 4) disconnect generator lead wire (“b” terminal wire) and coupler from generator. 5) remove gene...

  • Page 557

    Charging system: 1j-13 generator inspection s5jb0a1a06009 rotor • using ohmmeter, connect positive terminal to “fr” terminal and connect negative terminal to “b” terminal of generator, check that continuity between “b” terminal and “fr” terminal. If there is no continuity, replace rotor or regulator...

  • Page 558

    1j-14 charging system: stator • using ohmmeter, check all leads for continuity. If there is no continuity, replace stator (1). • using ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator. Brush and brush holder check each bru...

  • Page 559

    Charging system: 1j-15 rectifier 1) using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace ...

  • Page 560

    1j-16 charging system: specifications charging system specifications s5jb0a1a07001 battery note the battery used in each vehicle is one of the following two types, depending on specification. Generator note the generator used in each vehicle is one of the following three types, depending on specific...

  • Page 561: Exhaust System

    Exhaust system: 1k-1 exhaust system general description exhaust system description s5jb0a1b01001 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 emiss...

  • Page 562

    1k-2 exhaust system: for m16 engine model i5jb0a1b1002-03 [a]: installing location of exhaust manifold bold and nut. 9. Exhaust pipe no.2 18. Exhaust pipe no.1 bracket bolt 1. Exhaust manifold gasket 10. Exhaust center pipe 19. Exhaust center pipe nut 2. Exhaust manifold 11. Muffler 20. Exhaust cent...

  • Page 563

    Exhaust system: 1k-3 for j20 engine model i5jb0a1b1003-05 [a]: installing location of exhaust manifold bold and nut. 10. Exhaust center pipe 20. Exhaust center pipe gasket 1. Exhaust manifold gasket 11. Muffler 21. Muffler mounting 2. Exhaust manifold 12. Mounting 22. Exhaust pipe no.2 bracket 3. Ex...

  • Page 564

    1k-4 exhaust system: exhaust manifold removal and installation (for m16 engine model) s5jb0a1b06003 removal warning ! To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. 1) disconnect negative cable at battery. 2)...

  • Page 565

    Exhaust system: 1k-5 7) remove exhaust pipe no.1 bracket (1). 8) remove exhaust manifold (2) and its gasket (3) from cylinder head. Installation 1) install new gasket (1) to cylinder head and exhaust pipe no.1. Then install exhaust manifold (2). Tighten manifold bolts (4) and nuts (5) to specified t...

  • Page 566

    1k-6 exhaust system: specifications tightening torque specifications s5jb0a1b07001 note the specified tightening torque is also described in the following. “exhaust system components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fastener information: in...

  • Page 567: Section 2

    Table of contents 2- i 2 section 2 contents suspension precautions .................................................2-1 precautions............................................................. 2-1 precautions on suspension .................................. 2-1 suspension general diagnosis.............

  • Page 568

    2-ii table of contents rear wheel hub assembly, wheel bearing and wheel stud inspection .............................2c-27 rear wheel disc, nut and bearing check ........2c-27 rear suspension knuckle removal and installation.......................................................2c-28 rear suspension...

  • Page 569: Precautions

    Precautions: 2-1 precautions precautions precautions on suspension s5jb0a2000001 suspension caution refer to “suspension caution: in section 00”. Wheels and tires caution refer to “wheels and tires caution: in section 00”. General precautions refer to “general precautions: in section 00”. Vehicle li...

  • Page 570: Suspension General Diagnosis

    2a-1 suspension general diagnosis: suspension general diagnosis diagnostic information and procedures suspension, wheels and tires symptom diagnosis s5jb0a2104001 condition possible cause correction / reference item vehicle pulls (leads) mismatched or uneven tires replace tires. Tires not adequately...

  • Page 571

    Suspension general diagnosis: 2a-2 note *1: right-to-left trim height (“h”) difference should be within 15 mm (0.6 in.) with curb weight. (same with rear side.) body leans or sways in corners loose stabilizer bar tighten stabilizer bar bolts or nuts, or replace bushes. Faulty strut (shock absorber) ...

  • Page 572

    2a-3 suspension general diagnosis: specifications wheel alignment specifications s5jb0a2107001 wheel alignment specifications note toe value in the specifications table was measured by using a toe-in gauge. Item front rear front and rear toe (“b” – “a”) (total) in 0 ± 2.0 mm (0 ± 0.0787 in.) in 6.0 ...

  • Page 573: Front Suspension

    Front suspension: 2b-1 front suspension general description front suspension construction s5jb0a2201001 2 7 4 2 5 8 1 6 3 (a) (b) (c) (d) (e) (f) (g) (a) (a) (a) (h) (h) (b) (b) (f) (g) i5jb0a220001-02 1. Front strut assembly 7. Tie-rod : 200 n ⋅m (20.0 kgf-m, 145.0 lb-ft) 2. Stabilizer bar 8. Stabi...

  • Page 574

    2b-2 front suspension: front wheel alignment construction s5jb0a2201002 among factors for front wheel alignment, only toe setting can be adjusted. Camber and caster are not adjustable. Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or...

  • Page 575

    Front suspension: 2b-3 adjustment 1) loosen right and left tie-rod end lock nuts (1) first. 2) rotate right and left tie-rods (2) by the same amount to align toe to specification. In this adjustment, the lengths “a” of both right and left tie-rod should be equal. Note before rotating tie-rods (2), a...

  • Page 576

    2b-4 front suspension: front strut assembly components s5jb0a2206002 7 6 5 4 14 2 1 13 3 12 (a) (a) 8 (b) 9 (c) 11 10 i5jb0a220004-01 1. Strut assembly 7. Strut support 13. Stabilizer joint 2. Coil spring 8. Strut support nut 14. Strut dust cover 3. Bump stopper 9. Strut nut : 50 n ⋅m (5.0 kgf-m, 36...

  • Page 577

    Front suspension: 2b-5 front strut assembly removal and installation s5jb0a2206003 removal note when servicing component parts of strut assembly, remove strut rod cap and then loosen strut nut a little before removing strut assembly. This will make service work easier. Note that the nut must not be ...

  • Page 578

    2b-6 front suspension: installation install strut assembly by reversing removal procedure, noting the following instructions. • insert bolts in such direction as shown in figure. • tighten all fasteners to specified torque. Tightening torque strut bracket nut (a): 135 n·m (13.5 kgf-m, 98.0 lb- ft) b...

  • Page 579

    Front suspension: 2b-7 front strut assembly disassembly and assembly s5jb0a2206004 disassembly 1) attach special tool (a) to coil spring as shown. Turn special tool bolts alternately until coil spring tension is released. Rotate the strut around its axis to confirm that the coil spring is released o...

  • Page 580

    2b-8 front suspension: 4) pull strut rod as far up as possible and use care not to allow it to retract into strut. 5) attach coil spring seat to coil spring upper seat and then install strut dust cover firmly. 6) install coil spring upper seat with strut dust cover on coil spring and then spring upp...

  • Page 581

    Front suspension: 2b-9 front wheel hub assembly and steering knuckle components s5jb0a2206006 caution ! Never disassemble front wheel hub assembly. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. Front wheel hub assembly removal and installation s...

  • Page 582

    2b-10 front suspension: 5) pull brake disc (2) off by using two 8 mm bolts. 6) remove wheel hub housing bolts (3), and then remove wheel hub assembly (1) and dust cover (2). 7) remove hub bolts (1) with copper hammer or hydraulic press. Caution ! Never remove bolt unless replacement is necessary. Be...

  • Page 583

    Front suspension: 2b-11 5) install brake disk and brake caliper. 6) tighten caliper carrier bolt to specified torque. Tightening torque caliper carrier bolt: 85 n·m (8.5 kgf-m, 61.5 lb-ft) 7) depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to specified torque. Tightening ...

  • Page 584

    2b-12 front suspension: installation for installation, reverse removal procedure, noting the following instructions. 1) connect steering knuckle to suspension arm. 2) install strut bracket bolts (2) and nuts (1). 3) tighten strut bracket nuts (1) to specified torque. Tightening torque strut bracket ...

  • Page 585

    Front suspension: 2b-13 • check wear of wheel bearing. When measuring thrust play, apply a dial gauge to wheel hub as shown in figure. Thrust play limit 0.1 mm (0.004 in.) • check wheel bearing noise and smooth wheel rotation by rotating wheel in figure. If defective, replace bearing. Suspension con...

  • Page 586

    2b-14 front suspension: installation 1) install suspension control arm bolts (1) and tighten suspension control arm nuts (2) temporarily by hand. Caution ! If reuse suspension control arm nut, apply engine oil to thread and bearing. 2) connect suspension control arm (1) to steering knuckle and then ...

  • Page 587

    Front suspension: 2b-15 suspension control arm / bushing disassembly and assembly s5jb0a2206010 disassembly 1) remove rubber stopper (1). 2) cut rubber (2) of flange of suspension control arm front bushing. 3) using grinder (3), grind off flange (4) of front bushing. Caution ! Be careful not to dama...

  • Page 588

    2b-16 front suspension: suspension control arm / steering knuckle check s5jb0a2206011 inspect for cracks, deformation or damage. If defective, replace. Suspension control arm bushing check s5jb0a2206012 inspect for damage, wear or deterioration. If defective, replace. Suspension control arm joint ch...

  • Page 589

    Front suspension: 2b-17 front suspension frame, stabilizer bar and/or bushings components s5jb0a2206014 10 7 3 2 5 1 8 8 7 (a) 4 6 (b) 9 (b) 9 11 (b) f (c) (d) 12 i5jb0a220040-02 f: forward 6. Stabilizer joint nut 12. Stabilizer mount 1. Stabilizer bar 7. Suspension control arm : 50 n ⋅m (5.0 kgf-m,...

  • Page 590

    2b-18 front suspension: front suspension frame, stabilizer bar and/or bushings removal and installation s5jb0a2206015 removal 1) hoist vehicle and remove wheels (right & left). 2) remove engine under cover. 3) remove suspension control arm referring to “suspension control arm removal and installatio...

  • Page 591

    Front suspension: 2b-19 11) remove front propeller shaft referring to “propeller shaft removal and installation: in section 3d”. 12) fix radiator (2) to body with rope (1) to avoid the radiator (2) fall off when front suspension frame lowered. 13) support engine assemble as follows. • for using engi...

  • Page 592

    2b-20 front suspension: 18) remove stabilizer bar (1) and bushing (2) from suspension frame (3). Installation 1) when installing stabilizer, loosely assemble all components while insuring that stabilizer is centered, side-to-side. 2) install stabilizer bar (1), stabilizer bushing (2) and stabilizer ...

  • Page 593

    Front suspension: 2b-21 6) tighten suspension frame mounting bolts (1) and engine front body side mounting nuts (2) to specified torque. Caution ! If reuse suspension frame mounting bolt, apply engine oil to thread, bearing and trunk surface. Tightening torque suspension frame mounting bolt (a): 135...

  • Page 594

    2b-22 front suspension: 14) connect front fender lining clip (1) (if equipped with head light auto leveling system). 15) install stabilizer joints (1), and tighten nuts to specified torque. When tightening, hold stud with hexagon wrench. Tightening torque stabilizer joint nut (a): 60 n·m (6.0 kgf-m,...

  • Page 595

    Front suspension: 2b-23 stabilizer joint 1) check for smooth rotation. 2) check damages of ball stud. 3) check damages of dust cover. Note stabilizer joint (1) cannot be disassembled. If there is any damage to either parts, stabilizer joint assembly must be replaced as a complete unit. Front suspens...

  • Page 596

    2b-24 front suspension: special tools and equipment recommended service material s5jb0a2208001 special tool s5jb0a2208002 material suzuki recommended product or specification note grease suzuki super grease a p/no.: 99000–25010 ) 09900–00411 09900–00414 hexagon bit socket hexagon bit (6 mm) ) / ) ) ...

  • Page 597: Rear Suspension

    Rear suspension: 2c-1 rear suspension general description rear suspension construction s5jb0a2301001 4 5 (b) (b) a b a 3 8 1 2 (a) (f) (e) (b) (b) (b) b 6 7 8 9 (b) (b) (b) (g) (f) (b) (d) (c) 1 2 3 i5jb0a230001-03 [a]: view a 4. Control rod 9. Lower arm : 50 n ⋅m (5.0 kgf-m, 36.5 lb-ft) [b]: view b...

  • Page 598

    2c-2 rear suspension: rear wheel alignment construction s5jb0a2301002 among factors for rear wheel alignment, only toe and camber setting can be adjusted. Caster can’t be adjusted. Therefore, should caster be out of specification due to the damage caused by hazardous road conditions or collision, wh...

  • Page 599

    Rear suspension: 2c-3 adjustment control rod adjustment 1) loosen right and left control rod mount nuts (1). 2) adjust toe and camber to satisfy the specification by turning right and left control rod inner bolts (cam bolts) (1) with the same amount. Note when bolt is turned a-direction, camber beco...

  • Page 600

    2c-4 rear suspension: reference information side slip limit when checked with side slip tester, side slip should satisfy following specification. Side slip limit in 5.5 – in 9.5 mm/m (in 0.2166 – in 0.3740 in/3.3 ft) if side slip exceeds the limit, toe or wheel alignment may not be correct. Rear sho...

  • Page 601

    Rear suspension: 2c-5 rear shock absorber removal and installation s5jb0a2306006 removal 1) hoist vehicle, allowing rear suspension to hang free. 2) remove wheel. 3) support lower arm (1) with jack (2) and remove shock absorber bolts (3). 4) compress the shock absorber enough to remove it from body....

  • Page 602

    2c-6 rear suspension: shock absorber check s5jb0a2306026 • inspect for deformation or damage. • inspect bushings for wear or damage. • inspect for evidence of oil leakage. Replace any defective part. Warning ! When handling rear shock absorber (1) in which high-pressure gas is sealed, make sure to o...

  • Page 603

    Rear suspension: 2c-7 9) remove bump stopper (1) from suspension upper arm (2) by using special tool (a). Special tool (a): 09941–66010 10) remove bump stopper upper seat bolts (4), and bump stopper upper seat (3) from body. Installation 1) install bump stopper upper seat (1) to body and tighten bol...

  • Page 604

    2c-8 rear suspension: 6) with marks (1) on lower arm washer (2) and rear suspension frame (3) marked before remove aligned to each other, tighten lower arm mount nut (4) temporarily by hand. 7) install rear shock absorber referring to “rear shock absorber removal and installation: ”. 8) connect rear...

  • Page 605

    Rear suspension: 2c-9 rod and arm components s5jb0a2306009 1 5 2 21 18 16 6 8 11 9 13 (a) 3 (a) (a) 3 12 (a) 19 (a) 17 20 (c) (b) 4 (a) 7 (a) 15 (a) 10 14 f i5jb0a230017-02 1. Upper arm 8. Lower arm inner bolt 15. Control rod mount nut f: forward 2. Upper arm bolt 9. Lower arm washer 16. Trailing ro...

  • Page 606

    2c-10 rear suspension: control rod removal and installation s5jb0a2306010 removal 1) hoist vehicle and remove rear wheels. 2) support lower arm (1) with jack (2). 3) remove parking cable hanger bolt (1). 4) put match marks (1) on control rod washer (2) and on suspension frame (3) to install the bolt...

  • Page 607

    Rear suspension: 2c-11 e) the marks (5) on control rod washer (3) and rear suspension frame marked before its removal must be aligned and, tighten bolt and nut temporarily by hand. 2) tighten parking cable hanger bolt (1) to specified torque. Tightening torque parking cable hanger bolt (a): 10 n·m (...

  • Page 608

    2c-12 rear suspension: control rod / bushing disassembly and assembly s5jb0a2306029 disassembly 1) push out control rod bushing by using hydraulic press (1) and special tool. Special tool (a): 09913–84510 assembly 1) press-fit control rod bushing (1) by using press (2) and special tool. Caution ! Be...

  • Page 609

    Rear suspension: 2c-13 trailing rod removal and installation s5jb0a2306012 removal 1) hoist vehicle and remove rear wheels. 2) support lower arm (1) with jack (2). 3) remove air suction pipe bolts (1) for 5door model only. 4) remove trailing rod front bolt (1) and trailing rod rear bolt (2) and then...

  • Page 610

    2c-14 rear suspension: 2) install trailing rod (4). A) install trailing rod and insert trailing rod front bolt (1) from the body inside. B) insert trailing rod rear bolt (2). C) tighten trailing rod rear bolt (2) and trailing rod mount nut (3) temporarily by hand. Caution ! If reuse trailing rod mou...

  • Page 611

    Rear suspension: 2c-15 assembly 1) press-fit trailing rod bushing (2) by using press (1) and special tool. Caution ! • be sure to use new bushing. • install bushing following the direction shown in figure since diameter “b” is bigger than diameter “a”. Special tool (a): 09945–56510 2) press-fit bush...

  • Page 612

    2c-16 rear suspension: installation 1) install lower arm. A) install lower arm (1) to rear suspension frame. B) insert suspension lower arm inner bolt (2) from the vehicle rearward. C) install lower arm washer (3) with its graduated part facing up. D) the marks (4) on lower arm washer (3) and rear s...

  • Page 613

    Rear suspension: 2c-17 assembly 1) press-fit suspension lateral link bushing (2) by using press (1) and special tool. Caution ! Be sure to use new bushing. Special tool (a): 09913–85210 2) press-fit bushing (1) so that dimension “a” and “b” in figure become equal. Lower arm check s5jb0a2306033 • ins...

  • Page 614

    2c-18 rear suspension: installation 1) install upper arm. A) install upper arm (2) to rear suspension frame. B) insert upper arm bolt (1) from the upper arm inside. C) tighten upper arm mount nuts (3) temporarily by hand. Caution ! If reuse upper arm mount nut, apply engine oil to thread and bearing...

  • Page 615

    Rear suspension: 2c-19 upper arm / bushing disassembly and assembly s5jb0a2306035 disassembly 1) cut rubber (1) of flange of upper arm bushing. 2) using grinder (2), grind off flange (3) of upper arm bushing. Caution ! Be careful not to damage upper arm (4) when grinding flange (3) of upper arm bush...

  • Page 616

    2c-20 rear suspension: rear suspension frame components s5jb0a2306014 f 3 2 (a) (b) (b) (b) 1 3 4 5 4 5 6 6 7 8 8 i5jb0a230046-03 f: forward 4. Rear suspension frame mount stopper 8. Stiffener 1. Rear suspension frame 5. Upper mount stopper washer : 135 n ⋅m (13.5 kgf-m, 98.0 lb-ft) 2. Rear suspensi...

  • Page 617

    Rear suspension: 2c-21 rear suspension frame removal and installation s5jb0a2306015 removal 1) hoist vehicle and remove rear wheels. 2) remove muffler and exhaust center pipe referring to “exhaust system components: in section 1k”. 3) to facilitate reinstallation, put match marks (1) on rear propell...

  • Page 618

    2c-22 rear suspension: installation 1) remounting rear differential to rear suspension fame referring to “rear differential unit components: rear in section 3b”. 2) support rear suspension frame with rear differential by using mission jack, and jack up it. Warning ! When mounting rear suspension fra...

  • Page 619

    Rear suspension: 2c-23 12) install control rod referring to “control rod removal and installation: ”“control rod removal and installation: ”. 13) install rear wheel hub assembly referring to “rear wheel hub assembly removal and installation: ”. 14) connect rear propeller shaft to differential aligni...

  • Page 620

    2c-24 rear suspension: assembly 1) press-fit rear suspension frame bushing (2) by using press (1) and special tool. Caution ! Be sure to use new bushing. Special tool (a): 09913–75510 2) install rear suspension frame stopper (3) to rear suspension frame bushing (1) and press-fit upper mount stopper ...

  • Page 621

    Rear suspension: 2c-25 rear wheel hub assembly removal and installation s5jb0a2306039 removal 1) hoist vehicle and remove rear wheels. 2) uncaulk rear axle nut (1). 3) pull up parking brake lever fully and remove rear axle nut (1). 4) remove rear break shoe referring to “rear brake shoe removal and ...

  • Page 622

    2c-26 rear suspension: 3) install rear wheel assembly and back plate to rear suspension knuckle and tighten rear wheel hub housing bolts (1) to specified torque. Tightening torque rear wheel hub housing bolt (a): 50 n·m (5.0 kgf-m, 36.5 lb-ft) 4) tighten parking cable cap nut (1) to specified torque...

  • Page 623

    Rear suspension: 2c-27 rear wheel hub assembly, wheel bearing and wheel stud inspection s5jb0a2306020 • wheel bearing and wheel hub form a solid unit. • when wheel bearing is found defective and its replacement is necessary, replace hub assembly. Rear wheel disc, nut and bearing check s5jb0a2306021 ...

  • Page 624

    2c-28 rear suspension: rear suspension knuckle removal and installation s5jb0a2306040 removal 1) hoist vehicle and remove rear wheels. 2) remove rear wheel hub assembly referring to “rear wheel hub assembly removal and installation: ”. 3) remove abs wheel sensor (1) (if equipped). 4) loosen rear bra...

  • Page 625

    Rear suspension: 2c-29 8) loosen lower arm outer bolt (1). 9) disconnect upper arm joint from rear suspension knuckle (1) with puller (2) and remove rear suspension knuckle. Note do not remove upper arm joint nut (3) to avoid the rear suspension knuckle fall off. Installation 1) connect upper arm jo...

  • Page 626

    2c-30 rear suspension: 4) install trailing rod to rear suspension knuckle and then tighten trailing rod rear bolt (1) temporarily by hand. Caution ! If reuse trailing rod rear bolt, apply engine oil to thread, bearing and trunk surface. 5) install control rod to rear suspension knuckle tighten contr...

  • Page 627

    Rear suspension: 2c-31 11) upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable. Refer to “parking brake check and adjustment: in section 4d”. 12) install rear wheels. 13) check t...

  • Page 628

    2c-32 rear suspension: specifications tightening torque specifications s5jb0a2307001 note the specified tightening torque is also described in the following. “rear suspension construction: ” “rear shock absorber and rear coil spring components: ” “rod and arm components: ” “rear suspension frame com...

  • Page 629

    Rear suspension: 2c-33 special tools and equipment recommended service material s5jb0a2308001 note required service material is also described in the following. “rear shock absorber and rear coil spring components: ” special tool s5jb0a2308002 material suzuki recommended product or specification not...

  • Page 630: Wheels and Tires

    2d-1 wheels and tires: wheels and tires general description tires description s5jb0a2401001 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. Correct tire pressures and driv...

  • Page 631

    Wheels and tires: 2d-2 warning ! Do not mix different types of tires on the same vehicle such as radial, bias and bias- belted tires except in emergencies, because handling may be seriously affected and may result in loss of control. The metric term for tire inflation pressure is the kilo pascal (kp...

  • Page 632

    2d-3 wheels and tires: • wear is uneven across the tread of any front tire. • front tire treads have scuffed appearance with “feather” edges on one side of tread ribs or blocks. Wear indicators description s5jb0a2401004 original equipment tires have built-in tread wear indicators (1) to show when th...

  • Page 633

    Wheels and tires: 2d-4 equipment manufacture’s recommendations radial tire lead / pull description s5jb0a2401006 “lead / pull” is the deviation of the vehicle from a straight path on a level road even with no pressure on the steering wheel. Lead is usually caused by the following conditions. • impro...

  • Page 634

    2d-5 wheels and tires: repair instructions general balance procedures s5jb0a2406001 deposits of mud, etc. Must be cleaned from inside of rim. Warning ! Stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain good balance. Each tire should be insp...

  • Page 635

    Wheels and tires: 2d-6 wheel removal and installation s5jb0a2406003 removal 1) loosen wheel nuts by approximately 180 ° (half a rotation). 2) hoist vehicle. 3) remove wheel. Caution ! Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel...

  • Page 636

    2d-7 wheels and tires: specifications wheels and tires specifications s5jb0a2407001 tire size (standard) 225/70r16 102s or 225/65r17 101s wheel size (standard) 16 x 6 1/2 j (for 225/70r16) or 17 x 6 1/2 j (for 225/65r17) tightening torque wheel nut: 100 n·m (10.0 kgf-m, 72.5 lb-ft) note • tire infla...

  • Page 637: Section 3

    Table of contents 3- i 3 section 3 contents driveline / axle precautions .................................................3-1 precautions............................................................. 3-1 precautions for driveline / axle ............................. 3-1 drive shaft / axle ..............

  • Page 638

    3-ii table of contents input / output signal table of 4wd control module ............................................................3c-12 on-board diagnostic system description.........3c-12 can communication system description.........3c-13 diagnostic information and procedures..........3c-14 4wd ...

  • Page 639

    Table of contents 3-iii repair instructions ..............................................3d-2 propeller shaft joint check ................................3d-2 propeller shaft removal and installation............3d-2 propeller shaft disassembly and assembly .......3d-3 propeller shaft inspection.......

  • Page 640: Precautions

    3-1 precautions: precautions precautions precautions for driveline / axle s5jb0a3000001 differential gear oil note refer to “differential gear oil note: in section 00”. Fastener caution refer to “fastener caution: in section 00”. Precautions for transfer refer to “precautions in diagnosing trouble: ...

  • Page 641: Drive Shaft / Axle

    Drive shaft / axle: front 3a-1 drive shaft / axle front general description front drive shaft construction s5jb0a3111001 a constant velocity tripod joint is used on the differential side of both the right and left drive shaft assemblies. And, a constant velocity ball joint is used on the wheel side ...

  • Page 642

    3a-2 drive shaft / axle: front repair instructions front drive shaft boot and joint check s5jb0a3116001 • check boot for tear. If even a small tear is found, replace with new one. • check drive shaft joint for wear, breakage, and any other damage. Replace if any abnormality is found. Front drive sha...

  • Page 643

    Drive shaft / axle: front 3a-3 front drive shaft assembly removal and installation s5jb0a3116003 removal 1) undo caulking (1) and remove drive shaft nut (2). 2) hoist vehicle and remove wheel. 3) drain front differential oil. 4) disconnect tie-rod end from steering knuckle referring to “steering knu...

  • Page 644

    3a-4 drive shaft / axle: front 2) wipe off grease from shaft and take off snap ring (1) using snap ring plier (2). 3) remove tripod joint spider (1) using 3 arms puller (2). Caution ! To prevent any problem caused by washing solution, do not wash tripod joint except its housing. Degreasing of tripod...

  • Page 645

    Drive shaft / axle: front 3a-5 5) apply grease (including in spare parts) to inside of tripod joint housing (1), joint it with tripod joint. Grease color “a”: yellow amount “a”: 127 – 137 g (4.5 – 4.8 oz) (right side) “a”: 170 – 180 g (6.0 – 6.3 oz) (left side) 6) fit boot to grooves of shaft and ho...

  • Page 646

    3a-6 drive shaft / axle: front specifications tightening torque specifications s5jb0a3117001 note the specified tightening torque is also described in the following. “front drive shaft components: front” reference: for the tightening torque of fastener not specified in this section, refer to “fasten...

  • Page 647: Rear

    Drive shaft / axle: rear 3a-7 rear general description rear drive shaft construction s5jb0a3121002 refer to “front drive shaft construction: front”. Repair instructions rear drive shaft components s5jb0a3126007 i5jb0a312001-02 1. Differential side joint (constant velocity tripod joint) : apply yello...

  • Page 648

    3a-8 drive shaft / axle: rear rear drive shaft assembly removal and installation s5jb0a3126008 removal 1) undo caulking (1) of drive shaft nut (2) and then remove drive shaft nut. 2) hoist vehicle and remove wheel. 3) give match mark rear drive shaft flange (3) and rear drive shaft (4) as shown in f...

  • Page 649

    Drive shaft / axle: rear 3a-9 specifications tightening torque specifications s5jb0a3127001 note the specified tightening torque is also described in the following. “rear drive shaft components: rear” reference: for the tightening torque of fastener not specified in this section, refer to “fastener ...

  • Page 650: Differential

    3b-1 differential: front differential front general description front differential construction s5jb0a3211001 the differential assembly 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 specif...

  • Page 651

    Differential: front 3b-2 repair instructions front differential oil change s5jb0a3216012 1) before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) with vehicle lifted up, check leakage. If leakage exists, correct it. Note whenever vehicle is hoisted for any other...

  • Page 652

    3b-3 differential: front front differential unit components s5jb0a3216007 front differential dismounting and remounting s5jb0a3216008 dismounting 1) lift up vehicle and drain front differential oil. 2) remove front drive shafts referring to “front drive shaft assembly removal and installation: front...

  • Page 653

    Differential: front 3b-4 remounting reverse dismounting procedure for remounting noting the following. • tighten each bolts and nuts referring to “front differential unit components: front”, “front drive shaft components: front in section 3a” and “front suspension frame, stabilizer bar and/or bushin...

  • Page 654

    3b-5 differential: front front differential assembly disassembly and reassembly s5jb0a3216010 disassembly 1) remove front differential right mounting (1) and rear mounting (2). 2) drive out front drive shaft (1) from front shaft retainer (2) using plastic hammer (3). 3) remove differential side righ...

  • Page 655

    Differential: front 3b-6 5) support differential side right retainer (1) with soft jawed vise and remove oil seal (2) from differential side right retainer using special tool, if necessary. Special tool (a): 09913–50121 6) take out differential assembly (1), outer race and shim all at once. 7) pull ...

  • Page 656

    3b-7 differential: front b) make mating marks (1) on drive bevel pinion and companion flange. Caution ! Do not make mating mark on the coupling surface of the flange. C) remove flange (2) from drive bevel pinion. Use special tool if it is hard to remove. Special tool (a): 09913–65135 (b): 09925–8821...

  • Page 657

    Differential: front 3b-8 12) drive out rear bearing outer race (1) in the same manner as step 11). Reassembly judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. After disassembly, prepare replacing parts and proceed to reasse...

  • Page 658

    3b-9 differential: front 5) install special tool to differential case assembly (2) and check that preload is within specification. If preload exceeds specified value, check if foreign matter is caught or gear is damaged. Special tool (b): 09928–06510 side gear preload max. 2.5 n ⋅m (0.25 kgf-m, 1.8 ...

  • Page 659

    Differential: front 3b-10 8) to engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mo...

  • Page 660

    3b-11 differential: front 9) install special tools with bearings (3) and flange (2) to differential carrier (1). Note this installation requires no spacer or oil seal. Special tool (e): 09951–46010 (f): 09926–78311–002 10) tighten flange nut (1) so that specified bearing preload is obtained. Note • ...

  • Page 661

    Differential: front 3b-12 special tool (a): 09900–20607 (b): 09926–78311 (d): 09951–16070 (f): 09926–78311–002 : 09922–76520 13) obtain adjusting shim thickness by the following equation. “1 mm (0.039 in.)” is “a” + “b” (mounting dummy size) – “d” (drive bevel pinion mounting distance) 14) select ad...

  • Page 662

    3b-13 differential: front 17) while tightening flange nut gradually with special tool and power wrench (4 – 10 magnification) (1), set preload of pinion to specification. Note • before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand. • on measuring ...

  • Page 663

    Differential: front 3b-14 19) to measure bevel gear backlash, set dial gauge (1) at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear. Special tool (a): 09900–20607 (b): 09900–20701 note • be sure to apply measuring tip of dial gauge at right angles ...

  • Page 664

    3b-15 differential: front 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 (2) height adjusting shim and position pinion closer to gear center. • adjust drive bevel gear backlash to spe...

  • Page 665

    Differential: front 3b-16 23) upon completion of gear tooth contact check in step 22), caulk flange nut (2) with caulking tool (1) and hammer. 24) install rear cover (1) to differential carrier (2). Tightening torque rear cover bolt no.1 (a): 50 n·m (5.0 kgf-m, 36.5 lb-ft) rear cover bolt no.2 (b): ...

  • Page 666

    3b-17 differential: front 27) clean mating surface of right retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate right retainer with carrier and rear cover, and then tighten bolts ...

  • Page 667

    Differential: front 3b-18 specifications tightening torque specifications s5jb0a3217001 note the specified tightening torque is also described in the following. “front differential unit components: front” “front differential components: front” reference: for the tightening torque of fastener not spe...

  • Page 668

    3b-19 differential: front 09913–75510 09913–75520 bearing installer bearing installer ) ) / ) 09913–75821 09913–85210 bearing installer attachment bearing installer ) / ) ) 09922–66021 09922–75222 flange holder differential gear preload adjuster ) / ) ) / ) / ) 09922–76520 09924–74510 bevel pinion g...

  • Page 669

    Differential: front 3b-20 09928–06510 09930–30104 differential torque checking tool sliding shaft ) ) 09940–53111 09941–64511 differential side bearing installer bearing and oil seal remover (30 mm min.) ) ) 09951–16070 09951–16090 shim adjuster attachment oil seal installer ) / ) ) 09951–18210 0995...

  • Page 670: Rear

    3b-21 differential: rear rear general description rear differential construction s5jb0a3221001 refer to “front differential construction: front”. Diagnostic information and procedures rear differential symptom diagnosis s5jb0a3224001 refer to “front differential symptom diagnosis: front”. Repair ins...

  • Page 671

    Differential: rear 3b-22 rear differential dismounting and remounting s5jb0a3226012 dismounting 1) lift up vehicle and drain oil from rear differential. 2) remove rear propeller shaft referring to “propeller shaft removal and installation: in section 3d”. 3) remove exhaust center pipe referring to “...

  • Page 672

    3b-23 differential: rear remounting reverse dismounting procedure for remounting noting the following. • tighten rear differential mounting front and rear bolts to specified torque. Tightening torque rear differential front mounting bolt: 120 n·m ( 12.0 kgf-m, 87.0 lb-ft) rear differential rear moun...

  • Page 673

    Differential: rear 3b-24 rear differential assembly disassembly and reassembly s5jb0a3226013 disassembly 1) drive out rear drive right and left shaft using special tools. Special tool (a): 09942–15511 (b): 09943–17912 2) remove rear drive right and left retainers. 3) tapping rear cover flanges with ...

  • Page 674

    3b-25 differential: rear 5) disassembly rear drive left retainer in the same manner at step 4), if necessary. 6) take out differential assembly (1), outer race and shim all at once. 7) pull out differential side bearing (1) using special tools. Special tool (a): 09913–65135 (b): 09925–86010 8) remov...

  • Page 675

    Differential: rear 3b-26 d) remove drive bevel pinion (1) with rear bearing, shim and spacer from carrier. If it is hard to remove, screw an used nut (2) into drive bevel pinion and hammer (3) on that nut with a plastic hammer but never directly on drive bevel pinion. E) remove drive bevel pinion re...

  • Page 676

    3b-27 differential: rear reassembly judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. After disassembly, prepare replacing parts and proceed to reassembly according to procedures as described. Caution ! • drive bevel gear an...

  • Page 677

    Differential: rear 3b-28 5) install special tool to differential case assembly (2) and check differential gear for preload. If preload exceeds specified value, check if foreign matter is caught or gear is damaged. Special tool (b): 09928–06510 differential gear preload max. 2.5 n ⋅m (0.25 kgf-m, 1.8...

  • Page 678

    3b-29 differential: rear 8) to engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mou...

  • Page 679

    Differential: rear 3b-30 9) install special tools with bearings (3) and flange (2) to differential carrier (1). Note this installation requires no spacer or oil seal. Special tool (e): 09951–46010 (f): 09926–78311–002 10) tighten flange nut (1) so that specified bearing preload is obtained. Note • b...

  • Page 680

    3b-31 differential: rear special tool (a): 09900–20607 (b): 09926–78311 (d): 09951–16070 (f): 09926–78311–002 : 09922–76520 13) obtain adjusting shim thickness by the following equation. “1 mm (0.039 in.)” is “a” + “b” (mounting dummy size) – “d” (drive bevel pinion mounting distance) 14) select adj...

  • Page 681

    Differential: rear 3b-32 17) while tightening flange nut gradually with special tool and power wrench (4 – 10 magnification) (1), set preload of pinion to specification. Note • before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand. • on measuring p...

  • Page 682

    3b-33 differential: rear 19) to measure bevel gear backlash, set dial gauge (1) at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear. Special tool (a): 09900–20607 (b): 09900–20701 note • be sure to apply measuring tip of dial gauge at right angles t...

  • Page 683

    Differential: rear 3b-34 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 (2) height adjusting shim and position pinion closer to gear center. • adjust drive bevel gear backlash to spec...

  • Page 684

    3b-35 differential: rear 23) upon completion of gear tooth contact check in step 22), caulk flange nut (2) with caulking tool (1) and hammer. 24) install rear cover (1) to differential carrier (2). Tightening torque rear cover bolt no.1 (a): 50 n·m (5.0 kgf-m, 36.5 lb-ft) rear cover bolt no.2 (b): 8...

  • Page 685

    Differential: rear 3b-36 26) assembly rear drive left retainer in the same manner at step 25) in this assembly procedure. 27) clean mating surface of right retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (...

  • Page 686

    3b-37 differential: rear special tools and equipment recommended service material s5jb0a3228001 note required service material is also described in the following. “rear differential components: rear” special tool s5jb0a3228002 material suzuki recommended product or specification note grease suzuki s...

  • Page 687

    Differential: rear 3b-38 09924–84510–004 09924–84510–005 bearing installer attachment bearing installer attachment (d) ) / ) ) 09925–14520 09925–86010 bearing and oil seal installer (80 x 50 mm) bearing puller attachment ) ) 09925–88210 09926–78311–002 bearing puller attachment pinion mounting dummy...

  • Page 688

    3b-39 differential: rear 09951–18210 09951–46010 oil seal remover & installer no. 2 drive shaft oil seal installer ) ) / ).

  • Page 689: Transfer

    Transfer: motor-shift type (transfer with shift actuator) 3c-1 transfer motor-shift type (transfer with shift actuator) precautions transfer warning s5jb0a3310002 warning ! This transfer has a center differential. When testing with 2-wheel chassis dynamometer or speedometer tester (which tester roll...

  • Page 690

    3c-2 transfer: motor-shift type (transfer with shift actuator) the transfer has such a selective mechanism as to enable the shift actuator to make selection of high speed (direct connection with transmission output: main shaft), low speed (speed reduction by input gear, counter gear and low gear) or...

  • Page 691

    Transfer: motor-shift type (transfer with shift actuator) 3c-3 4wd control system description s5jb0a3311002 transfer shift control the 4wd control module controls the transfer shift actuator based on the signal from the transfer switch so that the transfer is shifted to the selected position (4h, 4h...

  • Page 692

    3c-4 transfer: motor-shift type (transfer with shift actuator) operation condition indicator buzzer differential lock indicator off — • ignition switch is off. • transfer is at 4h/n position. On — • within 2 seconds after ignition switch is turn on (checking indicator operation). • transfer is at 4h...

  • Page 693

    Transfer: motor-shift type (transfer with shift actuator) 3c-5 function of 4wd control system component s5jb0a3311003 4wd control system operation s5jb0a3311005 instead of the transfer shift lever assembly, the transfer position (4h, 4h-lock, n and 4l-lock) is shifted automatically by operating the ...

  • Page 694

    3c-6 transfer: motor-shift type (transfer with shift actuator) 4h-lock (4wd high center differential lock) position when 4h-lock position is selected from 4h position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “a”. The ...

  • Page 695

    Transfer: motor-shift type (transfer with shift actuator) 3c-7 the driving force from the transmission is transmitted from the transfer input gear to the rear output shaft, as in the case of 4h position. Also, as the front drive shaft and front drive sprocket bush are engaged via differential lock c...

  • Page 696

    3c-8 transfer: motor-shift type (transfer with shift actuator) n (neutral) position when n position is selected from 4h position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “a”. The shift cam shifts the high / low shift ...

  • Page 697

    Transfer: motor-shift type (transfer with shift actuator) 3c-9 4l-lock (4wd low center differential lock) position when 4l-lock position is selected from 4h-lock position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “a”. ...

  • Page 698

    3c-10 transfer: motor-shift type (transfer with shift actuator) a b c [a] [b] 1 2 5 4 4 3 5 9 8 6 7 11 10 12 13 17 15 18 16 14 19 i5jb0a332006-02 [a]: transfer position indicator 6. High / low shift fork 13. Rear output shaft [b]: transfer switch 7. Differential lock shift fork 14. Center lsd case 1...

  • Page 699

    Transfer: motor-shift type (transfer with shift actuator) 3c-11 4wd control system wiring circuit diagram s5jb0a3311006 5v 5v ig 5v 12v e91-2 5v 12v 12v +bb yel red/blk blu m e91-3 e91-25 e91-26 red e91-24 blk/yel e91-7 blk/orn e91-21 ppl/wht e91-22 e91-23 red wht e91-18 e91-19 e91-20 e91-13 e91-14 ...

  • Page 700

    3c-12 transfer: motor-shift type (transfer with shift actuator) terminal arrangement of 4wd control module s5jb0a3311007 input / output signal table of 4wd control module s5jb0a3311008 4wd control module outputs the following signals to actuators, indicators, warning buzzer, according to the transfe...

  • Page 701

    Transfer: motor-shift type (transfer with shift actuator) 3c-13 • dtc can be checked by either one of the following ways. – dtc can be checked by using suzuki scan tool (4) connected to dlc (5). – if equipped with diagnosis connector, dtc can be displayed on digital display odometer by shorting diag...

  • Page 702

    3c-14 transfer: motor-shift type (transfer with shift actuator) 4wd control module reception data diagnostic information and procedures 4wd control system check s5jb0a3314001 refer to the following items for the details of each step. Ecm tcm data receive engine speed vehicle speed brake pedal switch...

  • Page 703

    Transfer: motor-shift type (transfer with shift actuator) 3c-15 detail of 4wd control system check step 1: customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in t...

  • Page 704

    3c-16 transfer: motor-shift type (transfer with shift actuator) customer questionnaire (example) note the form is a standard sample. It should be modified according to conditions characteristic of each market. Step 2. Dtc / freeze frame data check, record and clearance first, referring to “dtc check...

  • Page 705

    Transfer: motor-shift type (transfer with shift actuator) 3c-17 step 5. Trouble symptom confirmation check trouble symptoms based on information obtained in “step 1: customer complaint analysis: motor-shift type (transfer with shift actuator)” and “step 2. Dtc / freeze frame data check, record and c...

  • Page 706

    3c-18 transfer: motor-shift type (transfer with shift actuator) e) check that 4l indicator blink, and then differential lock indicator and 4l indicator comes on steady. 3) inspect shift operation from 4l-lock to 4h-lock as follows. A) stop vehicle completely with engine running. B) position front wh...

  • Page 707

    Transfer: motor-shift type (transfer with shift actuator) 3c-19 dtc check s5jb0a3314006 using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel. Special tool (a): suzuki scan tool 3) turn ig...

