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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 s6rw0c0000001 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 s6rw0c0000004 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 catalytic converter s6rw0c0000005 for vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged. • conduct a spark jump test only when necessary, ma...

  • Page 16

    00-9 precautions: precautions for electrical circuit service s6rw0c0000008 • when replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire. • when disconnecting and connecting coupler, make sure t...

  • Page 17

    Precautions: 00-10 • be careful not to touch the electrical terminals of parts which use microcomputers (e.G. Electronic control unit like as ecm, pcm, p/s controller, etc.). The static electricity from your body can damage these parts. • never connect any tester (voltmeter, ohmmeter, or whatever) t...

  • Page 18

    00-11 precautions: air bag warning s6rw0c0000009 warning ! For vehicles equipped with supplemental restraint (air bag) system: • service on and around the air bag system components or wiring must be performed only by an authorized suzuki dealer. Refer to “air bag system components, wiring and connec...

  • Page 19

    Precautions: 00-12 repair instructions electrical circuit inspection procedure s6rw0c0006001 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 s6rw0c0006002 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 s6rw0c0101001 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 s6rw0c0101005 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 s6rw0c0103001 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 i6rw0c010001-02 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 s6rw0c0200001 air bag warning refer to “air bag warning in section 00”. Scheduled maintenance maintenance schedule under normal driving conditions s6rw0c0205001 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) maintenance recommended under severe driving conditions s6rw0c020500...

  • 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 fuel evaporative emission control system inspection s6rw0c0206013 check evap canister and fuel vapor hose referring to “evap canister inspection in section 1b” and “vacuum hose and purge valve chamber inspection in section 1b”. Brake discs and pads inspection s6rw0c...

  • Page 36

    0b-5 maintenance and lubrication: hvac air filter (if equipped) inspection s6rw0c0206034 check hvac air filter for dirt and dust referring to “hvac air filter inspection (if equipped) in section 7a”. Hvac air filter (if equipped) replacement s6rw0c0206035 replace hvac air filter with new one referri...

  • Page 37

    Maintenance and lubrication: 0b-6 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 n...

  • Page 38

    0b-7 maintenance and lubrication:.

  • Page 39: 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 40

    1-ii table of contents dtc p0171 / p0172: system too lean / too rich (sensor-1, bank-1) .................................1a-81 dtc p0222 / p0223: throttle position sensor (sub) circuit low / high ..................................1a-83 dtc p0300 / p0301 / p0302 / p0303 / p0304: random misfire detect...

  • Page 41

    Table of contents 1-iii accelerator pedal position (app) sensor assembly inspection .........................................1c-5 engine coolant temperature (ect) sensor removal and installation...................................1c-6 engine coolant temperature (ect) sensor inspection...................

  • Page 42

    1-iv table of contents oil pump components ........................................1e-8 oil pump removal and installation .....................1e-9 oil pump disassembly and reassembly ..........1e-10 oil pump inspection ..........................................1e-10 specifications.....................

  • Page 43

    Table of contents 1-v starting motor components ................................. 1i-5 starting motor inspection ..................................... 1i-6 specifications........................................................ 1i-9 cranking system specifications........................... 1i-9 tight...

  • Page 44: Precautions

    1-1 precautions: engine precautions precautions precautions for engine s6rw0c1000001 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 45

    Engine general information and diagnosis: 1a-1 engine engine general information and diagnosis precautions precautions on engine service s6rw0c1100003 the following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reliable engin...

  • Page 46

    1a-2 engine general information and diagnosis: • therefore, check both ecm and tcm for dtc when mil lights on. • 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 communica...

  • Page 47

    Engine general information and diagnosis: 1a-3 precaution on can troubleshooting s6rw0c1100008 can schematic and routing diagram 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-dt...

  • Page 48

    1a-4 engine general information and diagnosis: can-dtc even when dtc related to can (= can-dtc) as described below is detected, it is not possible to point out the specific trouble point by can-dtc itself. Be sure to troubleshoot according to “troubleshooting for can-dtc”. Can-dtc table communicatio...

  • Page 49

    Engine general information and diagnosis: 1a-5 engine diagnosis general description s6rw0c1101002 note there are two types of obd system depending on the vehicle specification. For identification, refer to “precaution on on- board diagnostic (obd) system”. The engine and emission control systems in ...

  • Page 50

    1a-6 engine general information and diagnosis: freeze frame data ecm stores the engine and driving conditions (in the form of data as shown) at the moment of the detection of a malfunction in its memory. This data is called “freeze frame data”. Therefore, it is possible to know engine and driving co...

  • Page 51

    Engine general information and diagnosis: 1a-7 • cmp sensor • ckp sensor • knock sensor • wheel speed sensor • cpu (central processing unit) of ecm • app sensor • radiator cooling fan relay • evap canister purge valve • starter relay ecm and mil operate as follows. • mil lights when the ignition swi...

  • Page 52

    1a-8 engine general information and diagnosis: can communication system description s6rw0c1101015 ecm (2), abs control module (1), tcm (3), bcm (4), 4wd control module (6), combination meter (7) and keyless start control module (5) communicate control data between each control module. Communication ...

