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Suzuki 2006 SX4 Service Manual

Other manuals for 2006 SX4: Service Manual

Summary of 2006 SX4

  • 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 genera...

  • Page 8: Precautions

    00-1 precautions: precautions precautions precautions precautions for vehicles equipped with a supplemental restraint (air bag) system s6rw0d0000001 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...

  • Page 9

    Precautions: 00-2 servicing and handling warning ! Many of service procedures require disconnection of “a/b” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, passenger, side and curtain air bag (inflator) modules • for handling and storage o...

  • Page 10

    00-3 precautions: warning ! Sdm • for handling and storage of a sdm, select a place where the ambient temperature below 65 °c (150 °f), without high humidity and away from electric noise. • during service procedures, be very careful when handling a sensing and diagnostic module (sdm). Never strike o...

  • Page 11

    Precautions: 00-4 warning ! • whenever raising a vehicle for service, be sure to follow the instructions under “vehicle lifting points in section 0a”. • when it is necessary to do service work with the engine running, make sure that the parking brake is set fully and the transmission is in neutral (...

  • Page 12

    00-5 precautions: • when removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. • when removing parts that are to be reused, be sure...

  • Page 13

    Precautions: 00-6 • after servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. • for vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure,...

  • Page 14

    00-7 precautions: precautions in servicing 4wd model s6rw0d0000014 caution ! • never perform any of the following [a], [b] and [c] types of service work. If it is performed while 4wd-auto mode or 4wd-lock mode is selected, front wheels (or rear wheels) drive rear wheels (or front wheels) and vehicle...

  • Page 15

    Precautions: 00-8 precautions for installing mobile communication equipment s6rw0d0000005 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 co...

  • Page 16

    00-9 precautions: • when connecting connectors, also hold connectors and put them together until they lock securely (a click is heard). • when installing the wiring harness, fix it with clamps so that no slack is left. • when installing vehicle parts, be careful so that the wiring harness is not int...

  • Page 17

    Precautions: 00-10 • when connecting meter probe (2) from terminal side of coupler (1) because it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its female terminal open for connection. In case of such coupler as shown connect probe as shown to avo...

  • Page 18

    00-11 precautions: fastener caution s6rw0d0000010 caution ! When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not a...

  • Page 19

    Precautions: 00-12 repair instructions electrical circuit inspection procedure s6rw0d0006001 while there are various electrical circuit inspection methods, described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. Open circuit check possible causes ...

  • Page 20

    00-13 precautions: voltage check if voltage is supplied to the circuit being checked, voltage check can be used as circuit check. 1) with all connectors connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground. A) if measurements were taken as...

  • Page 21

    Precautions: 00-14 intermittent and poor connection inspection s6rw0d0006002 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 22

    00-15 precautions:.

  • 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 information general description abbreviations s6rw0d0101001 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: ...

  • Page 25

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

  • Page 26

    0a-3 general information: there are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.E. “grn”). The dual-colored wire uses two color symbols (i.E. “grn/yel”). The first symbo...

  • Page 27

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

  • Page 28

    0a-5 general information: vehicle lifting points s6rw0d0101005 warning ! • before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • before lifting up the vehicle, check to be sur...

  • Page 29

    General information: 0a-6 in raising front or rear vehicle end off the floor by jacking, be sure to put the jack against engine front mounting member (1) or rear jacking bracket (2). To perform service with either front or rear vehicle end jacked up, be sure to place safety stands (1) under shaded p...

  • Page 30

    0a-7 general information: component location warning, caution and information labels location s6rw0d0103001 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 war...

  • Page 31

    General information: 0a-8 1 2 4 8 6 9 7 3 [a] 5 i6rw0d010001-01 1. Air bag label on driver air bag (inflator) module 6. Air bag label on sdm 2. Air bag label on contact coil assembly 7. Pretensioner label on seat belt retractor 3. Air bag label on passenger air bag (inflator) module 8. Side/curtain ...

  • Page 32: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance and lubrication s6rw0d0200001 air bag warning refer to “air bag warning in section 00”. Scheduled maintenance maintenance schedule under normal driving conditions s6rw0d0205001 n...

  • Page 33

    Maintenance and lubrication: 0b-2 note • “r”: replace or change • “i”: inspect and correct, replace or lubricate if necessary • for spark plugs, replace every 50,000 km if the local law requires. • nickel spark plug: bkr6e-11 (ngk) or k20pr-u11 (denso) • iridium spark plug: ifr6j11 (ngk) • periodic ...

  • Page 34

    0b-3 maintenance and lubrication: note • “i”: inspect and correct or replace if necessary • “r”: replace or change • *1: inspect or replace more frequently if the vehicle is used under dusty conditions. • *2: clean or replace more frequently if the air from the air conditioning decreases. Repair ins...

  • Page 35

    Maintenance and lubrication: 0b-4 engine oil and filter change s6rw0d0206004 warning ! • new and used engine oil can be hazardous. Be sure to read “warning” in “general precautions in section 00” and observe what is written there. • step 1) – 7) outlined below must be performed with engine not runni...

  • Page 36

    0b-5 maintenance and lubrication: 6) replenish oil until oil level is brought to full level mark on dipstick (oil pan and oil filter capacity). The filler inlet is at the top of the cylinder head cover. It is recommended to use engine oil of sg, sh, sj, sl or sm grade. Select the appropriate oil vis...

  • Page 37

    Maintenance and lubrication: 0b-6 air cleaner filter inspection s6rw0d0206008 1) remove air cleaner case clamps. 2) take air cleaner filter out of case. 3) check that filter is not excessively dirty, damaged or oily, clean filter with compressed air from air outlet side of filter. 4) install air cle...

  • Page 38

    0b-7 maintenance and lubrication: brake discs and pads (front) inspection s6rw0d0206014 1) remove wheel and caliper but don’t disconnect brake hose from caliper. 2) check front disc brake pads and discs for excessive wear, damage and deflection. Replace parts as necessary. For details, refer to “fro...

  • Page 39

    Maintenance and lubrication: 0b-8 2) check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever. 3) check parking brake lever for proper operation and stroke, and adjust it if necessary. For checking and adjusting procedures, refer to “parking brake inspe...

  • Page 40

    0b-9 maintenance and lubrication: suspension system inspection s6rw0d0206023 • inspect front struts and rear shock absorbers for evidence of oil leakage, dents or any other damage on sleeves; and inspect anchor ends for deterioration. Replace defective parts, if any. • check front and rear suspensio...

  • Page 41

    Maintenance and lubrication: 0b-10 propeller shaft (4wd) inspection s6rw0d0206026 1) check propeller shaft connecting bolts for looseness. If looseness is found, tighten to specified torque. 2) check propeller shaft joints for wear, play and damage. If any defect is found, replace. 3) check propelle...

  • Page 42

    0b-11 maintenance and lubrication: hvac air filter (if equipped) inspection s6rw0d0206034 check hvac air filter for dirt and dust referring to “hvac air filter inspection (if equipped) in section 7a”. If air filter is dirty, clean or replace air filter with new one. Hvac air filter (if equipped) rep...

  • Page 43

    Maintenance and lubrication: 0b-12 steering • check to ensure that steering wheel is free from instability, or abnormally heavy feeling. • check that the vehicle does not wander or pull to one side. Engine • check that engine responds readily at all speeds. • check that engine is free from abnormal ...

  • Page 44

    0b-13 maintenance and lubrication:.

  • Page 45: 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 46

    1-ii table of contents dtc p0123: throttle position sensor (main) circuit high .....................................................1a-89 dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor- 1).....................................................................1a-92 dtc p...

  • Page 47

    Table of contents 1-iii egr valve removal and installation (if equipped).......................................................... 1b-4 egr valve inspection (if equipped) ................... 1b-4 pcv hose inspection.......................................... 1b-5 pcv valve inspection ...................

  • Page 48

    1-iv table of contents crankshaft inspection .......................................1d-63 main bearings inspection..................................1d-65 sensor plate inspection ....................................1d-70 rear oil seal inspection ...................................1d-70 flywheel inspe...

  • Page 49

    Table of contents 1-v diagnostic information and procedures............1h-4 ignition system symptom diagnosis...................1h-4 reference waveform of ignition system.............1h-4 ignition system check ........................................1h-4 ignition spark test ............................

  • Page 50: Precautions

    1-1 precautions: engine precautions precautions precautions for engine s6rw0d1000001 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 t...

  • Page 51

    Engine general information and diagnosis: 1a-1 engine engine general information and diagnosis precautions precautions on engine service s6rw0d1100001 caution ! The following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reli...

  • Page 52

    1a-2 engine general information and diagnosis: • when checking ecm for dtc, keep in mind that dtc is displayed on the scan tool as follows depending on the scan tool used. – suzuki scan tool displays dtc detected by ecm. – can communication obd generic scan tool displays dtc detected by each of ecm ...

  • Page 53

    Engine general information and diagnosis: 1a-3 precaution on can troubleshooting s6rw0d1100007 can schematic and routing diagram 6 1 2 3 7 9 4 8 5 : [c] : [e] : [d] 6 1 2 3 7 9 4 8 5 [a] [b] i6rw0d110001-01.

  • Page 54

    1a-4 engine general information and diagnosis: outline of troubleshooting when there is a trouble with can, perform “troubleshooting for communication error with scan tool using can” and/ or “troubleshooting for can-dtc”. Not using this procedure or performing troubleshooting in any other way may sk...

  • Page 55

    Engine general information and diagnosis: 1a-5 general description statement on cleanliness and care s6rw0d1101001 an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch...

  • Page 56

    1a-6 engine general information and diagnosis: • as a condition for detecting a malfunction in some areas in the system being monitored by ecm and turning on the malfunction indicator lamp (1) due to that malfunction, 2 driving cycle detection logic is adopted to prevent erroneous detection. • when ...

  • Page 57

    Engine general information and diagnosis: 1a-7 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 58

    1a-8 engine general information and diagnosis: for information about the following items, refer to “euro obd model: ”. • warm-up cycle • driving cycle • 2 driving cycle detection logic • pending dtc data link connector (dlc) s6rw0d1101011 note there are two types of obd system depending on the vehic...

  • Page 59

    Engine general information and diagnosis: 1a-9 can communication system description s6rw0d1101005 ecm (1), abs control module (2), bcm (3), combination meter (4), keyless start control module (if equipped with keyless start control system) (5), 4wd control module (for 4wd model) (6)and tcm (for a/t ...

  • Page 60

    1a-10 engine general information and diagnosis: ecm transmission data ecm reception data bcm tcm combination meter data ecm transmit brake pedal switch signal vehicle speed signal engine speed signal engine torque signal accelerator pedal position signal 4wd control module keyless start control modu...

  • Page 61

    Engine general information and diagnosis: 1a-11 air intake system description s6rw0d1101006 the main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “description of electric throttle body system”.), and intak...

  • Page 62

    1a-12 engine general information and diagnosis: operation description ecm (5) detects opening (depressed extent of pedal) of the accelerator pedal based on signal voltage of the app sensor (1) and using that data and engine operation condition, it calculates the optimum throttle valve opening. On th...

  • Page 63

    Engine general information and diagnosis: 1a-13 engine and emission control system flow diagram intak e manif old exhaust manif old exhaust gas air fuel v apor wa rm u p catalyst exhaust pipe ev ap canister purge v alv e fuel injector ect sensor ecm heater control heater control (if equipped) barome...

  • Page 64

    1a-14 engine general information and diagnosis: ecm input / output circuit diagram 51 50 +b 54 ig1 +bb st 64 65 67 blk/wht wht/red brn/wht blk/red blk/red 57 : 71 : 72 : 5v : 12v 68 ig1 blk wht gry yel/grn wht 66 58 61 62 63 55 70 60 59 53 wht 4 +b 5 pnk red/yel blk/orn c01-20 c01-21 8 red 62 c01-56...

  • Page 65

    Engine general information and diagnosis: 1a-15 terminal arrangement of ecm coupler (viewed from harness side) 7. Ho2s-2 (if equipped) 31. Fuel injector no.1 55. Starting motor control relay 8. Knock sensor 32. Fuel injector no.2 56. Transmission range switch (a/t model) 9. Maf and iat sensor 33. Fu...

  • Page 66

    1a-16 engine general information and diagnosis: connector: c01 terminal wire color circuit terminal wire color circuit 1 blu/yel fuel injector no.1 output 31 — — 2 blu/wht fuel injector no.2 output 32 — — 3 grn/orn egr valve (stepper motor coil 2) output 33 — — 4 grn/red egr valve (stepper motor coi...

  • Page 67

    Engine general information and diagnosis: 1a-17 connector: e01 terminal wire color circuit terminal wire color circuit 1 blk/red main power supply 31 blk ground for ecm 2 wht/red power source for ecm internal memory 32 grn power supply of throttle actuator drive circuit. 3 red can communication line...

  • Page 68

    1a-18 engine general information and diagnosis: engine and emission control input / output table s6rw0d1101010 input output electric control device barometric pressure sensor brake light switch start switch ignition switch a/c refrigerant pressure sensor (if equipped with a/c) blower switch a/c swit...

  • Page 69

    Engine general information and diagnosis: 1a-19 schematic and routing diagram engine and emission control system diagram s6rw0d1102001 43 42 37 26 9 8 6 7 13 12 23 10 14 11 2 5 1 3 17 18 24 39 35 30 29 38 15 16 36 31 22 21 40 27 25 41 32 20 19 4 34 33 28 44 45 46 i5rw0c110009-02.

  • Page 70

    1a-20 engine general information and diagnosis: 1. Air cleaner 17. Radiator cooling fan 33. A/c switch (a/c model) 2. Evap canister purge valve 18. A/c condenser cooling fan 34. A/c evaporator outlet air temp. Sensor (manual a/c model) 3. Maf and iat sensor 19. Combination meter 35. Immobilizer coil...

  • Page 71

    Engine general information and diagnosis: 1a-21 component location electronic control system components location s6rw0d1103001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. H* e* 10 d g* c 6 a b* e 3* 12* a 8 13 ...

  • Page 72

    1a-22 engine general information and diagnosis: diagnostic information and procedures engine and emission control system check s6rw0d1104001 refer to the following items for the details of each step. Step action yes no 1 ) customer complaint analysis 1) perform customer complaint analysis referring ...

  • Page 73

    Engine general information and diagnosis: 1a-23 11 ) final confirmation test 1) clear dtc if any. 2) perform final confirmation test referring to “final confirmation test”. Is there any problem symptom, dtc or abnormal condition? Go to step 6. End. Step action yes no.

  • Page 74

    1a-24 engine general information and diagnosis: step 1: customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for p...

  • Page 75

    Engine general information and diagnosis: 1a-25 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 76

    1a-26 engine general information and diagnosis: • the mil is turned on when the ecm and/or tcm detect malfunction(s). Each ecm and tcm stores diagnostic information as the diagnostic trouble code (dtc) in its memory and outputs the dtc to the scan tool. Therefore, check both of the ecm and tcm for a...

  • Page 77

    Engine general information and diagnosis: 1a-27 wiring diagram 6 1 2 3 red wht red wht red wht red wht e01-3 e01-18 e08-1 e08-12 e08-2 e08-13 g05-1 g05-3 red wht red wht g16-19 g16-18 5 red wht g05-2 g05-4 8 9 red wht g26-23 g26-22 4 red wht g241-9 g241-7 g241-10 g241-6 7 red wht red wht c06-17 c06-...

  • Page 78

    1a-28 engine general information and diagnosis: trouble area • scan tool • connector related to can line (included in dlc) • can line • power or ground circuit of dlc • control module communicated by can – ecm – tcm – abs control module – bcm – combination meter – keyless start control module – 4wd ...

  • Page 79

    Engine general information and diagnosis: 1a-29 troubleshooting step action yes no 1 scan tool check 1) disconnect scan tool from dlc with ignition switch turned off. 2) check for proper connection to all terminals of scan tool connector. 3) if ok, connect scan tool to another vehicle of this type w...

  • Page 80

    1a-30 engine general information and diagnosis: 5 can line check between dlc and bcm 1) turn ignition switch to off position. 2) disconnect bcm connector from bcm. 3) check for proper connection to all terminals of bcm connector. 4) if ok, check can lines between dlc and bcm connector for open, shor...

  • Page 81

    Engine general information and diagnosis: 1a-31 8 communication check between scan tool and ecm 1) turn ignition switch to off position. 2) connect ecm, bcm, abs control module and combination meter connectors. 3) check communication between scan tool and ecm by dtc check in ecm. Is it possible to c...

  • Page 82

    1a-32 engine general information and diagnosis: dtc table s6rw0d1104005 note • there are two types of obd system depending on the vehicle specification. For identification, refer to “precaution on on-board diagnostic (obd) system”. • for non-euro-obd model, some of dtc no. With delta (u) mark in the...

  • Page 83

    Engine general information and diagnosis: 1a-33 ) *p0117 engine coolant temperature circuit low circuit voltage of ect sensor is less than specification. 1 driving cycle ) *p0118 engine coolant temperature circuit high circuit voltage of ect sensor is more than specification. 1 driving cycle ) *p012...

  • Page 84

    1a-34 engine general information and diagnosis: ) u*p0420 catalyst system efficiency below threshold output waveforms of ho2s-1 and ho2s-2 are similar. 2 driving cycles ) u*p0443 evaporative emission system purge control valve circuit monitor signal of evap canister purge valve is different from com...

  • Page 85

    Engine general information and diagnosis: 1a-35 ) *p2138 pedal position sensor (main / sub) voltage correlation difference between the opening angle based on accelerator pedal position sensor (main) and the opening angle based on accelerator pedal position sensor (sub) is more than specification. 1 ...

  • Page 86

    1a-36 engine general information and diagnosis: for vehicle equipped with a/t s6rw0d1104081 note there are two types of obd system depending on the vehicle specification. For identification, refer to “precaution on on-board diagnostic (obd) system”. When using can communication obd generic scan tool...

  • Page 87

    Engine general information and diagnosis: 1a-37 ) p0122 throttle position sensor (main) circuit low • ecm turns off throttle actuator control relay and throttle valve is fixed at the opening of about 7° from its completely closed position (default opening). • ecm controls fuel cut at specified engin...

  • Page 88

    1a-38 engine general information and diagnosis: scan tool data s6rw0d1104007 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 89

    Engine general information and diagnosis: 1a-39 * ) short ft b1 (short term fuel trim) at specified idle speed after warming up –20 – +20% * ) long ft b1 (long term fuel trim) at specified idle speed after warming up –20 – +20% ) total fuel trim b1 at specified idle speed after warming up –35 – +35%...

  • Page 90

    1a-40 engine general information and diagnosis: ) radiator fan (radiator cooling fan control relay) ignition switch on engine coolant temp.: lower than 97.5 °c (207.5 °f) off engine coolant temp.: 100 °c (212 °f) on ) a/c cond fan (a/c condenser cooling fan control relay) engine running blower motor...

  • Page 91

    Engine general information and diagnosis: 1a-41 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 92

    1a-42 engine general information and diagnosis: canist prg duty (evap canister purge flow duty, %) this parameter indicates valve on (valve open) time rate within a certain set cycle of evap canister purge valve which controls the amount of evap purge. Ignition advance (ignition timing advance for n...

  • Page 93

    Engine general information and diagnosis: 1a-43 throttle motor relay (on/off) on: throttle actuator (motor) control activated by ecm. Of: throttle actuator (motor) control stopped by ecm. Vehicle speed (km/h, mph) it is computed based on pulse signals from front wheel speed sensor (rh, lh) (for m/t ...

  • Page 94

    1a-44 engine general information and diagnosis: 4 check keyless start control system malfunction 1) check keyless start control system referring to “keyless start system operation inspection in section 10e”. Is check result satisfactory? Go to step 5. Keyless start control system malfunction. 5 is e...

  • Page 95

    Engine general information and diagnosis: 1a-45 engine symptom diagnosis s6rw0d1104010 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 / refere...

  • Page 96

    1a-46 engine general information and diagnosis: engine noise – valve noise note before checking mechanical noise, make sure that: • specified spark plug is used. • specified fuel is used. Improper valve lash “camshaft, tappet and shim inspection in section 1d” worn valve stem and guide “valves and v...

  • Page 97

    Engine general information and diagnosis: 1a-47 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 oil ...

  • Page 98

    1a-48 engine general information and diagnosis: excessive engine oil consumption – oil entering combustion chamber sticky piston ring “cylinders, pistons and piston rings inspection in section 1d” worn piston and cylinder “cylinders, pistons and piston rings inspection in section 1d” worn piston rin...

  • Page 99

    Engine general information and diagnosis: 1a-49 excessive detonation – engine makes continuously sharp metallic knocks that change with throttle opening. Sounds like pop corn popping. Faulty spark plug “spark plug inspection in section 1h” loose connection of high-tension cord “high-tension cord rem...

  • Page 100

    1a-50 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 “high-tension cord removal and installation in section 1h” faulty ignition coil with ignitor “ignition coil a...

  • Page 101

    Engine general information and diagnosis: 1a-51 excessive hydrocarbon (hc) emission or carbon monoxide (co) faulty spark plug “spark plug inspection in section 1h” leaky or disconnected high-tension cord “high-tension cord removal and installation in section 1h” faulty ignition coil with ignitor “ig...

  • Page 102

    1a-52 engine general information and diagnosis: malfunction indicator lamp does not come on with ignition switch on and engine stop (but engine can be started) s6rw0d1104011 wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn on (close the cont...

  • Page 103

    Engine general information and diagnosis: 1a-53 troubleshooting note • 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 tool to ecm and/or the ecm con...

  • Page 104

    1a-54 engine general information and diagnosis: malfunction indicator lamp remains on after engine starts s6rw0d1104012 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 swi...

  • Page 105

    Engine general information and diagnosis: 1a-55 dtc p0010: camshaft position actuator circuit (for engine with vvt system) s6rw0d1104013 system and wiring diagram circuit description actual valve timing fails to become close to target advance level of each function although advance control function ...

  • Page 106

    1a-56 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 ste...

  • Page 107

    Engine general information and diagnosis: 1a-57 dtc p0011 / p0012: camshaft position - timing over-advanced or system performance / retarded (for engine with vvt system) s6rw0d1104014 system description actual value of advanced valve timing does not reach target value. Valve timing is advanced altho...

  • Page 108

    1a-58 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 ste...

  • Page 109

    Engine general information and diagnosis: 1a-59 dtc p0031 / p0032: ho2s heater control circuit low / high (sensor-1) s6rw0d1104015 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 110

    1a-60 engine general information and diagnosis: 2 ho2s-1 heater power circuit check 1) disconnect connector from ho2s-1 with ignition switch turned off. 2) check for proper connection to ho2s-1 at “blk/wht” and “blk/red” wire terminals. 3) if wire and connection are ok, measure voltage between “blk/...

  • Page 111

    Engine general information and diagnosis: 1a-61 dtc p0037 / p0038: ho2s heater control circuit low / high (sensor-2) s6rw0d1104016 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 112

    1a-62 engine general information and diagnosis: 2 ho2s-2 heater power circuit check 1) disconnect connector from ho2s-2 with ignition switch turned off. 2) check for proper connection to ho2s-2 at “blk/wht” and “red/blu” wire terminals. 3) if wire and connection are ok, measure voltage between “blk/...

  • Page 113

    Engine general information and diagnosis: 1a-63 dtc p0101: mass air flow circuit range / performance s6rw0d1104017 wiring diagram dtc detecting condition and trouble area e01 c01 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...

  • Page 114

    1a-64 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 b...

  • Page 115

    Engine general information and diagnosis: 1a-65 4 maf sensor output voltage check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) measure voltage between “c01-26” and “c01-27” terminals of ecm connector referring to “mass air flow (maf) and intake air te...

  • Page 116

    1a-66 engine general information and diagnosis: dtc p0102: mass air flow circuit low input s6rw0d1104018 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 sca...

  • Page 117

    Engine general information and diagnosis: 1a-67 dtc p0103: mass air flow circuit high input s6rw0d1104019 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 sc...

  • Page 118

    1a-68 engine general information and diagnosis: 3) start engine and run it for 10 sec. 4) check dtc and pending dtc. Dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no ...

  • Page 119

    Engine general information and diagnosis: 1a-69 dtc p0106: manifold absolute pressure range / performance s6rw0d1104020 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 120

    1a-70 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p0107: manifold absolute pressure circuit low input s6rw0d1104021 wiring diagram ref...

  • Page 121

    Engine general information and diagnosis: 1a-71 dtc troubleshooting note before this troubleshooting 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 ste...

  • Page 122

    1a-72 engine general information and diagnosis: dtc p0108: manifold absolute pressure circuit high input s6rw0d1104022 wiring diagram refer to “dtc p0106: manifold absolute pressure range / performance”. Dtc detecting condition and trouble area note when dtc p0113 and p0118 are indicated together, i...

  • Page 123

    Engine general information and diagnosis: 1a-73 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/blk” and “gry/blu” wire terminals. 3) turn on ignition switch, measure vol...

  • Page 124

    1a-74 engine general information and diagnosis: dtc p0111: intake air temperature circuit range / performance s6rw0d1104023 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 125

    Engine general information and diagnosis: 1a-75 5) check dtc and pending dtc. Dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control syst...

  • Page 126

    1a-76 engine general information and diagnosis: dtc p0112: intake air temperature sensor circuit low s6rw0d1104024 wiring diagram refer to “dtc p0111: intake air temperature circuit range / performance”. Dtc detecting condition and trouble area 5 wire circuit check 1) disconnect connectors from ecm ...

  • Page 127

    Engine general information and diagnosis: 1a-77 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. 4) check dtc and pending dtc. Dtc troubleshooting note before this troubl...

  • Page 128

    1a-78 engine general information and diagnosis: dtc p0113: intake air temperature sensor circuit high s6rw0d1104025 wiring diagram refer to “dtc p0111: intake air temperature circuit range / performance”. Dtc detecting condition and trouble area note when dtc p0108 and p0118 are indicated together, ...

  • Page 129

    Engine general information and diagnosis: 1a-79 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 “blk/yel” and “gry/blu” wire terminals. 3) if ok, then turn on ignition switch, measure ...

  • Page 130

    1a-80 engine general information and diagnosis: dtc p0116: engine coolant temperature circuit range / performance s6rw0d1104026 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 131

    Engine general information and diagnosis: 1a-81 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 132

    1a-82 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 “gry/blu” and “lt grn” wire terminals. 3) if ok, then with ignition switch on, measure voltage between “l...

  • Page 133

    Engine general information and diagnosis: 1a-83 dtc p0117: engine coolant temperature circuit low s6rw0d1104027 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 tur...

  • Page 134

    1a-84 engine general information and diagnosis: 3 ecm voltage check 1) disconnect connector from ect sensor with ignition switch turned off. 2) check for proper connection to ect sensor at “lt grn” and “gry/blu” wire terminals. 3) if ok, then turn on ignition switch, measure voltage between “lt grn”...

  • Page 135

    Engine general information and diagnosis: 1a-85 dtc p0118: engine coolant temperature circuit high s6rw0d1104028 wiring diagram refer to “dtc p0116: engine coolant temperature circuit range / performance”. Dtc detecting condition and trouble area note when dtc p0108 and p0113 are indicated together,...

  • Page 136

    1a-86 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 “c01- 24” terminal. 4) if ok, then turn on ignition switch, measure voltage between “c01-2...

  • Page 137

    Engine general information and diagnosis: 1a-87 dtc p0122: throttle position sensor (main) circuit low s6rw0d1104029 wiring diagram dtc detecting condition and trouble area note when dtc p0122 and p0222 are indicated together, it is possible that “red” wire open circuit. E01 c01 3 4 18 19 5 6 7 10 1...

  • Page 138

    1a-88 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 139

    Engine general information and diagnosis: 1a-89 dtc p0123: throttle position sensor (main) circuit high s6rw0d1104030 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 is...

  • Page 140

    1a-90 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 141

    Engine general information and diagnosis: 1a-91 5 wire harness check 1) measure voltage between “grn” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned on. Is voltage 4 – 6 v? Go to step 9. Go to step 6. 6 wire harness check 1) turn off ignition...

  • Page 142

    1a-92 engine general information and diagnosis: dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-1) s6rw0d1104031 wiring diagram dtc detecting condition and trouble area e01 c01 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 143

    Engine general information and diagnosis: 1a-93 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 144

    1a-94 engine general information and diagnosis: 4 ho2s-1 ground check 1) disconnect connector from ho2s-1 with ignition switch turned off. 2) check for proper connection to ho2s-1 connector at “blk/red”, “wht”, “blk/wht” and “orn” wire terminals. 3) if connections are ok, measure resistance between ...

  • Page 145

    Engine general information and diagnosis: 1a-95 dtc p0133: o2 sensor (ho2s) circuit slow response (sensor-1) s6rw0d1104032 wiring diagram refer to “dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-1)”. Dtc detecting condition and trouble area dtc confirmation procedure ...

  • Page 146

    1a-96 engine general information and diagnosis: dtc p0134: o2 sensor (ho2s) circuit no activity detected (sensor-1) s6rw0d1104033 wiring diagram refer to “dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-1)”. Dtc detecting condition and trouble area dtc confirmation pro...

  • Page 147

    Engine general information and diagnosis: 1a-97 2 ho2s-1 output voltage check 1) connect scan tool to dlc with ignition switch turned off. 2) warm up engine to normal operating temperature and keep it at 2000 r/min. For 60 sec. 3) repeat racing engine (repeat depressing accelerator pedal 5 to 6 time...

  • Page 148

    1a-98 engine general information and diagnosis: dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2) s6rw0d1104034 wiring diagram dtc detecting condition and trouble area 8 air intake system check 1) check air intake system for clog or leak. Is it ok? Replace ho2s-1 refe...

  • Page 149

    Engine general information and diagnosis: 1a-99 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 150

    1a-100 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 “red/blu”, “brn”, “orn” and “blk/wht” wire terminals. 3) if connections are ok, measure resistance between...

  • Page 151

    Engine general information and diagnosis: 1a-101 dtc p0140: o2 sensor (ho2s) circuit no activity detected (sensor-2) s6rw0d1104035 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 pr...

  • Page 152

    1a-102 engine general information and diagnosis: 3 wire circuit check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) measure resistance between “brn” wire terminal of ho2s-2 connector and “c01-11” terminal of ecm connector. Is resistance less than 5 Ω ?...

  • Page 153

    Engine general information and diagnosis: 1a-103 dtc p0171 / p0172: fuel system too lean / rich s6rw0d1104036 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 154

    1a-104 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 st...

  • Page 155

    Engine general information and diagnosis: 1a-105 dtc p0222: throttle position sensor (sub) circuit low s6rw0d1104037 wiring diagram dtc detecting condition and trouble area note when dtc p0122 and p0222 are indicated together, it is possible that “red” wire open circuit. E01 c01 3 4 18 19 5 6 7 10 1...

  • Page 156

    1a-106 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 157

    Engine general information and diagnosis: 1a-107 dtc p0223: throttle position sensor (sub) circuit high s6rw0d1104038 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 is ...

  • Page 158

    1a-108 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 159

    Engine general information and diagnosis: 1a-109 5 wire harness check 1) measure voltage between “wht” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned on. Is voltage 4 – 6 v? Go to step 9. Go to step 6. 6 wire harness check 1) turn off ignitio...

  • Page 160

    1a-110 engine general information and diagnosis: dtc p0300 / p0301 / p0302 / p0303 / p0304: random misfire detected / cylinder 1 / cylinder 2 / cylinder 3 / cylinder 4 misfire detected s6rw0d1104039 system description ecm measures the angle of the crankshaft based on the pulse signal from the ckp se...

  • Page 161

    Engine general information and diagnosis: 1a-111 dtc troubleshooting note if the vehicle runs under fuel deficient condition (such as a condition in which the fuel pump is unable to draw fuel properly), dtc of misfire may possibly be detected due to fuel pressure drop even though there is no abnorma...

  • Page 162

    1a-112 engine general information and diagnosis: dtc p0327 / p0328: knock sensor circuit low / high s6rw0d1104040 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 163

    Engine general information and diagnosis: 1a-113 dtc troubleshooting note before this troubleshooting 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 st...

  • Page 164

    1a-114 engine general information and diagnosis: dtc p0335: crankshaft position (ckp) sensor circuit s6rw0d1104041 wiring diagram dtc detecting condition and trouble area 7 knock sensor circuit for high resistance check 1) turn off ignition switch, measure resistance between “c01-56” terminal of ecm...

  • Page 165

    Engine general information and diagnosis: 1a-115 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 troubleshooti...

  • Page 166

    1a-116 engine general information and diagnosis: dtc p0340: camshaft position (cmp) sensor circuit s6rw0d1104042 wiring diagram 5 ground circuit check 1) turn ignition switch to off position. 2) measure resistance between “blk/orn” wire terminal of ckp sensor connector and engine ground. Is measured...

  • Page 167

    Engine general information and diagnosis: 1a-117 system description the cmp sensor located on the transmission side of cylinder head (vvt model) or timing chain cover (non-vvt model) consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion (vvt model) or exhaust c...

  • Page 168

    1a-118 engine general information and diagnosis: 3 wire harness and connection check 1) disconnect connector from cmp sensor. 2) check for proper connection to cmp sensor at “blk/ red”, “red/yel” and “blk/orn” wire terminals. 3) if ok, turn on ignition switch and check voltage at “blk/ red”, “red/ye...

  • Page 169

    Engine general information and diagnosis: 1a-119 dtc p0401 / p0402: exhaust gas recirculation flow insufficient detected / excessive detected s6rw0d1104043 system and wiring diagram 7 cmp sensor check 1) check cmp sensor and signal rotor tooth referring to “camshaft position (cmp) sensor inspection ...

  • Page 170

    1a-120 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 acc...

  • Page 171

    Engine general information and diagnosis: 1a-121 dtc troubleshooting note before this troubleshooting 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 st...

  • Page 172

    1a-122 engine general information and diagnosis: dtc p0403: exhaust gas recirculation control circuit s6rw0d1104044 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 possibility of a...

  • Page 173

    Engine general information and diagnosis: 1a-123 dtc troubleshooting note before this troubleshooting 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 st...

  • Page 174

    1a-124 engine general information and diagnosis: dtc p0420: catalyst system efficiency below threshold s6rw0d1104045 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 175

    Engine general information and diagnosis: 1a-125 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 176

    1a-126 engine general information and diagnosis: dtc p0443: evaporative emission system purge control valve circuit s6rw0d1104046 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 177

    Engine general information and diagnosis: 1a-127 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 troubleshooting is performed, read the pr...

  • Page 178

    1a-128 engine general information and diagnosis: dtc p0462 / p0463: fuel level sensor circuit low / high s6rw0d1104047 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 us...

  • Page 179

    Engine general information and diagnosis: 1a-129 dtc p0480: fan 1 (radiator cooling fan) control circuit s6rw0d1104048 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 180

    1a-130 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 st...

  • Page 181

    Engine general information and diagnosis: 1a-131 dtc p0481: cooling fan 2 (a/c condenser fan) control circuit s6rw0d1104049 wiring diagram circuit description a/c condenser cooling fan motor is turned on and off by its relay which ecm controls. A/c condenser cooling fan motor is turned on when ecm o...

  • Page 182

    1a-132 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 engine to normal operating temperature. 4) run engine at idle and turn both a/c swi...

  • Page 183

    Engine general information and diagnosis: 1a-133 3 check wire circuit 1) disconnect a/c compressor control relay (1) from individual circuit fuse box no.1 with ignition switch turned off. 2) turn on ignition switch, measure voltage between engine ground and “blk/wht” wire terminal of a/c condenser f...

  • Page 184

    1a-134 engine general information and diagnosis: dtc p0500: vehicle speed sensor (vss) malfunction s6rw0d1104050 wiring diagram dtc detecting condition and trouble area 9 check a/c condenser cooling fan control 1) ignition switch turned off. 2) remove ecm from vehicle body referring to “engine contr...

  • Page 185

    Engine general information and diagnosis: 1a-135 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 186

    1a-136 engine general information and diagnosis: dtc p0532: a/c refrigerant pressure sensor circuit low s6rw0d1104051 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 d...

  • Page 187

    Engine general information and diagnosis: 1a-137 2 a/c refrigerant pressure sensor power supply circuit check 1) disconnect connector from a/c refrigerant pressure sensor with ignition switch turned off. 2) check for proper connection of a/c refrigerant pressure sensor at “gry/red”, “red/blu” and “o...

  • Page 188

    1a-138 engine general information and diagnosis: dtc p0533: a/c refrigerant pressure sensor circuit high s6rw0d1104052 wiring diagram refer to “dtc p0532: a/c refrigerant pressure sensor circuit low”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc wit...

  • Page 189

    Engine general information and diagnosis: 1a-139 dtc p0601 / p0602 / p0607: internal control module memory check sum error / control module programming error / control module performance s6rw0d1104053 system description internal control module is installed in ecm. Dtc detecting condition and trouble...

  • Page 190

    1a-140 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p0616: starter relay circuit low s6rw0d1104054 wiring diagram step action yes no 1 ...

  • Page 191

    Engine general information and diagnosis: 1a-141 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) start engine. 4) check dtc and pending dtc. Dtc troubleshooting not...

  • Page 192

    1a-142 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 st...

  • Page 193

    Engine general information and diagnosis: 1a-143 dtc p1510: ecm back-up power supply malfunction s6rw0d1104056 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 194

    1a-144 engine general information and diagnosis: dtc p2101: throttle actuator control motor circuit range / performance s6rw0d1104057 wiring diagram 2 battery voltage supply circuit check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) with engine runnin...

  • Page 195

    Engine general information and diagnosis: 1a-145 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 196

    1a-146 engine general information and diagnosis: dtc p2102: throttle actuator control motor circuit low s6rw0d1104058 wiring diagram refer to “dtc p2101: throttle actuator control motor circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition...

  • Page 197

    Engine general information and diagnosis: 1a-147 dtc p2103: throttle actuator control motor circuit high s6rw0d1104059 wiring diagram refer to “dtc p2101: throttle actuator control motor circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignitio...

  • Page 198

    1a-148 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p2111: throttle actuator control system - stuck open s6rw0d1104060 wiring diagram r...

  • Page 199

    Engine general information and diagnosis: 1a-149 dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p2119: throttle actuator control throttle body range / performance s6rw0d1104061 wi...

  • Page 200

    1a-150 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 st...

  • Page 201

    Engine general information and diagnosis: 1a-151 dtc p2122: pedal position sensor (main) circuit low input s6rw0d1104062 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 202

    1a-152 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 st...

  • Page 203

    Engine general information and diagnosis: 1a-153 dtc p2123: pedal position sensor (main) circuit high input s6rw0d1104063 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 204

    1a-154 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 st...

  • Page 205

    Engine general information and diagnosis: 1a-155 dtc p2127: pedal position sensor (sub) circuit low input s6rw0d1104064 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 ecm...

  • Page 206

    1a-156 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 207

    Engine general information and diagnosis: 1a-157 5 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 “e01- 34” terminal. 4) if ok, measure voltage between “e01-34” terminal of ecm connector ...

  • Page 208

    1a-158 engine general information and diagnosis: dtc p2128: pedal position sensor (sub) circuit high input s6rw0d1104065 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 tu...

  • Page 209

    Engine general information and diagnosis: 1a-159 4 ecm voltage check 1) disconnect connector from app sensor assembly with ignition switch turned off. 2) check for proper connection to app sensor assembly at “red”, “yel” and “wht” wire terminals. 3) if ok, measure voltage between “red” wire terminal...

  • Page 210

    1a-160 engine general information and diagnosis: dtc p2135: throttle position sensor (main / sub) voltage correlation s6rw0d1104066 wiring diagram 9 ground circuit check 1) remove ecm from its bracket with ecm connectors connected. 2) check for proper connection of ecm connector at “e01- 51” termina...

  • Page 211

    Engine general information and diagnosis: 1a-161 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 212

    1a-162 engine general information and diagnosis: 4 wire harness check 1) disconnect connectors from ecm with ignition switch turned off. 2) measure resistance between “c01-43” terminal of ecm connector and engine ground. Is resistance infinity? Go to step 5. “red” wire is shorted to other circuit. 5...

  • Page 213

    Engine general information and diagnosis: 1a-163 dtc p2138: pedal position sensor (main / sub) voltage correlation s6rw0d1104067 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 214

    1a-164 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting 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 st...

  • Page 215

    Engine general information and diagnosis: 1a-165 dtc p2227 / p2228 / p2229: barometric pressure circuit malfunction s6rw0d1104068 dtc p2227: barometric pressure circuit range / performance dtc p2228: barometric pressure circuit low dtc p2229: barometric pressure circuit high system description barom...

  • Page 216

    1a-166 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 217

    Engine general information and diagnosis: 1a-167 troubleshooting for can-dtc s6rw0d1104084 perform this troubleshooting when can-dtc is detected. Note • when performing this troubleshooting, be sure to have full understanding of “precaution on can troubleshooting” and observe it. • it may be possibl...

  • Page 218

    1a-168 engine general information and diagnosis: troubleshooting step action yes no 1 dtc check 1) turn ignition switch to off position. 2) connect scan tool to dlc. 3) check dtc in the following control modules. • ecm • tcm • bcm • keyless start control module • 4wd control module is there any dtc ...

  • Page 219

    Engine general information and diagnosis: 1a-169 3 can line check 1) turn ignition switch to off position. 2) disconnect connectors of all control module communicated by can. 3) check all the following can lines for open, short to power circuit, short to ground circuit, short to other can line and h...

  • Page 220

    1a-170 engine general information and diagnosis: 6 terminating resistance check in ecm and combination meter 1) turn ignition switch to off position and then disconnect negative (–) cable at battery. 2) measure resistance between can high terminal (2) and can low terminal (3) on dlc (1). If resistan...

  • Page 221

    Engine general information and diagnosis: 1a-171 12 can communication check of tcm 1) turn ignition switch to off position. 2) connect tcm connectors. 3) perform “communication bus check” under “bus check” using suzuki-sdt with ignition switch turned on. Are all of bcm, ecm, abs control module, comb...

  • Page 222

    1a-172 engine general information and diagnosis: inspection of ecm and its circuits s6rw0d1104072 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 223

    Engine general information and diagnosis: 1a-173 terminal no. Wire color circuit normal voltage condition remarks c01-1 blu/ yel fuel injector no.1 output 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 ...

  • Page 224

    1a-174 engine general information and diagnosis: c01-10 wht oxygen signal of heated oxygen sensor-1 0 – 1 v ignition switch turned on. — *deflects between over 0.5 v and under 0.45 v (“reference waveform no.8: ” and “reference waveform no.9: ”) while engine running at 2,000 r/min. For 1 min. Or long...

  • Page 225

    Engine general information and diagnosis: 1a-175 c01-19 wht/ red egr valve (stepper motor coil 3) output (if equipped 10 – 14 v ignition switch turned on. — *0 – 1 v ↑↓ 10 – 14 v (“reference waveform no.4: ”) ignition switch is turned to st (cranking) position. Output signal is active low duty pulse...

  • Page 226

    1a-176 engine general information and diagnosis: c01-34 — — — — — c01-35 — — — — — c01-36 — — — — — c01-37 — — — — — c01-38 — — — — — c01-39 — — — — — c01-40 wht throttle position sensor (sub) signal 1.57 – 1.90 v ignition switch turned on and accelerator pedal at idle position after warmed up engin...

  • Page 227

    Engine general information and diagnosis: 1a-177 c01-48 yel/ grn starting motor signal 0 – 1 v ignition switch turned on. — 6 – 14 v while engine cranking. C01-49 — — — — — c01-50 wht/ blu ground of ecm for shield wire below 0.3 v ignition switch turned on. — c01-51 — — — — — c01-52 — — — — — c01-53...

  • Page 228

    1a-178 engine general information and diagnosis: e01-4 brn engine revolution signal output for p/ s control module 0 – 0.8 v ignition switch turned on with engine at stop. — *0 – 1 v ↑↓ 8 – 14 v (“reference waveform no.24: ” and “reference waveform no.25: ”) while engine running. Output signal is pu...

  • Page 229

    Engine general information and diagnosis: 1a-179 e01-26 red/ blu eps signal 10 – 14 v ignition switch turned on. — 0 – 1 v with engine running at idle speed, and steering wheel turned to the right or left as far as it stops. E01-27 — — — — — e01-28 yel/ blk serial communication line for immobilizer ...

  • Page 230

    1a-180 engine general information and diagnosis: e01-46 lt grn radiator cooling fan relay output 10 – 14 v ignition switch turned on and ect is 97.5 °c (206 °f) or less without operating a/c. — 0 – 2 v ignition switch turned on and ect is 100 °c (212 °f) or more. E01-47 gry a/c compressor relay outp...

  • Page 231

    Engine general information and diagnosis: 1a-181 reference waveform no.1 fuel injector signal (1) with engine idling reference waveform no.2 no.1 fuel injector signal (2) with engine idling e01-58 red/ blk a/c condenser fan relay (if equipped with a/ c) 0 – 1 v blower speed selector on a/c or defros...

  • Page 232

    1a-182 engine general information and diagnosis: reference waveform no.3 no.2 fuel injector signal (2) with engine idling reference waveform no.4 egr valve signal measurement terminal ch1: “c01-20” to “c01-58” ch2: “c01-2” to “c01-58” oscilloscope setting ch1: 5 v/div, ch2: 20 v/div time: 40 ms/div ...

  • Page 233

    Engine general information and diagnosis: 1a-183 reference waveform no.5 ignition coil no.2 and no.3 signal (2) with engine idling reference waveform no.6 ignition coil signal (1) with engine idling reference waveform no.7 ignition coil no.1 and no.4 signal (2) with engine idling measurement termina...

  • Page 234

    1a-184 engine general information and diagnosis: reference waveform no.8 heated oxygen sensor-1 signal (1) with engine idling reference waveform no.9 heated oxygen sensor-1 heater signal (2) with engine idling reference waveform no.10 heated oxygen sensor-2 heater signal (4) with engine idling measu...

  • Page 235

    Engine general information and diagnosis: 1a-185 reference waveform no.11 no.3 fuel injector signal (2) with engine idling reference waveform no.12 no.4 fuel injector signal (2) with engine idling measurement terminal ch1: “c01-20” to “c01-58” ch2: “c01-16” to “c01-58” oscilloscope setting ch1: 5 v/...

  • Page 236

    1a-186 engine general information and diagnosis: reference waveform no.13 cmp sensor signal with engine idling reference waveform no.14 cmp sensor signal with engine idling measurement terminal ch1: “c01-20” to “c01-58” ch2: “c01-21” to “c01-58” oscilloscope setting ch1: 2 v/div, ch2: 2 v/div time: ...

  • Page 237

    Engine general information and diagnosis: 1a-187 reference waveform no.15 mass air flow sensor signal (1) with engine racing reference waveform no.16 evap canister purge valve signal reference waveform no.17 manifold absolute pressure sensor signal (1) with ignition switch turned on reference wavefo...

  • Page 238

    1a-188 engine general information and diagnosis: reference waveform no.19 knock sensor signal at engine speed 4000 r/min. Reference waveform no.20 knock sensor signal at engine speed 4000 r/min. Reference waveform no.21 oil control valve signal with engine idling (for engine with vvt system) referen...

  • Page 239

    Engine general information and diagnosis: 1a-189 reference waveform no.23 can communication line signal from abs / esp ® control module assembly or tcm with ignition switch turned on reference waveform no.24 ignition pulse (engine revolution) signal (2) with engine idling measurement terminal ch1: “...

  • Page 240

    1a-190 engine general information and diagnosis: reference waveform no.25 ignition pulse (engine revolution) signal (2) with engine idling reference waveform no.26 throttle actuator output signal with ignition switch turned on reference waveform no.27 throttle actuator output signal with ignition sw...

  • Page 241

    Engine general information and diagnosis: 1a-191 reference waveform no.28 ignition coil signal and fuel injector signal with engine cranking reference waveform no.29 throttle position sensor main (1) and sub (2) signal reference waveform no.30 pedal position sensor main (1) and sub (2) signal measur...

  • Page 242

    1a-192 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 conne...

  • Page 243

    Engine general information and diagnosis: 1a-193 ecm power and ground circuit check s6rw0d1104073 wiring diagram 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. E01 c01 3 4 18 19 5 6 7 10 11 17 20 47...

  • Page 244

    1a-194 engine general information and diagnosis: troubleshooting note • 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 tool to ecm and/or the ecm co...

  • Page 245

    Engine general information and diagnosis: 1a-195 6 ecm ground circuit check 1) turn ignition switch to off position. 2) disconnect connectors from ecm. 3) measure resistance between each “e01-31”, “c01-58”, “c01-15” and “c01-30” terminals of ecm connector and body ground. Is resistance 1 Ω or less? ...

  • Page 246

    1a-196 engine general information and diagnosis: fuel injector circuit check s6rw0d1104074 wiring diagram 11 sensor power source circuit check 1) connect connectors to ecm with ignition switch turned off. 2) turn on ignition switch, measure each voltage between “c01-14”, “e01-35”, “e01-34” and “c01-...

  • Page 247

    Engine general information and diagnosis: 1a-197 troubleshooting note • 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 tool to ecm and/or the ecm co...

  • Page 248

    1a-198 engine general information and diagnosis: fuel pump and its circuit check s6rw0d1104075 wiring diagram e01-1 e01-15 blk/red blk/yel blk/yel blk/red e01-29 blk/wht grn/wht blk/wht blk/wht pnk blk wht grn c01-58 c01-15 c01-30 blk/orn blk blk 7 8 9 6 4 3 2 5 e01 c01 3 4 18 19 5 6 7 10 11 17 20 4...