  • Page 708

    3c-20 transfer: motor-shift type (transfer with shift actuator) dtc clearance s5jb0a3314007 using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel. Special tool (a): suzuki scan tool 3) tur...

  • Page 709

    Transfer: motor-shift type (transfer with shift actuator) 3c-21 note “o” in transfer position indicator column of the above table means indicator lights up when dtc is detected. Fail-safe table s5jb0a3314010 this function is provided by the safe mechanism that assures safe drive ability even when th...

  • Page 710

    3c-22 transfer: motor-shift type (transfer with shift actuator) scan tool data s5jb0a3314009 scan tool data definitions s5jb0a3314011 vehicle speed (km/h, mph): this parameter indicates vehicle speed calculated by 4wd control module. Engine speed (rpm): this parameter indicates engine revolution cal...

  • Page 711

    Transfer: motor-shift type (transfer with shift actuator) 3c-23 mode switch 2 (transfer switch) (on / off): on: transfer switch to other than 4l-lock position. Off: transfer switch to 4l-lock position. Mode switch 3 (transfer switch) (on / off): on: transfer switch to 4h-lock or 4l-lock position. Of...

  • Page 712

    3c-24 transfer: motor-shift type (transfer with shift actuator) transfer position indicator does not come on at ignition switch on but engine stops s5jb0a3314039 wiring diagram gear slipping out of mesh worn control cover shift shaft check control cover shift shaft referring to “transfer assembly in...

  • Page 713

    Transfer: motor-shift type (transfer with shift actuator) 3c-25 circuit description transfer position indicator operates according to the signal from 4wd control module. If the transfer control system is in good condition, transfer position indicator light up for 2 seconds when ignition switch is tu...

  • Page 714

    3c-26 transfer: motor-shift type (transfer with shift actuator) transfer position indicator remains on steady at ignition switch on s5jb0a3314040 wiring diagram circuit description transfer position indicator operates according to the signal from 4wd control module. If the transfer control system is...

  • Page 715

    Transfer: motor-shift type (transfer with shift actuator) 3c-27 dtc c1213: transfer switch circuit open s5jb0a3314041 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) select transfer switch to “4h” position and keep its position for ...

  • Page 716

    3c-28 transfer: motor-shift type (transfer with shift actuator) dtc c1214: transfer switch circuit short s5jb0a3314042 wiring diagram dtc detecting condition and trouble area 3 transfer switch check 1) check transfer switch referring to “transfer switch inspection: motor-shift type (transfer with sh...

  • Page 717

    Transfer: motor-shift type (transfer with shift actuator) 3c-29 dtc confirmation procedure 1) clear dtc using scan tool. 2) select transfer switch to “4h” position and keep its position for 10 seconds. Similarly select transfer switch to “4h- lock”, “n” and “4l-lock” position. 3) check dtc. Troubles...

  • Page 718

    3c-30 transfer: motor-shift type (transfer with shift actuator) dtc c1223 / c1235: transfer shift actuator motor position switch 1 circuit open / transfer shift actuator motor position switch 2 circuit open s5jb0a3314043 wiring diagram dtc detecting condition and trouble area dtc confirmation proced...

  • Page 719

    Transfer: motor-shift type (transfer with shift actuator) 3c-31 troubleshooting step action yes no 1 was “4wd control system check” performed? Go to step 2. Go to “4wd control system check: motor- shift type (transfer with shift actuator)”. 2 transfer shift actuator motor position switch circuit che...

  • Page 720

    3c-32 transfer: motor-shift type (transfer with shift actuator) dtc c1224 / c1236: transfer shift actuator motor position switch 1 circuit short / transfer shift actuator motor position switch 2 circuit short s5jb0a3314044 wiring diagram dtc detecting condition and trouble area dtc confirmation proc...

  • Page 721

    Transfer: motor-shift type (transfer with shift actuator) 3c-33 troubleshooting step action yes no 1 was “4wd control system check” performed? Go to step 2. Go to “4wd control system check: motor- shift type (transfer with shift actuator)”. 2 transfer shift actuator motor position switch circuit che...

  • Page 722

    3c-34 transfer: motor-shift type (transfer with shift actuator) dtc c1227: 4l/n switch circuit open s5jb0a3314045 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) select transfer switch to “4l-lock” position and keep its position for...

  • Page 723

    Transfer: motor-shift type (transfer with shift actuator) 3c-35 dtc c1228: 4l/n switch circuit short s5jb0a3314046 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) select transfer switch to “4l-lock” position and keep its position fo...

  • Page 724

    3c-36 transfer: motor-shift type (transfer with shift actuator) troubleshooting step action yes no 1 was “4wd control system check” performed? Go to step 2. Go to “4wd control system check: motor- shift type (transfer with shift actuator)”. 2 4l/n switch circuit check 1) disconnect 4l/n switch conne...

  • Page 725

    Transfer: motor-shift type (transfer with shift actuator) 3c-37 dtc c1230: transfer actuator circuit malfunction s5jb0a3314047 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) select transfer switch to “4h” position and keep its posi...

  • Page 726

    3c-38 transfer: motor-shift type (transfer with shift actuator) dtc c1237: center differential lock switch circuit open s5jb0a3314048 wiring diagram 2 transfer shift actuator circuit check 1) disconnect transfer shift actuator connector “c54” with ignition switch off. 2) check for proper connection ...

  • Page 727

    Transfer: motor-shift type (transfer with shift actuator) 3c-39 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) select transfer switch to “4h” position and keep its position for 1 min. 3) check dtc. Troubleshooting dtc detecting condition trouble ...

  • Page 728

    3c-40 transfer: motor-shift type (transfer with shift actuator) dtc c1238: center differential lock switch circuit short s5jb0a3314049 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) select transfer switch to “4l-lock” position and ...

  • Page 729

    Transfer: motor-shift type (transfer with shift actuator) 3c-41 dtc c1240: 4wd control module power supply circuit malfunction s5jb0a3314050 wiring diagram 3 center differential lock switch check 1) check center differential lock switch referring to “transfer assembly inspection: motor-shift type (t...

  • Page 730

    3c-42 transfer: motor-shift type (transfer with shift actuator) dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and drive vehicle at 30 km/h (19 mph) or more vehicle speed at least for 1 min. 3) stop vehicle and check dtc. Troubleshoo...

  • Page 731

    Transfer: motor-shift type (transfer with shift actuator) 3c-43 dtc c1246: clutch pedal position (cpp) switch circuit short s5jb0a3314051 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and drive vehicle at 50 km/h (31 ...

  • Page 732

    3c-44 transfer: motor-shift type (transfer with shift actuator) dtc u1073: control module communication buss off s5jb0a3314052 wiring diagram 4 wire harness check 1) disconnect connector from 4wd control module connector “e91” with ignition switch off. 2) check for proper connection to “e91-7” termi...

  • Page 733

    Transfer: motor-shift type (transfer with shift actuator) 3c-45 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and run it for 1 min. Or more. 3) stop vehicle and check dtc. Troubleshooting [a]: keyless start control module connector ...

  • Page 734

    3c-46 transfer: motor-shift type (transfer with shift actuator) dtc u1100: lost communication with ecm s5jb0a3314053 wiring diagram 4 check dtc 1) turn ignition switch to off position. 2) disconnect each connector. • ecm • abs hydraulic unit / control module • bcm • tcm (if equipped) • keyless start...

  • Page 735

    Transfer: motor-shift type (transfer with shift actuator) 3c-47 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and run it for 1 min. Or more. 3) stop vehicle and check dtc. Troubleshooting [a]: keyless start control module connector ...

  • Page 736

    3c-48 transfer: motor-shift type (transfer with shift actuator) dtc u1101: lost communication with tcm s5jb0a3314054 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 31 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/red wht/red e...

  • Page 737

    Transfer: motor-shift type (transfer with shift actuator) 3c-49 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and run it for 1 min. Or more. 3) stop vehicle and check dtc. Troubleshooting dtc detecting condition trouble area recepti...

  • Page 738

    3c-50 transfer: motor-shift type (transfer with shift actuator) dtc u1121: lost communication with abs hydraulic unit / control module s5jb0a3314055 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 31 30 29 24 23 37 18 19 20 g28-8 g28-10 w...

  • Page 739

    Transfer: motor-shift type (transfer with shift actuator) 3c-51 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and run it for 1 min. Or more. 3) stop vehicle and check dtc. Troubleshooting inspection of 4wd control module and its cir...

  • Page 740

    3c-52 transfer: motor-shift type (transfer with shift actuator) voltage and signal check 1) check voltage using voltmeter (1) connected to each terminal of couplers. 2) check signal using oscilloscope (2) connected to each terminal of couplers. Note • as each terminal voltage is affected by the batt...

  • Page 741

    Transfer: motor-shift type (transfer with shift actuator) 3c-53 e91-9 — — — — e91-10 blk ground 0 – 1 v — e91-11 wht power source for internal memory 10 – 14 v — e91-12 blk/wht ignition switch 10 – 14 v ignition switch turned to on position e91-13 blk/wht 4l/n switch 10 – 14 v ignition switch turned...

  • Page 742

    3c-54 transfer: motor-shift type (transfer with shift actuator) repair instructions transfer oil level check s5jb0a3316033 1) lift up vehicle and check oil leakage. 2) remove oil level/filler plug (1) and check oil level is between 0 and 10 mm (0 and 0.394 in.) from the lower end of oil level / fill...

  • Page 743

    Transfer: motor-shift type (transfer with shift actuator) 3c-55 transfer oil seal removal and installation s5jb0a3316035 removal 1) lift up vehicle and drain transfer oil. 2) remove front propeller shaft and/or rear propeller shaft referring to “propeller shaft removal and installation: in section 3...

  • Page 744

    3c-56 transfer: motor-shift type (transfer with shift actuator) transfer switch inspection s5jb0a3316039 check continuity between following terminals when transfer switch (1) operated at each position. 4wd control module removal and installation s5jb0a3316038 removal 1) disconnect negative (–) cable...

  • Page 745

    Transfer: motor-shift type (transfer with shift actuator) 3c-57 transfer assembly dismounting and remounting s5jb0a3316040 dismounting 1) shift transfer to 4h position operating transfer switch. 2) disconnect negative (–) cable from battery. 3) remove gear shift control lever (for m/t model) referri...

  • Page 746

    3c-58 transfer: motor-shift type (transfer with shift actuator) transfer assembly components s5jb0a3316041 11 16 44 45 42 43 41 40 9 (c) (a) 39 38 (b) 37 (a) 37 35 (a) (a) 1217g 10 1217g 33 32 30 31 1217g 34 1217g 48 a oil 9 28 27 oil 9 oil oil 9 oil 9 oil 19 29 19 47 a 26 25 24 23 22 4 5 7 6 21 20 ...

  • Page 747

    Transfer: motor-shift type (transfer with shift actuator) 3c-59 transfer assembly disassembly and reassembly s5jb0a3316042 disassembly 1) remove harness bracket (1). 2) remove center differential lock switch (1) and 4l/n switch (2). 3) remove transfer actuator assembly (3) and breather pipe (4). 4) ...

  • Page 748

    3c-60 transfer: motor-shift type (transfer with shift actuator) 6) remove front case (1) using plastic hammer. 7) remove rear case bolts (1) and clamp (2) and then separate center case (3) using special tool. Special tool (a): 09912–34510 8) remove knock pin (1) and oil pipe (2) from center case (4)...

  • Page 749

    Transfer: motor-shift type (transfer with shift actuator) 3c-61 12) remove needle bearings (1), front drive shaft (2) and thrust needle bearing (4) from rear output shaft (3). 13) remove differential lock clutch sleeve (1) from rear output shaft (2). 14) remove front drive sprocket bush (1) from rea...

  • Page 750

    3c-62 transfer: motor-shift type (transfer with shift actuator) 20) remove input gear assembly (1) and counter gear assembly (2) from front case (3) using plastic hammer. 21) remove front oil seal no.2 (1) from front case (2) using flat end rod or the like, if necessary. Reassembly 1) install new fr...

  • Page 751

    Transfer: motor-shift type (transfer with shift actuator) 3c-63 4) install needle bearing (1) to rear case (2) using special tool as shown in figure. Distance between case and needle bearing “a” : 0 – 0.5 mm (0 – 0.008 in.) special tool (a): 09913–76010 5) install new rear oil seal (1) to rear case ...

  • Page 752

    3c-64 transfer: motor-shift type (transfer with shift actuator) 11) install low gear (3), center differential (4) and reduction shift sleeve (1) to rear output shaft (2). 12) select shim (1) as follows. A) install shim, washer (2) and used snap ring (3) into rear output shaft (4). B) check clearance...

  • Page 753

    Transfer: motor-shift type (transfer with shift actuator) 3c-65 15) install oil pipe (1) and knock pin (2) into center case (3). 16) install new front oil seal no.1 (4) into center case using special tool as shown in figure, and then apply grease to oil seal lip. Distance between case and oil seal “...

  • Page 754

    3c-66 transfer: motor-shift type (transfer with shift actuator) 21) clean mating surface of oil pump cover (1) and rear case (2), apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolts...

  • Page 755

    Transfer: motor-shift type (transfer with shift actuator) 3c-67 transfer assembly inspection s5jb0a3316043 • check needle bearing and bearing contacting surface for damage. Replace as required. • check gear tooth surface and shift mechanism in the same manner as with transmission. Correct or replace...

  • Page 756

    3c-68 transfer: motor-shift type (transfer with shift actuator) • check 4l/n switch and center differential lock switch for continuity between “a” and “b” terminals of switch. If check result is not as specified below, replace switch. 4l/n switch and center differential lock switch specification swi...

  • Page 757

    Transfer: motor-shift type (transfer with shift actuator) 3c-69 input gear assembly, counter gear assembly, front output shaft assembly and rear output shaft assembly components s5jb0a3316044 4 3 2 5 6 7 oil 2 oil 2 oil 2 oil 2 oil 1 1 1 1 2 oil i5jb0a331061-02 1. Snap ring 6. Counter gear 2. Bearin...

  • Page 758

    3c-70 transfer: motor-shift type (transfer with shift actuator) input gear assembly disassembly and reassembly s5jb0a3316045 disassembly 1) remove snap ring (1) from input gear, and then remove bearing (2). 2) remove snap rings (1). 3) remove bearing (1) from input gear (2) using bearing puller (3) ...

  • Page 759

    Transfer: motor-shift type (transfer with shift actuator) 3c-71 counter gear assembly disassembly and reassembly s5jb0a3316046 disassembly 1) remove snap ring (1) from counter gear (2). 2) remove bearing (1) from counter gear (2) using special tool, bearing puller (3) and press (4). Special tool (a)...

  • Page 760

    3c-72 transfer: motor-shift type (transfer with shift actuator) reassembly 1) clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary. 2) press-fit bearing (1) to front output shaft using special tool and press. Special tool (a): 09913–84510 3) press-...

  • Page 761

    Transfer: motor-shift type (transfer with shift actuator) 3c-73 3) press-fit bearing (1) to rear output shaft using special tools and press. Special tool (a): 09913–85210 (b): 09940–54910 4) install snap ring (1) to rear output shaft (2). Specifications tightening torque specifications s5jb0a3317001...

  • Page 762

    3c-74 transfer: motor-shift type (transfer with shift actuator) note required service material is also described in the following. “transfer assembly components: motor-shift type (transfer with shift actuator)” “input gear assembly, counter gear assembly, front output shaft assembly and rear output ...

  • Page 763

    Transfer: non-shift type (transfer without shift actuator) 3c-75 non-shift type (transfer without shift actuator) precautions transfer warning s5jb0a3320001 refer to “transfer warning: motor-shift type (transfer with shift actuator)”. General description transfer construction s5jb0a3321001 the alumi...

  • Page 764

    3c-76 transfer: non-shift type (transfer without shift actuator) diagnostic information and procedures transfer symptom diagnosis s5jb0a3324001 before attempting to repair the transfer or related components for any reason other than mechanical failure, the condition and possible causes should be ide...

  • Page 765

    Transfer: non-shift type (transfer without shift actuator) 3c-77 repair instructions transfer oil change s5jb0a3326002 refer to “transfer oil change: motor-shift type (transfer with shift actuator)”. Transfer oil level check s5jb0a3326003 refer to “transfer oil level check: motor-shift type (transfe...

  • Page 766

    3c-78 transfer: non-shift type (transfer without shift actuator) transfer assembly components s5jb0a3326006 37 36 9 38 (c) 32 (a) 25 20 (a) (a) 40 (a) 27 (b) (a) a oil 28 29 31 33 1217g 30 26 10 10 19 9 oil 9 oil 23 1217g 24 1217g 22 21 35 a 9 oil 9 oil 16 oil 18 17 15 14 13 12 11 9 oil 5 4 6 2 (a) ...

  • Page 767

    Transfer: non-shift type (transfer without shift actuator) 3c-79 1. Front oil seal no.1 : apply grease 99000-25010 to oil seal lip. 17. Differential lock clutch sleeve 33. Oil drain plug : apply sealant 99000-31260 to plug thread. 2. Front case bolt 18. Front drive sprocket bush 34. Transfer to tran...

  • Page 768

    3c-80 transfer: non-shift type (transfer without shift actuator) transfer assembly disassembly and reassembly s5jb0a3326007 disassembly 1) remove differential lock shift lever case (1). 2) remove oil pump cover (1). 3) remove oil pump inner rotor (1), outer rotor (2), oil strainer (4) and drive pin ...

  • Page 769

    Transfer: non-shift type (transfer without shift actuator) 3c-81 8) remove needle bearing (1), snap ring (2), washer (3) and shim(s) (4) from rear output shaft (5). 9) remove reduction shift sleeve (1) and center differential (3) from rear output shaft (2). 10) remove needle bearings (1), front driv...

  • Page 770

    3c-82 transfer: non-shift type (transfer without shift actuator) 16) remove needle bearing (1) from rear case (2) using special tool, if necessary. Special tool (a): 09913–76010 17) remove input gear plate (1), and then remove input gear assembly (3) from front case (2). 18) remove front oil seal no...

  • Page 771

    Transfer: non-shift type (transfer without shift actuator) 3c-83 6) install rear output shaft assembly (2) to rear case (3), and then install snap ring (1). 7) install front drive sprocket (1), front output shaft assembly (2), drive chain (3) and needle bearing (4) into rear case. 8) install front d...

  • Page 772

    3c-84 transfer: non-shift type (transfer without shift actuator) 13) select shim (1) as follows. A) install shim, washer (2) and used snap ring (3) into rear output shaft (4). B) check clearance between shim and washer. C) if clearance is out of specified value, select shim from the following table ...

  • Page 773

    Transfer: non-shift type (transfer without shift actuator) 3c-85 18) clean mating surface of both center case and rear case (1), apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, mate center case with rear case and then tighten bolts (2)...

  • Page 774

    3c-86 transfer: non-shift type (transfer without shift actuator) 22) clean mating surface of oil pump cover (1) and rear case (2), apply sealant to rear case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolt...

  • Page 775

    Transfer: non-shift type (transfer without shift actuator) 3c-87 specifications tightening torque specifications s5jb0a3327001 note the specified tightening torque is also described in the following. “transfer assembly components: non-shift type (transfer without shift actuator)” reference: for the ...

  • Page 776: Propeller Shafts

    3d-1 propeller shafts: propeller shafts precautions propeller shaft caution s5jb0a3400001 caution ! • all propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced w...

  • Page 777

    Propeller shafts: 3d-2 diagnostic information and procedures propeller shaft symptom diagnosis s5jb0a3404001 repair instructions propeller shaft joint check s5jb0a3406001 if universal joints and ball joints are suspected of producing chattering or rattling noise, inspect them for wear. For universal...

  • Page 778

    3d-3 propeller shafts: • install propeller shaft aligning match marks. Otherwise, vibration may occur during driving. • use the following specification to torque universal joint flange nuts and bolts. For front propeller shaft flange bolt (front differential side), apply thread lock cement to thread...

  • Page 779

    Propeller shafts: 3d-4 4) tapping yoke with a hammer, completely remove bearing race. 5) take out bearing race on the other side in the same way as in step 3) and 4). 6) push out bearing race on flange yoke side as described in step 2) and 3), and then, holding bearing race in a vise (1), tap flange...

  • Page 780

    3d-5 propeller shafts: 1) make sure to apply grease to spider bearing race. “a”: grease 99000–25030 (suzuki super grease c) 2) insert bearing race into yoke, using press, until it is flush with yoke face. When doing this, insert spider into bearing race to prevent rollers in bearing race from coming...

  • Page 781

    Propeller shafts: 3d-6 special tools and equipment recommended service material s5jb0a3408001 note required service material is also described in the following. “propeller shaft construction: ” special tool s5jb0a3408002 material suzuki recommended product or specification note grease suzuki super g...

  • Page 782

    3d-7 propeller shafts:.

  • Page 783: Section 4

    Table of contents 4- i 4 section 4 contents brakes precautions .................................................4-1 precautions............................................................. 4-1 precautions for brakes.......................................... 4-1 brake control system and diagnosis ......

  • Page 784

    4-ii table of contents abs............................................................4e-1 precautions...........................................................4e-1 precautions in diagnosing troubles ...................4e-1 precautions in on-vehicle service......................4e-1 general descrip...

  • Page 785: Precautions

    Precautions: 4-1 precautions precautions precautions for brakes s5jb0a4000001 suspension caution refer to “suspension caution: in section 00”. Wheels and tires caution refer to “wheels and tires caution: in section 00”. Brake caution refer to “brakes caution and note: in section 00”. General precaut...

  • Page 786

    4a-1 brake control system and diagnosis: brake control system and diagnosis general description brakes construction s5jb0a4101001 when the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder (2) to actuate pistons (two in front and four in rear). The master cylinder...

  • Page 787

    Brake control system and diagnosis: 4a-2 front brake hose / pipe construction s5jb0a4101006 i5jb0a410002-02 [a]: for lh steering vehicle 4. From abs hydraulic unit to left front brake 9. Master cylinder fixing nut [b]: for rh steering vehicle 5. Abs hydraulic unit / control module assembly 10. Brake...

  • Page 788

    4a-3 brake control system and diagnosis: rear brake hose / pipe construction s5jb0a4101007 master cylinder assembly construction s5jb0a4101003 the master cylinder has two pistons, two pressure seal (3) and two separating seal (4). Its hydraulic pressure is produced in the primary (a in the figure) a...

  • Page 789

    Brake control system and diagnosis: 4a-4 booster assembly construction s5jb0a4101004 the booster is located between the master cylinder and the brake pedal. It is so designed that the force created when the brake pedal is depressed is mechanically increased combined with the engine vacuum. Caution !...

  • Page 790

    4a-5 brake control system and diagnosis: substandard or contaminated brake fluid caution ! Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components in the hydraulic system to deteriorate. If primary piston cups are swollen, then rubber parts ...

  • Page 791

    Brake control system and diagnosis: 4a-6 dragging brakes (a very light drag is present in all disc brakes immediately after pedal is released) master cylinder pistons not returning correctly replace master cylinder. Restricted brake pipes or hoses check for soft hoses or damaged pipes and replace wi...

  • Page 792

    4a-7 brake control system and diagnosis: repair instructions excessive pedal travel check s5jb0a4106001 1) start engine. 2) depress brake pedal a few times. 3) with brake pedal depressed with approximately 30 kg (66 lbs) load, measure pedal to carpet clearance “c”. If clearance “c” is less than spec...

  • Page 793

    Brake control system and diagnosis: 4a-8 air bleeding of brake system s5jb0a4106004 caution ! Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. Bleeding operation is necessary to remove air whe...

  • Page 794

    4a-9 brake control system and diagnosis: brake pedal free height adjustment s5jb0a4106005 measure brake pedal free height between pedal and carpet installed on dash panel. If the measurement is not within the specification, check the position of booster push rod clevis and/or brake light switch, ref...

  • Page 795

    Brake control system and diagnosis: 4a-10 flushing brake hydraulic system s5jb0a4106009 it is recommended that entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in hydraulic system. Periodical change of brake fluid is also recommended. Booster oper...

  • Page 796

    4a-11 brake control system and diagnosis: check air tightness under load 1) with engine running, depress brake pedal. Then stop engine while holding brake pedal depressed. 2) hold brake pedal depressed for 30 seconds. If pedal height does not change, condition is good. But it isn’t if pedal rises. F...

  • Page 797

    Brake control system and diagnosis: 4a-12 master cylinder components s5jb0a4106026 caution ! Never disassemble master cylinder. Disassembly will spoil its original function. If faulty condition is found, replace it with new one as an assembly. [a] [b] 4 5 3 3 2 2 1 7 6 8 (a) i5jb0a410010-01 [a]: a/t...

  • Page 798

    4a-13 brake control system and diagnosis: master cylinder reservoir removal and installation s5jb0a4106013 caution ! Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid, flush it with water immediately if any fluid is spilled. Removal 1) disconnect re...

  • Page 799

    Brake control system and diagnosis: 4a-14 master cylinder assembly removal and installation s5jb0a4106014 caution ! • never disassemble master cylinder. Disassembly will spoil its original function. If faulty condition is found, replace it with new one as an assembly. • do not allow brake fluid to g...

  • Page 800

    4a-15 brake control system and diagnosis: 4) connect brake pipes to master cylinder and tighten brake pipe flare nuts (1) to specified torque. Tightening torque brake pipe flare nut (a): 16 n·m (1.6 kgf-m, 12.0 lb-ft) 5) connect clutch reservoir hose (1) to reservoir (2) for m/t vehicle. 6) connect ...

  • Page 801

    Brake control system and diagnosis: 4a-16 brake booster components s5jb0a4106018 note the difference between rh steering vehicle and lh steering vehicle booster components is the location of vacuum hose. 1 2 3 4 5 6 7 8 9 10 (a) (b) (c) i5jb0a410023-02 1. Brake master cylinder assembly 5. Clevis pin...

  • Page 802

    4a-17 brake control system and diagnosis: brake booster removal and installation s5jb0a4106020 removal 1) disconnect brake pipes from abs actuator if equipped. 2) remove master cylinder assembly, referring to “master cylinder assembly removal and installation: ”. 3) disconnect brake vacuum hose from...

  • Page 803

    Brake control system and diagnosis: 4a-18 specifications tightening torque specifications s5jb0a4107001 note the specified tightening torque is also described in the following. “front brake hose / pipe construction: ” “master cylinder components: ” “brake booster components: ” reference: for the tig...

  • Page 804: Front Brakes

    4b-1 front brakes: front brakes general description front disc brake caliper assembly construction s5jb0a4201001 this caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. Th...

  • Page 805

    Front brakes: 4b-2 repair instructions front disc brake components s5jb0a4206010 9 16 17 15 14 4 5 7 7 1 2 3 6 8 8 10 11 12 13 18 19 (b) (a) (c) (d) f i5jb0a420001-01 1. Caliper 10. Piston seal : apply small amount of brake fluid to all around part of piston seal. 19. Brake disc 2. Caliper pin bolt ...

  • Page 806

    4b-3 front brakes: front disc brake pad on-vehicle check s5jb0a4206001 inspect pad linings periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through hole of caliper and check lining thickness of outside and inside pads. If one...

  • Page 807

    Front brakes: 4b-4 2) install caliper and tighten caliper (slide) pin bolts (1) to specification. Note make sure that boots are fit into groove securely. Tightening torque caliper pin bolt (a): 36 n·m (3.6 kgf-m, 26.0 lb-ft) 3) tighten front wheel nuts to specification. Tightening torque wheel nut (...

  • Page 808

    4b-5 front brakes: front brake disc deflection limit: 0.1 mm (0.004 in.) slide pin bolt / cylinder slide pin check slide pin (bolt) for smooth movement as shown in the figure. If it is found faulty, correct or replace. Apply rubber grease to slide pin (bolt) outer surface. Rubber grease should be th...

  • Page 809

    Front brakes: 4b-6 3) install brake flexible hose as shown and tighten flexible hose joint bolt (1) to specification. Tightening torque flexible hose joint bolt (a): 23 n·m (2.3 kgf-m, 17.0 lb-ft) 4) tighten front wheel nuts to specification. Tightening torque wheel nut (a): 100 n·m (10.0 kgf-m, 72....

  • Page 810

    4b-7 front brakes: piston seal piston seal is used to seal piston and cylinder and to adjust clearance between pad and disc. Replace with a new one at every overhaul. Fit piston seal into groove in cylinder taking care not to twist it. Piston and boot 1) before inserting piston (1) into cylinder, ap...

  • Page 811

    Front brakes: 4b-8 piston seal excessive or uneven wear of pad lining may indicate unsmooth return of the piston. In such a case, replace rubber seal. Front brake disc removal and installation s5jb0a4206008 removal 1) hoist vehicle and remove front wheel. 2) remove caliper assembly (2) by loosening ...

  • Page 812

    4b-9 front brakes: specifications tightening torque specifications s5jb0a4207001 note the specified tightening torque is also described in the following. “front disc brake components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fastener information: in...

  • Page 813: Rear Brakes

    Rear brakes: 4c-1 rear brakes general description rear drum brake assembly construction s5jb0a4301001 the drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained appropriate at all times. Rear brake is a drum type. It uses leading trailing operatio...

  • Page 814

    4c-2 rear brakes: repair instructions rear drum brake assembly components s5jb0a4306001 16 17 4 2 9 (b) (c) 7 6 5 3 8 2 10 12 1 13 18 11 (a) 15 14 i5jb0a430001-03 1. Brake back plate 9. Shoe return lower spring 17. Rear wheel hub assembly 2. Brake shoe 10. Shoe hold down spring 18. Rear wheel hub ho...

  • Page 815

    Rear brakes: 4c-3 rear brake drum removal and installation s5jb0a4306003 removal 1) hoist vehicle and remove rear wheel. 2) release parking brake lever. 3) remove rear console box and loosen parking brake cable adjusting nut (1). 4) remove brake drum (1) by using 8 mm bolts (2) (2 pcs). Installation...

  • Page 816

    4c-4 rear brakes: rear brake drum and shoe inspection s5jb0a4306004 brake drum inspect brake drum for wear. If drum inner diameter is exceeds the limit or uneven or stepped wear is excessive, replace the drum. Rear brake drum inner diameter “a” standard: 254 mm (10.00 in.) limit: 256 mm (10.07 in.) ...

  • Page 817

    Rear brakes: 4c-5 rear brake shoe removal and installation s5jb0a4306006 warning ! Use special care when installing brake shoe return spring. Failure in its proper installation may allow it to springback and cause personal injury. Removal 1) remove brake drum referring to “rear brake drum removal an...

  • Page 818

    4c-6 rear brakes: 4) install brake adjuster (2) and upper shoe return spring (1). 5) install adjuster pawl lever (3) and adjuster spring. 6) for procedure hereafter, refer to “rear brake drum removal and installation: ”. Rear brake shoe inspection s5jb0a4306007 parking brake shoe lever inspect brake...

  • Page 819

    Rear brakes: 4c-7 installation 1) fit wheel cylinder to brake back plate, take off bleeder plug cap from brake pipe and connect pipe to wheel cylinder just enough to prevent fluid from leaking. 2) tighten wheel cylinder mounting bolts to brake back plate (1) to specified torque. Tightening torque wh...

  • Page 820

    4c-8 rear brakes: 4) remove brake drum referring to “rear brake drum removal and installation: ”. 5) remove brake shoe referring to “rear brake shoe removal and installation: ”. 6) remove wheel cylinder referring to “wheel cylinder removal and installation: ”. 7) remove parking brake cable (1) from ...

  • Page 821

    Rear brakes: 4c-9 8) install wheel and tighten wheel nuts to specified torque. 9) check to ensure that brake drum is free from dragging and proper braking is obtained. Remove vehicle from hoist and perform brake test (foot brake and parking brake). Specifications tightening torque specifications s5j...

  • Page 822: Parking Brake

    4d-1 parking brake: parking brake component location parking brake cable location s5jb0a4403001.

  • Page 823

    Parking brake: 4d-2 i5jb0a440001-02 t: top side 3. Equalizer 8. Parking brake shoe lever [a]: for 5door model f: front side 4. Parking cable bracket 9. Parking cable clamp nut [b]: for 3door model r: right side 5. Parking cable bracket bolt 10. Parking cable clamp bolt : 11 n ⋅m (1.1 kgf-m, 8.0 lb-f...

  • Page 824

    4d-3 parking brake: repair instructions parking brake check and adjustment s5jb0a4406001 check hold center of parking brake lever grip and pull it up with 200 n (20 kg, 44 lbs) force. With parking brake lever pulled up as shown, count ratchet notches. There should be 5 to 7 notches. Also, check if b...

  • Page 825

    Parking brake: 4d-4 parking brake lever removal and installation s5jb0a4406002 removal 1) disconnect negative (–) cable at battery. 2) block vehicle wheels and release parking brake lever. 3) remove console box. 4) disconnect lead wire of parking brake switch at coupler. 5) remove parking brake cabl...

  • Page 826

    4d-5 parking brake: installation install it by reversing removal procedure, noting the following points. • install clamps properly referring to “parking brake cable location: ”. • tighten bolts and nuts to specified torque referring to “parking brake cable location: ”. • adjust parking brake cable. ...

  • Page 827: Abs

    Abs: 4e-1 abs precautions precautions in diagnosing troubles s5jb0a4500001 to ensure that the trouble diagnosis is done accurately and smoothly, observe the following and follow “abs check: ”. • if the vehicles was operated in any of the following ways, abs warning lamp may light momentarily but thi...

  • Page 828

    4e-2 abs: this abs is equipped with electronic brake force distribution (ebd) system that controls a fluid pressure of rear wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sensor independently of change of load due to load capacity and so...

  • Page 829

    Abs: 4e-3 schematic and routing diagram abs schematic s5jb0a4502001 input output abs control module wheel speed sensor (lf) wheel speed sensor (lr) wheel speed sensor (rf) battery voltage ignition voltage pump motor driver (transistor) solenoid valve power supply driver (transistor) solenoid valve d...

  • Page 830

    4e-4 abs: abs wiring circuit diagram s5jb0a4502002 5. Solenoid valve driver (transistor) 13. Data link connector 21. Ecm 6. Pump motor driver (transistor) 14. Wheel speed sensor (right-front) 22. 4 way joint 7. Solenoid valve 15. Wheel speed sensor (left-front) 8. Pump motor 16. Wheel speed sensor (...

  • Page 831

    Abs: 4e-5 4. Circuit fuse box 16. Right-front wheel speed sensor 28. Brake fluid level switch 5. Combination meter 17. Left-front wheel speed sensor 29. Parking brake switch 6. Abs warning lamp 18. Data link connector 30. Can junction 7. Ebd warning lamp (brake warning lamp) 19. To ecm, tcm, sdm, bc...

  • Page 832

    4e-6 abs: component location abs components location s5jb0a4503001 note as for the difference of rh steering vehicle and lh steering vehicle, the location of the combination meter, data link connector, stop lamp switch and the brake master cylinder assembly only changes. 6 2 1 7 4 5 6 2 3 2 6 6 2 8 ...

  • Page 833

    Abs: 4e-7 diagnostic information and procedures abs check s5jb0a4504001 refer to the following items for the details of each step. Step 1: malfunction analysis customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this pu...

  • Page 834

    4e-8 abs: customer questionnaire (example) problem symptom confirmation check if what the customer claimed in “customer questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (this step should be shared with the customer if possible.) che...

  • Page 835

    Abs: 4e-9 step 3: dtc check recheck dtc referring to “dtc check: ”. Step 4: abs check according to abs check for the dtc confirmation in step 3, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator assembly or other part and repair or replace faulty parts. S...

  • Page 836

    4e-10 abs: 3) turn ignition switch to on position. 4) read dtc according to instructions displayed on suzuki scan tool and print it or write it down. Refer to suzuki scan tool operator’s manual for further details. Note if suzuki scan tool can not communicate abs hydraulic unit / control module, per...

  • Page 837

    Abs: 4e-11 scan tool data definition battery volt (v): battery voltage is an analog input signal read by the abs control module. Certain abs control module functions will be modified if the battery voltage falls below or rises above programmed thresholds. Pump motor driver (v): this parameter indica...

  • Page 838

    4e-12 abs: circuit description operation (on/off) of abs warning lamp is controlled by abs control module through lamp driver module in combination meter. If the antilock brake system is in good condition, abs control module turns abs warning lamp on at the ignition switch on, keeps it on for 2 seco...

  • Page 839

    Abs: 4e-13 abs warning lamp comes on steady s5jb0a4504009 wiring diagram circuit description operation (on/off) of abs warning lamp is controlled by abs control module through lamp driver module in combination meter. If the antilock brake system is in good condition, abs control module turns abs war...

  • Page 840

    4e-14 abs: troubleshooting step action yes no 1 1) perform diagnostic trouble code check. Is there any dtc(s)? Go to step 7 of “abs check: ”. Go to step 2. 2 are main fuses for abs pump motor and abs solenoid in good condition? Go to step 3. Replace fuse and check circuit for short to ground. 3 1) t...

  • Page 841

    Abs: 4e-15 abs warning lamp flashes continuously while ignition switch is on s5jb0a4504010 wiring diagram troubleshooting 3 4 2 1 8 e03-13 e03-26 12v 12v e03-1 e03-14 e03-7 grn/orn ppl/red blk/yel wht/grn wht/red wht/blu blk blk blk red wht red wht e03-12 e03-6 e03-20 12v [a] e03 11 10 9 5 7 6 15 16...

  • Page 842

    4e-16 abs: ebd warning lamp (brake warning lamp) comes on steady s5jb0a4504011 wiring diagram circuit description ebd warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and abs hydraulic unit / control module assembly through lamp driver module in combi...

  • Page 843

    Abs: 4e-17 serial data link circuit check s5jb0a4504012 inspection 3 4 2 1 12v 12v e03-1 e03-14 e03-7 grn/orn ppl/red blk/yel wht/grn wht/red wht/blu e03-13 e03-26 blk blk blk red wht red wht e03-12 e03-6 ppl/wht 12v +bb e03-5 [a] e03 10 11 9 8 g g1 5 7 6 12 15 16 17 18 19 20 21 22 23 24 25 2 3 4 5 ...

  • Page 844

    4e-18 abs: 4 1) turn ignition switch to off position. 2) check for proper connection to abs hydraulic unit / control module connector at terminals “e03-1” and “e03- 14”. 3) if ok then turn ignition switch to on position and measure voltage between each terminal of “e03-1”, “e03-14” and vehicle body ...

  • Page 845

    Abs: 4e-19 dtc c1015: g sensor circuit s5jb0a4504019 description if the signal voltage of g sensor while at a stop does not vary of from that while running, this dtc is set. Therefore, this dtc may be set when a vehicle is lifted up and its wheel(s) is turned. In such case, clear the dtc and check a...

  • Page 846

    4e-20 abs: dtc c1021, c1022 / c1025, c1026 / c1031, c1032 / c1035, c1036: right-front / left-front / right- rear / left-rear wheel speed sensor circuit or encoder s5jb0a4504013 wiring diagram dtc detecting condition the abs control module monitors the voltage at the terminal of each sensor while the...

  • Page 847

    Abs: 4e-21 3 1) disconnect applicable abs wheel speed sensor coupler with ignition switch off. 2) measure resistance between the following points. • both abs hydraulic unit / control module connector (1) terminals a pair of applicable sensor terminals. This check result should be no continuity. • be...

  • Page 848

    4e-22 abs: dtc c1041 / c1045 / c1051 / c1055, dtc c1042 / c1046 / c1052 / c1056: right-front / left-front / right-rear / left-rear inlet solenoid circuit, right-front / left-front / right-rear / left-rear outlet solenoid circuit s5jb0a4504014 wiring diagram dtc detecting condition the abs control mo...

  • Page 849

    Abs: 4e-23 dtc c1057: power source circuit s5jb0a4504015 wiring diagram dtc detecting condition the abs control module monitors the power source voltage at terminal “e03-14”. When the power source voltage becomes extremely high or low while vehicle is running at more than 20 km/h (13 mph), this dtc ...

  • Page 850

    4e-24 abs: dtc c1061: abs pump motor and/or motor driver circuit s5jb0a4504016 wiring diagram dtc detecting condition the abs control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition switch turned on. It sets this dtc when the voltage at the monitor ...

  • Page 851

    Abs: 4e-25 dtc c1063: solenoid valve power supply driver circuit s5jb0a4504017 wiring diagram dtc detecting condition abs control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned on. Also, immediately after ignition switch is turned on, perform i...

  • Page 852

    4e-26 abs: dtc c1071: abs control module s5jb0a4504018 wiring diagram dtc detecting condition this dtc will be set when an internal malfunction is detected in the abs control module. Dtc troubleshooting 1 2 wht/blu 12v m 3 4 e03-1 e03-14 blk blk e03-13 e03-26 wht/red [a] e03 15 16 17 18 19 20 21 22 ...

  • Page 853

    Abs: 4e-27 dtc u1073: control module communication bus off s5jb0a4504020 wiring diagram dtc detecting condition transmission error that is inconsistent between transmission data and transmission monitor (can bus monitor) data is detected more than 7 times continuously. Wht red wht red wht/blu wht/re...

  • Page 854

    4e-28 abs: dtc troubleshooting step action yes no 1 was “abs check” performed? Go to step 2. Go to “abs check: ”. 2 1) check connection of connectors of all control modules communicating by means of can. 2) recheck dtc. Is dtc u1073 indicated? Go to step 3. Intermittent trouble. Check for intermitte...

  • Page 855

    Abs: 4e-29 dtc u1100: lost communication with ecm (reception error) s5jb0a4504021 wiring diagram dtc detecting condition reception error of communication data for ecm is detected more than specified time continuously. Dtc troubleshooting 9 1) turn ignition switch to off position. 2) disconnect conne...

  • Page 856

    4e-30 abs: repair instructions abs hydraulic unit operation check s5jb0a4506001 1) check that basic brake system other than abs is in good condition. 2) check that battery voltage is 11 v or higher. 3) lift up vehicle. 4) set transmission to neutral and release parking brake. 5) turn each wheel grad...

  • Page 857

    Abs: 4e-31 abs hydraulic unit / control module assembly components s5jb0a4506002 caution ! Never disassemble abs hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of abs hydraulic unit / control m...

  • Page 858

    4e-32 abs: abs hydraulic unit / control module assembly removal and installation s5jb0a4506004 caution ! Never disassemble abs hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of abs hydraulic un...

  • Page 859

    Abs: 4e-33 installation 1) install hydraulic unit / control module assembly by reversing removal procedure. Tightening torque brake pipe flare nut (a): 16 n·m (1.6 kgf-m, 11.5 lb-ft) abs hydraulic unit / control module assembly bolt (b): 9 n·m (0.9 kgf-m, 6.5 lb-ft) abs hydraulic unit / control modu...

  • Page 860

    4e-34 abs: front wheel speed sensor on-vehicle inspection s5jb0a4506005 output voltage inspection 1) disconnect negative cable from battery. 2) hoist vehicle a little. 3) disconnect wheel speed sensor connector. 4) disconnect wheel speed grommet from vehicle body. 5) set up measuring devices as show...

  • Page 861

    Abs: 4e-35 front wheel speed sensor removal and installation s5jb0a4506006 removal 1) disconnect negative cable from battery. 2) disconnect front wheel speed sensor coupler (1). 3) hoist vehicle and remove wheel. 4) remove harness clamp, clamp bolts (2) and grommet (3). 5) remove front wheel speed s...

  • Page 862

    4e-36 abs: front wheel speed sensor inspection s5jb0a4506007 check sensor for damage. If any malcondition is found, replace. Rear wheel speed sensor on-vehicle inspection s5jb0a4506008 refer to “front wheel speed sensor on-vehicle inspection: ” since rear wheel speed sensor is the same as front whee...

  • Page 863

    Abs: 4e-37 rear wheel speed sensor inspection s5jb0a4506010 refer to “front wheel speed sensor inspection: ” since rear wheel speed sensor is the same as front wheel speed sensor. Front wheel encoder on-vehicle inspection s5jb0a4506011 before inspect front wheel encoder, remove front drive shaft ref...

  • Page 864

    4e-38 abs: specifications tightening torque specifications s5jb0a4507001 note the specified tightening torque is also described in the following. “abs hydraulic unit / control module assembly components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fast...

  • Page 865: Section 5

    Table of contents 5- i 5 section 5 contents transmission / transaxle precautions .................................................5-1 precautions............................................................. 5-1 precautions for transmission / transaxle............. 5-1 automatic transmission/transaxl...

  • Page 866

    5-ii table of contents dtc p1777: tcm lost communication with ecm (reception error) ...................................5a-66 dtc p1778: tcm lost communication with bcm (reception error) ...................................5a-67 dtc p1874 4l switch circuit malfunction (short) ............................

  • Page 867

    Table of contents 5-iii back up light switch removal and installation.......................................................5b-11 back up light switch inspection....................... 5b-11 gear shift control lever rear case assembly removal and installation ................5b-11 gear shift control...

  • Page 868: Precautions

    5-1 precautions: precautions precautions precautions for transmission / transaxle s5jb0a5000001 air bag warning refer to “air bag warning: in section 00”. Fastener caution refer to “fastener caution: in section 00”. Precautions in diagnosing trouble (for a/t) refer to “precautions in diagnosing trou...

  • Page 869

    Automatic transmission/transaxle: 5a-1 automatic transmission/transaxle precautions precautions in diagnosing trouble s5jb0a5100001 • do not disconnect couplers from tcm, battery cable from battery, tcm ground wire harness from engine or main fuse before checking the diagnostic information (dtc, fre...

  • Page 870

    5a-2 automatic transmission/transaxle: • select a clean place free from dust and dirt for overhauling. • place a rubber mat on the work bench to protect parts from damage. • work gloves or shop cloth should not be used. (use nylon cloth or paper towel.) • when separating the case joint, do not pry w...

  • Page 871

    Automatic transmission/transaxle: 5a-3 general description automatic transmission description s5jb0a5101001 this automatic transmission is a full automatic type with 3-speed plus overdrive (o/d). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically cont...

  • Page 872

    5a-4 automatic transmission/transaxle: item specifications torque converter type 3-element, 1-step, 2-phase type (with tcc (lock-up) mechanism) stall torque ratio 2.05 oil pump type trochoid type oil pump drive system engine driven gear change device type forward 4-step, reverse 1-step planetary gea...

  • Page 873

    Automatic transmission/transaxle: 5a-5 clutch / brake functions of automatic transmission s5jb0a5101002 i5jb0a510005-01 1. Overdrive clutch 5. Second coast brake 9. One-way clutch no.1 13. Intermediate shaft 2. Overdrive brake 6. Second brake 10. Overdrive one-way clutch 3. Forward clutch 7. Reverse...

  • Page 874

    5a-6 automatic transmission/transaxle: table of a/t system component operation s5jb0a5101003 solenoid valve no. 1–a solenoid valve no. 1–b o/d clutch forward clutch direct clutch o/d brake inner piston outer piston p { x { — — — — r (v ≤ 7 km/h) { x { — { { — r (v> 7 km/h) x { { — — — — n — — { — — ...

  • Page 875

    Automatic transmission/transaxle: 5a-7 can communication system description s5jb0a5101008 refer to “can communication system description: in section 1a” for can communication system description. Tcm communicates control data with each control module as follows. Tcm transmission data note *1: vehicle...

  • Page 876

    5a-8 automatic transmission/transaxle: electronic shift control input / output table s5jb0a5101004 note *1: for vehicle not equipped with engine diagnosis connector model (except rh steering vehicle not equipped with rear fog light model) *2: for vehicle not equipped with engine diagnosis connector ...

  • Page 877

    Automatic transmission/transaxle: 5a-9 note *1: for vehicle not equipped with engine diagnosis connector model (except rh steering vehicle not equipped with rear fog light model) input / output control accelerator effective position throttle position coolant temperature engine torque engine speed a/...

  • Page 878

    5a-10 automatic transmission/transaxle: electronic shift control system wiring diagram 13 34 34 34 34 11 12 35 p r n d 2 l 14 5v 12v 12v 12v 12v blk blk/orn blk/orn ig11 blk/red blk/wht +bb wht 16 21 17 18 20 12v 19 23 30 25 24 26 27 28 29 wht wht red wht red red 6 5 16 15 14 13 12 11 4 3 24 23 21 2...

  • Page 879

    Automatic transmission/transaxle: 5a-11 brake interlock system description s5jb0a5101005 shift lock solenoid control this system consists of shift lock solenoid control system and interlock cable control system. The shift lock solenoid control system is so designed that the select lever can not be s...

  • Page 880

    5a-12 automatic transmission/transaxle: 2 driving cycle detection logic the malfunction detected in the first driving cycle is stored in tcm memory (in the form of pending dtc and freeze frame data) but the malfunction indicator lamp does not light at this time. It lights up at the second detection ...

  • Page 881

    Automatic transmission/transaxle: 5a-13 2 driving cycle detection logic the malfunction detected in the first driving cycle is stored in tcm memory (in the form of pending dtc and freeze frame data) but the malfunction indicator lamp does not light at this time. It lights up at the second detection ...

  • Page 882

    5a-14 automatic transmission/transaxle: 3. Slip lock-up point in d and/or 3 position *1 power mode 1. Shift point in d position and power mode slip lock-up clutch status throttle opening (%) vehicle speed km/h (mph) remark 3 rd gear slip on 10 – 15% 29 – 34 (18 – 21) without lock-up condition slip o...

  • Page 883

    Automatic transmission/transaxle: 5a-15 2. Lock-up point in d position and power mode 3. Slip lock-up point in d and/or 3 position *1 note *1: for vehicle not equipped with engine diagnosis connector model (except rh steering vehicle not equipped with rear fog light model) the gear change is done at...

  • Page 884

    5a-16 automatic transmission/transaxle: bearing and race installation diagram s5jb0a5102002 bearing and race dimension 1 2 3 4 8 9 17 18 19 20 5 6 7 10 11 12 13 14 15 16 i5jb0a510013-01 no. Bearing and race inside diameter outside diameter 1 baring assy, o/d fr 24.32 mm (0.957 in.) 43.20 mm (1.701 i...

  • Page 885

    Automatic transmission/transaxle: 5a-17 component location electronic shift control system components location s5jb0a5103001 7 6 5 4 3 20 1 2 9 8 10 11 12 13 14 15 16 17 18 19 i5jb0a510014-01.

  • Page 886

    5a-18 automatic transmission/transaxle: diagnostic information and procedures a/t system check s5jb0a5104001 refer to the following items for the details of each step. 1. Engine 6. Transmission warning light (vehicle is equipped with engine diagnosis connector) 11. 4l/n low switch 16. Shift solenoid...

  • Page 887

    Automatic transmission/transaxle: 5a-19 step 1. Customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a inspection form will facilitate collecting information to the point required for proper ana...

  • Page 888

    5a-20 automatic transmission/transaxle: note the form is a standard sample. It should be modified according to conditions characteristic of each market. Step 2. Dtc / freeze frame data check, record and clearance first, referring to “dtc check: ”, check dtc (including pending dtc). If dtc exists, pr...

  • Page 889

    Automatic transmission/transaxle: 5a-21 dtc table s5jb0a5104005 note confirmation available table of automatic transmission related dtc is shown below. { : available-dtc can be confirmed x: not available-dtc can not be confirmed note a: driving cycles when mil lighting and storing dtc in tcm memory ...

  • Page 890

    5a-22 automatic transmission/transaxle: note *1: mil does not light although dtc is detected and stored. *2: transmission warning light does not light although dtc is detected and stored. Dtc check s5jb0a5104006 note for vehicle without engine diagnosis connector, the mil is turned on when the ecm a...

  • Page 891

    Automatic transmission/transaxle: 5a-23 3) read dtc according to instructions displayed on suzuki scan tool and write it down. Refer to suzuki scan tool operator’s manual for further details. 4) after completing the check, turn ignition switch off and disconnect suzuki scan tool from data link conne...

  • Page 892

    5a-24 automatic transmission/transaxle: dtc clearance using monitor connector (if equipped) 1) remove steering column hole cover (1). 2) turn ignition switch on. 3) after 6 seconds or more, repeat connecting and disconnecting diagnosis switch terminal (3) of monitor connector (2) and body ground 5 t...

  • Page 893

    Automatic transmission/transaxle: 5a-25 ) p09 62 pressure control solenoid “a” control circuit low • power supply for all solenoid valves is cut. • gear position is fixed according to select lever position as shown in the following. R: reverse d: 4th 3: 4th 2: 3rd l: 1st • lock-up function is inhibi...

  • Page 894

    5a-26 automatic transmission/transaxle: scan tool data s5jb0a5104009 as the data values given in the following table are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference value. Even when the vehicle is in good ...

  • Page 895

    Automatic transmission/transaxle: 5a-27 vehicle speed 1 at vehicle stop 0 km/h, 0 mph battery voltage ignition switch on and engine stop battery voltage is displayed (8 – 16 v) atf temp after driving at 60 km/h (37.5 mile/h) for 15 minutes or more, and a/t fluid temperature around sensor reaches 70 ...

  • Page 896

    5a-28 automatic transmission/transaxle: scan tool data definitions gear position (1 st , 2 nd , 3 rd , 4 th , n, r): this parameter is indicated actual gear position. Throttle position (%): throttle valve opening ratio sent from ecm on can communication line. Input shaft rev (rmp): input shaft revol...

  • Page 897

    Automatic transmission/transaxle: 5a-29 4wd low switch (on, off): inputted signal from 4l/ n switch on transfer case. On: transfer gear position is 4l off: transfer gear position is 4h d range signal (p/n range, d range): on: signal which tcm require ecm to increase idle speed off: signal which tcm ...

  • Page 898

    5a-30 automatic transmission/transaxle: road test s5jb0a5104012 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. • test requires 2 pers...

  • Page 899

    Automatic transmission/transaxle: 5a-31 manual road test s5jb0a5104013 this test checks the gears being used in “l”, “2”, “3” 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 se...

  • Page 900

    5a-32 automatic transmission/transaxle: troubleshooting stall test s5jb0a5104014 this test is to check overall performance of automatic transmission and engine by measuring stall speed at “d” and “r” ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature...

  • Page 901

    Automatic transmission/transaxle: 5a-33 time lag test s5jb0a5104015 this test is to check conditions of clutch, reverse brake and fluid pressure. “time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) with chocks placed before and behind front and rear ...

  • Page 902

    5a-34 automatic transmission/transaxle: 1) apply parking brake securely and place chocks against wheels. 2) remove fluid pressure check hole plug bolt. 3) attach oil pressure gauge to fluid pressure check hole in transmission case. Special tool (a): 09925–37811–001 caution ! After attaching oil pres...

  • Page 903

    Automatic transmission/transaxle: 5a-35 engine brake test s5jb0a5104017 warning ! Before test, make sure that there is no vehicle behind so as to prevent rear-end collision. 1) while driving vehicle in 4th gear of “d” range, shift select lever down to “3” range and check if engine brake operates. 2)...

  • Page 904

    5a-36 automatic transmission/transaxle: a/t symptom diagnosis s5jb0a5104019 trouble diagnosis 1 electrical repair condition possible cause correction / reference item excessive shift shock shift solenoid valve no.1 and/or no.2 circuit faulty inspect circuit for open, short and intermittent. If ng, r...

  • Page 905

    Automatic transmission/transaxle: 5a-37 poor 2 → 3 shift shift solenoid valve no.1 circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Output shaft speed sensor circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Transmission range sensor circu...

  • Page 906

    5a-38 automatic transmission/transaxle: poor o/d → 3 shift shift solenoid valve no.2 circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Pressure control solenoid valve circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Output shaft speed sens...

  • Page 907

    Automatic transmission/transaxle: 5a-39 incorrect gear shift point output shaft speed sensor circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Pressure control solenoid valve circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Can communicati...

  • Page 908

    5a-40 automatic transmission/transaxle: trouble diagnosis 2 on-vehicle repair condition possible cause correction / reference item unable to run in all range faulty valve body component replace valve body assembly. Excessive shift shock engine abnormal condition inspect and repair engine. Malfunctio...

  • Page 909

    Automatic transmission/transaxle: 5a-41 poor 3 → o/d shift malfunction of shift solenoid valve no.2 inspect. If ng, replace. Malfunction of output shaft speed sensor inspect. If ng, replace. Malfunction of transmission range sensor inspect. If ng, replace. Malfunction of “3” position switch inspect....

  • Page 910

    5a-42 automatic transmission/transaxle: trouble diagnosis 3 off-vehicle repair incorrect shift point engine abnormal condition inspect and repair engine malfunction of output shaft speed sensor inspect. If ng, replace. Malfunction of accelerator pedal position sensor inspect referring to “dtc p0122:...

  • Page 911

    Automatic transmission/transaxle: 5a-43 no gear shift to 4th gear s5jb0a5104020 system description tcm does not shift to 5th gear under any of the following condition. • “3” position switch signal is inputted. • 4l/n switch is turned on. (4l mode) • tcm detects the following dtcs. Dtc, p0722, p0752,...

  • Page 912

    5a-44 automatic transmission/transaxle: no lock-up occurs s5jb0a5104021 system description tcm turns tcc pressure control solenoid off under any of the following conditions. • engine coolant temperature is lower than 60 °c (140 °f). • 4l/n switch is turned on. (4l mode) • brake light switch is turne...

  • Page 913

    Automatic transmission/transaxle: 5a-45 transmission warning light circuit check – light does not come “on” at ignition switch on (vehicle is equipped with engine diagnosis connector) s5jb0a5104063 troubleshooting transmission warning light circuit check – light remains “on” at ignition switch on (v...

  • Page 914

    5a-46 automatic transmission/transaxle: “power” light circuit check – light does not come “on” at ignition switch on s5jb0a5104065 troubleshooting dtc p0705 transmission range sensor circuit malfunction s5jb0a5104026 wiring diagram dtc detecting condition and trouble area step action yes no 1 combin...

  • Page 915

    Automatic transmission/transaxle: 5a-47 dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start engine and shift select lever to “d” range. 4) keep engine running at idle speed for 25 seconds or more. 5) chec...

  • Page 916

    5a-48 automatic transmission/transaxle: dtc p0707 transmission range sensor circuit low s5jb0a5104027 wiring diagram refer to “dtc p0705 transmission range sensor circuit malfunction: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition swi...

  • Page 917

    Automatic transmission/transaxle: 5a-49 4 check transmission range sensor (switch) circuit for operation check without using suzuki scan tool: 1) turn ignition switch on. 2) check voltage at terminals “e93-1”, “e93-7”, “e93-8”, “e93-18”, “e93-19” and “e93-20” respectively with select lever shifted t...

  • Page 918

    5a-50 automatic transmission/transaxle: dtc p0712 transmission fluid temperature sensor “a” circuit low s5jb0a5104029 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by usin...

  • Page 919

    Automatic transmission/transaxle: 5a-51 dtc p0713 transmission fluid temperature sensor “a” circuit high s5jb0a5104030 wiring diagram refer to “dtc p0712 transmission fluid temperature sensor “a” circuit low: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool...

  • Page 920

    5a-52 automatic transmission/transaxle: dtc p0717 input / turbine speed sensor circuit no signal s5jb0a5104031 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan ...

  • Page 921

    Automatic transmission/transaxle: 5a-53 dtc p0722 output speed sensor circuit no signal s5jb0a5104032 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) ...

  • Page 922

    5a-54 automatic transmission/transaxle: dtc troubleshooting dtc p0741 / p0742 tcc circuit performance or stuck off / tcc circuit stuck on s5jb0a5104033 dtc detecting condition and trouble area step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check: ”. 2 check in...

  • Page 923

    Automatic transmission/transaxle: 5a-55 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out with 2 pe...

  • Page 924

    5a-56 automatic transmission/transaxle: dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out with 2 pe...

  • Page 925

    Automatic transmission/transaxle: 5a-57 table for detecting condition dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test s...

  • Page 926

    5a-58 automatic transmission/transaxle: dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start engine. 4) keep engine running at idle speed for 30 seconds or more. 5)...

  • Page 927

    Automatic transmission/transaxle: 5a-59 dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start engine. 4) keep engine running at idle speed for 10 seconds or more. 5) check dtc, pending dtc and freeze-frame ...

  • Page 928

    5a-60 automatic transmission/transaxle: dtc detecting condition and trouble area dtc confirmation procedure dtc p0973: 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start engine. 4) shift select lever to “n” and “d” range for each ...

  • Page 929

    Automatic transmission/transaxle: 5a-61 dtc p0974 / p0977 shift solenoid “a” control circuit high / shift solenoid “b” control circuit high s5jb0a5104042 wiring diagram refer to “dtc p0973 / p0976 shift solenoid “a” control circuit low / shift solenoid “b” control circuit low: ”. Dtc detecting condi...

  • Page 930

    5a-62 automatic transmission/transaxle: dtc p1702 internal control module memory check sum error s5jb0a5104044 dtc detecting condition and trouble area note dtc p1702 can never be cleared once it has been set. 1) ignition switch off. 2) replace tcm. 3) repeat “a/t system check: ”. Dtc p1703 can inva...

  • Page 931

    Automatic transmission/transaxle: 5a-63 dtc p1723 range select switch malfunction s5jb0a5104056 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start ...

  • Page 932

    5a-64 automatic transmission/transaxle: dtc p1774: can communication bus off s5jb0a5104057 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [h] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/red wht/red e23-4 e23-19 wht red e03-1...

  • Page 933

    Automatic transmission/transaxle: 5a-65 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 1 min. Or more. 4) check dtc and pendin...

  • Page 934

    5a-66 automatic transmission/transaxle: dtc p1777: tcm lost communication with ecm (reception error) s5jb0a5104058 wiring diagram refer to “dtc p1774: can communication bus off: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch tu...

  • Page 935

    Automatic transmission/transaxle: 5a-67 dtc p1778: tcm lost communication with bcm (reception error) s5jb0a5104059 wiring diagram refer to “dtc p1774: can communication bus off: ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch tu...

  • Page 936

    5a-68 automatic transmission/transaxle: dtc p1874 4l switch circuit malfunction (short) s5jb0a5104047 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) ...

  • Page 937

    Automatic transmission/transaxle: 5a-69 dtc p1875 4l switch circuit malfunction (open) s5jb0a5104048 wiring diagram refer to “dtc p1874 4l switch circuit malfunction (short): ”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. ...

  • Page 938

    5a-70 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 vehicle speed signal check 1) check dtc in ecm and abs hydraulic unit / control module referring to “dtc check: in section 1a” or “dtc check: in section 4e”. Is there dtc p p0500: vehicle speed sensor (vss) malfunction ...

  • Page 939

    Automatic transmission/transaxle: 5a-71 dtc p1878 torque converter clutch shudder s5jb0a5104060 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start engine and warm...

  • Page 940

    5a-72 automatic transmission/transaxle: dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • ...

  • Page 941

    Automatic transmission/transaxle: 5a-73 dtc p2764 torque converter clutch (tcc) circuit low s5jb0a5104052 wiring diagram refer to “dtc p2763 torque converter clutch (tcc) circuit high: ”. Dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, sel...

  • Page 942

    5a-74 automatic transmission/transaxle: inspection of tcm and its circuits s5jb0a5104061 tcm and its circuits can be checked at tcm wiring connectors by measuring voltage, pulse signal and resistance. Caution ! Tcm cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmet...

  • Page 943

    Automatic transmission/transaxle: 5a-75 connector “e92” terminal wire color circuit standard voltage condition 1 blk/orn ground 0 – 1 v ignition switch on 2 brn/red pressure control solenoid valve (–) 0.6 – 1.0 v ignition switch on 3 ppl/wht tcc pressure control solenoid valve (–) 0.6 – 1.0 v igniti...

  • Page 944

    5a-76 automatic transmission/transaxle: connector “e93” terminal wire color circuit standard voltage condition 1 red transmission range sensor (“r” range) 8 – 14 v ignition switch on, selector lever at “r” range 0 – 1 v ignition switch on, selector lever at other than “r” range 2 — — — — 3 — — — — 4...

  • Page 945

    Automatic transmission/transaxle: 5a-77 reference waveform no. 1 pressure control solenoid valve signal at engine idling. Reference waveform no. 2 tcc pressure control solenoid valve signal at engine idling. Reference waveform no. 3 can communication line (high & low) signal at engine idling. Refere...

  • Page 946

    5a-78 automatic transmission/transaxle: reference waveform no. 5 input shaft speed sensor signal at engine speed 3000 rpm. Tcm power and ground circuit check s5jb0a5104062 wiring diagram measurement terminal ch1: “e93-6” to “e92-1” oscilloscope setting ch1: 2 v/div time: 10 ms/div measurement condit...

  • Page 947

    Automatic transmission/transaxle: 5a-79 troubleshooting step action yes no 1 check tcm back-up power circuit 1) disconnect tcm connector with ignition switch off. 2) check for proper connection to tcm at “e92-24” terminal. 3) if ok, check voltage at terminal “e92-24” of disconnected tcm connector. I...

  • Page 948

    5a-80 automatic transmission/transaxle: repair instructions a/t fluid level check s5jb0a5106041 at normal operating temperature 1) drive vehicle so that a/t fluid temperature reach the normal operating temperature (70 – 80 °c (158 – 176 °f)). 2) stop vehicle with engine running and place it level. 3...

  • Page 949

    Automatic transmission/transaxle: 5a-81 a/t fluid change s5jb0a5106042 1) lift up vehicle. 2) when engine is cool, remove drain plug (1) from oil pan and drain a/t fluid. 3) install drain plug with new gasket. Tightening torque a/t fluid drain plug (a): 20 n·m (2.0 kgf-m, 14.5 lb-ft) 4) lower vehicl...

  • Page 950

    5a-82 automatic transmission/transaxle: manual selector assembly removal and installation s5jb0a5106044 removal 1) disconnect negative cable at battery. 2) remove front console box. 3) disconnect shift lever switch connector. 4) remove manual selector assembly mounting bolts. 5) disconnect select ca...

  • Page 951

    Automatic transmission/transaxle: 5a-83 select cable component s5jb0a5106047 select cable adjustment s5jb0a5106048 1) loosen manual select cable nut. 2) shift select lever to “n”. 3) align center line (1) on manual shift shaft (2) to “n” reference line (3) as shown in figure. 4) tighten manual selec...

  • Page 952

    5a-84 automatic transmission/transaxle: transmission range sensor removal and installation s5jb0a5106049 removal 1) disconnect negative cable at battery. 2) hoist vehicle. 3) disconnect transmission range sensor connector (1). 4) disconnect select cable (2) from manual select lever (3). 5) remove ma...

  • Page 953

    Automatic transmission/transaxle: 5a-85 3) check that engine starts in “n” and “p” ranges but it doesn’t start in “d”, “3”, “2”, “l” or “r” range. Also, check that back-up lamp lights in “r” range. If faulty condition cannot be corrected by adjustment, disconnect transmission range sensor connector ...

  • Page 954

    5a-86 automatic transmission/transaxle: 4) pass and connect interlock cable as shown in the figure. 5) pull out lock button (1) of selector side cable end (2). 6) shift selector lever to “n” position. 7) install cable casing cap (3) to selector bracket (4). 8) connect cable end (1) to interlock cam ...

  • Page 955

    Automatic transmission/transaxle: 5a-87 brake and key interlock system inspection s5jb0a5106052 1) check that selector lever cannot be moved to any other range from “p” range position when ignition switch key is at acc position, at lock position or it is removed from keyhole of ignition switch, or b...

  • Page 956

    5a-88 automatic transmission/transaxle: mode select switch inspection s5jb0a5106053 1) pull out mode select switch from front center console box. 2) disconnect mode select switch connector. 3) check continuity between mode select switch terminals. Mode select switch specification input shaft speed s...

  • Page 957

    Automatic transmission/transaxle: 5a-89 output shaft speed sensor removal and installation s5jb0a5106056 removal 1) disconnect negative cable at battery. 2) hoist vehicle. 3) disconnect output shaft speed sensor connector. 4) remove output shaft speed sensor (1) from transmission. Installation 1) ch...

  • Page 958

    5a-90 automatic transmission/transaxle: oil cooler hose and pipe components s5jb0a5106058 oil cooler hose and pipes removal and installation s5jb0a5106059 removal 1) lift up vehicle. 2) make sure to wash dirt off from around pipe joints. 3) with engine is cool, loosen oil cooler pipe union bolts (2)...

  • Page 959

    Automatic transmission/transaxle: 5a-91 installation when replacing them, be sure to note the followings. • to replace clamps at the same time • to insert hose as far as its limit mark • to clamp hose securely 1) use new union gaskets and connect oil cooler pipes to oil outlet unions. 2) connect hos...

  • Page 960

    5a-92 automatic transmission/transaxle: solenoid valves (shift solenoid-a, shift solenoid-b, tcc pressure control solenoid and pressure control solenoid inspection s5jb0a5106061 solenoid valves (shift solenoid–a and shift solenoid–b) resistance check caution ! Be very careful as dust etc. Does not e...

  • Page 961

    Automatic transmission/transaxle: 5a-93 operation check check pressure control solenoid valves (pressure control solenoid and tcc pressure control solenoid) (1) operation in either of the following methods. [using regulated dc power supply] 1) connect pressure control solenoid valve (1) with regulat...

  • Page 962

    5a-94 automatic transmission/transaxle: 7) disconnect shift solenoid–a connector (1), shift solenoid–b connector (2), tcc pressure control solenoid connector (4) and pressure control solenoid connector (3). 8) remove solenoid valves. 9) after removing bolt (1) pull out transmission wire connector (2...

  • Page 963

    Automatic transmission/transaxle: 5a-95 transmission control module (tcm) removal and installation s5jb0a5106064 caution ! Tcm consists of highly precise parts, so when handling it, be careful not to expose it to excessive shock. Removal 1) disconnect negative cable at battery. 2) disable air bag sy...

  • Page 964

    5a-96 automatic transmission/transaxle: automatic transmission unit components s5jb0a5106065 22 (b) (b) (c) (c) (c) (c) (d) (e) (e) (e) (f) 32 17 16 9 14 13 9 (c) 9 15 8 7 4 3 5 6 10 11 12 18 19 25 26 11 23 24 21 20 27 (f) 28 (f) 29 (a) 2 (a) 1 30 (b) 31 (b) 32 33 a (a) 34 i5jb0a510003-01.

  • Page 965

    Automatic transmission/transaxle: 5a-97 automatic transmission assembly dismounting and remounting s5jb0a5106066 dismounting 1) dismount engine with transmission and transfer referring to “engine assembly removal and installation: for j20 engine in section 1d”. 2) disconnect connectors from output s...

  • Page 966

    5a-98 automatic transmission/transaxle: automatic transmission unit disassembly s5jb0a5106067 1) extract torque converter. And remove oil filler tube and dipstick. Caution ! Remove torque converter as much straight as possible. Leaning it may cause damage to oil seal lip. 2) remove input shaft speed...

  • Page 967

    Automatic transmission/transaxle: 5a-99 10) check dimensions of overdrive (o/d) case (1) surface and clutch cylinder (2) surface for reassembly. 11) remove overdrive (o/d) clutch assembly by holding input shaft (3). 12) remove o/d case, bearing and bearing race. Note confirm direction of bearing and...

  • Page 968

    5a-100 automatic transmission/transaxle: 18) remove accumulator pistons (1) by blowing air into holes (2) as shown in the figure. Note hold accumulator piston (1) with shop cloth while blowing. 19) place transmission (1) upright as shown in the figure. Note • to prevent transmission case from gettin...

  • Page 969

    Automatic transmission/transaxle: 5a-101 26) remove center support assembly (1). 27) remove retaining ring (1), planetary gear assembly leaf spring, bearing and bearing race. Note • use care not to cause damage to case when removing retaining ring. • confirm direction of bearing and bearing race for...

  • Page 970

    5a-102 automatic transmission/transaxle: 33) remove manual shift shaft and lever as follows. A) undo caulking of sleeve cover (1) by using flat end rod or the like and hammer. B) drive out manual shift lever pin (1) by using special tool and hammer. Special tool (a): 09922–89810 c) pull out manual s...

  • Page 971

    Automatic transmission/transaxle: 5a-103 oil pump components s5jb0a5106068 4 6 fld 2 1 fld 3 5 (a) i5jb0a510090-01 1. Oil pump body oil seal 4. Seal ring : 7.5 n ⋅m (0.75 kgf-m, 5.5 lb-ft) 2. Oil pump cover o-ring 5. Oil pump body : do not reuse. 3. Oil pump cover 6. Oil pump bolt : apply a/t fluid..

  • Page 972

    5a-104 automatic transmission/transaxle: oil pump disassembly and assembly s5jb0a5106069 disassembly 1) remove 6 bolts, oil pump cover (1), drive gear and driven gear in that order. 2) remove oil pump cover o-ring. 3) remove oil pump body oil seal (1) using special tool. Special tool (a): 09913–5012...

  • Page 973

    Automatic transmission/transaxle: 5a-105 • check tip clearance between inner gear (1) and outer gear. Tip clearance between inner gear and outer gear standard: 0.11 – 0.14 mm (0.0043 – 0.0055 in.) service limit: 0.30 mm (0.0118 in.) note measure with torque converter installed. • check side clearanc...

  • Page 974

    5a-106 automatic transmission/transaxle: overdrive (planetary gear side) components s5jb0a5106071 overdrive (planetary gear side) disassembly and assembly s5jb0a5106072 disassembly 1) with overdrive (o/d) clutch cylinder (1) held stationary, turn o/d input shaft (2) clockwise to check that it turns ...

  • Page 975

    Automatic transmission/transaxle: 5a-107 2) remove o/d planetary gear assembly (1). 3) with o/d clutch assembly (2) installed to oil pump, apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole (3) in oil pump (1) and measure stroke of clutch piston. If it is not within stand...

  • Page 976

    5a-108 automatic transmission/transaxle: assembly assemble each component by reversing removal procedure and noting the following points. • when installing thrust washer (1), bring its oil groove (3) to the front. • when installing one-way clutch to one-way clutch outer race, bring its flange (2) to...

  • Page 977

    Automatic transmission/transaxle: 5a-109 • measure free length of piston return spring. Standard free length of o/d clutch piston return spring 16.9 mm (0.665 in.) • measure inside diameter of planetary gear bushing. If inside diameter exceeds limit, replace planetary gear. Planetary gear bushing in...

  • Page 978

    5a-110 automatic transmission/transaxle: overdrive (case side) disassembly and assembly s5jb0a5106075 disassembly 1) remove retaining ring (1), brake backing plate (2), brake disc (3) and brake plate (4) in that order. Then remove planetary ring gear, thrust bearing race and thrust bearing. 2) remov...

  • Page 979

    Automatic transmission/transaxle: 5a-111 assembly install each component by reversing removal procedure and noting the following points. • when installing rear seal ring, use care not to open it too wide. • apply a/t fluid to o-ring, disc, etc. Before installing them. • opening of retaining brake fr...

  • Page 980

    5a-112 automatic transmission/transaxle: forward clutch components s5jb0a5106077 forward clutch disassembly and assembly s5jb0a5106078 disassembly 1) after removing retaining ring (1), remove direct clutch hub (2) and forward clutch hub (3). 2) remove bearing race (1) and thrust bearing (2). 3) remo...

  • Page 981

    Automatic transmission/transaxle: 5a-113 4) using special tool and hydraulic press, compress forward clutch piston return spring and remove retaining return spring. Special tool (a): 09926–98310 caution ! Be careful when applying pressure, for overpressure will cause plate section of piston return s...

  • Page 982

    5a-114 automatic transmission/transaxle: 4) install forward clutch hub (3), direct clutch hub (2) and retaining ring (1) in that order. 5) install forward clutch (2) to o/d case (1). Apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole at the right of cut in o/d case and me...

  • Page 983

    Automatic transmission/transaxle: 5a-115 direct clutch components s5jb0a5106080 direct clutch disassembly and assembly s5jb0a5106081 disassembly 1) remove direct clutch assembly from center support and then remove retaining ring. 2) remove clutch backing plate (1) and then remove clutch disc (3) and...

  • Page 984

    5a-116 automatic transmission/transaxle: 3) using special tool and hydraulic press (1), compress direct clutch piston return spring (3) and remove retaining return spring ring (2). Special tool (a): 09926–98310 caution ! Be careful when applying pressure, for overpressure will cause plate section of...

  • Page 985

    Automatic transmission/transaxle: 5a-117 • install direct clutch assembly (1) to center support (2) and with compressed air (400 – 800 kpa, 4 – 8 kg/ cm 2 , 57 – 113 psi) applied to oil hole (3), measure stroke of direct clutch piston as shown in the figure. If it is not within standard range, selec...

  • Page 986

    5a-118 automatic transmission/transaxle: center support components s5jb0a5106083 1 3 4 5 8 11 4 5 9 15 14 9 9 2 fld 2 fld 10 fld 10 fld 6 fld 7 fld 13 fld 12 fld i5jb0a510116-01 1. Center support 6. Second coast brake plate 11. Second brake piston : do not reuse. 2. O-ring 7. Second coast brake disc...

  • Page 987

    Automatic transmission/transaxle: 5a-119 center support disassembly and assembly s5jb0a5106084 disassembly 1) remove retaining ring. Special tool (a): 09920–76010 2) pull out center support assembly (2) from planetary sun gear (1). 3) apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi...

  • Page 988

    5a-120 automatic transmission/transaxle: 8) apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole at the extreme left and remove second coast brake piston as shown in the figure. Then remove piston inner o-ring and piston outer o-ring from second coast brake piston. 9) remov...

  • Page 989

    Automatic transmission/transaxle: 5a-121 14) blow air into the second air hole from the left and remove second brake piston. Then remove piston inner o-ring and piston outer o-ring from second brake piston. 15) with second brake hub assembly (3) held stationary, turn planetary sun gear (4) clockwise...

  • Page 990

    5a-122 automatic transmission/transaxle: • when installing brake discs, brake plates and clutch backing plate, refer to “center support components: ”. • install clutch backing plate (1) with its flat side facing brake disc. • after installing each retaining backing plate ring, measure movement of br...

  • Page 991

    Automatic transmission/transaxle: 5a-123 planetary gears and output shaft components s5jb0a5106085 9 4 5 3 2 2 11 10 13 2 12 18 14 16 15 16 14 2 17 1 10 6 18 fld 8 fld 7 fld i5jb0a510125-01 1. Inner shaft 6. Front planetary gear 11. Front planetary ring gear 16. Bearing race 2. Retaining ring 7. Rev...

  • Page 992

    5a-124 automatic transmission/transaxle: planetary gears and output shaft disassembly and assembly s5jb0a5106086 disassembly 1) remove front planetary gear assembly (1) from output shaft assembly (2). 2) remove rear planetary thrust washer (1), reverse brake backing plate (2), reverse brake disc (3)...

  • Page 993

    Automatic transmission/transaxle: 5a-125 note a is longer than b. • fit retaining rings into groove securely. • install one-way clutch as shown in the figure. • install reverse brake reaction plate (2) to front planetary gear (1). With reverse brake reaction plate (2) fixed stationary, turn front pl...

  • Page 994

    5a-126 automatic transmission/transaxle: valve body assembly components s5jb0a5106087 automatic transmission unit assembly s5jb0a5106088 caution ! When replacing pressure control solenoid valve and/or tcc pressure control solenoid valve, it is strictly required to replace it together with valve body...

  • Page 995

    Automatic transmission/transaxle: 5a-127 3) measure free length of reverse brake piston return spring. Standard free length of reverse brake piston return spring 16.84 mm (0.663 in.) 4) install reverse brake piston assembly and brake piston return spring to transmission case, using care not to damag...

  • Page 996

    5a-128 automatic transmission/transaxle: 9) remove reverse brake reaction plate of planetary gear assembly and align lugs of reverse brake plate, reverse brake disc and reverse brake backing plate. Install planetary gear assembly to transmission case so that aligned lugs fit in groove in transmissio...

  • Page 997

    Automatic transmission/transaxle: 5a-129 13) after confirming that lugs of all brake plates and brake discs are in grooves securely, hold retaining ring (1) of planetary sun gear, install center support assembly by aligning bolt holes (2) in center support and transmission case. Note unless retainin...

  • Page 998

    5a-130 automatic transmission/transaxle: 18) when clutch disc and plate have been replaced, check height difference between forward clutch input shaft and transmission case (1) by measuring as shown in the figure. Note if measured value is less than standard value, remove forward clutch assembly and...

  • Page 999

    Automatic transmission/transaxle: 5a-131 23) apply a/t fluid to new housing o-ring and install it to o/d case. Then install converter housing (1) and tighten housing bolt to specified torque. Tightening torque torque converter housing bolt (a): 35 n·m (3.5 kgf-m, 25.5 lb-ft) torque converter housing...

  • Page 1000

    5a-132 automatic transmission/transaxle: 29) check that inner shaft runs smoothly. 30) apply grease to lip of new oil lip seal and drive in oil lip seal with special tool till it contacts transmission case. Special tool (a): 09923–46020 31) install a new spacer (1) to manual shift lever (2). 32) ins...

  • Page 1001

    Automatic transmission/transaxle: 5a-133 38) apply a/t fluid to new o-ring and spring and install them to accumulator piston and install accumulator piston to transmission case. Accumulator spring specification 39) after confirming that accumulator piston is pushed all the way down, match pin of man...

  • Page 1002

    5a-134 automatic transmission/transaxle: 43) connect solenoid coupler to each solenoid. 44) install oil strainer (1) to valve body assembly. Tightening torque oil strainer bolt (a): 5.5 n·m (0.55 kgf-m, 4.0 lb- ft) 45) install transmission oil pan (1) with new oil pan gasket. Note align cutout in oi...

  • Page 1003

    Automatic transmission/transaxle: 5a-135 51) confirm that torque converter is fully fitted in transmission. Confirmation can be done by measuring dimension between end surface of housing case (2) and drive plate installation seat. Standard dimension between end surface of case housing and drive plat...

  • Page 1004

    5a-136 automatic transmission/transaxle: special tools and equipment recommended service material s5jb0a5108001 note required service material is also described in the following. “oil pump components: ” “overdrive (planetary gear side) components: ” “overdrive (case side) components: ” “forward clut...

  • Page 1005

    Automatic transmission/transaxle: 5a-137 09926–98320 09926–98390 spring compressor no. 1 set remover ) / ) / ) ) / ) 09927–66520 09944–88210 oil pump remover bearing housing installer ) ) / ) suzuki scan tool — this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 ...

  • Page 1006

    5b-1 manual transmission/transaxle: manual transmission/transaxle general description manual transmission construction s5jb0a5201001 the manual transmission consists of the input shaft, output shaft, countershaft and reverse idle gear shaft which are installed in the die-cast aluminum alloy case. Th...

  • Page 1007

    Manual transmission/transaxle: 5b-2 diagnostic information and procedures manual transmission symptom diagnosis s5jb0a5204001 condition possible cause correction / reference item gear slipping out of mesh worn shift fork shaft replace. Worn shift fork or synchronizer sleeve replace. Weak or damaged ...

  • Page 1008

    5b-3 manual transmission/transaxle: repair instructions manual transmission assembly components s5jb0a5206001 6 9 19 20 21 10 18 5 a 3 8 4 27 oil 1217g 1217g 2 1 24 1322 23 22 25 26 17 16 15 12 11 28 29 13 14 a 30 31 32 33 7 1217g oil 1217g (a) (a) (a) (a) (a) (a) (a) (b) 34 (c) 34 (c) 34 (c) 35 (c)...

  • Page 1009

    Manual transmission/transaxle: 5b-4 1. Transmission front case : apply sealant 99000-31260 to mating surface of front case and rear case. 16. Reverse gear shift lever 31. 5th speed synchronizer ring 2. Transmission rear case : apply sealant 99000-31260 to mating surface of rear case and adapter case...

  • Page 1010

    5b-5 manual transmission/transaxle: gear shift control lever rear case assembly components s5jb0a5206002 2 10 11 16 6 13 15 3 4 5 12 7 (a) 14 (d) (c) 8 (b) 1 17 (b) 9 (c) 7 (a) i5jb0a520019-08 1. Gear shift control lever knob 9. Gear shift lever rear case bolt 17. Gear shift lever case cover bolt 2....

  • Page 1011

    Manual transmission/transaxle: 5b-6 gear shift lever front case assembly components s5jb0a5206026 17 1322 15 16 3 4 5 18 16 2 14 13 oil 1 oil a a 12 6 7 11 10 a 9 8 (a) (a) i5jb0a520001-02 1. Gear shift shaft 8. Gear shift locating retainer 15. Gear shift lever front case bolt 2. Gear shift lever fr...

  • Page 1012

    5b-7 manual transmission/transaxle: gear shift shaft and fork components s5jb0a5206027 1322 5 6 7 a a 6 4 7 a a 6 7 a a 6 7 a a 1 2 3 8 8 8 (a) 1322 5 (a) 1322 5 (a) 1322 5 (a) i5jb0a520002-02 1. Low speed gear shift shaft 4. Low speed gear shift fork 7. Gear shift shaft ball : apply grease 99000-25...

  • Page 1013

    Manual transmission/transaxle: 5b-8 input shaft assembly, output shaft assembly and countershaft assembly components s5jb0a5206003 6 4 3 2 18 24 25 34 35 37 36 26 27 28 30 31 29 32 33 30 29 19 20 21 22 5 1 7 9 8 10 11 12 9 8 13 14 17 23 [a] [b] [c] oil 15 16 oil oil oil (a) (a) 38 39 40 i5jb0a520003...