  • Page 249

    Engine general information and diagnosis: 1a-199 troubleshooting note • 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 tool to ecm and/or the ecm co...

  • Page 250

    1a-200 engine general information and diagnosis: 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 251

    Engine general information and diagnosis: 1a-201 fuel pressure check s6rw0d1104076 system diagram special tool (a): 09912–58442 (b): 09912–58432 (c): 09912–58490 troubleshooting note before using following flow, check to make sure that battery voltage is higher than 11 v. If battery voltage is low, ...

  • Page 252

    1a-202 engine general information and diagnosis: a/c condenser cooling fan control system inspection s6rw0d1104077 wiring diagram 4 fuel line check 1) check fuel pipe, fuel hose and joint for damage or deform. Are they in good condition? Faulty fuel pressure regulator. Repair or replace damaged or d...

  • Page 253

    Engine general information and diagnosis: 1a-203 troubleshooting step action yes no 1 check a/c condenser fan control system is a/c condenser fan started when a/c is operating? Intermittent trouble. Check for intermittent referring to “intermittent and poor connection inspection in section 00”. Go t...

  • Page 254

    1a-204 engine general information and diagnosis: 9 check wire circuit 1) install “a/c” fuse “20 a” to individual circuit fuse box no.1. 2) connect a/c condenser cooling fan control relay to individual circuit fuse box no.1 with ignition switch turn off. 3) start engine then turn on a/c switch and bl...

  • Page 255

    Engine general information and diagnosis: 1a-205 a/c system circuits check s6rw0d1104078 wiring diagram blu/wht blu/wht e01-19 e01-19 21 e01 c01 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 256

    1a-206 engine general information and diagnosis: troubleshooting note • 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 tool to ecm and/or the ecm co...

  • Page 257

    Engine general information and diagnosis: 1a-207 6 a/c evaporator outlet air temp. Sensor check 1) disconnect connectors from ecm with ignition switch turned off. 2) check for proper connection to “e01-57” and “e01-54” wire terminals of ecm connector. 3) if ok, measure resistance between “e01-57” an...

  • Page 258

    1a-208 engine general information and diagnosis: 11 a/c compressor relay circuit check 1) measure voltage between “e01-47” wire terminal of ecm connector and vehicle body ground under following conditions respectively. Voltage between “e01-47” terminal of ecm connector and ground while engine runnin...

  • Page 259

    Engine general information and diagnosis: 1a-209 electric load signal circuit check s6rw0d1104079 wiring diagram e01 c01 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 260

    1a-210 engine general information and diagnosis: troubleshooting note • 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 tool to ecm and/or the ecm co...

  • Page 261

    Engine general information and diagnosis: 1a-211 radiator cooling fan control system check s6rw0d1104080 wiring diagram troubleshooting warning ! Keep hands, tools, and clothing away from radiator cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the en...

  • Page 262

    1a-212 engine general information and diagnosis: repair instructions idle speed and iac throttle valve opening inspection s6rw0d1106001 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 263

    Engine general information and diagnosis: 1a-213 1) connect suzuki scan tool to dlc (1) with ignition switch turned off. Special tool (a): suzuki scan tool (suzuki-sdt) 2) warm up engine to normal operating temperature. 3) check engine idle speed and “iac throttle opening” by using “data list” mode ...

  • Page 264

    1b-1 aux. Emission control devices: engine aux. Emission control devices diagnostic information and procedures egr system inspection (if equipped) s6rw0d1204001 1) connect suzuki scan tool to data link connector (dlc) (1) with ignition switch turned off. 2) turn on ignition switch and erase dtc usin...

  • Page 265

    Aux. Emission control devices: 1b-2 1) prepare to operate evap canister purge valve as follows. A) when using suzuki scan tool: i) connect suzuki scan tool to dlc (1) with ignition switch turned off and disconnect purge valve vacuum hoses from intake manifold and evap canister. Ii) turn on ignition ...

  • Page 266

    1b-3 aux. Emission control devices: vacuum hose inspection s6rw0d1206004 check hoses for connection, leakage, clog and deterioration. Replace as necessary. Evap canister purge valve inspection s6rw0d1206005 warning ! Do not apply vacuum by mouth; otherwise harmful fuel vapor can be breathed in. Caut...

  • Page 267

    Aux. Emission control devices: 1b-4 evap canister inspection s6rw0d1206006 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 268

    1b-5 aux. Emission control devices: pcv hose inspection s6rw0d1206009 note be sure to check that there is no obstruction in pcv valve or its hoses before checking iac throttle valve opening, for obstructed pcv valve or hose hampers its accurate adjustment. Check hoses for connection, leakage, clog a...

  • Page 269: Engine Electrical Devices

    Engine electrical devices: 1c-1 engine engine electrical devices repair instructions engine control module (ecm) removal and installation s6rw0d1306001 caution ! As ecm consists of precision parts, be careful not to expose it to excessive shock. Removal 1) disconnect negative cable at battery. 2) di...

  • Page 270

    1c-2 engine electrical devices: manifold absolute pressure (map) sensor inspection (if equipped) s6rw0d1306002 1) remove air cleaner assembly. 2) disconnect connector from map sensor. 3) remove map sensor. 4) arrange 3 new 1.5 v batteries (2) in series (check that total voltage is 4.5 – 5.0 v) and c...

  • Page 271

    Engine electrical devices: 1c-3 throttle valve visual check 1) remove air cleaner outlet hose. 2) check that there isn’t any foreign matter caught between throttle valve and throttle body housing. If there is, take it out after removing throttle body referring to “electric throttle body assembly rem...

  • Page 272

    1c-4 engine electrical devices: throttle position sensor performance check 1) remove air cleaner outlet hose. 2) turn off ignition switch. 3) disconnect connector from electric throttle body assembly. 4) check throttle position sensor (main and sub) output voltage as following steps. A) for throttle...

  • Page 273

    Engine electrical devices: 1c-5 electric throttle body system calibration s6rw0d1306004 note if the service described under the “precautions of electric throttle body system calibration in section 1a” is performed, calibrate electric throttle body system as follows. 1) if electric throttle body asse...

  • Page 274

    1c-6 engine electrical devices: removal 1) disconnect negative cable at battery. 2) disconnect connector from app sensor assembly. 3) remove app sensor assembly from its bracket. Installation reverse removal procedure for installation noting the following. • tighten app sensor assembly upper nut (1)...

  • Page 275

    Engine electrical devices: 1c-7 engine coolant temperature (ect) sensor removal and installation s6rw0d1306008 removal 1) disconnect negative cable at battery. 2) drain coolant referring to “cooling system draining in section 1f”. Warning ! To avoid danger of being burned, do not remove radiator cap...

  • Page 276

    1c-8 engine electrical devices: heated oxygen sensor (ho2s-1 and ho2s-2) heater on-vehicle inspection (if equipped) s6rw0d1306010 1) disconnect sensor connector. 2) using ohmmeter, measure resistance between terminals “v b ” and “gnd” of sensor connector. If found faulty, replace oxygen sensor. Note...

  • Page 277

    Engine electrical devices: 1c-9 camshaft position (cmp) sensor removal and installation s6rw0d1306012 removal 1) disconnect negative cable at battery. 2) disconnect connector from cmp sensor. 3) remove camshaft position sensor from timing chain cover (non-vvt model) or cylinder head (vvt model). Ins...

  • Page 278

    1c-10 engine electrical devices: performance check 1) remove metal particles on end face of cmp sensor, if any. 2) arrange 12 v battery (1) and connect its positive terminal to “vin” terminal (2) and negative terminal to “ground” terminal (3) of sensor. Then using ohmmeter, measure resistance betwee...

  • Page 279

    Engine electrical devices: 1c-11 crankshaft position (ckp) sensor inspection s6rw0d1306015 visual check • check that o-ring is free from damage. • check that end face of sensor and signal pulley tooth are free from any metal particles and damage. Performance check 1) remove metal particles on end fa...

  • Page 280

    1c-12 engine electrical devices: main relay, fuel pump relay, starting motor control relay, throttle actuator control relay and radiator cooling fan relay inspection s6rw0d1306017 1) disconnect negative cable at battery. 2) remove main relay (1), fuel pump relay (3), starting motor control relay (2)...

  • Page 281

    Engine electrical devices: 1c-13 mass air flow (maf) and intake air temperature (iat) sensor removal and installation s6rw0d1306019 caution ! • do not disassemble maf and iat sensor. • do not expose maf and iat sensor to any shock. • do not clean maf and iat sensor. • if maf and iat sensor has been ...

  • Page 282

    1c-14 engine electrical devices: specifications tightening torque specifications s6rw0d1307001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. Fastening part tightening torque note n ⋅m kgf-m lb-ft ecm mounting bolt 8 0....

  • Page 283: Engine Mechanical

    Engine mechanical: 1d-1 engine engine mechanical general description engine construction description s6rw0d1401001 the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration and 16 v...

  • Page 284

    1d-2 engine mechanical: i5rw0c140033-01 [a]: for engine with vvt system [b]: for engine without vvt system.

  • Page 285

    Engine mechanical: 1d-3 camshaft position control (vvt variable valve timing) system description s6rw0d1401002 system description the vvt system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized i...

  • Page 286

    1d-4 engine mechanical: oil control valve the oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ecm. By this operation, the intake valve timing is varied continuously. Sig...

  • Page 287

    Engine mechanical: 1d-5 targeted timing varying operation diagnostic information and procedures compression check s6rw0d1404001 check compression pressure on all 4 cylinders as follows: 1) warm up engine to normal operating temperature. 2) stop engine after warming up. Note after warming up engine, ...

  • Page 288

    1d-6 engine mechanical: 8) disengage clutch (1) (to lighten starting load on engine) for m/t vehicle, and depress accelerator pedal (2) all the way to make throttle fully open. 9) crank engine with fully charged battery, and read the highest pressure on compression gauge. Note • for measuring compre...

  • Page 289

    Engine mechanical: 1d-7 7) install air cleaner assembly with air suction hose referring to “air cleaner assembly removal and installation”. 8) 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 cmh...

  • Page 290

    1d-8 engine mechanical: 2) lift down the valve by turning crankshaft to 360 °. 3) hold tappet at that position using special tool as follows. A) remove its housing bolts. B) check housing no. And select special tool corresponding to housing no., referring to “special tool selection table”. Special t...

  • Page 291

    Engine mechanical: 1d-9 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 above step 4)) and remove sp...

  • Page 292

    1d-10 engine mechanical: repair instructions air intake system components s6rw0d1406045 air cleaner filter removal and installation s6rw0d1406001 removal 1) open air cleaner case (1) by unhooking its clamps (2). 2) remove air cleaner filter from case. Installation reverse removal procedure for insta...

  • Page 293

    Engine mechanical: 1d-11 air cleaner assembly removal and installation s6rw0d1406046 removal 1) disconnect negative cable at battery. 2) disconnect maf sensor connector (1). 3) remove evap canister purge valve (2). 4) remove air cleaner assembly (3) with air suction hose (4). Installation reverse re...

  • Page 294

    1d-12 engine mechanical: installation 1) install new spark plug hole gaskets (1) and new cylinder head cover gasket (2) to cylinder head cover (3) as shown in figure. 2) remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning, apply sealant “a” to the follo...

  • Page 295

    Engine mechanical: 1d-13 throttle body and intake manifold components s6rw0d1406010 i6rw0d140001-01 1. Intake manifold 8. To cylinder head cover 15. Brake booster hose 22. Throttle body outlet water hose no.2 2. O-ring 9. Gasket (with egr) 16. To brake booster 23. Egr pipe plate (without egr) 3. Thr...

  • Page 296

    1d-14 engine mechanical: throttle body on-vehicle inspection s6rw0d1406006 check electric throttle body assembly referring to “throttle valve operation check” and “electric throttle body assembly operation check” under “electric throttle body assembly on-vehicle inspection in section 1c”. Electric t...

  • Page 297

    Engine mechanical: 1d-15 intake manifold removal and installation s6rw0d1406011 removal 1) remove throttle body referring to “electric throttle body assembly removal and installation”. 2) disconnect map sensor connector (1). 3) disconnect the following hoses: • brake booster hose (2) from cylinder h...

  • Page 298

    1d-16 engine mechanical: engine mountings components s6rw0d1406012 i6rw0d140002-01 [a]: for 4wd model 4. Engine left mounting : be sure to direct paint mark to forward. 12. Dynamic damper [b]: for 2wd model 5. Engine rear mounting : be sure to direct paint mark to forward. 13. Mounting member cushio...

  • Page 299

    Engine mechanical: 1d-17 engine assembly removal and installation s6rw0d1406013 removal 1) relieve fuel pressure according to “fuel pressure relief procedure in section 1g”. 2) disconnect negative and positive cable at battery. 3) disconnect ecm connectors. 4) remove battery and battery tray with ec...

  • Page 300

    1d-18 engine mechanical: 17) remove oil pressure switch bracket (1). 18) remove suspension control arm referring to “suspension control arm / bushing removal and installation in section 2b”. 19) disconnect right and left drive shaft joints from differential gear referring to “front drive shaft assem...

  • Page 301

    Engine mechanical: 1d-19 25) remove engine right mounting bracket (1) and engine left mounting bush bolt (2). 26) remove suspension frame mounting bolts and (1) front lower cross member bolts (2). 27) lower engine with transaxle, front suspension frame, front lower cross member, transfer (for 4wd mo...

  • Page 302

    1d-20 engine mechanical: 6) install engine right mounting bracket (1) and engine left mounting bush bolt (2), and then tighten bolt and nuts to specified torque. Tightening torque engine right mounting bracket nut (a): 65 n·m ( 6.5 kgf-m, 47.0 lb-ft) engine right mounting bush bolt (b): 55 n·m (5.5 ...

  • Page 303

    Engine mechanical: 1d-21 12) install oil pressure switch bracket (1). 13) connect right and left drive shaft joints to differential gear referring to “front drive shaft assembly removal and installation in section 3a”. 14) install suspension control arm referring to “suspension control arm / bushing...

  • Page 304

    1d-22 engine mechanical: timing chain cover components s6rw0d1406014 i5rw0c140041-01 [a]: for engine with vvt 8. Timing chain cover mounting nut 17. Oil control valve [b]: for engine without vvt 9. Oil gallery pipe no.1 18. Oil control valve mounting nut 1. Crankshaft pulley bolt 10. Copper washer 1...

  • Page 305

    Engine mechanical: 1d-23 timing chain cover removal and installation s6rw0d1406015 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 always clean. Removal 1) ...

  • Page 306

    1d-24 engine mechanical: 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 fit to timing chain cover...

  • Page 307

    Engine mechanical: 1d-25 8) for engine with vvt, install new o-ring (1) to oil gallery pipes no.2 (2) and no.3 (3). 9) for engine with vvt, 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 n...

  • Page 308

    1d-26 engine mechanical: oil control valve removal and installation (for engine with vvt) s6rw0d1406017 removal remove oil gallery pipe no.1 and oil control valve from timing chain cover. Installation 1) install new o-ring (4) to oil control valve (2). 2) install oil control valve to timing chain co...

  • Page 309

    Engine mechanical: 1d-27 timing chain and chain tensioner components s6rw0d1406019 timing chain and chain tensioner removal and installation s6rw0d1406020 removal caution ! After timing chain is removed, never turn crankshaft and camshafts independently more than its allowable turning range describe...

  • Page 310

    1d-28 engine mechanical: installation caution ! After timing chain is removed, never turn crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown in figure. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and ...

  • Page 311

    Engine mechanical: 1d-29 5) apply engine oil to sliding surface of timing chain no.1 guide (1) and install it as shown in figure. Tighten guide bolts to specified torque. Tightening torque timing chain no.1 guide bolt (a): 11 n·m (1.1 kgf-m, 8.0 lb-ft) 6) apply engine oil to sliding surface of chain...

  • Page 312

    1d-30 engine mechanical: 8) screw in plunger (1) by turning body (2) in arrow direction and install a retainer (3) (wire) to hold plunger in place. 9) install timing chain tensioner adjuster assembly (1) with a retainer (2). Tighten adjuster bolts to specified torque and then remove a retainer from ...

  • Page 313

    Engine mechanical: 1d-31 timing chain and chain tensioner inspection s6rw0d1406021 timing chain no.1 guide check shoe (1) 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. Timing chain check timing cha...

  • Page 314

    1d-32 engine mechanical: camshaft, tappet and shim components s6rw0d1406022 i4rs0b140014-03 [a]: for engine with vvt 4. Exhaust camshaft 9. Camshaft bearing : install a bearing half with some holes to upper side of intake camshaft no.1 bearing. [b]: for engine without vvt 5. Shim : shim no. On it fa...

  • Page 315

    Engine mechanical: 1d-33 camshaft, tappet and shim removal and installation s6rw0d1406023 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 always clean. Remo...

  • Page 316

    1d-34 engine mechanical: installation 1) install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to cylinder head. Note when installing shim, make sure to direct shim no. Side toward tappet. 2) for engine with vvt, install camshaft bearings (1) to cylinder head...

  • Page 317

    Engine mechanical: 1d-35 6) check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housings as indicated by these marks. 7) after applying engine oil to housing bolts, tighten them temporarily first. Tigh...

  • Page 318

    1d-36 engine mechanical: camshaft, tappet and shim inspection s6rw0d1406024 intake cam timing sprocket assembly (for engine with vvt) 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 ha...

  • Page 319

    Engine mechanical: 1d-37 6) tighten camshaft housing bolts evenly and gradually in numerical order (“1” through “21”) by repeating tightening sequence two or three times until specified torque is obtained. Note do not rotate camshaft while gauging plastic is installed. Tightening torque camshaft hou...

  • Page 320

    1d-38 engine mechanical: camshaft bearing thickness (for engine with vvt) : 1.5120 – 1.5180 mm (0.0596 – 0.0597 in.) 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 deter...

  • Page 321

    Engine mechanical: 1d-39 valves and cylinder head components s6rw0d1406025 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. Valve guide : tighten 2...

  • Page 322

    1d-40 engine mechanical: valves and cylinder head removal and installation s6rw0d1406026 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2) remove oil pan referring to “oil pan and oil pump strainer removal and installation in section 1e”. 3) r...

  • Page 323

    Engine mechanical: 1d-41 5) install cylinder head to cylinder block. Apply engine oil to new cylinder head bolts and tighten them gradually as follows. A) tighten cylinder head bolts (“1” – “10”) to 20 n ⋅m (2.0 kgf-m, 14.5 lb-ft) according to numerical order as shown by using a 12 corner socket wre...

  • Page 324

    1d-42 engine mechanical: valves and cylinder head disassembly and assembly s6rw0d1406027 disassembly 1) for ease in servicing cylinder head, remove intake manifold, injectors, exhaust manifold from cylinder head. 2) using special tools (valve lifter), compress valve spring and then remove valve cott...

  • Page 325

    Engine mechanical: 1d-43 assembly 1) before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as to remove burrs and make it truly round. Special tool (a): 09916–34542 (b): 09916–37320 2) install valve guide to cylinder head. Heat cylinder head uniforml...

  • Page 326

    1d-44 engine mechanical: 6) install valve to valve guide. Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore and valve stem. 7) install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Be ...

  • Page 327

    Engine mechanical: 1d-45 valves and valve guides inspection s6rw0d1406028 valve guide valve stem-to-guide clearance using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of...

  • Page 328

    1d-46 engine mechanical: 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 create contact pattern on ...

  • Page 329

    Engine mechanical: 1d-47 cylinder head inspection s6rw0d1406029 • remove all carbon deposits from combustion chambers. Note do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to valves and valve seats, to...

  • Page 330

    1d-48 engine mechanical: valve spring inspection s6rw0d1406030 valve spring free length and preload referring to data, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibilit...

  • Page 331

    Engine mechanical: 1d-49 pistons, piston rings, connecting rods and cylinders components s6rw0d1406031 pistons, piston rings, connecting rods and cylinders removal and installation s6rw0d1406032 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2...

  • Page 332

    1d-50 engine mechanical: 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 bolts. These guide hoses pr...

  • Page 333

    Engine mechanical: 1d-51 pistons, piston rings, connecting rods and cylinders disassembly and assembly s6rw0d1406033 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 follows. A) ease out piston...

  • Page 334

    1d-52 engine mechanical: cylinders, pistons and piston rings inspection s6rw0d1406034 cylinder visual inspection inspect cylinder walls for scratches, roughness or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size p...

  • Page 335

    Engine mechanical: 1d-53 piston clearance measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston. Note cylinder bore diam...

  • Page 336

    1d-54 engine mechanical: piston pins and connecting rods inspection s6rw0d1406035 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, connecting rod small end bore or...

  • Page 337

    Engine mechanical: 1d-55 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 micrometer (3). Calculate dif...

  • Page 338

    1d-56 engine mechanical: 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 undersize bearing, it is pain...

  • Page 339

    Engine mechanical: 1d-57 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 bearing due to an...

  • Page 340

    1d-58 engine mechanical: 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 figure. Each color indicated the following thickness at the center of bearing. Standard size of connecting rod b...

  • Page 341

    Engine mechanical: 1d-59 main bearings, crankshaft and cylinder block components s6rw0d1406037 i6rw0d140003-01 1. Ckp sensor : see “a” 11. Rear oil seal 21. Oil filter adapter bolt 2. Knock sensor 12. Input shaft bearing 22. Spring pin 3. Cylinder block 13. Flywheel or drive plate 23. Sensor plate b...

  • Page 342

    1d-60 engine mechanical: main bearings, crankshaft and cylinder block removal and installation s6rw0d1406038 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2) remove clutch cover, clutch disc and flywheel (drive plate for a/t) by using special...

  • Page 343

    Engine mechanical: 1d-61 installation note • use new bearing cap no.1 bolts. They are deformed once they are used because they are plastic deformation tightening bolts. • all parts to be installed must be perfectly clean. • be sure to oil crankshaft journals, journal bearings, thrust bearings, crank...

  • Page 344

    1d-62 engine mechanical: 6) install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side. After applying engine oil to main bearing cap no.1 bolts ((1) – (10)) and...

  • Page 345

    Engine mechanical: 1d-63 9) install rear oil seal housing (1) and tighten new bolts to specified torque by using special tool. Special tool (a): 09911–97720 tightening torque rear oil seal housing bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) 10) install flywheel (drive plate for a/t). Using special tool, loc...

  • Page 346

    1d-64 engine mechanical: 2) tighten main bearing cap no.1 bolts (1) – (10) and main bearing cap no.2 bolts (11) – (20) gradually as follows. A) tighten bolts (1) – (10) to 30 n ⋅m (3.0 kgf-m, 22.0 lb-ft) according to numerical order in figure. B) in the same manner as in step a), tighten them to 50 ...

  • Page 347

    Engine mechanical: 1d-65 main bearings inspection s6rw0d1406040 general information • service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. • upper half of bearing (1) has oil groove (2) as shown in f...

  • Page 348

    1d-66 engine mechanical: selection of main bearings standard bearing if bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. 1) first check journal diameter. As shown in figure, crank web no.2 has...

  • Page 349

    Engine mechanical: 1d-67 3) there are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing. Standard size of crankshaft main bea...

  • Page 350

    1d-68 engine mechanical: 5) using scale (1) on gauging plastic (2), check bearing clearance with newly selected standard bearing. If clearance still exceeds its limit, use next thicker bearing and recheck clearance. 6) when replacing crankshaft or cylinder block due to any reason, select new standar...

  • Page 351

    Engine mechanical: 1d-69 • if necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. A. Regrind journal to the following finished diameter. Finished journal diameter 51.7320 – 51.7500 mm (2.0367 – 2.0374 in.) b. Using micrometer, measure regrind journal diamete...

  • Page 352

    1d-70 engine mechanical: 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 bolt by using a micrometer (2). Calculate difference in diameters (“a” – “b”)...

  • Page 353

    Engine mechanical: 1d-71 honing or reboring cylinders 1) when any cylinder needs reboring, all other cylinders must also be rebored at the same time. 2) select oversized piston according to amount of cylinder wear. Oversize piston specification oversize 0.50: 78.453 – 78.468 mm (3.0887 – 3.0893 in.)...

  • Page 354

    1d-72 engine mechanical: note the specified tightening torque is also described in the following. “air intake system components” “engine mountings components” “timing chain cover components” “timing chain and chain tensioner components” “camshaft, tappet and shim components” “valves and cylinder hea...

  • Page 355

    Engine mechanical: 1d-73 special tools and equipment recommended service material s6rw0d1408001 note required service material is also described in the following. “timing chain cover components” “timing chain and chain tensioner components” “camshaft, tappet and shim components” “valves and cylinder...

  • Page 356

    1d-74 engine mechanical: 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 tappet holder (overseas) ) / )...

  • Page 357: Engine Lubrication System

    Engine lubrication system: 1e-1 engine engine lubrication system general description engine lubrication description s6rw0d1501001 the oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filter...

  • Page 358

    1e-2 engine lubrication system: diagnostic information and procedures oil pressure check s6rw0d1504001 warning ! To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Note prior to c...

  • Page 359

    Engine lubrication system: 1e-3 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 s6rw0d1506001 i2rh0b150006-01 1 2 3 4 (a) 5 (b) 6 (b) 8 (b) 9 (b...

  • Page 360

    1e-4 engine lubrication system: oil pan and oil pump strainer removal and installation s6rw0d1506002 removal 1) remove oil level gauge. 2) drain engine oil by removing drain plug. 3) for 4wd model, dismount transfer referring to “transfer dismounting and remounting in section 3c”. 4) remove clutch h...

  • Page 361

    Engine lubrication system: 1e-5 4) install oil pan to cylinder block temporarily. 5) insert dowel pin (1) in hole (2) of oil pan in order to locate oil pan precisely. Note dowel pin is available as a spare part (part number: 04211–13189). 6) after fitting oil pan to cylinder block, run in securing b...

  • Page 362

    1e-6 engine lubrication system: oil pump components s6rw0d1506004 oil pump removal and installation s6rw0d1506005 oil pump is incorporated with timing chain cover. For removal and installation, refer to “timing chain cover removal and installation in section 1d”. Oil pump disassembly and reassembly ...

  • Page 363

    Engine lubrication system: 1e-7 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 case. 4) apply engine oil...

  • Page 364

    1e-8 engine lubrication system: 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 (0.0122 in.) side clearance ...

  • Page 365

    Engine lubrication system: 1e-9 specifications tightening torque specifications s6rw0d1507001 note the specified tightening torque is also described in the following. “oil pan and oil pump strainer components” “oil pump components” reference: for the tightening torque of fastener not specified in th...

  • Page 366: Engine Cooling System

    1f-1 engine cooling system: engine engine cooling system general description cooling system description s6rw0d1601001 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...

  • Page 367

    Engine cooling system: 1f-2 schematic and routing diagram coolant circulation s6rw0d1602001 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 368

    1f-3 engine cooling system: diagnostic information and procedures engine cooling symptom diagnosis s6rw0d1604001 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 369

    Engine cooling system: 1f-4 repair instructions cooling system components s6rw0d1606001 i5rw0c160012-01 1. Radiator 11. Thermostat case water outlet pipe 21. Heater outlet no.1 hose 2. Reservoir 12. Thermostat case 22. Radiator cooling fan assembly for disassembly and reassembly, refer to “radiator ...

  • Page 370

    1f-5 engine cooling system: coolant level check s6rw0d1606002 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 371

    Engine cooling system: 1f-6 cooling system flush and refill s6rw0d1606005 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 cap is taken off too soon. Note for detail of cool...

  • Page 372

    1f-7 engine cooling system: thermostat removal and installation s6rw0d1606007 removal 1) drain coolant referring to “cooling system draining”. 2) remove intake manifold referring to “intake manifold removal and installation in section 1d”. 3) disconnect water hose (1) and heater hose (2) from each p...

  • Page 373

    Engine cooling system: 1f-8 radiator cooling fan assembly on-vehicle inspection s6rw0d1606009 1) check continuity between terminals. If there is no continuity, replace radiator fan assembly. 2) connect battery to radiator fan motor coupler as shown in figure, then check that the radiator fan motor o...

  • Page 374

    1f-9 engine cooling system: 5) remove cooling fan mounting bolts (1). 6) remove radiator cooling fan assembly (2). Installation reverse removal procedure for installation noting the following. • refill cooling system referring to step 7) to 17) of “cooling system flush and refill”. • after installat...

  • Page 375

    Engine cooling system: 1f-10 water pump / generator drive belt tension inspection and adjustment s6rw0d1606014 warning ! • disconnect negative cable at battery before checking and adjusting belt tension. • to help avoid danger of being burned, do not remove radiator cap while engine and radiator are...

  • Page 376

    1f-11 engine cooling system: installation 1) install belt (1) to water pump pulley (2), crankshaft pulley (3) and generator pulley (4). 2) adjust belt tension referring to “water pump / generator drive belt tension inspection and adjustment”. 3) if vehicle equipped with a/c, install compressor drive...

  • Page 377

    Engine cooling system: 1f-12 water pump inspection s6rw0d1606017 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 378: Fuel System

    1g-1 fuel system: engine fuel system precautions precautions on fuel system service s6rw0d1700001 warning ! Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. • disconnect negative cable at battery. •...

  • Page 379

    Fuel system: 1g-2 general description fuel system description s6rw0d1701001 caution ! This engine requires the unleaded fuel only. The leaded and/or low lead fuel can result in engine damage and reduce the effectiveness of the emission control system. The main components of the fuel system are fuel ...

  • Page 380

    1g-3 fuel system: schematic and routing diagram fuel delivery system diagram s6rw0d1702001 diagnostic information and procedures fuel pressure inspection s6rw0d1704001 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the ri...

  • Page 381

    Fuel system: 1g-4 4) check that battery voltage is 11 v or more. 5) measure fuel pressure at each condition. If measured pressure is out of specification, refer to “fuel pressure check in section 1a” and check each possibly defective part. Replace if found defective. A) turn ignition switch on to op...

  • Page 382

    1g-5 fuel system: repair instructions fuel system components s6rw0d1706001 i6rw0d170001-01 1. Fuel tank 11. Fuel vapor line 21. Fuel pump bolt 2. Fuel pump assembly 12. Fuel tank protector 22. Fuel tank inlet valve 3. Fuel tank filler hose 13. Insulator 23. Fuel pump gasket 4. Fuel tank filler neck ...

  • Page 383

    Fuel system: 1g-6 fuel hose disconnecting and reconnecting s6rw0d1706002 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. For connection other than quick joint • clamp around fuel tank ...

  • Page 384

    1g-7 fuel system: clamp other than around fuel tank for quick joint disconnecting 1) remove mud, dust and/or foreign material between pipe (1) and quick joint (fuel pipe) (2) by blowing compressed air. 2) unlock joint lock by inserting special tool between pipe and quick joint. Special tool (a): 099...

  • Page 385

    Fuel system: 1g-8 6) start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3 seconds each time in order to dissipate fuel pressure in lines. Fuel connections are now safe for servicing. 7) after servicing, connect fuel pump relay (1) to relay / fus...

  • Page 386

    1g-9 fuel system: fuel injector on-vehicle inspection s6rw0d1706007 1) using sound scope (1) or such, check operating sound of injector (2) when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, check injector cir...

  • Page 387

    Fuel system: 1g-10 installation reverse removal procedure for installation noting the following. • replace injector o-ring (1) with new one using care not to damage it. • check if cushion (2) is scored or damaged. If it is, replace with new one. • apply thin coat of fuel to o-rings (1), and then ins...

  • Page 388

    1g-11 fuel system: 4) install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting. 5) put graduated cylinder under injector. 6) 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 389

    Fuel system: 1g-12 fuel filler cap inspection s6rw0d1706010 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. Remove cap (1), and check gasket for even filler neck imprint, and deteriora...

  • Page 390

    1g-13 fuel system: fuel tank removal and installation s6rw0d1706011 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. Removal 1) relieve fuel pressure in fuel feed line according to “fue...

  • Page 391

    Fuel system: 1g-14 installation caution ! • when connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur. • never let the fuel hoses touch the abs sensor ...

  • Page 392

    1g-15 fuel system: fuel tank purging procedure s6rw0d1706013 warning ! • before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. • this purging procedure will not remove all fuel vapor. Do not attempt a...

  • Page 393

    Fuel system: 1g-16 installation caution ! When connecting joint, clean outside surface of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur. 1) clean mating surfaces of fuel pump assembly and ...

  • Page 394

    1g-17 fuel system: fuel pump inspection s6rw0d1706016 • check fuel pump assembly for damage. • check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank. • for electrical circuit, refer to “fuel pump and its circuit che...

  • Page 395

    Fuel system: 1g-18 special tools and equipment special tool s6rw0d1708001 09912–57610 09912–58421 injector checking tool plate checking tool set ) this kit includes the following items. 1. Tool body and washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose and clamp, 6. Body attachme...

  • Page 396: Ignition System

    1h-1 ignition system: engine ignition system general description ignition system construction s6rw0d1801001 the ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below. • ecm it detects the engine and vehicle conditions through the signals from...

  • Page 397

    Ignition system: 1h-2 schematic and routing diagram ignition system wiring circuit diagram s6rw0d1802001 e01-60 e01-29 12v 5v 5v e01-1 e01-16 blk/wht blk/red blk/red blk/red 80a blk/yel blk/yel blk/yel grn blk wht brn/wht blk/orn blk blk blk c01-20 blk/red pnk blk/orn 5v c01-21 blk/wht 7 3 4 1 12 5 ...

  • Page 398

    1h-3 ignition system: component location ignition system components location s6rw0d1803001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 12* 15* 13 1 6 8 9 11 10 7 4 5 14 2 3 16 i5rw0c180002-01 1. Ecm 7. Ect sens...

  • Page 399

    Ignition system: 1h-4 diagnostic information and procedures ignition system symptom diagnosis s6rw0d1804001 reference waveform of ignition system s6rw0d1804002 refer to “reference waveform no.5”, “reference waveform no.6” and “reference waveform no.7” under “inspection of ecm and its circuits in sec...

  • Page 400

    1h-5 ignition system: 6 ignition coil assembly power supply and ground circuit check 1) check ignition coil assembly power supply and ground circuits for open and short. Are circuits in good condition? Go to step 7. Repair or replace. 7 ignition coil assembly check 1) check ignition coil for resista...

  • Page 401

    Ignition system: 1h-6 ignition spark test s6rw0d1804004 1) remove air cleaner assembly with air intake pipe. 2) disconnect all injector couplers from injectors. Warning ! Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignit...

  • Page 402

    1h-7 ignition system: high-tension cord inspection s6rw0d1806002 measure resistance of high-tension cord (1) by using ohmmeter. If resistance exceeds specification, replace high-tension cord(s). High-tension cord resistance no.1 cylinder high-tension cord resistance: 1.4 – 4.0 k Ω no.3 cylinder high...

  • Page 403

    Ignition system: 1h-8 ignition coil assembly (including ignitor) removal and installation s6rw0d1806005 removal 1) disconnect negative cable at battery. 2) remove air cleaner assembly with air intake pipe and cylinder head upper cover. 3) disconnect ignition coil coupler. 4) disconnect high-tension ...

  • Page 404

    1h-9 ignition system: 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 within specification. 5) fix ignition timing by using “fixed spark control” of “engine / active tes...

  • Page 405

    Ignition system: 1h-10 specifications tightening torque specifications s6rw0d1807001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. Special tools and equipment special tool s6rw0d1808001 fastening part tightening torque...

  • Page 406: Starting System

    1i-1 starting system: engine starting system schematic and routing diagram cranking system circuit diagram s6rw0d1902001 diagnostic information and procedures cranking system symptom diagnosis s6rw0d1904001 possible symptoms due to starting system trouble would be as follows: • starting motor does n...

  • Page 407

    Starting system: 1i-2 condition possible cause correction / reference item motor not running (no operating sound of magnetic switch) transmission range sensor is not in p or n, or not adjusted (a/t model) shift in p or n, or adjust sensor. (a/t model) battery run down recharge battery. Battery volta...

  • Page 408

    1i-3 starting system: cranking system test s6rw0d1904002 caution ! Each test must be performed within 3 – 5 seconds to avoid coil from burning. Pull-in test connect battery to the magnetic switch as shown. Check that plunger and pinion move outward. If plunger and pinion don’t move, replace the magn...

  • Page 409

    Starting system: 1i-4 repair instructions starting motor dismounting and remounting s6rw0d1906001 dismounting 1) disconnect negative (–) battery lead at battery. 2) disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) detach shift & select control cable br...

  • Page 410

    1i-5 starting system: starting motor components s6rw0d1906002 i4rs0a190003-01 1. Front housing 7. Plate 13. Planetary gear 19. Rear bush 2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut 3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 n ⋅m (0.98 kgf-m, 7.0 lb-ft) 4. Over-...

  • Page 411

    Starting system: 1i-6 starting motor inspection s6rw0d1906003 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 412

    1i-7 starting system: spring inspect brush springs for wear, damage or other abnormal conditions. Replace if necessary. Brush spring tension standard: 2.2 kg (4.85 lb) limit: 0.6 kg (1.33 lb) brush holder • check movement of brush in brush holder. If brush movement within brush holder is sluggish, c...

  • Page 413

    Starting system: 1i-8 • inspect the commutator (1) for insulator (2) depth. Correct or replace if below limit. Commutator insulator depth “a” standard: 0.4 – 0.6 mm (0.016 – 0.023 in.) limit: 0.2 mm (0.008 in.) • check the commutator and armature core. If there is continuity, the armature is grounde...

  • Page 414

    1i-9 starting system: front housing bush inspect the bush for wear or damage. Replace if necessary. Specifications cranking system specifications s6rw0d1907002 tightening torque specifications s6rw0d1907003 note the specified tightening torque is also described in the following. “starting motor dism...

  • Page 415: Charging System

    Charging system: 1j-1 engine charging system general description battery description s6rw0d1a01001 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...

  • Page 416

    1j-2 charging system: care of battery warning ! • never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. • do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush any contacted ...

  • Page 417

    Charging system: 1j-3 generator description s6rw0d1a01002 the basic charging system is the ic integral regulator charging system. The internal components are connected electrically as shown below. Charging system circuit the generator features a solid state regulator that is mounted inside the gener...

  • Page 418

    1j-4 charging system: diagnostic information and procedures battery inspection s6rw0d1a04001 common causes of failure a battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the battery performs satisfactorily during test buy fails to oper...

  • Page 419

    Charging system: 1j-5 charging indicator lamp operation generator test (undercharged battery check) s6rw0d1a04003 this condition, as evidenced by slow cranking or low specific gravity can be caused by one or more of the following conditions even though indicator lamp may be operating normal. The fol...

  • Page 420

    1j-6 charging system: 3) ground “f” terminal and start engine, then measure voltage at “b” terminal as shown in figure. • voltage is higher than standard value. It is considered that generator itself is good but ic regulator has been damaged, replace ic regulator. • voltage is lower than standard va...

  • Page 421

    Charging system: 1j-7 1) set parking brake and place automatic transaxle in park (neutral on manual transaxle). Turn off ignition, turn off lights and all other electrical loads. 2) check electrolyte level. If it is below low level line, add distilled water. 3) attach end of one jumper cable to posi...

  • Page 422

    1j-8 charging system: 3) after loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tension to specification described at step 2) by loosening / tightening generator adjust bolt (1). 4) tighten generator bracket bolts and pivot bolt as specified torque. Tightening torque generator b...

  • Page 423

    Charging system: 1j-9 generator dismounting and remounting s6rw0d1a06003 1) disconnect negative cable at battery. 2) remove right side drive shaft referring to “front drive shaft assembly removal and installation in section 3a” 3) dismount in numerical order as shown in figure. 4) reverse dismountin...

  • Page 424

    1j-10 charging system: generator components s6rw0d1a06004 i4rs0a1a0004-01 1. Pulley nut 7. Bearing retainer 13. Seal plate 19. Brush holder cover : 3.6 n ⋅m (0.36 kgf-m, 3.0 lb-ft) 2. Pulley 8. Rotor 14. Rectifier 20. Rear end cover : 2.0 n ⋅m (0.2 kgf-m, 1.5 lb-ft) 3. Drive end frame 9. End housing...

  • Page 425

    Charging system: 1j-11 generator inspection s6rw0d1a06005 rotor 1) 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 regulato...

  • Page 426

    1j-12 charging system: 4) check slip rings for roughness or scoring. If rough or scored, replace the rotor. Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace the rotor. Slip ring diameter standard: 14.2 – 14.4 mm (0.560 – 0.566 in.) limit: 12.8 mm...

  • Page 427

    Charging system: 1j-13 specifications charging system specifications s6rw0d1a07003 battery note the battery used in each vehicle is one of the following two types, depending on specification. Battery : 46b24r (40.6ah/5hr), 55b24r (42.5ah/5hr) 12v generator tightening torque specifications s6rw0d1a07...

  • Page 428: Exhaust System

    1k-1 exhaust system: engine exhaust system general description exhaust system description s6rw0d1b01001 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 a...

  • Page 429

    Exhaust system: 1k-2 repair instructions exhaust system components s6rw0d1b06001 warning ! To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. [a] 1 2 3 4 5 6 7 8 9 10 11 12 12 26 ...

  • Page 430

    1k-3 exhaust system: exhaust manifold removal and installation s6rw0d1b06002 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) disconnect ho2s-1 conn...

  • Page 431

    Exhaust system: 1k-4 2) install new seal ring and connect exhaust no.1 pipe (1) to exhaust manifold. Tighten pipe fasteners to specified torque. Tightening torque exhaust no.1 pipe bolt (a): 50 n·m (5.0 kgf-m, 36.5 lb-ft) 3) install exhaust manifold stiffener (2). Tighten exhaust manifold stiffener ...

  • Page 432

    1k-5 exhaust system: specifications tightening torque specifications s6rw0d1b07001 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 “fasteners information in s...

  • Page 433: 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 434: Precautions

    2-1 precautions: suspension precautions precautions precautions on suspension s6rw0d2000001 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”. Ve...

  • Page 435: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension, wheels and tires symptom diagnosis s6rw0d2104001 condition possible cause correction / reference item vehicle pulls (leads) mismatched or uneven tires replace tires. Tires not...

  • Page 436

    2a-2 suspension general diagnosis: 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 437

    Suspension general diagnosis: 2a-3 specifications wheel alignment specifications s6rw0d2107001 toe “b” – “a” front: in 1 ± 1 mm (in 0.0393 ± 0.0393 (in.)) rear: in 5 ± 5 mm (in 0.1969 ± 0.1969 (in.)) toe (degree) (each wheel) “d” front: in 1’ ± 2’ (reference information) rear: in 17’ ± 17’ (referenc...

  • Page 438: Front Suspension

    2b-1 front suspension: suspension front suspension general description front suspension construction s6rw0d2201001 1 4 3 2 7 6 8 ) ) 5 9 (a) (b) (b) (b) (b) (c) (c) (d) (d) (e) (f) (g) (h) (i) (h) f i7rw01220002-03 1. Front strut assembly 8. Front suspension frame : 200 n ⋅m (20.0 kgf-m, 145.0 lb-ft...

  • Page 439

    Front suspension: 2b-2 front wheel alignment construction s6rw0d2201002 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 440

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

  • Page 441

    Front suspension: 2b-4 front strut assembly components s6rw0d2206002 1 2 3 4 5 7 6 8 9 10 11 12 13 14 15 (a) (b) (c) (a) i7rw01220003-03 1. Front strut 6. Coil spring upper seat 11. Strut nut : 50 n ⋅m (5.0 kgf-m, 36.5 lb-ft) 2. Coil spring 7. Strut bearing 12. Strut bracket bolt : insert from vehic...

  • Page 442

    2b-5 front suspension: front strut assembly removal and installation s6rw0d2206003 caution ! When rebound stopper and strut assembly were removed, check strut support lower nut for specified torque before installing strut assembly. Removal 1) remove hood rear seal (1), and then remove cowl top garni...

  • Page 443

    Front suspension: 2b-6 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): 140 n·m (14.0 kgf-m, 101.5 lb-ft) b...

  • Page 444

    2b-7 front suspension: front strut assembly disassembly and reassembly s6rw0d2206004 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...

  • Page 445

    Front suspension: 2b-8 3) install bump stopper and strut dust cover onto strut rod. For installing direction, refer to the figure in “front strut assembly components”. 4) pull strut rod as far up as possible and use care not to allow it to retract into strut. 5) install spring seat on coil spring an...

  • Page 446

    2b-9 front suspension: front wheel hub and steering knuckle components s6rw0d2206006 front wheel hub, steering knuckle and wheel bearing removal and installation s6rw0d2206007 caution ! When removal and installing steering knuckle assembly, be careful not to damage dust boots of control arm joint by...

  • Page 447

    Front suspension: 2b-10 6) pull out wheel hub (1) with special tools. Special tool (a): 09943–17912 (b): 09942–15511 caution ! When wheel hub is removed, replace wheel bearing with new one. 7) disconnect tie-rod end (1) from steering knuckle (2) with puller (3). 8) remove wheel speed sensor (1) from...

  • Page 448

    2b-11 front suspension: 15) remove wheel bearing outside inner race (1). Special tool (a): 09913–65810 (b): 09913–85230 16) remove hub bolts (1) with copper hammer or hydraulic press. Caution ! Never remove bolt unless replacement is necessary. Be sure to use a new bolt for replacement. Installation...

  • Page 449

    Front suspension: 2b-12 4) drive in dust cover so that dimensions “a” and “b” become equal as shown in the figure. Caution ! When drive in dust cover, be careful not to deform it. 5) caulk more than 6 places with a punch. 6) using special tool and hydraulic press, press fit wheel hub (1) into wheel ...

  • Page 450

    2b-13 front suspension: 9) install ball joint bolt (1), washer (2), strut bracket bolts (4) and new nuts (3) from the direction shown in figure. 10) tighten suspension arm ball joint bolt (2) to specified torque. Tightening torque suspension arm ball joint bolt (a): 60 n·m (6.0 kgf-m, 43.5 lb-ft) 11...

  • Page 451

    Front suspension: 2b-14 front wheel hub, disc, bolt and bearing check s6rw0d2206008 • inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. • check rust of installation face inside of wheel disc. As rust affects adversely, remove it thoroughly....

  • Page 452

    2b-15 front suspension: installation 1) install suspension control arm as shown but tighten suspension control arm bolts (1) only temporarily. Caution ! Use new control arm bolt. 2) install steering knuckle with front wheel hub referring to step 7) to 17) of “installation” under “front wheel hub, st...

  • Page 453

    Front suspension: 2b-16 assembly 1) front bushing press-fit front bushing (1) by using special tools and press (2). Special tool (a): 09943–76310 (b): 09913–75821 caution ! Be sure to use new bushing. Note • before installing bushing, apply soap water on its circumference to facilitate bushing insta...

  • Page 454

    2b-17 front suspension: front suspension frame, stabilizer bar and/or bushing components s6rw0d2206014 1 2 3 4 5 6 7 8 8 (c) (a) 6 (b) (b) (c) (c) i6rw0d220001-02 1. Stabilizer bar 4. Stabilizer bar mounting bracket bolt 7. Front suspension frame : 95 n ⋅m (9.5 kgf-m, 36.5 lb-ft) 2. Stabilizer bushi...

  • Page 455

    Front suspension: 2b-18 front suspension frame, stabilizer bar and/or bushing removal and installation s6rw0d2206015 warning ! When supporting and installing front suspension frame, be sure to apply some supporting equipment (such as mission jack) at well-balanced position in the center section of f...

  • Page 456

    2b-19 front suspension: installation 1) install stabilizer bar (1), stabilizer bushing (2) and stabilizer mounting bracket (3) to front suspension frame as shown in figure while ensuring that stabilizer is centered, side-to-side. Note • for proper installing direction of stabilizer mounting bracket ...

  • Page 457

    Front suspension: 2b-20 12) install exhaust no.1, no.2 and center pipe referring to “exhaust system components in section 1k”. 13) install wheel and tighten nut to specified torque. Tightening torque wheel nut: 85 n·m (8.5 kgf-m, 61.5 lb-ft) 14) install air cleaner assembly referring to “air cleaner...

  • Page 458

    2b-21 front suspension: specifications tightening torque specifications s6rw0d2207001 note the specified tightening torque is also described in the following. “front suspension construction” “front strut assembly components” “front wheel hub and steering knuckle components” “front suspension frame, ...

  • Page 459

    Front suspension: 2b-22 special tools and equipment recommended service material s6rw0d2208001 special tool s6rw0d2208002 material suzuki recommended product or specification note grease suzuki super grease h p/no.: 99000–25121 ) 09913–65810 09913–75510 crankshaft bearing puller bearing installer ) ...

  • Page 460: Rear Suspension

    2c-1 rear suspension: suspension rear suspension repair instructions rear suspension components s6rw0d2306001 i6rw0d230001-01 f: forward 7. Vehicle body 16. Rear drive shaft nut [a]: 2wd model 8. Rear shock absorber 17. Rear wheel hub assembly [b]: 4wd model 9. Lower washer : 73 n ⋅m (7.3 kgf-m, 53....

  • Page 461

    Rear suspension: 2c-2 rear shock absorber removal and installation s6rw0d2306002 removal 1) hoist vehicle and remove rear wheel. 2) remove access hole cover (1) in quarter inner trim (2). 3) support rear axle by using floor jack to prevent it from lowering. 4) remove absorber lower nut (1) and lower...

  • Page 462

    2c-3 rear suspension: 3) remove floor jack from rear axle. 4) install rear wheel and tighten wheel nuts to specified torque. Tightening torque wheel nut: 85 n·m (8.5 kgf-m, 61.5 lb-ft) 5) lower hoist and bounce vehicle up and down several times to stabilize suspension. 6) tighten nuts to specified t...