  • Page 1014

    5b-9 manual transmission/transaxle: manual transmission oil change s5jb0a5206004 1) before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) with vehicle lifted up, check oil level and leakage. If leakage exists, correct or repair it. Note whenever vehicle is hoist...

  • Page 1015

    Manual transmission/transaxle: 5b-10 transmission shift control lever removal and installation s5jb0a5206005 removal 1) remove front console box referring to “console box components: in section 9h”. 2) lift up boot cover (1), boot (2) and sheet (3). 3) remove case cover (4) and take out shift contro...

  • Page 1016

    5b-11 manual transmission/transaxle: back up light switch removal and installation s5jb0a5206007 removal warning ! Refrain from work while exhaust no.2 pipe is hot. Note • when replacing switch, use care not to let dust enter transmission through switch hole. 1) hoist vehicle and disconnect connecto...

  • Page 1017

    Manual transmission/transaxle: 5b-12 installation 1) install gear shift control lever rear case assembly with its plate to transfer case referring to figure for proper installing direction of control shaft joint bolt (2). Tighten plate bolts (1) and control shaft joint nut (3) to specified torque. T...

  • Page 1018

    5b-13 manual transmission/transaxle: 1) clean mating surface of both rear case and gear shift lever front case (2), and uniformly apply sealant to lever case as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter, and then mate it with gear shift lever front case. “a”: ...

  • Page 1019

    Manual transmission/transaxle: 5b-14 2) assemble components parts referring to “gear shift lever front case assembly components: ”. 3) set new gear shift arm inner pin (1) and outer pin (2) facing each gap (“a”, “b”) as shown in figure. Drive gear shift arm pins by using special tool, till the lengt...

  • Page 1020

    5b-15 manual transmission/transaxle: 5) disconnect clutch fluid joint from pipe of clutch operating cylinder assembly referring to “clutch operating cylinder assembly removal and installation: in section 5c”. 6) hoist vehicle. 7) drain oil from transmission and transfer. 8) remove propeller shafts r...

  • Page 1021

    Manual transmission/transaxle: 5b-16 remounting for remounting, reverse dismounting procedure. • apply grease to input shaft. “a”: grease 99000–25010 (suzuki super grease a) • slant the rear of the engine down, using support device (1) and install transmission to engine. • use specified torques as g...

  • Page 1022

    5b-17 manual transmission/transaxle: manual transmission unit disassembly s5jb0a5206012 1) remove clutch operating cylinder assembly from transmission front case referring to “clutch operating cylinder assembly removal and installation: in section 5c” 2) remove gear shift control lever rear cause as...

  • Page 1023

    Manual transmission/transaxle: 5b-18 15) remove input shaft assembly (1), countershaft assembly (2), high speed gear shift fork (3) and low speed gear shift fork (4) as assembly from front case (5) tapping input shaft end by plastic hammer lightly. Manual transmission unit reassembly s5jb0a5206013 1...

  • Page 1024

    5b-19 manual transmission/transaxle: 6) install oil gutter. 7) install 5th speed synchronizer levers and 5th speed synchronizer ring as follows. A) fit 5th speed synchronizer levers (1) to hub (2) aligning protrusion “a” of 5th speed synchronizer levers with groove of hub. B) install synchronizer ri...

  • Page 1025

    Manual transmission/transaxle: 5b-20 14) install output shaft assembly into rear case. 15) select a countershaft shim and output shaft shim as follows. A) measure depth “a” from mating surface of adapter case (1) to face processed for installation of countershaft rear bearing (2) and measure depth “...

  • Page 1026

    5b-21 manual transmission/transaxle: 18) install rear case to adapter case. Tighten case bolts (2) to specified torque. Tightening torque adapter case bolt (a): 23 n·m (2.3 kgf-m, 17.0 lb- ft) 19) install transfer assembly to transmission assembly. Tighten transfer fastening bolts to specified torqu...

  • Page 1027

    Manual transmission/transaxle: 5b-22 input shaft inspection s5jb0a5206017 • check clearance “a” between synchronizer ring (2) and gear (1), key slot width “b” in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth. C...

  • Page 1028

    5b-23 manual transmission/transaxle: • using cylinder gauge (1), check inside diameter of each gear. If its inside diameter exceeds specification, replace it. Inside diameter (standard) of gear 3rd and 4th gear: 40.000 – 40.025 mm (1.5748 – 1.5757 in.) • check chamfered part of each sleeve for damag...

  • Page 1029

    Manual transmission/transaxle: 5b-24 6) drive in high speed synchronizer assembly (1) using special tool and hammer. Note • while press-fitting sleeve & hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly. • check free rotation of 4th gear after press f...

  • Page 1030

    5b-25 manual transmission/transaxle: 12) caulk input shaft 5th hub nut (2) using caulking tool. 13) drive in new input shaft union (1) using puller and hydraulic press. Countershaft disassembly and assembly s5jb0a5206019 disassembly 1) remove countershaft rear bearing (1) using bearing puller, metal...

  • Page 1031

    Manual transmission/transaxle: 5b-26 assembly 1) clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary. 2) to ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction. 3) drive in countershaft rear bearing (1)...

  • Page 1032

    5b-27 manual transmission/transaxle: 7) check 2nd gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part. 2nd gear thrust clearance “a”: 0.10 – 0.25 mm (0.004 – 0.010 in.) 8) apply oil to countershaft gear needle bearing, and t...

  • Page 1033

    Manual transmission/transaxle: 5b-28 countershaft and reverse idle gear inspection s5jb0a5206020 • using micrometer, check diameter of countershaft (1) and needle bush (2) as shown. If measured value is out of specification, replace counter and/or bush. Countershaft diameter (standard) • measure wid...

  • Page 1034

    5b-29 manual transmission/transaxle: • check oil clearance between reverse idle gear (2) and shaft (1) measuring inside diameter “a” of gear and diameter “b” of shaft and calculate as follows: if clearance exceeds limit, replace gear and shaft. Oil clearance “c” between reverse idle gear and shaft s...

  • Page 1035

    Manual transmission/transaxle: 5b-30 manual transmission front case disassembly and assembly s5jb0a5206022 disassembly remove pump seal (1) and oil seal (2) from front case using special tools. Special tool (a): 09941–64511 (b): 09930–30104 assembly 1) set new oil seal to front case with its spring ...

  • Page 1036

    5b-31 manual transmission/transaxle: specifications tightening torque specifications s5jb0a5207001 note the specified tightening torque is also described in the following. “manual transmission assembly components: ” “gear shift control lever rear case assembly components: ” “gear shift lever front c...

  • Page 1037

    Manual transmission/transaxle: 5b-32 special tools and equipment recommended service material s5jb0a5208001 note required service material is also described in the following. “manual transmission assembly components: ” “gear shift control lever rear case assembly components: ” “gear shift lever fron...

  • Page 1038

    5b-33 manual transmission/transaxle: 09941–64511 bearing and oil seal remover (30 mm min.) ).

  • Page 1039: Clutch

    Clutch: 5c-1 clutch general description clutch (hydraulic type) construction s5jb0a5301001 the clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing...

  • Page 1040

    5c-2 clutch: component location clutch fluid pipe and hose location s5jb0a5303001 diagnostic information and procedures clutch (hydraulic type) symptom diagnosis s5jb0a5304001 1 1 2 2 2 3 4 5 5 6 6 7 [a] i5jb0a530002-02 [a]: right-hand steering vehicle 3. Clutch fluid hose 6. Brake master cylinder r...

  • Page 1041

    Clutch: 5c-3 clutch pedal height inspection s5jb0a5304002 measure clutch pedal height “a” from brake pedal (2). If pedal height is excessive low or high, check installation position of clutch position switch, clutch fluid leakage, bending of clutch pedal arm and bending of push rod of clutch master ...

  • Page 1042

    5c-4 clutch: repair instructions clutch pedal position (cpp) switch removal and installation s5jb0a5306001 removal 1) disconnect connector of cpp switch (1) with ignition switch off. 2) remove cpp switch (1) from pedal bracket. Installation 1) instal cpp switch to pedal bracket. 2) adjust switch pos...

  • Page 1043

    Clutch: 5c-5 4) disconnect fluid pipe (1) from hose (2). Note to disconnect pipe (1) from hose (2), separate them by using flare nut wrench (4) and spanner (3) so as not to kink them. 5) pull clamp (1) of fluid pipe joint (2) and disconnect fluid hose (3). Installation reverse removal sequence notin...

  • Page 1044

    5c-6 clutch: installation reverse removal procedure for installation noting the following. • apply grease to push rod clevis pin (1). “a”: grease 99000–25100 (suzuki silicone grease) • tighten master cylinder attaching nuts (2) to specified torque. Tightening torque clutch master cylinder attaching ...

  • Page 1045

    Clutch: 5c-7 installation 1) install clutch operating cylinder assembly (2) to transmission front case. Tighten mounting bolts to specified torque. Tightening torque clutch operating cylinder assembly mounting bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) 2) connect clutch fluid pipe (4) to clutch operati...

  • Page 1046

    5c-8 clutch: clutch cover, clutch disc and flywheel removal and installation s5jb0a5306012 removal 1) dismount transmission assembly referring to “manual transmission assembly dismounting and remounting: in section 5b”. 2) hold flywheel stationary with special tool and remove clutch cover bolts (1),...

  • Page 1047

    Clutch: 5c-9 3) aligning clutch disc to flywheel center by 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 by hand so that disc centered. • tighten cover bolts little b...

  • Page 1048

    5c-10 clutch: specifications tightening torque specifications s5jb0a5307001 note the specified tightening torque is also described in the following. “clutch cover, clutch disc and flywheel components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fastene...

  • Page 1049: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions for steering ....................................... 6-1 steering general diagnosis.............

  • Page 1050

    6-ii table of contents steering gear case mount bushing removal and installation.................................6c-14 steering gear case mount bushing inspection........................................................6c-14 rack boot / tie-rod removal and installation...................................

  • Page 1051: Precautions

    Precautions: 6-1 precautions precautions precautions for steering s5jb0a6000001 air bag warning refer to “air bag warning: in section 00”. Fastener caution refer to “fastener caution: in section 00”. Service precautions of air bag steering wheel and column refer to “service precautions of air bag st...

  • Page 1052: Steering General Diagnosis

    6a-1 steering general diagnosis: steering general diagnosis diagnostic information and procedures steering symptom diagnosis s5jb0a6104001 since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road te...

  • Page 1053: Steering Wheel and Column

    Steering wheel and column: 6b-1 steering wheel and column precautions service precautions of air bag steering wheel and column s5jb0a6200001 for service precautions, refer to “precautions on service and diagnosis of air bag system: in section 8b”. Handling and storage of air bag steering wheel and c...

  • Page 1054

    6b-2 steering wheel and column: 16 10 (b) 17 (b) 9 8 4 6 7 15 (c) 14 (c) 12 (b) 2 (a) 5 1 11 (b) 13 3 i5jb0a620001-03 1. Steering wheel 8. Steering upper shaft assembly 15. Steering upper shaft mounting bolt 2. Steering shaft nut 9. Steering column lower seal 16. Steering lower shaft assembly lower ...

  • Page 1055

    Steering wheel and column: 6b-3 diagnostic information and procedures air bag steering wheel and column symptom diagnosis s5jb0a6204001 for diagnosis of the steering wheel and steering column, refer to “steering symptom diagnosis: in section 6a”. For diagnosis of the air bag system, refer to “air ba...

  • Page 1056

    6b-4 steering wheel and column: • check steering upper shaft assembly for following conditions. – steering upper shaft assembly (1) is not bent or damaged. – lower seal (2) is not damaged. – upper joint (3) turns with light hand force and lower joint (4) turns at the same time. – shaft (1) expands a...

  • Page 1057

    Steering wheel and column: 6b-5 5) remove steering wheel (1) with special tool. Caution ! Do not hammer the end of the shaft. Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column. Special tool (a): 09944–36011 installation 1...

  • Page 1058

    6b-6 steering wheel and column: 3) remove steering column cover screws (1) (3 pieces). 4) separate upper cover (2) and lower cover (3), then remove them. 5) disconnect all connectors for contact coil cable assembly. 6) remove contact coil cable assembly (1) from steering column. Installation 1) chec...

  • Page 1059

    Steering wheel and column: 6b-7 contact coil cable assembly inspection s5jb0a6206014 caution ! Do not turn contact coil cable assembly more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively), or coil will break. Check conta...

  • Page 1060

    6b-8 steering wheel and column: removal warning ! Never rest a steering column assembly on the steering wheel with air bag (inflator) module face down and column vertical. Otherwise personal injury may result. Caution ! Never turn steering wheel while steering column with steering wheel is removed. ...

  • Page 1061

    Steering wheel and column: 6b-9 installation caution ! After tightening steering column assembly mounting bolts and nuts, steering shaft joint bolts should be tightened. 1) be sure that front wheels and steering wheel are in straight-ahead position. 2) align flat part “a” of steering upper shaft upp...

  • Page 1062

    6b-10 steering wheel and column: 12) install instrument panel under cover (1) to instrument panel. 13) install steering column hole cover (1). 14) if steering wheel is removed, install it by referring to “steering wheel removal and installation: ”. 15) connect negative (–) cable to battery. 16) afte...

  • Page 1063

    Steering wheel and column: 6b-11 steering lock assembly (ignition switch) removal and installation s5jb0a6206008 removal 1) remove steering column assembly. Refer to “steering column assembly removal and installation: ”. 2) using center punch (with sharp point) (1) as shown in the figure, loosen and...

  • Page 1064

    6b-12 steering wheel and column: removal 1) turn steering wheel so that vehicle’s front tires are at straight-ahead position. 2) turn ignition switch to lock position and remove key. 3) remove steering column assembly from vehicle referring to “steering column assembly removal and installation: ”. 4...

  • Page 1065

    Steering wheel and column: 6b-13 steering lower shaft assembly removal and installation s5jb0a6206012 caution ! Never turn steering wheel while steering lower shaft assembly is removed. Should it have been turned and contact coil cable assembly have got out of its centered position, it needs to be c...

  • Page 1066

    6b-14 steering wheel and column: specifications tightening torque specifications s5jb0a6207001 note the specified tightening torque is also described in the following. “steering wheel and column construction: ” reference: for the tightening torque of fastener not specified in this section, refer to ...

  • Page 1067

    Power assisted steering system: 6c-1 power assisted steering system precautions p/s system note s5jb0a6300001 note • some parts in the power steering gear case cannot be disassembled or adjusted. For detailed information, refer to the description of “steering gear case construction: ”. • all steerin...

  • Page 1068

    6c-2 power assisted steering system: steering gear case construction s5jb0a6301002 the steering gear case consists of two sections: one including a cylinder and the other a valve. Main components of the cylinder section are a gear case (7), a rack (8) and a tube and those of the valve section are a ...

  • Page 1069

    Power assisted steering system: 6c-3 schematic and routing diagram p/s fluid flow diagram s5jb0a6302001 diagnostic information and procedures p/s system symptom diagnosis s5jb0a6304001 iysq01630002-01 1. Power steering pump 3. P/s fluid reservoir 5. Pinion 2. Valve section 4. Rack 6. Cylinder condit...

  • Page 1070

    6c-4 power assisted steering system: steering wheel check s5jb0a6304002 • check steering wheel for looseness or rattle by trying to move it in its shaft direction and lateral direction. If found defective, repair or replace. • check steering wheel for play, holding car in straight forward condition ...

  • Page 1071

    Power assisted steering system: 6c-5 steering force check s5jb0a6304003 1) place vehicle on level road and set steering wheel at straight-ahead position. 2) check that tire inflation pressure is as specified. (refer to tire placard.) 3) start engine and keep it running till power steering fluid is w...

  • Page 1072

    6c-6 power assisted steering system: 2) check each connection for fluid leakage and bleed air. Refer to “p/s system air bleeding procedure: ”. 3) with engine idling, turn steering wheel and warm up engine till temperature of fluid in tank rises to 50 – 60 °c (122 – 140 °f). 4) check back pressure by...

  • Page 1073

    Power assisted steering system: 6c-7 repair instructions p/s fluid change s5jb0a6306016 caution ! Do not use any fluid other than the specified p/s fluid. Use of any fluid other than the specified p/s fluid may cause juddering or some other faulty condition to occur. 1) lift up vehicle. 2) remove fr...

  • Page 1074

    6c-8 power assisted steering system: p/s fluid leakage check s5jb0a6306002 start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided. Then visually check p/s gear case assembly (1), p/s pump (2) and p/s fluid reservoir (3) themselves and each joi...

  • Page 1075

    Power assisted steering system: 6c-9 p/s pump and a/c compressor (if equipped) drive belt inspection and adjustment for m16 engine model s5jb0a6306004 inspection • check that belt is free from any damage and properly fitted in pulley groove. • check belt tension by measuring how much it deflects whe...

  • Page 1076

    6c-10 power assisted steering system: p/s pump and a/c compressor (if equipped) drive belt removal and installation for j20 engine model s5jb0a6306019 refer to “water pump and generator drive belt removal and installation (for j20 engine): in section 1j”. Steering rack boot check s5jb0a6306005 • che...

  • Page 1077

    Power assisted steering system: 6c-11 installation 1) install tie-rod end lock nut (3) and tie-rod end (4) to tie-rod (1). Tighten lock nut (3) to mark (2) on tie-rod thread. 2) install tie-rod end (4) to knuckle (5). Tighten new tie- rod end nut (6) to specified torque. Tightening torque tie-rod en...

  • Page 1078

    6c-12 power assisted steering system: p/s gear case assembly components s5jb0a6306020 7 8 (b) 8 (b) 6 (d) 6 (d) 4 3 5 5 2 (c) 7 4 3 10 [a] (a) 10 (a) 9 (e) 1 1 10 (a) 10 (a) [b] 2 (c) 11 11 11 11 i5jb0a630016-06 [a]: lh steering vehicle 6. Tie-rod end lock nut : 43 n ⋅m (4.3 kgf-m, 31.0 lb-ft) [b]: ...

  • Page 1079

    Power assisted steering system: 6c-13 p/s gear case assembly removal and installation s5jb0a6306009 caution ! Never disassemble p/s gear case assembly. Disassembling will adversely affect original performance of p/s gear case assembly. Removal 1) disconnect negative (–) cable at battery. 2) take out...

  • Page 1080

    6c-14 power assisted steering system: tightening torque steering lower shaft bolt: 25 n·m (2.5 kgf-m, 18.5 lb-ft) gear case high pressure pipe union bolt: 35 n·m (3.5 kgf-m, 25.5 lb-ft) gear case cylinder pipe flare nut: 25 n·m (2.5 kgf- m, 18.0 lb-ft) gear case mounting bolt: 105 n·m (10.5 kgf-m, 7...

  • Page 1081

    Power assisted steering system: 6c-15 rack boot / tie-rod removal and installation s5jb0a6306010 removal 1) remove p/s gear case assembly, referring to “p/s gear case assembly removal and installation: ”. 2) for ease of adjustment after installation, make marking (4) of tie-rod end lock nut position...

  • Page 1082

    6c-16 power assisted steering system: p/s hose / pipe components s5jb0a6306011 [a] [b] 7 1 6 4 2 11 9 3 5 6 6 (b) 13 13 13 1 10 (a) 15 (a) 14 (a) (c) 10 (c) 12 (c) 12 (c) 13 16 16 7 5 2 16 16 3 6 4 9 6 6 11 (a) 15 (a) 14 (a) (b) i5jb0a630024-04.

  • Page 1083

    Power assisted steering system: 6c-17 [c] [d] 9 (b) 13 5 2 16 16 1 4 3 6 7 11 (a) (c) 13 6 6 12 (c) 9 10 (b) 13 16 16 12 6 (c) 10 (c) 6 4 5 11 (a) 2 7 1 3 6 i5jb0a630025-04 [a]: m16 engine lh steering vehicle 5. Suction hose 13. Washer [b]: m16 engine rh steering vehicle 6. Low pressure return hose ...

  • Page 1084

    6c-18 power assisted steering system: p/s pump removal and installation for m16 engine model s5jb0a6306012 removal note be sure to clean each joint of suction and discharge sides thoroughly before removal. 1) disconnect negative (–) cable at battery. 2) take out p/s fluid in reservoir with syringe o...

  • Page 1085

    Power assisted steering system: 6c-19 6) remove water pump and generator drive belt referring to “water pump and generator drive belt removal and installation (for j20 engine): in section 1j”. 7) remove p/s pump mounting bolts (1) and then remove p/s pump. Note plug each port of removed pump to prev...

  • Page 1086

    6c-20 power assisted steering system: p/s pump assembly components for j20 engine model s5jb0a6306022 p/s pump disassembly and assembly for m16 engine model s5jb0a6306013 disassembly 1) clean its exterior thoroughly. 2) with aluminum plates placed on vise first, grip pump body (15) with it. 3) remov...

  • Page 1087

    Power assisted steering system: 6c-21 4) apply power steering fluid to sliding surface of rotor (1). 5) install rotor (1) to shaft, directing dot (3) marked side of rotor facing up. 6) install new snap ring (2) to shaft, then make sure to fit snap into shaft groove securely. Note never reuse the rem...

  • Page 1088

    6c-22 power assisted steering system: 18) apply power steering fluid to relief valve (flow control valve). 19) install relief valve (flow control valve) to pump body. 20) install flow control spring. 21) apply power steering fluid to o-rings of plug. 22) install o-rings to plug. 23) tighten plug to ...

  • Page 1089

    Power assisted steering system: 6c-23 relief valve (flow control valve) and its spring • check fluid passage of relief valve and orifice of connector for obstruction (clogged). • check sliding surface of relief valve for wear and damage. • check free length of relief valve spring (1). Replace if any...

  • Page 1090

    6c-24 power assisted steering system: special tools and equipment recommended service material s5jb0a6308001 note required service material is also described in the following. “p/s gear case assembly components: ” special tool s5jb0a6308002 material suzuki recommended product or specification note g...

  • Page 1091: Section 7

    Table of contents 7- i 7 section 7 contents hvac precautions .................................................7-1 precautions............................................................. 7-1 precautions for hvac........................................... 7-1 heater and ventilation......................

  • Page 1092

    7-ii table of contents diagnostic information and procedures..........7b-11 air conditioning system check.........................7b-11 dtc check........................................................7b-13 dtc clearance .................................................7b-14 dtc table..................

  • Page 1093

    Table of contents 7-iii magnet clutch operating check for j20 engine model .................................................. 7b-76 magnet clutch removal and installation for m16 engine model ..........................................7b-77 magnet clutch removal and installation for j20 engine model ...

  • Page 1094: Precautions

    7-1 precautions: precautions precautions precautions for hvac s5jb0a7000001 air bag warning refer to “air bag warning: in section 00”. A/c system caution refer to “a/c system caution: in section 00”. Precautions on servicing a/c system refer to “precautions on servicing a/c system: in section 7b”. P...

  • Page 1095: Heater and Ventilation

    Heater and ventilation: 7a-1 heater and ventilation general description heater and ventilation construction s5jb0a7101001 the heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator ...

  • Page 1096

    7a-2 heater and ventilation: body ventilation construction s5jb0a7101002 the body ventilation system of this vehicle has a fresh air intake (1) located at the cowl top panel. When fresh air intake air selector is at fre position (fresh), ventilating air is drawn into the interior from the cowl cente...

  • Page 1097

    Heater and ventilation: 7a-3 hvac control system description (for vehicle without a/c) s5jb0a7101005 for can communication system, refer to description on “can communication system description: in section 1a”. When following data are sent from control modules to bcm through can communication, they a...

  • Page 1098

    7a-4 heater and ventilation: electronic components location for heater (for vehicle without a/c) s5jb0a7102002 note the figure shows left-hand steering vehicle. For right hand steering vehicle, parts with (*) are installed at the opposite side. 2 3 1* 4* 5* 18 6 17 19 8 15 16 10 9 14 7 11 12 13 i5jb...

  • Page 1099

    Heater and ventilation: 7a-5 diagnostic information and procedures heater and ventilation system check s5jb0a7104009 step action yes no 1 ) customer complaint analysis 1) perform “customer complaint analysis”. Was customer complaint analysis performed? Go to step 2. Perform customer complaint analys...

  • Page 1100

    7a-6 heater and ventilation: description for each step step 1. Customer complaint analysis talk to customer, and then record details of the problem. Customer questionnaire (example) note the form is a standard sample. It should be modified according to conditions characteristic of each market. Step ...

  • Page 1101

    Heater and ventilation: 7a-7 visual inspection s5jb0a7104007 check visually the following parts and systems. Dtc check s5jb0a7104002 dtc check is the same as vehicle equipped with a/c system. Refer to “dtc check: in section 7b”. Dtc clearance s5jb0a7104003 dtc clearance is the same as vehicle equipp...

  • Page 1102

    7a-8 heater and ventilation: heater and ventilation symptom diagnosis s5jb0a7104001 condition possible cause correction / reference item blower won’t work even when blower speed selector is on blower fuse blown replace fuse to check for short. Blower motor faulty check blower motor referring to “blo...

  • Page 1103

    Heater and ventilation: 7a-9 repair instructions blower unit and heater unit components s5jb0a7106001 as heater unit and blower unit are incorporated as an assembly named hvac unit, they cannot be removed individually from vehicle body. Same hvac unit is used whether vehicle is equipped with a/c sys...

  • Page 1104

    7a-10 heater and ventilation: blower motor controller removal and installation s5jb0a7106005 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove glove box. 4) remove passenger lower member. 5) disconnect blo...

  • Page 1105

    Heater and ventilation: 7a-11 heater core removal and installation s5jb0a7106010 removal 1) remove instrument panel referring to “instrument panel removal and installation: in section 9c”. 2) remove hvac unit. Refer to “hvac unit removal and installation: in section 7b”. 3) remove heater core pipe c...

  • Page 1106

    7a-12 heater and ventilation: 4) connect battery positive (+) terminal to terminal “b” and battery positive (–) terminal to terminal “a”. Check if position of air flow control actuator changes def position to vent position. If malfunction is found, replace air flow control actuator with new one. Tem...

  • Page 1107

    Heater and ventilation: 7a-13 air intake control actuator removal and installation s5jb0a7106017 removal 1) disconnect negative (–) cable at battery. 2) remove glove box. 3) disconnect air intake control actuator connector (2). 4) remove screws and then, remove air intake control actuator (1) from h...

  • Page 1108

    7a-14 heater and ventilation: center ventilation louver removal and installation s5jb0a7106020 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove center garnish with audio unit and hvac control module refer...

  • Page 1109

    Heater and ventilation: 7a-15 installation 1) reverse removal procedure, noting the following. • install side ventilation louver (1) to instrument panel (2) as shown in figure. • when installing defroster duct to instrument panel, put claws of defroster duct into hole of ventilator duct surely. Rear...

  • Page 1110: Air Conditioning System

    7b-1 air conditioning system: air conditioning system precautions a/c system caution s5jb0a7200004 caution ! The air conditioning system of this vehicle uses refrigerant hfc-134a (r-134a). None of refrigerant, compressor oil and component parts is interchangeable between two types of a/c: one using ...

  • Page 1111

    Air conditioning system: 7b-2 precautions on servicing refrigerant line s5jb0a7200008 • when connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling nuts and o-ring. For m16 engine model for j20 engine model 4 [a] [b] oil 1 oil 1 oil 2 oil 2 oil 3 oil 4...

  • Page 1112

    7b-3 air conditioning system: • never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible. • keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting imme...

  • Page 1113

    Air conditioning system: 7b-4 precautions on servicing compressor assembly s5jb0a7200002 caution ! • none of refrigerant, compressor oil and component parts is interchangeable between two types of a/c: one using cfc-12 (r-12) and the other using hfc-134a (r-134a). For identification between these tw...

  • Page 1114

    7b-5 air conditioning system: auto a/c electronic control input / output table s5jb0a7201006 hvac control module operation description s5jb0a7201007 temperature control hvac control module calculates the target temperature control door position based on signals from the temperature selector, inside ...

  • Page 1115

    Air conditioning system: 7b-6 sub-cool a/c system description s5jb0a7201008 in the sub-cool a/c system (condenser (3) integrated with receiver / dryer (4)), the inside of the condenser is divided into the condensation part and the sub-cooler part, and the receiver / dryer is located between those. I...

  • Page 1116

    7b-7 air conditioning system: a/c evaporator temperature sensor description s5jb0a7201002 the a/c evaporator temperature sensor (1) is a temperature sensor to sense the temperature of air discharged from evaporator. The electrical characteristic is shown. When temperature is lower than specified, a/...

  • Page 1117

    Air conditioning system: 7b-8 schematic and routing diagram a/c system wiring circuit diagram s5jb0a7202002 12v 5v m 12v m 5v 5v m 12v 12v g52-1 g52-2 g52-8 g52-4 g52-15 g52-19 g52-20 12v m 5v 5v g52-21 g52-22 g52-23 g52-27 g52-28 g52-31 g52-32 g52-29 g52-30 g52-14 5v 5v g52-18 g52-12 5v 12v 12v 5v ...

  • Page 1118

    7b-9 air conditioning system: component location major components of a/c system s5jb0a7203002 1. Battery 17. Compressor relay 33. Refrigerant pressure sensor 2. Main fuse 18. Rear defogger relay 34. To fuse box 3. Fuse box 19. Blower motor relay 35. Alarm indicator 4. To radiator fan relay no.1 20. ...

  • Page 1119

    Air conditioning system: 7b-10 a/c control system components location s5jb0a7203001 note the figure shows left-hand steering vehicle. For right-hand vehicle, parts with (*) are installed at the opposite side. 1 *2 *7 *3 *6 *11 *10 9 8 4 5 25 12 24 26 14 22 23 16 15 21 13 17 19 18 20 i5jb0a720009-05.

  • Page 1120

    7b-11 air conditioning system: diagnostic information and procedures air conditioning system check s5jb0a7204007 to ensure that system diagnosis is done accurately and smoothly, read “precautions in diagnosing trouble: ” and follow “air conditioning system check: ”. 1. Outside temperature sensor 10....

  • Page 1121

    Air conditioning system: 7b-12 customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the figure will facilitate collecting information to the point required for p...

  • Page 1122

    7b-13 air conditioning system: dtc check s5jb0a7204028 note to know how to use suzuki scan tool in detail, refer to its operator’s manual. Using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument p...

  • Page 1123

    Air conditioning system: 7b-14 5) after completing above check, turn ignition switch to “off” position. Note hvac control module returns to a original state at the following conditions. • ignition switch turned to “off” position • temperature selector is operated • blower speed selector is operated ...

  • Page 1124

    7b-15 air conditioning system: note when no abnormality is detected, “fre” indicator lamp and “rec” indicator lamp repeat cycle of on for 2 seconds and off for 1 second. ) b1511 6 1 8 temperature control actuator (position sensor) and/or its circuit malfunction open 2 9 short ) b1513 3 10 temperatur...

  • Page 1125

    Air conditioning system: 7b-16 example of “rec” indicator lamp flashing pattern example of “fre” indicator lamp flashing pattern note locked actuator, data error and refrigerant pressure malfunction are indicated by flashing pattern of “fre” indicator lamp specified for each of them. Display timing ...

  • Page 1126

    7b-17 air conditioning system: fail-safe table s5jb0a7204031 when any of the following malfunctions (dtcs) is detected, hvac control module enters fail-safe mode. However, when hvac control module detects normal operation of a/c system, fail-safe mode is canceled. [a]: b1520 (15 – 1) (a): “rec” indi...

  • Page 1127

    Air conditioning system: 7b-18 scan tool data s5jb0a7204032 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 vehicles are in good condition, there may be...

  • Page 1128

    7b-19 air conditioning system: scan tool data definitions temp cont switch: position of temperature control selector of hvac control module cabin temperature: in-car temperature detected by inside air temperature sensor installed in hvac control module outside air temp (outside air temperature): out...

  • Page 1129

    Air conditioning system: 7b-20 visual inspection s5jb0a7204008 visually check the following parts and systems. A/c system performance inspection s5jb0a7204027 1) confirm that vehicle and environmental conditions are as follows. • vehicle is put indoors. • ambient air temperature is within 15 – 35 °c...

  • Page 1130

    7b-21 air conditioning system: 7) wait for ten minutes to stabilize a/c operation. 8) keep all windows, doors and engine food open. 9) with about 20 mm (0.8 in.) of dry bulb thermometer (1) put right in front of center ventilation louver and a wet and dry bulb thermometer (2) near air inlet (3) of h...

  • Page 1131

    Air conditioning system: 7b-22 high pressure gauge low pressure gauge condition possible cause correction pressure is higher than acceptable range (“a” area) refrigerant overcharged recharge. Expansion valve frozen or clogged check expansion valve. Clogged refrigerant passage of high side clean or r...

  • Page 1132

    7b-23 air conditioning system: 11) check inlet port temperature-to-outlet port temperature relationship using graph. For example, if a/c evaporator inlet port temperature is 25 °c (77 °f) and center ventilation louver temperature is 13 °c (55.4 °f), their crossing point is within acceptable range as...

  • Page 1133

    Air conditioning system: 7b-24 condition possible cause correction manifold gauge mpa (kg/cm 2 ) (psi) detail lo hi m16 engine model 0.23 – 0.33 (2.3 – 3.3) (33 – 47) j20 engine model 0.22 – 0.31 (2.2 – 3.1) (31 – 44) m16 engine model 0.96 – 1.16 (9.6 – 11.6) (136 – 165) j20 engine model 1.10 – 1.45...

  • Page 1134

    7b-25 air conditioning system: m16 engine model 0.35 – 0.45 (3.5 – 4.5) (50 – 64) j20 engine model 0.33 – 0.45 (3.3 – 4.5) (47 – 64) 2.0 – 2.5 (20 – 25) (285 – 355) high pressure reading on both low and high pressure sides. Overcharged a/c system. Faulty condenser cooling operation. Faulty radiator ...

  • Page 1135

    Air conditioning system: 7b-26 a/c system symptom diagnosis s5jb0a7204001 condition possible cause correction / reference item no cool air comes out (a/ c system does not operate) no refrigerant perform recovery, evacuation and charge referring to “operation procedure for charging a/c with refrigera...

  • Page 1136

    7b-27 air conditioning system: no cool air comes out (blower motor does not operate) fuse blown check related fuses, and then check for short circuit to ground. Blower motor controller faulty check blower motor controller referring to “blower motor controller inspection: in section 7a”. Blower speed...

  • Page 1137

    Air conditioning system: 7b-28 abnormal noise diagnosis s5jb0a7204002 there are various types of noise, ranging from those produced in the engine compartment to those from the passenger compartment, also from rumbling noises to whistling noises. Abnormal noise symptom diagnosis of a/c system s5jb0a7...

  • Page 1138

    7b-29 air conditioning system: abnormal noise from magnetic clutch abnormal noise from tubing abnormal noise from condenser assembly abnormal noise from crankshaft pulley abnormal noise from tension pulley abnormal noise from a/c evaporator abnormal noise from blower motor condition possible cause c...

  • Page 1139

    Air conditioning system: 7b-30 dtc b1502: inside air temperature sensor and/or its circuit malfunction s5jb0a7204033 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dt...

  • Page 1140

    7b-31 air conditioning system: dtc b1503: a/c evaporator air temperature sensor and/or its circuit malfunction s5jb0a7204034 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and ...

  • Page 1141

    Air conditioning system: 7b-32 dtc troubleshooting note when dtc b1502, b1511, b1512 and b1530 are indicated together, it is possible that “blk/red” wire circuit open. Step action yes no 1 evaporator temperature sensor signal circuit check 1) disconnect evaporator temperature sensor connector with i...

  • Page 1142

    7b-33 air conditioning system: dtc b1504: sunload sensor and/or its circuit malfunction s5jb0a7204035 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan to...

  • Page 1143

    Air conditioning system: 7b-34 dtc b1511: temperature control actuator (position sensor) and/or its circuit malfunction s5jb0a7204036 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition sw...

  • Page 1144

    7b-35 air conditioning system: dtc troubleshooting note when dtc b1502, b1503, b1512 and b1530 are indicated together, it is possible that “blk/red” wire circuit open. Step action yes no 1 position sensor power supply circuit check 1) disconnect temperature control actuator connector with ignition s...

  • Page 1145

    Air conditioning system: 7b-36 7 position sensor signal circuit check 1) connect hvac control module connector with ignition switch turned off. 2) measure voltage between “wht/red” wire terminal of temperature control actuator connector and vehicle body ground with ignition switch turned on. Is volt...

  • Page 1146

    7b-37 air conditioning system: dtc b1512: air flow control actuator (position sensor) and/or its circuit malfunction s5jb0a7204037 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switc...

  • Page 1147

    Air conditioning system: 7b-38 3 position sensor power supply circuit check 1) disconnect air intake control actuator connector with ignition switch turned off. 2) measure voltage between “red/wht” wire terminal of temperature control actuator connector and vehicle body ground with ignition switch t...

  • Page 1148

    7b-39 air conditioning system: dtc b1513: temperature control actuator and/or its circuit malfunction s5jb0a7204038 wiring diagram dtc detecting condition and trouble area 10 position sensor signal circuit check 1) measure voltage between “wht/blu” wire terminal of air flow control actuator connecto...

  • Page 1149

    Air conditioning system: 7b-40 dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) start a/c system and select temperature selector at “max cool” position or “max hot” position. 4) wait for 1 minute. 5) ...

  • Page 1150

    7b-41 air conditioning system: 7 wire harness check 1) connect connector to hvac control module with ignition switch turned off. 2) measure voltage between “gry/blu” wire terminal of temperature control actuator connector and vehicle body ground with ignition switch turned on when temperature select...

  • Page 1151

    Air conditioning system: 7b-42 dtc b1514: air flow control actuator and/or its circuit malfunction s5jb0a7204039 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc us...

  • Page 1152

    7b-43 air conditioning system: 3 wire harness check 1) disconnect connector from air flow control actuator with ignition switch turned off. 2) check for proper connection to air flow control actuator connector at “gry/red” and “gry/blk” wire terminals. 3) if ok, measure voltage between “gry/red” wir...

  • Page 1153

    Air conditioning system: 7b-44 dtc b1520: temperature selector and/or its circuit malfunction s5jb0a7204021 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) tu...

  • Page 1154

    7b-45 air conditioning system: dtc b1521: blower speed selector and/or its circuit malfunction s5jb0a7204022 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) t...

  • Page 1155

    Air conditioning system: 7b-46 dtc detecting condition and trouble area note when dtc b1502, b1503, b1511 and b1512 are indicated together, it is that “blk/red” wire circuit open. Dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and c...

  • Page 1156

    7b-47 air conditioning system: 5 position sensor power supply circuit check 1) measure resistance between “red/wht” wire terminal of air intake control actuator connector and vehicle body ground. Is resistance infinity? Go to step 6. “red/wht” wire shorted to ground circuit. 6 position sensor power ...

  • Page 1157

    Air conditioning system: 7b-48 dtc b1531: air intake control actuator and/or its circuit malfunction s5jb0a7204041 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc ...

  • Page 1158

    7b-49 air conditioning system: 3 wire harness check 1) disconnect connector from hvac control module with ignition switch turned off. 2) check for proper connection to hvac control module connector at “g52-31” and “g52-32” terminals. 3) if ok, measure resistance between “orn” wire terminal of air in...

  • Page 1159

    Air conditioning system: 7b-50 dtc b1546: a/c refrigerant pressure malfunction s5jb0a7204042 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and ...

  • Page 1160

    7b-51 air conditioning system: dtc b1551: serial communication circuit malfunction s5jb0a7204043 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3...

  • Page 1161

    Air conditioning system: 7b-52 dtc troubleshooting step action yes no 1 dtc check 1) connect scan tool to dlc with ignition switch turned off. 2) turn ignition switch on and clear dtc referring to “dtc clearance: ”. 3) disconnect connector from information display with ignition switch turned off. 4)...

  • Page 1162

    7b-53 air conditioning system: dtc b1552: serial communication circuit malfunction s5jb0a7204044 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) check dtc. Dt...

  • Page 1163

    Air conditioning system: 7b-54 dtc b1556: camshaft position (cmp) sensor and/or its circuit malfunction s5jb0a7204046 dtc detecting condition and trouble area dtc troubleshooting dtc b1557: wheel speed sensor and/or its circuit malfunction s5jb0a7204047 dtc detecting condition and trouble area dtc t...

  • Page 1164

    7b-55 air conditioning system: dtc b1562: outside air temperature sensor and/or its circuit malfunction s5jb0a7204049 dtc detecting condition and trouble area dtc troubleshooting dtc b1563: a/c refrigerant pressure sensor and/or its circuit malfunction s5jb0a7204050 dtc detecting condition and troub...

  • Page 1165

    Air conditioning system: 7b-56 hvac control module voltage table terminal wire color circuit normal value condition g52-1 ppl/red power supply 10 – 14 v ignition switch turned on. G52-2 wht electric power source for back-up 10 – 14 v constantly. G52-3 ppl/wht serial communication line of data link c...

  • Page 1166

    7b-57 air conditioning system: g52-19 wht/blk evaporator temperature sensor signal approx. 3.6 v ignition switch turned on, evaporator temperature 0 °c (32 °f). Approx. 3.4 v ignition switch turned on, evaporator temperature 10 °c (50 °f). Approx. 2.4 v ignition switch turned on, evaporator temperat...

  • Page 1167

    Air conditioning system: 7b-58 reference waveform no. 1 serial communication line to bcm (1) a/c system inspection at ecm s5jb0a7204051 caution ! • ecm connectors are waterproofed. Each terminal of the ecm connectors is sealed up with the grommet. Therefore, do not measure circuit voltage and resist...

  • Page 1168

    7b-59 air conditioning system: repair instructions operation procedure for charging a/c with refrigerant s5jb0a7206001 warning ! • your eyes should not be exposed to refrigerant (liquid). Any liquid refrigerant-134a escaping by accident shows a temperature as low as approx. –6 °c (21.2 °f) below fre...

  • Page 1169

    Air conditioning system: 7b-60 recovery when discharging refrigerant out of a/c system, always recover it by using refrigerant recovery and recycling equipment (1). Discharging refrigerant hfc-134a (r134a) into atmosphere would cause adverse effect to environments. Note • after recovering refrigeran...

  • Page 1170

    7b-61 air conditioning system: checking of a/c system for pressure leaks after completing the evacuation, close manifold gauge high pressure valve (hi) and low-pressure valve (lo) and wait 10 minutes. Verify that low-pressure gauge reading has not changed. Caution ! If the gauge reading moves closer...