  • Page 463

    Rear suspension: 2c-4 rear coil spring removal and installation s6rw0d2306005 caution ! Removal and installation both coil springs (right and left) at the same time to avoid rear axle twisting and other damage. Removal 1) hoist vehicle and remove rear wheels. 2) dismount rear differential (4wd model...

  • Page 464

    2c-5 rear suspension: installation 1) install spring upper seat (1) to vehicle body and lower seat (2) to rear axle. Caution ! For proper installing direction of spring upper seat (1) and spring lower seat (2), refer to the figure. 2) install coil spring (3) on spring lower seat (2) of rear axle and...

  • Page 465

    Rear suspension: 2c-6 rear axle removal and installation s6rw0d2306007 caution ! Do not drop brake fluid onto painted surface. Painted surfaces will be damaged. Removal 1) hoist vehicle and remove exhaust center pipe and muffler. 2) disconnect rear height sensor link (if equipped) from rear axle ref...

  • Page 466

    2c-7 rear suspension: 6) connect rear height sensor link (if equipped) to rear axle referring to “height sensor removal and installation (if equipped) in section 9b”. 7) install exhaust center pipe and muffler. 8) after installing removed parts, bleed air from brake system referring to “air bleeding...

  • Page 467

    Rear suspension: 2c-8 rear wheel hub assembly removal and installation s6rw0d2306012 caution ! Do not allow brake fluid to get on painted surfaces. Painted surface will be damaged. Removal 1) hoist vehicle. Then remove rear wheel and brake drum. 2) for 4wd model, remove rear drive shaft referring to...

  • Page 468

    2c-9 rear suspension: installation 1) insert wheel stud bolt (1) in hub hole. Rotate wheel stud bolt slowly to assure that serrations are aligned with those made by original bolt. 2) install brake back plate, rear wheel hub and new rear wheel hub bolts and then tighten rear wheel hub mounting bolts ...

  • Page 469

    Rear suspension: 2c-10 specifications tightening torque specifications s6rw0d2307001 note the specified tightening torque is also described in the following. “rear suspension components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information i...

  • Page 470: Wheels and Tires

    2d-1 wheels and tires: suspension wheels and tires general description tires description s6rw0d2401001 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 pressur...

  • Page 471

    Wheels and tires: 2d-2 replacement tires when replacement is necessary, the original equipment type tire should be used. Refer to the tire placard. Replacement tires should be of the same size, load range and construction as those originally on the vehicle. Use of any other size or type tire may aff...

  • Page 472

    2d-3 wheels and tires: irregular and/or premature wear description s6rw0d2401003 irregular and premature wear has many causes. Some of them are as follows: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, tire rotation i...

  • Page 473

    Wheels and tires: 2d-4 equipment manufacture’s recommendations radial tire lead / pull description s6rw0d2401006 “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 474

    2d-5 wheels and tires: repair instructions wheel discs inspection s6rw0d2406006 inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Wheel balance inspection and adjustment s6rw0d2406001 refer to “balancing wheels description”. Deposits of mud...

  • Page 475

    Wheels and tires: 2d-6 wheel (with tire) removal and installation s6rw0d2406003 removal caution ! Never use heat to loosen tight wheel because the application of heat to wheel causes the wheel life shorter and the wheel bearing damage. 1) loosen wheel nuts by approximately 180 ° (half a rotation). 2...

  • Page 476

    2d-7 wheels and tires: specifications wheels and tires specifications s6rw0d2407001 tire size (standard) : 205/60 r16 92h wheel size (standard) : 16 x 6j (for 205/60 r16) tightening torque wheel nut: 85 n·m (8.5 kgf-m, 61.5 lb-ft) note • tire inflation pressure should be checked when tires are cool....

  • Page 477: Section 3

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

  • Page 478

    3-ii table of contents dtc u0100: lost communication with ecm ....3b-27 dtc u0121: lost communication with abs / esp ® control module.....................................3b-27 dtc u0155: lost communication with instrument panel cluster (ipc) control module ..............................................

  • Page 479: Precautions

    Precautions: 3-1 driveline / axle precautions precautions precautions on driveline / axle s6rw0d3000001 precaution for rear differential oil leakage refer to “precaution for rear differential oil leakage in section 3b”. Precaution in diagnosing trouble refer to “precautions in diagnosing trouble in ...

  • Page 480: Drive Shaft / Axle

    3a-1 drive shaft / axle: front driveline / axle drive shaft / axle front general description front drive shaft construction s6rw0d3111001 a constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For a/t vehicle, a tripod type constant velocity join...

  • Page 481

    Drive shaft / axle: front 3a-2 diagnostic information and procedures front drive shaft symptom diagnosis s6rw0d3114001 repair instructions front drive shaft components s6rw0d3116001 condition possible cause correction / reference item abnormal noise worn or breakage of the drive shaft joint replace....

  • Page 482

    3a-3 drive shaft / axle: front front drive shaft assembly on-vehicle inspection s6rw0d3116002 • check boots for breakage or deterioration. • check wheel side joint for rattle or smooth rotation. • check differential side (or center shaft side) joint for smooth rotation. If any abnormality is found, ...

  • Page 483

    Drive shaft / axle: front 3a-4 9) remove drive shaft assembly. 10) remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from differential side gear, if equipped. Installation caution ! • be careful not to damage oil seals and boots when installing drive...

  • Page 484

    3a-5 drive shaft / axle: front 2) remove differential side (or center shaft side) boot small band (1) using flat end rod (2) or the like. 3) slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out of outer race (3). 4) wipe off grease and remove ci...

  • Page 485

    Drive shaft / axle: front 3a-6 for tripod joint type caution ! • disassembly of wheel side joint is not allowed. If any noise or damage exists in it, replace it as assembly. • do not disassemble tripod joint spider. If any malcondition is found in it, replace it as differential side joint assembly. ...

  • Page 486

    3a-7 drive shaft / axle: front reassembly for doj type judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly and doj housing are washed...

  • Page 487

    Drive shaft / axle: front 3a-8 10) install damper (1) to specified position on drive shaft. Drive shaft damper installing position “a”: 354 mm (13.9 in.) (right side) “a”: 252 mm (9.9 in.) (left side) 11) set new differential side (or center shaft side) small band and new differential side (or cente...

  • Page 488

    3a-9 drive shaft / axle: front 17) fit boot (1) to grooves of shaft and housing (2) and adjust length to specification below. Insert screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure. Drive shaft boot fixing position (distance be...

  • Page 489

    Drive shaft / axle: front 3a-10 for tripod joint type judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly (1) and tripod joint housin...

  • Page 490

    3a-11 drive shaft / axle: front 8) install damper (1) to specified position on drive shaft, if equipped. Drive shaft damper installing position “a”: 354 mm (13.9 in.) (right side) “a”: 252 mm (9.9 in.) (left side) 9) set new differential side (or center shaft side) small band and new differential si...

  • Page 491

    Drive shaft / axle: front 3a-12 15) fasten differential side (or center shaft side) boot big band (1) and small band (5) by drawing hooks (2) with special tool and engage hooks (3) in slot and window (4). Special tool (a): 09943–57021 center shaft and center bearing support disassembly and reassembl...

  • Page 492

    3a-13 drive shaft / axle: front • when installing left oil seal (1) and right oil seal (2) using special tool, use care so that oil seals in proper direction and position as shown in the figure. Special tool : 09925–15410 distance “a”: 0 – 1 mm (0 – 0.04 in.) “b”: 8 – 9 mm (0.13 – 0.35 in.) • be sur...

  • Page 493

    Drive shaft / axle: front 3a-14 special tools and equipment recommended service material s6rw0d3118001 note required service material is also described in the following. “front drive shaft components” special tool s6rw0d3118002 material suzuki recommended product or specification note grease suzuki ...

  • Page 494: Rear

    3a-15 drive shaft / axle: rear rear general description rear drive shaft construction s6rw0d3121001 refer to “front drive shaft construction”. Repair instructions rear drive shaft components s6rw0d3126001 i5rw0a312001-01 1. Differential side joint (constant velocity doj joint) : apply dark gray grea...

  • Page 495

    Drive shaft / axle: rear 3a-16 rear drive shaft assembly removal and installation s6rw0d3126002 removal 1) hoist vehicle and remove rear wheel. 2) undo caulking of drive shaft nut (1) and then remove drive shaft nut with pull up parking brake lever. 3) remove rear drive shaft flange nuts (1), and th...

  • Page 496

    3a-17 drive shaft / axle: rear reassembly refer to “front drive shaft disassembly and reassembly” note the following points which is different from the front drive shaft is described. • apply grease to each joint. Grease color wheel side: black differential side: dark gray amount wheel side: 50 – 70...

  • Page 497

    Drive shaft / axle: rear 3a-18 specifications tightening torque specifications s6rw0d3127001 note the specified tightening torque is also described in the following. “rear drive shaft components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners info...

  • Page 498: Differential

    3b-1 differential: driveline / axle differential precautions precaution for rear differential oil leakage s6rw0d3200001 whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage. Precautions in diagnosing trouble s6rw0d3200002 • do not disconnect t...

  • Page 499

    Differential: 3b-2 general description rear differential description s6rw0d3201001 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 specified torque is compulsory. F...

  • Page 500

    3b-3 differential: 4wd control system components s6rw0d3201003 2 1 3 6 5 4 i5rw0a320002-04 1. 4wd control module 3. 4wd lock indicator 5. Coupling assembly 2. 4wd auto indicator 4. 2wd/4wd switch 6. Coupling air temperature sensor.

  • Page 501

    Differential: 3b-4 4wd control system description s6rw0d3201004 4wd shift control the 4wd control module operates the coupling assembly according to the 2wd/4wd switch operation to the selected position (2wd, 4wd-auto or 4wd-lock). Also, the 4wd control system has 4wd auto indicator and 4wd lock ind...

  • Page 502

    3b-5 differential: 4wd control system wiring circuit diagram s6rw0d3201006 terminal arrangement of 4wd control module s6rw0d3201007 5v 5v 12v g26-3 yel gry g26-2 g26-22 g26-23 red wht g26-13 g26-14 g26-12 g26-11 g26-10 blk wht/red red/blk gry/yel red/wht 12v l102-1 l102-4 1 3 7 9 10 12 13 14 12v g26...

  • Page 503

    Differential: 3b-6 input / output signal table of 4wd control module s6rw0d3201008 4wd control module outputs the following signals to coupling assembly, indicators, according to the 2wd/4wd switch operation. On-board diagnostic system description s6rw0d3201009 for 4wd control system, 4wd control mo...

  • Page 504

    3b-7 differential: can communication system description s6rw0d3201010 refer to “can communication system description in section 1a” for can communication system description. When 4wd control module receive the signal of abnormal as following information, vehicle is not changed to 4wd- auto and 4wd-l...

  • Page 505

    Differential: 3b-8 diagnostic information and procedures 4wd control system check s6rw0d3204001 refer to the following items for the details of each step. Step action yes no 1 ) customer complaint analysis 1) perform customer complaint analysis. Was customer complaint analysis performed? Go to step ...

  • Page 506

    3b-9 differential: 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 the following will facilitate collecting infor...

  • Page 507

    Differential: 3b-10 step 2. Dtc check, record and clearance first, referring to “dtc check”, check dtc and pending dtc. If dtc exists, print or write down dtc and then clear malfunction dtc(s) by referring to “dtc clearance”. Malfunction dtc indicates malfunction in the system but it is not possible...

  • Page 508

    3b-11 differential: visual inspection s6rw0d3204004 check the following parts and systems visually. Dtc check s6rw0d3204005 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 to...

  • Page 509

    Differential: 3b-12 dtc table s6rw0d3204007 note “o” in transfer position indicator column of the above table means indicator lights up when dtc is detected. Fail-safe table s6rw0d3204008 this function is provided by the safe mechanism that assures safe driveability even when the coupling assembly, ...

  • Page 510

    3b-13 differential: scan tool data s6rw0d3204009 scan tool data definitions accel pedal pos (accelerator pedal position) (%) accelerator pedal opening ratio detected by signal on can communication line fed from ecm. Engine speed (rpm) this parameter indicates engine revolution calculated by 4wd cont...

  • Page 511

    Differential: 3b-14 rear differential symptom diagnosis s6rw0d3204011 4wd control symptom diagnosis s6rw0d3204012 diagnose 4wd system after performing the following inspections. • perform 4wd control system check referring to “4wd control system check”. Condition possible cause correction / referenc...

  • Page 512

    3b-15 differential: 4wd position indicator does not come on at ignition switch on but engine stops s6rw0d3204013 wiring diagram circuit description 4wd position indicator operates according to the signal from 4wd control module. If the 4wd control system is in good condition, 4wd position indicator ...

  • Page 513

    Differential: 3b-16 4wd position indicator remains on steady at ignition switch on s6rw0d3204014 wiring diagram refer to “4wd position indicator does not come on at ignition switch on but engine stops”. Circuit description transfer position indicator operates according to the signal from 4wd control...

  • Page 514

    3b-17 differential: dtc c1240: 4wd control module power supply circuit malfunction s6rw0d3204015 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) turn ignition switch to on position for 10 seconds. 3) check dtc. Troubleshooting [a]: ...

  • Page 515

    Differential: 3b-18 dtc c1243: internal circuit malfunction of 4wd control module s6rw0d3204016 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and run it for 10 seconds. Or more. 3) stop vehicle and check dtc. Troubleshooting substit...

  • Page 516

    3b-19 differential: dtc c1250: coupling air temperature sensor circuit open s6rw0d3204017 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) turn ignition switch to on position for 10 seconds. 3) check dtc. [a]: 4wd control module conn...

  • Page 517

    Differential: 3b-20 troubleshooting step action yes no 1 was “4wd control system check” performed? Go to step 2. Go to “4wd control system check”. 2 coupling air temperature sensor circuit check 1) disconnect connector from coupling air temperature sensor with ignition switch turned off. 2) check fo...

  • Page 518

    3b-21 differential: dtc c1251: coupling air temperature sensor circuit short s6rw0d3204018 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) turn ignition switch to on position for 10 seconds. 3) check dtc. Troubleshooting [a]: 4wd co...

  • Page 519

    Differential: 3b-22 dtc c1252: coupling assembly circuit open s6rw0d3204019 wiring diagram dtc detecting condition and trouble area 3 coupling assembly ground circuit check 1) disconnect connector from 4wd control module with ignition switch turned off. 2) measure resistance between “orn” terminal o...

  • Page 520

    3b-23 differential: dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and select 2wd/4wd switch to “lock” position. 3) keep engine running at 2000 rpm for 10 seconds. Or more. 4) stop engine and check dtc. Troubleshooting step action yes no 1 was “4wd control system check” per...

  • Page 521

    Differential: 3b-24 dtc c1253: coupling assembly circuit short s6rw0d3204020 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and select 2wd/4wd switch to “lock” position. 3) keep engine running at 2000 rpm for 10 second...

  • Page 522

    3b-25 differential: dtc c1254: 2wd/4wd switch malfunction s6rw0d3204021 wiring diagram 4 coupling assembly check 1) check coupling assembly referring to “coupling assembly inspection”. Is it in good condition? Substitute a known- good 4wd control module and recheck. Replace coupling assembly. 5 coup...

  • Page 523

    Differential: 3b-26 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) select 2wd/4wd switch to “2wd” position and keep its position for 10 seconds. Similarly select 2wd/4wd switch to “auto” and “lock” position. 3) check dtc. Troubleshooting dtc dete...

  • Page 524

    3b-27 differential: dtc u0073: control module communication bus off s6rw0d3204022 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0100: lost communication with ecm s6rw0d3204023 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0121: lost communication with abs / esp ® control mo...

  • Page 525

    Differential: 3b-28 terminal arrangement of 4wd control module connector (viewed from harness side) 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 26 i4ja01332054-01 terminal number wire color circuit normal voltage condition g26-1 — — — — g26-2 grn coupling assembly (ground) abou...

  • Page 526

    3b-29 differential: reference waveform no.1 coupling assembly signal reference waveform no.2 can communication signal g26-24 orn coupling air temperature sensor (ground) about 2.5 v ignition switch turned on position g26-25 brn coupling air temperature sensor (power) about 2.5 v ignition switch turn...

  • Page 527

    Differential: 3b-30 repair instructions rear differential oil level check s6rw0d3206001 1) lift up vehicle and check oil leakage. Repair leaky point, if any. 2) remove oil level / filler plug (1) and check oil contamination and oil level is lower end of oil level / filler plug hole (2). If oil is ex...

  • Page 528

    3b-31 differential: 2wd/4wd switch removal and installation s6rw0d3206003 removal 1) disconnect negative cable at battery. 2) remove console box (2). 3) remove 2wd/4wd switch (1) from console box. Installation reverse removal procedure for installation. 2wd/4wd switch inspection s6rw0d3206004 check ...

  • Page 529

    Differential: 3b-32 coupling air temperature sensor inspection s6rw0d3206007 caution ! Do not heat up coupling air temperature sensor more than 100 °c (212 °f). Otherwise, coupling air temperature sensor will be damaged. • blow hot air to temperature sensing part (2) of coupling air temperature sens...

  • Page 530

    3b-33 differential: rear differential mountings components s6rw0d3206009 1 8 10 10 3 2 4 5 4 6 (a) 11 (a) (b) 9 (b) 7 (b) i5rw0a320022-04 1. Rear differential 6. Front mounting to body bolt 11. Rear mounting bolt 2. Front mounting arm 7. Front mounting to body nut : 80 n ⋅m (8.0 kgf-m, 58.0 lb-ft) 3...

  • Page 531

    Differential: 3b-34 front mounting arm and/or rear mounting bracket assembly removal and installation s6rw0d3206010 remove and install front mounting arm and/or rear mounting bracket after rear differential removed. For tightening torque of each bolt and nut, refer to “rear differential mountings co...

  • Page 532

    3b-35 differential: rear differential components s6rw0d3206013 4 5 9 2 30 6 (a) 13 12 (a) 3 a 3 a 14 16 17 21 18 29 3 a 1 (b) 22 1217g 10 1217g 11 8 oil 15 oil 19 20 oil 23 oil 25 oil 27 oil 27 oil 25 oil 19 oil 18 26 28 oil 26 oil 23 oil 24 oil (c) 14 7 i5rw0a320026-02 1. Flange nut 13. Differentia...

  • Page 533

    Differential: 3b-36 rear differential disassembly and reassembly s6rw0d3206014 disassembly 1) remove rear mounting bracket from rear differential referring to “front mounting arm and/or rear mounting bracket assembly removal and installation”. 2) remove drive shaft flanges. 3) separate coupling case...

  • Page 534

    3b-37 differential: 8) remove oil seals from rear differential (1) using special tool. Special tool (a): 09913–50121 9) remove differential cover (1) using special tool, and then take out differential assembly, outer race and shim all at once. Special tool (a): 09912–34510 10) pull out differential ...

  • Page 535

    Differential: 3b-38 14) using a hammer and brass bar (1), drive out front bearing outer race (2). 15) using a hammer and brass bar (1), drive out rear bearing outer race (2). Reassembly judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear...

  • Page 536

    3b-39 differential: 4) align holes of pinion shaft and differential case and drive in differential pinion shaft pin till they are flush with end surface of case. Special tool (a): 09922–85811 5) put bevel gear (2) on differential case (3) and tighten new bolts (1) to specified torque. Caution ! Use ...

  • Page 537

    Differential: 3b-40 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 mounting...

  • Page 538

    3b-41 differential: 9) set special tools and make drive bevel pinion mounting dummy. Special tool (a): 09922–76120 (b): 09922–76250 10) install dial gauge (1) to mounting dummy as shown in figure. Special tool set distance “a”: 38.0 mm (1.496 in.) “b”: 0 mm (0.000 in.) 11) set special tools and make...

  • Page 539

    Differential: 3b-42 14) set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate. Note • when setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge. • with dial gauge set, turn dummy bac...

  • Page 540

    3b-43 differential: 19) using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) as shown in figure. Then apply grease to oil seal lip. Note install oil seal horizontally to surface of differential carrier. “a”: grease 99000–25010 (suzuki super grease a) distance betwe...

  • Page 541

    Differential: 3b-44 23) remove differential cover. 24) to measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear. If bevel gear backlash is out of specification, repeat step 22). Note • be sure to apply measu...

  • Page 542

    3b-45 differential: 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 specifica...

  • Page 543

    Differential: 3b-46 26) clean mating surface of differential carrier (1) and differential cover, apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate differential cover with differential carrier, and then tighten bolts to specified torqu...

  • Page 544

    3b-47 differential: 31) clean mating surface of differential carrier (1) and coupling case (2), apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate coupling case with differential carrier as shown in figure, and then tighten bolts to sp...

  • Page 545

    Differential: 3b-48 specifications tightening torque specifications s6rw0d3207001 note the specified tightening torque is also described in the following. “rear differential mountings components” “rear differential components” reference: for the tightening torque of fastener not specified in this se...

  • Page 546

    3b-49 differential: special tool s6rw0d3208002 09900–20607 09900–20701 dial gauge magnetic stand ) ) 09912–34510 09913–50121 case separator oil seal remover ) / ) ) / ) 09913–60910 09913–65135 bearing and gear puller (40- 60mm) bearing puller ) ) 09913–70123 09913–75510 bearing installing tool beari...

  • Page 547

    Differential: 3b-50 09922–76150 09922–76250 bevel pinion nut bevel gear dummy ) / ) ) / ) 09922–76330 09922–76340 bevel pinion rear collar bevel pinion rear collar ) / ) / ) ) / ) / ) 09922–76420 09922–76530 bevel pinion front collar bevel pinion gauge block ) / ) / ) ) / ) 09922–85811 09925–18011 s...

  • Page 548: Transfer

    3c-1 transfer: driveline / axle transfer general description transfer description s6rw0d3301001 the transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in transaxle coupled by involute spline. Driving force from transaxle is transmitted...

  • Page 549

    Transfer: 3c-2 repair instructions transfer oil level check s6rw0d3306001 1) lift up vehicle and check oil leakage. Repair leaky point, if any. 2) remove oil level / filler plug (1) and check oil contamination and oil level is lower end of oil level / filler plug hole (2). If oil is excessive dirty ...

  • Page 550

    3c-3 transfer: transfer dismounting and remounting s6rw0d3306003 dismounting 1) disconnect negative cable at battery. 2) drain transaxle oil and transfer oil. 3) remove drive shafts assembly referring to “front drive shaft assembly removal and installation in section 3a”. 4) remove exhaust no.1, no....

  • Page 551

    Transfer: 3c-4 • pour transaxle oil and transfer oil referring to “manual transaxle oil change in section 5b” and “transfer oil change”. Transfer assembly components s6rw0d3306004 1 2 6 9 11 10 8 7 3 a 4 5 36 oil (a) 5 (a) oil 28 18 30 27 25 21 28 13 12 22 oil oil 32 a 31 a 1322 (d) 34 a 33 23 a 20 ...

  • Page 552

    3c-5 transfer: transfer assembly disassembly and reassembly s6rw0d3306005 disassembly note it is possible to disassemble transfer assembly without removing intermediate shaft with step 1) to 4) performed if not necessary. 1) remove right case oil seal no.1 (1) from transfer right case using special ...

  • Page 553

    Transfer: 3c-6 d) select a shim which is close to half thickness of the calculated value (necessary shim thickness) from among the available shims to install it between bearing and case at each of right and left sides. For example: measure distance “a” is 110.75 mm (4.360 in.). Measure depth “b” is ...

  • Page 554

    3c-7 transfer: 9) install intermediate shaft bearing (1) to intermediate shaft (2) by using special tool. Special tool (a): 09913–84510 10) install intermediate shaft (2) with bearing (3) in transfer. 11) install new snap ring (1) to transfer right case by using snap ring pliers. 12) apply grease to...

  • Page 555

    Transfer: 3c-8 reduction driven gear assembly disassembly and reassembly s6rw0d3306007 disassembly 1) remove left bearing (1) and bevel gear (2) using special tool, bearing puller (3) and hydraulic press (4). Special tool (a): 09925–98221 2) in order to remove right bearing (1) from reduction driven...

  • Page 556

    3c-9 transfer: 3) install left bearing (1) to reduction driven gear (2) using special tools and hydraulic press. Special tool (a): 09913–84510 (b): 09924–84510–005 transfer right case and left case disassembly and reassembly s6rw0d3306008 disassembly 1) remove oil seals from right case (1) using spe...

  • Page 557

    Transfer: 3c-10 transfer output retainer assembly disassembly and reassembly s6rw0d3306009 disassembly 1) uncaulk transfer output flange nut. 2) remove transfer output flange nut while holding flange (1) by using special tool. Special tool (a): 09930–40113 3) remove transfer output flange (1) by bea...

  • Page 558

    3c-11 transfer: reassembly caution ! • bevel gear and pinion must be replaced as a set when either replacement becomes necessary. • when replacing taper roller bearing, replace as inner race and outer race assembly. 1) to mesh bevel gears correctly, it is prerequired to install bevel pinion to trans...

  • Page 559

    Transfer: 3c-12 c) tighten bevel pinion nut (special tool) so that specified bearing preload is obtained. Note before taking measurement, check for rotation by hand more than 15 revolutions. Tightening torque rotational torque of bevel pinion (bearing preload): 0.50 – 1.30 n·m (0.05 – 0.13 kgf-m, 0....

  • Page 560

    3c-13 transfer: 2) press-fit outer races (front and rear) by using special tool and hydraulic press. Special tool (a): 09913–75520 3) press-fit front taper roller bearing (1) by using special tool and hydraulic press. Special tool (a): 09925–18011 4) install bevel pinion with new pinion shaft spacer...

  • Page 561

    Transfer: 3c-14 8) install transfer output flange (1) by tapping with plastic hammer and tighten transfer output flange nut gradually so as rotational torque of bevel pinion to be in specified value. Note • if rotational torque of bevel pinion exceeds specification given in the following, replace pi...

  • Page 562

    3c-15 transfer: 4) bring painted part up and check contact pattern referring to the following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart. Note • be careful not to turn bevel gear more than one full revolution, for it will hinder accura...

  • Page 563

    Transfer: 3c-16 specifications tightening torque specifications s6rw0d3307001 note the specified tightening torque is also described in the following. “transfer assembly components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in sec...

  • Page 564

    3c-17 transfer: special tools and equipment recommended service material s6rw0d3308001 note required service material is also described in the following. “transfer assembly components” special tool s6rw0d3308002 material suzuki recommended product or specification note grease suzuki super grease a p...

  • Page 565

    Transfer: 3c-18 09922–76430 09924–07710 bevel pinion front collar synchronizer hub installer ) / ) ) 09924–74510 09924–84510–005 bearing and oil seal handle bearing installer attachment (d) ) ) / ) 09925–15410 09925–16310 oil seal installer bearing installer ) / ) / ) / ) ) 09925–18011 09925–98221 t...

  • Page 566: Propeller Shafts

    3d-1 propeller shafts: driveline / axle propeller shafts precautions propeller shaft caution s6rw0d3400001 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 m...

  • Page 567

    Propeller shafts: 3d-2 repair instructions propeller shaft joint check s6rw0d3406001 if universal joints and ball joint are suspected of producing chattering or rattling noise, inspect them for wear. For universal joint, check to see if cross spider rattles in yokes are worn down and replace defecti...

  • Page 568

    3d-3 propeller shafts: specifications tightening torque specifications s6rw0d3407001 note the specified tightening torque is also described in the following. “propeller shaft construction” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information...

  • Page 569: 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 570

    4-ii table of contents specifications.......................................................4d-4 tightening torque specifications........................4d-4 abs............................................................4e-1 precautions...........................................................4e-1...

  • Page 571: Precautions

    Precautions: 4-1 brakes precautions precautions precautions for brakes s6rw0d4000001 suspension caution refer to “suspension caution in section 00”. Wheels and tires caution refer to “wheels and tires caution in section 00”. Brake caution refer to “brake caution in section 00”. General precautions r...

  • Page 572

    4a-1 brake control system and diagnosis: brakes brake control system and diagnosis precautions precautions on brake s6rw0d4100001 air bag warning refer to“air bag warning in section 00”. Brakes diagnosis note refer to “brakes diagnosis note”. General description brakes construction s6rw0d4101001 whe...

  • Page 573

    Brake control system and diagnosis: 4a-2 brake pedal foot protection system construction (if equipped) s6rw0d4101004 should a front crash occur and the engine push the dash panel toward the interior side, the brake pedal bracket is also pushed toward the interior side. In this case, the brake pedal ...

  • Page 574

    4a-3 brake control system and diagnosis: front brake hose / pipe construction s6rw0d4101002 i6rw0c410002-01 [a]: lhd 4. From abs hydraulic unit to left front brake 9. Master cylinder fixing nut [b]: rhd 5. Abs hydraulic unit / control module assembly : 18 n ⋅m (1.8 kgf-m, 13.0 lb-ft) 1. From master ...

  • Page 575

    Brake control system and diagnosis: 4a-4 rear brake hose / pipe construction s6rw0d4101003 diagnostic information and procedures brakes diagnosis note s6rw0d4104001 road testing brakes brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road test brakes b...

  • Page 576

    4a-5 brake control system and diagnosis: brakes symptom diagnosis s6rw0d4104002 condition possible cause correction / reference item not enough braking force brake oil leakage from brake lines locate leaking point and repair. Brake disc or pad stained with oil clean or replace. Overheated brakes det...

  • Page 577

    Brake control system and diagnosis: 4a-6 dragging brakes (without a very light drag is present in all 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...

  • Page 578

    4a-7 brake control system and diagnosis: repair instructions brake pedal components s6rw0d4106018 caution ! If equipped brake pedal foot protection system, never disassemble brake pedal assembly. Disassemble will spoil its original function. If faulty condition is found, replace it with new one. Bra...

  • Page 579

    Brake control system and diagnosis: 4a-8 brake fluid level inspection s6rw0d4106004 caution ! Do not use shock absorber fluid or any other fluid which contains mineral oil. Do not use a container which has been used for mineral oil or a container which is wet from water. Mineral oil will cause swell...

  • Page 580

    4a-9 brake control system and diagnosis: 1) fill master cylinder reservoir with specified brake fluid and keep at least one-half full of fluid during bleeding operation. Brake fluid : refer to reservoir cap 2) remove bleeder plug cap. Attach a vinyl tube to bleeder plug, and insert the other end int...

  • Page 581

    Brake control system and diagnosis: 4a-10 • check to make sure that flexible hose doesn’t contact any part of suspension, both in extreme right and extreme left turn conditions. If it does at any point, remove and correct. Fill and maintain brake fluid level in reservoir. • bleed brake system. Refer...

  • Page 582

    4a-11 brake control system and diagnosis: master cylinder and brake booster components s6rw0d4106010 caution ! Never disassemble master cylinder and brake booster. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. Master cylinder reservoir removal a...

  • Page 583

    Brake control system and diagnosis: 4a-12 3) drain brake fluid in reservoir. 4) disconnect clutch reservoir hose from reservoir (m/t model). 5) remove reservoir connector pin (1) by using special tool and then reservoir. Special tool (a): 09916–44310 installation 1) when using new grommets (2), lubr...

  • Page 584

    4a-13 brake control system and diagnosis: 3) drain brake fluid in reservoir. 4) disconnect clutch reservoir hose from reservoir (m/t model). 5) disconnect brake pipes (1) connected to master cylinder. 6) remove master cylinder fixing nuts (2). 7) remove master cylinder (3) and o-ring. Installation 1...

  • Page 585

    Brake control system and diagnosis: 4a-14 booster operation inspection s6rw0d4106014 there are two ways to perform this inspection, with and without a tester. Ordinarily, it is possible to roughly determine its condition without using a tester. Note for this check, make sure that no air is in hydrau...

  • Page 586

    4a-15 brake control system and diagnosis: 2) hold brake pedal depressed for 30 seconds. If pedal height does not change, condition is good. But it isn’t if pedal rises. Brake booster removal and installation s6rw0d4106015 removal 1) remove master cylinder assembly from booster referring to “master c...

  • Page 587

    Brake control system and diagnosis: 4a-16 booster push clevis rod adjustment s6rw0d4106017 install push clevis rod (1) so that measurement “a” is obtained and torque nut (2) to specification. Tightening torque clevis pin lock nut (a): 26 n·m (2.6 kgf-m, 19.0 lb-ft) clevis installing position (length...

  • Page 588: Front Brakes

    4b-1 front brakes: brakes front brakes repair instructions front disc brake components s6rw0d4206001 i7rw01420001-05 1. Caliper 9. Disk brake piston : apply rubber grease included in piston seal set or brake fluid to contact surface of cylinder. 17. Brake flexible hose : be sure to direct mark (18) ...

  • Page 589

    Front brakes: 4b-2 front disc brake pad on-vehicle inspection s6rw0d4206002 inspect pad linings (1) periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end and inspection hole of caliper and check lining thickness o...

  • Page 590

    4b-3 front brakes: 3) install caliper and tighten caliper pin bolts to specified torque. Tightening torque caliper pin bolt (a): 26 n·m (2.6 kgf-m, 19.0 lb-ft) 4) install front wheel referring to “wheel (with tire) removal and installation in section 2d”. 5) check brake effectiveness. Front disc bra...

  • Page 591

    Front brakes: 4b-4 3) connect flexible hose (3) to caliper as shown in figure. 4) torque flexible hose joint bolt to specification. Tightening torque flexible hose joint bolt (a): 23 n·m (2.3 kgf-m, 17.0 lb-ft) warning ! • make sure that flexible hose is not twisted when tightening joint bolt. If it...

  • Page 592

    4b-5 front brakes: assembly assemble parts in reverse order of disassembly, observing the following instructions. Caution ! • wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir. • never use other fluid or thinner. • before installing piston seal...

  • Page 593

    Front brakes: 4b-6 5) to confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out. Note boot’s face (1) should be at the same level from cylinder’s face (2) all around. 6) insert piston into cylinder by hand. Front disc brake cal...

  • Page 594

    4b-7 front brakes: installation 1) install caliper assembly to steering knuckle. Caution ! Make sure that flexible hose is not twisted when installing caliper assembly. If it is twisted, reinstall it using care not to twist it. 2) torque caliper carrier bolts to specification. Tightening torque cali...

  • Page 595

    Front brakes: 4b-8 specifications tightening torque specifications s6rw0d4207001 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 “fasteners information in s...

  • Page 596: Rear Brakes

    4c-1 rear brakes: brakes rear brakes repair instructions rear drum brake components s6rw0d4306001 11 2 3 4 5 6 7 12 14 1 13 10 16 19 15 17 9 8 18 f (a) (b) (c) (d) i6rw0d430001-01 1. Brake drum 10. Wheel cylinder 19. Bleeder plug 2. Brake shoe 11. Brake back plate : 73 n ⋅m (7.3 kgf-m, 53 lb-ft) 3. ...

  • Page 597

    Rear brakes: 4c-2 rear brake drum removal and installation s6rw0d4306002 removal 1) hoist vehicle and remove rear wheel. 2) release parking brake lever. 3) remove brake drum (1) by using 8 mm bolts (2) (2 pcs). Installation 1) before installing brake drum, to maximize brake shoe-to-drum clearance, p...

  • Page 598

    4c-3 rear brakes: cracked, scored or grooved drum a cracked drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and it will probably be necessary to resurface dr...

  • Page 599

    Rear brakes: 4c-4 3) remove return springs, brake shoes and adjuster. 4) disconnect parking brake shoe lever (1) from parking brake cable (2). 5) remove push nut (1). 6) remove parking brake shoe lever (2) from shoe rim (3). Installation install parts in reverse order of removal, noting the followin...

  • Page 600

    4c-5 rear brakes: installation 1) take off bleeder plug cap from brake pipe and connect pipe to wheel cylinder (1) just enough to prevent fluid from leaking. 2) install wheel cylinder (1) to brake back plate (2), and tighten wheel cylinder mounting bolt to specified torque. Tightening torque wheel c...

  • Page 601

    Rear brakes: 4c-6 installation install brake back plate by reversing removal procedure, noting the instructions. Caution ! Never reuse rear wheel hub mounting bolts. • install rear wheel hub and brake back plate, and then tighten mounting bolt. Refer to “rear drum brake components”. • install parkin...

  • Page 602: Parking Brake

    4d-1 parking brake: brakes parking brake general description parking brake cable construction s6rw0d4401001 4 6 f t t f f r 3 [a] f 9 ( a ) 2 ( a ) 5 1 3 4 [a] ( a ) 10 ( a ) 10 ( b ) 11 ( b ) ( b ) 10 10 11 11 ( a ) ( a ) 11 7 8 ( b ) i6rw0d440001-01 t: top side 3. Equalizer 8. Parking brake cable ...

  • Page 603

    Parking brake: 4d-2 repair instructions parking brake inspection and adjustment s6rw0d4406001 inspection hold center of parking brake lever grip and pull it up with 200 n (20 kg, 44 lbs) force. With parking brake lever pulled up as shown, count ratchet notches. There should be 4 – 9 notches. Also, c...

  • Page 604

    4d-3 parking brake: parking brake lever removal and installation s6rw0d4406003 removal 1) remove console box. 2) block vehicle wheels and release parking brake lever. 3) disconnect lead wire of parking brake switch at coupler. 4) loosen parking brake cable adjusting nut (1). 5) remove parking brake ...

  • Page 605

    Parking brake: 4d-4 specifications tightening torque specifications s6rw0d4407001 note the specified tightening torque is also described in the following. “parking brake cable construction” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners informatio...

  • Page 606: Abs

    4e-1 abs: brakes abs precautions precautions in diagnosing troubles s6rw0d4500001 to ensure that the trouble diagnosis is done accurately and smoothly, observe the following and follow “abs check”. • diagnostic information stored in abs control module memory can be cleared as well as checked by usin...

  • Page 607

    Abs: 4e-2 general description abs description s6rw0d4501001 the abs (antilock brake system) controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This abs has also the following function. W...

  • Page 608

    4e-3 abs: abs hydraulic unit / control module assembly description s6rw0d4501002 abs control module is a component of abs hydraulic unit / control module assembly and has the following functions. Self-diagnosis function abs control module diagnoses conditions of the system component parts (whether o...

  • Page 609

    Abs: 4e-4 schematic and routing diagram abs schematic s6rw0d4502001 1 3 2 8 6 5 7 12 4 15 17 16 14 9 18 19 11 10 20 21 22 13 23 input output abs control module wheel speed sensor (lr) wheel speed sensor (rf) g sensor (4wd model only) wheel speed sensor (lf) pump motor driver (transistor) solenoid va...

  • Page 610

    4e-5 abs: abs wiring circuit diagram s6rw0d4502002 1. Abs hydraulic unit / control module assembly 9. Brake light switch 17. Wheel speed sensor (left-rear) 2. Abs control module 10. Abs warning light 18. Battery 3. Abs hydraulic unit 11. Ebd warning light (brake warning light) 19. Ignition switch 4....

  • Page 611

    Abs: 4e-6 17 +bb 18 blu wht 12v grn/orn 3 4 30 e08-9 red wht 12 26 wht/red 12v e08-7 19 grn grn e08-16 12v 5 7 6 21 red red/blk 12v blk wht e08-22 e08-11 23 blk wht lt grn/blk lt grn 12v e08-10 e08-21 e08-23 e08-26 e08-1 e08-12 24 blk wht 12v yel brn e08-19 e08-20 27 1 2 red/blk wht red wht red wht ...

  • Page 612

    4e-7 abs: terminal circuit e08 1 can communication line (high) for ecm 2 can communication line (high) for bcm 3 g sensor ground (4wd model only) 4 — 5 — 6 g sensor signal (4wd mode only) 7 brake light switch 8 — 9 ignition switch 10 left-rear wheel speed sensor (–) 11 left-front wheel speed sensor ...

  • Page 613

    Abs: 4e-8 component location abs components location s6rw0d4503001 diagnostic information and procedures abs check s6rw0d4504001 refer to the following items for the details of each step. 1 2 6 2 6 2 6 2 6 4 5 7 3 8 i5rw0a450006-02 1. Abs hydraulic unit / control module assembly 5. Ebd warning light...

  • Page 614

    4e-9 abs: 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 purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the point req...

  • Page 615

    Abs: 4e-10 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.) check warning lights related to bra...

  • Page 616

    4e-11 abs: dtc check s6rw0d4504004 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (1). Special tool (a): suzuki scan tool 3) turn ignition switch to on position. 4) read dtc according to instructions displayed on suzuki scan tool and print it or write it ...

  • Page 617

    Abs: 4e-12 scan tool data s6rw0d4504007 the parameter data below are values measured with the scan tool when the normally operating vehicle is under the following conditions. When taking measurements for comparison by using the scan tool, be sure to check that the vehicle is under the following cond...

  • Page 618

    4e-13 abs: abs warning light does not come on at ignition switch on s6rw0d4504008 wiring diagram e08 [c] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 g241 [d] 1 3 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 18 20 2122 23 24 25 26 27 28 29 30 3132 wht grn 3 e08-2 e08-13 red wht 5...

  • Page 619

    Abs: 4e-14 circuit description abs control module transmits indication on signal of abs warning light to combination meter in order to turn abs warning light on. And then, combination meter turns abs warning light on. If the abs is in good condition, abs control module transmits indication on signal...

  • Page 620

    4e-15 abs: abs warning light comes on steady s6rw0d4504009 wiring diagram refer to “warning diagram” under “abs warning light does not come on at ignition switch on”. Circuit description refer to “circuit description” under “abs warning light does not come on at ignition switch on”. Troubleshooting ...

  • Page 621

    Abs: 4e-16 ebd warning light (brake warning light) comes on steady s6rw0d4504010 wiring diagram referring to “wiring diagram” under “abs warning light does not come on at ignition switch on”. Circuit description ebd warning lamp (brake warning lamp) is controlled by abs control module and bcm throug...

  • Page 622

    4e-17 abs: serial data link circuit check s6rw0d4504011 wiring diagram 5 can communication line circuit check 1) turn ignition switch to off position. 2) disconnect connectors of all control modules communicating by means of can. 3) check for proper connection to can communication line wire. 4) if o...

  • Page 623

    Abs: 4e-18 wht grn 3 e08-2 e08-13 red wht 5 4 12 9 e08-23 e08-26 blk blk 7 6 blk red wht g241-7 g241-10 g241-16 12v e08-25 e08-24 e08-9 wht/red wht/blu grn/orn 9 red wht g05-1 g05-3 red wht g05-4 g05-2 9 2 1 13 g241-31 red/blk 8 11 +bb b g g1 12v e08-16 14 blu 10 [c] e08 1 2 3 4 5 6 7 12 13 14 15 16...

  • Page 624

    4e-19 abs: trouble shooting step action yes no 1 scan tool communication check can scan tool communicate with bcm? Go to step 2. Go to step 3. 2 abs hydraulic unit / control module assembly power and ground circuit check 1) check that abs hydraulic unit / control module assembly power supply circuit...

  • Page 625

    Abs: 4e-20 dtc c1013: control module mismatch s6rw0d4504012 wiring diagram dtc detecting condition and trouble area note when abs hydraulic unit / control module assembly for 4wd model is installed to 2wd model, this dtc is set. Replace to the correct abs hydraulic unit / control module assembly. Tr...

  • Page 626

    4e-21 abs: dtc c1015: g sensor circuit (4wd model) s6rw0d4504013 wiring diagram refer to “wiring diagram” under “dtc c1013: control module mismatch”. Dtc detecting condition and trouble area note when a vehicle is lifted up and its wheel(s) is turned, this dtc is set. In such case, clear the dtc and...

  • Page 627

    Abs: 4e-22 dtc 1016: brake light switch s6rw0d4504014 wiring diagram dtc detecting condition and trouble area note when a vehicle is lifted up and its wheel(s) is turned, this dtc is set. In such case, clear the dtc and check again. Troubleshooting wht grn 3 4 7 12v e08-7 e08-9 grn/orn 2 8 1 12v grn...

  • Page 628

    4e-23 abs: dtc c1021 / c1022 / c1025 / c1026 / c1031 / c1032 / c1035 / c1036: wheel speed sensor circuit / sensor or encoder s6rw0d4504015 dtc c1021 / c1025 / c1031 / c1035: right-front / left-front / right-rear / left-rear wheel speed sensor circuit dtc c1022 / c1026 / c1032 / c1036: right-front / ...

  • Page 629

    Abs: 4e-24 dtc troubleshooting step action yes no 1 was “abs check” performed? Go to step 2. Go to “abs check”. 2 check tire condition 1) check that tire pressure is specifications. Are they in good condition? Go to step 3. Replace tire or adjust tire pressure and recheck. 3 wheel speed sensor circu...

  • Page 630

    4e-25 abs: dtc c1033: wheel speed sensor deviation s6rw0d4504016 wiring diagram refer to “wiring diagram” under “dtc c1021 / c1022 / c1025 / c1026 / c1031 / c1032 / c1035 / c1036: wheel speed sensor circuit / sensor or encoder”. Dtc detecting condition and trouble area dtc troubleshooting dtc detect...

  • Page 631

    Abs: 4e-26 dtc c1041 / c1042 / c1045 / c1046 / c1051 / c1052 / c1055 / c1056: inlet / outlet solenoid s6rw0d4504017 dtc c1041 / c1045 / c1051 / c1055: right-front / left-front / right-rear / left- rear inlet solenoid dtc c1042 / c1046 / c1052 / c1056: right-front / left-front / right-rear / left- re...

  • Page 632

    4e-27 abs: dtc c1057: power supply voltage too high / too low s6rw0d4504018 wiring diagram dtc detecting condition and trouble area dtc troubleshooting wht grn 3 4 5 e08-23 blk 12v e08-9 grn/orn 2 1 [a] e08 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 i7rw01450009-03 [a]: abs...

  • Page 633

    Abs: 4e-28 dtc c1061: pump motor circuit s6rw0d4504019 wiring diagram dtc detecting condition and trouble area dtc troubleshooting wht/red 1 2 5 m 3 4 12v e08-25 e08-26 blk e08 [a] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 i7rw01450010-02 [a]: abs control module connector ...

  • Page 634

    4e-29 abs: dtc c1063: solenoid valve power supply driver circuit s6rw0d4504020 wiring diagram dtc detecting condition and trouble area dtc troubleshooting e08 [a] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 wht grn 3 4 7 e08-23 blk 12v e08-9 grn/orn 2 1 wht/blu 5 e08-24 6 i7...

  • Page 635

    Abs: 4e-30 dtc c1071: control module internal defect s6rw0d4504021 dtc detecting condition and trouble area dtc troubleshooting abs hydraulic unit / control module assembly power and ground circuit check s6rw0d4504022 wiring diagram circuit description when the ignition switch is turned on, power su...

  • Page 636

    4e-31 abs: troubleshooting repair instructions abs hydraulic unit operation check s6rw0d4506001 1) check that basic brake system other than abs is in good condition. 2) check that battery voltage is 11 v or more. 3) hoist vehicle. 4) set transmission to neutral (p range for a/t) and release parking ...

  • Page 637

    Abs: 4e-32 7) turn ignition switch to on position and select menu to “hydraulic control test” under “miscellaneous test” (“misc. Test”) mode of suzuki scan tool. 8) perform the following checks with help of another person. Brake pedal (1) should be depressed and then select testing wheel by suzuki s...

  • Page 638

    4e-33 abs: abs hydraulic unit / control module assembly on-vehicle inspection s6rw0d4506003 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 ...

  • Page 639

    Abs: 4e-34 installation 1) install hydraulic unit / control module assembly by reversing removal procedure noting the following. Install abs hydraulic unit / control module assembly bracket bolt as follows. A) tighten bracket bolt (1) and (2) by hand. B) then tighten bracket bolt to specified torque...

  • Page 640

    4e-35 abs: 5) measure voltage at resistance without wheel rotation.If voltage is out of specification, check sensor, mating encoder and their installation conditions. Voltage at the resistance (115 Ω) without wheel rotation 680 – 960 mv 6) measure voltage at resistance with wheel rotation and confir...

  • Page 641

    Abs: 4e-36 installation 1) check that no foreign material is attached to sensor (1) and wheel speed sensor encoder (included in wheel hub assembly). 2) install it by reversing removal procedure. Note before fitting wheel speed sensor, be sure to silicon grease to its o-ring. Tightening torque front ...

  • Page 642

    4e-37 abs: front wheel speed sensor encoder on-vehicle inspection s6rw0d4506010 before inspecting front wheel speed sensor encoder, remove front drive shaft referring to “front drive shaft assembly removal and installation in section 3a”. • check sensor encoder (1) for crack, damage or deformation. ...

  • Page 643

    Abs: 4e-38 g sensor removal and installation (4wd model) s6rw0d4506014 caution ! • do not drop and shock g sensor. It will affect its original performance. • regarding g sensor removal and installation, confirm specified torque and use hand tool to avoid damage. Removal 1) disconnect negative (–) ca...

  • Page 644

    4e-39 abs: specifications tightening torque specifications s6rw0d4507001 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 “fasten...

  • Page 645: Section 5

    Table of contents 5- i 5 section 5 contents transmission / transaxle precautions .................................................5-1 precautions............................................................. 5-1 precautions on transmission / transaxle ............. 5-1 automatic transmission/transaxl...

  • Page 646

    5-ii table of contents dtc p1723: range select switch malfunction......................................................5a-68 dtc p1878: torque converter clutch shudder ..........................................................5a-69 dtc p2762: torque converter clutch (tcc) pressure control solenoid c...