  • Page 1171

    Air conditioning system: 7b-62 5) start engine and keep engine speed at 1,500 rpm. Then, operate a/c system. 6) charge a/c system with refrigerant in vapor state. At this time, refrigerant container should be held upright. 7) when refrigerant container (3) is emptied, the use following procedure to ...

  • Page 1172

    7b-63 air conditioning system: check a/c system for refrigerant leaks whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result in malfunction lines and/or connections, it is advisable to check for leaks. Common sense should be used in perfor...

  • Page 1173

    Air conditioning system: 7b-64 3) remove front bumper assembly referring to “front bumper components: in section 9k”. 4) remove front bumper upper member referring to “front bumper components: in section 9k”. 5) disconnect compressor discharge hose (1) and liquid pipe (2) from condenser assembly (4)...

  • Page 1174

    7b-65 air conditioning system: hvac air filter removal and installation s5jb0a7206009 removal 1) disconnect negative (–) cable at battery. 2) remove glove box. 3) remove filter cover (1). 4) pull out filter element (1). Installation reverse removal procedure for installation noting the followings: •...

  • Page 1175

    Air conditioning system: 7b-66 hvac unit components s5jb0a7206011 20 19 21 25 16 17 22 22 18 3 2 1 5 23 24 16 15 26 26 26 27 26 4 6 14 1 7 9 13 12 10 8 11 i5jb0a720042-03 1. Blower upper case 10. Blower lower case 19. Temperature control links 2. Air intake control actuator 11. Blower motor 20. Temp...

  • Page 1176

    7b-67 air conditioning system: caution ! Be careful not to damage a/c evaporator fins. If a/c evaporator fin is bent, straighten it by using flat head screwdriver or pair of pliers. Hvac unit removal and installation s5jb0a7206012 removal warning ! Failure to follow the following procedure and warni...

  • Page 1177

    Air conditioning system: 7b-68 a/c evaporator removal and installation s5jb0a7206013 removal 1) remove hvac unit referring to “hvac unit removal and installation: ”. 2) remove evaporator (1) from hvac unit by disassembling hvac unit. Installation reverse removal procedure to install a/c evaporator n...

  • Page 1178

    7b-69 air conditioning system: reverse the removal procedure nothing the following instruction. • install evaporator temperature sensor (1) onto evaporator (2) as shown. Expansion valve on-vehicle inspection s5jb0a7206018 refer to “a/c system performance inspection: ”. Expansion valve removal and in...

  • Page 1179

    Air conditioning system: 7b-70 a/c refrigerant pressure sensor removal and installation s5jb0a7206050 removal 1) recover refrigerant from the a/c system with the recovery and recycling equipment referring to “recovery” in “operation procedure for charging a/ c with refrigerant: ”. 2) disconnect nega...

  • Page 1180

    7b-71 air conditioning system: sunload sensor inspection s5jb0a7206053 1) remove sunload sensor. Refer to “sunload sensor removal and installation: ”. 2) light over the sensor vertically with an incandescent lamp of approximately 100 watt. 3) the distance between the sensor and the lamp should be ap...

  • Page 1181

    Air conditioning system: 7b-72 air intake control actuator removal and installation s5jb0a7206060 refer to “air intake control actuator removal and installation: in section 7a”. Air intake control actuator inspection s5jb0a7206061 refer to “air intake control actuator inspection: in section 7a”. Tem...

  • Page 1182

    7b-73 air conditioning system: 3) check that there is no continuity between terminals “c” and “d”. If there is continuity, replace integration relay no.2 (1). 4) connect battery positive (+) terminal to terminal “b” of relay. Connect battery negative (–) terminal to terminal “a” of relay. Check for ...

  • Page 1183

    Air conditioning system: 7b-74 installation reverse removal procedure noting the following instructions. • if compressor is replaced, pour new compressor oil referring to “precautions on replenishing compressor oil: ”. • evacuate and charge the a/c system referring to “evacuation” and “charge” in “o...

  • Page 1184

    7b-75 air conditioning system: magnet clutch components for m16 engine model s5jb0a7206044 6 9 7 4 5 2 1 8 (b) 3 (a) i5jb0a720060-01 1. Armature plate bolt 5. Shim(s) 9. Thermal switch 2. Armature plate 6. Magnet clutch coil : 15 n ⋅m (1.5 kgf-m, 11.0 lb-ft) 3. Circlip 7. Compressor body assembly : ...

  • Page 1185

    Air conditioning system: 7b-76 magnet clutch components for j20 engine model s5jb0a7206045 magnet clutch operating check for m16 engine model s5jb0a7206046 check the following items. • inspect armature plate and rotor for signs of oil. • check clutch bearings for noise and grease leakage. • using an...

  • Page 1186

    7b-77 air conditioning system: magnet clutch removal and installation for m16 engine model s5jb0a7206048 removal 1) remove compressor from vehicle. Refer to “compressor assembly removal and installation for m16 engine model: ”. 2) fix armature plate (1) with special tool (a) and remove armature plat...

  • Page 1187

    Air conditioning system: 7b-78 3) install magnet clutch pulley (1). A) set magnet clutch squarely over clutch installation boss. B) place special tool (a) onto clutch bearing. Ensure that edge rests only on inner race of bearing. Special tool (a): 09951–15510 c) install snap ring (1) using special t...

  • Page 1188

    7b-79 air conditioning system: magnet clutch removal and installation for j20 engine model s5jb0a7206049 removal 1) remove compressor from vehicle referring to “compressor assembly removal and installation for j20 engine model: ”. 2) fix armature plate (1) with special tool (a) and remove armature p...

  • Page 1189

    Air conditioning system: 7b-80 2) install new snap ring (1) using special tool (a). Special tool (b): 09900–06107 3) install magnet clutch pulley. A) set magnet clutch horizontally over clutch installation boss. B) place special tool (b) onto magnet clutch bearing. Ensure that edge rests only inner ...

  • Page 1190

    7b-81 air conditioning system: thermal switch removal and installation for m16 engine model s5jb0a7206066 removal 1) disconnect negative (–) cable from battery. 2) disconnect thermal switch connectors. 3) remove thermal switch (1) from compressor assembly (2) using flat head (3). Installation revers...

  • Page 1191

    Air conditioning system: 7b-82 installation • reverse removal procedure nothing the following instructions. • do not reuse relief valve o-ring (1). • apply compressor oil to o-ring (1) and install o-ring (1) to relief valve (2). • tighten relief valve (2) to specified torque. Tightening torque relie...

  • Page 1192

    7b-83 air conditioning system: special tools and equipment recommended service material s5jb0a7208001 note required service material is also described in the following. “precautions on servicing refrigerant line: ” special tool s5jb0a7208002 material suzuki recommended product or specification note ...

  • Page 1193: Section 8

    Table of contents 8- i 8 section 8 contents restraint precautions .................................................8-1 precautions............................................................. 8-1 precautions on restraint....................................... 8-1 seat belts ............................

  • Page 1194

    8-ii table of contents dtc b1322 / b1326: left / right side-air bag initiator circuit resistance low ...............8b-77 dtc b1323 / b1327: left / right side-air bag initiator circuit short to ground ...............8b-80 dtc b1324 / b1328: left / right side-air bag initiator circuit short to power ...

  • Page 1195: Precautions

    Precautions: 8-1 precautions precautions precautions on restraint s5jb0a8000001 air bag system service warning refer to “air bag warning: in section 00”. Fastener caution refer to “fastener caution: in section 00”. Precautions on service and diagnosis of seat belt refer to “precautions on service an...

  • Page 1196: Seat Belts

    8a-1 seat belts: seat belts precautions precautions on service and diagnosis of seat belt s5jb0a8100001 warning ! If replacing seat belt is necessary, replace buckle and seat belt assembly together as a set. This is for the reason of ensuring locking of tongue plate with buckle. If these parts are r...

  • Page 1197

    Seat belts: 8a-2 seat belt with elr the seat belt with emergency locking retractor (elr) is designed so that it locks immediately (to prevent the webbing from being pulled out of the retractor any further) when any of the following items is detected as exceeding each set value; • speed at which the ...

  • Page 1198

    8a-3 seat belts: repair instructions front seat belt components s5jb0a8106001 warning ! • never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service ...

  • Page 1199

    Seat belts: 8a-4 front seat belt removal and installation s5jb0a8106002 warning ! • never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service and di...

  • Page 1200

    8a-5 seat belts: caution ! If seat belt pretensioner (retractor assembly) was dropped from a height of 30 cm (1 ft) or more, it should be replaced. Seat belts and attaching parts can affect the vital components and systems of a vehicle. Therefore, they should be inspected carefully and replaced with...

  • Page 1201

    Seat belts: 8a-6 rear seat belt components s5jb0a8106004 warning ! Be sure to read “precautions on service and diagnosis of seat belt: ” before starting to work and observe every precaution during work. (a) (a) (a) (a) (a) 3 1 4 6 5 2 i5jb0a810006-01 1. Upper anchor 4. Rear center retractor assembly...

  • Page 1202

    8a-7 seat belts: rear seat belt removal and installation s5jb0a8106005 warning ! Be sure to read “precautions on service and diagnosis of seat belt: ” before starting to work and observe every precaution during work. Removal 1) remove rear side sill scuff, rear side lower trim and rear pillar trim r...

  • Page 1203: Air Bag System

    Air bag system: 8b-1 air bag system precautions precautions on service and diagnosis of air bag system s5jb0a8200001 warning ! • if the air bag system and another vehicle system both need repair, suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system act...

  • Page 1204

    8b-2 air bag system: • never attempt disassembly of sdm. • when storing sdm, select a place where neither high temperature nor high humidity is anticipated and oil, water and dust are kept off. • if sdm has been dropped, replace it with a new one. • if sdm installation part of floor was damaged, rep...

  • Page 1205

    Air bag system: 8b-3 warning ! • 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. • when carrying a live air bag (inflator) module, make sure the bag opening is pointed...

  • Page 1206

    8b-4 air bag system: • when an abnormality is noted as existing in the live (inactivated) seat belt pretensioner, be sure to activate it before discarding it. • when grease, cleaning agent oil, water, etc., got on the seat belt pretensioners (retractor assembly), wipe it off immediately with a dry c...

  • Page 1207

    Air bag system: 8b-5 precautions on disposal of air bag and seat belt pretensioner s5jb0a8200003 do not dispose of the live (undeployed) air bag (inflator) modules and the live (inactivated) seat belt pretensioners. When disposal is necessary, be sure to deploy / activate the air bag and seat belt p...

  • Page 1208

    8b-6 air bag system: the air bag system is designed to activate only in severe frontal and sideward collisions. It is not designed to activate in rear impacts, rollovers, or minor frontal and sideward collisions, since it would offer no protection in those types of accidents. Air bag system input / ...

  • Page 1209

    Air bag system: 8b-7 schematic and routing diagram air bag system wiring circuit diagram s5jb0a8202001 air bag system without side-air bag and curtain-air bag grn/orn grn/yel blu/orn blu/yel grn/orn grn/yel blu/orn blu/yel 12v 5v 5v yel orn pnk/blk orn pnk/blk ppl/wht “e77” “g06” “l36” “e24” “e13” p...

  • Page 1210

    8b-8 air bag system: terminal arrangement of sdm (viewed from harness side) connector “g47” (sdm connector) 1. Sdm connector “g47” terminal terminal symbol circuit terminal terminal symbol circuit g47-1 pp+ passenger seat belt pretensioner (+) g47-13 st dlc g47-2 pp– passenger seat belt pretensioner...

  • Page 1211

    Air bag system: 8b-9 air bag system with side-air bag and curtain-air bag ppl “g34” 1 2 5 red ppl/red blk/yel yel/blk grn/orn grn/yel blu/orn blu/yel 12v 5v yel orn pnk/blk orn pnk/blk ppl/wht “e79” “l36” “l12” blk g46-7 g46-11 g46-15 g46-9 g46-6 l33-5 l33-6 l33-8 l33-7 g46-16 l6 l5 l4 l3 l2 l1 ads ...

  • Page 1212

    8b-10 air bag system: terminal arrangement of sdm (viewed from harness side) connector “g46” (sdm connector) connector “l32” (sdm connector) connector “l33” (sdm connector) 1. Sdm connector “g46” 3. Sdm connector “l33” 2. Sdm connector “l32” terminal terminal symbol circuit terminal terminal symbol ...

  • Page 1213

    Air bag system: 8b-11 component location air bag system components, wiring and connectors location s5jb0a8203001 8 15 13 10 11 5 7 11 12 12 7 13 13 8 11 1 17 14 2 3 5 6 4 5 16 2 1 (a) (b) (c) (d) (b) (d) 9 8 i5jb0a820012-02 1. Passenger air bag (inflator) module 8. Side-air bag (inflator) module (if...

  • Page 1214

    8b-12 air bag system: diagnostic information and procedures air bag diagnostic system check s5jb0a8204001 warning ! To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or ac powered voltmeter, ohmmeter, etc., or any type of elec...

  • Page 1215

    Air bag system: 8b-13 step action yes no 1 1) make sure that battery voltage is about 11 v or higher. 2) note “air bag” warning lamp as ignition switch is turned on. Does “air bag” warning lamp come on when ignition switch is turned on? Go to step 2. Proceed to ““air bag” warning lamp does not come ...

  • Page 1216

    8b-14 air bag system: dtc table s5jb0a8204003 sdm dtc dtc “air bag” warning lamp flashing pattern diagnosis no. Mode — 0000 normal — ) b1013 1013 sdm sdm fault diagnose trouble according to diagnostic flow corresponding to each code no. ) b1016 1016 power source voltage too high ) b1017 1017 too low...

  • Page 1217

    Air bag system: 8b-15 ) b1086 1086 left side-sensor performance problem diagnose trouble according to diagnostic flow corresponding to each code no. ) b1087 1087 communication error ) b1096 1096 right side-sensor performance problem ) b1097 1097 communication error ) b1321 1321 left side-air bag res...

  • Page 1218

    8b-16 air bag system: dtc check s5jb0a8204004 using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) located on underside of instrument panel at driver’s seat side. Special tool (a): suzuki scan tool 3) turn ignition switch to on posi...

  • Page 1219

    Air bag system: 8b-17 dtc clearance s5jb0a8204005 using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) in the same manner as when making this connection for dtc check. Special tool (a): suzuki scan tool 3) turn ignition switch t...

  • Page 1220

    8b-18 air bag system: scan tool data s5jb0a8204006 data list of sdm scan tool data definition back up volt (v): this parameter indicates the capacity of the backup condenser installed to maintain the ignition current (as much as possible) even when the power supply to sdm that ignites the inflator i...

  • Page 1221

    Air bag system: 8b-19 “air bag” warning lamp comes on steady s5jb0a8204007 wiring diagram caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Blk g47-18 g47-20 l2 l1 gnd wl “g47” 12v 1 2 6 8 4 5 red ppl/red blk/yel yel/blk blk red yel/blk “g01” 7 “g28” ...

  • Page 1222

    8b-20 air bag system: flow test description step 1: check for “air bag” fuse blown. Step 2: check for loose connection between junction block assembly connector and junction block assembly. Step 3: check for loose connection between sdm connector and sdm. Step 4: check for sdm power supply circuit. ...

  • Page 1223

    Air bag system: 8b-21 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • repeat “air bag diagnostic system check: ” to confirm that the trouble has been corrected. 5 1) disconnec...

  • Page 1224

    8b-22 air bag system: “air bag” warning lamp does not come on s5jb0a8204008 wiring diagram refer to ““air bag” warning lamp comes on steady: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Flow test description step 1: check combination meter pow...

  • Page 1225

    Air bag system: 8b-23 “air bag” warning lamp flashes s5jb0a8204009 wiring diagram caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Flow test description step 1: check that vehicle is equipped with or without “air bag” monitor connector. Step 2: check...

  • Page 1226

    8b-24 air bag system: “air bag” warning lamp cannot indicate flashing pattern of dtc (if equipped with “air bag” monitor coupler) s5jb0a8204049 wiring diagram refer to ““air bag” warning lamp flashes: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow...

  • Page 1227

    Air bag system: 8b-25 dtc b1013: sdm fault s5jb0a8204010 dtc will set when an internal sdm fault is detected by sdm. Note dtc b1013 can never be cleared once it has been set. Dtc troubleshooting 1) turn ignition switch off. 2) replace sdm. 3) repeat “air bag diagnostic system check: ”. Dtc b1016: po...

  • Page 1228

    8b-26 air bag system: dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic syste...

  • Page 1229

    Air bag system: 8b-27 dtc b1017: power source voltage low s5jb0a8204013 wiring diagram refer to “dtc b1016: power source voltage high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set when the power source voltage is below specified v...

  • Page 1230

    8b-28 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1231

    Air bag system: 8b-29 dtc b1021: air bag module deployed s5jb0a8204014 dtc will set when the sdm detects a crash of sufficient force to warrant activation of the air bag system. (sdm outputs a deployment command.) flow test description step 1: check that dtc b1021 has been set although air bag has n...

  • Page 1232

    8b-30 air bag system: dtc b1031: driver air bag initiator circuit resistance high s5jb0a8204018 wiring diagram caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set when the combined resistance of the driver air bag (inflator) module, contact...

  • Page 1233

    Air bag system: 8b-31 dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect contact coil connector located under of the steering column. 2) check proper connection to contact coil at terminal in “g26” or “g27” connector. 3) if ok, then connect special tools (b) and (c) to ...

  • Page 1234

    8b-32 air bag system: 2 1) with ignition switch off, disconnect sdm connector “g47” or “g46”. 2) check proper connection to sdm at terminals “g47-5” and “g47-6” or “g46-1” and “g46-2”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure...

  • Page 1235

    Air bag system: 8b-33 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1236

    8b-34 air bag system: dtc b1032: driver air bag initiator circuit resistance low s5jb0a8204019 wiring diagram refer to “dtc b1031: driver air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set when...

  • Page 1237

    Air bag system: 8b-35 2 1) with ignition switch off, disconnect sdm connector “g47” or “g46”. 2) check proper connection to sdm at terminals “g47-5” and “g47-6” or “g46-1” and “g46-2”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure...

  • Page 1238

    8b-36 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1239

    Air bag system: 8b-37 dtc b1033: driver air bag initiator circuit short to ground s5jb0a8204020 wiring diagram refer to “dtc b1031: driver air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set whe...

  • Page 1240

    8b-38 air bag system: 2 1) with ignition switch off, disconnect special tools (b) and (c) or (d) from “g26” or “g27” connector and sdm connector “g47” or “g46” from sdm respectively. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure resistan...

  • Page 1241

    Air bag system: 8b-39 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1242

    8b-40 air bag system: dtc b1034: driver air bag initiator circuit short to power circuit s5jb0a8204021 wiring diagram refer to “dtc b1031: driver air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will ...

  • Page 1243

    Air bag system: 8b-41 2 1) with ignition switch off, disconnect special tools (b) and (c) or (d) from “g26” or “g27” connector and sdm connector “g47” or “g46” from sdm respectively. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure voltage ...

  • Page 1244

    8b-42 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1245

    Air bag system: 8b-43 dtc b1041: passenger air bag initiator circuit resistance high s5jb0a8204022 wiring diagram caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set when the combined resistance of the passenger air bag (inflator) module, h...

  • Page 1246

    8b-44 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect passenger air bag (inflator) module connector. 2) check proper connection to passenger air bag (inflator) module at terminals in “g65” connector. 3) if ok, then connect special tools (a), (b) and (...

  • Page 1247

    Air bag system: 8b-45 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1248

    8b-46 air bag system: dtc b1042: passenger air bag initiator circuit resistance low s5jb0a8204023 wiring diagram refer to “dtc b1041: passenger air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will se...

  • Page 1249

    Air bag system: 8b-47 2 1) with ignition switch off, disconnect “g67” connector located near the glove box. 2) check proper connection to instrument panel harness connector at terminal “g67-1” and “g67-2”. 3) if ok, then connect special tools (b) and (c) to “g67” connector disconnected in step 1). S...

  • Page 1250

    8b-48 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1251

    Air bag system: 8b-49 dtc b1043: passenger air bag initiator circuit short to ground s5jb0a8204024 wiring diagram refer to “dtc b1041: passenger air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will s...

  • Page 1252

    8b-50 air bag system: 2 1) with ignition switch off, disconnect “g67” connector located near the glove box. 2) check proper connection to instrument panel harness connector at terminal “g67-1” and “g67-2”. 3) if ok, then connect special tools (b) and (c) to “g67” connector disconnected in step 1). S...

  • Page 1253

    Air bag system: 8b-51 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1254

    8b-52 air bag system: dtc b1044: passenger air bag initiator circuit short to power circuit s5jb0a8204025 wiring diagram refer to “dtc b1041: passenger air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc...

  • Page 1255

    Air bag system: 8b-53 2 1) with ignition switch off, disconnect “g67” connector located near the glove box. 2) check proper connection to instrument panel harness connector at terminal “g67-1” and “g67-2”. 3) if ok, then connect special tools (b) and (c) to “g67” connector disconnected in step 1). S...

  • Page 1256

    8b-54 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1257

    Air bag system: 8b-55 dtc b1051 / b1055: driver / passenger pretensioner initiator circuit resistance high s5jb0a8204026 wiring diagram caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set when the resistance of driver or passenger seat belt...

  • Page 1258

    8b-56 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, remove center pillar lower trim of driver or passenger side and disconnect seat belt pretensioner connector “l12” or “l36” (1). 2) check proper connection to seat belt pretensioner at terminals in “l12” or “l...

  • Page 1259

    Air bag system: 8b-57 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1260

    8b-58 air bag system: dtc b1052 / b1056: driver / passenger pretensioner initiator circuit resistance low s5jb0a8204027 wiring diagram refer to “dtc b1051 / b1055: driver / passenger pretensioner initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air ba...

  • Page 1261

    Air bag system: 8b-59 2 1) with ignition switch off, disconnect “g55” connector located near the console box. 2) check proper connection to applicable seat belt pretensioner at terminal in “g55” connector. 3) if ok, then connect special tools (b) and (d) to “g55” connector. Special tool (b): 09932–7...

  • Page 1262

    8b-60 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1263

    Air bag system: 8b-61 dtc b1053 / b1057: driver / passenger pretensioner initiator circuit short to ground s5jb0a8204028 wiring diagram refer to “dtc b1051 / b1055: driver / passenger pretensioner initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air b...

  • Page 1264

    8b-62 air bag system: 2 1) with ignition switch off, disconnect “g55” connector located near the console box. 2) check proper connection to applicable seat belt pretensioner at terminal in “g55” connector. 3) if ok, then connect special tools (b) and (d) to “g55” connector. Special tool (b): 09932–7...

  • Page 1265

    Air bag system: 8b-63 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1266

    8b-64 air bag system: dtc b1054 / b1058: driver / passenger pretensioner initiator circuit short to power circuit s5jb0a8204029 wiring diagram refer to “dtc b1051 / b1055: driver / passenger pretensioner initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in...

  • Page 1267

    Air bag system: 8b-65 2 1) with ignition switch off, disconnect “g55” connector located near the console box. 2) check proper connection to applicable seat belt pretensioner at terminal in “g55” connector. 3) if ok, then connect special tools (b) and (d) to “g55” connector. Special tool (b): 09932–7...

  • Page 1268

    8b-66 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1269

    Air bag system: 8b-67 dtc b1073 / b1077: driver / passenger forward-sensor circuit short to ground s5jb0a8204036 wiring diagram caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set when forward-sensor abnormal signal is detected by sdm. Flow...

  • Page 1270

    8b-68 air bag system: dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic syste...

  • Page 1271

    Air bag system: 8b-69 dtc b1074 / b1078: driver / passenger forward-sensor circuit short to power circuit or open s5jb0a8204037 wiring diagram refer to “dtc b1073 / b1077: driver / passenger forward-sensor circuit short to ground: ”. Caution ! Be sure to observe instructions under caution in “air ba...

  • Page 1272

    8b-70 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1273

    Air bag system: 8b-71 dtc b1085: wrong side-sensor id s5jb0a8204042 dtc will set when sdm receives wrong id (part no.) signal from side-sensor. Dtc troubleshooting 1) turn ignition switch off. 2) replace driver or passenger side-sensor referring to “side-sensor removal and installation: ”. 3) repeat...

  • Page 1274

    8b-72 air bag system: dtc will set when side-sensor abnormal signal is detected by sdm. Flow test description step 1: check for open circuit in forward sensor circuit. Step 2: check for short circuit between forward sensor circuit and ground. Step 3: check for short circuit between forward sensor ci...

  • Page 1275

    Air bag system: 8b-73 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confir...

  • Page 1276

    8b-74 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect side-air bag (inflator) module connector under front seat cushion. 2) check proper connection to left or right side-air bag (inflator) module at terminals in “l25” or “l30” connector. 3) if ok, the...

  • Page 1277

    Air bag system: 8b-75 2 1) with ignition switch off, disconnect sdm connector “l33”. 2) check proper connection to sdm at terminals “l33-1” and “l33-2” or “l33-3” and “l33-4”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure resistan...

  • Page 1278

    8b-76 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1279

    Air bag system: 8b-77 dtc b1322 / b1326: left / right side-air bag initiator circuit resistance low s5jb0a8204031 wiring diagram refer to “dtc b1321 / b1325: left / right side-air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnostic...

  • Page 1280

    8b-78 air bag system: 2 1) with ignition switch off, disconnect sdm connector “l33”. 2) check proper connection to sdm at terminals “l33-1” and “l33-2” or “l33-3” and “l33-4”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure resistan...

  • Page 1281

    Air bag system: 8b-79 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1282

    8b-80 air bag system: dtc b1323 / b1327: left / right side-air bag initiator circuit short to ground s5jb0a8204032 wiring diagram refer to “dtc b1321 / b1325: left / right side-air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag diagnosti...

  • Page 1283

    Air bag system: 8b-81 2 1) with ignition switch off, disconnect special tools and sdm connector “l33”. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure resistance between “l33-1” and body ground, and between “l33-2” and body ground (for dtc...

  • Page 1284

    8b-82 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1285

    Air bag system: 8b-83 dtc b1324 / b1328: left / right side-air bag initiator circuit short to power circuit s5jb0a8204033 wiring diagram refer to “dtc b1321 / b1325: left / right side-air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “air bag di...

  • Page 1286

    8b-84 air bag system: 2 1) with ignition switch off, disconnect special tools (b), (c) and sdm connector “l33”. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure voltage between “l33-1” and body ground, and between “l33-2” and ground (for dt...

  • Page 1287

    Air bag system: 8b-85 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1288

    8b-86 air bag system: caution ! Be sure to observe instructions under caution in “air bag diagnostic system check flow”. Dtc will set when the combined resistance of the side curtain-air bag (inflator) module (left or right), harness wiring and connector terminal contact is above a specified value f...

  • Page 1289

    Air bag system: 8b-87 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1290

    8b-88 air bag system: dtc b1332 / b1336: left / right side curtain-air bag initiator circuit resistance low s5jb0a8204044 wiring diagram refer to “dtc b1331 / b1335: left / right side curtain-air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “ai...

  • Page 1291

    Air bag system: 8b-89 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1292

    8b-90 air bag system: dtc b1333 / b1337: left / right side curtain-air bag initiator circuit short to ground s5jb0a8204045 wiring diagram refer to “dtc b1331 / b1335: left / right side curtain-air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under caution in “a...

  • Page 1293

    Air bag system: 8b-91 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1294

    8b-92 air bag system: dtc b1334 / b1338: left / right side curtain-air bag initiator circuit short to power circuit s5jb0a8204046 wiring diagram refer to “dtc b1331 / b1335: left / right side curtain-air bag initiator circuit resistance high: ”. Caution ! Be sure to observe instructions under cautio...

  • Page 1295

    Air bag system: 8b-93 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm t...

  • Page 1296

    8b-94 air bag system: special tool (a): 09932-76010 connector test adapter kit • poor terminal-to-wire connection. Check each wire harness in problem circuits for poor connection by shaking it by hand lightly. If any abnormal condition is found, change the wire harness assembly or component parts wi...

  • Page 1297

    Air bag system: 8b-95 accident with deployment / activation – component replacement when driver and passenger air bags are deployed, the following components must be replaced. • driver and passenger air bag (inflator) modules • driver and passenger seat belt pretensioners • sdm • driver / passenger ...

  • Page 1298

    8b-96 air bag system: – check connector or lead wire of sdm for scorching, melting or damage. – check sdm connector and terminals for tightness. – check if sdm sets a dtc and is judged as malfunctioning according to the diagnostic flow. • air bag wire harness and connections – check for damages, def...

  • Page 1299

    Air bag system: 8b-97 repair instructions disabling air bag system s5jb0a8206001 1) turn steering wheel so that vehicle’s wheels (front tires) are pointing straight ahead. 2) disconnect negative (–) cable at battery. 3) turn ignition switch to “lock” position and remove key. 4) remove “a/b” fuse fro...

  • Page 1300

    8b-98 air bag system: enabling air bag system s5jb0a8206002 1) confirm that battery negative (–) cable is disconnected. 2) turn ignition switch to “lock” position and remove key. 3) connect yellow connector (1) of contact coil and combination switch assembly by pushing connector till click is heard ...

  • Page 1301

    Air bag system: 8b-99 removal 1) disconnect negative cable at battery. 2) disable air bag system referring to “disabling air bag system: ”. 3) remove console rear panel referring to “console box components: in section 9h”. 4) disconnect sdm connector (1) from sdm (2). 5) remove sdm (1) from vehicle....

  • Page 1302

    8b-100 air bag system: caution ! • do not connect a tester whatever type it may be. • never repair or disassemble sdm. • if sdm has been dropped, it should be replaced. If any faulty condition is found in the following checks, replace. • check sdm for dents, cracks or deformation. • check sdm connec...

  • Page 1303

    Air bag system: 8b-101 2) install driver air bag (inflator) module (1) to steering wheel (2), taking care so that no part of wire harness is caught between them. 3) make sure that clearance between module (1) and steering wheel (2) is uniform all the way. 4) tighten left side bolt (3) of driver air ...

  • Page 1304

    8b-102 air bag system: 3) remove passenger air bag (inflator) module (1) from instrument panel as shown. Warning ! • when carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. Never carry air bag (inflator) module by wires or connector on the side of the modu...

  • Page 1305

    Air bag system: 8b-103 passenger air bag (inflator) module inspection s5jb0a8206008 warning ! • never measure resistance of passenger air bag (inflator) module or disassemble it. Otherwise personal injury may result. • never attempt to disassemble or repair the passenger air bag (inflator) module. I...

  • Page 1306

    8b-104 air bag system: warning ! • when carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. Never carry air bag (inflator) module by wires or connector on the side of the module. In case of an accidental deployment, the bag will then deploy with minimal cha...

  • Page 1307

    Air bag system: 8b-105 side-air bag (inflator) inspection s5jb0a8206010 warning ! • never attempt to disassemble or repair the side-air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service and diagnosis of ai...

  • Page 1308

    8b-106 air bag system: 4) remove side curtain-air bag (inflator) module bolts (1) and clip (2). 5) remove side curtain-air bag (inflator) module. Warning ! • when carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. Never carry air bag (inflator) module by w...

  • Page 1309

    Air bag system: 8b-107 side curtain-air bag (inflator) module inspection s5jb0a8206012 warning ! • never measure resistance of side curtain- air bag (inflator) module or disassemble it. Otherwise personal injury may result. • never attempt to disassemble or repair the side curtain-air bag (inflator)...

  • Page 1310

    8b-108 air bag system: installation caution ! Proper operation of forward-sensor requires sensor be rigidly attached to vehicle structure and that the arrow on sensor be pointing toward the front of the vehicle. 1) check that none of the following faulty conditions exists. • bend, deformity or rust ...

  • Page 1311

    Air bag system: 8b-109 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system. Refer to “disabling air bag system: ”. 3) remove center pillar lower trim and side sill scuff. 4) disconnect side-sensor connector sliding connector outer (1) as shown. 5) remove side-sensor bolts ...

  • Page 1312

    8b-110 air bag system: caution ! • never disassemble side-sensor. • sensor should be replaced when it was dropped from a height of 90 cm (3 ft) or more. • check sensor (1) for dents, crack, deformation. • check sensor connector (sensor side and harness side), lock mechanism or sensor lead wire for d...

  • Page 1313

    Air bag system: 8b-111 deployment / activation outside of vehicle when you intend to return the vehicle to service, deploy the air bag (inflator) module(s) or activate seat belt pretensioner(s) outside of the vehicle. 1) turn ignition switch to lock position and remove key. 2) wear safety glasses du...

  • Page 1314

    8b-112 air bag system: warning ! • for handling and storage of seat belt pretensioner, select place where ambient temperature is below 65 °c (150 °f), without high humidity and away from electric noise. • never carry seat belt pretensioner by webbing. • when placing seat belt pretensioner on workben...

  • Page 1315

    Air bag system: 8b-113 • for side-air bag (inflator) module a. Remove sleeve (1) and sleeve lock nut (2), if equipped. B. Clear space (3) on ground about 185 cm (6 ft) in diameter where side-air bag (inflator) module for deployment. Paved, outdoor location where there is no activity is preferred. If...

  • Page 1316

    8b-114 air bag system: • for seat belt pretensioner a. Cut webbing (1) at tongue plate stopper (3) of seat belt pretensioner (2) side as shown. Note hold seat belt pretensioner (2) vertically in the same condition as it is installed. Otherwise, webbing can’t be pulled out. B. Remove tongue plate (4)...

  • Page 1317

    Air bag system: 8b-115 • for side curtain-air bag (inflator) module [d] a. Connect adapter cable (b) to side curtain-air bag (inflator) module. B. Pile 2 tires (2) and wheel-installed tire (3) on top of tire with side curtain-air bag (inflator) (4), and tie them with wire harness (5) as shown. Wire ...

  • Page 1318

    8b-116 air bag system: 12) notify all people in immediate area that you intend to deploy / activate air bag (inflator) module or seat belt pretensioner. Note • when air bag (inflator) module deploys and seat belt pretensioner activates, rapid gas expansion will create substantial report. Wear suitab...

  • Page 1319

    Air bag system: 8b-117 21) wash your hands with mild soap and water afterward. Note remaining steps are to be followed in the unlikely event that air bag (inflator) module did not deploy or seat belt pretensioner did not activate. 22) ensure that deployment harness has been disconnected from 12 volt...

  • Page 1320

    8b-118 air bag system: 5) check that there is no open, short or damage in special tools (deployment harness (a), adapter cable (b), (c) and (d)). If any faulty condition is found, do not use it and be sure to use new special tool. And connect adapter cable (b), (c) or (d) to deployment harness (a) a...

  • Page 1321

    Air bag system: 8b-119 8) route deployment harness (1) out of vehicle. 9) check that inside of vehicle and area surrounding vehicle are clear of all people and loose or flammable objects. 10) stretch deployment harness (1) to its full length 10 m (33 ft). 11) place 12 volts vehicle battery (2) near ...

  • Page 1322

    8b-120 air bag system: 21) disconnect adapter cable (special tool) from air bag (inflator) module or seat belt pretensioner as soon as possible. This will prevent adapter cable (special tool) from damage due to possible contact with hot air bag (inflator) module or hot seat belt pretensioner. 22) ch...

  • Page 1323

    Air bag system: 8b-121 specifications tightening torque specifications s5jb0a8207001 note the specified tightening torque is also described in the following. “air bag system components, wiring and connectors location: ” reference: for the tightening torque of fastener not specified in this section, ...

  • Page 1324

    8b-122 air bag system: special tool (b): 09932–75010 (air bag driver / passenger load tool) this tool is used as a diagnostic aid and safety device to prevent inadvertent air bag (inflator) module deployment. The load tool has three connectors attached to its case which are electrically functional a...

  • Page 1325

    Air bag system: 8b-123 special tool s5jb0a8208003 09932–75010 09932–75031 air bag load tool air bag deployment harness ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / )...

  • Page 1326

    8b-124 air bag system: suzuki scan tool — this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loopback adapter, 7. Battery power cable, 8. Rs232 cable, 9. Rs232 adapter, 10. Rs232 loop back connector, 11. Storage case, 12. Powe...

  • Page 1327: Section 9

    Table of contents 9- i 9 section 9 contents body, cab and accessories precautions .................................................9-1 precautions............................................................. 9-1 precautions on body, cab and accessories......... 9-1 precautions for body service.........

  • Page 1328

    9-ii table of contents b-8 seat heater circuit diagram.......................9a-88 b-9 smart key system circuit diagram ............9a-89 b-10 sliding roof circuit diagram ....................9a-90 b-11 headlight cleaner circuit diagram ...........9a-91 c-1 combination meter circuit diagram ...........

  • Page 1329

    Table of contents 9-iii stop (brake) lamp switch inspection ...............9b-22 turn signal light switch (in lighting switch) removal and installation................................. 9b-23 turn signal light switch (in lighting switch) inspection........................................... 9b-23 tur...

  • Page 1330

    9-iv table of contents gps antenna removal and installation (if equipped)........................................................9c-20 horn removal and installation ..........................9c-20 horn inspection .................................................9c-20 horn relay inspection..............

  • Page 1331

    Table of contents 9-v door lock function of keyless start system symptom diagnosis (if equipped) ....... 9f-4 repair instructions .............................................. 9f-4 front door lock assembly components ............ 9f-4 front door lock assembly removal and installation..................

  • Page 1332

    9-vi table of contents roof drip molding removal and installation (if equipped) .................................................... 9m-1 roof rail removal and installation (if equipped)......................................................... 9m-2 splash guard removal and installation (if equipped)...

  • Page 1333: Precautions

    Precautions: 9-1 precautions precautions precautions on body, cab and accessories s5jb0a9000001 air bag warning refer to “air bag warning: in section 00”. Fastener caution refer to “fastener caution: in section 00”. Precautions for body service refer to “precautions for body service: ”. Fastener cau...

  • Page 1334: Wiring Systems

    9a-1 wiring systems: wiring systems precautions cautions in body electrical system servicing s5jb0a9100001 when performing works related to electric systems, observe the cautions described in “precautions for electrical circuit service: in section 00” for the purpose of protection of electrical part...

  • Page 1335

    Wiring systems: 9a-2 general description abbreviations s5jb0a9101002 wire / connector color symbols s5jb0a9101003 abbreviation full term abbreviation full term 2wd 2 wheel drive vehicles ig ignition 4wd 4 wheel drive vehicles ig coil ignition coil a/b air bag ill illumination a/c air conditioning in...

  • Page 1336

    9a-3 wiring systems: symbols and marks s5jb0a9101004 battery ground normal fuse slow blow fuse circuit breaker coil, solenoid heater bulb cigarette lighter motor pump horn speaker buzzer chime condenser thermistor reed switch resistance variable resistance transistor npn pnp photo transistor diode z...

  • Page 1337

    Wiring systems: 9a-4 ignition switch keyless entry immobilizer system combination meter lighting switch headlight leveling hazard warning light front fog light rear fog light spark plug radiator fan fuel pump injector xx control module windshield wiper windshield washer rear wiper rear washer rear d...

  • Page 1338

    9a-5 wiring systems: how to read connector layout diagram s5jb0a9101005 [a-1]: harness symbol and corresponding harness name a: battery harness b: a/c harness c: engine harness d: injector harness e: main harness, oil pressure switch wire, console wire g: instrument panel harness j: side door wire (...

  • Page 1339

    Wiring systems: 9a-6 how to read connector codes and terminal nos. S5jb0a9101006 1) connector code/terminal no./terminal layout • the connector shape and terminal layout shown in this manual are those when viewed from “z” in the illustration. Refer to “list of connectors: ”. Note molded terminal num...

  • Page 1340

    9a-7 wiring systems: 3) terminals in one connector (broken line) (b15)/terminals in different connectors (b14, b16) 4) joint connector (j/c) • the joint connector (j/c) connects several different wires with the same wire color at one place instead of connecting them by welding or caulking one by one...

  • Page 1341: Cross-Reference

    Wiring systems: 9a-8 5) junction block (j/b) 6) connector location, shape and terminal no. Refer to “connector layout diagram: ”. Refer to “system circuit diagram: ”. Refer to “list of connectors: ”. Immobi ig ig1 ig coil, etc e39 e41 e40 bcm g34 g33 g32 k01 l04 l05 l06 ig coil ig1 15a mtr 10a a/b 1...

  • Page 1342: Cross-Reference

    9a-9 wiring systems: how to read ground point s5jb0a9101007 refer to “system circuit diagram: ”. Refer to “ground (earth) point: ”. Left side shown 10 11 12 "system circuit diagram" "ground point" cross-reference windoshield washer motor individual circuit fuse box 20 15a windoshield wiper motor e40...

  • Page 1343

    Wiring systems: 9a-10 how to read power supply diagram s5jb0a9101008 refer to “power supply diagram: ”. Refer to “system circuit diagram: ”. Connection to the system indicated. "power supply diagram" - + 1 battery 80a 2 15a 3 15a 4 15a 5 25a 6 7 8 50a 30a 29 30a 32 15a 9 60a 60a blk yel/blk pnk/blk ...

  • Page 1344

    9a-11 wiring systems: how to read system circuit diagram s5jb0a9101009 the circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of the diagram (ground) as if giving an image of water flow. [a]: fuse no. [b]: circuit jumping page / direction note t...

  • Page 1345

    Wiring systems: 9a-12 switch blu blu grn/blk grn/red grn/blk 1 2 grn grn c26 2 1 blk 5 blk 2 1 c40 grn/blk "xx" solenoid fuse fuse 3 15a main relay on off 1 15a 6 20a 1 sensor 1 2 8 brn/red e52 1 2 e52 1 brn/red red 2 brn/red brn/red motor m m 6 5 5 a b a b 5 6 1 2 5 6 4 6 4 4-door 2-door 2 c71 e03 ...

  • Page 1346

    9a-13 wiring systems: harness routing and connector layout diagram connector layout diagram s5jb0a910a006 refer to “engine compartment: ”. Refer to “instrument panel: ”. Refer to “door, roof: ”. Refer to “floor: ”. Refer to “rear: ”. Engine compartment s5jb0a910a001 c: engine harness (m16a rhd) c: e...

  • Page 1347

    Wiring systems: 9a-14 c: engine harness (m16a lhd) c: engine harness c11/blk throttle position sensor c35/blu main harness (to e55) c12/blk map sensor c36/gry a/f sensor c13/blk maf sensor c37/gry ecm c14/blk evap canister purge valve c40/gry ig coil #1 & #4 c15/n rear heated oxygen sensor c41/gry i...