  • Page 647

    Table of contents 5-iii diagnostic information and procedures............5b-5 manual transaxle symptom diagnosis............... 5b-5 repair instructions ..............................................5b-5 manual transaxle oil level check ..................... 5b-5 manual transaxle oil change ...........

  • Page 648: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions on transmission / transaxle s6rw0d5000001 air bag warning refer to “air bag warning in section 00”. Precautions in diagnosing trouble refer to “precautions in diagnosing trouble in section 5a”. Precautions for disassembly ...

  • Page 649

    Automatic transmission/transaxle: 5a-1 transmission / transaxle automatic transmission/transaxle precautions precautions in diagnosing trouble s6rw0d5100001 • do not disconnect couplers from tcm, battery cable from battery, tcm ground wire harness from engine or main fuse before checking the diagnos...

  • Page 650

    5a-2 automatic transmission/transaxle: caution ! • keep component parts in group for each subassembly and avoid mixing them up. • clean all parts with cleaning solvent thoroughly and air dry them. • use kerosene or automatic transaxle fluid as cleaning solvent. • do not use wiping cloths or rags to ...

  • Page 651

    Automatic transmission/transaxle: 5a-3 general description a/t description s6rw0d5101001 this automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (o/d) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped...

  • Page 652

    5a-4 automatic transmission/transaxle: i5rw0c510070-01 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (tcc) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23. Short planet pinion 4. Input shaft 14. One-way no.2 clutch 24. Countersha...

  • Page 653

    Automatic transmission/transaxle: 5a-5 specifications item specifications torque converter type stall torque ratio 3-element, 1-step, 2-phase type (with tcc (lock-up) mechanism) 1.9 – 2.1 oil pump type drive system internal involute gear type oil pump (non crescent type) engine driven gear change de...

  • Page 654

    5a-6 automatic transmission/transaxle: clutch / brake / planetary gear function of automatic transaxle s6rw0d5101002 functions 1 2 4 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 i4rs0a510001-01 1. Input shaft and intermediate shaft 8. One-way no.2 clutch 15. Front sun gear 2. Direct clutch 9. 2nd brake...

  • Page 655

    Automatic transmission/transaxle: 5a-7 table of component operation s6rw0d5101003 { : on ×: off u: on only when tcc is operating a/t diagnosis general description s6rw0d5101004 this vehicle is equipped with an electronic transaxle control system, which controls the automatic shift up and shift down ...

  • Page 656

    5a-8 automatic transmission/transaxle: on-board diagnostic system description s6rw0d5101005 note there are two types of obd system depending on the vehicle specification.For identification, refer to “precaution on on- board diagnostic (obd) system in section 1a”. For automatic transaxle control syst...

  • Page 657

    Automatic transmission/transaxle: 5a-9 can communication system description s6rw0d5101006 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 tcm reception dat...

  • Page 658

    5a-10 automatic transmission/transaxle: schematic and routing diagram transmission control module (tcm) wiring diagram s6rw0d5102001 12v 12v 12v ig1 11 8 9 10 p r n d 2 l 12 2.5v 5v 12v 5v 12v 12v 12v wht blk blk blk blk ppl blk/wht blk/orn ig11 red/blk yel/blk yel/blu lt grn/blk +bb wht/red 14 20 1...

  • Page 659

    Automatic transmission/transaxle: 5a-11 operation of shift solenoid valves, timing solenoid valve and tcc solenoid valve { : on (turn power on) ×: off (turn power off) u: on only when tcc is operating selector position gear position solenoid condition shift solenoid valve-a (no.1) shift solenoid val...

  • Page 660

    5a-12 automatic transmission/transaxle: automatic gear shift table s6rw0d5102002 automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the d position. M16a engine model 1.Shift point in d, 3 and/or 2 position 2. Lock-up point in d and/or 3 position t...

  • Page 661

    Automatic transmission/transaxle: 5a-13 m15a engine model 1.Shift point in d, 3 and/or 2 position 2. Lock-up point in d and/or 3 position throttle opening (%) shift vehicle speed km/h (mph) remark up shift over 90% 1st → 2nd 50 – 55 (31 - 34) d, 3, 2 range 2nd → 3rd 100 – 105 (62 - 65) d, 3 range 3r...

  • Page 662

    5a-14 automatic transmission/transaxle: component location electronic shift control system components location s6rw0d5103001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 5* 17 15 1 2 8 9 10 11 12 13 16* 18 19 14...

  • Page 663

    Automatic transmission/transaxle: 5a-15 6. Output shaft speed sensor (vss) 14. Transmission range sensor engine torque converter with torque converter clutch oil pump regulator valves in valve body planetary gear unit clutches and brakes control valves in valve body shift solenoid valves, tcc soleno...

  • Page 664

    5a-16 automatic transmission/transaxle: diagnostic information and procedures a/t system check s6rw0d5104001 refer to the following items for the details of each step. Step action yes no 1 ) customer complaint analysis 1) perform customer complaint analysis. Was customer complaint analysis performed...

  • Page 665

    Automatic transmission/transaxle: 5a-17 step 1. Customer complaint analysis record details of the problem such as failure, complaint and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for pro...

  • Page 666

    5a-18 automatic transmission/transaxle: step 2. Dtc / freeze frame data check, record and clearance first, referring to “dtc check”, check dtc and pending dtc. If dtc exists, print or write down dtc and freeze frame data and then clear malfunction dtc(s) by referring to “dtc clearance”. Malfunction ...

  • Page 667

    Automatic transmission/transaxle: 5a-19 malfunction indicator lamp (mil) check s6rw0d5104003 refer to the same item in “malfunction indicator lamp (mil) check in section 1a” for checking procedure. Transmission warning light check (non-euro-obd model) s6rw0d5104053 1) turn ignition switch on. 2) che...

  • Page 668

    5a-20 automatic transmission/transaxle: dtc no. Detecting item detecting condition (dtc will set when detecting) a b ) up0602 control module programming error data programming error. — — ) p0705 transmission range sensor circuit malfunction (prndl input) multiple signals are inputted simultaneously....

  • Page 669

    Automatic transmission/transaxle: 5a-21 dtc check s6rw0d5104005 note • there are two types of obd system depending on the vehicle specification.For identification, refer to “precaution on on- board diagnostic (obd) system in section 1a”. • for euro-obd model, the mil is turned on when the ecm and/or...

  • Page 670

    5a-22 automatic transmission/transaxle: dtc clearance s6rw0d5104006 warning ! When performing a driving test, select a safe place where there is neither any traffic nor any traffic accident possibility and be very careful during testing to avoid occurrence of an accident. After repair or replace mal...

  • Page 671

    Automatic transmission/transaxle: 5a-23 ) p0787 shift / timing solenoid control circuit low • power supply for all solenoid valves is cut. • gear position is fixed in 3rd gear. • line pressure control at gear shifting is inhibited. • look-up function is inhibited to operate. ) p0788 shift / timing s...

  • Page 672

    5a-24 automatic transmission/transaxle: scan tool data s6rw0d5104008 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 values. Even when the vehicle is in good...

  • Page 673

    Automatic transmission/transaxle: 5a-25 ) shift solenoid- b command at vehicle stop on at 60 km/h (37.5 mile/h) constant speed, 20% or less throttle opening and 3rd gear (“3” range) off ) shift solenoid- b monitor at vehicle stop on at 60 km/h (37.5 mile/h) constant speed, 20% or less throttle openi...

  • Page 674

    5a-26 automatic transmission/transaxle: scan tool data definitions: gear position current gear position computed by throttle position coming from ecm and vehicle speed. Engine speed (rpm) engine speed computed by reference pulses from crankshaft position sensor. Input shaft revolution (rpm) input sh...

  • Page 675

    Automatic transmission/transaxle: 5a-27 mil request on: signal which tcm requires combination meter to turn on malfunction indicator lamp. Off: signal which tcm does not require combination meter to turn on malfunction indicator lamp. A/t basic check s6rw0d5104009 this check is important for trouble...

  • Page 676

    5a-28 automatic transmission/transaxle: troubleshooting condition possible cause correction / reference item unable to run in all range faulty valve body component replace valve body assembly. Faulty oil pump inspect. If ng, replace. Seized or broken planetary gear inspect. If ng, replace. Faulty on...

  • Page 677

    Automatic transmission/transaxle: 5a-29 o/d → 3 downshift fails to occur malfunction of shift solenoid valve-a inspect. If ng, replace. Malfunction of “3” position switch inspect. If ng, replace. Malfunction of output shaft speed sensor (vss) inspect. If ng, replace. Malfunction of input shaft speed...

  • Page 678

    5a-30 automatic transmission/transaxle: manual road test s6rw0d5104011 warning ! Carry out test in very little traffic area to prevent an accident. Test requires 2 persons, a driver and a tester. The purpose of this test is to judge whether causal factor of trouble which occurred in automatic transa...

  • Page 679

    Automatic transmission/transaxle: 5a-31 stall test s6rw0d5104013 this test is to check overall performance of automatic transaxle and engine by measuring stall speed at “d” and “r” ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is betw...

  • Page 680

    5a-32 automatic transmission/transaxle: time lag test s6rw0d5104014 this test is to check conditions of clutch, brake and fluid pressure. “time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) with chocks placed before and behind front and rear wheels r...

  • Page 681

    Automatic transmission/transaxle: 5a-33 caution ! After attaching oil pressure gauge, check that no fluid leakage exists. 4) depress foot brake fully, run engine at idle and stall then check fluid pressure in “d” or “r” range. Caution ! • do not continue running engine at stall speed longer than 5 s...

  • Page 682

    5a-34 automatic transmission/transaxle: a/t symptom diagnosis s6rw0d5104017 trouble diagnosis 1 electrical repair condition possible cause correction / reference item excessive shift shock shift solenoid valve-a and/or -b circuit faulty inspect circuit for open, short and intermittent. If ng, repair...

  • Page 683

    Automatic transmission/transaxle: 5a-35 poor 2 → 3 shift shift solenoid valve-a circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Output shaft speed sensor (vss) circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Transmission range sensor ci...

  • Page 684

    5a-36 automatic transmission/transaxle: poor 4 → 3 shift shift solenoid valve-b circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Pressure control solenoid valve circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Timing solenoid valve circui...

  • Page 685

    Automatic transmission/transaxle: 5a-37 non operate tcc (lock- up) system tcc solenoid valve circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Shift solenoid valve-a and/or-b circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Pressure contro...

  • Page 686

    5a-38 automatic transmission/transaxle: trouble diagnosis 2 on-vehicle repair condition possible cause correction / reference item unable to run in all range faulty valve body component replace valve body assembly. Excessive shift shock engine abnormal condition inspect and repair engine. Malfunctio...

  • Page 687

    Automatic transmission/transaxle: 5a-39 poor 3 → 4 shift malfunction of shift solenoid valve-b inspect. If ng, replace. Malfunction of timing solenoid valve inspect. If ng, replace. Malfunction of output shaft speed sensor (vss) inspect. If ng, replace. Malfunction of input shaft speed sensor inspec...

  • Page 688

    5a-40 automatic transmission/transaxle: trouble diagnosis 3 off-vehicle repair non operate tcc (lock- up) system malfunction of tcc solenoid valve inspect. If ng, replace. Malfunction of shift solenoid valve-a and/or -b inspect. If ng, replace. Malfunction of output shaft speed sensor (vss) inspect....

  • Page 689

    Automatic transmission/transaxle: 5a-41 transmission warning light circuit check – light remains “on” at ignition switch on (non-euro- obd model) s6rw0d5104054 troubleshooting transmission warning light circuit check – light does not come “on” at ignition switch on (non- euro-obd model) s6rw0d510405...

  • Page 690

    5a-42 automatic transmission/transaxle: dtc p0602: control module programming error s6rw0d5104047 system description internal control module is installed in ecm. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn o...

  • Page 691

    Automatic transmission/transaxle: 5a-43 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm memory by using scan tool. 3) start engine and shift select lever to “d” range. 4) keep engine running at idle speed ...

  • Page 692

    5a-44 automatic transmission/transaxle: table for step 4 dtc p0707: transmission range sensor circuit low s6rw0d5104021 wiring diagram dtc detecting condition and trouble area 7 1) check transmission range sensor referring to “transmission range sensor inspection and adjustment”. Are check results s...

  • Page 693

    Automatic transmission/transaxle: 5a-45 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 694

    5a-46 automatic transmission/transaxle: table for step 4 dtc p0711: transmission fluid temperature sensor “a” control range / performance s6rw0d5104048 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if availabl...

  • Page 695

    Automatic transmission/transaxle: 5a-47 dtc troubleshooting dtc p0712: transmission fluid temperature sensor circuit low s6rw0d5104022 wiring diagram 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 inspect tran...

  • Page 696

    5a-48 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 697

    Automatic transmission/transaxle: 5a-49 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 698

    5a-50 automatic transmission/transaxle: dtc p0717: input / turbine speed sensor circuit malfunction s6rw0d5104024 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 possibility of a t...

  • Page 699

    Automatic transmission/transaxle: 5a-51 dtc p0722: output speed sensor (vss) circuit no signal s6rw0d5104025 wiring diagram dtc detecting condition and trouble area 3 inspect input shaft speed sensor 1) inspect input shaft speed sensor referring to “input shaft speed sensor inspection”. Is result sa...

  • Page 700

    5a-52 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 701

    Automatic transmission/transaxle: 5a-53 dtc p0741 / p0742: tcc circuit performance or stuck off / tcc circuit stuck on s6rw0d5104026 dtc detecting condition and trouble area dtc p0741 dtc p0742 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traff...

  • Page 702

    5a-54 automatic transmission/transaxle: dtc troubleshooting dtc p0751 / p0752 / p0756 / p0757: shift solenoid malfunction s6rw0d5104027 dtc p0751: shift solenoid-a (no.1) performance or stuck off dtc p0752: shift solenoid-a (no.1) stuck on dtc p0756: shift solenoid-b (no.2) performance or stuck off ...

  • Page 703

    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 704

    5a-56 automatic transmission/transaxle: dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine and shift select lever to “n” range. 4) repeat shifting select lever from “n” range to “d” range and vice versa for 3 tim...

  • Page 705

    Automatic transmission/transaxle: 5a-57 dtc p0788: shift / timing solenoid control circuit high s6rw0d5104029 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start en...

  • Page 706

    5a-58 automatic transmission/transaxle: dtc p0961: pressure control solenoid “a” control circuit range / performance s6rw0d5104049 wiring diagram 4 check timing solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on transaxle. 3) check for prope...

  • Page 707

    Automatic transmission/transaxle: 5a-59 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine. 4) keep engine running at idle speed for 30 seconds or more. 5) stop vehicle an...

  • Page 708

    5a-60 automatic transmission/transaxle: dtc p0962: pressure control solenoid control circuit low s6rw0d5104030 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start e...

  • Page 709

    Automatic transmission/transaxle: 5a-61 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check pressure control solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic ...

  • Page 710

    5a-62 automatic transmission/transaxle: dtc p0963: pressure control solenoid control circuit high s6rw0d5104031 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start ...

  • Page 711

    Automatic transmission/transaxle: 5a-63 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check pressure control solenoid circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper...

  • Page 712

    5a-64 automatic transmission/transaxle: dtc p0973 / p0976: shift solenoid-a (no.1) control circuit low / shift solenoid-b (no.2) control circuit low s6rw0d5104032 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a plac...

  • Page 713

    Automatic transmission/transaxle: 5a-65 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check shift solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transmissio...

  • Page 714

    5a-66 automatic transmission/transaxle: dtc p0974 / p0977: shift solenoid-a (no.1) / shift solenoid-b (no.2) control circuit high s6rw0d5104033 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no...

  • Page 715

    Automatic transmission/transaxle: 5a-67 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check shift solenoid valve circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper conn...

  • Page 716

    5a-68 automatic transmission/transaxle: dtc p1702: internal control module memory check sum error s6rw0d5104034 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtc in tcm memory. 3) after 10 seconds passed from turnin...

  • Page 717

    Automatic transmission/transaxle: 5a-69 dtc troubleshooting dtc p1878: torque converter clutch shudder s6rw0d5104041 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 accid...

  • Page 718

    5a-70 automatic transmission/transaxle: dtc p2762: torque converter clutch (tcc) pressure control solenoid control circuit range / performance s6rw0d5104050 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if ava...

  • Page 719

    Automatic transmission/transaxle: 5a-71 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check tcc solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transaxle. 3)...

  • Page 720

    5a-72 automatic transmission/transaxle: dtc p2763: torque converter clutch (tcc) pressure control solenoid control circuit high s6rw0d5104042 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no t...

  • Page 721

    Automatic transmission/transaxle: 5a-73 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check tcc solenoid valve circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper connec...

  • Page 722

    5a-74 automatic transmission/transaxle: dtc p2764: torque converter clutch (tcc) circuit pressure control solenoid control circuit low s6rw0d5104043 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there ...

  • Page 723

    Automatic transmission/transaxle: 5a-75 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check tcc solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transaxle. 3)...

  • Page 724

    5a-76 automatic transmission/transaxle: dtc u0073: control module communication bus off s6rw0d5104051 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0100: lost communication with ecm / pcm “a” s6rw0d5104052 refer to “troubleshooting for can-dtc in section 1a”. Inspection of tcm and its c...

  • Page 725

    Automatic transmission/transaxle: 5a-77 connector “c06” terminal wire color circuit standard voltage condition 1 blk ground 0 – 1 v ignition switch on 2 lt grn/ blk pressure control solenoid valve (–) 0.6 – 1.0 v ignition switch on 3 wht/blk tcc solenoid valve (–) 0.6 – 1.0 v ignition switch on 4 gr...

  • Page 726

    5a-78 automatic transmission/transaxle: connector “c07” terminal wire color circuit standard voltage condition 1 red transmission range sensor (“r” range) 8 – 14 v ignition switch on, select lever at “r” range 0 – 1 v ignition switch on, select lever at other than “r” range 2 — — — — 3 — — — — 4 — —...

  • Page 727

    Automatic transmission/transaxle: 5a-79 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 728

    5a-80 automatic transmission/transaxle: reference waveform no. 5 output shaft speed sensor (vss) signal at vehicle speed 60 km/h (37 mile/h). Tcm power and ground circuit check s6rw0d5104045 wiring diagram measurement terminal ch1: “c07-25” to “c06-1” oscilloscope setting ch1: 5 v/div time: 20 ms/di...

  • Page 729

    Automatic transmission/transaxle: 5a-81 troubleshooting brake interlock system inspection s6rw0d5104046 1) check that select 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...

  • Page 730

    5a-82 automatic transmission/transaxle: • with shift lock solenoid release button (1) pushed and ignition key turned to acc position, select lever can be shifted from “p” range position to any other range. • with shift lock solenoid release button (1) pushed and ignition key turned to lock position,...

  • Page 731

    Automatic transmission/transaxle: 5a-83 7) pull out fluid level gauge (1) again and check fluid level indicated on it. The lowest fluid level should be between full hot (2) and low hot (3). If it is below low hot, add suzuki atf 3317 or mobil atf 3309 up to full hot. Automatic transaxle fluid suzuki...

  • Page 732

    5a-84 automatic transmission/transaxle: 5) lower vehicle and pour proper amount of suzuki atf 3317 or mobil atf 3309. 6) check fluid level referring to “a/t fluid level check”. Automatic transaxle fluid : suzuki atf 3317 or mobil atf 3309 automatic transaxle fluid capacity when draining from drain p...

  • Page 733

    Automatic transmission/transaxle: 5a-85 select lever inspection s6rw0d5106005 check select lever for smooth and clear-cut movement individually. If a malfunction is found, replace select lever assembly. “3” position switch inspection s6rw0d5106016 1) remove console box referring to “console box comp...

  • Page 734

    5a-86 automatic transmission/transaxle: select cable components s6rw0d5106006 select cable removal and installation s6rw0d5106007 removal 1) remove console box referring to “console box components in section 9h”. 2) disconnect select cable from select lever and then detach from bracket. 3) remove cl...

  • Page 735

    Automatic transmission/transaxle: 5a-87 2) remove adjuster (cable end) from select lever pin of select lever assembly. 3) remove adjuster (cable end) from select lever pin of select lever assembly. 4) release lock plate (1) which restrict moving of cable end holder (2). 5) push cable end holder (1) ...

  • Page 736

    5a-88 automatic transmission/transaxle: installation 1) lay interlock cable to its original cabling route. C 1 2 3 4 5 6 1 9 [c] [a] 7 1 2 3 4 5 6 7 8 2 [b] i5rw0c510073-01 [a]: lh steering vehicle 2. Clamp 6. Eps control module [b]: rh steering vehicle 3. Steering lock assembly / steering lock unit...

  • Page 737

    Automatic transmission/transaxle: 5a-89 2) turn ignition switch to acc position. 3) insert cable casing cap (1) into key cylinder cover (2) securely. 4) pull out lock button (1) of select lever side cable end (2). 5) shift select lever to “n” position. Note if select lever is in “p” position, shift ...

  • Page 738

    5a-90 automatic transmission/transaxle: 3) check that engine starts in “n” and “p” ranges but it doesn’t start in “d”, “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 and c...

  • Page 739

    Automatic transmission/transaxle: 5a-91 input shaft speed sensor removal and installation s6rw0d5106012 removal 1) disconnect negative cable at battery. 2) disconnect input shaft speed sensor connector (2). 3) remove input shaft speed sensor (1) by removing its bolt. Installation 1) apply a/t fluid ...

  • Page 740

    5a-92 automatic transmission/transaxle: installation reverse removal procedure to install valve body harness and valve body assembly noting the following points. • for details of valve body assembly and their connectors installation, refer to “automatic transaxle unit assembly”. • for details of a/t...

  • Page 741

    Automatic transmission/transaxle: 5a-93 7) remove oil strainer assembly (3). 8) remove transmission fluid temperature sensor (1) from sensor clamp. 9) disconnect solenoid connectors (2). 10) remove shift solenoid valve-a (no.1) (1), shift solenoid valve-b (no.2) (2) and timing solenoid valve (3) by ...

  • Page 742

    5a-94 automatic transmission/transaxle: 4) install oil strainer assembly (1). Tightening torque oil strainer bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) 5) install new oil pan gasket (1) and oil pan (2). 6) tighten oil pan bolts to specified torque diagonally and little by little. Tightening torque oil ...

  • Page 743

    Automatic transmission/transaxle: 5a-95 timing solenoid valve caution ! • do not insert air gun against strainer installed on inlet of solenoid valve too deeply, when blowing air into solenoid valve. If not, the strainer will be damaged. • be very careful as dust etc. Does not enter when solenoid va...

  • Page 744

    5a-96 automatic transmission/transaxle: 10) remove valve body assembly referring to “automatic transaxle unit disassembly”. 11) remove pressure control solenoid valve and tcc pressure control solenoid valve referring to “valve body assembly disassembly and reassembly”. Installation reverse removal p...

  • Page 745

    Automatic transmission/transaxle: 5a-97 transmission control module (tcm) removal and installation s6rw0d5106021 caution ! • tcm and ecm consists of highly precise parts, therefore when handling it, be careful not to expose to excessive shock. • when replacing tcm with used one, all learned contents...

  • Page 746

    5a-98 automatic transmission/transaxle: differential side oil seal replacement s6rw0d5106023 1) lift up vehicle and drain automatic transaxle fluid. 2) remove drive shaft assembly and center shaft referring to “front drive shaft assembly removal and installation in section 3a”. 3) remove differentia...

  • Page 747

    Automatic transmission/transaxle: 5a-99 automatic transaxle unit components s6rw0d5106028 i5rw0c510050-01 1. Drive plate 6. Transaxle and engine fastening bolt : 19 n ⋅m (1.9 kgf-m, 14.0 lb-ft) 2. Drive plate bolt 7. Transaxle and engine fastening nut : 69 n ⋅m (6.9 kgf-m, 50.0 lb-ft) 3. Drive plate...

  • Page 748

    5a-100 automatic transmission/transaxle: automatic transaxle unit dismounting and remounting s6rw0d5106029 dismounting 1) take down transaxle with engine. For its procedure, refer to “engine assembly removal and installation in section 1d”. 2) remove transaxle housing lower plate (1). 3) remove driv...

  • Page 749

    Automatic transmission/transaxle: 5a-101 remounting 1) make sure that torque converter is installed correctly to transaxle. Refer to “automatic transaxle unit assembly”. 2) attach transaxle to engine. Tighten engine oil pan bolts (1) to specified torque. Warning ! Be sure to keep transaxle with torq...

  • Page 750

    5a-102 automatic transmission/transaxle: automatic transaxle assembly components s6rw0d5106030 i5rw0c510057-01.

  • Page 751

    Automatic transmission/transaxle: 5a-103 1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly 2. Torque converter housing : apply sealant 99000-31230 to mating surface to transaxle case. 38. Cooler check valve 74. Rear sun gear thrust bearing race 3. Oil strainer...

  • Page 752

    5a-104 automatic transmission/transaxle: automatic transaxle unit disassembly s6rw0d5106031 caution ! • thoroughly clean transaxle exterior before overhauling it. • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to damage them. • do...

  • Page 753

    Automatic transmission/transaxle: 5a-105 9) remove fluid cooler pipes (1) and pipe unions (2). 10) remove fluid level gauge (3) and fluid filler tube (4). 11) remove oil pan (1) and oil pan gasket (2). Note • for removal of oil pan, do not turn transaxle over as this will contaminate valve body with...

  • Page 754

    5a-106 automatic transmission/transaxle: 16) remove valve body harness (1). Caution ! When pulling valve body harness out of transaxle case, take care not to damage transmission fluid temperature sensor (2) at narrow exit of case. Careless sensor treatment might cause sensor malfunction. 17) remove ...

  • Page 755

    Automatic transmission/transaxle: 5a-107 20) remove transaxle case plug (1). 21) remove torque converter housing bolts. 22) remove torque converter housing (1) while tapping around it lightly with plastic hammer. 23) remove breather hose (1). 24) remove breather union (2). 25) measure input shaft th...

  • Page 756

    5a-108 automatic transmission/transaxle: 29) remove input shaft rear thrust bearing (1) and thrust bearing race (2). Note if input shaft rear thrust bearing is not found, it may have been taken out with direct clutch assembly. 30) remove direct clutch hub (1). 31) remove differential assembly (1) an...

  • Page 757

    Automatic transmission/transaxle: 5a-109 36) remove 2nd brake gasket (1). 37) measure o/d and 2nd coast brake piston stroke. If piston stroke exceeds specification, inspect and replace plates and discs. • measure dimension “a” from mating surface of transaxle case to o/d and 2nd coast brake rear pla...

  • Page 758

    5a-110 automatic transmission/transaxle: 40) remove o/d and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4). 41) remove forward clutch hub (1). 42) remove rear sun gear thrust bearing (1) from forward clutch hub (2). Note if rear sun gear thrust bearing is not ...

  • Page 759

    Automatic transmission/transaxle: 5a-111 48) remove o/d and 2nd coast brake retaining plate snap ring (1). 49) remove front planetary sun gear (1). 50) remove front sun gear thrust bearing race (2) from front planetary sun gear (1). 51) before disassembling 2nd brake piston assembly (4), check 2nd b...

  • Page 760

    5a-112 automatic transmission/transaxle: 53) remove 2nd brake piston assembly (1). 54) remove 2nd brake return spring subassembly (2). 55) remove 2nd brake separator plates (1), discs (2) and retaining plate (3). 56) remove brake drum gasket (1). 57) remove one-way clutch outer race retainer (1). 58...

  • Page 761

    Automatic transmission/transaxle: 5a-113 61) measure 1st and reverse brake piston stroke. If piston stroke exceeds specified value, disassemble, inspect and replace discs and plates. • using special tool, measure 1st and reserve brake piston stroke when compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 ,...

  • Page 762

    5a-114 automatic transmission/transaxle: 67) using special tools and hydraulic press, remove planetary ring gear subassembly (1). Caution ! Do not reuse planetary ring gear subassembly. Otherwise it may cause damage to planetary gear unit and/or reduction gears. Special tool (a): 09913–84510 (b): 09...

  • Page 763

    Automatic transmission/transaxle: 5a-115 71) remove parking lock pawl bracket (1). 72) with slotted screwdriver, cut and unfold manual valve lever spacer (1) and proceed to remove manual valve lever spacer. 73) using spring pin remover with 3 mm (0.12 in.) in diameter and hammer, drive out manual va...

  • Page 764

    5a-116 automatic transmission/transaxle: oil pump assembly components s6rw0d5106032 oil pump assembly disassembly and reassembly s6rw0d5106033 disassembly 1) remove o-ring from pump body. 2) remove 8 oil pump subassembly bolts (1) and stator shaft assembly (2). 3) remove oil seal (1) using special t...

  • Page 765

    Automatic transmission/transaxle: 5a-117 reassembly 1) install new oil pump body oil seal (1). Use special tool and hammer to install it, and then apply grease to its lip portion. Special tool (a): 09913–85210 “a”: grease 99000–25030 (suzuki super grease c) 2) install driven gear and drive gear to o...

  • Page 766

    5a-118 automatic transmission/transaxle: 3) check side clearance of both gears. Using a straightedge (1) and a feeler gauge (2), measure side clearance between gears and pump body. If clearance exceeds its standard value, replace oil pump assembly. Side clearance between gears and oil pump body stan...

  • Page 767

    Automatic transmission/transaxle: 5a-119 direct clutch assembly components s6rw0d5106035 direct clutch assembly preliminary check s6rw0d5106036 install direct clutch assembly (1) to oil pump assembly (2) blow in air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (3) of oil pump assem...

  • Page 768

    5a-120 automatic transmission/transaxle: direct clutch assembly disassembly and reassembly s6rw0d5106037 caution ! When clutch disc, retaining plate and/or separator plate of direct clutch have been replaced, all learned contents, which have been stored in tcm memory by executing learning control, s...

  • Page 769

    Automatic transmission/transaxle: 5a-121 reassembly reverse disassembly procedure for assembly, noting the following points. • use new seal ring and o-ring. Apply a/t fluid before installation. • do not damage direct clutch return spring subassembly (1) and piston by pressing in direct clutch return...

  • Page 770

    5a-122 automatic transmission/transaxle: direct clutch assembly inspection s6rw0d5106038 clutch discs, plates and retaining plate check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt. If necessary, replace. Note • if disc lining is exfoliated, discolo...

  • Page 771

    Automatic transmission/transaxle: 5a-123 forward and reverse clutch assembly components s6rw0d5106039 forward and reverse clutch assembly preliminary check s6rw0d5106040 1) install forward and reverse clutch assembly (1) to transaxle rear cover (2), blow in compressed air (400 – 800 kpa, 4 – 8 kg/cm...

  • Page 772

    5a-124 automatic transmission/transaxle: 2) blow compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (1) of transaxle rear cover with the special tool attached on the upper surface of forward clutch retaining plate, and measure forward clutch piston stroke. If piston stroke...

  • Page 773

    Automatic transmission/transaxle: 5a-125 6) install intermediate shaft subassembly (1) to transaxle rear cover (2). Apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole (3) of transaxle rear cover to remove forward clutch piston (4). 7) apply compressed air (400 – 800 kpa, ...

  • Page 774

    5a-126 automatic transmission/transaxle: • apply a/t fluid to forward clutch separator plates (1), discs (2) and retaining plate (3). • install forward clutch separator plates (1), discs (2) and retaining plate (3), then snap ring (4) to forward clutch drum. • install forward clutch plate snap ring ...

  • Page 775

    Automatic transmission/transaxle: 5a-127 • install reverse clutch plate snap ring so that its both ends would be positioned in correct locations as shown in figure. • measure reverse clutch piston stroke in the same manner as “forward and reverse clutch assembly preliminary check”. When piston strok...

  • Page 776

    5a-128 automatic transmission/transaxle: forward clutch piston lip and forward clutch balancer lip check each lip for wear, deformation, cut and/or hardening. If necessary, replace. Forward clutch drum lip check each lip for wear, deformation, cut and/or hardening. If necessary, replace. 2nd brake p...

  • Page 777

    Automatic transmission/transaxle: 5a-129 2) remove inner o-ring (1) and outer o-ring (2). Reassembly reverse disassembly procedure for assembly, noting the following points. • use new o-rings. Apply a/t fluid to the o-rings, before installation. • install 2nd brake piston (1) to which a/t fluid is a...

  • Page 778

    5a-130 automatic transmission/transaxle: transaxle rear cover (o/d and 2nd coast brake piston) assembly disassembly and reassembly s6rw0d5106046 disassembly 1) remove snap ring by using special tools and hydraulic press. Special tool (a): 09926–96030 (b): 09946–06710 caution ! Do not press o/d and 2...

  • Page 779

    Automatic transmission/transaxle: 5a-131 reassembly reverse disassembly procedure for assembly, noting the following points. • use new seal rings and o-rings. Apply a/t fluid to seal rings and o-rings before installation. • tighten rear cover plugs to specified torque. Tightening torque rear cover p...

  • Page 780

    5a-132 automatic transmission/transaxle: countershaft assembly components s6rw0d5106048 countershaft assembly disassembly and reassembly s6rw0d5106049 disassembly 1) remove countershaft lh bearing (1) and reduction driven gear (2) at once by using special tool and hydraulic press. Special tool (a): ...

  • Page 781

    Automatic transmission/transaxle: 5a-133 3) install countershaft lh bearing (1) with special tools and hydraulic press. Special tool (a): 09913–84510 (b): 09925–88210 valve body assembly components s6rw0d5106050 i2rh0b510214-01 i4rs0a510044-01 1. Pressure control solenoid valve 6. Temperature sensor...

  • Page 782

    5a-134 automatic transmission/transaxle: valve body assembly disassembly and reassembly s6rw0d5106051 caution ! When replacing pressure control solenoid valve and/or tcc pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing press...

  • Page 783

    Automatic transmission/transaxle: 5a-135 reassembly reverse disassembly procedure for assembly, noting the following points. • shift solenoid valve-a and -b are identical • after applying a/t fluid to new o-rings, fit them to solenoid valves, then install solenoid valves to valve body. • tighten sol...

  • Page 784

    5a-136 automatic transmission/transaxle: differential assembly disassembly and reassembly s6rw0d5106053 disassembly 1) remove final gear bolts (1), and then final gear (2). 2) remove differential side rh bearing by using special tools. Special tool (a): 09926–37610 (b): 09926–37610–001 (c): 09926–37...

  • Page 785

    Automatic transmission/transaxle: 5a-137 2) as shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. 3) tighten final gear bolts (1) to specified torque. Note to avoid rust, apply a/t fluid to final driven gear after installation. Tightening torque final...

  • Page 786

    5a-138 automatic transmission/transaxle: torque converter housing disassembly and reassembly s6rw0d5106055 disassembly 1) remove fluid reservoir rh plate (1) and lubrication tube clamp (2). 2) remove lubrication lh tube (1) and rh tube (2). Note do not bend lubrication tube with excessive force. 3) ...

  • Page 787

    Automatic transmission/transaxle: 5a-139 reassembly 1) after applying a/t fluid to new o-rings, fit them to housing plugs. Finally install plugs to torque converter housing. Tightening torque torque converter housing plug (a): 7.5 n·m (0.75 kgf-m, 5.5 lb-ft) 2) using special tools, assemble differen...

  • Page 788

    5a-140 automatic transmission/transaxle: transaxle case disassembly and reassembly s6rw0d5106056 disassembly 1) remove differential side oil seal (1). 2) remove countershaft lh bearing cup and shim with special tools. Special tool (a): 09944–96011 (b): 09942–15511 3) remove differential side lh bear...

  • Page 789

    Automatic transmission/transaxle: 5a-141 3) install new differential side oil seal to transaxle case by using special tools. Special tool (a): 09913–75810 differential side oil seal installing depth “a”: 3.8 – 4.8 mm (0.15 – 0.19 in.) 4) apply grease to oil seal lip. “a”: grease 99000–25030 (suzuki ...

  • Page 790

    5a-142 automatic transmission/transaxle: one-way clutch no.1 assembly 1) install one-way clutch no.1 assembly (2) to rear planetary sun gear subassembly (1). 2) securing rear planetary sun gear subassembly, ensure that one-way clutch no.1 assembly rotates only in one direction. If the one-way clutch...

  • Page 791

    Automatic transmission/transaxle: 5a-143 countershaft bearing preload 1) after applying a/t fluid to countershaft assembly (1) and differential assembly (2), fit them. 2) install torque converter housing to transaxle case, then tighten bolts to specified torque. Tightening torque torque converter ho...

  • Page 792

    5a-144 automatic transmission/transaxle: automatic transaxle unit assembly s6rw0d5106058 caution ! • automatic transaxle consists of highly precise parts. As even flaw in small part may cause oil leakage or decrease in function, check each part carefully before installation. • clean all parts with c...

  • Page 793

    Automatic transmission/transaxle: 5a-145 6) install parking lock pawl bracket (1) to transaxle case. Tightening torque parking lock pawl bracket bolt (a): 7.5 n·m (0.75 kgf-m, 5.5 lb-ft) 7) after applying a/t fluid to new o-rings, install them to 1st and reverse brake piston (3). 8) install 1st and ...

  • Page 794

    5a-146 automatic transmission/transaxle: 12) install 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations as shown in figure. 13) using special tools, measure 1st and reverse brake piston stroke when compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – ...

  • Page 795

    Automatic transmission/transaxle: 5a-147 16) install new planetary ring gear subassembly (1) to reduction drive gear (3) by using special tools and hydraulic press. Caution ! • do not reuse planetary ring gear subassembly. Otherwise it may cause damage to planetary gear unit and/or reduction gears. ...

  • Page 796

    5a-148 automatic transmission/transaxle: 20) check for correct installation of planetary gear assembly as follows. Measure the distance “a” by using micrometer caliper (1) and straightedge (2). If measured value is out of specification, remove planetary gear assembly and reinstall it properly. Dista...

  • Page 797

    Automatic transmission/transaxle: 5a-149 26) apply a/t fluid to 2nd brake piston assembly (1), and align the projection of 2nd brake piston assembly with the groove of transaxle case, then put together. 27) install 2nd brake piston snap ring (1) by using special tool and hydraulic press. Caution ! D...

  • Page 798

    5a-150 automatic transmission/transaxle: 31) install o/d and 2nd coast brake retaining plate snap ring (1). Caution ! Be sure to install o/d and 2nd coast brake retaining plate snap ring correctly in groove of transaxle case. 32) after applying grease to slide contact face of planetary carrier thrus...

  • Page 799

    Automatic transmission/transaxle: 5a-151 39) after applying a/t fluid to intermediate shaft thrust bearing rear race (3), thrust bearing (2) and front race (1), install them to forward and reverse clutch assembly (4). Bearing race dimension 40) apply a/t fluid to forward and reverse clutch assembly ...

  • Page 800

    5a-152 automatic transmission/transaxle: 43) measure o/d and 2nd coast brake piston stroke. • measure dimension “a” from end face of transaxle case to o/d and 2nd coast brake rear plate (1) using straightedge and micrometer caliper. • measure dimension “b” from o/d and 2nd coast brake piston (2) to ...

  • Page 801

    Automatic transmission/transaxle: 5a-153 48) install transaxle rear cover assembly on transaxle case. 49) install hook (2) to location shown in figure. 50) tighten rear cover bolts (1). Tightening torque rear cover bolt (a): 25 n·m (2.5 kgf-m, 18.0 lb-ft) 51) install fluid reservoir lh plate (1). Ti...

  • Page 802

    5a-154 automatic transmission/transaxle: 57) apply a/t fluid to direct clutch assembly (1). Install direct clutch assembly while rotating clockwise and counterclockwise frequently to fit clutch discs to mating hub. Note before installation, align teeth of direct clutch discs to facilitate installati...

  • Page 803

    Automatic transmission/transaxle: 5a-155 61) measure input shaft thrust play. Apply dial gauge onto input shaft end (1) and measure thrust play of input shaft. Special tool (a): 09900–20607 (b): 09900–20701 input shaft thrust play 0.3 – 0.9 mm (0.012 – 0.035 in.) when input shaft thrust play is out ...

  • Page 804

    5a-156 automatic transmission/transaxle: 68) install new o-rings to each accumulator piston and apply a/t fluid to them. Accumulator o-ring dimension note make sure that o-rings are not twisted or caught when installing. 69) install b1, c1, c2 accumulator pistons and springs. Accumulator piston iden...

  • Page 805

    Automatic transmission/transaxle: 5a-157 72) after applying a/t fluid to new o-ring, fit it to valve body harness connector (3), then install valve body harness to transaxle case. Caution ! When put valve body harness (1) into transaxle case, take care not to damage transmission fluid temperature se...

  • Page 806

    5a-158 automatic transmission/transaxle: 76) install oil strainer assembly (1). Tightening torque oil strainer bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) 77) install oil cleaner magnets (1) in oil pan (2). Note if metal particles are attached to the magnets, clean them before installing. 78) install ne...

  • Page 807

    Automatic transmission/transaxle: 5a-159 83) install select cable bracket (1). Tightening torque select cable bracket bolt (a): 23 n·m (2.3 kgf-m, 17.0 lb-ft) 84) apply a/t fluid to o-rings of each sensor and install input shaft speed sensor (1) and output shaft speed sensor (vss) (2). Tightening to...

  • Page 808

    5a-160 automatic transmission/transaxle: 94) install manual select lever (1). Tightening torque manual select lever nut (a): 13 n·m (1.3 kgf-m, 9.5 lb-ft) 95) install engine mounting lh bracket (1). Tighten engine mounting lh bracket bolts and nut to specified torque referring to “engine mountings c...

  • Page 809

    Automatic transmission/transaxle: 5a-161 specifications tightening torque specifications s6rw0d5107001 note the specified tightening torque is also described in the following. “select cable components” “automatic transaxle unit components” “automatic transaxle assembly components” “oil pump assembly...

  • Page 810

    5a-162 automatic transmission/transaxle: special tools and equipment recommended service material s6rw0d5108001 note required service material is also described in the following. “select cable components” “automatic transaxle assembly components” “oil pump assembly components” “direct clutch assembl...

  • Page 811

    Automatic transmission/transaxle: 5a-163 09913–84510 09913–85210 bearing installer bearing installer ) / ) / ) / ) ) 09923–78210 09924–74510 bearing installer bearing and oil seal handle ) ) / ) / ) / ) 09925–37811–001 09925–88210 oil pressure gauge bearing puller attachment ) ) / ) 09925–98210 0992...

  • Page 812

    5a-164 automatic transmission/transaxle: 09926–97620 09926–98310 spring compressor clutch spring compressor ) / ) ) / ) 09928–06050 09942–15511 differential preload adapter sliding hammer ) / ) ) / ) / ) / ) 09944–78210 09944–88220 bearing installer support oil seal installer ) / ) ) / ) / ) / ) 099...

  • Page 813

    Manual transmission/transaxle: 5b-1 transmission / transaxle manual transmission/transaxle general description manual transaxle construction s6rw0d5201001 the transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts-input shaft, countershaft...

  • Page 814

    5b-2 manual transmission/transaxle: 4wd 2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub 3. Input shaft 5th gear 8. Reverse gear shaft 13. Countershaft 5th gear 18. Countershaft 1st gear 4. Input shaft 4th gear 9. Reverse idler gear 14. Countershaft 4th gear 19. Final...

  • Page 815

    Manual transmission/transaxle: 5b-3 gear shift mechanism the gear shifting control system consists of the following main parts. Movement of gear shift control lever is transmitted to gear shift & select shaft through gear shift and gear select cables. I5rw0a520003-02 1. Gear shift control cable 7. R...

  • Page 816

    5b-4 manual transmission/transaxle: 5th & reverse gear shift cam 5th & reverse gear shift cam, cam guide return spring and 5th to reverse interlock guide bolt are provided to prevent the gear from being directly shifted from 5th to reverse. 1) when shift lever is at neutral position between 3rd and ...

  • Page 817

    Manual transmission/transaxle: 5b-5 diagnostic information and procedures manual transaxle symptom diagnosis s6rw0d5204001 repair instructions manual transaxle oil level check s6rw0d5206001 1) lift up vehicle and check oil leakage. Repair leaky point, if any. 2) remove oil level / filler plug (1) an...

  • Page 818

    5b-6 manual transmission/transaxle: manual transaxle oil change s6rw0d5206002 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 service wo...

  • Page 819

    Manual transmission/transaxle: 5b-7 differential side oil seal replacement s6rw0d5206003 1) lift up vehicle and drain transaxle oil. 2) remove drive shaft assembly and center shaft referring to “front drive shaft assembly removal and installation in section 3a”. 3) remove oil seal (1) by using speci...

  • Page 820

    5b-8 manual transmission/transaxle: gear shift control lever and cable components s6rw0d5206004 1 7 3 4 (a) 6 a 8 (b) 2 (c) 5 9 a i5rw0a520008-02 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut : 10 n ⋅m (1.0 kgf-m, 7.5 lb-ft) 2. Cable bracket bolt 7. Gear shift co...

  • Page 821

    Manual transmission/transaxle: 5b-9 gear shift control lever and cable removal and installation s6rw0d5206005 removal 1) remove console box. 2) disconnect cable ends (5) from pivot (6) of gear shift control lever assembly by removing clip. 3) disconnect gear shift and select control cables (1) from ...

  • Page 822

    5b-10 manual transmission/transaxle: 3) apply grease to pin (5) of gear shift control lever, and then install adjuster (1) into pin of gear shift control lever securely. “a”: grease 99000–25011 (suzuki super grease a) 4) push cable end holder (2) in the direction of a. Note at this time, do not appl...

  • Page 823

    Manual transmission/transaxle: 5b-11 manual transaxle unit components s6rw0d5206009 3 7 (a) 4 6 5 8 2 [a] 1 10 (a) 7 (a) 9 (c) 11 (b) i5rw0a520010-02 [a]: forward 5. Ground cable bolt 10. Transaxle to engine nut 1. Engine 6. Ground cable 11. Stiffener bolt 2. Transaxle 7. Transaxle to engine bolt : ...

  • Page 824

    5b-12 manual transmission/transaxle: manual transaxle unit dismounting and remounting s6rw0d5206010 dismounting 1) drain coolant. 2) remove battery and tray with ecm. 3) remove air cleaner case and resonator. 4) remove clutch fluid pipe referring to “clutch fluid pipe removal and installation in sec...

  • Page 825

    Manual transmission/transaxle: 5b-13 gear shift and select shaft assembly components s6rw0d5206011 1 10 3 4 9 2 6 12 7 11 5 8 (a) (a) (a) (a) 1217g 1217g 1217g a 13 i6rw0c520001-01 1. Gear shift & select shaft 7. Gear shift guide case bolt no.1 : apply sealant 99000-31260 to bolt thread. 13. Oil sea...

  • Page 826

    5b-14 manual transmission/transaxle: gear shift and select shaft assembly removal and installation s6rw0d5206012 removal 1) remove battery and tray with ecm. 2) disconnect gear shift and gear select control cables from transaxle. 3) remove gear shift interlock bolt (1) and 5th to reverse interlock g...

  • Page 827

    Manual transmission/transaxle: 5b-15 gear shift and select shaft assembly disassembly and reassembly s6rw0d5206013 1) push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and specified spring pin removers as shown bellow. Special tool (a): 09922–85811 4...

  • Page 828

    5b-16 manual transmission/transaxle: manual transaxle assembly components s6rw0d5206014 i5rw0a520018-03 1. Transaxle right case 22. Shift fork bolt : apply thread lock 99000-32110 to all around thread part of bolt. 2. Transaxle left case : apply sealant 99000-31260 to mating surface of left case and...

  • Page 829

    Manual transmission/transaxle: 5b-17 fifth gear disassembly and reassembly s6rw0d5206015 disassembly 1) remove cover bolts and take off transaxle side cover. Caution ! Care should be taken not to distort side cover when it is removed from left case. 2) using special tool, remove circlip (1). Special...

  • Page 830

    5b-18 manual transmission/transaxle: reassembly 1) install countershaft 5th gear (1) to countershaft facing machined boss “a” inward. 2) apply transaxle oil to needle bearing, and install it to input shaft. 3) install input shaft 5th gear (1) to input shaft. 4) install special tool in order to stop ...

  • Page 831

    Manual transmission/transaxle: 5b-19 7) fit 5th gear shift fork (1) to sleeve (3) and hub (2) assembly, and install them into input shaft and gear shift shaft, aligning punch mark (4) with matching mark (5) on input shaft. 8) tighten shift fork shaft bolt (2) to which thread lock cement has been app...

  • Page 832

    5b-20 manual transmission/transaxle: 2) remove bearing set shim. 3) remove snap ring (1) using special tool. Special tool (a): 09900–06107 4) remove gear shift locating bolts (1), then take out locating springs and steel balls. 5) remove reverse shaft bolt (2) with washer. 6) remove transaxle case b...

  • Page 833

    Manual transmission/transaxle: 5b-21 reassembly 1) install differential assembly into right case. 2) join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft (3) assemblies all together, then install them into right case (1) so as not to damage oil seal ...

  • Page 834

    5b-22 manual transmission/transaxle: 6) clean mating surfaces of both right and left cases, apply sealant to left case (2) as shown in the figure by such amount that its section is 1.5 mm (0.059 in.) in diameter then mate it with right case (1). “a”: sealant 99000–31260 (suzuki bond no.1217g) 7) tig...

  • Page 835

    Manual transmission/transaxle: 5b-23 12) to seat countershaft left bearing outer race (2) to bearing cone, tap cup by using special tool and plastic hammer. Special tool (a): 09913–70123 13) before selecting shim, keep pushing outer race with the power of 100 n (10.0 kgf) and turn countershaft (2) 1...

  • Page 836

    5b-24 manual transmission/transaxle: 16) place left case plate (2) inserting its end in groove of shift guide shaft (4) and then tighten bolts (1) to which thread lock cement has been applied. Note after tightening bolts, make sure that countershaft can be rotated by hand feeling certain load. “a”: ...

  • Page 837

    Manual transmission/transaxle: 5b-25 2) install countershaft right bearing outer race (1) by using special tools and hammer. Special tool (a): 09913–75821 (b): 09924–84510–004 3) install differential side bearing outer race by using special tool and hammer. Special tool (a): 09924–74510 (b): 09925–1...

  • Page 838

    5b-26 manual transmission/transaxle: reassembly 1) if oil gutter has been removed, install it with bolt to which thread lock cement has been applied. “a”: thread lock cement 99000–32110 (thread lock cement super 1322) tightening torque oil gutter bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) 2) select dif...

  • Page 839

    Manual transmission/transaxle: 5b-27 input shaft and countershaft components s6rw0d5206019 i3rh0a520017-01 1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer center cone 2. Oil seal : apply grease 99000-25010 to oil seal lip. 13. Circlip 24. 2nd gear synchronizer inner ring 3. Inp...

  • Page 840

    5b-28 manual transmission/transaxle: input shaft disassembly and reassembly s6rw0d5206020 disassembly 1) remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and hydraulic press. 2) drive out 5th gear spacer (2), left bearing (3) and 4th gear (4) all at once using pulle...

  • Page 841

    Manual transmission/transaxle: 5b-29 reassembly 1) clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary. 2) check clearance “a” between synchronizer ring (2) and gear (1), key slot width “b” in synchronizer ring and each chamfered tooth of gear and...

  • Page 842

    5b-30 manual transmission/transaxle: 6) install 3rd gear needle bearing (4), apply oil to it, then install 3rd gear (1) and synchronizer ring (2). 7) drive in high speed sleeve & hub assembly (3) by using special tool and hydraulic press. Note • while press-fitting sleeve & hub, make sure that synch...

  • Page 843

    Manual transmission/transaxle: 5b-31 countershaft disassembly and reassembly s6rw0d5206021 disassembly 1) drive out left bearing cone (2) with 4th gear (3) by using puller (4) and hydraulic press. Caution ! • use puller and hydraulic press that will bear at least 5 ton (11,000 lb) safely. • to avoid...

  • Page 844

    5b-32 manual transmission/transaxle: 6) disassemble synchronizer sleeve & hub assembly. 7) take out 1st gear needle bearing from shaft. 8) in order to remove right bearing (1) from countershaft, grind with a grinder (2) one part “a” of right bearing (1) as illustrated till it becomes thin. Caution !...

  • Page 845

    Manual transmission/transaxle: 5b-33 5) fit low speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure. Note • no specific direction is assigned to each key but it is assigned as sleeve & hub assembly. • size of low speed synchronizer keys and s...

  • Page 846

    5b-34 manual transmission/transaxle: 9) install circlip (1) and confirm that circlip is installed in groove securely. Install needle bearing (2) and apply oil to needle bearing. With synchronizer outer ring (3), center cone (4) and inner ring (5) put together and installed to 2nd gear (6) as shown i...

  • Page 847

    Manual transmission/transaxle: 5b-35 gear shift shaft components s6rw0d5206022 5th and reverse gear shift shafts disassembly and reassembly s6rw0d5206023 disassembly disassemble component parts by using special tool and hammer. Special tool : 09922–85811 reassembly replace or correct parts as requir...

  • Page 848

    5b-36 manual transmission/transaxle: differential components s6rw0d5206025 differential disassembly and reassembly s6rw0d5206026 disassembly 1) using special tool, remove left bearing (1). Special tool (a): 09913–65135 (b): 09913–85230 2) using special tool, remove right bearing (1). Special tool (a...

  • Page 849

    Manual transmission/transaxle: 5b-37 3) support differential case (1) with soft jawed vise and remove final gear bolts then take out final gear. 4) drive out differential pinion shaft (3) pin by using special tool and hammer and then disassemble components parts. Special tool (a): 09922–85811 reasse...

  • Page 850

    5b-38 manual transmission/transaxle: 4) press-fit right bearing (1) by using special tools and hydraulic press. Special tool (a): 09925–15410 (b): 09924–07720 (c): 09913–85230 5) hold differential assembly with soft jawed vise (3), install final gear (2) and then tighten new final gear bolts (1). Ca...

  • Page 851

    Manual transmission/transaxle: 5b-39 special tools and equipment recommended service material s6rw0d5208001 note required service material is also described in the following. “gear shift control lever and cable components” “gear shift and select shaft assembly components” “manual transaxle assembly ...

  • Page 852

    5b-40 manual transmission/transaxle: 09913–76010 09913–80113 bearing installer bearing installer ) / ) ) / ) / ) 09913–84510 09913–85210 bearing installer bearing installer ) ) / ) 09913–85230 09922–85811 bearing remover tool spring pin remover (4.5 mm) ) / ) / ) ) / ) / ) 09923–78210 09924–07710 be...

  • Page 853

    Manual transmission/transaxle: 5b-41 09940–54910 09940–54950 front fork oil seal install driver bearing installer attachment ) ) 09941–64511 09942–15511 bearing and oil seal remover (30 mm min.) sliding hammer ) ) 09944–96011 09952–06010 bearing outer race remover dial gauge plate no.1 ) ).

  • Page 854: Clutch

    5c-1 clutch: transmission / transaxle clutch general description clutch (hydraulic type) construction s6rw0d5301001 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...

  • Page 855

    Clutch: 5c-2 diagnostic information and procedures clutch system symptom diagnosis s6rw0d5304001 condition possible cause correction / reference item slipping improper clutch pedal free travel bleed air or replace master cylinder. Worn or oily clutch disc facing replace disc. Warped disc, pressure p...

  • Page 856

    5c-3 clutch: repair instructions clutch pedal inspection s6rw0d5306001 cylinder push rod play “a” 1) press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and measure how much pedal has moved (push rod play) as represented by “a” as shown. Push rod play “a”: m...

  • Page 857

    Clutch: 5c-4 clutch fluid pipe and hose location s6rw0d5306004 clutch fluid pipe removal and installation s6rw0d5306005 removal caution ! Do not allow fluid to get on painted surface. It may cause painted surface damage. 1) remove dust and dirt from each joint of pipe to be disconnected and clean ar...

  • Page 858

    5c-5 clutch: clutch master cylinder removal and installation s6rw0d5306007 removal 1) clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake master cylinder reservoir. 2) disconnect clutch fluid pipe (4) from clutch master cylinder (1) referring to “clutc...

  • Page 859

    Clutch: 5c-6 installation 1) install clutch operating cylinder assembly (2) to transaxle. Tighten new 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 operating cylinde...

  • Page 860

    5c-7 clutch: clutch cover, clutch disc and flywheel removal and installation s6rw0d5306011 removal 1) dismount manual transaxle assembly referring to “manual transaxle unit dismounting and remounting in section 5b”. 2) hold flywheel with special tool and remove clutch cover bolts (1), clutch cover (...

  • Page 861

    Clutch: 5c-8 2) using special tool, install input shaft bearing to flywheel (1). Special tool (b): 09925–98210 3) aligning clutch disc to flywheel center using special tool, install clutch cover (1) and bolts (2). Then tighten bolts (2) to specification. Note • while tightening clutch cover bolts, c...

  • Page 862

    5c-9 clutch: clutch disc measure depth of rivet head depression, i.E. Distance between rivet head and facing surface. If depression is found to have reached service limit at any of rivet holes (2), replace clutch disc assembly (1). Rivet head depth standard: 1.65 – 2.25 mm (0.06 – 0.09 in.) limit: 0...

  • Page 863

    Clutch: 5c-10 special tools and equipment recommended service material s6rw0d5308001 special tool s6rw0d5308002 material suzuki recommended product or specification note grease suzuki silicone grease p/no.: 99000–25100 ) suzuki super grease i p/no.: 99000–25210 ) 09921–26020 09923–36320 bearing remo...

  • Page 864

    5c-11 clutch:.

  • Page 865: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions on steering........................................ 6-1 steering general diagnosis..............

  • Page 866

    6-ii table of contents tie-rod end inspection.....................................6c-37 steering shaft joint on-vehicle inspection.......6c-37 steering gear case assembly removal and installation.......................................................6c-37 steering rack boot inspection..................

  • Page 867: Precautions

    Precautions: 6-1 steering precautions precautions precautions on steering s6rw0d6000001 air bag warning refer to “air bag system service warning in section 00”. Precautions for steering diagnosis refer to “precautions for steering diagnosis in section 6a”. Service precautions of steering wheel and c...

  • Page 868: Steering General Diagnosis

    6a-1 steering general diagnosis: steering steering general diagnosis precautions precautions for steering diagnosis s6rw0d6100001 since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the ve...

  • Page 869

    Steering general diagnosis: 6a-2 steering system inspection s6rw0d6104002 check steering system referring to the following items. Erratic steering when braking worn wheel bearings replace wheel bearing. Broken or sagging coil springs replace coil spring. Wheel tires are inflated unequally inflate ti...

  • Page 870: Steering Wheel and Column

    6b-1 steering wheel and column: steering steering wheel and column precautions service precautions of steering wheel and column s6rw0d6200001 for service precautions, refer to “precautions on service and diagnosis of air bag system in section 8b”. Service and diagnosis for diagnosis and servicing, r...

  • Page 871

    Steering wheel and column: 6b-2 diagnostic information and procedures checking steering column for accident damage s6rw0d6204001 note vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed may have a damaged or misaligned steering column....

  • Page 872

    6b-3 steering wheel and column: repair instructions steering wheel and column construction s6rw0d6206001 4 6 8 13 11 (b) 2 (a) 12 (b) 10 (c) 9 7 (c) 5 1 3 i6rw0c620001-01 1. Steering wheel 9. Steering column assembly mounting nut no.1 2. Steering shaft nut 10. Steering column assembly mounting nut n...

  • Page 873

    Steering wheel and column: 6b-4 steering wheel removal and installation s6rw0d6206002 caution ! Do not turn the contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively) with steering wheel removed, or coil will ...

  • Page 874

    6b-5 steering wheel and column: 4) connect horn connector and audio control switch connector, if necessary. 5) install driver air bag (inflator) module to steering wheel. Refer to “driver air bag (inflator) module removal and installation in section 8b”. 6) connect negative (–) cable to battery. 7) ...

  • Page 875

    Steering wheel and column: 6b-6 3) install steering column upper cover (1) and lower cover (2). Caution ! When installing covers, be careful so that each lead wire is not caught between covers. Otherwise, each lead wire is damaged. 4) install steering wheel to steering column. Refer to “steering whe...

  • Page 876

    6b-7 steering wheel and column: removal warning ! Never rest a steering column assembly on the steering wheel with the air bag (inflator) module face down and column vertical. Otherwise, personal injury may result. 1) disconnect negative (–) cable at battery. 2) disable air bag system. Refer to “dis...

  • Page 877

    Steering wheel and column: 6b-8 3) align flat part “a” of steering lower shaft (1) with bolt hole “b” of shaft joint (2) of column as shown. Then insert lower shaft into shaft joint of steering column. 4) tighten lower shaft upper joint bolt (3) to specified torque. Caution ! After tightening column...

  • Page 878

    6b-9 steering wheel and column: steering lock assembly (ignition switch) removal and installation s6rw0d6206011 removal 1) remove steering column. Refer to “steering column removal and installation”. 2) using center punch (1), loosen and remove steering lock mounting bolts (2). Note use care not to ...

  • Page 879

    Steering wheel and column: 6b-10 steering lower shaft removal and installation s6rw0d6206012 caution ! Never turn steering wheel while steering lower shaft is removed. Should it have been turned and contact coil have got out of its centered position, it needs to be centered again. Also, turning stee...

  • Page 880

    6b-11 steering wheel and column: specifications tightening torque specifications s6rw0d6207001 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 “f...

  • Page 881

    Power assisted steering system: 6c-1 steering power assisted steering system precautions p/s system note s6rw0d6300001 note all steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. The...

  • Page 882

    6c-2 power assisted steering system: general description p/s system description s6rw0d6301001 this electronic power steering (eps) system consists of a power steering (p/s) control module (3), a torque sensor (4), a p/s motor (5). In this system, the p/s control module determines the level and direc...

  • Page 883

    Power assisted steering system: 6c-3 eps diagnosis general description s6rw0d6301002 the p/s system in this vehicle is controlled by the p/s control module. The p/s control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have ...

  • Page 884

    6c-4 power assisted steering system: schematic and routing diagram eps system wiring circuit diagram s6rw0d6302001 [a] 1 2 3 4 5 3 2 1 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 1 2 [b] 1 2 [c] [d] 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 26 25 24 23 22 21 20 19 18 17 32 31 30 29 28 27 [f] [e] 1 2 b...

  • Page 885

    Power assisted steering system: 6c-5 terminal arrangement of p/s control module coupler (viewed from harness side) diagnostic information and procedures eps system check s6rw0d6304001 warning ! Carry out test drive in light traffic area to prevent an accident. Refer to the following items for the de...

  • Page 886

    6c-6 power assisted steering system: note • as execution of “dtc clearance” will clear all dtcs, be sure to record all dtcs before service. • dtc c1122 is indicated when ignition switch is at on position and engine is not running, it means that nothing is abnormal. • current dtc and history dtc can ...

  • Page 887

    Power assisted steering system: 6c-7 step 1: customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analy...

  • Page 888

    6c-8 power assisted steering system: step 8: steering symptom diagnosis and p/s system symptom diagnosis perform basic steering system check according to “steering symptom diagnosis in section 6a” first. When the end of the flow has been reached, check the parts of the system suspected as a possible...

  • Page 889

    Power assisted steering system: 6c-9 dtc clearance s6rw0d6304004 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel at driver’s seat side. Special tool (a): suzuki scan tool 3) turn ignition switch to on posi...

  • Page 890

    6c-10 power assisted steering system: ) c1121 no vehicle speed signal (60 seconds or more) vehicle speed signal is 0 km/h even though engine speed is more than 4000 rpm for more than 60 seconds continuously (before elapse of 5 min from engine start) or vehicle speed signal is 0 km/h even though engi...

  • Page 891

    Power assisted steering system: 6c-11 visual inspection s6rw0d6304006 visually check the following parts and systems. ) c1141 p/s motor circuit voltage voltage between both motor drive circuit is more than 8.5 v or less than 0.2 v for 0.5 second continuously while motor is not driven. • p/s motor ci...

  • Page 892

    6c-12 power assisted steering system: scan tool data s6rw0d6304007 note when p/s motor is cold condition (that is, armature coil of p/s motor is not heated), normal value with asterisk (*) mark in the following table is displayed on scan tool scan tool data definitions power supply voltage this para...

  • Page 893

    Power assisted steering system: 6c-13 motor drive voltage (v) this parameter indicates the voltage between motor terminals. System power status (eps system power, on, off) this parameter indicates input status of eps system power supply. Ign switch status (on, off) this parameter indicates the condi...

  • Page 894

    6c-14 power assisted steering system: dlc and its communication check (no communication to p/s control module) s6rw0d6304009 wiring diagram troubleshooting [a] 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 1 2 [b] 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 26 25 24 23 22 21 20 19 18 17 32 31 30 29 ...

  • Page 895

    Power assisted steering system: 6c-15 3 communication check 1) check dlc terminal for deformation and wear. 2) if it is in good condition, connect suzuki scan tool to dlc with ignition switch tuned off. 3) check if communication is possible by making communication with other control modules (bcm, ab...

  • Page 896

    6c-16 power assisted steering system: “eps” warning light does not come on with ignition switch turned on before engine starts s6rw0d6304010 wiring diagram 8 scan tool operation check 1) check if communication is possible by making communication with other vehicles. Is it possible to communicate wit...

  • Page 897

    Power assisted steering system: 6c-17 circuit description operation (on/off) of “eps” warning light is controlled by p/s control module through combination meter. If the p/s system is in good condition, p/s control module turns “eps” warning light on at the ignition switch on, and then turns it off ...

  • Page 898

    6c-18 power assisted steering system: “eps” warning light remains on steady after engine starts s6rw0d6304011 wiring diagram refer to ““eps” warning light does not come on with ignition switch turned on before engine starts”. Circuit description operation (on/off) of “eps” warning light is controlle...

  • Page 899

    Power assisted steering system: 6c-19 dtc c1111 / c1113 / c1115: torque sensor circuit failure s6rw0d6304012 dtc c1111: steering torque sensor (main) circuit voltage dtc c1113: steering torque sensor (main and sub) circuit correlation dtc c1115: steering torque sensor (sub) circuit voltage wiring di...

  • Page 900

    6c-20 power assisted steering system: dtc troubleshooting step action yes no 1 was “eps system check” performed? Go to step 2. Go to “eps system check”. 2 dtc check is dtc c1153 or c1116 indicated, together? Go to applicable diag. Flow. Go to step 3. 3 torque sensor signal circuit check 1) with igni...

  • Page 901

    Power assisted steering system: 6c-21 dtc c1116: steering torque sensor power supply circuit s6rw0d6304013 wiring diagram dtc detecting condition and trouble area dtc troubleshooting [a] 1 2 3 4 5 3 2 1 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 1 2 [b] [c] lt grn/ blk wht grn blk e11-1 e11-10 e11...

  • Page 902

    6c-22 power assisted steering system: dtc c1121 / c1123 / c1124: vehicle speed signal circuit failure s6rw0d6304014 dtc c1121: no vehicle speed signal (60 seconds or more) dtc c1123: no vehicle speed signal (30 seconds or more) dtc c1124: vehicle speed performance (impossible deceleration) wiring di...

  • Page 903

    Power assisted steering system: 6c-23 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area dtc c1121: vehicle speed signal is 0 km/h even though engine speed is more than 4000 rpm for more than 60 seconds continuously (before elapse of 5 min from engine s...

  • Page 904

    6c-24 power assisted steering system: dtc c1122: engine speed signal s6rw0d6304015 wiring diagram 6 vehicle speed signal circuit check 1) with ignition switch turned off, disconnect connectors from bcm. 2) check bcm connector for proper connection. 3) if ok, turn on ignition switch, measure voltage ...

  • Page 905

    Power assisted steering system: 6c-25 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area engine speed signal is less than 220 rpm for more than 0.8 seconds. Or engine speed signal is less than 220 rpm for more than 20 seconds continuously even though ve...

  • Page 906

    6c-26 power assisted steering system: dtc c1141 / c1142 / c1143 / c1145: motor circuit failure s6rw0d6304016 dtc c1141: p/s motor circuit voltage dtc c1142: p/s motor circuit range/performance dtc c1143: p/s motor circuit current too high dtc c1145: p/s motor circuit current too low wiring diagram d...

  • Page 907

    Power assisted steering system: 6c-27 dtc troubleshooting dtc c1153: p/s control module power supply circuit s6rw0d6304017 wiring diagram dtc detecting condition and trouble area step action yes no 1 was “eps system check” performed? Go to step 2. Go to “eps system check”. 2 dtc check is dtc c1153 a...

  • Page 908

    6c-28 power assisted steering system: dtc troubleshooting dtc c1155: p/s control module internal failure s6rw0d6304018 wiring diagram refer to “dtc c1153: p/s control module power supply circuit”. Dtc detecting condition and trouble area dtc troubleshooting step action yes no 1 was “eps system check...

  • Page 909

    Power assisted steering system: 6c-29 p/s control module power supply and ground circuit check s6rw0d6304019 wiring diagram refer to “dtc c1153: p/s control module power supply circuit”. Dtc troubleshooting step action yes no 1 circuit fuse check 1) disconnect p/s control module connector with ignit...

  • Page 910

    6c-30 power assisted steering system: inspection of p/s control module and its circuits s6rw0d6304020 the p/s control module and its circuits can be checked at the p/s control module wiring couplers by measuring voltage and resistance. Caution ! P/s control module cannot be checked by itself. It is ...

  • Page 911

    Power assisted steering system: 6c-31 terminal wire color circuit normal voltage condition e11-1 lt grn/blk ignition switch signal for p/s control module 10 – 14 v ignition switch on e11-2 — — — — e11-3 — — — — e11-4 ppl vehicle speed signal *0 – 1 v ↑↓ 8 – 14 v (“reference waveform no.7” under “ins...

  • Page 912

    6c-32 power assisted steering system: note *: the voltage of this circuit may not be checked by voltmeter. If so, use oscilloscope. Reference waveform no.1 motor output signal 1(1), motor output signal 2(2), with engine idling e11-20 red reference sensor power supply for torque sensor about 3.0 – 3....

  • Page 913

    Power assisted steering system: 6c-33 reference waveform no.2 motor output signal 1(1), motor output signal 2(2), with engine idling reference waveform no.3 motor output signal 1(1), motor output signal 2(2), with engine idling measurement terminal ch1: “e12-1” to vehicle body ground ch1: “e12-2” to...

  • Page 914

    6c-34 power assisted steering system: steering wheel play check s6rw0d6304021 • check steering wheel for looseness or rattle by moving it in its shaft direction and lateral direction. If found defective, repair or replace. • check steering wheel for play, holding vehicle in straight forward conditio...

  • Page 915

    Power assisted steering system: 6c-35 repair instructions steering gear case assembly components s6rw0d6306001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle the figure is symmetrical. 8 6 5 9 13 18 17 3 12 7 (b) (b) (a) (c) 2 1 (e) (d) 3 (a) 2 5 6 8 7 9 (b) (b) 16...

  • Page 916

    6c-36 power assisted steering system: tie-rod end boot on-vehicle inspection s6rw0d6306002 check boot for crack and damage. If any defect is found, replace it with a new one. Tie-rod end removal and installation s6rw0d6306003 removal 1) hoist vehicle, and then remove front wheel. 2) remove tie-rod e...

  • Page 917

    Power assisted steering system: 6c-37 3) inspect for proper toe referring to “front wheel alignment inspection and adjustment in section 2b”. 4) after confirming proper toe, tighten tie-rod end lock nut to specified torque. Tightening torque tie-rod end lock nut (a): 45 n·m (4.5 kgf-m, 32.5 lb-ft) 5...

  • Page 918

    6c-38 power assisted steering system: 2) install steering gear case to vehicle, and then install front suspension frame referring to “front suspension frame, stabilizer bar and/or bushing removal and installation in section 2b”. 3) install steering gear case to suspension frame (3) as follows. A) se...

  • Page 919

    Power assisted steering system: 6c-39 7) unbend bent part of tie-rod lock washer (1). 8) remove tie-rod (3) from rack (2). Installation 1) install tie-rod (1) and new tie-rod lock washer (3) to rack (2). 2) hold rack with soft jawed vise and tighten tie-rod to specified torque. Tightening torque tie...

  • Page 920

    6c-40 power assisted steering system: steering rack plunger removal and installation s6rw0d6306009 removal 1) loosen lock nut (1) with holding damper screw (2). 2) remove lock nut (1), rack damper screw (2), rack plunger spring (3), washer (5), spring washers (6), o-ring (7) and rack plunger (4). In...

  • Page 921

    Power assisted steering system: 6c-41 p/s control module removal and installation s6rw0d6306011 removal 1) disconnect negative cable at battery. 2) remove console box. 3) disconnect connectors (1) from p/s control module. 4) remove p/s control module and bracket (2) from floor panel. 5) separate p/s...

  • Page 922

    6c-42 power assisted steering system: 5) turn on ignition switch without engine running and select scan tool “data list” mode due to checking “sensor (main) torque” and “sensor (sub) torque” displayed on scan tool when steering wheel turned left and right (if used). 6) check that characteristic of t...

  • Page 923

    Power assisted steering system: 6c-43 8) using ammeter (2), check that p/s motor current (1) is as following table with idling engine. If check result is not satisfactory, check p/s control module for torque sensor signal and p/s motor output referring to “inspection of p/s control module and its ci...

  • Page 924

    6c-44 power assisted steering system: special tools and equipment recommended service material s6rw0d6308001 note required service material is also described in the following. “steering gear case assembly components” special tool s6rw0d6308002 material suzuki recommended product or specification not...

  • Page 925: Section 7

    Table of contents 7- i 7 section 7 contents hvac precautions .................................................7-1 precautions............................................................. 7-1 precautions on hvac ........................................... 7-1 heater and ventilation......................

  • Page 926

    7-ii table of contents compressor drive belt removal and installation.......................................................7b-31 compressor assembly removal and installation.......................................................7b-31 compressor assembly components.................7b-32 magnet clutc...

  • Page 927

    Table of contents 7-iii condenser assembly removal and installation.......................................................7b-87 evaporator inspection ....................................... 7b-87 evaporator temperature sensor removal and installation................................................7b...

  • Page 928: Precautions

    7-1 precautions: hvac precautions precautions precautions on hvac s6rw0d7000001 air bag warning refer to “air bag warning in section 00”. A/c system caution refer to “a/c system caution in section 7b” or “a/c system caution in section 7b”. Precautions on servicing a/c system refer to “precautions on...

  • Page 929: Heater and Ventilation

    Heater and ventilation: 7a-1 hvac heater and ventilation general description heater and ventilation construction s6rw0d7101001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6rw0c710001-02 a: air flow 7. Defroste...

  • Page 930

    7a-2 heater and ventilation: schematic and routing diagram heater and ventilation wiring circuit diagram s6rw0d7102001 non–a/c manual a/c refer to “a/c system wiring diagram in section 7b”. Auto a/c refer to “a/c system wiring diagram in section 7b”. Component location electronic control system comp...

  • Page 931

    Heater and ventilation: 7a-3 diagnostic information and procedures heater and ventilation symptom diagnosis s6rw0d7104001 condition possible cause correction / reference item blower motor does not operate with blower speed selector on fuse blown check related fuses, and then check for short circuit ...

  • Page 932

    7a-4 heater and ventilation: repair instructions hvac unit components s6rw0d7106001 for non-a/c and manual a/c, refer to “hvac unit components in section 7b”. For auto a/c, refer to “hvac unit components in section 7b”. Hvac unit removal and installation (non-a/c) s6rw0d7106002 for manual a/c and au...

  • Page 933

    Heater and ventilation: 7a-5 • check for operation and current. A. Put blower motor (1) in a soft-jawed vise. B. Connect battery to blower motor as shown. C. Check if blower motor operates smoothly without noise. D. Check if ammeter indicates the specified current. If measured current is out of spec...

  • Page 934

    7a-6 heater and ventilation: blower motor relay inspection s6rw0d7106007 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system in section 8b”. 3) remove junction block assembly (2). 4) disconnect blower motor relay (1) from junction block assem...

  • Page 935

    Heater and ventilation: 7a-7 hvac control unit removal and installation s6rw0d7106009 removal 1) disconnect negative (–) cable at battery. 2) remove steering column hole cover from instrument panel. 3) remove audio unit from instrument panel referring to “audio unit removal and installation (if equi...

  • Page 936

    7a-8 heater and ventilation: b. Move temperature control lever (1) to “max hot” position “a” (lh steering vehicle) or “max cool” position “b” (rh steering vehicle), then fix temperature control inner cable (2) to pin of temperature control lever and fix outer cable (3) to cable lock clamp (4). Lh st...

  • Page 937

    Heater and ventilation: 7a-9 blower speed selector inspection s6rw0d7106010 check blower speed selector for each terminal to terminal continuity. If check result does not meet the following conditions, replace hvac control unit. Air intake selector inspection s6rw0d7106011 • check that there is cont...

  • Page 938

    7a-10 heater and ventilation: installation reverse removal procedure noting the following instruction. • be sure to insert the linkage rod (1) into the hole (2) of air intake control actuator. Air intake control actuator inspection s6rw0d7106013 check air intake control actuator as follows: 1) using...

  • Page 939

    Heater and ventilation: 7a-11 center ventilation louver removal and installation s6rw0d7106014 removal 1) disconnect negative (–) cable from battery. 2) remove audio unit from instrument panel referring to “audio unit removal and installation (if equipped) in section 9c”. 3) remove center ventilatio...

  • Page 940

    7a-12 heater and ventilation: rear duct removal and installation (if equipped) s6rw0d7106016 removal 1) disconnect negative (–) cable at battery. 2) remove front seats referring to “front seat removal and installation in section 9g”. 3) remove console box referring to “console box components in sect...

  • Page 941: Air Conditioning System

    Air conditioning system: manual type 7b-1 hvac air conditioning system manual type precautions a/c system caution s6rw0d7210001 caution ! The a/c system of this vehicle uses hfc-134a (r-134a) refrigerant, specified compressor oil and specified parts. Do not use cfc-12 (r-12) refrigerant, r-12 exclus...

  • Page 942

    7b-2 air conditioning system: manual type refrigerant recovery when discharging refrigerant out of a/c system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant hfc-134a (r-134a) into atmosphere would cause adverse effect to environments referrin...

  • Page 943

    Air conditioning system: manual type 7b-3 manual a/c electronic input output table s6rw0d7211002 a/c operation description at ecm s6rw0d7211003 ecm controls the a/c compressor relay and condenser cooling fan relay according to signals from hvac control unit, a/c refrigerant pressure sensor, ect sens...

  • Page 944

    7b-4 air conditioning system: manual type schematic and routing diagram a/c system air flow diagram s6rw0d7212001 13 12 13 9 9 10 11 11 15 14 17 18 : a : b 4 7 3 5 6 2 16 8 19 1 20 i7rw01721002-03 a: air flow 5. Discharge hose 11. Foot air 17. Air intake door b: refrigerant flow 6. Suction hose 12. ...

  • Page 945

    Air conditioning system: manual type 7b-5 a/c system wiring diagram s6rw0d7212002 [a] 7 wht grn 5 yel blk 3 g154-3 g154-4 g154-7 g154-8 g154-10 g154-13 g154-5 g154-6 g155-5 g155-2 g155-3 g155-7 g155-6 g155-1 g154-9 g154-14 blk/wht yel blu/wht red brn grn/wht red/blk red grn grn/yel red/yel red/blu 2...

  • Page 946

    7b-6 air conditioning system: manual type component location a/c system major components location s6rw0d7213001 7 8 2 4 3 5 6 9 9 (a) (a) (a) (b) (b) (c) 1 i7rw01721004-03 1. Hvac unit 6. Discharge hose : 25 n ⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Compressor 7. Suction hose : 3.5 n ⋅m (0.35 kgf-m, 2.51 lb-f...

  • Page 947

    Air conditioning system: manual type 7b-7 electronic control system components location s6rw0d7213002 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. [a] 8* 9* 10* 11 1 5 7* 6 7* 12 13 14 17 15 16 4 2 3 i6rw0c72100...

  • Page 948

    7b-8 air conditioning system: manual type diagnostic information and procedures a/c system performance inspection s6rw0d7214001 1) confirm that vehicle and environmental conditions are as follows. • vehicle is put indoors. • ambient temperature is within 25 – 35 °c (77 – 95 °f). • relative humidity ...

  • Page 949

    Air conditioning system: manual type 7b-9 10) check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective part referring to the following table. When diagnosing troubles of abnormal pressure on the low...

  • Page 950

    7b-10 air conditioning system: manual type low pressure gauge 11) check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature near air inlet of hvac unit is 30 °c (86 °f) and the one at air outlet of center ventilation louver is 17 °c (62.6 °f), ...

  • Page 951

    Air conditioning system: manual type 7b-11 thermometer at center ventilation louver trouble diagnosis for abnormal pressure s6rw0d7214002 note normal pressure values on high side and low side in following table are measured when the ambient temperature is 30 °c. As normal pressure values on high sid...

  • Page 952

    7b-12 air conditioning system: manual type a/c system inspection at ecm s6rw0d7214003 when checking voltage at ecm terminals related to a/c system, refer to “inspection of ecm and its circuits in section 1a”. 0.05 – 0.15 (0.5 – 1.5) (4.2 – 21.3) 0.7 – 1.0 (7 – 10) (100 – 142) both low and high press...

  • Page 953

    Air conditioning system: manual type 7b-13 a/c system symptom diagnosis s6rw0d7214004 condition possible cause correction / reference item no cool air comes out (a/ c compressor does not operate) no refrigerant perform recovery, evacuation and charge referring to “operation procedure for refrigerant...

  • Page 954

    7b-14 air conditioning system: manual type cool air does not come out or insufficient cooling (a/c compressor normal operation) insufficient or excessive charge of refrigerant check the amount of refrigerant and system for leaks. Condenser clogged check condenser referring to “condenser assembly on-...

  • Page 955

    Air conditioning system: manual type 7b-15 abnormal noise symptom diagnosis of a/c system s6rw0d7214005 abnormal noise from compressor abnormal noise from magnetic clutch insufficient air flow of cooled air a/c evaporator clogged or frosted check a/c evaporator and evaporator temperature sensor refe...

  • Page 956

    7b-16 air conditioning system: manual type 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 correction / reference it...

  • Page 957

    Air conditioning system: manual type 7b-17 repair instructions operation procedure for refrigerant charge s6rw0d7216001 warning ! • your eyes should not be exposed to refrigerant (liquid). Any liquid hfc-134a (r-134a) escaping by accident shows a temperature as low as approximately – 6 °c (21.2 °f) ...

  • Page 958

    7b-18 air conditioning system: manual type recovery when discharging refrigerant out of a/c system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant hfc-134a (r-134a) into atmosphere would cause adverse effect to environments. Note • after recov...

  • Page 959

    Air conditioning system: manual type 7b-19 evacuation caution ! Do not evacuate before recovering refrigerant in a/c system. Note once air conditioning system circuit is opened (exposed) to atmospheric air, system must be evacuated by using a vacuum pump. The a/c system should be attached with a man...

  • Page 960

    7b-20 air conditioning system: manual type charge caution ! • because the sight glass is not used for this a/c system, do not perform an additional charge to the a/c system. To charge the proper amount of refrigerant, recover and evacuate the a/c system first. And then, charge the proper amount of r...

  • Page 961

    Air conditioning system: manual type 7b-21 7) when refrigerant container (1) is emptied, use the following procedure to replace it with a new refrigerant container. A) close low pressure valve. B) replace empty container with a refrigerant container which has been charged with refrigerant. When usin...

  • Page 962

    7b-22 air conditioning system: manual type 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 of lines and connections, it is advisable to check for leaks. Common sense should be us...

  • Page 963

    Air conditioning system: manual type 7b-23 condenser cooling fan inspection s6rw0d7216003 1) check condenser cooling fan motor for resistance between terminal “a” and “b” as shown. If there is no continuity, replace condenser cooling fan motor. 2) connect battery to condenser cooling fan motor termi...

  • Page 964

    7b-24 air conditioning system: manual type 5) move condenser assembly from the vehicle in the arrow direction in the order of 1, 2 and 3 as shown, and it can be removed. Installation reverse the removal procedure to install condenser noting the following instructions. • replenish specified amount of...

  • Page 965

    Air conditioning system: manual type 7b-25 hvac unit components s6rw0d7216007 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 1 10 1 9 8 25 25 3 20 3 19 19 19 24 24 21 4 23* 27 15 16* 14 25* 18* 2 25 26 17* 13 12 1...

  • Page 966

    7b-26 air conditioning system: manual type hvac unit removal and installation s6rw0d7216008 removal 1) recover refrigerant from a/c system with recovery and recycling equipment referring to “recovery” in “operation procedure for refrigerant charge”. 2) drain engine coolant referring to “cooling syst...

  • Page 967

    Air conditioning system: manual type 7b-27 installation reverse removal procedure noting the following instructions. • replenish specified amount of compressor oil to compressor suction side referring to “replenishing compressor oil” in “operation procedure for refrigerant charge”. • install the pad...

  • Page 968

    7b-28 air conditioning system: manual type evaporator temperature sensor inspection s6rw0d7216011 check resistance between terminals of evaporator temperature sensor (1). If check results are as not specified, replace evaporator temperature sensor. Evaporator temperature sensor resistance 0 °c (32 °...

  • Page 969

    Air conditioning system: manual type 7b-29 a/c refrigerant pressure sensor and its circuit inspection s6rw0d7216014 1) disconnect a/c refrigerant pressure sensor connector. 2) turn ignition switch to on position. 3) check if voltage between “red” wire terminal and “orn” wire terminal of a/c refriger...

  • Page 970

    7b-30 air conditioning system: manual type a/c system relay inspection s6rw0d7216017 note do not use blue relay for the substitute of white relay because internal durability of a blue relay is different from the durability of a white relay. 1) disconnect negative (–) cable from battery. 2) remove co...

  • Page 971

    Air conditioning system: manual type 7b-31 compressor drive belt removal and installation s6rw0d7216019 removal 1) loosen tension pulley nut (1). 2) loosen belt tension loosening tension pulley adjusting bolt (2). 3) remove compressor drive belt (3). Installation reverse removal procedure noting the...

  • Page 972

    7b-32 air conditioning system: manual type compressor assembly components s6rw0d7216021 magnet clutch inspection s6rw0d7216022 • check armature plate and magnet clutch pulley for wear and oil soak respectively. • check magnet clutch pulley bearing for noise, wear and grease leakage. • measure magnet...

  • Page 973

    Air conditioning system: manual type 7b-33 magnet clutch removal and installation s6rw0d7216023 removal 1) remove compressor from vehicle referring to “compressor assembly removal and installation”. 2) fix armature plate (1) with special tool and remove armature plate bolt (2). Special tool (a): 099...

  • Page 974

    7b-34 air conditioning system: manual type installation 1) install magnet clutch coil (2) fitting protrusion (4) of magnet clutch coil onto hole (5) of compressor (3). 2) install circlip (1) directing chamfer side (6) downward. Special tool (b): 09900–06107 3) install thermal switch to compressor re...

  • Page 975

    Air conditioning system: manual type 7b-35 f) read stroke of armature plate from dial gauge by performing step d) and e) repeatedly. (stroke of armature plate is clearance between armature plate and magnet clutch pulley.) standard clearance between armature plate and magnet clutch pulley: 0.3 – 0.5 ...

  • Page 976

    7b-36 air conditioning system: manual type relief valve inspection s6rw0d7216026 by using special tool, check is there is refrigerant leakage. If there is refrigerant leakage, replace the relief valve. Special tool (a) : 09990–86012 relief valve removal and installation s6rw0d7216027 removal 1) reco...

  • Page 977

    Air conditioning system: manual type 7b-37 specifications tightening torque specifications s6rw0d7217001 note the specified tightening torque is also described in the following. “a/c system major components location” “compressor assembly components” reference: for the tightening torque of fastener n...

  • Page 978: Automatic Type

    7b-38 air conditioning system: automatic type automatic type precautions a/c system caution s6rw0d7220001 refer to “a/c system caution”. Precautions in diagnosing trouble s6rw0d7220002 • do not disconnect couplers from hvac control module, battery cable from battery, hvac control module ground wire ...

  • Page 979

    Air conditioning system: automatic type 7b-39 general description auto a/c system description s6rw0d7221001 the automatic type air conditioning system (auto a/c) is provided with the function to automatically control the inside air temperature, fan speed, air flow outlet direction and air intake pos...

  • Page 980

    7b-40 air conditioning system: automatic type hvac control description s6rw0d7221002 temperature control hvac control module calculates the target temperature control door position based on signals from the temperature selector, inside air temperature sensor, outside air temperature sensor and sunlo...

  • Page 981

    Air conditioning system: automatic type 7b-41 on-board diagnostic system description s6rw0d7221004 note the diagnostic information as diagnostic trouble code (dtc) can be known by using suzuki scan tool. For further details, refer to “dtc check”. Hvac control module detects malfunctions, which may o...

  • Page 982

    7b-42 air conditioning system: automatic type a/c system wiring diagram s6rw0d7222002 19 13 15 16 10 11 12 5v 12v wht/blu red gry/blu brn/wht gry/red brn/yel pnk blk/orn red/blk red/blk red/blk 14 red wht wht/red blu yel wht wht/blu grn wht g20-18 g20-7 23 1 2 4 6 17 24 5v 5v 5v 5v 5v 12v 12v orn or...

  • Page 983

    Air conditioning system: automatic type 7b-43 component location a/c system major components location s6rw0d7223001 refer to “a/c system major components location”. [a]: illumination control model 10. Air intake actuator 22. Compressor 34. “a/c” indicator light [b]: junction block with bcm 11. Air f...

  • Page 984

    7b-44 air conditioning system: automatic type electronic control system components location s6rw0d7223002 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. [a] 2 3 5 1 4 7 8* 18 19 20 23 22 21 9* 10* 11* 12* 13* 15* ...

  • Page 985

    Air conditioning system: automatic type 7b-45 diagnostic information and procedures air conditioning system check s6rw0d7224001 step action yes no 1 customer complaint analysis 1) perform )”customer complaint analysis”. Was customer complaint analysis performed? Go to step 2. Perform customer compla...

  • Page 986

    7b-46 air conditioning system: automatic type description for each step step 1. Customer complaint analysis talk to customer, and then record details of the problem. Customer questionnaire (example) note the form is a standard sample. It should be modified according to conditions characteristic of e...

  • Page 987

    Air conditioning system: automatic type 7b-47 a/c system symptom diagnosis s6rw0d7224002 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 refrigerant ...

  • Page 988

    7b-48 air conditioning system: automatic type cool air does not come out or insufficient cooling (a/c compressor normal operation) insufficient or excessive charge of refrigerant check the amount of refrigerant and system for leaks. Condenser clogged check condenser referring to “condenser assembly ...

  • Page 989

    Air conditioning system: automatic type 7b-49 abnormal noise symptom diagnosis of a/c system s6rw0d7224003 refer to “abnormal noise symptom diagnosis of a/c system”. Dtc check s6rw0d7224004 using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link conne...

  • Page 990

    7b-50 air conditioning system: automatic type not using suzuki scan tool note in case of malfunction of temperature selector, blower speed selector and air flow selector, dtc can not be checked by the following procedure. Use suzuki scan tool for dtc check. 1) light over sunload sensor vertically wi...

  • Page 991

    Air conditioning system: automatic type 7b-51 dtc clearance s6rw0d7224005 using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel at driver’s seat side. Special tool (a): suzuki scan tool 3)...

  • Page 992

    7b-52 air conditioning system: automatic type dtc table s6rw0d7224006 caution ! Be sure to perform “air conditioning system check” before starting diagnosis. Note • history dtc is such dtc which hvac control module saves in its memory when it detects current dtc for 60 seconds or more continuously. ...

  • Page 993

    Air conditioning system: automatic type 7b-53 ) b1521 blower speed selector malfunction 16 1 signal voltage of blower speed selector in hvac control module is higher than specification. Flashed 16 2 signal voltage of blower speed selector in hvac control module is lower than specification. Flashed )...

  • Page 994

    7b-54 air conditioning system: automatic type dtc of a/c system detected by ecm note when no dtc is detected, “fre” [a] and “rec” [b] indicator lights on hvac control module flash at the same time in specific pattern. Fail-safe table s6rw0d7224007 when any of the following malfunctions (dtcs) is det...

  • Page 995

    Air conditioning system: automatic type 7b-55 scan tool data s6rw0d7224008 as the data values given in the following are standard values estimated on the basis of values obtained from the normally operation vehicles by using a scan tool, use them as reference values. Even when the vehicles are in go...

  • Page 996

    7b-56 air conditioning system: automatic type scan tool data definitions temp cont switch: (temperature control selector position, max cool, °c / °f, max hot): this parameter indicates the selected position of temperature control selector. Cabin temperature: (in-car temperature, °c, °f): this parame...

  • Page 997

    Air conditioning system: automatic type 7b-57 sun load (w/m 2 ): this parameter indicates the amount of sunlight detected by sunload sensor. Mode cont switch (air flow selector position, auto, face, b/l, foot, d/f, def): this parameter indicates the selected position of air flow selector. Fan cont s...

  • Page 998

    7b-58 air conditioning system: automatic type dtc detecting condition and trouble area dtc troubleshooting note when dtc b1503, b1504, b1511 and b1512 are indicated together, it is possible that sensor ground circuit is open. Dtc detecting condition trouble area inside air temperature sensor signal ...

  • Page 999

    Air conditioning system: automatic type 7b-59 dtc b1503: evaporator temperature sensor circuit malfunction s6rw0d7224011 wiring diagram dtc detecting condition and trouble area dtc troubleshooting note when dtc b1502, b1504, b1511 and b1512 are indicated together, it is possible that sensor ground c...

  • Page 1000

    7b-60 air conditioning system: automatic type dtc b1504: sunload sensor circuit malfunction s6rw0d7224012 wiring diagram dtc detecting condition and trouble area note when dtc b1502, b1503, b1511 and b1512 are indicated together, it is possible that sensor ground circuit is open. 3 evaporator temper...

  • Page 1001

    Air conditioning system: automatic type 7b-61 dtc troubleshooting dtc b1511: temperature control actuator (position sensor) and/or its circuit malfunction s6rw0d7224013 wiring diagram step action yes no 1 was “air conditioning system check” performed? Go to step 2. Go to “air conditioning system che...

  • Page 1002

    7b-62 air conditioning system: automatic type dtc detecting condition and trouble area dtc troubleshooting note • when dtc b1502, b1503, b1504 and b1512 are indicated together, it is possible that sensor ground circuit is open. • when dtc b1512 is indicated together, it is possible that position sen...

  • Page 1003

    Air conditioning system: automatic type 7b-63 dtc b1512: air flow control actuator (position sensor) and/or its circuit malfunction s6rw0d7224014 wiring diagram dtc detecting condition and trouble area 4 temperature control actuator check 1) check position sensor of temperature control actuator for ...

  • Page 1004

    7b-64 air conditioning system: automatic type dtc troubleshooting note • when dtc b1502, b1503, b1504 and b1511 are indicated together, it is possible that sensor ground circuit is open. • when dtc b1511 is indicated together, it is possible that position sensor power supply circuit is open. Step ac...

  • Page 1005

    Air conditioning system: automatic type 7b-65 dtc b1513: temperature control actuator (motor) and/or its circuit malfunction s6rw0d7224015 wiring diagram dtc detecting condition and trouble area 5 position sensor of temperature control actuator power supply voltage check 1) turn ignition switch to o...

  • Page 1006

    7b-66 air conditioning system: automatic type dtc troubleshooting step action yes no 1 was “air conditioning system check” performed? Go to step 2. Go to “air conditioning system check”. 2 dtc check 1) connect scan tool to dlc with ignition switch turned off. 2) turn ignition switch to on position a...

  • Page 1007

    Air conditioning system: automatic type 7b-67 dtc b1514: air flow control actuator (motor) and/or its circuit malfunction s6rw0d7224016 wiring diagram dtc detecting condition and trouble area dtc troubleshooting g20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30 brn...

  • Page 1008

    7b-68 air conditioning system: automatic type dtc b1520 / b1521 / b1522: temperature / blower speed / air flow selector malfunction s6rw0d7224017 dtc detecting condition and trouble area dtc troubleshooting 5 wire harness check check position sensor circuit of temperature control actuator for condit...

  • Page 1009

    Air conditioning system: automatic type 7b-69 dtc b1541: back-up power supply circuit malfunction s6rw0d7224018 wiring diagram dtc detecting condition and trouble area note when checking dtc after connecting battery cable, be sure to turn ignition switch from off to on and from on to off at least on...

  • Page 1010

    7b-70 air conditioning system: automatic type dtc b1546: a/c refrigerant pressure malfunction s6rw0d7224019 dtc detecting condition and trouble area dtc troubleshooting dtc b1551: serial communication circuit malfunction s6rw0d7224020 wiring diagram dtc detecting condition trouble area • a/c refrige...

  • Page 1011

    Air conditioning system: automatic type 7b-71 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area serial communication signal is higher than or lower than specified value for specified time continuously. • back-up power supply circuit • serial communicat...

  • Page 1012

    7b-72 air conditioning system: automatic type dtc b1552: hvac control module check sum error s6rw0d7224021 dtc detecting condition and trouble area dtc troubleshooting dtc b1553: can communication circuit malfunction s6rw0d7224022 dtc detecting condition and trouble area dtc troubleshooting dtc dete...

  • Page 1013

    Air conditioning system: automatic type 7b-73 dtc b1557: vss signal failure s6rw0d7224023 dtc detecting condition and trouble area dtc troubleshooting dtc b1561: ect signal failure s6rw0d7224024 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area hvac co...

  • Page 1014

    7b-74 air conditioning system: automatic type dtc b1562: outside air temperature signal failure s6rw0d7224025 dtc detecting condition and trouble area dtc troubleshooting dtc b1563: a/c refrigerant pressure signal failure s6rw0d7224026 dtc detecting condition and trouble area dtc troubleshooting dtc...

  • Page 1015

    Air conditioning system: automatic type 7b-75 dtc b1570: engine type signal failure s6rw0d7224027 dtc detecting condition and trouble area dtc troubleshooting dtc b1571: combination meter spec signal failure s6rw0d7224028 dtc detecting condition and trouble area dtc troubleshooting dtc detecting con...

  • Page 1016

    7b-76 air conditioning system: automatic type inspection of hvac control module and its circuit s6rw0d7224029 hvac control module and its circuits can be checked at hvac control module wiring couplers by measuring voltage. Caution ! Hvac control module can not be checked by itself. It is strictly pr...

  • Page 1017

    Air conditioning system: automatic type 7b-77 g20-8 blu/wht electric load signal for blower motor 10 – 14 v • ignition switch turned on, blower speed selector off or 1st position • ignition switch turned on, blower speed selector from 1st to 2nd position 0 – 2 v • ignition switch turned on, blower s...