  • Page 1348

    9a-15 wiring systems: c: engine harness (j20a rhd) c12/blk map sensor c36/gry a/f sensor c13/blk maf sensor c37/gry ecm c14/blk evap canister purge valve c40/gry ig coil #1 & #4 c15/n rear heated oxygen sensor c41/gry ig coil #2 & #3 c17/blk a/c compressor c47/blk noise filter c18/n oil pressure sen...

  • Page 1349

    Wiring systems: 9a-16 c: engine harness no./color connective position no./color connective position c01/- battery (-) c30/blk (m/t) back-up light switch c02/- battery fuse box c31/- battery fuse box c03/- fuse box no.1 c32/- fuse box no.1 c04/gry injector #1 c33/n p/s pump pressure switch c05/gry in...

  • Page 1350

    9a-17 wiring systems: c: engine harness (j20a lhd) c: engine harness c34 (to e54) c49 (to e88) c50 (to e89) c27 (a/t) c30 (m/t) c25 (a/t) c29 (a/t) c48 (to e87) c35 (to e55) 1 c01 c32 c03 c31 c02 c07 c54 c52 c53 c47 c55 c18 c08 c10 c09 c28 c23 c14 c26 c21 c22 c24 c33 c12 c13 c11 c06 c04 c05 c40 c41 ...

  • Page 1351

    Wiring systems: 9a-18 b: a/c compressor wire / e: main harness, front height sensor wire (rhd) b: a/c compressor wire c23/blk starting motor #1 c51/blu j/c c24/- starting motor #2 c52/blk t/f 4l switch c25/blu (a/ t) output shaft speed sensor c53/n t/f position switch c26/gry knock sensor c54/gry t/...

  • Page 1352

    9a-19 wiring systems: e: main harness e: front height sensor wire no./color connective position no./color connective position e01/gry windshield wiper motor e32/blk fuse box no.2 (starting motor relay & headlight hi relay & headlight lo relay) e02/gry brake fluid level switch e33/blk fuse box no.2 (...

  • Page 1353

    Wiring systems: 9a-20 b: a/c compressor wire / e: main harness, front height sensor wire (lhd) b: a/c compressor wire e: main harness 6 7 8 9 e54 (to c34) e55 (to c35) e40 e06 e36 e35 e32 e34 e45 e59 e07 e44 e43 e09 e08 e46 e37 e12 e86 front height sensor wire e33 e38 e61 e42 e64 e62 e63 e02 e24 e05...

  • Page 1354

    9a-21 wiring systems: e: front height sensor wire e10/n windshield washer motor e42/n fuse box no.2 e11/n rear washer motor e43/gry (5 dr) hid headlight (r) e12/blk front fog light (r) e44/blk (5 dr) headlight lo (r) e13/yel forward sensor (driver side) e45/gry headlight beam leveling actuator (r) e...

  • Page 1355

    Wiring systems: 9a-22 instrument panel s5jb0a910a002 e: main harness, controller wire (rhd) e: main harness e: controller wire 10 e76 (to g04) e79 (to l03) e74 (to g36) e75 (to g37) e88 (to c49) e89 (to c50) e87 (to c48) e90 (to g71) e92 e93 e91 e67 (a/t) e77 (to g06) e78 (to g05) e80 (to l01) e67 (...

  • Page 1356

    9a-23 wiring systems: e: main harness, controller wire (lhd) e: main harness e: controller wire 10 e76 (to g04) e79 (to l03) e74 (to g36) e75 (to g37) e88 (to c49) e89 (to c50) e87 (to c48) e90 (to g71) e92 e93 e91 e67 e77 (to g06) e78 (to g05) e80 (to l01) e68 e70 e82 e83 e69 e72 controller wire e7...

  • Page 1357

    Wiring systems: 9a-24 b: a/c wire / f: console wire / g: instrument panel harness / q: a/b wire (rhd) b: a/c wire f: console wire g: instrument panel harness 17 11 g04 (to e76) g08 (to l09) g07 (to l08) g14 q02 g77 g44 g78 g63 g48 g13 g12 g52 g59 g15 g17 g81 g80 g53 g28 g76 g23 g75 g74 g22 g32 g49 g...

  • Page 1358

    9a-25 wiring systems: q: a/b wire b: a/c wire / f: console wire / g: instrument panel harness / q: a/b wire (lhd) b: a/c wire g14/yel multi information display g53/n room temperature sensor g15/n evap thermistor g54/blk steering switch g16/n a/c wire (to b03) g55/yel floor harness (to l29) g17/n fan...

  • Page 1359

    Wiring systems: 9a-26 f: console wire g: instrument panel harness q: a/b wire no./color connective position no./color connective position f01/n instrument panel harness (to g56) f05/n instrument panel harness (to g57) f02/grn seat heater switch (driver side) f06/grn seat heater switch (passenger sid...

  • Page 1360

    9a-27 wiring systems: door, roof s5jb0a910a003 j: front and rear door wire, rear door joint wire / k: roof wire (rhd, 5dr) j: front door wire (drive side) j: front door wire (passenger side) j: rear door wire k: roof wire j02 j08 j31 j27 j06 j19 j03 j07 k01 k04 k06 k02 k07 k05 k03 j10 j24 j25 j01 (t...

  • Page 1361

    Wiring systems: 9a-28 j: front and rear door wire, rear door joint wire / k: roof wire (lhd, 5dr) j: front door wire (drive side) j: front door wire (passenger side) j: rear door wire k: roof wire j02 j15 j32 j29 j13 j19 j03 j07 k04 k06 k02 k07 k05 k03 j10 j24 j25 j01 (to l07) j16 (to l13) j28 j14 j...

  • Page 1362

    9a-29 wiring systems: j: front and rear door wire / k: roof wire (rhd, 3dr) j: front door wire (drive side) j: front door wire (passenger side) k: roof wire j08 j06 j03 j07 k01 k02 j01 (to l07) j05 j04 j11 j12 j15 j14 j13 front door wire j09 (to l31) k j i5jb0a910913-02 no./color connective position...

  • Page 1363

    Wiring systems: 9a-30 j: front and rear door wire / k: roof wire (lhd, 3dr) j: front door wire (drive side) j: front door wire (passenger side) k: roof wire j15 j13 j03 j07 k02 j01 (to l07) j14 j04 j11 j12 k01 j08 j05 j06 front door wire j09 (to l31) k j i5jb0a910914-03 no./color connective position...

  • Page 1364

    9a-31 wiring systems: floor s5jb0a910a004 l: floor harness, rear height sensor wire / r: fuel pump wire (rhd, 5dr) l: floor harness { l15 r10 { l17 l66 l18 l21 l16 l44 l33 l06 l05 l11 l10 l12 l25 l04 l32 l45 l59 l30 l38 l19 l47 l41 l48 l26 l43 l54 l49 l53 l23 l35 l36 l22 l14 r02 r03 l40 l20 l67 l52 ...

  • Page 1365

    Wiring systems: 9a-32 l: rear height sensor wire r: fuel pump wire l: floor harness, rear height sensor wire / r: fuel pump wire (lhd, 5dr) l21/blk diode #3 l52/n licence plate light #1 l22/n j/c l53/n licence plate light #2 l23/n j/c l54/n rear end door switch l25/yel side air-bag inflator (r) l56/...

  • Page 1366

    9a-33 wiring systems: l: floor harness l: rear height sensor wire r: fuel pump wire no./color connective position no./color connective position l01/n main harness (to e80) l29/yel instrument panel harness (to g55) l03/yel main harness (to e79) l30/yel side air-bag inflator (l) l04/blk turn signal re...

  • Page 1367

    Wiring systems: 9a-34 l: floor harness, luggage compartment light wire, rear height sensor wire / r: fuel pump wire (rhd, 3dr) l: floor harness { l15 r01 { l19 l68 l23 l12 l44 l33 l06 l05 l11 l25 l04 l32 l59 l30 l36 l41 l64 l69 l47 l48 l26 l43 l54 l53 l38 l35 l34 l14 r02 r03 l20 l52 fuel pomp wire l...

  • Page 1368

    9a-35 wiring systems: l: luggage compartment light wire r: fuel pump wire l: floor harness, luggage compartment light wire, rear height sensor wire / r: fuel pump wire (lhd, 3dr) l27/n instrument panel harness (to g72) l63/n rear speaker (r) l28/n instrument panel harness (to g73) l64/n rear speaker...

  • Page 1369

    Wiring systems: 9a-36 l: floor harness l: luggage compartment light wire r: fuel pump wire no./color connective position no./color connective position l01/n main harness (to e80) l30/yel side air-bag inflator (l) l03/yel main harness (to e79) l31/gry front door wire (passenger side) (to j09) l04/blk...

  • Page 1370

    9a-37 wiring systems: rear s5jb0a910a005 o: rear end door harness o: rear end door harness o08 o01 (to l42) o o03 o09 o06 o07 o02 o04 o05 20 i5jb0a910919-01 no./color connective position no./color connective position o01/n floor harness (to l42) o06/blk rear defogger (–) o02/blk rear defogger (+) o0...

  • Page 1371

    Wiring systems: 9a-38 ground point ground (earth) point s5jb0a910c001 refer to “connector layout diagram: ”. 13 14 6 7 16 15 3 4 18 20 11 1 5 12 10 17 passenger side 19 driver side right side shown right side shown right side shown fwd j20a m16a fwd fwd m16a 5 j20a m16a 3 4 j20a 2 j20a 2 m16a fwd r ...

  • Page 1372

    9a-39 wiring systems: power supply diagram power supply diagram s5jb0a910d001.

  • Page 1373

    Wiring systems: 9a-40 wht/red 4 g21 3 1 2 19 blk/gry 2 1 blk/gry 17 18 19 21 2 e56 1 e42 1 blk/red 28 22 23 25 26 27 wht/blu 17 18 wht/red blu wht/blu 21 wht/grn wht/grn blk/red 22 wht/red 25 red/blu 26 27 blk/red blu/yel 23 15a 20 wht/red 20 30a 40a 50a 15a 40a 20a 30a 10a 10a 40a blk wht wht 2 e57...

  • Page 1374

    9a-41 wiring systems: 1 e41 4 g02 1 e83 2 e37 e38 "a-5" 11 11 9 10 11 9 10 red grn blu/red 15a 15a 20a wht/grn wht/grn 41 51 15a 36 15a 20a j/b power integration no.2 fuse box no.2 a/c compressor relay 9 12 wht/red pnk blk wht/red red/yel blk wht blu 15a 20a wht/grn wht/grn blk/red blk/red blk/red y...

  • Page 1375

    Wiring systems: 9a-42 2 g02 blk/yel 1 yel wht/grn e40 1 6 e35 red/yel 10 3 4 5 7 "a-8" bcm "a-8" bcm "a-8" bcm relay power integration no.1 13 25a 15 20a relay "b-3" blk/red blk/red blk/red e80 l01 9 l42 o01 4 blu/blk blu/blk e78 g05 9 orn orn e80 l01 1 e74 g36 22 8 blu/blk blu blu blu 7 e36 30 10a ...

  • Page 1376

    9a-43 wiring systems: fuses and the protected parts s5jb0a910d002 the chart below describes what parts each fuse protects. Fuses in battery fuse box, fuse box no.1 s5jb0a910d003 2 3 4 5 6 7 8 1 80a alt i5jb0a910924-01 no. Fuse protected circuit 80 a all electric circuit battery fuse box no.1 40 a ra...

  • Page 1377

    Wiring systems: 9a-44 fuse box no.2 (in power integration no.1, power integration no.2), relay box s5jb0a910d004 13 9 9 10 10 11 12 11 12 14 15 16 28 52 27 21 20 19 26 25 24 23 22 18 17 j20a m16a starting motor relay "a-1" e32 headlight hi relay "d-1" e32 headlight lo relay "d-1" e32 "a-5" e33 relay...

  • Page 1378

    9a-45 wiring systems: fuse box no.3 (in j/b) s5jb0a910d005 10 a h/l l headlight (l) headlight hi (l) 10 a h/l r headlight (r) headlight hi (r) 10 a h/l headlight hi relay headlight lo relay 40 a st starting motor relay 40 a ign ig switch 15 a di blank no. Fuse description on the cover protected circ...

  • Page 1379

    Wiring systems: 9a-46 20 a ig coil generator ig coil #1 ig coil #2 ig coil #3 ig coil #4 noise filter ecm fuel pump relay heated oxygen relay a/t relay icm 4wd control module 10 a meter bcm comb meter turn signal relay auto a/c unit 15 a acc acc relay bcm power mirror switch smart ecm audio multi in...

  • Page 1380

    9a-47 wiring systems: junction block (j/b) connector / fuse layout s5jb0a910d006 fuse side 1 1 1 2 3 4 5 6 11 12 13 14 15 16 7 8 17 18 9 10 19 20 1 2 3 4 5 6 11 12 13 14 15 16 7 8 17 18 9 10 19 20 2 1 8 3 9 4 10 5 11 6 12 7 2 1 8 3 9 4 10 5 11 6 12 7 2 1 3 4 2 1 3 4 1 2 3 4 5 6 9 10 11 12 13 14 7 8 ...

  • Page 1381

    Wiring systems: 9a-48 junction block inner circuit (overview) s5jb0a910d007 ig2 ig sw st ig1 acc cigar bcm dome inp earth j/c shift lever meter comb sw lp meter s/h sw dr as a/b cont lev sw strg snsr comb sw wiper acc socket-2 bcm cigar ill radio radio bcm radio bcm meter immobi cont * adsl * sun r ...

  • Page 1382

    9a-49 wiring systems: junction block inner circuit (detail) s5jb0a910d008 e82 k01 l05 l06 e83 g01 g02 g03 e82 g02 g01 e83 g03 k01 l05 l06 j/b connector no. / terminal no. (continued) 1 2 3 4 5 6 13 14 15 16 17 18 9 10 11 12 21 22 23 24 7 8 19 20 1 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 2 1 3 4 1 2 3...

  • Page 1383

    Wiring systems: 9a-50 e82 k01 l05 l06 e83 g01 g02 g03 e82 g02 g01 e83 g03 k01 l05 l06 j/b connector no. / terminal no. (continued) 1 2 3 4 5 6 13 14 15 16 17 18 9 10 11 12 21 22 23 24 7 8 19 20 1 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 2 1 3 4 1 2 3 4 5 6 11 12 13 14 15 16 7 8 17 18 9 10 19 20 1 2 5 ...

  • Page 1384

    9a-51 wiring systems: e82 k01 l05 l06 e83 g01 g02 g03 e82 g02 g01 e83 g03 k01 l05 l06 j/b connector no. / terminal no. (continued) 1 2 3 4 5 6 13 14 15 16 17 18 9 10 11 12 21 22 23 24 7 8 19 20 1 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 2 1 3 4 1 2 3 4 5 6 11 12 13 14 15 16 7 8 17 18 9 10 19 20 1 2 5 ...

  • Page 1385

    Wiring systems: 9a-52 e82 k01 l05 l06 e83 g01 g02 g03 e82 g02 g01 e83 g03 k01 l05 l06 j/b connector no. / terminal no. 1 2 3 4 5 6 13 14 15 16 17 18 9 10 11 12 21 22 23 24 7 8 19 20 1 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 2 1 3 4 1 2 3 4 5 6 11 12 13 14 15 16 7 8 17 18 9 10 19 20 1 2 5 6 3 4 9 10 7...

  • Page 1386

    9a-53 wiring systems: system circuit diagram system circuit diagram s5jb0a910e033 refer to “a-1 cranking system circuit diagram: ”. Refer to “a-2 charging system circuit diagram: ”. Refer to “a-3 ignition system circuit diagram (m16a): ”. Refer to “a-3 ignition system circuit diagram (j20a): ”. Refe...

  • Page 1387

    Wiring systems: 9a-54 a-1 cranking system circuit diagram s5jb0a910e001 starting motor relay p r n d 2 l transmission range sensor c28 4 5 e32 c23 1 c24 1 starting motor m off on 1 blk/gry blk/gry c31 c01 1 1 battery e55 c35 12 blk/red fuse box no.2 battery fuse box 27 40a 47 7.5a blk blk e55 c35 7 ...

  • Page 1388

    9a-55 wiring systems: a-2 charging system circuit diagram s5jb0a910e002 10 e55 c35 e54 c34 blk/wht blk/wht blk/wht 80a battery fuse box fuse box no.1 c22 j/b 1 c02 1 c03 1 c32 ig coil 1 20a 39 generator ic regulator 1 e82 23 c21 2 4 wht/red wr bcm "a-8" 1 g05 e78 5 wht/red wht/red 1 bb ecm "a-5" brn...

  • Page 1389

    Wiring systems: 9a-56 a-3 ignition system circuit diagram (m16a) s5jb0a910e003 20a 10 e55 c35 2 c40 1 3 ig coil #1 c41 blk/orn blk/wht blk/wht brn blk/wht j/b ecm b bb 39 ig coil blk/orn blk/orn ig coil #2 e82 23 5 brn/blk 1 3 2 c37 20 21 weld splice c55 blk/wht blk/wht blk/wht weld splice e62 noise...

  • Page 1390

    9a-57 wiring systems: a-3 ignition system circuit diagram (j20a) s5jb0a910e040 20a 10 e55 c35 2 c40 3 1 ig coil #1 c41 blk/orn blk/wht brn/blk brn/wht brn blk/wht blk/wht j/b ecm b bb 2 c42 3 1 ig coil #3 blk/orn 39 ig coil blk/orn blk/orn ig coil #2 e82 23 5 5 3 1 2 c37 20 21 weld splice c55 blk/wh...

  • Page 1391

    Wiring systems: 9a-58 a-4 cooling system circuit diagram s5jb0a910e004 e27 m 1 1 2 "a-5" rb relay #1 e29 3 e58 2 e82 5 1 5 relay #2 motor #2 e30 5 1 2 relay #3 e31 3 5 1 2 2 e26 m 2 motor #1 1 blu/blk blu/wht yel/grn yel/grn blu/yel yel/grn red blk blu/red red/blk blu/red red/yel blu blu yel/grn blu...

  • Page 1392

    9a-59 wiring systems: a-5 engine and a/c control system circuit diagram (m16a) s5jb0a910e005 1 2 3 4 yel/red e80 l01 8 15 1 4 pnk yel/red p pnk yel/red 3 1 3 7 3 6 yel/grn blk/yel blk/yel blk/yel blk/yel 6 blk 4 2 1 2 r02 and fuel gauge main relay 1 2 blk/wht pnk blk grn blk/wht yel/grn blk/wht blk/...

  • Page 1393

    Wiring systems: 9a-60 2 c09 1 c12 c13 c37 c37 knock sensor c19 ecm c04 2 1 c05 2 1 c06 2 1 c07 2 1 #2 #1 #3 #4 evap canister purge valve c14 ect sensor gry/grn gry/grn maf sensor 5 5 map sensor gry/grn gry/grn gry/grn gry/grn 1 "a-4" 3 rb 40a rdtr2 3 relay #1 motor #1 throttle motor relay relay #2 "...

  • Page 1394

    9a-61 wiring systems: egr stepper motor ecm 4 c10 yel yel/grn yel/blk 6 4 3 1 2 5 ckp sensor cmp sensor blk/yel blk/yel blk/yel blk/orn blk/orn 3 15 58 30 2 3 1 2 3 1 c08 c20 c37 4 3 5 6 52 51 wht/blu wht/red 5 yel/red blk/yel blk/yel 4 29 31 9 9 blk/yel blk/yel blu/orn blk/yel c56 weld splice blu/b...

  • Page 1395

    Wiring systems: 9a-62 g80 dlc g20 e74 g36 28 c34 e54 4 e74 g36 29 blk/yel blk/yel blk/yel 4 blk 15 j/c g81 5 5 5 16 wht 10 wht c37 brn brn/blk 20 21 wht/red wr gw abs cont.M 4 "f-2" 19 a a a a ppl/wht ppl/wht ppl/wht wht blk blk blk 17 11 a wht/blu j/c ecm e82 13 j/b 15a dome 44 20 15a stop 38 e23 e...

  • Page 1396

    9a-63 wiring systems: ecm yel acceleration pedal sensor throttle position sensor throttle sensor sub open close open close open close open close main sub main throttle motor e23 12 orn wht/blu wht blu/yel blu/grn orn/blu grn red blk wht blu/yel blu/red e68 1 6 c11 6 5 2 1 3 4 5 2 3 4 41 40 54 53 44 ...

  • Page 1397

    Wiring systems: 9a-64 a-5 engine and a/c control system circuit diagram (j20a) s5jb0a910e041 1 2 5 3 4 yel/red e80 l01 8 15 1 4 pnk yel/red p pnk yel/red 3 1 3 7 3 6 yel/grn blk/yel blk/yel blk/yel blk/yel 6 blk 4 2 1 2 r02 and fuel gauge main relay 1 2 blk/wht pnk blk blk/wht yel/grn blk/wht blk/wh...

  • Page 1398

    9a-65 wiring systems: 2 c09 1 c12 c13 c37 c37 knock sensor ecm c04 2 1 c05 2 1 c06 2 1 c07 2 1 #2 #1 #3 #4 evap canister purge valve c14 ect sensor gry/grn gry/grn maf sensor 9 9 map sensor gry/grn gry/grn gry/grn gry/grn gry/grn 1 "a-4" 3 rb 40a rdtr2 3 relay #1 motor #1 throttle motor relay relay ...

  • Page 1399

    Wiring systems: 9a-66 egr stepper motor cmp sensor ecm 4 c10 yel yel/grn yel/blk 6 4 3 1 2 5 blk/yel blk/orn blk/orn 3 15 58 30 2 1 3 c08 c37 4 3 5 6 33 52 wht/red 5 yel/red gry/red blk/yel blk/yel 4 3 29 31 10 10 blk/yel blk/yel blu/orn blk blk/yel blk/yel c56 weld splice blu/blk blu/blk blu/blk bl...

  • Page 1400

    9a-67 wiring systems: g80 dlc g20 e74 g36 28 16 c34 e54 4 e74 g36 29 g05 e78 14 13 12 blk/yel blk/yel blk/yel 4 blk j/c g81 5 5 5 16 wht 11 wht c37 brn brn/blk 20 21 wht/red wr gw abs cont.M 4 "f-2" 19 a a a a ppl/wht ppl/wht ppl/wht wht blk blk blk 17 11 a wht/blu j/c ecm e82 13 j/b 15a dome 44 20 ...

  • Page 1401

    Wiring systems: 9a-68 ecm yel acceleration pedal sensor throttle position sensor throttle sensor sub open close open close open close open close main sub main throttle motor e23 12 orn wht/blu wht blu/yel blu/grn orn/blu grn red blk wht blu/yel blu/red e68 1 6 c11 2 1 5 6 4 3 5 2 3 4 41 40 54 53 44 ...

  • Page 1402

    9a-69 wiring systems: a-6 a/t control system circuit diagram s5jb0a910e006 blu/yel brake light switch e67 yel/grn 20 8 7 19 18 6 1 9 7 3 8 grn/orn back-up light acc relay shift rock relay "d-8" "g-2" r transmission range sensor tcm g50 4 3 range switch a/t shift lever yel/blk red red 1 red red red b...

  • Page 1403

    Wiring systems: 9a-70 2 tcm bcm lock up solenoid a/t fluid temperature sensor shift solenoid no.2 shift solenoid no.1 11 12 c29 1 5 grn/red 3 grn orn 8 15 4 2 5 3 7 ppl/wht grn/yel pressure control solenoid brn/red yel/red 2 6 shift solenoid yel/blk grn/red grn orn ppl/wht grn/yel brn/red yel/red ye...

  • Page 1404

    9a-71 wiring systems: a-7 immobilizer system circuit diagram s5jb0a910e007 ecm icm dlc g20 4 j/c g81 5 5 7 3 ig coil g03 g03 2 j/b 29 20a 39 dome 15a 44 blk/wht 13 28 gry/blu gry/blu blk/wht gb pb e74 g36 28 c34 e54 4 e74 g36 29 blk/yel blk/yel blk/yel blk blk blk blk 16 wht e23 3 g24 1 4 blk 2 6 e7...

  • Page 1405

    Wiring systems: 9a-72 a-8 body control system circuit diagram s5jb0a910e008 1 3 wht red red red wht wht 2 g20 4 6 14 wht red brn yel/grn g31 dlc 4 blk 18 19 20 receiver 35 ppl/wht ppl/wht a a j/c g80 e74 g36 28 g05 e78 1 l08 g07 9 20 10 6 e54 c34 4 blk/yel 5 3 j/b 15a dome 44 g03 15 wht wht blk/yel ...

  • Page 1406

    9a-73 wiring systems: 38 39 "d-5" blk/orn blk/red blk/red blk/orn blk/orn 28 orn/blu 17 lt grn/red orn/blu blk red/grn blk blk blk blk blk blk blk blk red/grn 3 e e g32 g30 blu/red wht/blk 13 wht e j/c g76 g22 4 1 main switch (key switch) security option dome g03 13 15a 44 2 acc 8 15a 41 wht wht/blk...

  • Page 1407

    Wiring systems: 9a-74 22 blu/blk blu/blk blu/blk "g-4" navigation g30 "b-5" "b-5" "b-5" 10 g32 11 rear front front motor motor lt grn lt grn grn/red grn/red 15 5 "d-5" blk/red g32 luggage compartment light br bb "d-9" bb gr lg gr lg lg gr lg gr motor (r) "b-5" rear motor (l) bcm a/lev cont.M blk/red...

  • Page 1408

    9a-75 wiring systems: "b-5" front motor 2 blu/yel blu/wht rear end door lock motor bw br by by "b-5" "b-5" front motor "b-5" rear motor (r) "b-5" rear motor (l) bcm g08 l09 3 br blu/red blu/red 5 g08 l09 19 6 12 l42 o01 blu/red blu/red blu/red blu/red blu/red blu/red 11 blu/yel blu/yel blu/yel blu/y...

  • Page 1409

    Wiring systems: 9a-76 19 g30 12 1 g32 blk blk blk "f-1" yel a/b sdm y "a-2" generator g31 g31 10 wht/red wr "b-3" relay bb 16 5 a a a g30 g30 g31 j/c g78 yel/red pnk/blk yel/red 22 blk 25 yel 23 pnk/blu pb 11 red/blu rb 9 lt grn/blk lgb 4 pnk/grn pg 21 gry g 10 pnk/blu pb yr yel/red yr "g-2" multi i...

  • Page 1410

    9a-77 wiring systems: a-10 4wd control system circuit diagram s5jb0a910e034 1 4wd cont.M bcm 40a 4 4wd fuse box no.1 e91 11 wht wht 4 e88 c49 e88 c49 pnk/wht red/grn pnk c52 t/f 4l switch c53 t/f position switch red/grn pnk/wht pnk/wht 1 2 1 b b 2 2 3 e90 g71 22 blk blk blk 13 14 blk blk 7 10 m blu ...

  • Page 1411

    Wiring systems: 9a-78 g59 4wd switch 2wd 4wd 4wd- low lt grn blu/orn 18 7 8 19 20 19 red/yel wht red/blu red/yel 2 3 4 5 1 6 blk blk red/blu blk blk blk blk blk blk lt grn blu/orn blu/blk blu/blk 7 15 17 1 e72 clutch 4wd switch 2 blk/orn blk/orn blk/orn 7 21 e90 g71 10a tail 43 j/b e91 4wd cont.M 17...

  • Page 1412

    9a-79 wiring systems: b-1 windshield wiper and washer circuit diagram s5jb0a910e009 j/b lo hi e01 2 blk blk blk blk blk blk e82 18 17 g23 23 switch 12 blu/wht blu/wht 3 8 blu/red blu/red blu blu 24 wip 20a 33 2 e10 1 g01 16 yel/red m m yel/red blu/blk 17 15 7 blk off on wf ew p t mist off int lo hi ...

  • Page 1413

    Wiring systems: 9a-80 b-2 rear wiper and washer circuit diagram s5jb0a910e010 j/b o03 2 1 l05 9 g23 10 l42 o01 16 o01 l42 e82 16 wash off int on on+wash wr ew +1r p t blk 1 e11 2 yel/red yel/red yel/red m blu/yel blu/yel yel/red grn/yel grn/yel grn/yel 20a wip 33 21 e74 g36 blu/yel r.Int switch rela...

  • Page 1414

    9a-81 wiring systems: b-3 rear defogger circuit diagram s5jb0a910e011 l42 o01 4 o02 1 o06 1 20 25a rr def 13 relay blk/red blk/red 7 blu/blk blk/red blu/blk blk/red e36 8 auto unit blk blk 17 blk g52 8 power integration no.1 bb bb l09 g08 3 e78 g05 9 e80 l01 9 "a-8" bcm 11 j/c g09 a i5jb0a910955-05.

  • Page 1415

    Wiring systems: 9a-82 b-4 power window circuit diagram s5jb0a910e012 2 1 j15 l31 j09 j01 l07 2 14 1 13 9 1 2 2 3 5 10 11 17 16 1 4 30a p/w 50 sub switch main switch j14 1 2 red yel blk blk yel 15 l06 4 5 j/b blk blk 9 13 blu/wht blu/wht 3 blu/wht blu/wht blu/wht 1 6 2 3 4 5 grn/blk blu/wht red/blk g...

  • Page 1416

    9a-83 wiring systems: j24 l37 j21 j19 2 3 5 2 1 2 3 3 2 l13 j16 1 2 3 5 j23 j18 grn/yel grn/yel blu/wht red/yel blu/wht red/yel 10 3 4 j01 l07 1 4 1 2 m red yel 1 4 1 2 red yel 1 6 2 3 4 5 unlock up off down up off down lock ig e rlu rld rear (l) sub switch rear motor (l) m unlock up off down up off...

  • Page 1417

    Wiring systems: 9a-84 b-5 power door lock circuit diagram s5jb0a910e013 36 37 21 32 8 3 switch j06 l07 j01 l31 j09 pnk/blu pnk main switch 1 14 9 26 27 33 22 l08 g07 9 20 j08 pnk/grn blk blk blk blk blk pnk/blk pnk/blu pnk pnk/grn pnk/blk pnk/blu pnk pnk/grn pnk/blk up off down lock unlock e receive...

  • Page 1418

    9a-85 wiring systems: 1 5 3 4 14 12 11 l42 o01 o04 rear motor (l) lt grn 1 j25 grn/red 3 m m 4or2 m lt grn grn/red blu/yel blu/red blu/wht red/wht blu/wht bcm 1 2 4 3 blu/red motor rear end bw lg 10 l37 j21 blu/yel blu/yel by gr 19 blu/red blu/red br 10 3 4 19 rear motor (r) lt grn 1 j20 grn/red m m...

  • Page 1419

    Wiring systems: 9a-86 b-6 power mirror circuit diagram s5jb0a910e014 13 8 5 9 r l 3 19 7 7 j07 l06 l07 j01 18 e80 l01 9 e78 g05 6 j03 j11 1 j01 l07 j01 l07 blk blk switch motor (r) m m down up 5 r l 6 motor (l) m m down up 2 1 2 wht/blk wht/blk acc 15a 41 18 7 27 28 18 27 28 l31 j09 7 l07 j01 brn/ye...

  • Page 1420

    9a-87 wiring systems: b-7 horn circuit diagram s5jb0a910e015 1 4 power integration no.1 15a horn 14 grn/blk grn/blk grn/blk orn orn 1 horn switch steering switch (contact coil) horn (lo) trailer h 3 b b b j/c horn relay e16 1 horn (hi) h e15 g76 e36 without auto cruise with auto cruise a b o gb "d-4...

  • Page 1421

    Wiring systems: 9a-88 b-8 seat heater circuit diagram s5jb0a910e035 yel/grn yel/grn red/yel red/yel grn/red blk f06 5 6 l59 3 4 4 1 2 f02 5 l57 3 4 red/grn red/blk grn/red red/blk blk 4 1 2 red/grn switch free lock free lock switch 6 j/c g79 a a a 4 g01 ig2 sig 15a 32 red/blu red/yel yel/grn 10a tai...

  • Page 1422

    9a-89 wiring systems: b-9 smart key system circuit diagram s5jb0a910e036 g03 smart ecm bcm wht wht wht blu/red wht red wht red brn/red "a-8" w r g44 14 34 20 18 19 blk 9 13 j/b 15a dome 44 g01 3 10a back 31 8 15a acc 41 e e e j/c g76 wht/blk wht/blk c c j/c g77 main switch (key switch) steering lock...

  • Page 1423

    Wiring systems: 9a-90 b-10 sliding roof circuit diagram s5jb0a910e042 k07 sliding roof switch sliding roof unit 2 3 5 k06 9 10 7 3 25a 45 s/r j/b 5 pnk 6 15a 32 ig2 sig 8 yel/grn pnk/blu blk pnk/blk blk blk blk k01 10 8 j/b k01 g01 11 j/c g09 a i5jb0a910964-03.

  • Page 1424

    9a-91 wiring systems: b-11 headlight cleaner circuit diagram s5jb0a910e043 g62 2 30a 23 h/l cnlr fuse box no.2 j/b 3 blu/yel blu yel/red blu 16 20a 33 wip 6 blu/blk 5 blk g01 a a j/c g77 e e j/c g78 12 j/c g10 a blk 11 j/c g09 a hlc cont.M bb "b-1" e75 g37 1 e74 g36 13 hlc motor hlc switch headlight...

  • Page 1425

    Wiring systems: 9a-92 c-1 combination meter circuit diagram s5jb0a910e017 dome 15a 44 meter 10a 40 wht wht ppl/red 14 13 15 lcd break g03 11 ppl/red 12 blu/wht j/b 15 blk d d j/c turn signal relay c c g76 4 7 j/c 3 6 l05 g01 "d-10" "d-6" bw 16 yel/blk yb "d-4" 22 blu ill cancel switch b g28 grn/orn ...

  • Page 1426

    9a-93 wiring systems: a a j/c b b g75 g74 "a-8" g28 red wht 10 8 red r w 2 hight can low cpu smart red abs low fuel immobi at mode power train cheak engine hi beam door seat belt oil charge ill on smart blue at-l at-2 at-3 at-d at-n at-r wht bcm 1 (can line) i5jb0a910967-05.

  • Page 1427

    Wiring systems: 9a-94 d-1 headlight system circuit diagram (one bulb type) s5jb0a910e019 1 headlight (r) headlight (l) headlight hi relay wht/blu red/blu dimmer / passing switch light switch 2 2 3 3 1 e08 e21 red/blu wht/red 9 g25 10a 25 10a 24 h/l r h/l l 10a 26 h/l red/wht red red red 2 red/blu re...

  • Page 1428

    9a-95 wiring systems: d-1 headlight system circuit diagram (with projector light) s5jb0a910e044 headlight hi relay wht/blu dimmer/ passing switch light switch red/blu wht/red 9 g25 10a 25 10a 24 h/l r wht/red 15a 18 h/l lo r h/l l 10a 26 h/l red/wht red red red 2 red/blu red/blu red/blk red/blu blk ...

  • Page 1429

    Wiring systems: 9a-96 d-1 headlight system circuit diagram (with discharge bulb) s5jb0a910e045 headlight hi relay wht/blu dimmer/ passing switch light switch red/blu wht/red 9 g25 10a 25 10a 24 h/l r h/l l 10a 26 h/l red red red 2 red/blu red/blu red/blk red/blu blk red/blk red/blu red/blu red/blu r...

  • Page 1430

    9a-97 wiring systems: d-2 position, tail and licence plate light system circuit diagram s5jb0a910e020 3 5 l20 1 2 l52 12 11 g31 g30 (l) (r) (l) (r) blk red/yel red/yel 16 g03 blk g25 10a tail 43 1 2 e07 1 2 e22 blk blk blk red/yel j/b l05 7 2 e82 3 15 blk blk e60 weld splice licence plate light #1 3...

  • Page 1431

    Wiring systems: 9a-98 d-3 front fog light system circuit diagram s5jb0a910e021 fr fog (r) (l) 1 e18 2 1 e12 2 20a 15 tail 10a 43 relay switch 8 e35 6 7 red/yel red/yel red/blu lt grn lt grn/blk blk blk lt grn lt grn 6 a a a 4 7 8 16 19 g29 g77 g03 1 e82 red/grn blk 5 8 6 blk blk lt grn/red lt grn/re...

  • Page 1432

    9a-99 wiring systems: d-4 illumination light system circuit diagram s5jb0a910e022 red/blu red/blu a/t shift lever g50 2 5 ill cancel switch g41 7 5 8 red/grn g58 1 2 blk blk blk blk grn j/b 16 g03 blk g25 17 a/t red/yel red/yel l05 e36 7 2 4 trailer 3 l26 5 4 8 "d-3" ry switch j/c g77 red/yel ry red...

  • Page 1433

    Wiring systems: 9a-100 d-5 interior light system circuit diagram s5jb0a910e023 15a 44 dome j/b off door on k02 2 5 3 1 interior light console lamp 38 39 off on off on l10 1 1 blk/orn blk/orn blk/blu off door on k03 3 2 1 rear interior light off on off on l16 l34 1 l40 1 off on l54 1 rear door switch...

  • Page 1434

    9a-101 wiring systems: d-6 turn signal and hazard warning light system circuit diagram s5jb0a910e024 6 g48 5 switch turn signal relay 1 l04 8 red/yel yel/red yel/red yel/red red/yel ppl/red wht/grn red/blu yel/red turn signal switch g25 grn/yel grn/red grn/yel grn/red j/b l n r turn t p tb tl tr 4 g...

  • Page 1435

    Wiring systems: 9a-102 grn/red grn/red 7 (turn (l)) (turn (r)) e06 6 g01 7 8 grn/yel grn/yel grn/red grn/yel "c-1" gr gy front turn signal light (r) side turn signal light (r) e09 2 e19 front turn signal light (l) side turn signal light (l) blk blk 8 6 e82 19 11 1 2 1 2 1 2 1 e20 1 2 j/b grn/yel grn...

  • Page 1436

    9a-103 wiring systems: d-7 brake light system circuit diagram s5jb0a910e025 brake light switch steering switch (l) brake light grn blk (r) 15a 38 stop e67 l20 grn/wht grn/wht grn/wht grn/wht 5 "a-5" ecm gw gw gw ecm 4 2 3 1 20 blu/blk blu/blk blu/blk 10a 35 cruise j/b l43 2 5 o07 1 2 high mounted st...

  • Page 1437

    Wiring systems: 9a-104 d-8 back-up light system circuit diagram s5jb0a910e026 blk blk back-up light switch back-up light (r) red red yel yel on off j/b 10a 31 back e54 c34 15 e80 l01 10 c48 e87 3 c30 2 1 9 l43 1 l20 1 red red a/t m/t p r n d 2 l transmission range sensor yel c28 r red red 1 red "a-6...

  • Page 1438

    9a-105 wiring systems: d-9 headlight beam leveling system circuit diagram (manual leveling) s5jb0a910e037 10a yel grn grn grn blk blk switch 31 back yel/red yel/grn e49 g01 3 e45 3 1 3 6 e82 10 1 2 g40 e74 g36 5 3 4 32 g36 e74 31 2 blk blk actuator (l) actuator (r) yel r1 p0 p1 p2 p3 p4 r2 r3 r4 r5 ...

  • Page 1439

    Wiring systems: 9a-106 d-9 headlight beam leveling system circuit diagram (auto leveling) s5jb0a910e046 g51 3 e86 blu/red blu/red blu/red 13 a/lev cont.M 3 b b 10a 31 back j/b 1 yel yel grn/blk grn/blk g01 1 e49 24 j/c g78 bcm bw "a-8" "d-1" "c-1" actuator (l) 5 diagnosis connector #4 g43 2 12 e75 g...

  • Page 1440

    9a-107 wiring systems: d-10 rear fog light circuit diagram s5jb0a910e038 7.5a rr fog blk grn/orn grn/orn pnk/blu off on 5 4 "c-1" go go g25 3 g01 15 4 j/b g07 l08 22 37 l20 l43 b a b a 18 j/c l22 a 19 j/c rear fog switch (comb switch) l23 a rhd lhd a b i5jb0a910981-02.

  • Page 1441

    Wiring systems: 9a-108 e-2 auto a/c system circuit diagram s5jb0a910e047 1 2 g49 g52 12 18 5 17 4 12v 1 blk red/yel red/yel red/blu ppl/red ppl/red wht wht 11 g03 4 16 ill auto a/c panel sunlight sensor auto unit 11 pnk/grn "a-8" pg rb ry bcm "a-8" bcm bcm pnk yel 3 ppl/wht ppl/wht wht blk red/grn 5...

  • Page 1442

    9a-109 wiring systems: g15 1 2 13 19 2 16 g52 20 b04 m 29 28 30 23 14 27 21 1 2 m 3 g17 13 g03 wht wht red/blk wht/red gry gry/blu red/wht wht/blu gry/blk gry/red wht/blk blk/red red/wht wht/red gry red/wht wht/blu gry/blk blk/red blk blk/red blk/red gry/blu gry/red blk/red blk/red blu/wht blk blu/w...

  • Page 1443

    Wiring systems: 9a-110 f-1 air-bag system circuit diagram (without side a/b and curtain a/b) s5jb0a910e028 2 orn y yb a/b sdm g47 j/b 15a a/b 29 red wht wht g01 bcm 14 blk 1 15a dome 44 g03 15 e77 g06 1 pnk/blk e13 forward sensor check terminal 2 1 contact coil g26 1 2 yel/red grn/red q02 1 2 1 2 ye...

  • Page 1444

    9a-111 wiring systems: f-1 air-bag system circuit diagram (with side a/b and curtain a/b) s5jb0a910e048 2 orn y yb a/b sdm g46 l33 l33 j/b 15a a/b 29 red wht wht g01 bcm 14 blk 1 15a dome 44 g03 15 e79 l03 1 pnk/blk e13 forward sensor check terminal 2 1 contact coil g26 1 2 yel/red grn/red q02 1 2 1...

  • Page 1445

    Wiring systems: 9a-112 l30 l25 l18 l41 1 2 1 2 a/b sdm l33 l33 l32 l11 l35 1 2 2 4 3 1 2 4 3 1 2 16 15 13 14 sensor sensor lt grn blk/yel yel/grn yel/blu wht/grn wht/red lt grn/blk brn/wht brn 1 2 gry/red gry brn/yel 1 2 1 i5jb0a910986-05.

  • Page 1446

    9a-113 wiring systems: f-2 anti-lock brake system circuit diagram s5jb0a910e029 13 26 1 14 8 12 6 e03 abs cont.M ecm blk 50a abs1 21 30a abs2 20 wht/red wht/blu 10 blk red r red w wht wht 1 6 g05 e78 j/b 10a abs 30 e82 24 grn/orn 7 wb "a-5" bcm "a-8" wht/blu 10 wr wht/red fuse box no.2 j/c g75 g74 a...