  • Page 1018

    7b-78 air conditioning system: automatic type g20-25 pnk sunload sensor signal approx. 3.5 v ignition switch turned on, amount of insolation is 500 w/m 2 approx. 5 v ignition switch turned on, amount of insolation is 0 w/m 2 g20-26 blk/red rear defogger indicator 0 – 1 v ignition switch turned on, r...

  • Page 1019

    Air conditioning system: automatic type 7b-79 reference waveform no. 1 rear defogger switch or a/c switch signal (1) reference waveform no. 2 serial communication line of bcm (1) a/c system inspection at ecm s6rw0d7224030 when checking voltage at ecm terminals related to a/c system, refer to “inspec...

  • Page 1020

    7b-80 air conditioning system: automatic type hvac unit components s6rw0d7226002 1 10 1 29 9 8 3 29 21 3 20 20 20 19 23 22 5* 4 28* 15 16* 30 29* 30 17* 18* 2 13 12 11 5* 26 27 25 14 24 29 6 7 * i6rw0c722008-01 1. Blower upper case 9. Air intake control link 17. Expansion valve 25. Inside air temper...

  • Page 1021

    Air conditioning system: automatic type 7b-81 hvac unit removal and installation s6rw0d7226003 refer to “hvac unit removal and installation”. Temperature control actuator removal and installation s6rw0d7226004 removal 1) disconnect negative (–) cable at battery. 2) remove steering column hole cover ...

  • Page 1022

    7b-82 air conditioning system: automatic type 6) measure output voltage variation while temperature control actuator is operated from “max cool” position (b) to “max hot” position (a) as following specification. If measure voltage is out of specification or does not vary linearly as the shown in gra...

  • Page 1023

    Air conditioning system: automatic type 7b-83 air flow control actuator removal and installation s6rw0d7226006 removal 1) disconnect negative cable at battery. 2) remove steering column hole cover from instrument panel. 3) remove driver side foot duct from hvac unit. 4) disconnect air flow control a...

  • Page 1024

    7b-84 air conditioning system: automatic type 7) set air flow selector of hvac control module to “def” position with ignition switch turned on, and make sure if the position of actuator lever is “def” position (a). 8) turn ignition switch to off position, and then disconnect connector from air flow ...

  • Page 1025

    Air conditioning system: automatic type 7b-85 blower motor controller inspection s6rw0d7226012 1) check internal circuit of controller for resistance as follows. A) measure resistance between “1” terminal and “2” terminal of blower motor controller. Blower motor controller resistance “1” – “2”: appr...

  • Page 1026

    7b-86 air conditioning system: automatic type installation reverse removal procedure noting the following instructions. • install sunload sensor (1) to instrument panel fitting tab (2) of sunload sensor into the groove (3) of instrument panel as shown in figure. Sunload sensor inspection s6rw0d72260...

  • Page 1027

    Air conditioning system: automatic type 7b-87 condenser cooling fan relay inspection s6rw0d7226020 refer to “a/c system relay inspection”. Condenser cooling fan removal and installation s6rw0d7226021 refer to “condenser cooling fan removal and installation”. Condenser cooling fan inspection s6rw0d72...

  • Page 1028

    7b-88 air conditioning system: automatic type special tools and equipment recommended service material s6rw0d7228001 note required service material is also described in the following. “hvac unit components” special tool s6rw0d7228002 suzuki scan tool — this kit includes following items. 1. Tech 2, 2...

  • Page 1029: 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 1030

    8-ii table of contents dtc b1062 / b1066: side-air bag circuit low resistance ......................................................8b-59 dtc b1063 / b1067: side-air bag circuit shorted to ground ..........................................8b-61 dtc b1064 / b1068: side-air bag circuit shorted to power...

  • Page 1031: Precautions

    Precautions: 8-1 restraint precautions precautions precautions on restraint s6rw0d8000001 air bag warning refer to “air bag system service 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 se...

  • Page 1032: Seat Belts

    8a-1 seat belts: restraint seat belts precautions precautions on service and diagnosis of seat belt s6rw0d8100001 warning ! If replacing seat belt is necessary, replace buckle and seat belt together as a set. This is for the reason of ensuring locking of tongue plate with buckle. If these parts are ...

  • Page 1033

    Seat belts: 8a-2 general description seat belt construction s6rw0d8101001 1 1 6 6 6 5 5 5 6 6 2 2 3 4 6 5 5 6 2 2 5 7 [a] [b] i6rw0c810001-01 [a]: a-elr rear center seat belt model 4. Buckle for front seat belt [b]: non-a-elr rear center seat belt model 5. Buckle for rear seat belt 1. Front seat bel...

  • Page 1034

    8a-3 seat belts: 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 1035

    Seat belts: 8a-4 repair instructions front seat belt components s6rw0d8106001 warning ! • never attempt to disassemble or repair the seat belt pretensioner (retractor). If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service and diagn...

  • Page 1036

    8a-5 seat belts: front seat belt removal and installation s6rw0d8106002 warning ! • never attempt to disassemble or repair the retractor (seat belt pretensioner). 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 o...

  • Page 1037

    Seat belts: 8a-6 front seat belt inspection s6rw0d8106003 warning ! • never attempt to disassemble or repair the seat belt pretensioner (retractor). 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 seat belt”, ...

  • Page 1038

    8a-7 seat belts: rear seat belt components s6rw0d8106004 warning ! Be sure to read “precautions on service and diagnosis of seat belt” before starting to work and observe every precaution during work. I6rw0c810002-01 [a]: a-elr rear center seat belt model 9. Anchor bolt : tighten retractor mounting ...

  • Page 1039

    Seat belts: 8a-8 rear seat belt removal and installation s6rw0d8106005 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) fold rear seats referring to “folding rear seats” in owners manual. 2) rem...

  • Page 1040: Air Bag System

    8b-1 air bag system: restraint air bag system precautions precautions on service and diagnosis of air bag system s6rw0d8200004 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 ...

  • Page 1041

    Air bag system: 8b-2 • 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 1042

    8b-3 air bag system: 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 1043

    Air bag system: 8b-4 • never attempt to disassemble the seat belt pretensioners (retractor assembly). • if any abnormality is found, be sure to replace it with new one as an assembly. • when an abnormality is noted as existing in the live (inactivated) seat belt pretensioner, be sure to activate it ...

  • Page 1044

    8b-5 air bag system: precautions on disposal of air bag and seat belt pretensioner s6rw0d8200003 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 1045

    Air bag system: 8b-6 the air bag system is designed to activate only in severe frontal “a” and sideward “b” 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 ...

  • Page 1046

    8b-7 air bag system: air bag system input / output table s6rw0d8201002 forward inpact-sensor driver side inpact- sensor passenger side inpact- sensor mecanical longitudinal g sensor in sdm x-y g sensor (longitudinal / lateral acceleration) in sdm output (deployment & activation device) input (sensor...

  • Page 1047

    Air bag system: 8b-8 schematic and routing diagram air bag system wiring circuit diagram s6rw0d8202001 blk yel/grn yel/grn yel/blu yel/blu wht/red lt grn/blk wht/grn lt grn 22 23 15 29 21 19 20 grn/red grn/red grn grn [a] [b] “e40”, “e388”, “g04” “e388”, “l04” “l395”, “q102” “q134”, “s121” and “s172...

  • Page 1048

    8b-9 air bag system: terminal arrangement of sdm (viewed from harness side) [a]: shorting bar 11. Bcm 25. Driver seat belt pretensioner [b]: connector 12. Combination meter 26. Passenger seat belt pretensioner [c]: junction block with bcm model 13. “air bag” warning light 27. Driver side-air bag (in...

  • Page 1049

    Air bag system: 8b-10 connector “l04” (sdm connector) terminal circuit terminal circuit l04-1 — l04-27 ignition switch (power source) l04-2 “air bag” warning light l04-28 ground l04-3 driver air bag (–) l04-29 — l04-4 driver air bag (+) l04-30 — l04-5 passenger air bag (+) l04-31 — l04-6 passenger a...

  • Page 1050

    8b-11 air bag system: component location air bag system components, wiring and connectors location s6rw0d8203001 17 14 7 b 19 a 20 16 18 18 4 3 1 a 5 c 2 b 10 11 8 9 6 15 c 5 5 13 12 i6rw0c820004-01.

  • Page 1051

    Air bag system: 8b-12 diagnostic information and procedures air bag diagnostic system check s6rw0d8204001 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 1052

    8b-13 air bag system: air bag diagnostic system check flow s6rw0d8204002 caution ! • be sure to perform “air bag diagnostic system check” before starting diagnosis according to each flow. • when measurement of resistance or voltage is required in the flow, use a tester along with a correct terminal ...

  • Page 1053

    Air bag system: 8b-14 dtc table s6rw0d8204003 note the dtcs (b1022 and b1023) shown with asterisk (*) below have been established only for the m15a engine model with 4a/t equipped with slip-control (i.E., hong kong model). These codes are meant to be recorded when external scrapping deployment contr...

  • Page 1054

    8b-15 air bag system: ) b1026 seat belt pretensioner activation record activation of seat belt pretensioner has been recorded in sdm. If this dtc has been recorded even though pretensioner has not been activated • sdm • driver and/or passenger seat belt pretensioner • those initiator circuit ) b1027...

  • Page 1055

    Air bag system: 8b-16 ) b1057 passenger seat belt pretensioner circuit shorted to ground passenger seat belt pretensioner circuit has been shorted to ground for more than 4 sec. • passenger seat belt pretensioner circuit • sdm ) b1058 passenger seat belt pretensioner circuit shorted to power supply ...

  • Page 1056

    8b-17 air bag system: ) b1085 driver side impact-sensor communication data inconsistent driver side impact-sensor has been communicated with inconsistent id code for more than 4 sec. • driver side impact-sensor • sdm ) b1091 passenger side impact-sensor no response communication with passenger side ...

  • Page 1057

    Air bag system: 8b-18 dtc check s6rw0d8204004 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 position. 4) read dtc accor...

  • Page 1058

    8b-19 air bag system: scan tool data definition buck up volt (v) this parameter indicates the capacity of the backup capacitor installed to maintain the ignition current (as much as possible) even when the power supply to sdm that ignites the inflator is shut off. Battery voltage (v) battery voltage...

  • Page 1059

    Air bag system: 8b-20 troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 sdm power supply and ground circuit check 1) check sdm power supply and ground circuit referring to “sdm power supply and gro...

  • Page 1060

    8b-21 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. • repeat “air bag diagnostic system check” to confirm that the trouble has been corrected. 5 “air bag” warn...

  • Page 1061

    Air bag system: 8b-22 “air bag” warning light does not come on s6rw0d8204008 wiring diagram refer to ““air bag” warning light comes on steady”. Troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all co...

  • Page 1062

    8b-23 air bag system: serial data link circuit check s6rw0d8204051 wiring diagram 1 2 3 3 18 12v red 7 14 9 10 “l313” “g273” yel/blk l04-2 l04-27 “l04” ppl/wht “g04” l04-32 12v 8 grn 15 +bb 5 6 wht wht 4 blu blu blk 16 11 12 “g241” 13 blk l04-28 red/blk wht/red yel/blk blk “g271” “g272” wht/red blk/...

  • Page 1063

    Air bag system: 8b-24 troubleshooting step action yes no 1 “air bag” warning light check 1) turn ignition switch to on position. Does “air bag” warning light come on steady? Go to ““air bag” warning light comes on steady”. Go to step 2. 2 scan tool condition check 1) make sure that suzuki scan tool ...

  • Page 1064

    8b-25 air bag system: dtc b1013: sdm internal failure s6rw0d8204010 dtc detecting condition and trouble area note dtc b1013 can never be cleared once it has been set. Dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system c...

  • Page 1065

    Air bag system: 8b-26 dtc b1014: “air bag” warning light circuit s6rw0d8204011 wiring diagram refer to““air bag” warning light comes on steady”. Dtc detecting condition and trouble area dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect a...

  • Page 1066

    8b-27 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 system ...

  • Page 1067

    Air bag system: 8b-28 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 system ...

  • Page 1068

    8b-29 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. • repeat “air bag diagnostic system check” to confirm that the trouble has been corrected. • clear dtcs of ...

  • Page 1069

    Air bag system: 8b-30 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. • repeat “air bag diagnostic system check” to confirm that the trouble has been correct...

  • Page 1070

    8b-31 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. • repeat “air bag diagnostic system check” to confirm that the trouble has been corrected. • clear dtc b115...

  • Page 1071

    Air bag system: 8b-32 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 drive air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector located under the steer...

  • Page 1072

    8b-33 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 confirm th...

  • Page 1073

    Air bag system: 8b-34 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector located under the stee...

  • Page 1074

    8b-35 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 confirm th...

  • Page 1075

    Air bag system: 8b-36 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector “g347” located under t...

  • Page 1076

    8b-37 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 confirm th...

  • Page 1077

    Air bag system: 8b-38 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector “g347” located under t...

  • Page 1078

    8b-39 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 confirm th...

  • Page 1079

    Air bag system: 8b-40 dtc b1041: passenger air bag circuit high resistance s6rw0d8204022 wiring diagram dtc detecting condition and trouble area “l04” [a] blk l04-28 6 8 7 red grn “l313” l04-27 9 10 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 26 27 28 29 30 31 32 33 34 35 36 37...

  • Page 1080

    8b-41 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 passenger air bag check 1) remove passenger air bag (inflator) module referring to “passenger air bag (inflator) module r...

  • Page 1081

    Air bag system: 8b-42 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 confirm th...

  • Page 1082

    8b-43 air bag system: dtc b1042: passenger air bag circuit low resistance s6rw0d8204023 wiring diagram refer to “dtc b1041: passenger air bag circuit high resistance”. Dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area passenger air bag circuit is less ...

  • Page 1083

    Air bag system: 8b-44 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 confirm th...

  • Page 1084

    8b-45 air bag system: dtc b1043: passenger air bag circuit shorted to ground s6rw0d8204024 wiring diagram refer to “dtc b1041: passenger air bag circuit high resistance”. Dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area passenger air bag circuit has b...

  • Page 1085

    Air bag system: 8b-46 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 confirm th...

  • Page 1086

    8b-47 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 confirm th...

  • Page 1087

    Air bag system: 8b-48 dtc b1051 / b1055: seat belt pretensioner circuit high resistance s6rw0d8204026 dtc b1051: driver seat belt pretensioner circuit high resistance dtc b1055: passenger seat belt pretensioner circuit high resistance wiring diagram dtc detecting condition and trouble area dtc troub...

  • Page 1088

    8b-49 air bag system: 2 seat belt pretensioner circuit check 1) with ignition switch turned off, remove center pillar lower trim of applicable side and disconnect seat belt pretensioner connector “l283” or “l285”. 2) check for proper connection to applicable seat belt pretensioner at terminals in “l...

  • Page 1089

    Air bag system: 8b-50 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 confirm th...

  • Page 1090

    8b-51 air bag system: dtc b1052 / b1056: seat belt pretensioner circuit low resistance s6rw0d8204027 dtc b1052: driver seat belt pretensioner circuit low resistance dtc b1056: passenger seat belt pretensioner circuit low resistance wiring diagram refer to “dtc b1051 / b1055: seat belt pretensioner c...

  • Page 1091

    Air bag system: 8b-52 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 confirm th...

  • Page 1092

    8b-53 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 system ...

  • Page 1093

    Air bag system: 8b-54 dtc b1054 / b1058: seat belt pretensioner circuit shorted to power supply s6rw0d8204029 dtc b1054: driver seat belt pretensioner circuit shorted to power supply dtc b1058: passenger seat belt pretensioner circuit shorted to power supply wiring diagram refer to “dtc b1051 / b105...

  • Page 1094

    8b-55 air bag system: dtc b1061 / b1065: side-air bag circuit high resistance s6rw0d8204053 dtc b1061: driver side-air bag circuit high resistance dtc b1065: passenger side-air bag circuit high resistance wiring diagram dtc detecting condition and trouble area “l04” [a] blk l04-28 6 8 7 red grn “l31...

  • Page 1095

    Air bag system: 8b-56 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 side-air bag circuit check 1) remove applicable driver / passenger side-air bag (inflator) module from seat back referrin...

  • Page 1096

    8b-57 air bag system: 3 side-air bag circuit check 1) with ignition switch turned off, disconnect special tools from applicable side-air bag (inflator) connector “q104” or “q105”. 2) disconnect sdm connector “l04”. 3) check for proper connection to sdm connector at terminal “l04-11” and “l04-12” (fo...

  • Page 1097

    Air bag system: 8b-58 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 that ...

  • Page 1098

    8b-59 air bag system: dtc b1062 / b1066: side-air bag circuit low resistance s6rw0d8204054 dtc b1062: driver side-air bag circuit low resistance dtc b1066: passenger side-air bag circuit low resistance wiring diagram refer to “dtc b1061 / b1065: side-air bag circuit high resistance”. Dtc detecting c...

  • Page 1099

    Air bag system: 8b-60 3 side-air bag circuit check 1) with ignition switch turned off, disconnect special tools from applicable side-air bag (inflator) connector “q104” or “q105”. 2) disconnect sdm connector “l04”. 3) check for proper connection to sdm connector at terminal “l04-11” and “l04-12” (fo...

  • Page 1100

    8b-61 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 that ...

  • Page 1101

    Air bag system: 8b-62 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 side-air bag circuit check 1) remove applicable driver / passenger side-air bag (inflator) module from seat back referrin...

  • Page 1102

    8b-63 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 that ...

  • Page 1103

    Air bag system: 8b-64 dtc b1064 / b1068: side-air bag circuit shorted to power supply s6rw0d8204056 dtc b1064: driver side-air bag circuit shorted to power supply dtc b1068: passenger side-air bag circuit shorted to power supply wiring diagram refer to “dtc b1061 / b1065: side-air bag circuit high r...

  • Page 1104

    8b-65 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 that ...

  • Page 1105

    Air bag system: 8b-66 dtc b1071: driver forward impact-sensor communication data inconsistent s6rw0d8204034 dtc detecting condition and trouble area dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensu...

  • Page 1106

    8b-67 air bag system: dtc b1073: driver forward impact-sensor circuit shorted to ground s6rw0d8204036 wiring diagram dtc detecting condition and trouble area dtc troubleshooting 10 “l04” “l372” “e388” “e40” orn pnk/blk orn pnk/blk l04-50 l04-51 11 30v “l04” blk l04-28 6 8 7 red grn “l313” l04-27 9 1...

  • Page 1107

    Air bag system: 8b-68 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 confirm th...

  • Page 1108

    8b-69 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 system ...

  • Page 1109

    Air bag system: 8b-70 dtc b1081 / b1091: side impact-sensor no response s6rw0d8204066 dtc b1081: driver side impact-sensor no response dtc b1091: passenger side impact-sensor no response dtc detecting condition and trouble area dtc troubleshooting note upon completion of inspection and repair work, ...

  • Page 1110

    8b-71 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 system ...

  • Page 1111

    Air bag system: 8b-72 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 system ...

  • Page 1112

    8b-73 air bag system: dtc b1084 / b1094: side impact-sensor circuit open s6rw0d8204060 dtc b1084: driver side impact-sensor circuit open dtc b1094: passenger side impact-sensor circuit open wiring diagram refer to “dtc b1083 / b1093: side impact-sensor circuit shorted to ground”. Dtc detecting condi...

  • Page 1113

    Air bag system: 8b-74 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 confirm th...

  • Page 1114

    8b-75 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 confirm th...

  • Page 1115

    Air bag system: 8b-76 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver / passenger curtain-air bag circuit check 1) with ignition switch turned off, remove rear quarter upper trim of ap...

  • Page 1116

    8b-77 air bag system: 3 driver / passenger curtain-air bag circuit check 1) disconnect special tools from applicable side curtain-air bag connector d or p. 2) with ignition switch turned off, disconnect sdm connector “l04”. 3) check for proper connection to sdm connector at terminal “l04-19” and “l0...

  • Page 1117

    Air bag system: 8b-78 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 that ...

  • Page 1118

    8b-79 air bag system: dtc b1362 / b1366: curtain-air bag circuit low resistance s6rw0d8204063 dtc b1362: driver curtain-air bag circuit low resistance dtc b1366: passenger curtain-air bag circuit low resistance wiring diagram refer to “dtc b1361 / b1365: curtain-air bag circuit high resistance”. Dtc...

  • Page 1119

    Air bag system: 8b-80 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 that ...

  • Page 1120

    8b-81 air bag system: dtc b1363 / b1367: curtain-air bag circuit shorted to ground s6rw0d8204064 dtc b1363: driver curtain-air bag circuit shorted to ground dtc b1367: passenger curtain-air bag circuit shorted to ground wiring diagram refer to “dtc b1361 / b1365: curtain-air bag circuit high resista...

  • Page 1121

    Air bag system: 8b-82 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 that ...

  • Page 1122

    8b-83 air bag system: dtc b1364 / b1368: curtain-air bag circuit shorted to power supply s6rw0d8204065 dtc b1364: driver curtain-air bag circuit shorted to power supply dtc b1368: passenger curtain-air bag circuit shorted to power supply wiring diagram refer to “dtc b1361 / b1365: curtain-air bag ci...

  • Page 1123

    Air bag system: 8b-84 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 that ...

  • Page 1124

    8b-85 air bag system: sdm power supply and ground circuit check s6rw0d8204049 wiring diagram troubleshooting “l04” 14 5 9 red red/blk grn yel/blk blk 8 7 11 12 15 l04-2 l04-28 l04-27 “g241” “g271” “l313” 13 12v 6 1 blk wht wht wht/red 2 3 4 3 10 blk “g273” “e324” 16 12v 5v 30v 17 i6rw0c820016-01 1. ...

  • Page 1125

    Air bag system: 8b-86 4 power supply circuit check 1) with ignition switch turned off, disconnect connector from sdm. 2) check for proper connection to sdm terminal at “l04- 27”. 3) with ignition switch turned on, measure voltage between “l04-27” terminal of sdm connector and body ground. Special to...

  • Page 1126

    8b-87 air bag system: contact coil cable and its circuit check s6rw0d8204050 troubleshooting step action yes no 1 driver air bag circuit check 1) remove driver air bag (inflator) module referring to “driver air bag (inflator) module removal and installation”. 2) with ignition switch turned off, disc...

  • Page 1127

    Air bag system: 8b-88 3 contact coil circuit (horn and audio control switch circuit) check (non cruise control model) 1) check for continuity between each terminal of horn switch terminals [a] and audio control switch terminals [b] (if equipped) as shown in figure. Is each measured resistance 3 Ω or...

  • Page 1128

    8b-89 air bag system: inspection of intermittent and poor connections s6rw0d8204047 most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diagnostic flow, perform careful check of suspect circuits. If any abnormality is found, ...

  • Page 1129

    Air bag system: 8b-90 • improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal included in the connector test adapter kit (special tool). If contact tension is not enough, reform th...

  • Page 1130

    8b-91 air bag system: caution ! After detecting one time of such collision as to meet deployment conditions, the sdm must not be used. Refer to “air bag diagnostic system check” when checking the sdm. Accident with deployment / activation – component replacement when driver and passenger air bags ar...

  • Page 1131

    Air bag system: 8b-92 – 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 1132

    8b-93 air bag system: repair instructions disabling air bag system s6rw0d8206001 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 1133

    Air bag system: 8b-94 5) install driver and passenger side front pillar lower trim. 6) side-air bag (inflator) model: connect yellow connector (1) of side-air bag (inflator) module by pushing connector till click is heard from it. 7) side curtain-air bag (inflator) model: connect yellow connector (1...

  • Page 1134

    8b-95 air bag system: installation 1) check that none of the following faulty conditions exists. • bend, scratch, deformity in vehicle body where sdm is mounted. • foreign matter or rust on mating surface of vehicle body where sdm is mounted. 2) install sdm (2) to vehicle. Caution ! Ensure that arro...

  • Page 1135

    Air bag system: 8b-96 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system. Refer to “disabling air bag system”. 3) loosen driver air bag (inflator) module mounting bolts (1) till it turns freely, pull them out and fix them to bolt clamps. 4) remove air bag (inflator) modul...

  • Page 1136

    8b-97 air bag system: driver air bag (inflator) module inspection s6rw0d8206006 warning ! Never disassemble air bag (inflator) module or measure its resistance. Otherwise, personal injury may result. Caution ! If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should ...

  • Page 1137

    Air bag system: 8b-98 7) remove passenger air bag (inflator) module (1) from its facing cover (2). 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...

  • Page 1138

    8b-99 air bag system: passenger air bag (inflator) module inspection s6rw0d8206008 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. If...

  • Page 1139

    Air bag system: 8b-100 removal 1) disable air bag system. Refer to “disabling air bag system”. 2) loosen seat back surface fastener (1) and roll up backside of seat back surface. 3) remove sleeve lock nut (1) from side-air bag (inflator) module (2). 4) remove side-air bag (inflator) module from seat...

  • Page 1140

    8b-101 air bag system: 2) install new sleeve (1) and sleeve lock nut (2) to side- air bag (inflator) module, then tighten nut to specified torque. Tightening torque sleeve lock nut (a): 2.5 n·m (0.25 kgf-m, 2.0 lb- ft) 3) connect side-air bag (inflator) module connector (1) securely as shown in the ...

  • Page 1141

    Air bag system: 8b-102 side curtain-air bag (inflator) module removal and installation s6rw0d8206022 warning ! • never attempt to disassemble or repair the side curtain-air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “preca...

  • Page 1142

    8b-103 air bag system: 3) connect side curtain-air bag (inflator) module connector (1) securely as shown in figure. A) connect connector. B) lock connector with lock button (2). 4) install head lining referring to “head lining removal and installation in section 9h”. 5) enable air bag system. Refer ...

  • Page 1143

    Air bag system: 8b-104 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system”. 3) remove front bumper referring to “front bumper and rear bumper components in section 9k”. 4) disconnect forward impact-sensor connector (1) sliding connec...

  • Page 1144

    8b-105 air bag system: side impact-sensor removal and installation s6rw0d8206024 warning ! During service procedures, be very careful when handling a sensor. • never strike or jar a sensor. • a sensor bolt must be carefully torqued to assure proper operation. Under loose connection, it could cause i...

  • Page 1145

    Air bag system: 8b-106 passenger air bag (inflator) module repair harness installation s6rw0d8206017 replace passenger air bag (inflator) module repair harness (2) according to the following procedure when the harness (9) connected with passenger air bag (inflator) module of the air bag harness incl...

  • Page 1146

    8b-107 air bag system: 7) install passenger air bag (inflator) module referring to “passenger air bag (inflator) module removal and installation”. 8) enabling air bag system referring to “enabling air bag system”. 9) confirm that there is no dtc detected to sdm with ignition switch turned on. Air ba...

  • Page 1147

    Air bag system: 8b-108 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 1148

    8b-109 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 1149

    Air bag system: 8b-110 • 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 1150

    8b-111 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 1151

    Air bag system: 8b-112 10) connect adapter cable (b) as follows. Special tool (b): 09932–76510 • for driver air bag (inflator) module [a]: check that driver air bag (inflator) module is placed with its vinyl trim cover facing up, and connect adapter cable (b) to driver air bag (inflator) module. • f...

  • Page 1152

    8b-113 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 1153

    Air bag system: 8b-114 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 1154

    8b-115 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 1155

    Air bag system: 8b-116 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 1156

    8b-117 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 1157

    Air bag system: 8b-118 specifications tightening torque specifications s6rw0d8207001 note the specified tightening torque is also described in the following. “side-air bag (inflator) module removal and installation” reference: for the tightening torque of fastener not specified in this section, refe...

  • Page 1158

    8b-119 air bag system: the adapter (1) will also give an idea of whether or not contact tension is sufficient, helping to find an open or intermittent open due to poor terminal contact. An sdm short bar release tool (2) is included in the connector test adapter kit. Inserting it into the sdm connect...

  • Page 1159

    Air bag system: 8b-120 special tool s6rw0d8208002 09932–75010 09932–75031 air bag load tool air bag deployment harness ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) ) / ) / ) 09932–75041 09932–76010 passenger air bag (inflator) module deployment fixture connector test adapter set ) / ) this set includes...

  • Page 1160

    8b-121 air bag system:.

  • Page 1161: 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 1162

    9-ii table of contents b-9 keyless start system circuit diagram......9a-103 c-1 combination meter circuit diagram (meter) ..........................................................9a-104 c-2 combination meter circuit diagram (indicator) ......................................................9a-105 c-...

  • Page 1163

    Table of contents 9-iii headlight bulb replacement (discharge headlight model).............................................9b-19 ballast removal and installation (discharge headlight model).............................................9b-19 igniter removal and installation (discharge headlight model)...

  • Page 1164

    9-iv table of contents front speaker removal and installation (if equipped)........................................................9c-19 rear speaker removal and installation (if equipped)........................................................9c-19 gps antenna removal and installation (if equipped)...

  • Page 1165

    Table of contents 9-v power door lock system symptom diagnosis (if equipped)..................................... 9f-3 power door lock system operation inspection (if equipped) .................................... 9f-3 keyless entry system symptom diagnosis (if equipped)................................

  • Page 1166

    9-vi table of contents repair instructions ............................................. 9m-1 roof molding removal and installation.............. 9m-1 splash guard removal and installation (if equipped)......................................................... 9m-2 specifications .......................

  • Page 1167: Precautions

    Precautions: 9-1 body, cab and accessories precautions precautions precautions on body, cab and accessories s6rw0d9000001 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 ...

  • Page 1168: Wiring Systems

    9a-1 wiring systems: body, cab and accessories wiring systems precautions cautions in body electrical system servicing s6rw0d9100001 when servicing the electric systems, observe the cautions described in “air bag warning in section 00” to protect electrical parts and to prevent a fire. General descr...

  • Page 1169

    Wiring systems: 9a-2 symbols and marks s6rw0d9101003 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 1170

    9a-3 wiring systems: 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 1171

    Wiring systems: 9a-4 how to read connector layout diagram s6rw0d9101004 [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 1172

    9a-5 wiring systems: how to read connector codes and terminal nos. S6rw0d9101005 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 numbe...

  • Page 1173

    Wiring systems: 9a-6 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 1174: Cross-Reference

    9a-7 wiring systems: 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 15a 2 6...

  • Page 1175: Cross-Reference

    Wiring systems: 9a-8 how to read ground point s6rw0d9101006 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 e09...

  • Page 1176

    9a-9 wiring systems: how to read power supply diagram s6rw0d9101007 refer to “power supply diagram”. Refer to “system circuit diagram”. How to read system circuit diagram s6rw0d9101008 the circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of th...

  • Page 1177

    Wiring systems: 9a-10 [d]: terminals-in-one-connector mark [e]: wire color [f]: shield wire [g]: ground point [h]: “from” or “to” (with id letter (s)) [i]: specification variation the white arrow between a and b means “or”. [j]: “from” (with id letter (s)) [k] “to” (with id letter (s)) [l]: connecto...

  • Page 1178

    9a-11 wiring systems: connector layout diagram connector layout diagram s6rw0d910a001 refer to “engine compartment”. Refer to “instrument panel”. Refer to “door, roof”. Refer to “floor”. Refer to “rear”. Engine compartment s6rw0d910a002 a: battery cable / c: engine harness (m15a engine rhd) c: engin...

  • Page 1179

    Wiring systems: 9a-12 a: battery cable / c: engine harness (m16a engine rhd) c: engine harness c42/grn heated oxygen sensor c194/blk generator c44/blu (a/ t) input sensor c195/blk starting motor c46/gry current sensor c196/- starting motor c47/blk maf sensor c282/- main fuse box c48/blk throttle pos...

  • Page 1180

    9a-13 wiring systems: a: battery cable / c: engine harness (m16a engine lhd) c: engine harness c37/gry knock sensor c165/blk (m/t) back-up light switch c39/blk ect sensor c166/gry (a/t) transaxle range sensor c42/blk heated oxygen sensor #1 c192/- generator c43/grn heated oxygen sensor #2 c194/blk g...

  • Page 1181

    Wiring systems: 9a-14 a: battery cable / c: engine harness (j20a engine rhd) c: engine harness c32/blk or gry cmp sensor c139/gry (a/t) shift solenoid c34/gry (a/t) vss c141/blk a/c compressor c36/blk map sensor c162/- oil pressure switch c37/gry knock sensor c165/blk (m/t) back-up light switch c39/...

  • Page 1182

    9a-15 wiring systems: a: battery cable / c: engine harness (j20a engine lhd) c06/n (a/t) tcm c102/gry ig coil #2 c07/n (a/t) tcm c103/gry ig coil #3 c31/gry ckp sensor c104/gry ig coil #4 c32/n cmp sensor c123/blu evap canister purge valve c37/gry knock sensor c139/gry (a/t) shift solenoid c39/blk e...

  • Page 1183

    Wiring systems: 9a-16 c: engine harness e: main harness (rhd) no./color connective position no./color connective position c01/gry ecm c101/gry ig coil #1 c06/n (a/t) tcm c102/gry ig coil #2 c07/n (a/t) tcm c103/gry ig coil #3 c31/gry ckp sensor c104/gry ig coil #4 c32/n cmp sensor c123/blu evap cani...

  • Page 1184

    9a-17 wiring systems: e: main harness no./color connective position no./color connective position e01/gry ecm e164/blk front fog light (l) e08/blk abs control module e165/n side turn signal light (r) e33/n wheel speed sensor (fr) e166/n side turn signal light (l) e35/blu wheel speed sensor (fl) e183...

  • Page 1185

    Wiring systems: 9a-18 e: main harness (lhd) e: main harness e40 e33 e165 e36 e161 e68 e151 e159 e70 e281 e163 e62 e63 e65 e37 e164 e64 e183 e08 e311 e312 e222 e224 e225 e223 e221 e371 (to c343) e166 e227 e229 e234 e230 e01 e35 e69 e248 e247 e233 e232 e241 e162 e152 e160 e231 e226 8 9 7 6 e i6rw0c910...

  • Page 1186

    9a-19 wiring systems: instrument panel s6rw0d910a003 e: main harness, power steering wire (rhd) e: main harness e: power steering wire e159/gry front turn signal light (r) e247/blk (taiwan) headlight lo relay (r) e160/gry front turn signal light (l) e248/blk (taiwan) headlight lo relay (l) e161/n fr...

  • Page 1187

    Wiring systems: 9a-20 e: main harness, power steering wire (lhd) e: main harness e: power steering wire e12 e13 e11 e387 (to l371) e04 e388 (to l372) e31 e61 e377 e378 e325 e323 e324 e381 (to g333) e382 (to g334) e191 e181 10 power steering wire e i6rw0c910909-02 no./color connective position no./co...

  • Page 1188

    9a-21 wiring systems: g: instrument panel harness, instrument panel antenna wire / s: contact coil (rhd) g: instrument panel harness g146 g141 g309 g34 g26 g253 g266 g255 g144 g241 g17 g310 g153 g248 g311 g61 g259 13 11 14 g16 g341 (to l374) g354 (to k154) g342 (to l375) g348 (to k153) g254 g152 g04...

  • Page 1189

    Wiring systems: 9a-22 g: instrument panel antenna wire s: contact coil g147/n ig switch g335/grn (if eqpd) main harness (to e383) g150/gry (if eqpd) ill cancel switch g341/blu floor harness (to l374) g151/grn front fog switch g342/n (if eqpd) floor harness (to l375) g152/n (if eqpd) headlight leveli...

  • Page 1190

    9a-23 wiring systems: g: instrument panel harness, instrument panel antenna wire / s: contact coil (lhd) g: instrument panel harness g146 g141 g309 g34 g253 g266 g255 g144 g241 g17 g311 g153 g63 g248 g310 g61 g259 g243 g267 g355 (to l409) 13 11 14 g16 g341 (to l374) g354 (to k154) g342 (to l375) g34...

  • Page 1191

    Wiring systems: 9a-24 g: instrument panel antenna wire s: contact coil g150/gry (if eqpd) ill cancel switch g341/blu floor harness (to l374) g151/grn front fog switch g342/n (if eqpd) floor harness (to l375) g152/n (if eqpd) headlight leveling switch g343/n floor harness (to l376) g153/n hazard swit...

  • Page 1192

    9a-25 wiring systems: door, roof s6rw0d910a004 j: front and rear door wire and rear door wire / k: roof wire, roof audio antenna wire (rhd) j: door harness (driver side) j: door harness (passenger side) j21 j153 j31 j83 j35 k51 j28 j154 k121 j32 k152 (to l383) j27 j85 j151 j25 k52 j22 j148 j86 j152 ...

  • Page 1193

    Wiring systems: 9a-26 j: rear door wire k: roof wire k: roof audio antenna wire j: front and rear door wire and rear door wire / k: roof wire, roof audio antenna wire (lhd) no./color connective position no./color connective position j25/blk rear power window motor (r) j145/n rear speaker (r) j26/blk...

  • Page 1194

    9a-27 wiring systems: j: door harness (driver side) j: door harness (passenger side) j: rear door wire k: roof wire k: roof audio antenna wire no./color connective position no./color connective position j21/blk front power window motor (driver side) j87/n mirror switch j27/n mirror motor (driver sid...

  • Page 1195

    Wiring systems: 9a-28 floor s6rw0d910a005 l: floor harness, coupling harness, floor antenna wire / q: side curtain air-bag wire, side air-bag (r) harness, side air-bag (l) harness / r: fuel pump wire (rhd) l: floor harness 21 20 24 19 17 18 15 16 l383 (to k152) l390 (to o231) l391 (to o232) l164 l13...

  • Page 1196

    9a-29 wiring systems: l: coupling harness l: floor antenna wire q: side curtain air-bag wire q: side air-bag (r) harness q: side air-bag (l) harness r: fuel pump wire l164/n rear door switch (l) l381/n rear door wire (to j217) l167/blk parking brake switch l382/n rear door wire (to j218) l170/n seat...

  • Page 1197

    Wiring systems: 9a-30 l: floor harness, floor antenna wire / q: side curtain air-bag wire, side air-bag (r) harness, side air-bag (l) harness / r: fuel pump wire (lhd) l: floor harness 21 22 20 24 19 17 18 15 16 l383 (to k152) l390 (to o231) l391 (to o232) l410 (to o240) l164 l308 l134 l292 l293 l32...

  • Page 1198

    9a-31 wiring systems: l: floor antenna wire q: side curtain air-bag wire q: side air-bag (r) harness q: side air-bag (l) harness r: fuel pump wire l170/n seat belt switch l381/n rear door wire (to j217) l171/yel (if eqpd) seat heater switch (driver side) l382/n rear door wire (to j218) l172/grn (if ...

  • Page 1199

    Wiring systems: 9a-32 rear s6rw0d910a006 o: rear end door harness, high mounted stop light wire, rear end door antenna wire o: rear end door harness o: high mounted stop light wire o: rear end door antenna wire 23 o231 (to l390) o232 (to l391) o181 o240 (to l410) o94 o122 o121 o95 o21 o92 o187 o186 ...

  • Page 1200

    9a-33 wiring systems: ground point ground (earth) point s6rw0d910c001 refer to “connector layout diagram”. 23 21 22 left side shown (lh) 19 20 (rh) 3 4 5 2 8 9 17 10 11 fwd fwd (rh) 12 13 (lh) 15 16 fwd 18 fwd 6 7 1 fwd 14 24 13 (rh) 11 (lh) lhd rhd i6rw0c910917-02.

  • Page 1201

    Wiring systems: 9a-34 power supply diagram power supply diagram s6rw0d910d001 g273 j/b j/b 3 wht/blu grn/wht red/wht 4 g147 3 1 2 8 blk 2 1 blk/gry 15a 15a 15a 2 3 1 4 6 7 8 1 e311 2 wht 11 12 14 15 16 blk/yel gry 3 yel/blu 2 1 blu/yel 4 blu red wht wht wht/red 11 wht/grn 14 wht/blu 15 16 wht/red gr...

  • Page 1202

    9a-35 wiring systems: 5 4 3 2 yel blu blu grn g273 1 e323 7 g273 5 2 j/b 42 19 30a 15a 25 30a 35 10a 23 15a 24 15a 20 15a 21 10a 22 10a 26 10a 27 15a 28 10a relay blower fan relay bcm 1 wht e324 2 29 10a 30 15a 39 15a 36 10a 38 30a 31 20a 37 15a flasher relay relay tail light relay relay h bcm excep...

  • Page 1203

    Wiring systems: 9a-36 fuses and the protected parts s6rw0d910d002 the chart below describes what parts each fuse protects. Fuses in main fuse box s6rw0d910d003 no. Fuse protected circuit 80 a all electric circuit battery generator 50 a j/b 50 a j/b 43 45 44 i7rw01910910-01.

  • Page 1204

    9a-37 wiring systems: individual circuit fuse box no. 1 s6rw0d910d004 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 use the desingnated fuses and relays only. Relay #1 "a-5" e222 relay #2 "a-5" e223 relay #3 "a-5" e224 "a-5" e227 relay relay "d-3" e234 compressor relay "e-1" e229 condenser fan relay ...

  • Page 1205

    Wiring systems: 9a-38 individual circuit fuse box no. 2 (in j/b (except taiwan)) s6rw0d910d009 19 25 20 26 34 21 27 35 22 28 36 23 29 37 24 30 38 31 39 32 40 33 41 42 use the desingnated fuses and relays only. I7rw01910912-02 no. Fuse description on the cover protected circuit 15 a rr wip rear wiper...

  • Page 1206

    9a-39 wiring systems: 30 a wip comb switch windshield washer motor windshield wiper motor rear wiper relay drl controller 10 a ig1 sig power steering control module a/t relay brake light switch 15 a a/b a/b sdm 10 a abs abs control module g sensor 10 a tail comb switch drl controller 15 a stop brake...

  • Page 1207

    Wiring systems: 9a-40 individual circuit fuse box no. 2 (in j/b (taiwan)) s6rw0d910d005 19 25 20 26 34 21 27 35 22 28 36 23 29 37 24 30 38 31 39 32 40 33 41 42 use the desingnated fuses and relays only. I7rw01910912-02 no. Fuse description on the cover protected circuit 15 a rr wip rear wiper motor ...

  • Page 1208

    9a-41 wiring systems: 10 a abs abs control module g sensor blank blank blank 15 a stop brake light switch 20 a d/l bcm blank blank blank 10 a st sig starting motor relay blank blank blank 10 a ig2 sig blower fan relay 10 a tail tail light relay 15 a dome audio bcm comb meter dlc ecm interior light i...

  • Page 1209

    Wiring systems: 9a-42 junction block (j/b) connector / fuse layout s6rw0d910d006 bcm side 2 1 6 5 3 4 4 3 2 12 1 11 14 13 15 5 9 8 7 17 6 16 19 18 20 10 6 5 4 3 2 8 1 7 10 9 12 11 3 4 6 5 2 1 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 g272 g271 g273 bcm (j/b side connector) 3 4 1 2 5 15 14 1...

  • Page 1210

    9a-43 wiring systems: relay side junction block inner circuit (overview (except taiwan)) s6rw0d910d010 abbreviations 5 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 blower fan relay relay 2 3 4 1 2 1 1 2 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 1 2 3 4 5 6 7 8 9 ...

  • Page 1211

    Wiring systems: 9a-44 1 ig2 sw 2 6 lamp fl 1 a/b cont a/b signal k-line k-line a/b signal bcm ig1 d/sl-in d/l-in d/ul-1 sequlity in hazard tail bcm d/l (bcm) rr def rly bcm (+b) dome lp cont acc r/wip gnd signal gnd (bcm) 4 a/b ind 3 2 9 8 25 11 24 23 20 6 14 12 18 1 2 15 10 7 22 17 3 1 ig 3 lp-l 2 ...

  • Page 1212

    9a-45 wiring systems: junction block inner circuit (detail (except taiwan)) s6rw0d910d011 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3...

  • Page 1213

    Wiring systems: 9a-46 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1214

    9a-47 wiring systems: e323 e325 e324 bcm g272 g271 g273 l312 l313 l314 l315 j/b 7 18 8 5 4 14 6 3 (continued) def ind rr def 6 htr mir (r) 7 htr mir (l) rr def rly rr-def rly epi stop sw dome (+b) dome (+b) dome lp (+b) 15 10 tail (+b) rr def dome horn-haz 30a 15a 15a 2 38 tail 10a 29 8 4wd cont rr ...

  • Page 1215

    Wiring systems: 9a-48 (continued) bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 ...

  • Page 1216

    9a-49 wiring systems: bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1217

    Wiring systems: 9a-50 junction block inner circuit (overview (taiwan)) s6rw0d910d007 abbreviations abbreviation full term abbreviation full term as assistant (front passenger) lp lamp ctr center o/h over head dr driver r/b relay box f-l front l r-l rear l f-r front r r-r rear r fr front rr rear inp ...

  • Page 1218

    9a-51 wiring systems: 1 ig2 sw 2 6 lamp fl 1 a/b cont 4 a/b ind 3 2 9 8 25 11 24 23 20 6 14 12 18 1 2 15 10 7 22 17 3 1 ig 3 lp-l 2 lp-r 4 +b 5 sw-l 7 gnd 6 sw-r 8 haz dome lp (+b) 5 4 3 gnd sp are-1 6 htr 4 st 1 ig2 5 ac c 3 ig sw (+b) 2 ig1 18 10 7 g271 4 15 g272 7 g272 19 g272 1 g272 12 g271 9 g2...

  • Page 1219

    Wiring systems: 9a-52 junction block inner circuit (detail (taiwan)) s6rw0d910d008 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 ...

  • Page 1220

    9a-53 wiring systems: bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1221

    Wiring systems: 9a-54 e323 e325 e324 bcm g272 g271 g273 l312 l313 l314 l315 j/b 7 14 8 5 4 14 6 3 (continued) def ind rr def 6 htr mir (r) 7 htr mir (l) rr def rly rr-def rly epi stop sw dome (+b) dome (+b) dome lp (+b) rr def dome horn-haz 30a 15a 15a 2 38 2 stop 15a 30 37 39 (continued) individual...

  • Page 1222

    9a-55 wiring systems: (continued) bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 ...

  • Page 1223

    Wiring systems: 9a-56 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1224

    9a-57 wiring systems: system circuit diagram system circuit diagram s6rw0d910e001 refer to “a-1 cranking system circuit diagram”. Refer to “a-2 charging system circuit diagram”. Refer to “a-3 ignition system circuit diagram (m15a engine, m16a engine)”. Refer to “a-3 ignition system circuit diagram (...

  • Page 1225

    Wiring systems: 9a-58 a-1 cranking system circuit diagram s6rw0d910e002 starting motor relay w "a-5" ecm e225 c195 1 c196 1 starting motor m blk 1 blk/gry c282 1 battery e371 c343 3 red individual circuit fuse box (no.1) 8 30a 33 10a wht wht j/b e325 10 4 2 3 1 red/wht st st sig yel/grn yel/grn yg "...

  • Page 1226

    9a-59 wiring systems: a-2 charging system circuit diagram s6rw0d910e003 20 e371 c343 20 g334 e382 blk/wht blk/wht blk/wht 80a main fuse box c192 j/b 1 c283 ig coil 43 15a 20 generator ic regulator 1 e325 5 c194 2 4 wht/blu wb bcm "a-8" 1 blu/yel by 3 brn/wht bw ecm "a-5" 9 wht/blu blk weld splice ta...

  • Page 1227

    Wiring systems: 9a-60 a-3 ignition system circuit diagram (m15a engine, m16a engine) s6rw0d910e004 15a 20 e371 c343 2 c101 1 3 ig coil #1 c102 blk blk/wht grn/yel blk/wht j/b ecm gy gw 20 ig coil blk blk ig coil #2 e325 5 3 grn/wht 1 3 2 c01 5 6 weld splice c312 blk/wht blk/wht i6rw0c910935-01.

  • Page 1228

    9a-61 wiring systems: a-3 ignition system circuit diagram (j20a engine) s6rw0d910e039 15a 20 e371 c343 2 c101 3 1 ig coil #1 c102 blk blk/wht blk/wht blk/wht grn/yel blk/wht j/b ecm gy gw 20 ig coil blk blk blk blk blk ig coil #2 e325 5 3 grn/wht 4 3 1 2 c01 20 21 weld splice c312 blk/wht gb grn/blk...

  • Page 1229

    Wiring systems: 9a-62 a-4 cooling system circuit diagram (m15a engine, m16a engine) s6rw0d910e005 e65 4 5 9 "a-5" lg br bw relay motor e222 3 1 2 1 blu/red lt grn brn/wht gry blk/red blk/yel blk/yel 30a rdtr 10 e221 1 2 15a fi 1 3 4 main relay blk ecm individual circuit fuse box (no.1) m i6rw0c91091...

  • Page 1230

    9a-63 wiring systems: a-4 cooling system circuit diagram (j20a engine) s6rw0d910e040 e65 4 5 9 lt grn "a-5" lg br bb bw g brn/wht bw blk/yel blk/yel relay #1 motor e222 3 1 2 4 3 1 blu/red blu/red blu/blk blk blu/red blu/red gry gry blu/wht grn grn 30a rdtr 10 e221 1 2 15a fi 1 3 4 main relay blk bl...

  • Page 1231

    Wiring systems: 9a-64 a-5 engine and a/c control system circuit diagram (m15a engine) s6rw0d910e006 yel/red e387 l371 10 12 l389 r151 4 2 pnk yel/red p pnk yel/red 3 1 4 3 3 3 1 e371 c343 blk/orn blk/orn blk/orn blk/orn 19 8 blk 4 2 r101 1 and fuel gauge main relay 1 blk/wht blk/red blu/yel c312 wel...