  • Page 1447

    Wiring systems: 9a-114 lt grn/blk abs cont.M l38 yel yel/blk yel yel/blk l01 e80 13 4 wheel speed sensor (rl) lt grn lt grn/blk lt grn 5 14 l14 wheel speed sensor (rr) grn e05 wheel speed sensor (fr) grn/blk blu/blk e25 wheel speed sensor (fl) blu 18 19 22 21 25 24 16 15 e03 1 2 1 2 1 2 1 2 5 dlc pp...

  • Page 1448

    9a-115 wiring systems: g-1 audio system circuit diagram s5jb0a910e031 g03 3 g11 1 15 16 15 16 7 16 8 2 1 1 2 2 1 1 2 2 1 2 1 5 15 6 16 11 "d-4" b "d-4" ry wht g12 1 g77 j/b 15a dome 44 red/yel j/c wht/blk wht/blk 15a acc 41 blk tweeter (l) front (l) j12 j10 tweeter (r) front (r) j04 j02 rear (r) j/b...

  • Page 1449

    Wiring systems: 9a-116 g-2 multi information display / accessory socket system circuit diagram s5jb0a910e032 8 wht/blk wht/blk wht wht yel/red yel/red wht/blu 15a acc 41 15a acc 2 34 15a acc 3 36 j/c g77 g56 f01 yr multi information display j/b bcm 2 blk 15a dome 44 g03 15 g14 1 4 5 red/yel red/yel ...

  • Page 1450

    9a-117 wiring systems: g-4 navigation system circuit diagram s5jb0a910e039 navigation g13 3 back-up light switch "a-8" bb m/t bcm 2 red red red blu/blk 1 rb red/blk red red "d-8" r r l08 g07 4 e80 l01 10 c34 e54 9 transmission range sensor a/t "d-8" j/c c51 c c i5jb0a910991-03.

  • Page 1451

    Wiring systems: 9a-118 list of connectors list of connectors s5jb0a910f009 refer to “b connector: ”. Refer to “c connector: ”. Refer to “e connector: ”. Refer to “f connector: ”. Refer to “g connector: ”. Refer to “j connector: ”. Refer to “k connector: ”. Refer to “l connector: ”. Refer to “o conne...

  • Page 1452

    9a-119 wiring systems: c25 c26 c27 c28 c29 c30 a/t a/t a/t a/t c31 c32 c33 c34 (to e54) c35 (to e55) c36 c37 c38 c39 j20a j20a c40 c40 c41 c41 c42 c43 m16a j20a m16a j20a j20a j20a c46 c47 c48 (to e87) c49 (to e88) j20a j20a j20a c50 (to e89) c51 c52 c53 c54 j20a j20a j20a j20a j20a c55 c56 1 2 mcon...

  • Page 1453

    Wiring systems: 9a-120 e connector s5jb0a910f002 e01 e02 e03 e04 e05 e06 e07 e08 e09 e10 e11 e12 e13 e14 e15 e16 e17 (to b01) e18 e19 e20 e21 e22 j20a e23 e24 e25 e26 e27 e28 e29 e30 e31 e32 e33 e34 m16a e35 e36 e37 j20a e38 e40 e41 e42 e43 j20a j20a 1 2 5 4 3 mconf050027-01 2 1 mconf020115-01 1 2 3...

  • Page 1454

    9a-121 wiring systems: e44 e45 e46 e47 e48 e49 e50 e51 e52 (to e85) e54 (to c34) e55 (to c35) e56 e57 e58 e59 e60 e61 e62 e63 e64 e67 e68 e69 if eqpd e70 e71 e72 e74 (to g36) e75 (to g37) e76 (to g04) e77 (to g06) e78 (to g05) e79 (to l03) if eqpd e80 (to l01) e82 e83 e85 (to e52) e86 e87 (to c48) e...

  • Page 1455

    Wiring systems: 9a-122 f connector s5jb0a910f011 g connector s5jb0a910f003 e90 (to g71) e91 e92 e93 a/t a/t f01 (to g56) f02 f03 f04 f05 (to g57) f06 lhd a/t f07 f08 rhd a/t g01 g02 g03 g04 (to e76) g05 (to e78) g06 (to e77) g07 (to l08) g08 (to l09) g09 g10 g11 g12 g13 g14 g15 g16 (to b03) g17 g18 ...

  • Page 1456

    9a-123 wiring systems: g20 g21 g22 g23 g24 g25 g26 g27 g28 g29 g30 g31 g32 g33 g34 g35 g36 (to e74) g37 (to e75) g38 if eqpd g39 g40 g41 g43 g44 g46 g47 if eqpd g48 g49 g50 g51 g52 g53 g54 g55 (to l29) 8 7 6 5 4 3 2 1 9 10 11 12 13 14 15 16 mconm160003-01 3 2 1 6 5 4 mconf060063-01 2 5 1 4 7 6 8 3 m...

  • Page 1457

    Wiring systems: 9a-124 g56 (to f01) g57 (to f05) g58 g59 g62 g63 g64 g67 (to q01) g69 g71 (to e90) if eqpd g72 (to l27) g73 (to l28) g74 g75 g76 g77 g78 g79 g80 g81 g82 3 8 13 1 2 4 9 7 12 6 11 5 10 mconm130003-01 3 8 13 1 2 4 9 7 12 6 11 5 10 mconm130003-01 1 2 mconf020140-01 1 2 3 4 5 6 mconf06004...

  • Page 1458

    9a-125 wiring systems: j connector s5jb0a910f004 j01 (to l07) j02 j03 j04 j05 j06 j07 j08 j09 (to l31) j10 j11 j12 j13 j14 j15 j16 (to l13) 26 25 24 23 34 22 33 21 31 14 13 12 6 11 5 10 7 8 2 9 1 4 3 30 32 20 29 19 28 18 17 16 15 27 mconm340003-02 2 1 mconf020159-01 6 2 1 7 5 4 3 mconm070005-01 1 2 ...

  • Page 1459

    Wiring systems: 9a-126 k connector s5jb0a910f005 j17 j18 j19 j20 j21 (to l37) j22 j23 j24 j25 j26 j27 j28 j29 j31 j32 k01 k02 k03 k04 k05 k06 k07 1 2 mconf020008-01 1 2 mconf020236-01 1 2 3 4 5 mconf050021-01 5 6 7 8 9 10 1 4 3 2 mconf100061-01 1 12 21 11 20 10 19 9 18 8 17 7 16 6 15 5 14 4 2 3 13 m...

  • Page 1460

    9a-127 wiring systems: l connector s5jb0a910f006 l01 (to e80) l03 (to e79) l04 l05 if eqpd l06 l07 (to j01) l08 (to g07) l09 (to g08) l10 l11 l12 l13 (to j16) l14 l15 (to r01) l16 if eqpd l17 (to l66) l18 l19 (to l68) l19 l20 l21 if eqpd 3 dr 5 dr l22 l23 l25 l26 l27 (to g72) if eqpd 7 4 5 6 1 16 15...

  • Page 1461

    Wiring systems: 9a-128 l28 (to g73) l29 (to g55) l30 l31 (to j09) l32 if eqpd if eqpd l33 l34 l35 l36 l37 (to j27) if eqpd if eqpd l38 l40 l41 l42 (to o01) l43 l44 if eqpd l45 l47 l48 l49 l52 l53 5 dr 5 dr l54 l56 l57 l59 l63 l64 3 dr 3 dr l66 (to l17) l67 l68 (to l19) l69 3 dr 3 dr 9 8 18 17 2 1 11...

  • Page 1462

    9a-129 wiring systems: o connector s5jb0a910f007 q connector s5jb0a910f012 r connector s5jb0a910f008 o01 (to l42) o02 o03 o04 o05 o06 o07 o08 o09 q01 (to g67) q02 r01 (to l15) r02 r03 2 1 8 3 9 7 14 13 6 5 15 12 11 4 10 16 mconf160010-01 1 mconm010034-01 2 1 4 3 mconm040022-01 1 2 3 4 mconf040069-01...

  • Page 1463: Lighting Systems

    Lighting systems: 9b-1 lighting systems precautions precautions for discharge headlight service (if equipped) s5jb0a9200001 warning ! • do not touch igniter or ballast when lighting switch is at “head” position to avoid possible electric shock. • do not measure voltage or resistance with tester conn...

  • Page 1464

    9b-2 lighting systems: general description discharge headlight description (if equipped) s5jb0a9201001 discharge headlight provides more brightness and consumes less electricity as compared with the conventional halogen headlight. It consists of a ballast (1), igniter (2) and discharge headlight bul...

  • Page 1465

    Lighting systems: 9b-3 auto leveling headlight system description (if equipped) s5jb0a9201002 auto leveling headlight system adjusts the optical axis of the headlight automatically to be suitable for the varied vehicle position while the headlights are lit. It consists of front height sensor (1), re...

  • Page 1466

    9b-4 lighting systems: front and rear height sensors height sensor (1) is installed to the front and rear suspension frames respectively and connected to the lower arm (4) with the link (3). Each height sensor converts vertical movement of the lower arm into the resistance value and outputs the dete...

  • Page 1467

    Lighting systems: 9b-5 headlight leveling actuator headlight leveling actuator is (1) located in the headlight housing (2). It moves the reflector (3) in the headlight housing according to the drive signal from the headlight leveling control module so as to adjust the optical axis of the headlight t...

  • Page 1468

    9b-6 lighting systems: d.R.L. System description (if equipped) s5jb0a9201004 the d.R.L. System is controlled by bcm (1). It lights headlights when following two conditions are met.Conditions for d.R.L. Operation: • the engine is running • the lighting switch is at “off” position schematic and routin...

  • Page 1469

    Lighting systems: 9b-7 component location lighting system components location s5jb0a9203001 note the following figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 26* 15* 8* 15* 19* 1 1 1 2 1 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 10*...

  • Page 1470

    9b-8 lighting systems: interior light system location s5jb0a9203002 diagnostic information and procedures self-diagnosis function for auto leveling headlight system s5jb0a9204015 the headlight leveling control module has self-diagnosis function to monitor the system components and circuits while the...

  • Page 1471

    Lighting systems: 9b-9 headlight symptom diagnosis (vehicle equipped with discharge headlight) s5jb0a9204001 headlight symptom diagnosis (vehicle not equipped with discharge headlight) s5jb0a9204017 condition possible cause correction / reference item only one low beam does not light up circuit fuse...

  • Page 1472

    9b-10 lighting systems: auto-on headlight system symptom diagnosis (if equipped) s5jb0a9204018 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of suzuki...

  • Page 1473

    Lighting systems: 9b-11 headlight auto leveling system symptom diagnosis (if equipped) s5jb0a9204019 headlight manual leveling system symptom diagnosis (if equipped) s5jb0a9204010 turn signal and hazard warning light symptom diagnosis s5jb0a9204002 condition possible cause correction / reference ite...

  • Page 1474

    9b-12 lighting systems: clearance, tail and license plate light symptom diagnosis s5jb0a9204003 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of suzuk...

  • Page 1475

    Lighting systems: 9b-13 stop (brake) lamp symptom diagnosis s5jb0a9204005 front fog light (if equipped) symptom diagnosis s5jb0a9204006 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagn...

  • Page 1476

    9b-14 lighting systems: interior light symptom diagnosis s5jb0a9204007 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of suzuki scan tool” under “scan ...

  • Page 1477

    Lighting systems: 9b-15 inspection of headlight leveling control module and its circuit (vehicle equipped with auto leveling headlight system) s5jb0a9204021 headlight auto leveling control module and its circuits can be checked at headlight auto leveling control module wiring couplers by measuring v...

  • Page 1478

    9b-16 lighting systems: reference waveform no.1 vehicle speed signal (1). Vehicle speed signal is pulse. Pulse frequency varies depending on vehicle speed. 12 power supply for rear height sensor about 5 v ignition switch is at on position. 13 power supply for front height sensor about 5 v ignition s...

  • Page 1479

    Lighting systems: 9b-17 repair instructions headlight housing removal and installation s5jb0a9206001 warning ! Be sure to read “precautions for discharge headlight service (if equipped): ” before starting to service work. Neglecting them may result in personal injury. Removal 1) disconnect negative ...

  • Page 1480

    9b-18 lighting systems: other than discharge headlight bulb 1) disconnect negative (–) cable at battery. 2) disconnect coupler from bulb (1). 3) remove socket cover (2) (if equipped). 4) replace bulb and assemble all removed parts. Ballast removal and installation s5jb0a9206023 warning ! Be sure to ...

  • Page 1481

    Lighting systems: 9b-19 igniter removal and installation s5jb0a9206024 warning ! Be sure to read “precautions for discharge headlight service (if equipped): ” carefully before working. Neglecting them may result in personal injury. Removal 1) remove ballast referring to “ballast removal and installa...

  • Page 1482

    9b-20 lighting systems: a a x x 4 3 3 b b [a] [b] a a x x 4 3 3 b b [a] [b] 11 2 1 7 6 5 12 12 5 10 9 8 10 9 8 7 6 “b” “a” “h” “h” “h” “h” “h” [f] [e] [c] [d] i5jb0a920022-01 2. Headlight bulb 9. Turning (for right adjustment) [a]: left headlight 3. Cut line (bounding line) 10. Turning (for left adj...

  • Page 1483

    Lighting systems: 9b-21 headlight switch (in lighting switch) removal and installation s5jb0a9206004 removal 1) disconnect negative cable at battery. 2) remove steering column hole cover (1). 3) remove steering column covers (2). Turn steering wheel to access steering column cover screws (3). 4) rem...

  • Page 1484

    9b-22 lighting systems: headlight relay inspection 1) disconnect negative (–) cable at battery. 2) remove headlight relay from main fuse box. 3) check that there is no continuity between terminal “3” and “4”. If there is continuity, replace relay. 4) connect battery positive (+) terminal to terminal...

  • Page 1485

    Lighting systems: 9b-23 turn signal light switch (in lighting switch) removal and installation s5jb0a9206009 for removal and installation, refer to “headlight switch (in lighting switch) removal and installation: ”. Turn signal light switch (in lighting switch) inspection s5jb0a9206010 check for con...

  • Page 1486

    9b-24 lighting systems: license lamp assembly removal and installation s5jb0a9206013 removal 1) disconnect negative (–) cable at battery. 2) disconnect coupler (1) from license lamp assembly (2). 3) push locking part to arrow direction, and then remove license lamp assembly (2). Installation reverse...

  • Page 1487

    Lighting systems: 9b-25 front fog light switch inspection (if equipped) s5jb0a9206016 note front fog lights light up only when headlight switch is in headlight position (low or high beams) or small position. Front fog lights turn off automatically when headlight switch is turned to off position. If ...

  • Page 1488

    9b-26 lighting systems: 3) if it is not set properly, align front fog light to specification by rotating aiming gear. Headlight manual leveling switch (if equipped) inspection s5jb0a9206019 check for continuity between terminals at each switch position. If check result is not as specified, replace s...

  • Page 1489

    Lighting systems: 9b-27 headlight leveling actuator inspection (if equipped) s5jb0a9206026 vehicle equipped with headlight auto leveling system 1) make sure all couplers of headlight and leveling actuator are connected securely. 2) park vehicle in front of blank wall (screen). 3) turn ignition switc...

  • Page 1490

    9b-28 lighting systems: height sensor removal and installation (if equipped) s5jb0a9206027 removal caution ! • do not remove bracket (4) and link (3) from height sensor (2). Removal will spoil its original function. If faulty condition is found, replace it with new one in a set. • if height sensor w...

  • Page 1491

    Lighting systems: 9b-29 height sensor and its circuit inspection (if equipped) s5jb0a9206028 1) remove front or rear height sensor from vehicle referring to “height sensor removal and installation (if equipped): ”. 2) connect connector to height sensor. 3) vary position of height sensor link (1) and...

  • Page 1492

    9b-30 lighting systems: without initialization of the auto leveling headlight system, it is not possible to obtain its proper function. Also, if the auto leveling headlight system is not initialized after replacing the headlight leveling control module, the headlight leveling warning light in the co...

  • Page 1493

    Lighting systems: 9b-31 auto-on headlight sensor inspection (if equipped) s5jb0a9206031 1) disconnect negative (–) cable at battery. 2) remove auto-on headlight sensor (1) located on the passenger side of the dashboard (2). Be careful not to damage the sensor (1) and dashboard by using rag (3). 3) m...

  • Page 1494

    9c-1 instrumentation / driver info. / horn: instrumentation / driver info. / horn precautions precautions in diagnosing troubles for combination meter s5jb0a9300001 • combination meter uses signals (information) from each control module by can communication to control speedometer, tachometer, fuel m...

  • Page 1495

    Instrumentation / driver info. / horn: 9c-2 • data from abs control module (if equipped) – abs warning lamp control signal – ebd warning light control signal (brake warning light control signal) – diagnostic trouble code (dtc) of abs hydraulic unit/control module • data from keyless start control mo...

  • Page 1496

    9c-3 instrumentation / driver info. / horn: terminal arrangement of coupler viewed from combination meter side component location audio system component location s5jb0a9303001 terminal circuit terminal circuit g28-1 — g28-12 to headlight auto leveling control module g28-2 — g28-13 power source g28-3...

  • Page 1497

    Instrumentation / driver info. / horn: 9c-4 diagnostic information and procedures speedometer symptom diagnosis s5jb0a9304022 tacho meter symptom diagnosis s5jb0a9304023 engine coolant temperature (ect) meter symptom diagnosis s5jb0a9304024 fuel meter symptom diagnosis s5jb0a9304025 condition possib...

  • Page 1498

    9c-5 instrumentation / driver info. / horn: low fuel warning light symptom diagnosis s5jb0a9304026 note confirm that fuel meter is in good condition before referring to the following possible causes. • when fuel level meter circuit is shorted to ground circuit, fuel level meter indicates empty even ...

  • Page 1499

    Instrumentation / driver info. / horn: 9c-6 brake and parking brake warning light symptom diagnosis s5jb0a9304028 seat belt reminder light symptom diagnosis (if equipped) s5jb0a9304029 note seat belt reminder can be canceled by scan tool or specified procedure. If neither warning buzzer nor seat bel...

  • Page 1500

    9c-7 instrumentation / driver info. / horn: illumination indicator symptom diagnosis s5jb0a9304031 headlight auto leveling indicator symptom diagnosis (if equipped) s5jb0a9304032 a/t power mode indicator symptom diagnosis (a/t model only) s5jb0a9304033 condition possible cause correction / reference...

  • Page 1501

    Instrumentation / driver info. / horn: 9c-8 a/t shift position indicator (a/t model only) symptom diagnosis s5jb0a9304034 charge warning light symptom diagnosis s5jb0a9304035 main beam (high beam) indicator symptom diagnosis s5jb0a9304036 a/t power mode indicator stays on data (information) can not ...

  • Page 1502

    9c-9 instrumentation / driver info. / horn: warning buzzer circuit symptom diagnosis s5jb0a9304012 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of su...

  • Page 1503

    Instrumentation / driver info. / horn: 9c-10 information display symptom diagnosis (if equipped) s5jb0a9304015 note this thermometer indicates the ambient temperature in back of front bumper member. Under any one of the following listed conditions, however, even when the ambient temperature goes up,...

  • Page 1504

    9c-11 instrumentation / driver info. / horn: audio system symptom diagnosis (if equipped) s5jb0a9304016 radio note electronic part / system with undiagnosed problem may cause electromagnetic interference. Electromagnetic interference condition may have poor radio reception. To test for presence of e...

  • Page 1505

    Instrumentation / driver info. / horn: 9c-12 remote audio control switch symptom diagnosis (if equipped) s5jb0a9304017 navigation symptom diagnosis (if equipped) s5jb0a9304021 repair instructions ignition switch removal and installation s5jb0a9306001 removal 1) disconnect negative cable at battery. ...

  • Page 1506

    9c-13 instrumentation / driver info. / horn: ignition switch inspection s5jb0a9306002 • check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Combination meter removal and installation s5jb0a9306003 removal 1) disconnect negative (–) cab...

  • Page 1507

    Instrumentation / driver info. / horn: 9c-14 fuel level sensor inspection s5jb0a9306005 • check that resistance between terminals “a” and “b” of fuel level sensor changes with change of float position. • check resistance between terminals “a” and “b” at each float position in the following. If the m...

  • Page 1508

    9c-15 instrumentation / driver info. / horn: oil pressure switch inspection s5jb0a9306007 1) disconnect oil pressure switch (1) lead wire. 2) check for continuity between oil pressure switch terminal (2) and cylinder block (3) as shown. If check result is not as specified, replace oil pressure switc...

  • Page 1509

    Instrumentation / driver info. / horn: 9c-16 door switch (front / rear / rear end door) inspection s5jb0a9306013 remove door switch from body and check switch for continuity. If found defective, replace switch. Door switch (front / rear / rear end door) specification off position (door closed): no c...

  • Page 1510

    9c-17 instrumentation / driver info. / horn: removal 1) disconnect negative cable at battery. 2) remove driver side instrument panel under cover (1) and passenger side instrument panel under cover (2). 3) disable air bag system referring to “disabling air bag system: in section 8b”. 4) remove steeri...

  • Page 1511

    Instrumentation / driver info. / horn: 9c-18 installation reverse removal procedure noting the following. • when installing each part, be careful not to catch any cable or wiring harness. • tighten instrument panel mounting bolts to specified torque tightening torque instrument panel mounting bolt (...

  • Page 1512

    9c-19 instrumentation / driver info. / horn: front speaker removal and installation s5jb0a9306020 removal 1) remove door trim referring to step 1) to 3) of “front door glass removal and installation: in section 9e”. 2) remove 3 front speaker mounting screws (1). 3) remove front speaker (2) from fron...

  • Page 1513

    Instrumentation / driver info. / horn: 9c-20 gps antenna removal and installation (if equipped) s5jb0a9306028 removal 1) remove center ventilation louver referring to step 1) and 2) of “information display (clock) removal and installation: ”. 2) disconnect gps antenna connector from navigation unit ...

  • Page 1514

    9c-21 instrumentation / driver info. / horn: 3) check that there is no continuity between terminal “a” and “b”. If there is continuity, replace relay. 4) check that there is continuity between terminals “a” and “b” when a 12 v battery is connected to terminal “a” and “c”. If malfunction is found, re...

  • Page 1515

    Instrumentation / driver info. / horn: 9c-22 remote audio control switch inspection s5jb0a9306026 1) remove driver air bag (inflator) module referring to “driver air bag (inflator) module removal and installation: in section 8b”. 2) disconnect remote audio control switch connector from contact coil....

  • Page 1516: Wipers / Washers

    9d-1 wipers / washers: wipers / washers diagnostic information and procedures front wiper and washer symptom diagnosis s5jb0a9404001 rear wiper and washer symptom diagnosis (if equipped) s5jb0a9404002 condition possible cause correction / reference item wiper malfunctions circuit fuse blown replace ...

  • Page 1517

    Wipers / washers: 9d-2 headlight washer symptom diagnosis (if equipped) s5jb0a9404003 headlight washer operation inspection s5jb0a9404004 1) turn ignition switch to on position. 2) turn lighting switch to “head” position. 3) make sure that washer fluid is spouted out from the headlight washer nozzle...

  • Page 1518

    9d-3 wipers / washers: inspection of headlight washer control module and its circuit s5jb0a9404005 1) remove headlight washer control module from blower unit. 2) connect connector to headlight washer control module. 3) check that the voltage between the following terminals and vehicle body ground ar...

  • Page 1519

    Wipers / washers: 9d-4 repair instructions wipers and washers components s5jb0a9406001 (c) (b) 11 10 5 6 13 16 10 (a) (a) 1 2 2 4 3 (b) 15 (e) 11 9 7 8 10 10 20 1 14 12 14 18 19 17 i5jb0a940002-01 1. Windshield wiper blade 8. Washer pump for rear washer (if equipped) 15. Windshield wiper bolt : 8.5 ...

  • Page 1520

    9d-5 wipers / washers: washer tank and washer pump removal and installation s5jb0a9406002 removal 1) disconnect negative (–) cable at battery. 2) remove front bumper referring to “front bumper components: in section 9k”. 3) remove right headlight housing from vehicle body referring to “headlight hou...

  • Page 1521

    Wipers / washers: 9d-6 windshield wiper removal and installation s5jb0a9406004 removal 1) disconnect negative (–) cable at battery. 2) remove wiper pivot caps (1) and wiper arm nuts (2), and remove windshield wiper arms with wiper blades (3). 3) remove cowl top garnish referring to “cowl top compone...

  • Page 1522

    9d-7 wipers / washers: windshield wiper motor inspection s5jb0a9406005 note make sure that battery voltage is 12 v or more. 1) disconnect negative (–) cable at battery. 2) remove windshield wiper arms with wiper blades referring to “windshield wiper removal and installation: ”. 3) remove cowl top ga...

  • Page 1523

    Wipers / washers: 9d-8 • for automatic stop operation a. Connect battery positive (+) terminal to terminal “1” and its negative (–) terminal to terminal “5” and let the motor turn. B. Disconnect terminal “1” from battery positive (+) terminal, and let the motor stop. C. Connect terminals “1” and “3”...

  • Page 1524

    9d-9 wipers / washers: 2) connect coupler to rear wiper motor 3) install rear end door trim referring to “rear end door lock assembly removal and installation: in section 9f”. 4) install rear wiper arm with blade assembly (1) to specified position as shown in figure. 5) tighten rear wiper arm nut to...

  • Page 1525

    Wipers / washers: 9d-10 • for automatic stop operation a. Connect battery positive (+) terminal to terminal “1” and its negative (–) terminal to body ground and let the motor turn. B. Connect terminal “2” and “3” by a jumper wire. C. Observe the motor (4) turns once again then stops at a specified p...

  • Page 1526

    9d-11 wipers / washers: windshield wiper and washer switch inspection s5jb0a9406009 windshield wiper and washer switch check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Intermittent wiper relay circuit 1) turn the windshield wiper sw...

  • Page 1527

    Wipers / washers: 9d-12 washer linked circuit 1) make sure that front wiper switch is at “off” position. 2) connect battery positive (+) terminal to terminal “5” and its negative (–) terminal to terminal “2”. 3) connect voltmeter positive lead to terminal “4” and its negative lead to terminal “2”. 4...

  • Page 1528

    9d-13 wipers / washers: rear wiper relay inspection s5jb0a9406013 1) check that there is no continuity between terminal “4” and “5”. If there is continuity, replace relay. 2) check that there is continuity between terminal “3” and “5”. If there is no continuity, replace relay. 3) connect battery pos...

  • Page 1529

    Wipers / washers: 9d-14 specifications tightening torque specifications s5jb0a9407001 note the specified tightening torque is also described in the following. “wipers and washers components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fastener informat...

  • Page 1530: Glass / Windows / Mirrors

    9e-1 glass / windows / mirrors: glass / windows / mirrors general description rear end door window defogger system description s5jb0a9501001 the rear end door window defogger is controlled by bcm. For the bcm description refer to “bcm general description: in section 10b”. Windshield construction s5j...

  • Page 1531

    Glass / windows / mirrors: 9e-2 use the specific adhesive which has the following property. Glass adhesive shearing strength 40 kg/cm 2 (569 lb/in 2 ) or more adhesive materials and tools required for removal and installation. • one component urethane adhesive and primers used in combination (for on...

  • Page 1532

    9e-3 glass / windows / mirrors: use the specific adhesive which has the following property. Glass adhesive shearing strength 40 kg/cm 2 (569 lb/in 2 ) or more adhesive materials and tools required for removal and installation. • one component urethane adhesive and primers used in combination (for on...

  • Page 1533

    Glass / windows / mirrors: 9e-4 power window control system symptom diagnosis s5jb0a9504002 power door mirror control system symptom diagnosis (if equipped) s5jb0a9504003 door mirror heater symptom diagnosis (if equipped) s5jb0a9504005 note • use of suzuki scan tool makes it easy to check whether a ...

  • Page 1534

    9e-5 glass / windows / mirrors: repair instructions windshield removal and installation s5jb0a9506001 removal 1) clean both inside and outside of glass and around it. 2) remove wiper arms and cowl top garnish. 3) remove windshield side garnish. 4) using tape, cover body surface around glass to preve...

  • Page 1535

    Glass / windows / mirrors: 9e-6 12) when reusing windshield, remove the adhesive (1) from it, using care not to damage primer coated surface (2). Installation 1) using cleaning solvent, clean windshield edge where windshield glass is to be adhered. (let it dry for more than 10 minutes.) 2) to determ...

  • Page 1536

    9e-7 glass / windows / mirrors: 7) using new brush, apply sufficient amount of primer onto glass along glass edge. Note • be sure to refer to maker’s instruction for proper handling and drying time. • do not apply primer on outside of ceramic coated surface. • do not touch primer coated surface. Wid...

  • Page 1537

    Glass / windows / mirrors: 9e-8 11) check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If water still leaks even after that, remove glass and start installation procedure all over again. Note • do not use hig...

  • Page 1538

    9e-9 glass / windows / mirrors: 6) cut adhesive all around rear quarter window (1) with piano string (2). When using tool, windshield knife (3), to cut adhesive, be careful not to cause damage to windshield. Use wire to cut adhesive along lower part of windshield. Note use piano string (2) as close ...

  • Page 1539

    Glass / windows / mirrors: 9e-10 3) clean glass surface to be adhered to body with clean cloth. If cleaning solvent is used, let it dry for 10 minutes or more. Cleaning area for rear quarter window (distance from the edge of glass or molding) 30 – 50 mm (1.18 – 1.97 in.) 4) using new brush, apply su...

  • Page 1540

    9e-11 glass / windows / mirrors: 5) apply primer for molding along molding surface all around. 6) apply adhesive (1) referring to figure. Note • press glass (2) against fittings surface of body panel quickly after adhesive (1) is applied. • use of rubber sucker grip is helpful to hold and carry glas...

  • Page 1541

    Glass / windows / mirrors: 9e-12 7) holding rubber sucker grip (1), place glass onto body by aligning mating marks marked in step 3) and press it. 8) check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If wate...

  • Page 1542

    9e-13 glass / windows / mirrors: front door window components s5jb0a9506002 1 2 5 3 6 7 4 8 “1” “3” “2” i5jb0a950009-01 1. Door glass : tightening order rear to front. 4. Door trim 7. Front door sash 2. Window regulator assembly : apply lithium grease 99000-25010 to sliding part. : tightening order ...

  • Page 1543

    Glass / windows / mirrors: 9e-14 front door glass removal and installation s5jb0a9506003 removal 1) remove door mirror trim (1), front door inner garnish (2) (3 door model only) and door trim screw cover (3). 2) remove door trim screw (5). 3) remove door trim (4) as shown. And disconnect power windo...

  • Page 1544

    9e-15 glass / windows / mirrors: • install front door trim. Front door trim attaching order (1) → (2) → (3) → (4) → (5) → (6) → (7) → (8) front door window regulator removal and installation s5jb0a9506004 removal 1) remove door glass referring to “front door glass removal and installation: ”. 2) dis...

  • Page 1545

    Glass / windows / mirrors: 9e-16 rear door window components s5jb0a9506006 rear door glass removal and installation s5jb0a9506007 removal 1) remove door trim screw cover (1). 2) remove door trim screw (2). 3) remove door trim (1) as shown. 4) remove door sealing cover (1). 8 7 3 9 1 4 2 5 “a” “b” “3...

  • Page 1546

    9e-17 glass / windows / mirrors: 5) detach rear part of glass run from door sash (1), and remove door sash (1). 6) remove door glass (2) as shown. Installation reverse removal procedure noting the following instructions. • if there is deformity for glass run, replace it with a new one. • tighten rea...

  • Page 1547

    Glass / windows / mirrors: 9e-18 installation reverse removal procedure noting the following. • apply grease to sliding and rotating portions of window regulator. : grease 99000–25010 • tighten rear door window regulator mounting screw (1) first and then (2). • tighten rear door window mounting scre...

  • Page 1548

    9e-19 glass / windows / mirrors: rear end door glass removal and installation s5jb0a9506011 refer to “windshield removal and installation: ” as removal and installation procedures are basically the same. However, note the following. • observe the following precautions when applying adhesive (1) alon...

  • Page 1549

    Glass / windows / mirrors: 9e-20 rear end door window defogger wire inspection s5jb0a9506014 note • when cleaning rear end door window glass, use a dry cloth to wipe it along heat wire (1) direction. • when cleaning glass, do not use detergent or abrasive-containing glass cleaner. • when measuring w...

  • Page 1550

    9e-21 glass / windows / mirrors: 3) connect 12 v battery positive (+) terminal to terminal “ig” of power window main switch and its negative (– ) terminal to terminal “e” of power window main switch. 4) check for continuity between terminals as shown below. If check result is not as specified, repla...

  • Page 1551

    Glass / windows / mirrors: 9e-22 power window sub switch inspection s5jb0a9506017 1) remove front and/or rear door trim from door panel, refer to step 1) to 3) of “front door glass removal and installation: ” and/or “rear door glass removal and installation: ”. 2) remove power window sub switch from...

  • Page 1552

    9e-23 glass / windows / mirrors: door mirror removal and installation s5jb0a9506019 when removing or installing door mirror, refer to the figure in “door mirror components: ”. Power door mirror switch inspection (if equipped) s5jb0a9506020 1) remove driver side door trim referring to step 1) to 3) o...

  • Page 1553

    Glass / windows / mirrors: 9e-24 door mirror heater relay inspection (if equipped) s5jb0a9506024 1) disconnect negative (–) cable from battery. 2) remove door mirror heater relay (included in integration relay) (1) from main fuse box (2). 3) check that there is no continuity between terminals “a” an...

  • Page 1554: Security and Locks

    9f-1 security and locks: security and locks general description key coding construction s5jb0a9601001 key usage and identification key is used for ignition and door lock cylinders. Key is cut on both edges to make them reversible. Key identification is obtained from five character key code stamped o...

  • Page 1555

    Security and locks: 9f-2 diagnostic information and procedures power door lock system symptom diagnosis s5jb0a9604001 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output ...

  • Page 1556

    9f-3 security and locks: keyless entry system symptom diagnosis (if equipped) s5jb0a9604004 note • confirm that power door lock system is in good condition before referring to the following possible causes. • check each part in the order from the top of the following list. Condition possible cause c...

  • Page 1557

    Security and locks: 9f-4 keyless entry system operation inspection s5jb0a9604005 1) confirm that power door lock system operates normally, refer to “power door lock system operation inspection: ”. 2) all doors are closed and unlocked. 3) check the following operation: a) push “lock” button (1) on tr...

  • Page 1558

    9f-5 security and locks: front door lock assembly removal and installation s5jb0a9606002 removal 1) remove door mirror trim (1), front door inner garnish (2) (3 door model only) and door trim screw cover (3). 2) remove door trim (4) after removing door trim screw (5) and clips. 3) disconnect door il...

  • Page 1559

    Security and locks: 9f-6 installation reverse removal procedure to install front door lock assembly noting the following instructions. • apply grease to sliding parts of door latch assembly. : grease 99000–25010 • tighten door latch screws to specified torque. Tightening torque door latch screw (a):...

  • Page 1560

    9f-7 security and locks: power door lock switch inspection s5jb0a9606004 check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Door key cylinder switch inspection s5jb0a9606005 1) remove front door trim referring to step 1) to 3) of “fro...

  • Page 1561

    Security and locks: 9f-8 for front door for rear door [a]: without deadlock [b]: with deadlock [a] [b] a b c d e f right side switch terminals b a c lock unlock unlock lock deadlock unlock left side switch terminals d c a deadlock lock d b lock unlock f g terminals lock unlock unlock lock terminals ...

  • Page 1562

    9f-9 security and locks: for rear end door rear door lock assembly components s5jb0a9606007 lock unlock unlock lock terminals b a lock unlock c d terminals b a c d i5jb0a960011-01 (a) (a) (a) (b) 1 7 2 6 3 4 5 i5jb0a960012-03 1. Outside handle : apply lithium grease 99000-25010 to sliding part. 4. L...

  • Page 1563

    Security and locks: 9f-10 rear door lock assembly removal and installation s5jb0a9606008 removal 1) remove rear door trim referring to step 1) to 3) of “rear door glass removal and installation: in section 9e”. 2) disconnect door lock motor lead wire. 3) remove door latch mounting screws (1) and rem...

  • Page 1564

    9f-11 security and locks: rear end door lock assembly components s5jb0a9606010 rear end door lock assembly removal and installation s5jb0a9606011 removal 1) remove door trim (1) from rear end door panel (2). 2) disconnect door lock motor lead wire and door opening control rod. 3) loosen door latch b...

  • Page 1565

    Security and locks: 9f-12 installation reverse removal procedure to install rear end door lock assembly noting the following instruction. • tighten rear end door latch bolt to specified torque. Tightening torque rear end door latch bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) • adjust door latch striker ...

  • Page 1566

    9f-13 security and locks: programming transmitter code for keyless entry system (vehicle without keyless start system) s5jb0a9606015 note • three transmitter codes can be registered. • when a new transmitter code is registered, the oldest one will be cleared. • as for vehicle equipped with keyless s...

  • Page 1567

    Security and locks: 9f-14 keyless entry receiver and its circuit inspection s5jb0a9606017 1) check that the voltage between the following terminals and body ground are specifications under each conditions. If check result is not as specified, check applicable circuit for open or short. If circuit is...

  • Page 1568

    9f-15 security and locks: specifications tightening torque specifications s5jb0a9607001 note the specified tightening torque is also described in the following. “front door lock assembly components: ” “rear door lock assembly components: ” “rear end door lock assembly components: ” reference: for th...

  • Page 1569: Seats

    Seats: 9g-1 seats diagnostic information and procedures front seat heater symptom diagnosis (if equipped) s5jb0a9704001 repair instructions front seat components s5jb0a9706001 condition possible cause correction / reference item both seat back and cushion do not become hot although seat heater switc...

  • Page 1570

    9g-2 seats: front seat removal and installation s5jb0a9706002 removal 1) disable air bag system referring to “disabling air bag system: in section 8b”. 2) disconnect seat harness coupler, seat heater coupler and side air bag coupler, if equipped. 3) remove 4 mounting bolts to remove seat assembly. 4...

  • Page 1571

    Seats: 9g-3 rear seat components s5jb0a9706003 rear seat removal and installation s5jb0a9706004 removal 1) remove seat mounting bolt(s) in the bracket. 2) fold rear seat back and unlock the seat cushion lock to pull forward the seat cushion. 3) remove seat mounting nuts (bolts) to remove rear seat a...

  • Page 1572: Interior Trim

    9h-1 interior trim: interior trim repair instructions floor carpet removal and installation s5jb0a9806001 removal 1) remove front seats and rear seats. 2) remove seat belt lower anchor bolt. 3) remove side sill scuffs (1) (front and rear for 5 door model), front pillar lower trims (2), center pillar...

  • Page 1573

    Interior trim: 9h-2 3) remove front pillar upper trims (1), side sill scuffs (2) (front and rear for 5 door model), center pillar inner lower trims (3) (for 5 door model), center pillar inner upper trims (4) (for 5 door model), back panel trim (5), rear quarter lower trims (6) and rear quarter upper...

  • Page 1574

    9h-3 interior trim: 5 door model • for equipped with sliding roof, hook on bracket (1) of roof lining to sliding roof housing (2). • for equipped with sliding roof, adhere fasteners (1) on roof lining to fasteners of sliding roof frame securely. • for tightening torque of seat belt anchor bolt, refe...

  • Page 1575

    Interior trim: 9h-4 console box components s5jb0a9806003 a a a a a a a 1 2 3 4 i5jb0a980008-02 1. Front console box 3. Gear shift panel 2. Rear console box 4. Console rear panel.

  • Page 1576

    9i-1 sun roof / t-top / convertible top: sun roof / t-top / convertible top general description power sliding (sun) roof system description s5jb0a9901001 the controller is included in the sliding roof motor unit. The sliding roof functions are controlled with the sliding roof position data. Sliding ...

  • Page 1577

    Sun roof / t-top / convertible top: 9i-2 sliding (sun) roof glass removal and installation s5jb0a9906002 removal 1) open sunshade (1) fully and tilt up sliding roof. 2) disconnect negative (–) cable at battery. 3) remove sliding roof covers. 4) remove sliding roof glass by removing bolts (torx ® t25...

  • Page 1578

    9i-3 sun roof / t-top / convertible top: sliding (sun) roof motor removal and installation s5jb0a9906006 removal 1) remove spot lamp assembly from head lining. 2) disconnect coupler (3) and remove sliding roof motor (1) by removing 2 bolts (2). Installation for installation, reverse removal procedur...

  • Page 1579

    Sun roof / t-top / convertible top: 9i-4 sliding (sun) roof assembly components s5jb0a9906008 1 2 2 8 9 10 12 13 14 5 4 3 14 13 12 8 9 7 10 6 11 11 i5jb0a990009-02 1. Sliding roof glass 6. Sunshade 11. No.1 peace 2. Sliding roof cover 7. Drip channel 12. Rail stopper 3. Sliding roof housing 8. Panel...

  • Page 1580

    9i-5 sun roof / t-top / convertible top: sliding (sun) roof assembly removal and installation s5jb0a9906009 removal 1) remove head lining referring to “head lining removal and installation: in section 9h”. 2) remove sliding roof glass referring to “sliding (sun) roof glass removal and installation: ...

  • Page 1581

    Sun roof / t-top / convertible top: 9i-6 sliding (sun) roof assembly disassembly and reassembly s5jb0a9906010 disassembly 1) remove sliding roof motor (1). 2) slide sunshade (1) to full-position. 3) remove deflector (2) from holder (3) with holding deflector. 4) remove no.1 peaces (1) and then pull ...

  • Page 1582: Hood / Fenders / Doors

    9j-1 hood / fenders / doors: hood / fenders / doors repair instructions hood removal and installation s5jb0a9a06001 removal caution ! Place cloth to prevent body from any damage. 1) remove hood silencer (4). 2) disconnect window washer hose (1) from hood. 3) remove 4 mounting bolts (3) to detach hoo...

  • Page 1583

    Hood / fenders / doors: 9j-2 front fender components s5jb0a9a06003 front fender removal and installation s5jb0a9a06004 removal 1) remove splash guard (if equipped) referring to “splash guard removal and installation (if equipped): in section 9m”. 2) remove front fender lining. 3) remove front bumper...

  • Page 1584

    9j-3 hood / fenders / doors: front door assembly components s5jb0a9a06005 2 2 1 (a) 4 (a) 4 (a) 5 3 (b) 7 (b) (b) 7 6 i5jb0a9a0005-01 1. Door panel 5. Door open stopper bolt : 23 n ⋅m (2.3 kgf-m, 17.0 lb- ft) 2. Door hinge : apply lithium grease 99000-25010 to rotating part. : apply sealant 99000-31...