  • Page 1232

    9a-65 wiring systems: 2 c39 lt grn 1 c47 c01 c01 grn/orn grn/red brn/yel wht/red c122 3 blk/red blk/red blk/red blk/red 55 red/blk gry/red gry/blu weld splice c311 egr valve 4 6 3 1 2 5 3 4 5 6 map sensor c36 3 1 2 c124 ecm c91 2 1 c92 2 1 c93 2 1 c94 2 1 #2 #1 #3 #4 blu/red blu/wht blu/yel blu/orn ...

  • Page 1233

    Wiring systems: 9a-66 weld splice c311 ckp sensor 3 c31 51 pnk blk/orn blk/red 1 2 gw j/b 2 15a stop 30 15a dome 37 e01 20 grn/wht grn/wht grn e323 4 e181 brake light switch 1 2 ecm 2 cmp sensor c01 c01 blk blk blk 3 4 6 3 15 29 30 31 1 c32 52 c01 e01 22 30 28 13 red/yel blk/orn blk blk blk blk blk/...

  • Page 1234

    9a-67 wiring systems: tcm wht red 7 17 c06 49 44 c01 14 e01 36 41 35 12 27 c01 21 20 50 ecm wht abs cont.M app sensor throttle position sensor throttle sensor sub open close open close open close open close main sub main throttle motor red blu grn brn wht yel red blk wht grn red yel blu e08 4 19 1 1...

  • Page 1235

    Wiring systems: 9a-68 a-5 engine and a/c control system circuit diagram (m16a engine) s6rw0d910e041 yel/red e387 l371 10 12 l389 r151 4 2 pnk yel/red p pnk yel/red 3 1 4 3 1 e371 c343 blk/orn blk/orn blk/orn blk/orn 19 8 blk 4 2 r101 1 and fuel gauge main relay 1 blk/wht blk/red blu/yel c312 weld sp...

  • Page 1236

    9a-69 wiring systems: 2 c39 lt grn 1 c47 c01 c01 c124 ecm c91 2 1 c92 2 1 c93 2 1 c94 2 1 #2 #1 #3 #4 blu/red blu/wht blu/yel blu/orn blk/red blu/blk grn/orn grn/red brn/yel wht/red evap canister purge valve c123 c122 ect sensor gry/blu gry/blu "a-4" lg 30a rdtr 10 relay motor "a-1" generator blu/re...

  • Page 1237

    Wiring systems: 9a-70 weld splice c311 gw j/b 2 15a stop 30 15a dome 37 e01 20 grn/wht grn/wht grn e323 4 e181 brake light switch 1 2 ecm 2 cmp sensor c01 blk 3 6 15 31 30 1or3 c32 20 c01 e01 48 30 28 13 red/yel blk/orn blk/orn blk/orn blk blk blk c01 e01 58 blk/red 3or2 2or1 j/b e325 1 2 yg yel/grn...

  • Page 1238

    9a-71 wiring systems: tcm wht red 7 17 c06 12 4 c01 e01 14 54 57 19 55 26 c01 6 5 13 ecm wht abs cont.M app sensor throttle position sensor throttle sensor sub open close open close open close open close main sub main throttle motor red blu grn brn wht yel red blk wht grn red yel blu e08 3 18 1 12 e...

  • Page 1239

    Wiring systems: 9a-72 a-5 engine and a/c control system circuit diagram (j20a engine) s6rw0d910e042 yel/red e387 l371 10 12 l389 r151 4 2 pnk yel/red p pnk yel/red 3 1 4 3 3 3 1 e371 c343 blk/orn blk/orn blk/orn blk/orn 19 8 blk 4 2 r101 1 and fuel gauge main relay 1 blk/wht blk/red blu/yel c312 wel...

  • Page 1240

    9a-73 wiring systems: 2 c39 lt grn 1 c47 c01 c01 pressure switch c64 ecm c91 2 1 c92 2 1 c93 2 1 c94 2 1 #2 #1 #3 #4 blu/red blu/wht blu/yel blu/orn blk/red grn/blk blu/wht blu/blk evap canister purge valve c123 ect sensor gry/blu gry/blu gry "a-4" lg g 30a rdtr 10 relay #1 motor "a-1" generator blu...

  • Page 1241

    Wiring systems: 9a-74 g333 e381 s171 g346 16 15 14 gw gy j/b 2 15a stop 30 15a dome 37 e01 20 grn/wht grn/wht grn 12 10a ig1 sig 26 lt grn/blk 8 grn/yel 6 22 red/wht lt grn 21 blk/yel red/wht red/blk lt grn blk/yel rb e325 e323 e325 e323 4 15a ig coil 20 5 e181 3 4 brake light switch main resume/ ac...

  • Page 1242

    9a-75 wiring systems: tcm wht red 7 17 c06 49 44 c01 14 e01 36 41 35 12 27 c01 21 20 50 ecm wht abs cont.M app sensor throttle position sensor throttle sensor sub open close open close open close open close main sub main throttle motor red blu grn brn wht yel red blk wht grn red yel blu e08 4 19 1 1...

  • Page 1243

    Wiring systems: 9a-76 a-6 a/t control system circuit diagram s6rw0d910e007 grn/red shift lock relay e241 grn/red c07 20 8 7 19 18 e371 c343 grn/yel back-up light 14 red "d-8" brake light switch "d-7" r gw transaxle range sensor tcm l101 4 a/t select switch a/t shift lock solenoid a/t shift lever ass...

  • Page 1244

    9a-77 wiring systems: tcm lock up solenoid a/t fluid temperature sensor shift solenoid no.2 shift solenoid no.1 11 12 c139 1 2 9 blk/yel brn orn 15 4 2 5 wht/blu pressure control solenoid lt grn/blk gry shift solenoid lt grn ecm wht red wht/red ppl wht/red blk/wht blk/red blk/red blk/red blk/wht blk...

  • Page 1245

    Wiring systems: 9a-78 a-7 immobilizer system circuit diagram s6rw0d910e008 j/b side connector (bcm) except taiwan taiwan except m16a engine m/t m16a engine m/t a b c d e c b b c d e ecm icm dlc if eqpd g211 4 j/c g309 5 7 11 4 ig coil g272 6 j/b 29 15a 20 blk/wht 13 28 yel/blk yb w yr e382 g334 19 g...

  • Page 1246

    9a-79 wiring systems: a-8 body control system circuit diagram (except taiwan) s6rw0d910e009 4 g04 e04 g04 2 wht red 3 g211 1 6 14 wht red pnk lt grn g04 dlc 4 11 14 blk blk blk b b j/c g309 13 l312 5 2 14 12 receiver 5 e04 9 blu blu blu blu blu blu wht "f-2" "f-3" p/s cont.M abs cont.M "b-9" kls ecm...

  • Page 1247

    Wiring systems: 9a-80 15 7 "d-5" 16 b b g04 10 blu/yel blu/yel j/c g308 g146 1 4 7 4 main switch (key switch) rhd flasher relay dome g271 5 15a 37 acc mtr 15a 23 22 8 1 12 horn -haz 15a 39 11 10a 22 wht/red wht/red yel/red yel/blk 1 e37 2 ambient temperature sensor "b-5" switch 6 14 16 17 12 5 red/b...

  • Page 1248

    9a-81 wiring systems: 18 17 grn/wht grn/yel "e-1" "e-2" mode control switch auto unit g04 l01 "b-5" "b-5" "b-5" "b-5" 11 9 l346 10 b e e rear grn grn red/blu grn red/blu b l347 red/blu grn red/blu grn red/blu b 1 10 b e grn/red red/blu blu/yel grn rear end 4 wht/red rear end door lock switch 3 d d f...

  • Page 1249

    Wiring systems: 9a-82 3 a a g271 6 l312 13 j/c g309 blk/orn blk/orn 4 l314 16 blk/orn c c j/c g308 c c j/c l346 yel "a-2" generator rhd "d-5" spot light "d-5" interior light e04 4 wht/blu wb wht/red wht/red wht/red wr wr 11 yel y gry 8 g04 g "g-2" multi information display bcm auto unit "e-2" j/b a ...

  • Page 1250

    9a-83 wiring systems: a-8 body control system circuit diagram (taiwan) s6rw0d910e043 1 g05 3 wht red 2 g211 4 6 14 wht red pnk lt grn g05 dlc 4 11 14 12 blk blk blk b b j/c g309 18 blk/wht g04 1 wht/red 13 19 20 receiver 35 blu 15 blu blu blu blu blu blu wht wht "f-2" "f-3" p/s cont.M abs cont.M "b-...

  • Page 1251

    Wiring systems: 9a-84 38 39 "d-5" "d-1" blk/blu 3 a a b b g04 2 blu/yel blu/yel j/c g307 1 g265 j/c g308 g146 1 4 main switch (key switch) dome g271 5 15a 37 acc g272 5 15a 23 wht/red wht/blk wht/red yel/red yel/red yel/blk yel/blk 1 e37 2 ambient temperature sensor "b-5" switch 8 40 37 36 27 26 red...

  • Page 1252

    9a-85 wiring systems: 6 20 grn/wht grn/yel "e-1" "e-2" mode control switch auto unit g05 g04 g05 g06 "b-5" "b-5" "b-5" "b-5" 7 2 l346 3 b e e rear grn grn red/blu grn red/blu b l347 red/blu grn red/blu grn red/blu b 9 8 b e grn/red red/blu blu/yel blu/yel grn rear end 30 wht/red rear end door lock s...

  • Page 1253

    Wiring systems: 9a-86 19 g04 1 b b g06 11 j/c g309 a a j/c g306 blk 14 blk "f-1" yel blk a/b sdm switch auto unit "d-6" model control switch "e-1" "e-2" a/t shift lever "d-4" switch "d-3" audio "g-1" y g04 34 g05 wht w 14 blk/yel blk/yel by c c j/c g306 14 blk/yel c c j/c g308 yel blk by "a-2" gener...

  • Page 1254

    9a-87 wiring systems: a-10 4wd control system (except taiwan) s6rw0d910e010 4wd cont.M g26 12 3 2 11 2wd/4wd switch dlc g211 6 14 l174 1 5 6 4 2 10 7 5 4 16 21 l376 g343 19 e382 g334 19 e371 c343 8 17 r w "c-3" r ry w bcm "a-8" "d-4" 11 16 11 4 blk g272 g271 g271 8 8 5 j/b 21 10a back 15a 4wd 32 15a...

  • Page 1255

    Wiring systems: 9a-88 b-1 windshield wiper and washer circuit diagram s6rw0d910e011 j/b lo hi e64 blk e323 3 9 g141 11 switch motor motor 18 blu/wht blu/wht blu/red blu/red blu/yel blu/yel 4 wip 30a 25 2 e62 1 g271 1 yel/grn m yel/grn blu/orn 13 7 blk off on wf ew p t mist off int lo hi +b +2 +1 +s ...

  • Page 1256

    9a-89 wiring systems: b-2 rear wiper and washer circuit diagram (except taiwan) s6rw0d910e044 j/b o21 4 2 3 blk blk blk blk blk l312 l314 4 g272 9 b g141 9 g272 8 1 g04 l390 o231 2 o231 l391 20 m wash off int on on+wash wr ew +1r p t blk blk 2 e63 1 yel yel yel m yel/blk orn orn yel 30a wip j/c g309...

  • Page 1257

    Wiring systems: 9a-90 b-2 rear wiper and washer circuit diagram (taiwan) s6rw0d910e012 j/b o21 4 2 3 blk blk blk blk blk l312 l314 4 g272 9 b g141 9 g272 4 8 1 3 g04 l390 o231 2 o231 l391 5 20 m wash off int on on+wash wr ew +1r p t blk blk 2 e63 1 yel yel red yel m yel/blk orn orn yel 30a wip j/c g...

  • Page 1258

    9a-91 wiring systems: b-3 rear defogger circuit diagram (except taiwan) s6rw0d910e045 l390 o231 3 o231 l390 2 blk/red o181 1 o182 1 23 21 4 3 2 1 30a rr def 38 relay grn/yel g04 17 g271 7 blk/red blk/red l314 8 rear def mode control switch blk/orn 13 blk/orn g309 j/c a a blk blk blk g154 g20 j/b gy ...

  • Page 1259

    Wiring systems: 9a-92 b-3 rear defogger circuit diagram (taiwan) s6rw0d910e013 l390 o231 3 o231 l390 2 blk/red o181 1 o182 1 23 21 4 3 2 1 30a rr def 38 relay grn/yel brn g04 20 g271 7 g272 14 blk/red blk/red l314 8 rear def mode control switch blk/orn 13 blk/orn g309 j/c a g05 14 a blk blk blk g154...

  • Page 1260

    9a-93 wiring systems: b-4 power window circuit diagram s6rw0d910e014 2 1 j82 l380 j216 j215 l379 12 12 13 6 14 6 16 2 3 5 10 11 17 16 1 4 30a p/w 42 sub switch main switch j22 1 2 grn red red 15 l314 j/b blk blk blk 14 13 wht/blu wht/blu wht/blu wht/blu wht/blu wht/blu 1 2 3 4 5 6 red/wht wht/blu gr...

  • Page 1261

    Wiring systems: 9a-94 j84 l382 j218 j83 2 3 5 2 2 6 1 3 5 l381 j217 2 6 1 5 j26 j25 red/blk blu/yel wht/blu grn/yel wht/blu wht/grn 11 4 3 j215 l379 1 4 1 2 m grn red 1 4 1 2 grn red 1 2 3 4 5 6 unlock up off down up off down lock ig e rlu rld rear (l) sub switch rear motor (l) m unlock up off down ...

  • Page 1262

    9a-95 wiring systems: b-5 power door lock circuit diagram (except taiwan) s6rw0d910e047 17 16 23 34 switch j31 l379 j215 blk main switch 13 14 9 5 12 22 33 j81 blk blk brn lt grn/blk gry/red gry/wht 17 blk 20 up off down lock unlock e receiver g254 g04 l01 lt grn pnk 14 13 12 3 1 4 up off down lock ...

  • Page 1263

    Wiring systems: 9a-96 11 4 l346 7 4 2 l381 j217 8 b e e 7 l382 j218 8 7 l390 o231 o121 rear motor (r) j/c grn grn b j35 red/blu grn red/blu grn yel red/blu 3 m b 1 j32 l347 l01 m 1 3 rear motor (l) j36 m b e 25 26 m 24 l380 j216 2 o231 l390 grn 3 yel yel red/blu grn 3 yel yel red/blu grn red/blu yel...

  • Page 1264

    9a-97 wiring systems: b-5 power door lock circuit diagram (taiwan) s6rw0d910e015 36 37 23 34 switch j31 l379 j215 brn blk lt grn/blk main switch 13 14 9 26 27 22 33 g352 l402 8 9 4 5 1 j81 gry/red blk blk gry/wht brn lt grn/blk gry/red gry/wht 17 blk 20 up off down lock unlock e receiver g254 g05 g0...

  • Page 1265

    Wiring systems: 9a-98 7 4 l346 7 4 2 l381 j217 8 b e e 7 l382 j218 8 7 l390 o231 3 10 2 12 11 g352 l402 o121 rear motor (r) j/c grn grn grn red/blu blk/red b j35 5 g06 red/blu grn red/blu grn grn red/blu 3 m b 9 2 3 j32 l347 g06 g05 4 g271 m 1 3 1 3 rear motor (l) j36 m b e 25 26 m l380 j216 2 o231 ...

  • Page 1266

    9a-99 wiring systems: b-6 power mirror circuit diagram (except taiwan) s6rw0d910e048 13 13 5 9 r l 3 20 7 7 j87 l315 l379 j215 6 j27 j28 13 j215 l379 j215 l379 blk blk 17 17 20 17 switch motor if eqpd m m down up 5 r l 6 motor m m m down set rtr up m set rtr 4 3 27 b b 4 2 1 blu/wht blu/wht acc 15a ...

  • Page 1267

    Wiring systems: 9a-100 b-6 power mirror circuit diagram (taiwan) s6rw0d910e016 13 10 4 12 5 13 5 9 r l 3 20 7 7 j87 l315 l379 j215 6 j27 j28 13 j215 l379 j215 l379 blk blk 17 17 20 17 switch motor m m down up 5 r l 6 motor m m m down set rtr up m set rtr 4 3 27 b b 4 2 1 blu/wht blu/wht acc 15a 23 r...

  • Page 1268

    9a-101 wiring systems: b-7 horn circuit diagram s6rw0d910e017 3 3 j/b 15a horn-haz 39 grn blu 1 1 steering switch (horn switch) contact coil h 4 3 1 2 20 relay h e281 s61 e325 g272 b g346 s171 1 j/b side connector (bcm) except taiwan a b bcm a b i6rw0c910971-01.

  • Page 1269

    Wiring systems: 9a-102 b-8 seat heater circuit diagram s6rw0d910e060 lt grn lt grn lt grn red/yel red/yel red/yel red/yel blu blk l171 5 6 l281 3 4 4 1 2 l172 5 l282 3 4 blk gry blk 4 1 2 blk blk blk blk blk switch free lock free lock switch l314 15 15a s/h 34 j/b 6 j/c l346 c a l347 ry b g "d-4" 7 ...

  • Page 1270

    9a-103 wiring systems: b-9 keyless start system circuit diagram s6rw0d910e018 g271 kls ecm bcm wht/red wht/red wht/red wht/red blu/yel wht red wht red orn blu/yel "a-8" w wr r g16 14 34 20 18 19 blk/orn blk/orn 9 5 j/b 15a dome 37 g272 8 10a back 21 11 15a acc2 24 b b b b j/c j/c g308 b g307 b a a j...

  • Page 1271

    Wiring systems: 9a-104 c-1 combination meter circuit diagram (meter) s6rw0d910e019 dome j/b 15a 37 mtr 10a 22 wht/red wht/red (can) g241 32 31 5 stepper motor and led output driver voltage regulator micro controller interface circuit ill (dial) ill (display) ill (pointer) g271 6 red/blk 16 b b blk b...

  • Page 1272

    9a-105 wiring systems: c-2 combination meter circuit diagram (indicator) s6rw0d910e020 dome 15a 37 mtr 10a 22 wht/red wht/red 32 31 5 stepper motor and led output driver voltage regulator micro controller keyless start g271 6 red/blk "d-1" beam 22 red (dimmer / passing) j/b 16 b b blk blk j/c g308 1...

  • Page 1273

    Wiring systems: 9a-106 c-3 combination meter circuit diagram (warning light) s6rw0d910e021 j/b mtr 10a 22 31 stepper motor and led output driver voltage regulator micro controller g271 6 red/blk 5 16 yb yel/blk "f-1" can high low wht wht red r w 10 g241 9 7 l01 g05 red/blu brn/yel l167 1 parking bra...

  • Page 1274

    9a-107 wiring systems: gear abs belt door charge check engine airbag oil drl d/f lock 4wd auto set cruise immobi brake fuel dome 15a 37 32 5 wht/red wht/red j/b g271 g241 1 2 j/c g308 b b if eqpd i6rw0c910976-01.

  • Page 1275

    Wiring systems: 9a-108 d-1 headlight system circuit diagram (except taiwan) s6rw0d910e049 1 headlight (r) headlight (l) wht/blu red dimmer / passing switch light switch 2 2 3 3 15 1 22 g241 e151 g272 e152 g271 5 32 wht/red wht/red wht/red 15a 37 dome wht/red blk 13 g144 15a 16 15a 15 h/l r h/l l 13 ...

  • Page 1276

    9a-109 wiring systems: yel/grn red/wht red/grn 3 red/yel 5 20 e382 g334 30a wip 25 drl controller g214 10 wht/red 8 blu/wht 6 g271 1 4 9 gry gry blk/orn blk/orn 2 blk blk 1 "c-3" 1 4 2 3 g ry j/b bcm "d-4" 11 14 13 a a j/c j/b with drl controller g309 i6rw0d910917-01.

  • Page 1277

    Wiring systems: 9a-110 d-1 headlight system circuit diagram (taiwan) s6rw0d910e022 2 headlight (l) headlight (r) headlight hi relay (l) wht/red wht/red wht/blu red/wht red/wht dimmer / passing switch light switch 1 1 3 3 2 e152 e151 red/yel wht/blu 8 2 13 g144 15a 15 15a 16 h/l l h/l r brn brn/wht w...

  • Page 1278

    9a-111 wiring systems: d-2 position, tail and licence plate light system circuit diagram (except taiwan) s6rw0d910e051 3 5 l134 1 2 o95 1 2 o94 (r) (l) (l) (r) blk 7 15 g272 g144 10a tail 29 1 2 e161 1 2 e162 blk blk blk blk blk j/b l314 3 e325 16 blk blk licence plate light #2 licence plate light #...

  • Page 1279

    Wiring systems: 9a-112 d-2 position, tail and licence plate light system circuit diagram (taiwan) s6rw0d910e023 3 5 l134 1 2 o95 1 2 o94 (r) (l) (r) (l) blk 18 7 12 g272 10 11 blk g144 13 g05 g04 12 10a tail 36 1 2 e161 1 2 e162 blk blk blk blk blk j/b l314 3 e325 16 blk blk licence plate light #2 l...

  • Page 1280

    9a-113 wiring systems: d-3 front fog light system circuit diagram (except taiwan) s6rw0d910e052 fr fog (r) (l) 2 e164 1 2 e163 1 20a 14 relay switch 3 e234 2 1 4 wht/grn gry/red lt grn blk blk blk lt grn lt grn 1 d d g334 e382 free ig load e il ile terminal position push 6 7 4 8 g306 g151 red/yel re...

  • Page 1281

    Wiring systems: 9a-114 d-3 front fog light system circuit diagram (taiwan) s6rw0d910e024 fr fog (r) (l) 2 e164 1 2 e163 1 20a 14 relay switch 3 e234 2 1 4 wht/grn red/yel red/yel lt grn blk blk blk lt grn lt grn 14 d d g333 e381 13 e381 g333 free ig load e il ile terminal position push 7 6 4 8 g306 ...

  • Page 1282

    9a-115 wiring systems: d-4 illumination light system circuit diagram (except taiwan) s6rw0d910e053 blk blk blk red/blu red/blu 11 j/c j/c b b 14 g309 a a c c g306 blk/yel red/yel by yel yel y y multi information display "g-2" audio "g-1" "c-3" ill cancel switch g150 7 5 8 4 push free wht/red 10a tai...

  • Page 1283

    Wiring systems: 9a-116 d-4 illumination light system circuit diagram (taiwan) s6rw0d910e025 blu/wht red/yel 10a tail 36 j/b 12 g272 10 g144 13 13 17 21 red/yel red/yel red/yel red/yel red/yel l314 3 blk blk blk blk "d-3" a/t ry switch j/c g306 red/yel ry red/yel switch auto unit ry red/yel mode cont...

  • Page 1284

    9a-117 wiring systems: d-5 interior light system circuit diagram (except taiwan) s6rw0d910e054 15a 37 dome j/b off door on on off k51 l312 2 6 3 1 interior light spot light off on off on l161 1 1 blk blk blk off on off on l164 l162 1 l163 1 rear door switch front door switch blk blk blk blk wht blk ...

  • Page 1285

    Wiring systems: 9a-118 d-5 interior light system circuit diagram (taiwan) s6rw0d910e026 15a 37 dome j/b off door on on off k51 l312 2 6 3 1 interior light spot light off on off on l161 1 1 blk/blu blk blk blk off on off on l164 l162 1 l163 1 rear door switch front door switch blk/red blk blk blk blk...

  • Page 1286

    9a-119 wiring systems: d-6 turn signal and hazard warning light system circuit diagram (except taiwan) s6rw0d910e055 4 d d g153 g306 2 switch blk/orn rear turn signal light 6 l134 blk 11 8 12 22 haz lp-l lp-r flasher relay red/yel wht red/yel turn signal switch g144 10a mtr 22 red/blu blu/red j/b l ...

  • Page 1287

    Wiring systems: 9a-120 9 grn/red grn/red grn/red 9 turn (l) turn (r) e165 12 g271 6 blu/yel blu/yel blu/yel grn/red blu/yel "c-2" gr by front turn signal light (r) side turn signal light (r) e159 2 e166 front turn signal light (l) side turn signal light (l) blk e323 5 blk blk blk blk 1 2 1 2 1 2 1 e...

  • Page 1288

    9a-121 wiring systems: d-6 turn signal and hazard warning light system circuit diagram (taiwan) s6rw0d910e027 4 d d g153 g306 2 switch blk/orn rear turn signal light 6 l134 blk 11 8 1 3 2 4 haz lp-l lp-r flasher relay red/yel wht red/yel blu/wht wht wht turn signal switch 6 g144 7 5 10a mtr 22 red/b...

  • Page 1289

    Wiring systems: 9a-122 9 grn/red grn/red grn/red 9 turn (l) turn (r) e165 12 g271 6 blu/yel blu/yel blu/yel grn/red blu/yel "c-2" gr by front turn signal light (r) side turn signal light (r) e159 2 e166 front turn signal light (l) side turn signal light (l) blk e323 5 blk blk blk blk 1 2 1 2 1 2 1 e...

  • Page 1290

    9a-123 wiring systems: d-7 brake light system circuit diagram s6rw0d910e028 brake light switch shift lock relay (r) brake light grn lt grn/blk blk (l) e181 l134 grn/wht grn/wht grn/wht grn/wht 5 l315 e325 j/b "f-2" abs cont.M grn/wht 2 2 1 "a-5" ecm 21 gw gw grn/yel "a-5" ecm gy gw 4 2 3 1 j/b l133 ...

  • Page 1291

    Wiring systems: 9a-124 d-8 back-up light system circuit diagram s6rw0d910e029 blk blk blk 20 21 blk blk 23 back-up light switch back-up light back-up light (r) red red red/blk red/blk on off j/b 10a 21 back e371 c343 c165 2 1 l134 1 l133 1 red red red l315 3 e325 11 j/b e325 14 5 5 (l) r 14 13 l390 ...

  • Page 1292

    9a-125 wiring systems: d-9 headlight beam leveling system circuit diagram (manual leveling) s6rw0d910e056 10a grn grn red/blk grn blk blk switch 21 back red/blk red/blk e69 g272 3 e68 3 2or1 8 e325 14 2or1 1or2 g152 e381 g333 4 3 5 1 g333 e381 2 1or2 blk blk actuator (l) actuator (r) control circuit...

  • Page 1293

    Wiring systems: 9a-126 d-10 rear fog light circuit diagram s6rw0d910e061 20 21 23 blk blk blk l390 o231 2 15a rr fog blk yel/grn yel/grn yel/blk off on 5 4 "c-1" yg yg g144 3 g272 10 4 j/b g343 l376 4 36 l133 l134 b a a b switch (comb switch) rhd lhd a b i6rw0d910922-03.

  • Page 1294

    9a-127 wiring systems: e-1 heater system circuit diagram s6rw0d910e030 brn grn/wht 10a back 21 m blk/red j/b j/b blk/orn g309 j/c g62 fresh / recircle actuator 6 1 4 grn red 9 g154 7 8 g306 j/c 4 g272 bcm "a-8" gw bcm "b-3" gy grn/yel 8 red/yel red/yel red/blk red/blk red/blk 10 13 14 5 6 rear def r...

  • Page 1295

    Wiring systems: 9a-128 red m blu/wht yel blk/wht blk/wht blu/wht blu/wht blk/wht g155 5 brn j/b blk/yel 2 1 g61 11 g65 fan driver 4 2 1 3 blower fan motor g273 6 1 3 2 7 6 fan heater fan switch 4 2 5 1 3 30a blw 6 10a 35 ig2 sig blower fan relay e323 7 g272 9 g309 j/c 11 14 b b blk blk blk blk blu 1...

  • Page 1296

    9a-129 wiring systems: e-2 auto a/c system circuit diagram s6rw0d910e031 except taiwan taiwan except m16a engine m/t m16a engine m/t a b c d g20 5 23 6 12v blk blk blk blk blk/orn red/yel 26 blk/red red/yel g271 ill auto a/c panel auto unit 13 yel "a-8" y "b-3" br 3 7 blu wht/red wht/red blu wht/red...

  • Page 1297

    Wiring systems: 9a-130 g32 1 3 24 9 29 g20 10 25 g64 m 16 2 15 28 12 1 27 3 1 m 2 g65 blk/wht gry/blu gry/red wht brn/wht wht/blk orn pnk wht yel wht wht/blu brn/yel orn orn orn blk/yel blk blk/yel blk/yel blu blk/wht gry 30 4 blu/red blk/wht blk fan driver diode #1 auto unit blower fan motor evap t...

  • Page 1298

    9a-131 wiring systems: f-1 air-bag system circuit diagram (4ch) s6rw0d910e032 2 orn y a/b sdm l04 j/b 15a a/b 27 red l313 bcm 15 blk 1 15a dome 37 wht/red g271 5 e388 l372 1 g349 l399 2 pnk/blk e40 forward sensor 1 2 contact coil g347 s172 l377 g344 2 l399 g349 1 1 l283 1 2 s121 yel/red grn 1 2 2 1 ...

  • Page 1299

    Wiring systems: 9a-132 f-1 air-bag system circuit diagram (8ch) s6rw0d910e033 y a/b sdm l04 j/b 15a a/b 27 red wht/red l313 bcm 15 blk 1 15a dome 37 g271 5 2 28 32 27 37 "a-8" yel yel g349 l399 j/c g308 b b l399 g349 1 5 4 11 14 e382 g334 19 c343 e371 8 blk/orn wht/red blk/orn blk/orn 7 blu ppl/wht ...

  • Page 1300

    9a-133 wiring systems: q102 q103 1 2 21 22 20 19 blk/yel brn/yel yel/grn yel/blu blk/yel brn/yel yel/grn yel/blu 1 2 l395 q132 1 2 2 45 44 46 47 sensor sensor lt grn wht/grn wht/red lt grn/blk 1 2 orn yb e388 l372 1 pnk/blk e40 forward sensor check terminal 1 2 2 50 51 orn pnk/blk yel/blk yel/blk "c...

  • Page 1301

    Wiring systems: 9a-134 f-2 anti-lock brake system circuit diagram s6rw0d910e034 23 26 24 25 7 2 13 e08 blk 30a abs sol 40a abs mot 11 wht/red wht/blu grn/wht 8 blk r red w wht red wht red wht "a-8" "a-5" j/b 10a abs 28 e325 9 grn/orn 9 l315 l33 8 3 2 grn/yel grn/orn 6 gw "d-7" brake light switch ind...

  • Page 1302

    9a-135 wiring systems: a yel abs cont.M l32 lt grn/blk lt grn lt grn/blk lt grn l371 e387 2 8 wheel speed sensor (rl) brn yel brn 7 1 l31 wheel speed sensor (rr) wht/blk e33 wheel speed sensor (fr) wht red e35 wheel speed sensor (fl) red/blk 18 17 11 22 19 20 21 10 e08 1 2 1 2 1 2 1 2 16 dlc e382 g3...

  • Page 1303

    Wiring systems: 9a-136 f-4 power steering system circuit diagram s6rw0d910e036 p/s cont.M 60a p/s 12 e325 12 j/b 10a ig1 sig 26 red 20 e377 e378 torque sensor blk e13 10 grn lt grn/blk wht 10 grn 8 yel 18 blk 9 19 1 2 1 e11 ppl ppl 4 lt grn/blk 1 e377 e378 4 ppl g333 e381 e31 e13 e11 e11 individual ...

  • Page 1304

    9a-137 wiring systems: b p/s cont.M 3 e377 e378 e61 m red blk e12 ecm "a-5" brn 1 2 11 12 brn 6 e11 red/blu 5 rb 14 red/blu g211 dlc 4 blk blk b b j/c motor g309 blu blu e382 g334 19 e382 g334 12 e371 c343 8 blk/orn 5 j/b 15a dome 37 g271 5 wht/red blk/orn 7 16 b b j/c g308 blk/orn 11 14 wht/red blk...

  • Page 1305

    Wiring systems: 9a-138 g-1 audio system circuit diagram s6rw0d910e037 g271 5 5 4 11 2 1 2 1 5 15 6 16 "d-4" ry wht/red wht/red g248 1 g307 j/b 15a dome 37 j/c blu/wht blu/wht red/yel 15a acc2 24 rear (r) j/c rear (l) gry/red gry lt grn/blk lt grn gry/red gry lt grn/blk lt grn gry/red gry lt grn/blk ...

  • Page 1306

    9a-139 wiring systems: k121 1 2 10 2 10 2 2 1 1 2 2 1 1 2 11 g248 g248 blk tweeter (l) front (l) j142 j148 tweeter (r) front (r) j141 j147 blk yel blk audio g306 j/c ill cancel switch a a c c g306 j/c c c steering switch (audio control switch) 19 g267 10 1 20 blk grn wht/grn blk blu pnk blu pnk blu ...

  • Page 1307

    Wiring systems: 9a-140 g-2 multi information display / accessory socket system circuit diagram s6rw0d910e038 11 15a acc 2 24 j/c g307 g y multi information display j/b bcm 13 blk/orn 2 blk/orn 15a dome 37 15a acc 23 5 wht/red gry yel blu/wht g253 1 4 3 wht/red yel red/yel 7 g309 j/c j/b 5 g272 g271 ...

  • Page 1308

    9a-141 wiring systems: g-4 navigation system circuit diagram s6rw0d910e059 g271 5 5 4 11 2 1 2 1 5 15 6 16 "d-4" ry wht/red wht/red g248 g248 1 g307 j/b 15a dome 37 j/c blu/wht blu/wht red/yel 15a acc2 24 rear (r) j/c rear (l) gry/red gry lt grn/blk lt grn gry/red gry lt grn/blk lt grn gry/red gry l...

  • Page 1309

    Wiring systems: 9a-142 k121 l307 1 2 10 2 10 2 2 1 1 2 2 1 1 2 11 g248 g248 blk tweeter (l) front (l) j142 j148 tweeter (r) front (r) j141 j147 blk blk navigation g306 j/c a a c c g306 j/c c c steering switch (audio control switch) 19 g267 10 2 20 blk grn wht/grn blk blu pnk blu pnk blu pnk blu blk ...

  • Page 1310

    9a-143 wiring systems: list of connector list of connectors s6rw0d910f001 refer to “c connector”. Refer to “e connector”. Refer to “g connector”. Refer to “j connector”. Refer to “k connector”. Refer to “l connector”. Refer to “o connector”. Refer to “q connector (8ch)”. Refer to “r connector”. Refe...

  • Page 1311

    Wiring systems: 9a-144 c91 c92 c93 c94 c101 c101 m15a engine, m16a engine j20a engine c102 c102 c103 c104 c122 c123 m15a engine, m16a engine j20a engine j20a engine j20a engine if eqpd m15a engine, m16a engine c123 c124 c139 c139 c141 c162 j20a engine if eqpd m15a engine a/t, m16a engine a/t j20a en...

  • Page 1312

    9a-145 wiring systems: e connector s6rw0d910f003 e01 e04 except taiwan e08 e11 e12 e13 e31 e33 e35 e36 e37 e40 e61 e62 e63 e64 e65 m16a engine e65 e68 e69 e70 e151 e152 j20a engine if eqpd if eqpd e159 e160 e161 e162 e163 e164 e165 e166 e181 e183 e191 e192 e221 e222 e223 e224 e225 j20a engine j20a e...

  • Page 1313

    Wiring systems: 9a-146 g connector s6rw0d910f004 e226 e227 e229 e230 e231 e232 a/t if eqpd e233 e234 e241 e247 e248 e281 if eqpd if eqpd if eqpd e311 e312 e323 e324 e325 e371 (to c343) e377 (to e378) e378 (to e377) e381 (to g333) e382 (to g334) e387 (to l371) e388 (to l372) g04 g04 except taiwan tai...

  • Page 1314

    9a-147 wiring systems: g17 g20 auto a/c g26 g32 g34 g35 if eqpd auto a/c auto a/c g61 g62 g63 g64 g65 g65 auto a/c auto a/c auto a/c manual a/c g141 g144 g146 g147 g150 g151 g152 g153 g154 if eqpd if eqpd manual a/c g155 g211 g214 manual a/c if eqpd g241 g248 if eqpd g251 g253 g254 g255 g259 if eqpd...

  • Page 1315

    Wiring systems: 9a-148 g272 g273 g306 g307 g308 g309 if eqpd g310 g311 g333 (to e381) auto a/c g334 (to e382) g335 (to e383) g341 (to l374) if eqpd g342 (to l375) g343 (to l376) g344 (to l377) g345 (to l378) g346 (to s171) if eqpd with auto cruise g346 (to s171) g347 (to s172) g347 (to s172) g348 (t...

  • Page 1316

    9a-149 wiring systems: j connector s6rw0d910f005 k connector s6rw0d910f006 j21 j21 j22 j25 j26 j27 type a type b j28 j31 j32 j35 j36 j81 j82 j83 j84 j85 if eqpd j86 j87 j141 j142 j145 if eqpd j146 j147 j148 j151 j152 j153 if eqpd if eqpd if eqpd if eqpd if eqpd j154 j215 (l379) j216 (l380) j217 (to ...

  • Page 1317

    Wiring systems: 9a-150 l connector s6rw0d910f007 l01 l04 except taiwan l31 l32 l33 l35 l36 l37 if eqpd 8ch 8ch if eqpd l40 l101 l102 l132 l133 l134 if eqpd if eqpd l161 l162 l163 l164 l167 l170 l171 l172 l174 l281 l282 l283 if eqpd if eqpd if eqpd if eqpd if eqpd l285 l292 l293 l294 l296 l301 if eqp...

  • Page 1318

    9a-151 wiring systems: l348 l371 (to e387) l372 (to e388) l374 (to g341) l375 (to g342) l376 (to g343) l377 (to g344) if eqpd l378 (to g345) l379 (j215) l380 (j216) l381 (to j217) l382 (to j218) l383 (to k152) l384 (to q133) l385 (to q134) l389 (to r151) l390 (to o231) l391 (to o232) l393 (to o233) ...

  • Page 1319

    Wiring systems: 9a-152 o connector s6rw0d910f008 q connector (8ch) s6rw0d910f009 r connector s6rw0d910f010 s connector s6rw0d910f011 o21 o92 o94 o95 o121 o122 o181 o182 o186 o187 o231 (to l390) o232 (to l391) if eqpd if eqpd if eqpd o233 (to l393) o240 (to l410) if eqpd q102 q103 q104 q105 q132 (to ...

  • Page 1320: Lighting Systems

    9b-1 lighting systems: body, cab and accessories lighting systems precautions precautions for discharge headlight service (if equipped) s6rw0d9200001 warning ! • do not touch igniter or ballast when lighting switch is at “head” position to avoid possible electric shock. • do not measure voltage or r...

  • Page 1321

    Lighting systems: 9b-2 igniter igniter generates high voltage needed to turn on the discharge headlight. It is charged with high voltage raised by the ballast and it applies voltage pulse as high as about 20,000v to the tungsten electrode in the discharge headlight bulb. After the discharge headligh...

  • Page 1322

    9b-3 lighting systems: with more passenger(s) or luggage in the vehicle, the vehicle position differs from that in such vehicle state with one person and no load in the vehicle and angle of the headlight optical axis varies accordingly. This system automatically adjusts the varied angle to maintain ...

  • Page 1323

    Lighting systems: 9b-4 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 1324

    9b-5 lighting systems: schematic and routing diagram headlight auto leveling system wiring circuit diagram s6rw0d9202001 g14-12 g14-19 g14-21 g14-10 g14-23 +b 5v 5v grn/yel gry/red blk g14-1 12v brn lt blu gry red/blk 3 g14-13 g14-20 g14-22 5v pnk blu yel/grn 2 4 5 9 10 11 1 5v 5v 12v g14-16 g14-3 p...

  • Page 1325

    Lighting systems: 9b-6 component location lighting system components location s6rw0d9203001 note below figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 10 11 9 [d] 25* 30 21 27* 26* 29 31* 20* 1 3 4 2 4 [a] [b] 8 1 3 2 7 5 6...

  • Page 1326

    9b-7 lighting systems: interior light system location s6rw0d9203002 diagnostic information and procedures self-diagnosis function for headlight auto leveling system s6rw0d9204014 the headlight leveling control module has self-diagnosis function to monitor the system components and circuits while the...

  • Page 1327

    Lighting systems: 9b-8 headlight leveling warning light check s6rw0d9204015 1) turn ignition switch to on position. 2) check that headlight leveling warning light (1) lights for about 2 seconds and then goes off. If the headlight leveling warning light lights up again 10 seconds after it turned off,...

  • Page 1328

    9b-9 lighting systems: headlight symptom diagnosis (other than discharge headlight model) s6rw0d9204017 auto-on headlight system symptom diagnosis (if equipped) s6rw0d9204018 condition possible cause correction / reference item only one low beam does not light up circuit fuse blown replace fuse and ...

  • Page 1329

    Lighting systems: 9b-10 drl system symptom diagnosis (if equipped) s6rw0d9204002 headlight auto leveling system symptom diagnosis (if equipped) s6rw0d9204019 headlight manual leveling system symptom diagnosis (if equipped) s6rw0d9204003 condition possible cause correction / reference item headlight ...

  • Page 1330

    9b-11 lighting systems: turn signal and hazard warning light symptom diagnosis s6rw0d9204004 clearance, tail and license plate light symptom diagnosis s6rw0d9204005 condition possible cause correction / reference item flash rate high or one side only flashes bulb blown on “flash rate high”-side repl...

  • Page 1331

    Lighting systems: 9b-12 back-up light symptom diagnosis s6rw0d9204020 brake light symptom diagnosis s6rw0d9204007 front fog light symptom diagnosis (if equipped) s6rw0d9204008 rear fog light symptom diagnosis (if equipped) s6rw0d9204009 condition possible cause correction / reference item back-up li...

  • Page 1332

    9b-13 lighting systems: illumination cancel system symptom diagnosis (if equipped) s6rw0d9204010 interior light symptom diagnosis s6rw0d9204011 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 t...

  • Page 1333

    Lighting systems: 9b-14 6) check that the voltage between the following terminals and vehicle body ground are specifications under each condition. 7) check that voltage between the following terminals and body ground are as specification under each condition. If measuring voltage is not within speci...

  • Page 1334

    9b-15 lighting systems: auto-on headlight operation inspection (if equipped) s6rw0d9204021 1) turn ignition switch to on position and then turn lighting switch to “auto” position. 2) check headlights for operation as follows. If headlights do not turn on or off, go to “inspection of auto-on headligh...

  • Page 1335

    Lighting systems: 9b-16 inspection of headlight leveling control module and its circuit (headlight auto leveling system) s6rw0d9204023 headlight auto leveling control module and its circuits can be checked at headlight auto leveling control module wiring couplers by measuring voltage and pulse signa...

  • Page 1336

    9b-17 lighting systems: terminal circuit specification condition 1 power source 10 – 14 v ignition switch is at on position. 2 — — — 3 lighting switch less than 1.5 v lighting switch is at “head” position. 10 – 14 v lighting switch is at off position. 4 — — — 5 diagnosis switch terminal about 5 v ig...

  • Page 1337

    Lighting systems: 9b-18 reference waveform no.1 vehicle speed signal (1). Vehicle speed signal is pulse. Pulse frequency varies depending on vehicle speed. Repair instructions headlight housing removal and installation s6rw0d9206001 warning ! • to avoid danger of being burned, don’t touch when the b...

  • Page 1338

    9b-19 lighting systems: headlight bulb replacement (discharge headlight model) s6rw0d9206002 warning ! • to avoid danger of being burned, don’t touch when the bulb is hot. • don’t touch glass surface of bulb, to avoid deteriorate as the case may be unclear when bulb light on at dirty condition. • be...

  • Page 1339

    Lighting systems: 9b-20 igniter removal and installation (discharge headlight model) s6rw0d9206024 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 “ba...

  • Page 1340

    9b-21 lighting systems: 1 “h” “b” “a” 2 10 [g] [f] [e] 7 8 9 6 7 5 10 11 8 9 7 6 5 a a 4 3 b b a a 4 b b “h” “h” “h” “h” [c] [d] a a 4 b b [a] [b] “h” “h” x x x x x x a a 4 b b [a] [b] “h” “h” [i] [h] [i] [h] 3 3 3 3 3 3 3 x x [a] [b] [a] [b] 6 5 8 9 i6rw0c920018-02 2. Headlight bulb 10. Headlight h...

  • Page 1341

    Lighting systems: 9b-22 headlight switch (in lighting switch) removal and installation s6rw0d9206004 removal 1) disconnect negative (–) cable at battery. 2) remove steering column hole cover (3). 3) remove steering column covers (1). Turn steering wheel to access steering column cover screws (2). 4)...

  • Page 1342

    9b-23 lighting systems: with auto-on headlight switch hazard warning switch removal and installation s6rw0d9206006 removal 1) disconnect negative (–) cable at battery. 2) remove center ventilation louver (1) referring to “center ventilation louver removal and installation in section 7a”. 3) disconne...

  • Page 1343

    Lighting systems: 9b-24 turn signal light switch (in lighting switch) removal and installation s6rw0d9206009 for removal and installation, refer to “headlight switch (in lighting switch) removal and installation”. Turn signal light switch (in lighting switch) inspection s6rw0d9206010 check for conti...

  • Page 1344

    9b-25 lighting systems: turn signal and hazard warning relay inspection s6rw0d9206012 1) connect turn signal and hazard warning relay (1), battery (2) and six test bulbs ((12v, 21w) (3) and 12 v, 5w (4)) as shown. 2) check turn l circuit connect terminal “5” and battery negative (–) terminal by a ju...

  • Page 1345

    Lighting systems: 9b-26 front fog light assembly removal and installation (if equipped) s6rw0d9206014 warning ! • to avoid danger of being burned, don’t touch when the bulb is hot. • don’t touch glass surface of bulb to avoid deteriorate as the case may be unclear when bulb light on at dirty conditi...

  • Page 1346

    9b-27 lighting systems: 2) check to see if hot spot (high intensity zone) of each front fog light axis falls as shown in the figure. Note if the fog lights interfere each other and make it hard to see the cut line clearly, cover the fog light on one side. This helps to make aiming adjustment easier....

  • Page 1347

    Lighting systems: 9b-28 headlight manual levering switch inspection (if equipped) s6rw0d9206019 check for resistance between terminals at each switch position. If check result is not as specified, replace switch. Headlight leveling actuator inspection (if equipped) s6rw0d9206026 headlight auto level...

  • Page 1348

    9b-29 lighting systems: height sensor removal and installation (if equipped) s6rw0d9206027 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 1349

    Lighting systems: 9b-30 height sensor and its circuit inspection (if equipped) s6rw0d9206028 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 m...

  • Page 1350

    9b-31 lighting systems: without initialization of the headlight auto leveling system, it is not possible to obtain its proper function. Also, if the headlight auto leveling system is not initialized after replacing the headlight leveling control module, the headlight leveling warning light in the co...

  • Page 1351

    Lighting systems: 9b-32 illumination cancel switch inspection (if equipped) s6rw0d9206022 check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Tail light relay, headlight relay, front fog light relay inspection (if equipped) s6rw0d92060...

  • Page 1352

    9b-33 lighting systems: specifications tightening torque specifications s6rw0d9207001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. Fastening part tightening torque note n ⋅m kgf-m lb-ft height sensor bolt 5.5 0.6 4.0 ...

  • Page 1353

    Instrumentation / driver info. / horn: 9c-1 body, cab and accessories instrumentation / driver info. / horn precautions precautions in diagnosing troubles for combination meter s6rw0d9300001 combination meter uses signals (information) from each control module by can communication to control speedom...

  • Page 1354

    9c-2 instrumentation / driver info. / horn: combination meter reception data ecm bcm keyless start control module (if equipped) combination meter 4wd control module (if equipped) tcm (a/t model) engine speed signal immobilizer indicator light control signal vehicle speed signal engine coolant temper...

  • Page 1355

    Instrumentation / driver info. / horn: 9c-3 auto volume control system description (if equipped) s6rw0d9301002 function of auto volume control system is to vary sound volume according to changes of vehicle speed. How much sound volume varies depends on selected level. Reference correlation chart of ...

  • Page 1356

    9c-4 instrumentation / driver info. / horn: schematic and routing diagram combination meter circuit diagram s6rw0d9302001 7 6 5 4 g241-9 9 g241-5 1 2 11 g241-13 23 g241-31 g241-26 3 g241-16 g241-22 12 g241-25 13 g241-1 3 8 17 15 14 20 g241-32 g241-6 9 16 18 19 g241-21 21 g241-7 g241-10 10 10 g241-19...

  • Page 1357

    Instrumentation / driver info. / horn: 9c-5 terminal arrangement of coupler viewed from terminal side note molded numbers (1) have no relation to the terminal numbers. Component location audio system component location s6rw0d9303001 terminal circuit terminal circuit g241-1 to turn signal light switc...

  • Page 1358

    9c-6 instrumentation / driver info. / horn: diagnostic information and procedures speedometer and vss symptom diagnosis s6rw0d9304001 tachometer symptom diagnosis s6rw0d9304002 engine coolant temperature (ect) meter symptom diagnosis s6rw0d9304003 fuel meter symptom diagnosis s6rw0d9304004 condition...

  • Page 1359

    Instrumentation / driver info. / horn: 9c-7 low fuel warning light symptom diagnosis s6rw0d9304005 note • confirm that fuel meter is in good condition before referring to the following possible causes. • when fuel level sensor circuit is open or short, fuel level meter indicates empty even if fuel t...

  • Page 1360

    9c-8 instrumentation / driver info. / horn: brake and parking brake warning light symptom diagnosis s6rw0d9304007 seat belt reminder light symptom diagnosis s6rw0d9304008 a/t shift position indicator symptom diagnosis (a/t model) s6rw0d9304009 condition possible cause correction / reference item bra...