  • Page 1585

    Hood / fenders / doors: 9j-4 front door assembly removal and installation s5jb0a9a06006 removal 1) remove front fender referring to “front fender components: ”. 2) disconnect door harness lead wires at each coupler. 3) remove door open stopper (1). 4) support door panel (1) using a jack (2) with rag...

  • Page 1586

    9j-5 hood / fenders / doors: rear door assembly components s5jb0a9a06007 rear door assembly removal and installation s5jb0a9a06008 refer to “front door assembly removal and installation: ” as removal and installation procedures are basically the same. However, note the following. • tighten rear door...

  • Page 1587

    Hood / fenders / doors: 9j-6 rear end door assembly components s5jb0a9a06009 a a a a a a a a a a a e e e a a a a a a a a 1 2 4 5 5 6 (a) 3 3 i5jb0a9a0009-01 1. Rear end door panel assembly 4. Rear end door balancer : 23 n ⋅m (2.3 kgf-m, 17.0 lb-ft) 2. Rear end door window glass 5. Rear end door trim...

  • Page 1588

    9j-7 hood / fenders / doors: rear end door assembly removal and installation s5jb0a9a06010 removal 1) remove rear end door trims (1). 2) remove spare tire. 3) disconnect rear end door harness coupler (2) and washer hose (3). 4) remove rear end door balancer (4). 5) remove door hinge bolts (5) and re...

  • Page 1589

    Hood / fenders / doors: 9j-8 specifications tightening torque specifications s5jb0a9a07001 note the specified tightening torque is also described in the following. “front door assembly components: ” “rear door assembly components: ” “rear end door assembly components: ” reference: for the tightening...

  • Page 1590: Body Structure

    9k-1 body structure: body structure repair instructions front bumper components s5jb0a9b06001 7 5 6 7 3 1 4 8 2 i5jb0a9b0001-02 1. Front bumper 3. Front bumper net 5. Front bumper absorber 7. Front bumper holder 2. Radiator grill 4. Front air dam skirt 6. Front bumper member 8. Seal.

  • Page 1591

    Body structure: 9k-2 rear bumper components s5jb0a9b06004 [a] [b] 4 4 1 2 3 4 4 1 3 2 i5jb0a9b0002-01 [a]: 5 door model 1. Rear bumper 3. Rear bumper no.2 holder [b]: 3 door model 2. Rear bumper no.1 holder 4. Reflector.

  • Page 1592

    9k-3 body structure: cowl top components s5jb0a9b06003 a a a a a 2 1 i5jb0a9b0003-01 1. Cowl top garnish 2. Hood rear seal.

  • Page 1593

    Body structure: 9k-4 specifications body dimensions s5jb0a9b07001 engine room hole to hole distance g h i j f' i' c' c e f j' g' h' b' d' e' a b d i5jb0a9b0004-01 a. Cowl top installation center hole e (e’). Headlight installation hole i (i’). Headlight installation hole b (b’). Front fender install...

  • Page 1594

    9k-5 body structure: rear end door hole to hole distance for 5 door model hole to hole distance for 3 door model a b c d e j k l m f g h i a' b' f' g' i' h' a a [a] [b] i5jb0a9b0005-01 [a]: 5 door model c (c’). Rear combination lamp installation hole g (g’). Rear combination lamp clip installation h...

  • Page 1595

    Body structure: 9k-6 side body 5 door model hole to hole distance note use jig hole (o) as datum point to check symmetry of body structure. A' a b b' c, (c') d, (d') e, (e') f, (f') n, (n') g, (g') h, (h') i, (i') j, (j') k, (k') l, (l') m, (m') k, (k') l, (l') o a, (a') j, (j') i, (i') i5jb0a9b0006...

  • Page 1596

    9k-7 body structure: 3 door model hole to hole distance note use jig hole (o) as datum point to check symmetry of body structure. A' a b b' c, (c') d, (d') e, (e') f, (f') g, (g') h, (h') o a, (a') h, (h') g, (g') i5jb0a9b0007-01 a (a’). Jig hole ( φ 8 mm) d (d’). Door lower hinge installation front...

  • Page 1597

    Body structure: 9k-8 hole to hole distance for 5 door model hole to hole distance for 3 door model c, (c') d, (d') e, (e') f, (f') c, (c') f, (f') e, (e') d, (d') e, (e') e, (e') f, (f') f, (f') c, (c') c, (c') [a] [b] a' a b' b a, (a') b, (b') i5jb0a9b0008-01 [a]: 5 door model b (b’). Front pillar ...

  • Page 1598

    9k-9 body structure: under body 5 door model hole to hole distance hole to hole distance a' b' c' d' e' f' g' h' i' j' k' l' n' m' a b c d e f g h i j k l n m a' b' c' d' e' f' g' j' n' m' a b c d e g h i j l n m i5jb0a9b0009-01 a (a’). Jig hole ( φ 16 mm) f (f’). Engine rear mounting member install...

  • Page 1599

    Body structure: 9k-10 3 door model a’-b: 868 mm (34.17 in.) e-f’: 1067 mm (42.01 in.) g’-j’: 718 mm (28.27 in.) a’-g: 2523 mm (99.33 in.) e-g: 1381 mm (54.37 in.) g’-l: 1446 mm (56.93 in.) b-e: 750 mm (29.53 in.) f’-g: 1380 mm (54.33 in.) g’-n: 1892 mm (74.49 in.) b’-c’: 249 mm (9.80 in.) f’-g’: 864...

  • Page 1600

    9k-11 body structure: hole to hole distance hole to hole distance 5 door model hole to hole distance a-a’: 860 mm (33.86 in.) f-f’: 1013 mm (39.88 in.) k-k’: 1154 mm (45.43 in.) b-b’: 830 mm (32.68 in.) g-g’: 1144 mm (45.04 in.) l-l’: 937 mm (36.89 in.) c-c’: 840 mm (33.07 in.) h-h’: 1134 mm (44.65 ...

  • Page 1601

    Body structure: 9k-12 projection dimension from standard line “a” 3 door model hole to hole distance projection dimension from standard line “a” a: 166 mm (6.54 in.) f: 66 mm (2.60 in.) k: 436 mm (17.17 in.) b: 193 mm (7.60 in.) g: 64 mm (2.52 in.) l: 252 mm (9.92 in.) c: 263 mm (10.35 in.) h: 72 mm...

  • Page 1602

    9k-13 body structure: front suspension frame hole to hole distance hole to hole distance projection dimension from standard line “a” a b c d e f g a' b' c' c' d' e' f' g' i5jb0a9b0013-01 a (a’). Front suspension frame installation front side bolt hole d (d’). Front suspension frame stud g (g’). Fron...

  • Page 1603

    Body structure: 9k-14 panel clearance s5jb0a9b07002 a b b c c d e f g f h i j k l m n o p aa bb cc dd ee ff x e d h g i j q l m r v u t s p aa bb cc dd ee gg [a] [b] i5jb0a9b0015-01.

  • Page 1604

    9k-15 body structure: panel to panel distance [a]: 3 door model j: 4.0 – 6.0 mm (0.158 – 0.236 in.) u: 1.8 – 3.8 mm (0.071 – 0.149 in.) [b]: 5 door model k: 4.4 – 6.4 mm (0.213 – 0.251 in.) v: 3.3 – 5.3 mm (0.130 – 0.208 in.) a: 4.9 – 6.9 mm (0.193 – 0.271 in.) l: 3.0 – 5.0 mm (0.119 – 0.196 in.) w:...

  • Page 1605: Paint / Coatings

    Paint / coatings: 9l-1 paint / coatings general description anti-corrosion treatment construction s5jb0a9c01001 warning ! Standard shop practices, particularly eye protection, should be followed during the performance of the following operations to avoid personal injury. As rust proof treatment, ste...

  • Page 1606

    9l-2 paint / coatings: plastic parts finishing s5jb0a9c01002 paintable plastic parts are abs plastic parts. Painting rigid or hand abs plastic needs no primer coating. General acrylic lacquers can be painted properly over hard abs plastic in terms of adherence. 1) use cleaning solvent for paint fini...

  • Page 1607

    Paint / coatings: 9l-3 dash panel and front floor panel (5 door model) i5jb0a9c0002-01 “a”: apply sealant. “e”: flatten sealant. “b”: fill gap / hole with sealant. 1. 88 mm (3.46 in.) diameter “c”: smooth out sealant with a brush. 2. 60 mm (2.36 in.) diameter hole “d”: do not apply sealant..

  • Page 1608

    9l-4 paint / coatings: dash panel and front floor panel (3 door model) i5jb0a9c0003-01 “a”: apply sealant. “e”: flatten sealant. “b”: fill gap / hole with sealant. 1. 88 mm (3.46 in.) diameter “c”: smooth out sealant with a brush. 2. 60 mm (2.36 in.) diameter hole “d”: do not apply sealant..

  • Page 1609

    Paint / coatings: 9l-5 front and rear door panels (5 door model) i5jb0a9c0004-02 “a”: apply sealant. “d”: wipe off sealant so as not to protrude from this surface. “a”: min. 6 mm (0.24 in.) “b”: wipe off excess sealant after application. “e”: do not protrude sealant backward from this line. “b”: max...

  • Page 1610

    9l-6 paint / coatings: front door panel (3 door model) i5jb0a9c0005-01 “a”: apply sealant. “c”: apply wide sealant. “b”: wipe off excess sealant after application. “d”: wipe off sealant so as not to protrude from this surface..

  • Page 1611

    Paint / coatings: 9l-7 rear end door panel and hood panel i5jb0a9c0006-02 “a”: apply sealant. “a”: min. 6 mm (0.24 in.) “b”: apply wide sealant. “b”: max. 3 mm (0.12 in.) “c”: apply sealant covering flange end..

  • Page 1612

    9l-8 paint / coatings: rear structure panel (5 door model) i5jb0a9c0007-02 “a”: apply sealant. “c”: do not apply sealant. “b”: smooth out sealant with a brush..

  • Page 1613

    Paint / coatings: 9l-9 rear structure panel (3 door model) i5jb0a9c0008-02 “a”: apply sealant. “c”: do not apply sealant. “b”: smooth off sealant with a brush..

  • Page 1614

    9l-10 paint / coatings: floor panel (5 door model) i5jb0a9c0009-01 “a”: apply sealant. “c”: do not apply sealant. “b”: smooth off sealant with a brush. “d”: flatten sealant..

  • Page 1615

    Paint / coatings: 9l-11 floor panel (3 door model) i5jb0a9c0010-01 “a”: apply sealant. “c”: do not apply sealant. “b”: smooth off sealant with a brush. “d”: flatten sealant..

  • Page 1616

    9l-12 paint / coatings: under coating application areas s5jb0a9c03002 5 door model i5jb0a9c0011-01 “a”: apply undercoating (pvc, 400 µm or more). “c”: do not apply undercoating. “b”: apply black painting. “d”: apply undercoating (pvc, 400 µm or more) covering flange end..

  • Page 1617

    Paint / coatings: 9l-13 i5jb0a9c0012-01 “a”: apply undercoating (pvc, 400 µm or more). “c”: do not apply undercoating. “b”: apply black painting..

  • Page 1618

    9l-14 paint / coatings: 3 door model i5jb0a9c0013-01 “a”: apply undercoating (pvc, 400 µm or more). “c”: do not apply undercoating. “b”: apply black painting. “d”: apply undercoating (pvc, 400 µm or more) covering flange end..

  • Page 1619

    Paint / coatings: 9l-15 i5jb0a9c0014-01 “a”: apply undercoating (pvc, 400 µm or more). “c”: do not apply undercoating. “b”: apply black painting..

  • Page 1620

    9l-16 paint / coatings: anti-corrosion compound application area s5jb0a9c03003 5 door model i5jb0a9c0015-01 “a”: apply rust proof wax (hot wax 50 µm or more). “b”: apply rust proof wax (high viscosity wax 50 µm or more)..

  • Page 1621

    Paint / coatings: 9l-17 3 door model i5jb0a9c0016-01 “a”: apply rust proof wax (hot wax 50 µm or more). “b”: apply rust proof wax (high viscosity wax 50 µm or more)..

  • Page 1622: Exterior Trim

    9m-1 exterior trim: exterior trim repair instructions roof drip molding removal and installation (if equipped) s5jb0a9d06005 * 1 3 2 4 4 6 5 5 [a] [b] a a b b c 5 5 5 4 i5jb0a9d0001-02 [a]: molding cap removal remove cap by pushing in arrow direction shown on cap and then pulling in alphabetical ord...

  • Page 1623

    Exterior trim: 9m-2 roof rail removal and installation (if equipped) s5jb0a9d06007 1 2 3 4 4 4* 5 5 5* i5jb0a9d0002-03 1. Roof rail 3. Roof drip molding clip (push-in type) 5. Roof rail bolt 2. Roof drip front molding 4. Roof rail cap *: 5 door model only.

  • Page 1624

    9m-3 exterior trim: splash guard removal and installation (if equipped) s5jb0a9d06006 a * a a b a a a a a b 1 ** 2 a a a a a a a a a a a 3** a a a a a a 4 4 i5jb0a9d0003-02 1. Side sill splash guard 3. Rear door splash guard *: 3 door model only 2. Front door splash guard 4. Cap **: 5 door model onl...

  • Page 1625: Section 10

    Table of contents 10- i 10 section 10 contents control systems precautions ...............................................10-1 precautions........................................................... 10-1 precautions for control systems......................... 10-1 cruise control system.................

  • Page 1626

    10-ii table of contents immobilizer control system wiring circuit diagram ..........................................................10c-4 diagnostic information and procedures..........10c-5 immobilizer control system check ...................10c-5 diagnostic trouble code (dtc) check.............10c...

  • Page 1627: Precautions

    Precautions: 10-1 precautions precautions precautions for control systems s5jb0aa000001 air bag warning refer to “air bag warning: in section 00”..

  • Page 1628: Cruise Control System

    10a-1 cruise control system: cruise control system general description cruise control system construction s5jb0aa101001 the cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.G., on a highway. It allows the driver to drive his vehicle at a const...

  • Page 1629

    Cruise control system: 10a-2 components and functions of cruise control system s5jb0aa101002 component function ecm and electric throttle body assembly ecm executes centralized control over all functions including setting a constant speed, resuming it, setting coast, cancelling cruise control limiti...

  • Page 1630

    10a-3 cruise control system: cancel conditions of cruise control system s5jb0aa101003 constant cruising is cancelled under the following conditions. • *ignition switch is turned off. • main switch is turned off. • vehicle speed becomes lower than minimum operating speed (40 km/h (25 mile/h)). • *veh...

  • Page 1631

    Cruise control system: 10a-4 schematic and routing diagram cruise control system wiring diagram s5jb0aa102001 ig1 +bb +bb ig1 red g44-19 wht red e03-12 e03-6 wht/blu wht/red wht/blu wht/red e23-4 e23-19 e23-56 5v 5v 5v 5v 12v 12v e03-8 e03-10 wht red e92-17 e92-7 wht red e91-22 e91-23 wht red g31-1 ...

  • Page 1632

    10a-5 cruise control system: diagnostic information and procedures cruise control system symptom diagnosis s5jb0aa104001 note • ecm uses tcm, abs hydraulic unit/control module and can communication to transmit and receive data for cruise control. Therefore, check that no dtc is detected from ecm, tc...

  • Page 1633

    Cruise control system: 10a-6 inspection of cruise control system circuit s5jb0aa104012 cruise control system is controlled by ecm. Each switch and circuit can be checked by taking measurement of terminal voltage and terminal to terminal resistance of ecm. When measuring these values, be sure to read...

  • Page 1634

    10a-7 cruise control system: resistance check 1) remove driver air bag (inflator) module from steering wheel referring to “driver air bag (inflator) module removal and installation: in section 8b”. 2) measure resistance between the following terminals with ecm connector disconnected. E23 c37 3 4 18 ...

  • Page 1635

    Cruise control system: 10a-8 repair instructions cruise control switch removal and installation s5jb0aa106001 for removal and installation, refer to “remote audio control switch removal and installation: in section 9c”. Cruise control switch inspection s5jb0aa106002 note never disassemble cruise con...

  • Page 1636

    10a-9 cruise control system: installation 1) install cpp switch (for cruise control) (2) to pedal bracket. 2) with clutch pedal (1) released, adjust switch position so that clearance between end of thread and clutch pedal bracket is within specification. Clearance between end of thread and clutch pe...

  • Page 1637

    Body electrical control system: 10b-1 body electrical control system precautions precautions in diagnosing trouble s5jb0aa200001 • diagnostic information stored in bcm memory can be cleared as well as checked by using suzuki scan tool. Before using scan tool, read its operator’s (instruction) manual...

  • Page 1638

    10b-2 body electrical control system: • data which bcm receives from 4wd control module – buzzer request for 4wd control system • data which bcm transmits to combination meter – lighting switch signal – brake fluid level switch signal (brake warning light control signal) – parking brake switch signa...

  • Page 1639

    Body electrical control system: 10b-3 red/blk ppl/grn pnk/blk pnk/grn red/blk red wht wht/blk ig1 pnk/blk yel/blk yel/red yel/grn brn yel/blk blk/orn blk/red ig1 g31-1 g31-3 ppl/wht on door off blk/red g32-15 yel/red g31-34 +b +b +b red/blu g31-12 g31-13 +b yel g30-19 blu/blk g30-22 +b +b blu g31-15...

  • Page 1640

    10b-4 body electrical control system: connector layout diagram of bcm s5jb0aa202002 bcm connectors (viewed from harness side) 1. Bcm 22. Navigation 43. Dimmer and passing switch 2. Auto-on headlight sensor 23. Power/normal mode switch 44. Horn relay 3. Rear wiper motor 24. Headlight auto leveling co...

  • Page 1641

    Body electrical control system: 10b-5 component location bcm and related system component location s5jb0aa203001 1 4 8 10 7 9 6 7 2 26 24 21 22 5 3 28 27 19 18 29 23 15 14 17 20 16 13 12 11 25 i5jb0aa20003-02 1. Generator 11. Keyless entry receiver (if equipped) 21. Headlight high beam relay 2. Brak...

  • Page 1642

    10b-6 body electrical control system: diagnostic information and procedures bcm self-diagnosis function s5jb0aa204001 • bcm monitors conditions of the system components and its circuit with ignition switch turned to on position. When an abnormality in the system occurs, the area where that abnormali...

  • Page 1643

    Body electrical control system: 10b-7 combination meter • lighting switch • brake fluid level switch • seat belt reminder lamp signal • generator • oil presser switch • parking brake switch • power/normal mode select switch (for a/t model only) • dimmer switch (high beam) • illumination controller (...

  • Page 1644

    10b-8 body electrical control system: body electrical control system check s5jb0aa204002 customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the figure will fac...

  • Page 1645

    Body electrical control system: 10b-9 customer questionnaire (example) problem symptom confirmation check if what the customer claimed in “customer questionnaire” is accurately found in the vehicle. If that symptom is found, check whether the symptom is identified as a failure. (this step should be ...

  • Page 1646

    10b-10 body electrical control system: scan tool data s5jb0aa204003 scan tool data definitions vehicle speed (km/h, mph): this parameter indicates the vehicle speed computed by ecm. Outside air temp ( °c, °f): it is detected by outside air temperature sensor. Battery voltage (v): this parameter indi...

  • Page 1647

    Body electrical control system: 10b-11 pass door sw (other than driver side door switch) (open / close): this parameter indicates the state of the door switches other than driver side door switch. Brake fluid level (low / normal): low: brake fluid level is lower than specified level. Normal: brake f...

  • Page 1648

    10b-12 body electrical control system: dtc check s5jb0aa204005 using suzuki scan tool 1) prepare suzuki scan tool. 2) with ignition switch turned off, connect it to data link connector (dlc) located on underside of instrument panel of driver’s side. Special tool (a): suzuki scan tool 3) turn ignitio...

  • Page 1649

    Body electrical control system: 10b-13 3) check dtc displayed on odometer of combination meter or read flashing pattern of alarm indicator lamp which represents dtc as shown in the following example and write it down. When more than 2 dtcs are stored in memory, flashing for each dtc starts with the ...

  • Page 1650

    10b-14 body electrical control system: bcm power circuit and ground circuit check s5jb0aa204007 wiring diagram troubleshooting 7 8 9 10 11 12 13 14 15 6 5 4 3 2 1 g32 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 g30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ...

  • Page 1651

    Body electrical control system: 10b-15 dtc b1133 (dtc no. 1133): battery voltage too high s5jb0aa204008 wiring diagram dtc detecting condition and possible cause flow test description step 1: check charging system dtc troubleshooting 4 ground circuit check 1) turn ignition switch to off position. 2)...

  • Page 1652

    10b-16 body electrical control system: dtc b1141 / dtc b1142 / dtc b1143 (no. 1141 / no. 1142/ no. 1143) outside air temperature (ambient temp.) sensor circuit malfunction s5jb0aa204009 wiring diagram dtc detecting condition and possible cause flow test description step 1: check whether malfunction ...

  • Page 1653

    Body electrical control system: 10b-17 dtc troubleshooting dtc b1150 (no. 1150): air bag communication circuit malfunction s5jb0aa204010 wiring diagram step action yes no 1 check outside air temperature sensor 1) turn ignition switch to off position. 2) disconnect connector from outside air temperat...

  • Page 1654

    10b-18 body electrical control system: dtc detecting condition and possible cause flow test description step 1: check air bag communication circuit. Step 2: check air bag communication circuit. Step 3: check air bag communication circuit. Dtc troubleshooting dtc detecting condition possible cause af...

  • Page 1655

    Body electrical control system: 10b-19 dtc b1157 (no. 1157) air bag deployment signal input s5jb0aa204011 wiring diagram dtc detecting condition and possible cause flow test description step 1: check dtc for sdm. Dtc troubleshooting dtc b1170 (no. 1170): eeprom access error s5jb0aa204012 dtc detecti...

  • Page 1656

    10b-20 body electrical control system: dtc u1073 (no. 1073): control module communication bus off s5jb0aa204014 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [h] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/red wht/red e23-4...

  • Page 1657

    Body electrical control system: 10b-21 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 1 min. Or more. 4) check dtc and pending...

  • Page 1658

    10b-22 body electrical control system: 3 check dtc in bcm 1) turn ignition switch to off position. 2) connect connectors of disconnected control modules communicating by means of can. 3) disconnect connector from any one of control modules other than bcm. 4) recheck dtc for bcm. Is dtc u1073 detecte...

  • Page 1659

    Body electrical control system: 10b-23 dtc u1100 (no. 1100): lost communication with ecm s5jb0aa204015 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [h] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/red wht/red e23-4 e23-19 w...

  • Page 1660

    10b-24 body electrical control system: dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 1 min. Or more. 4) check dtc. Troublesho...

  • Page 1661

    Body electrical control system: 10b-25 dtc u1101 (no. 1101): lost communication with tcm s5jb0aa204016 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [h] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/red wht/red e23-4 e23-19 w...

  • Page 1662

    10b-26 body electrical control system: dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 1 min. Or more. 4) check dtc. Troublesho...

  • Page 1663

    Body electrical control system: 10b-27 dtc u1144 (no. 1144): lost communication with keyless start control module s5jb0aa204018 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [h] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/r...

  • Page 1664

    10b-28 body electrical control system: dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance: ”. 2) start engine and run it for 1 min. Or more. 3) check dtc referring to “dtc check: ”. Troubleshooting dtc detecting condition trouble area bcm can...

  • Page 1665

    Body electrical control system: 10b-29 inspection of bcm and its circuits s5jb0aa204017 bcm and its circuits can be checked at bcm wiring couplers by measuring voltage and resistance. Caution ! Bcm cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to bcm with co...

  • Page 1666

    10b-30 body electrical control system: bcm connector “g31” g30-7 rear wiper int switch 0 – 1 v ↑↓ 10 – 14 v refer to “reference waveform no. 3: ” 0 v ignition switch is at on position and rear wiper switch is at int position g30-8 — — — g30-9 front fog light switch 10 – 14 v lighting switch is at cl...

  • Page 1667

    Body electrical control system: 10b-31 g31-10 generator “l” terminal 10 – 14 v engine is running 0 v ignition switch is at on position g31-11 — — — g31-12 tail light relay control 10 – 14 v lighting switch is at off position 0 v lighting switch is at any position other than off position g31-13 rear ...

  • Page 1668

    10b-32 body electrical control system: bcm connector “g32” g31-36 driver side door key cylinder switch (unlock) 10 – 14 v driver side key cylinder switch is at any position other than unlock position 0 v driver side key cylinder switch is at unlock position g31-37 driver side door key cylinder switc...

  • Page 1669

    Body electrical control system: 10b-33 reference waveform no. 1 hvac control module serial communication signal (1) reference waveform no. 2 hvac control module and information display serial communication signal (1) reference waveform no. 3 rear wiper low or int signal (1) reference waveform no. 4 ...

  • Page 1670

    10b-34 body electrical control system: reference waveform no. 5 vehicle speed pulse output signal (1) reference waveform no. 6 can communication signal reference waveform no. 7 brake fluid level, parking brake or driver seat belt switch signal (1) measurement terminal ch1: “g30-22” to “g30-12” oscil...

  • Page 1671

    Body electrical control system: 10b-35 reference waveform no. 8 oil pressure switch signal (1) reference waveform no. 9 keyless entry receiver signal (1) repair instructions bcm removal and installation s5jb0aa206001 removal 1) disconnect negative cable from battery. 2) remove steering column hole c...

  • Page 1672

    10b-36 body electrical control system: outside air temperature sensor inspection s5jb0aa206003 for inspection, refer to “outside air temperature sensor inspection (if equipped): in section 9c”. Drl function setting procedure drl is controlled by bcm which has a function to set operable / non-operabl...

  • Page 1673: Immobilizer Control System

    Immobilizer control system: 10c-1 immobilizer control system precautions precautions in diagnosing troubles s5jb0aa300001 • before confirming the diagnostic trouble code (dtc), do not disconnect connector from ecm, battery cable from battery, ground wire harness, or main fuse. Such disconnection wil...

  • Page 1674

    10c-2 immobilizer control system: general description immobilizer control system introduction s5jb0aa301001 the immobilizer control system is an anti-theft device that immobilizes the vehicle. It stops the engine from working and prevents the vehicle from being stolen. It mainly consists of the foll...

  • Page 1675

    Immobilizer control system: 10c-3 on-board diagnostic system description (self-diagnosis function) s5jb0aa301003 ecm diagnoses if there is any trouble with the immobilizer control system. The diagnostic information is stored as the diagnostic trouble code (dtc) in ecm. To read the diagnostic informa...

  • Page 1676

    10c-4 immobilizer control system: schematic and routing diagram immobilizer control system wiring circuit diagram s5jb0aa302001 note for more details about power supply and ground wire circuits for ecm, bcm, abs, keyless start control module and combination meter, refer to “system circuit diagram: i...

  • Page 1677

    Immobilizer control system: 10c-5 diagnostic information and procedures immobilizer control system check s5jb0aa304001 1. Battery 6. Data link connector (dlc) 11. Keyless start control module 16. Immobilizer control module (icm) connector (harness side view) 2. Fuse 7. Ecm 12. Combination meter 17. ...

  • Page 1678

    10c-6 immobilizer control system: diagnostic trouble code (dtc) check s5jb0aa304002 note to know how to use suzuki scan tool in detail, refer to its operator’s manual. 1) turn the ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located under instrument p...

  • Page 1679

    Immobilizer control system: 10c-7 note if any dtc other than the above dtcs is detected, refer to “dtc table: in section 1a”. Scan tool data s5jb0aa304005 the data listed below is the standard data obtained from the normal vehicle by using suzuki scan tool. Those are output from ecm. Use them as ref...

  • Page 1680

    10c-8 immobilizer control system: immobilizer indicator lamp does not come on with ignition switch on and engine stop s5jb0aa304012 wiring diagram refer to “immobilizer control system wiring circuit diagram: ”. Circuit description when the ignition switch is turned on, ecm transmits the indication o...

  • Page 1681

    Immobilizer control system: 10c-9 immobilizer indicator lamp remains on after engine start s5jb0aa304013 wiring diagram refer to “immobilizer control system wiring circuit diagram: ”. Circuit description when the ignition switch is turned on, ecm transmits the indication on signal to the combination...

  • Page 1682

    10c-10 immobilizer control system: dtc p1615: steering lock unit communication error (for vehicle with keyless start system) s5jb0aa304014 circuit description when the transponder code in the ignition key is registered in ecm, the remote controller id code is registered in both ecm and keyless start...

  • Page 1683

    Immobilizer control system: 10c-11 troubleshooting step action yes no 1 diagnostic trouble code (dtc) confirmation 1) clear dtc(s) referring to “diagnostic trouble code (dtc) clearance: ”. 2) turn the ignition switch to off position. 3) check if any dtc is detected referring to “diagnostic trouble c...

  • Page 1684

    10c-12 immobilizer control system: 8 check for short of wire circuits between steering lock unit and keyless start control module 1) measure resistance at the following connector terminals. • between “g22-3”, “g22-7” and “g22-8” terminal of steering lock unit connector. • between “g42-20”, “g42-29” ...

  • Page 1685

    Immobilizer control system: 10c-13 dtc p1616: unregistered keyless start control module (for vehicle with keyless start system) s5jb0aa304015 circuit description p1616 is detected when ecm detects different id codes registered in ecm and keyless control module after turning engine start knob to on p...

  • Page 1686

    10c-14 immobilizer control system: troubleshooting step action yes no 1 diagnostic trouble code (dtc) confirmation 1) clear dtc(s) referring to “diagnostic trouble code (dtc) clearance: ”. 2) turn the ignition switch to off position. 3) check if any dtc is detected referring to “diagnostic trouble c...

  • Page 1687

    Immobilizer control system: 10c-15 dtc p1621: immobilizer communication line error s5jb0aa304007 detecting condition and trouble area 6 check for short to ground wire circuit in can communication wire circuits 1) measure resistance at the following wire terminals. • between “e03-6” wire terminal at ...

  • Page 1688

    10c-16 immobilizer control system: troubleshooting step action yes no 1 diagnostic trouble code (dtc) confirmation 1) clear dtc(s) referring to “diagnostic trouble code (dtc) clearance: ”. 2) turn the ignition switch to off position. 3) check if any dtc is detected referring to “diagnostic trouble c...

  • Page 1689

    Immobilizer control system: 10c-17 8 check for short to ground circuit in communication wire circuit 1) with immobilizer control module (icm) connector “g24” and ecm connector “e23” disconnected, check resistance between “g24-3” wire terminal at immobilizer control module (icm) connector and body gr...

  • Page 1690

    10c-18 immobilizer control system: dtc p1622: eeprom error s5jb0aa304008 detecting condition and trouble area troubleshooting 1) clear dtc(s) referring to “diagnostic trouble code (dtc) clearance: ”. 2) turn the ignition switch to off position. 3) check if dtc p1622 is still detected referring to “d...

  • Page 1691

    Immobilizer control system: 10c-19 dtc p1625: immobilizer antenna error s5jb0aa304010 detecting condition and trouble area troubleshooting 4 immobilizer control module (icm) check 1) check immobilizer control module (icm) referring to “inspection of immobilizer control module (icm) and its circuit: ...

  • Page 1692

    10c-20 immobilizer control system: dtc p1636: immobilizer information registration failure s5jb0aa304017 dtc detecting condition and trouble area troubleshooting detecting condition trouble area the registration of the immobilizer control system information in ecm is failed. • can communication wire...

  • Page 1693

    Immobilizer control system: 10c-21 dtc p1638: immobilizer information mismatched s5jb0aa304018 dtc detecting condition and trouble area troubleshooting detecting condition trouble area • the immobilizer control system information in ecm and the one in bcm does not match. • the registration of the im...

  • Page 1694

    10c-22 immobilizer control system: inspection of immobilizer control module (icm) and its circuit s5jb0aa304011 immobilizer control module (icm) and its circuit can be checked at immobilizer control module (icm) wiring connector by measuring voltage. Caution ! Immobilizer control module (icm) cannot...

  • Page 1695

    Immobilizer control system: 10c-23 reference waveform note when ecm cannot read the transponder code at the first try, ecm tries to read the transponder code repeatedly up to 8 times. The second waveform is the example showing that ecm read the transponder code successfully at the second try. [a]: t...

  • Page 1696

    10c-24 immobilizer control system: repair instructions immobilizer control module (icm) removal and installation s5jb0aa306001 removal 1) disconnect negative (–) cable from battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove driver air bag (inflator) ...

  • Page 1697

    Immobilizer control system: 10c-25 special tools and equipment special tool s5jb0aa308001 suzuki scan tool — this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loopback adapter, 7. Battery power cable, 8. Rs232 cable, 9. Rs232...

  • Page 1698: Keyless Start System

    10e-1 keyless start system: keyless start system general description keyless start system description s5jb0aa501001 keyless start system consisting of the parts shown below has three functions as described below. • keyless engine start function: with the remote controller which has been registered i...

  • Page 1699

    Keyless start system: 10e-2 parts and functions s5jb0aa501002 [a]: driver side door outside handle 5. Luggage room antenna 11. Lock button [b]: passenger side or rear end door outside handle 6. Driver side door antenna 12. Bcm 1. Keyless start control module 7. Passenger side door antenna 13. Key in...

  • Page 1700

    10e-3 keyless start system: keyless engine start function s5jb0aa501003 when the ignition knob switch (2) installed to the steering lock unit (1) is pushed, the keyless start control module (3) activates the center antenna (4) to send out the request signal in the vehicle compartment. When the remot...

  • Page 1701

    Keyless start system: 10e-4 door lock function of keyless start system s5jb0aa501004 when the request switch (1) incorporated in the outside handle of the driver side door, front passenger side door or rear end door is pushed, the keyless start control module (2) activates the center antenna (3) and...

  • Page 1702

    10e-5 keyless start system: operation area of remote controller s5jb0aa501005 shown below are the operation areas of the remote controller for the keyless engine start function and door lock function of the keyless start system. However, even when the remote controller is within the operation area a...

  • Page 1703

    Keyless start system: 10e-6 alarm function s5jb0aa501006 under conditions as described in the table below, the keyless start control module makes the key indicator lamp flash in red and the buzzer sound to call the driver’s attention. Can communication of keyless start system s5jb0aa501007 keyless s...

  • Page 1704

    10e-7 keyless start system: schematic and routing diagram keyless start system electric wiring circuit diagram s5jb0aa502001 blk g44-9 g44-15 g44-14 g44-37 g44-33 g44-16 g44-20 g44-29 g44-30 g44-36 g44-32 g44-10 g44-34 g44-11 wht/blk wht wht red/blu blu/yel blu yel/red red/blk yel 5v 5v 5v 5v 5v 5v ...

  • Page 1705

    Keyless start system: 10e-8 diagnostic information and procedures precautions in diagnosing troubles s5jb0aa504001 • the keyless start system executes data transmission/ reception by means of the radio wave. Therefore, proper operation may not be obtained if use of the door lock function and engine ...

  • Page 1706

    10e-9 keyless start system: customer questionnaire (example) s5jb0aa504005 3 1) inspect and repair basic parts referring to “keyless start system symptom diagnosis: ”. Is there faulty condition? Repair or replace malfunction part(s), and go to step 5. Go to step 4. 4 1) check for intermittent proble...

  • Page 1707

    Keyless start system: 10e-10 key indicator lamp check s5jb0aa504006 push the ignition knob switch (2) of the steering lock unit (1) and check that the key indicator lamp (3) in the combination meter lights up in red or blue. If it does not light, go to “key indicator lamp circuit check (key indicato...

  • Page 1708

    10e-11 keyless start system: 6) read flashing pattern of key indicator lamp (1) which represents dtc as shown in example below and write it down. When more than 2 dtcs are stored in memory, flashing for each dtc is repeated three times starting with the smallest dtc number in increasing order. Note ...

  • Page 1709

    Keyless start system: 10e-12 dtc clearance s5jb0aa504009 1) perform steps 1) through 5) of dtc check procedure and have dtc indicated. 2) open driver side door. 3) close driver side door and within 10 seconds after that, perform steps a) to c) described below. A) push unlock side (3) of driver side ...

  • Page 1710

    10e-13 keyless start system: keyless engine start function note before performing symptom diagnosis procedure for keyless engine start system, check that engine starts by using ignition key. If it cannot be started by using ignition key, go to “engine symptom diagnosis: in section 1a”. Keyless start...

  • Page 1711

    Keyless start system: 10e-14 door lock operation (keyless start system) s5jb0aa504012 1) check that all door locks are released and all doors are closed. 2) with remote controller of which id code is registered in keyless start control module carried with yourself, check that pushing driver door req...

  • Page 1712

    10e-15 keyless start system: g44 [a] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 i5jb0aa50012-02 [a]: keyless start control module connector (viewed from harness side) terminal number circuit normal voltage condition g44-1 driver side door antenna (–) refer to “reference wav...

  • Page 1713

    Keyless start system: 10e-16 reference waveform no. 1 driver, passenger and rear end door antenna request signals (request signal (1) transmitted by each door antenna when each door request switch is pushed) g44-18 can communication line (low) for combination meter refer to “reference waveform no. 4...

  • Page 1714

    10e-17 keyless start system: reference waveform no. 2 center antenna signal (request signal (1) transmitted by center antenna when each door request switch is pushed) reference waveform no. 3 luggage room antenna signal (request signal (1) transmitted by luggage room antenna when each door request s...

  • Page 1715

    Keyless start system: 10e-18 reference waveform no. 6 driver and passenger side door lock switch signals. (this signal indicates door lock status.) in case the position of driver and passenger side door lock is changed from the unlock to the lock. In case the position of passenger side door lock is ...

  • Page 1716

    10e-19 keyless start system: in case the position of driver and passenger side door lock is changed from the lock to the unlock. No dtc detection after performing dtc check s5jb0aa504022 wiring diagram measurement terminal driver side door lock switch • ch1: “g42-33” to “g42-9” passenger side door l...

  • Page 1717

    Keyless start system: 10e-20 description the keyless start control module detects dtc by using signals from the key reminder and driver side door request switches. The keyless start control module makes the key indicator lamp in the combination meter flash on and off by using can communication. Trou...

  • Page 1718

    10e-21 keyless start system: key indicator lamp circuit check (key indicator lamp doesn’t light when ignition knob switch is pushed.) s5jb0aa504014 wiring diagram description when the ignition knob switch is pushed, the key indicator lamp lights up in blue if you carry the remote controller register...

  • Page 1719

    Keyless start system: 10e-22 keyless start control module power and ground circuit check s5jb0aa504015 wiring diagram 4 wire harness check 1) turn ignition switch to off position. 2) disconnect connector from keyless start control module, steering lock unit and combination meter. 3) check for open, ...

  • Page 1720

    10e-23 keyless start system: troubleshooting dtc no. 11: communication error with steering lock unit s5jb0aa504016 wiring diagram step action yes no 1 fuse check 1) turn ignition switch to off position. 2) check circuit fuse and main fuse for condition. Are fuses in good condition? Go to step 2. Rep...

  • Page 1721

    Keyless start system: 10e-24 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance: ”. 2) turn ignition knob switch pushing ignition knob switch. 3) check dtc referring to “dtc check: ”. Troubleshooting dtc detecting condition trouble area no co...

  • Page 1722

    10e-25 keyless start system: dtc no. 13 / no. 14: release signal error from steering lock unit / steering lock unit malfunction s5jb0aa504017 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance: ”. 2) turn ignition knob switch pushing ignition...

  • Page 1723

    Keyless start system: 10e-26 dtc no. 31: lost communication with bcm s5jb0aa504019 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [h] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/red wht/red e23-4 e23-19 wht red e03-12 e03-10...

  • Page 1724

    10e-27 keyless start system: dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance: ”. 2) turn ignition key knob by pushing ignition key knob. 3) check dtc referring to “dtc check: ”. Troubleshooting dtc detecting condition trouble area keyless ...

  • Page 1725

    Keyless start system: 10e-28 dtc no. 33: control module communication bus off s5jb0aa504020 wiring diagram wht red wht red g44-18 g44-19 g44 [a] [b] [c] [h] [g] 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 g28-8 g28-10 wht/blu wht/blu wht/red wht/red e23-4 e23-19 wht red e03-...

  • Page 1726

    10e-29 keyless start system: dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance: ”. 2) start engine and run it for 1 min. Or more. 3) check dtc referring to “dtc check: ”. Troubleshooting dtc detecting condition trouble area communication is ...

  • Page 1727

    Keyless start system: 10e-30 dtc no. 51 / no. 52 / no. 53: driver side / passenger side / rear end door request switch failure s5jb0aa504021 wiring diagram 5 dtc check 1) turn ignition switch to off position. 2) connect connectors of disconnected control modules communicating by means of can. 3) dis...

  • Page 1728

    10e-31 keyless start system: dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance: ”. 2) push request switch of each door. 3) check dtc referring to “dtc check: ”. Troubleshooting dtc detecting condition trouble area dtc no. 51: input signal fr...

  • Page 1729

    Keyless start system: 10e-32 repair instructions antennas and request switches removal and installation s5jb0aa506001 remove and install antennas and request switches referring to the following figures. [a] [b] [c] [d] 1 1 2 3 4 i5jb0aa50019-01 [a]: driver side door antenna and request switch (inclu...

  • Page 1730

    10e-33 keyless start system: front door (driver and passenger side) rear end door request switch inspection s5jb0aa506002 1) remove door trim from door panel. For front door trim, refer to step 1) to 3) of “front door glass removal and installation: in section 9e”. For rear end door trim, refer to s...

  • Page 1731

    Keyless start system: 10e-34 keyless start control module removal and installation s5jb0aa506006 removal 1) disconnect negative cable at battery. 2) remove glove box from instrument panel. 3) disconnect connector from keyless start control module (1). 4) remove keyless start control module mounting ...

  • Page 1732

    10e-35 keyless start system: 3) remove battery (4) from lower case (5). Caution ! Use care not to allow grease or dirt to be attached on the printed circuit board and the battery. 4) replace the battery (lithium disc-type cr 2032 or equivalent battery) so its (+) terminal faces on remote controller ...

  • Page 1733

    Keyless start system: 10e-36 if remote controller or keyless start control module is replaced with a new one or additional remote controller is necessary, register id code(s) of remote controller. 1) sit in driver seat and close all doors. 2) check that door lock of driver seat is unlocked. 3) inser...

  • Page 1734

    Prepared by 1st ed. Apr., 2005.

  • Page 1735: Service Manual

    99500-64j00-01e service manual volume 1 of 2 34.4 mm 99 50 0- 64 j0 0- 01 e s e r v ic e m a n u a l vol. 1 of 2.

  • Page 1736: Service Manual

    99500-64j00-01e service manual volume 2 of 2 vol. 2 of 2 35.5 mm 99500-64j00-01e ser vice manu al.