  • Page 1361

    Instrumentation / driver info. / horn: 9c-9 charge warning light symptom diagnosis s6rw0d9304010 main beam (high beam) indicator symptom diagnosis s6rw0d9304011 warning buzzer circuit symptom diagnosis s6rw0d9304012 note • use of suzuki scan tool makes it easy to check whether a faulty condition is ...

  • Page 1362

    9c-10 instrumentation / driver info. / horn: cigarette lighter symptom diagnosis (if equipped) s6rw0d9304013 horn symptom diagnosis s6rw0d9304014 information display symptom diagnosis (if equipped) s6rw0d9304015 note this thermometer indicates the ambient temperature in the under side of front bumpe...

  • Page 1363

    Instrumentation / driver info. / horn: 9c-11 clock system diagnosis (if equipped) s6rw0d9304016 display of thermometer does not change at 50 ° c (122 ° f) outside air temperature is 50 °c (122 °f) or more — outside air temperature sensor faulty check outside air temperature sensor referring to “outs...

  • Page 1364

    9c-12 instrumentation / driver info. / horn: audio system symptom diagnosis (if equipped) s6rw0d9304017 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 1365

    Instrumentation / driver info. / horn: 9c-13 auto volume control system remote audio control switch symptom diagnosis (if equipped) s6rw0d9304018 navigation symptom diagnosis (if equipped) s6rw0d9304019 cd player is operative, but all speakers does not sound wiring or grounding faulty repair circuit...

  • Page 1366

    9c-14 instrumentation / driver info. / horn: repair instructions ignition switch removal and installation s6rw0d9306001 removal 1) disconnect negative cable at battery. 2) confirm that ignition key is removed. 3) remove dash side trim (4) and steering column hole cover (1). 4) turn steering wheel to...

  • Page 1367

    Instrumentation / driver info. / horn: 9c-15 3) remove center ventilation louver referring to step 1) and 2) of “information display (clock) removal and installation”. 4) remove combination meter cluster panel (1) pulling it in arrow direction shown in figure. 5) remove screws (1) fastening combinat...

  • Page 1368

    9c-16 instrumentation / driver info. / horn: engine coolant temperature (ect) sensor inspection s6rw0d9306008 check engine coolant temperature sensor for resistance, refer to “engine coolant temperature (ect) sensor inspection in section 1c”. Brake fluid level switch inspection s6rw0d9306009 check f...

  • Page 1369

    Instrumentation / driver info. / horn: 9c-17 outside air temperature sensor removal and installation (if equipped) s6rw0d9306013 removal 1) disconnect negative (–) cable at battery. 2) remove front bumper referring to “front bumper and rear bumper components in section 9k”. 3) disconnect connector f...

  • Page 1370

    9c-18 instrumentation / driver info. / horn: 10) remove front pillar trims (1). 11) disconnect instrument panel harness connectors, heater control cables and antenna cable for instrument panel removal. 12) remove steering column assembly referring to “steering column removal and installation in sect...

  • Page 1371

    Instrumentation / driver info. / horn: 9c-19 3) remove information display (clock) (1) from instrument panel (2) pulling it in arrow direction shown in figure. 4) disconnect information display coupler. Installation reverse removal procedure. Audio unit removal and installation (if equipped) s6rw0d9...

  • Page 1372

    9c-20 instrumentation / driver info. / horn: gps antenna removal and installation (if equipped) s6rw0d9306027 removal 1) remove combination meter cluster panel referring to step 1) to 4) of “combination meter removal and installation”. 2) disconnect gps antenna connector from navigation unit referri...

  • Page 1373

    Instrumentation / driver info. / horn: 9c-21 antenna base removal and installation s6rw0d9306023 removal 1) remove head lining referring to “head lining removal and installation in section 9h”. 2) remove antenna (1) from antenna base (2). 3) disconnect antenna feeder from antenna base (2). 4) remove...

  • Page 1374

    9c-22 instrumentation / driver info. / horn: remote audio control switch inspection (if equipped) s6rw0d9306025 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 ...

  • Page 1375: Wipers / Washers

    Wipers / washers: 9d-1 body, cab and accessories wipers / washers diagnostic information and procedures front wiper and washer symptom diagnosis s6rw0d9404001 rear wiper and washer symptom diagnosis s6rw0d9404002 condition possible cause correction / reference item wiper malfunctions circuit fuse bl...

  • Page 1376

    9d-2 wipers / washers: repair instructions wipers and washers components s6rw0d9406001 11 5 6 (b) (a) 1 1 (b) 2 13 14 14 [a] 14 12 15 (c) (b) (a) 3 2 4 7 10 10 10 11 11 8 16 9 16 i7rw01940001-03 1. Windshield wiper blade 8. Washer pump for rear washer 15. Windshield wiper bolt :tighten bolts in spec...

  • Page 1377

    Wipers / washers: 9d-3 washer tank and washer pump removal and installation s6rw0d9406002 removal 1) disconnect negative (–) cable at battery. 2) remove front bumper referring to “front bumper and rear bumper components in section 9k”. 3) disconnect washer pump lead wire couplers and hoses. 4) remov...

  • Page 1378

    9d-4 wipers / washers: installation 1) install windshield wiper assembly (1), and tighten bolts to specified torque in order of “i”, “ii” and “iii” indicated in figure. Tightening torque windshield wiper bolt (a): 8 n·m (0.8 kgf-m, 6.0 lb-ft) 2) connect coupler to windshield wiper motor. 3) install ...

  • Page 1379

    Wipers / washers: 9d-5 • for motor operation in high speed a. Connect battery positive (+) terminal to “2” and its negative (–) terminal to terminal “5”. B. Check if motor revolution speed is as specification. If check result is not as specified, replace motor. Specification 63 – 77 r/min (rpm) • fo...

  • Page 1380

    9d-6 wipers / washers: rear wiper removal and installation s6rw0d9406006 removal 1) disconnect negative (–) cable at battery. 2) remove arm cover (1), rear wiper arm nut (2), rear wiper arm with blade assembly (3), rear wiper pivot cap (4), rear wiper nut (5) and rear wiper seal (6). 3) remove rear ...

  • Page 1381

    Wipers / washers: 9d-7 rear wiper motor inspection s6rw0d9406007 note make sure that battery voltage is 12 v or more. 1) make a mark (1) on rear wiper motor (2) stop position as shown. 2) check rear wiper motor for operation as follows. • for motor operation a. Connect battery positive terminal to t...

  • Page 1382

    9d-8 wipers / washers: windshield wiper and washer switch removal and installation s6rw0d9406008 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 rear end screws (3...

  • Page 1383

    Wipers / washers: 9d-9 intermittent wiper relay circuit 1) turn the windshield wiper switch to “int” 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 ...

  • Page 1384

    9d-10 wipers / washers: rear wiper and washer switch removal and installation s6rw0d9406010 for removal and installation, refer to “windshield wiper and washer switch removal and installation”. Rear wiper and washer switch inspection s6rw0d9406011 check for continuity between terminals at each switc...

  • Page 1385

    Wipers / washers: 9d-11 specifications tightening torque specifications s6rw0d9407001 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 “fasteners informati...

  • Page 1386: Glass / Windows / Mirrors

    9e-1 glass / windows / mirrors: body, cab and accessories glass / windows / mirrors precautions precautions for power window service (pinching prevention function model) s6rw0d9500001 warning ! When checking the pinching prevention function, never attempt intentionally to have your hand, arm or any ...

  • Page 1387

    Glass / windows / mirrors: 9e-2 schematic and routing diagram power window circuit diagram (pinching prevention function model) s6rw0d9502001 6 5 [c] [d] ds b ig e sg sv sb sa dru drd sg sv sb sa dru drd asu, rru or rlu asd, rrd or rld [c] [c] d u [c] [d] su sb b [c] [d] [e] [e] e sg sv sb sa dru dr...

  • Page 1388

    9e-3 glass / windows / mirrors: diagnostic information and procedures rear end door window defogger symptom diagnosis s6rw0d9504001 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...

  • Page 1389

    Glass / windows / mirrors: 9e-4 inspection of pinching prevention function (pinching prevention function model) s6rw0d9504032 1) open driver side door glass fully. 2) hold a hummer so that its handle (wooden) (1) is placed as shown. Warning ! Never attempt to have your hand, arm or any other part of...

  • Page 1390

    9e-5 glass / windows / mirrors: door mirror heater symptom diagnosis (if equipped) s6rw0d9504004 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 suzu...

  • Page 1391

    Glass / windows / mirrors: 9e-6 windshield removal and installation s6rw0d9506002 preparation the windshield is installed by using a special type of adhesive (that is, one component urethane adhesive used with primer). For the windshield replacement, it is important to use an adhesive which provides...

  • Page 1392

    9e-7 glass / windows / mirrors: 9) cut adhesive all around windshield (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 to glass ...

  • Page 1393

    Glass / windows / mirrors: 9e-8 4) clean contact surfaces of old adhesive (4), paint or bare metal thoroughly. If surfaces of paint or bare metal come out, apply primer (2) for body with caution not to apply primer (2) to surface of adhesive remaining on body. Note • be sure to refer to primer maker...

  • Page 1394

    9e-9 glass / windows / mirrors: 10) 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 glass after adhesive (1) is applied. • perform steps 8) to 9) with...

  • Page 1395

    Glass / windows / mirrors: 9e-10 caution ! Upon completion of installation, note the following. • sudden closing of door before adhesive is completely set may cause glass to become loose or to come off. Therefore, if door is opened or closed before adhesive is completely set, make sure to open all d...

  • Page 1396

    9e-11 glass / windows / mirrors: rear quarter window components s6rw0d9506005 rear quarter window removal and installation s6rw0d9506006 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. However, note the following. • observe t...

  • Page 1397

    Glass / windows / mirrors: 9e-12 rear end door window components s6rw0d9506007 rear end door glass removal and installation s6rw0d9506008 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. However, note the following. • observe ...

  • Page 1398

    9e-13 glass / windows / mirrors: front door window components s6rw0d9506009 2 8 11 4 1 7 3 6 9 10 12 5 i7rw01950002-01 1. Door glass 5. Door sealing cover 9. Front door inner weather-strip 2. Window regulator assembly: apply lithium grease 99000-25011 to sliding part. 6. Door panel 10. Front door ou...

  • Page 1399

    Glass / windows / mirrors: 9e-14 front door glass removal and installation s6rw0d9506010 note (for pinching prevention function model) after disconnecting the power window main switch, make sure to execute to the initial setting, (to have the door glass closed position learned) refer to “power windo...

  • Page 1400

    9e-15 glass / windows / mirrors: • install front door trim. Front door trim attaching order (1) → (2) → (3) → (4) → (5) → (6) → (7) → (8) → (9) front door window regulator removal and installation s6rw0d9506011 note (for pinching prevention function model) after replacing or disconnecting the driver...

  • Page 1401

    Glass / windows / mirrors: 9e-16 rear door window components s6rw0d9506013 rear door glass removal and installation s6rw0d9506014 removal 1) remove rear door inner garnish (1). 2) remove door trim mounting screws (2). 3) remove door trim (1) as shown. 2 8 12 4 6 3 13 10 11 9 7 5 1 i5rw0a950022-02 1....

  • Page 1402

    9e-17 glass / windows / mirrors: 4) remove door outer garnish (1). 5) remove door outer weather-strip (2). 6) remove door inner weather-strip (3). 7) remove door trim bracket (1). 8) remove door sealing cover (2). 9) detach rear part of glass run (2) with rear door sash (1). 10) remove door glass as...

  • Page 1403

    Glass / windows / mirrors: 9e-18 rear door window regulator removal and installation s6rw0d9506015 removal 1) remove door glass referring to “rear door glass removal and installation”. 2) disconnect power window motor lead wire at coupler. 3) loosen regulator mounting screws, and then remove rear wi...

  • Page 1404

    9e-19 glass / windows / mirrors: rear end door window defogger relay inspection s6rw0d9506018 1) disconnect negative (–) cable from battery. 2) remove junction block for inspection of rear end door window defogger relay. 3) remove rear end door window defogger relay (1) from junction block (2). 4) c...

  • Page 1405

    Glass / windows / mirrors: 9e-20 4) touch voltmeter negative (–) lead to defogger wire ground terminal end (1). 5) touch voltmeter positive (+) lead with a foil strip to defogger wire power source terminal end (2), then move it along wire to defogger wire ground terminal end (1). The place where vol...

  • Page 1406

    9e-21 glass / windows / mirrors: with pinching prevention function model note after replacing or disconnecting the power window main switch, make sure to execute to the initial setting, (to have the door glass closed position learned) refer to “power window main switch initialization (pinching preve...

  • Page 1407

    Glass / windows / mirrors: 9e-22 switch for other window than driver side 1) remove driver side door trim referring to step 1) to 3) of “front door glass removal and installation”. 2) remove power window main switch from door trim. 3) check for continuity between terminals as shown below. If check r...

  • Page 1408

    9e-23 glass / windows / mirrors: pulse sensor and its circuit inspection (pinching prevention function model) s6rw0d9506029 note after replacing or disconnecting the driver side power window regulator (motor), power window main switch, battery and/or fuse, make sure to execute the initial setting, (...

  • Page 1409

    Glass / windows / mirrors: 9e-24 power window main switch initialization (pinching prevention function model) s6rw0d9506030 caution ! • after replacing or disconnecting the driver side door window regulator (motor), power window main switch, battery or fuse, be sure to execute initial setting (to ha...

  • Page 1410

    9e-25 glass / windows / mirrors: door mirror removal and installation s6rw0d9506024 when removing or installing door mirror, refer to the figure in “door mirror components”. Power door mirror switch inspection s6rw0d9506025 1) remove driver side door trim referring to step 1) to 3) of “front door gl...

  • Page 1411

    Glass / windows / mirrors: 9e-26 door mirror heater inspection (if equipped) s6rw0d9506027 1) remove door trim referring to step 1) to 3) of “front door glass removal and installation”. 2) disconnect door mirror connector (1). 3) check for continuity between terminals “a” and “b”. If no continuity, ...

  • Page 1412: Security and Locks

    9f-1 security and locks: body, cab and accessories security and locks general description key coding construction s6rw0d9601001 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 ch...

  • Page 1413

    Security and locks: 9f-2 component location power door lock and keyless entry system component location (if equipped) s6rw0d9603001 3 7 4 5 6 1 2 8 9 i6rw0c960002-01 1. Keyless entry receiver 4. Front door actuator 7. Door switch 2. Transmitter 5. Rear door actuator 8. Bcm (junction block with bcm t...

  • Page 1414

    9f-3 security and locks: diagnostic information and procedures power door lock system symptom diagnosis (if equipped) s6rw0d9604001 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...

  • Page 1415

    Security and locks: 9f-4 keyless entry system symptom diagnosis (if equipped) s6rw0d9604003 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 1416

    9f-5 security and locks: keyless entry system operation inspection (if equipped) s6rw0d9604004 note when performing the this inspection, make sure to have any of the door once opened / closed after the ignition key has been removed from the ignition key cylinder. 1) confirm that power door lock syst...

  • Page 1417

    Security and locks: 9f-6 repair instructions front door lock assembly components s6rw0d9606001 front door lock assembly removal and installation s6rw0d9606002 removal 1) remove door trim and door sealing cover referring to step 1) to 6) of “front door glass removal and installation in section 9e”. 2...

  • Page 1418

    9f-7 security and locks: 7) remove door latch screws (2) and remove door lock assembly (3). Installation reverse removal procedure to install front door lock assembly noting the following instructions. • apply grease to sliding parts of door latch assembly. : grease 99000–25011 (suzuki super grease ...

  • Page 1419

    Security and locks: 9f-8 front door lock assembly inspection s6rw0d9606003 • check that door open and closes smoothly and properly. • check that door stops in the secondary latched position properly (preventing door from opening freely) and that door closed completely in the fully latched position. ...

  • Page 1420

    9f-9 security and locks: power door lock actuator inspection (if equipped) s6rw0d9606006 1) remove door trim from door panel. For front door, refer to step 1) to 3) of “front door glass removal and installation in section 9e”. For rear door, refer to step 1) to 3) of “rear door glass removal and ins...

  • Page 1421

    Security and locks: 9f-10 rear door lock assembly components s6rw0d9606007 rear door lock assembly removal and installation s6rw0d9606008 removal 1) remove rear door glass referring to “rear door glass removal and installation in section 9e”. 2) disconnect door lock motor lead wire (if equipped). 3)...

  • Page 1422

    9f-11 security and locks: rear end door lock assembly components s6rw0d9606010 1 3 (a) (b) 4 5 2 6 7 8 i ii iv iii (c) 8 (c) 8 (c) i7rw01960007-04 1. Rear end door latch assembly (rear end door switch is built in this assembly) 5. Emergency lever : rear end door is unlocked by pushing emergency leve...

  • Page 1423

    Security and locks: 9f-12 rear end door lock assembly removal and installation s6rw0d9606011 removal 1) remove door trim (1) from rear end door panel (2). 2) disconnect door lock motor lead wire (if equipped). 3) loosen door latch bolts (1) and remove door latch assembly (2). Installation reverse re...

  • Page 1424

    9f-13 security and locks: if check result is not as specified, replace switch. Replacement of transmitter battery (other than keyless start model) s6rw0d9606014 note for keyless start model, perform “replacement of remote controller battery in section 10e” instead of “replacement of transmitter batt...

  • Page 1425

    Security and locks: 9f-14 6) push “unlock” button (2) on transmitter (3) within 20 seconds after step 5). All doors automatically lock and unlock once. With this, code registration is completed. 7) if an additional transmitter, needs to be programed repeat the procedure of step 1). Keyless entry ans...

  • Page 1426

    9f-15 security and locks: keyless entry receiver and its circuit inspection (if equipped) s6rw0d9606017 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....

  • Page 1427

    Security and locks: 9f-16 specifications tightening torque specifications s6rw0d9607001 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 the tigh...

  • Page 1428: Seats

    9g-1 seats: body, cab and accessories seats diagnostic information and procedures front seat heater symptom diagnosis (if equipped) s6rw0d9704001 condition possible cause correction / reference item both seat back and cushion do not become hot although seat heater switch is on position wiring or gro...

  • Page 1429

    Seats: 9g-2 repair instructions front seat components s6rw0d9706001 3 2 8 7 a c 4 d b 1 5 5 4 6 6 4 a b c d (b) (b) (b) (b) (a) (a) (a) (a) a a a (b) (c) b a a a b a b i6rw0c970001-01 1. Seat cushion 7. Side air bag module (if equipped) 2. Seat back : apply lithium grease 99000-25011 to sliding part...

  • Page 1430

    9g-3 seats: front seat removal and installation s6rw0d9706002 removal 1) disable air bag system referring to “disabling air bag system in section 8b”. 2) disconnect seat harness coupler and side air bag coupler, if equipped. 3) remove 4 mounting bolts to remove seat assembly. 4) disassemble and repa...

  • Page 1431

    Seats: 9g-4 rear seat components s6rw0d9706003 rear seat removal and installation s6rw0d9706004 removal 1) fold rear seat back forward. 2) remove seat mounting bolts and nuts to remove seat assembly. 3) disassemble and repair seat as necessary. Installation reverse removal procedure to install rear ...

  • Page 1432

    9g-5 seats: specifications tightening torque specifications s6rw0d9707001 note the specified tightening torque is also described in the following. “front seat components” “rear seat components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners inform...

  • Page 1433: Interior Trim

    Interior trim: 9h-1 body, cab and accessories interior trim repair instructions floor carpet removal and installation s6rw0d9806001 removal 1) remove front seat and rear seat referring to “front seat removal and installation in section 9g” and “rear seat removal and installation in section 9g”. 2) r...

  • Page 1434

    9h-2 interior trim: head lining removal and installation s6rw0d9806002 warning ! Refer to “air bag system service warning in section 00” before starting service work. Removal 1) remove sun visor (1). 2) remove dome lights of front (1) and center (2). 3) remove front pillar upper trims (1) rear side ...

  • Page 1435

    Interior trim: 9h-3 4) remove assistant grip (1). 5) remove head lining clips (2) at rear end and remove head lining (3). Installation reverse removal procedure noting the following. • fix sun visor clip (1) first and adjust head lining in position and fix three clips (2) at rear end. • tighten sun ...

  • Page 1436

    9h-4 interior trim: specifications tightening torque specifications s6rw0d9807001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. Fastening part tightening torque note n ⋅m kgf-m lb-ft sun visor screw 4 0.4 3.0 ).

  • Page 1437: Hood / Fenders / Doors

    Hood / fenders / doors: 9j-1 body, cab and accessories hood / fenders / doors repair instructions hood removal and installation s6rw0d9a06001 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 mounti...

  • Page 1438

    9j-2 hood / fenders / doors: front fender components s6rw0d9a06003 front fender removal and installation s6rw0d9a06004 removal 1) remove side sill splash guard and front fender splash guard (if equipped) referring to “splash guard removal and installation (if equipped) in section 9m”. 2) remove fron...

  • Page 1439

    Hood / fenders / doors: 9j-3 front door assembly components s6rw0d9a06005 front door assembly removal and installation s6rw0d9a06006 removal 1) remove front fender referring to “front fender removal and installation”. 2) disconnect door harness lead wires at each coupler. 3) remove door open stopper...

  • Page 1440

    9j-4 hood / fenders / doors: 5) remove door assembly (1) by loosening hinge mounting bolts (2). Installation reverse removal procedure to install door assembly noting the following instructions. • when replacing door, coat replacement door inside with wax for proper anti-corrosion treatment. Refer t...

  • Page 1441

    Hood / fenders / doors: 9j-5 rear door assembly components s6rw0d9a06007 rear door assembly removal and installation s6rw0d9a06008 refer to “front door assembly removal and installation” as removal and installation procedures are basically the same. However, note the following. • tighten rear door h...

  • Page 1442

    9j-6 hood / fenders / doors: rear end door assembly components s6rw0d9a06009 rear end door assembly removal and installation s6rw0d9a06010 warning ! Be careful enough when you open and shut with door balancer has not adhered to rear end door. Otherwise, rear end door doses in weight and is injured. ...

  • Page 1443

    Hood / fenders / doors: 9j-7 warning ! Handling of rear end door balancer (damper) • handle balancer carefully. Do not scar or scratch exposed surface of its piston rod, and never allow any paint or oil to stick to its surface. • do not turn piston rod with balancer fully extended. • do not disassem...

  • Page 1444

    9j-8 hood / fenders / doors: specifications tightening torque specifications s6rw0d9a07001 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 torqu...

  • Page 1445: Body Structure

    Body structure: 9k-1 body, cab and accessories body structure repair instructions front bumper and rear bumper components s6rw0d9b06001 1 2 4 5 6 3 7 8 9 10 i6rw0c9b0003-01 1. Front bumper 5. Front bumper lower member 9. Reflector 2. Radiator upper grill 6. Front bumper holder 10. License garnish(if...

  • Page 1446

    9k-2 body structure: cowl top and front lower crossmember components s6rw0d9b06002 4. Front bumper upper member 8. Rear bumper i6rw0d9b0001-01 1. Cowl top garnish 3. Hood rear seal : 55 n ⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Cowl top panel 4. Front lower crossmember.

  • Page 1447

    Body structure: 9k-3 specifications body dimensions s6rw0d9b07001 engine room hole to hole distance a b c d e f g h i j l k b' c' d' g' h' j' i5rw0a9b0003-01 a. Jig hole ( φ 8 mm) e. Cover installation hole ( φ 12 mm) i. Jig hole left side ( φ 7 mm) b (b’). Cowl top side cover installation hole f. H...

  • Page 1448

    9k-4 body structure: rear end door hole to hole distance a a' b' b f c c' f' d d' e i5rw0a9b0004-03 a (a’). Wire harness hole c (c’). Combination lamp installation upper hole e. Rear end door striker installation left side hole b (b’). Rear end door balancer lower hole d (d’). Rear bumper installati...

  • Page 1449

    Body structure: 9k-5 side body hole to hole distance o d e k f l i m n g j h o a c b d e k f l i m n g j h a c b i5rw0a9b0005-02 a. Instrumental panel upper mounting bolt hole f. Front shoulder adjuster bracket installation upper hole k. Curtain-air bag module installation hole b. Front door lower h...

  • Page 1450

    9k-6 body structure: hole to hole distance c a a’ a b b’ c b’ i5rw0a9b0006-03 a (a’). Front end of windshield upper installation section c. Parking brake cable bracket installation front hole b (b’). Front end of windshield lower installation section a-a’: 1,052 mm (41.417 in.) a-b’: 1,428 mm (56.22...

  • Page 1451

    Body structure: 9k-7 under body hole to hole distance hole to hole distance a b c d e f g h i j a' b' c' d' e' f' g' h' i' j' a b c d e f g h i j a' b' c' d' e' f' g' h' i' j' i5rw0a9b0007-01 a (a’). Jig hole ( φ 20 mm) e (e’). Jig hole ( φ 10 mm) i (i’). Drain hole ( φ 10 mm) b (b’). Front suspensi...

  • Page 1452

    9k-8 body structure: hole to hole distance projection dimension from standard line “a” front suspension frame hole to hole distance a b c d e f g h i j “a” i5rw0a9b0008-03 a. Jig hole ( φ 20 mm) e. Jig hole ( φ 10 mm) i. Drain hole ( φ 10 mm) b. Front suspension frame installation hole f. Jig hole (...

  • Page 1453

    Body structure: 9k-9 hole to hole distance projection dimension from standard line “a” engine front mounting member hole to hole distance a b c d e “a” e d c a b i5rw0a9b0010-03 a. Stud d. Front suspension frame installation hole b. Front suspension frame installation hole e. Front suspension contro...

  • Page 1454

    9k-10 body structure: panel clearance s6rw0d9b07002 panel to panel distance tightening torque specifications s6rw0d9b07003 note the specified tightening torque is also described in the following. “cowl top and front lower crossmember components” reference: for the tightening torque of fastener not s...

  • Page 1455: Paint / Coatings

    Paint / coatings: 9l-1 body, cab and accessories paint / coatings general description anti-corrosion treatment construction s6rw0d9c01001 warning ! Standard shop practices, particularly eye protection, should be followed during the performance of the following operations to avoid personal injury. As...

  • Page 1456

    9l-2 paint / coatings: plastic parts finishing s6rw0d9c01002 painting rigid or hard 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 finish to wash each part. 2) apply conventional acr...

  • Page 1457

    Paint / coatings: 9l-3 component location sealant application areas s6rw0d9c03001 i7rw019c0007-01.

  • Page 1458

    9l-4 paint / coatings: i7rw019c0002-01 [a]: rh side “b”: wipe off excess sealant after application. “e”: never fill up drain holes with sealant. [b]: lh side “c”: smooth out sealant with a brush. “f”: fill gap / hole with sealant. “a”: apply sealant. “d”: do not apply sealant. “g”: r end.

  • Page 1459

    Paint / coatings: 9l-5 i7rw019c0008-01 “a”: apply sealant. “d”: do not apply sealant. “b”: fill gap / hole with sealant. “e”: wipe off excess sealant after application. “c”: smooth out sealant with a brush..

  • Page 1460

    9l-6 paint / coatings: i7rw019c0004-01 “a”: apply sealant. “c”: never fill up drain holes (“a” to “f”) with sealant. “b”: wipe off excess sealant after application. “d”: apply sealant covering flange end..

  • Page 1461

    Paint / coatings: 9l-7 i6rw0c9c0004-01 “a”: apply sealant. “d”: smooth out sealant with a brush. “g” apply sealant covering flange end. “b”: wipe off excess sealant application. “e”: smooth out sealant with a brush. Do not fill hole with sealant. “c”: fill gap / hole with sealant. “f”: do not apply ...

  • Page 1462

    9l-8 paint / coatings: i5rw0c9c0005-01 “a”: apply sealant. 1. Hole.

  • Page 1463

    Paint / coatings: 9l-9 i5rw0c9c0006-01 “a”: apply sealant covering flange end..

  • Page 1464

    9l-10 paint / coatings: under coating application areas s6rw0d9c03002 i6rw0c9c0005-02 [a]: lh side “c”: do not apply undercoating. [b]: rh side “d”: apply under coating after panting black color..

  • Page 1465

    Paint / coatings: 9l-11 [c]: both side “e”: apply under coating (pvc, 600 µm or more). “a”: apply undercoating (pvc, 400 µm or more). “f”: do not apply undercoating and anti-chip coat. “b”: apply anti-chip coat (300 µm or more) (except vehicle with splash guard). I7rw019c0005-01 [a]: 2wd vehicle “b”...

  • Page 1466

    9l-12 paint / coatings: anti-corrosion compound application area s6rw0d9c03003 i5rw0c9c0013-01 “a”: apply rust proof wax (hot wax 50 µm or more). “b”: apply rust proof wax (high viscosity wax 50 µm or more). “c”: never fill up drain holes with rust proof wax..

  • Page 1467

    Paint / coatings: 9l-13 i5rw0a9c0010-01 “a”: apply rust proof wax (hot wax 50 µm or more). “b”: never fill up drain holes with rust proof wax..

  • Page 1468: Exterior Trim

    9m-1 exterior trim: body, cab and accessories exterior trim repair instructions roof molding removal and installation s6rw0d9d06001 2 3 1 2 3 4 4 [a] a b [b] 5 6 (a) (a) i5rw0c9d0002-04 [a]: roof molding installation position roof molding with touching a to b. 3. Roof rail nut (if equipped) [b]: roo...

  • Page 1469

    Exterior trim: 9m-2 splash guard removal and installation (if equipped) s6rw0d9d06002 specifications tightening torque specifications s6rw0d9d07001 note the specified tightening torque is also described in the following. “roof molding removal and installation” reference: for the tightening torque of...

  • Page 1470

    9m-3 exterior trim:.

  • Page 1471: 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 body electrical control system .......

  • Page 1472

    10-ii table of contents immobilizer indicator light remains on after engine start ..................................................10c-10 dtc p1614: transponder response error.....10c-10 dtc p1615: steering lock unit communication error ....................................10c-11 dtc p1616: unregist...

  • Page 1473: Precautions

    Precautions: 10-1 control systems precautions precautions precautions for control systems s6rw0da000001 air bag warning refer to “air bag warning in section 00”. Precaution of troubleshooting for can refer to “precaution on can troubleshooting in section 1a”..

  • Page 1474

    10b-1 body electrical control system: control systems body electrical control system precautions precautions in diagnosing trouble s6rw0da200001 • 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 (ins...

  • Page 1475

    Body electrical control system: 10b-2 bcm reception data theft deterrent light s6rw0da201003 the information display or clock (1) of this vehicle includes a theft deterrent light (2) for the theft preventive purpose. The bcm makes the theft deterrent light flash at certain intervals after the igniti...

  • Page 1476

    10b-3 body electrical control system: when “b” mode is selected and the door is locked using keyless entry transmitter or door request switch, the theft deterrent light (1) flashes at 0.1 second interval for 20 seconds and the security alarm system is set to the stand-by mode (2). Once it is set to ...

  • Page 1477

    Body electrical control system: 10b-4 blk/blu blk/yel blk/red 12v 12v +bb blu/yel wht/blu +bb red/yel g272-7 yel/red yel/blk 5v ig1 ig2 ig2 l312-4 orn l314-9 yel blu l313-3 blu ppl/wht +b +b grn/red grn grn red/blu l315-9 l315-10 l01-10 l01-1 on door off +b +b ig1 wht l312-5 12v lt grn blk 5v 5v 5v ...

  • Page 1478

    10b-5 body electrical control system: 1. Bcm 23. Brake fluid level switch 45. Passenger side door lock actuator (if equipped) 2. Rear end door opener actuator (if equipped) 24. Parking brake switch 46. Rear door lock actuator (if equipped) 3. Rear end door opener relay (if equipped) 25. Door key cyl...

  • Page 1479

    Body electrical control system: 10b-6 connector layout diagram of bcm and junction block s6rw0da202002 bcm and junction block connectors (viewed from harness side) i6rw0ca20004-01 [a]: junction block (viewed from bcm side) 2. Junction block 5. Rear wiper relay [b]: junction block (viewed from relay ...

  • Page 1480

    10b-7 body electrical control system: component location bcm and related system component location s6rw0da203001 13 12 17 18 21 19 14 24 25 25 26 27 22 23 22 24 7 6 20 11 5 15 16 15 16 [a] [b] 2 9 10 3 8 4 1 i6rw0da20002-01 [a]: auto a/c 9. Rear end door opener switch (if equipped) 19. Lighting swit...

  • Page 1481

    Body electrical control system: 10b-8 diagnostic information and procedures bcm self-diagnosis function s6rw0da204001 • 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 1482

    10b-9 body electrical control system: body electrical control system check s6rw0da204002 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 1483

    Body electrical control system: 10b-10 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 1484

    10b-11 body electrical control system: scan tool data s6rw0da204003 scan tool data condition normal condition / reference value vehicle speed ) at stop with ignition switch turned on 0 km/h outside air temp ) reference value is relative to outside air temperature –40 °c – 70 °c (–40 °f – 158 °f) bat...

  • Page 1485

    Body electrical control system: 10b-12 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 indicates battery positive voltag...

  • Page 1486

    10b-13 body electrical control system: dtc table s6rw0da204004 dtc (displayed on suzuki scan tool) dtc (indicated by theft deterrent light) dtc (displayed on odometer in combination meter) detected item detecting condition no dtc 0000 0000 — no dtc detected ) b1133 1133 b1133 battery voltage too hig...

  • Page 1487

    Body electrical control system: 10b-14 dtc check s6rw0da204005 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 1488

    10b-15 body electrical control system: 3) check dtc displayed on odometer of combination meter or read flashing pattern of theft deterrent light 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 1489

    Body electrical control system: 10b-16 bcm power circuit and ground circuit check s6rw0da204007 wiring diagram troubleshooting +b ig1 +bb grn g273-2 blk blk/orn g272-9 g271-3 blk/orn l314-4 blu g273-5 wht e324-2 2 3 1 e324 l314 1 2 4 5 3 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 1 2 4 5 3 6 1 2 4 5 3 6...

  • Page 1490

    10b-17 body electrical control system: dtc b1133 (dtc no. 1133): battery voltage too high s6rw0da204008 wiring diagram refer to “bcm power circuit and ground circuit check”. Dtc detecting condition and possible cause flow test description step 1: check charging system dtc troubleshooting 4 ground ci...

  • Page 1491

    Body electrical control system: 10b-18 dtc b1141 / dtc b1142 (no. 1141 / no. 1142) outside air temperature (ambient temp.) sensor circuit malfunction s6rw0da204009 wiring diagram dtc detecting condition and possible cause flow test description step 1: check whether malfunction is in outside air temp...

  • Page 1492

    10b-19 body electrical control system: dtc b1150 (no. 1150): air bag communication circuit malfunction s6rw0da204010 wiring diagram dtc detecting condition and possible cause flow test description step 1: check air bag communication circuit. Step 2: check air bag communication circuit. Dtc troublesh...

  • Page 1493

    Body electrical control system: 10b-20 dtc b1157 (no. 1157) air bag deployment signal input s6rw0da204011 wiring diagram refer to “dtc b1150 (no. 1150): air bag communication circuit malfunction”. Dtc detecting condition and possible cause flow test description step 1: check dtc for sdm. Dtc trouble...

  • Page 1494

    10b-21 body electrical control system: inspection of bcm and its circuits s6rw0da204017 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 1495

    Body electrical control system: 10b-22 bcm connector “e04” l01-10 driver side door lock actuator control (unlock) (if equipped) 10 – 14 v unlock signal is output for driver side door lock actuator 0 v unlock signal is not output for driver side door lock actuator l01-11 rear end door opener actuator...

  • Page 1496

    10b-23 body electrical control system: bcm connector “g04” e04-13 — — — e04-14 — — — terminal circuit normal voltage condition g04-1 can communication line (low) for dlc *1.6 – 2.5 v refer to “reference waveform no. 3: ” g04-2 can communication line (low) for each control module *1.6 – 2.5 v g04-3 c...

  • Page 1497

    Body electrical control system: 10b-24 junction block connector “e324” junction block connector “e325” junction block connector “g271” junction block connector “g272” junction block connector “g273” junction block connector “l312” junction block connector “l313” terminal circuit normal voltage condi...

  • Page 1498

    10b-25 body electrical control system: junction block connector “l314” junction block connector “l315” terminal circuit normal voltage condition l314-4 ground for bcm 0 v ignition switch is at all positions l314-6 right side door mirror heater (if equipped) 10 – 14 v engine is running and rear end d...

  • Page 1499

    Body electrical control system: 10b-26 reference waveform no. 1 parking brake or brake fluid level switch signal (1) reference waveform no. 2 driver seat belt switch signal (1) reference waveform no. 3 can communication signal reference waveform no. 4 oil pressure switch signal (1) measurement termi...

  • Page 1500

    10b-27 body electrical control system: reference waveform no. 5 information display and hvac control module serial communication signal (1) reference waveform no. 6 keyless entry receiver signal (1) reference waveform no. 7 vehicle speed pulse output signal (1) reference waveform no. 8 a/c or rear e...

  • Page 1501

    Body electrical control system: 10b-28 reference waveform no. 9 rear wiper switch signal (1) reference waveform no. 10 sdm communication signal (1) repair instructions bcm (included in junction block) removal and installation s6rw0da206001 caution ! Do not attempt removal of bcm from junction block ...

  • Page 1502

    10b-29 body electrical control system: 5) disconnect connectors from bcm and junction block. 6) detach wiring harness clamp from junction block. Installation reverse removal procedure for installation, noting following points. • connect connectors securely. • enable air bag system referring to “enab...

  • Page 1503: Immobilizer Control System

    Immobilizer control system: 10c-1 control systems immobilizer control system precautions precautions in diagnosing troubles s6rw0da300001 • before confirming the diagnostic trouble code (dtc), do not disconnect connector from ecm, battery cable from battery, ground wire harness, or main fuse. Such d...

  • Page 1504

    10c-2 immobilizer control system: • do not leave ignition key in a place where temperature is high. High temperature may cause damage to the transponder built in the ignition key. • do not turn ignition switch to on position by bringing radio antenna close to coil antenna. Or, the immobilizer contro...

  • Page 1505

    Immobilizer control system: 10c-3 schematic and routing diagram immobilizer control system wiring circuit diagram s6rw0da302001 note for more details about power supply circuit, ground wire circuit, and each circuit for ecm, bcm, abs control module, keyless start control module and combination meter...

  • Page 1506

    10c-4 immobilizer control system: blk/wht blk/orn 12v g17-1 g17-2 12v 5v 12v 12v yel/red yel/blk g17-4 g17-3 5v brn brn/yel blk/yel 1 2 2 2 2 3 4 2 5 10 14 15 1 2 3 4 g17 [a] 5 6 g16-20 g16-29 g16-30 g146-3 g146-7 g146-8 wht/red 5v 5v 9 g16-18 g16-19 e01-13 e01-28 blu red wht e08-12 e08-1 e01-18 e01...

  • Page 1507

    Immobilizer control system: 10c-5 component location immobilizer control system components location s6rw0da303001 diagnostic information and procedures immobilizer control system check s6rw0da304001 3 4 5 6 7 1 2 2 1 3 i6rw0ba30001-01 1. Ecm 5. Ignition key (non keyless entry model) 2. Immobilizer i...

  • Page 1508

    10c-6 immobilizer control system: dtc check s6rw0da304002 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 panel at driver’s seat side...

  • Page 1509

    Immobilizer control system: 10c-7 dtc table s6rw0da304004 ecm note ecm detects dtc. Icm does not. Note if any dtc other than the above dtcs is detected, refer to “dtc table in section 1a”. Dtc no. Detecting item detecting condition immobilizer indicator light ) p1614 transponder response error trans...

  • Page 1510

    10c-8 immobilizer control system: scan tool data s6rw0da304005 suzuki scan tool displays the following data using “registration information” mode. Scan tool data definitions component id (****) this parameter indicates the vehicle id number of four digits used for the suzuki scan tool. Keyfree syste...

  • Page 1511

    Immobilizer control system: 10c-9 immobilizer indicator light does not come on with ignition switch on and engine stop s6rw0da304006 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description when the ignition switch is turned on, ecm transmits the indication on...

  • Page 1512

    10c-10 immobilizer control system: immobilizer indicator light remains on after engine start s6rw0da304007 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description refer to “immobilizer indicator light does not come on with ignition switch on and engine stop”....

  • Page 1513

    Immobilizer control system: 10c-11 dtc p1615: steering lock unit communication error s6rw0da304009 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description when the transponder code in the ignition key is registered in ecm, the id code is registered in both ec...

  • Page 1514

    10c-12 immobilizer control system: dtc p1616: unregistered keyless start control module s6rw0da304010 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description p1616 is detected when ecm detects different id codes registered in ecm and keyless start control mod...

  • Page 1515

    Immobilizer control system: 10c-13 dtc p1618: keyless start control module can communication error s6rw0da304011 refer to “troubleshooting for can-dtc in section 1a”. Dtc p1621: immobilizer communication line error s6rw0da304012 wiring diagram refer to “immobilizer control system wiring circuit diag...

  • Page 1516

    10c-14 immobilizer control system: dtc p1622: eeprom reading / writing error s6rw0da304013 detecting condition and trouble area troubleshooting 1) clear dtc(s) referring to “dtc clearance”. 2) turn the ignition switch to off position. 3) check if dtc p1622 is still detected referring to “dtc check”....

  • Page 1517

    Immobilizer control system: 10c-15 dtc p1625: immobilizer antenna error s6rw0da304015 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Detecting condition and trouble area troubleshooting dtc p1636: immobilizer information registration failure s6rw0da304016 wiring diagram...

  • Page 1518

    10c-16 immobilizer control system: dtc p1638: immobilizer information mismatched s6rw0da304017 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Detecting condition and trouble area troubleshooting 4 can communication circuit check 1) disconnect connectors from ecm, bcm an...

  • Page 1519

    Immobilizer control system: 10c-17 inspection of icm and its circuit s6rw0da304018 icm and its circuit can be checked at icm wiring connector by measuring voltage. Caution ! Icm cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to icm with connector disconnected...

  • Page 1520

    10c-18 immobilizer control system: 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. Termin...

  • Page 1521

    Immobilizer control system: 10c-19 repair instructions icm removal and installation s6rw0da306001 removal 1) disconnect negative (–) cable at battery. 2) remove dash side trim (4) and steering column hole cover (3). 3) remove steering column covers (1). Turn steering wheel to access steering column ...

  • Page 1522

    10c-20 immobilizer control system: special tools and equipment special tool s6rw0da308001 suzuki scan tool (suzuki- sdt) — this kit includes following items. 1. Suzuki-sdt 2. Dlc3 cable 3. Usb cable 4. Ac/dc power supply 5. Voltage meter probe 6. Storage case ) / ) 1 2 3 4 5 6.

  • Page 1523: Keyless Start System

    Keyless start system: 10e-1 control systems keyless start system general description keyless start system description s6rw0da501001 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 b...

  • Page 1524

    10e-2 keyless start system: parts and functions s6rw0da501002 parts function keyless start control module • activates each antenna • verifies id code of remote controller • requests steering lock unit to release steering lock • requests bcm to lock or unlock doors • controls key indicator light in c...

  • Page 1525

    Keyless start system: 10e-3 keyless engine start function s6rw0da501003 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 1526

    10e-4 keyless start system: door lock function of keyless start system s6rw0da501004 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 1527

    Keyless start system: 10e-5 operation area of remote controller s6rw0da501005 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 1528

    10e-6 keyless start system: • the ignition knob switch cannot be turned using the keyless engine start function fails to turn: – the remote controller which has been registered in the keyless start control module and another un-registered one are both carried at the same time – the remote controller...

  • Page 1529

    Keyless start system: 10e-7 keyless start control module reception data schematic and routing diagram keyless start system electric wiring circuit diagram s6rw0da502001 vehicle speed signal ecm-keyless start control module code door switch status door lock status charging system signal engine oil pr...

  • Page 1530

    10e-8 keyless start system: diagnostic information and procedures precautions in diagnosing troubles s6rw0da504001 • 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 1531

    Keyless start system: 10e-9 keyless start system check s6rw0da504004 step action yes no 1 1) record details of the problem. For your record, use of a questionnaire form will facilitate collecting information for proper analysis and diagnosis. 2) check if the problem described in “customer questionna...

  • Page 1532

    10e-10 keyless start system: customer questionnaire (example) s6rw0da504005 key indicator light check s6rw0da504006 push the ignition knob switch (2) of the steering lock unit (1) and check that the key indicator light (3) in the combination meter lights up in red or blue. If it does not light, go t...

  • Page 1533

    Keyless start system: 10e-11 dtc check s6rw0da504007 1) check to make sure that all doors are closed. 2) open driver side door window glass and door. 3) check to make sure that ignition key is not inserted in ignition key cylinder. If it is, remove it. 4) perform “key indicator light check”. 5) clos...

  • Page 1534

    10e-12 keyless start system: dtc table s6rw0da504008 dtc clearance s6rw0da504009 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 ...

  • Page 1535

    Keyless start system: 10e-13 keyless start system symptom diagnosis s6rw0da504010 door lock function of keyless start system note before performing trouble diagnosis procedure for door lock function of keyless start system, check that power door lock system operates properly referring to “power door...

  • Page 1536

    10e-14 keyless start system: keyless start system operation inspection s6rw0da504011 keyless engine start operation 1) sit in driver seat with remote controller carried with you. 2) check that all doors are closed and ignition key is not inserted in ignition key cylinder. 3) while pushing ignition k...

  • Page 1537

    Keyless start system: 10e-15 voltage check 1) disconnect negative cable (–) at battery. 2) remove keyless start control module from vehicle body referring to “keyless start control module removal and installation”. 3) connect connector to keyless start control module. 4) check voltage at each termin...

  • Page 1538

    10e-16 keyless start system: g16-18 can communication line (low) *1.6 – 2.5 v refer to “reference waveform no. 4: ” g16-19 can communication line (high) *2.5 – 3.6 v g16-20 power supply for steering lock unit 4 – 6 v full time g16-21 — — — g16-22 — — — g16-23 passenger side door antenna (–) *0 – 5 v...

  • Page 1539

    Keyless start system: 10e-17 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) reference waveform no. 2 center antenna signal (request signal (1) transmitted by center ant...

  • Page 1540

    10e-18 keyless start system: reference waveform no. 4 can communication signals (can signal communicated to each control module when ignition switch is turned on) reference waveform no. 5 steering lock unit signal (signal (1) communicated between keyless start control module and steering lock unit w...

  • Page 1541

    Keyless start system: 10e-19 in case the position of passenger side door lock is changed from the lock to the unlock when the position of driver and passenger side door is at the lock in case the position of driver side door lock is changed from the lock to the unlock when the position of driver and...

  • Page 1542

    10e-20 keyless start system: no dtc detection after performing dtc check s6rw0da504014 wiring diagram 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 light ...

  • Page 1543

    Keyless start system: 10e-21 key indicator light circuit check (key indicator light doesn’t light when ignition knob switch is pushed) s6rw0da504015 wiring diagram 4 keyless start control module power and ground circuit check 1) check keyless start control module power and ground circuit for conditi...

  • Page 1544

    10e-22 keyless start system: description when the ignition knob switch is pushed, the key indicator light lights up in blue if you carry the remote controller registered in the keyless start control module and it lights in red if you carry the remote controller which has not been registered in the k...

  • Page 1545

    Keyless start system: 10e-23 keyless start control module power and ground circuit check s6rw0da504016 wiring diagram troubleshooting blk/orn g16-9 g16-15 g16-10 g16-11 blu/wht wht/red red/blk 5v 12v 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 [a] 4 2 3 3 1 g16 5 8 6 7 3 i7r...

  • Page 1546

    10e-24 keyless start system: dtc no. 11: communication error with steering lock unit s6rw0da504017 wiring diagram 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 ref...

  • Page 1547

    Keyless start system: 10e-25 dtc no. 13 / no. 14: release signal error from steering lock unit / steering lock unit malfunction s6rw0da504018 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance”. 2) turn ignition knob switch pushing ignition k...

  • Page 1548

    10e-26 keyless start system: dtc no. 31: lost communication with bcm s6rw0da504020 refer to “troubleshooting for can-dtc in section 1a”. Dtc no. 33: control module communication bus off s6rw0da504021 refer to “troubleshooting for can-dtc in section 1a”. Dtc no. 51 / no. 52 / no. 53: driver side / pa...

  • Page 1549

    Keyless start system: 10e-27 repair instructions antennas and request switches removal and installation s6rw0da506001 remove and install antennas and request switches referring to the following figures. 2 request switch check 1) check related door request switch for function referring to “front door...

  • Page 1550

    10e-28 keyless start system: front door (driver and passenger side), rear end door request switch inspection s6rw0da506002 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 1551

    Keyless start system: 10e-29 keyless start control module removal and installation s6rw0da506006 removal 1) disconnect negative cable at battery. 2) remove glove box from instrument panel. 3) disconnect connector from keyless start control module. 4) remove keyless start control module mounting bolt...

  • Page 1552

    10e-30 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 1553

    Keyless start system: 10e-31 if remote controller or keyless start control module is replaced 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) insert ignition key ...

  • Page 1554

    Prepared by 1st ed. Feb., 2007.

  • Page 1555: Service Manual

    34.5 mm 99 50 0- 52 l 00 -0 1e s e r v ic e m a n u a l vol. 1 of 2 99500-52l00-01e service manual volume 1 of 2 rw415/rw416.

  • Page 1556: Service Manual

    28.0 mm 99 50 0- 52 l 00 -0 1e s e r v ic e m a n u a l vol. 2 of 2 99500-52l00-01e service manual volume 2 of 2 rw415/rw416.