  • Page 53

    Engine general information and diagnosis: 1a-9 ecm transmission data engine torque signal accelerator pedal position signal engine speed signal throttle position signal driving cycle active warm up cycle active immobiliz light control signal er indicator mil control signal engine coolant temperature...

  • Page 54

    1a-10 engine general information and diagnosis: ecm reception data air intake system description s6rw0c1101016 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 s...

  • Page 55

    Engine general information and diagnosis: 1a-11 description of electric throttle body system s6rw0c1101017 the electric throttle body system consists of electric throttle body assembly, accelerator pedal position (app) sensor assembly, ecm and throttle actuator control relay. Among them, assembly co...

  • Page 56

    1a-12 engine general information and diagnosis: description of electric throttle body system calibration s6rw0c1101018 ecm calculates controlled opening of the throttle valve on the basis of the completely closed throttle valve position of the electric throttle body system. The completely closed pos...

  • Page 57

    Engine general information and diagnosis: 1a-13 electronic control system description s6rw0c1101022 the electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ecm which controls various devices according to the signals from the sensors an...

  • Page 58

    1a-14 engine general information and diagnosis: 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 barometr ic pressure...

  • Page 59

    Engine general information and diagnosis: 1a-15 ecm input / output circuit diagram 33 34 35 36 37 +b 59 ig1 +bb ig2 ig2 63 : 64 : 75 74 blu/yel blu/wht blu/red blu/orn blu/blk blk/wht wht/red brn/wht blk/red 67 71 : 5v : 12v 72 60 ig1 e01-29 e01-2 c01-58 e01-1 e01-16 c01-15 c01-30 48 e01-60 yel/blk ...

  • Page 60

    1a-16 engine general information and diagnosis: terminal arrangement of ecm coupler (viewed from harness side) connector: c01 6. Maf and iat sensor 31. Throttle actuator 56. Brake light switch 7. Ect sensor 32. Tp sensor 57. “stop” fuse 8. A/c refrigerant pressure sensor 33. Fuel injector no.1 58. “...

  • Page 61

    Engine general information and diagnosis: 1a-17 connector: e01 20 grn/wht ignition coil no.2 50 red can (high) communication line (active high signal) to tcm 21 grn/yel ignition coil no.1 51 pnk ckp sensor (+) 22 yel/grn starting motor signal 52 red/yel cmp sensor signal 23 — — 53 red output for 5 v...

  • Page 62

    1a-18 engine general information and diagnosis: engine and emission control input / output table s6rw0c1101023 24 yel/red fuel level sensor signal 54 blu ground for app sensor (main) 25 — — 55 grn app sensor (main) signal 26 — — 56 brn output for 5 v power source of app sensor (main) 27 red/blu eps ...

  • Page 63

    Engine general information and diagnosis: 1a-19 idle speed control throttle actuator • ckp sensor • maf sensor • iat sensor • tp sensor • ect sensor • app sensor • wheel speed sensor (vss) • a/c refrigerant pressure sensor • a/c evaporator outlet air temp. Sensor • p/s control module • abs control m...

  • Page 64

    1a-20 engine general information and diagnosis: radiator cooling fan control radiator cooling fan relay no.1, no.2 and no.3 • ignition switch • a/c switch • blower fan selector • wheel speed sensor (vss) • ect sensor • a/c refrigerant pressure sensor • a/c evaporator outlet air temp. Sensor mil cont...

  • Page 65

    Engine general information and diagnosis: 1a-21 a/c condenser cooling fan control a/c condenser cooling fan relay • wheel speed sensor (vss) • a/c refrigerant pressure sensor • a/c evaporator outlet air temp. Sensor • ect sensor • a/c switch • blower fan switch • ignition switch function output inpu...

  • Page 66

    1a-22 engine general information and diagnosis: schematic and routing diagram engine and emission control system diagram s6rw0c1102001 23 29 14 13 15 16 17 11 12 10 1 2 19 20 21 39 42 41 40 38 36 28 3 30 31 37 26 27 32 4 5 22 24 35 34 33 6 7 9 8 25 18 i6rw0c110008-01.

  • Page 67

    Engine general information and diagnosis: 1a-23 1. Air cleaner 15. Ho2s 29. Throttle actuator control relay 2. Maf and iat sensor 16. Warm-up three way catalytic converter 30. Radiator cooling fan relay 3. Tp sensor 17. Three way catalytic converter 31. A/c condenser cooling fan relay 4. Throttle ac...

  • Page 68

    1a-24 engine general information and diagnosis: component location electronic control system components location s6rw0c1103001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 3* h* d b* l 11 f l k 1 b 2 9 4 8 5 6 a...

  • Page 69

    Engine general information and diagnosis: 1a-25 diagnostic information and procedures engine and emission control system check s6rw0c1104001 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 70

    1a-26 engine general information and diagnosis: 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 71

    Engine general information and diagnosis: 1a-27 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 72

    1a-28 engine general information and diagnosis: 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 73

    Engine general information and diagnosis: 1a-29 dtc check s6rw0c1104003 note • there are two types of obd system depending on the vehicle specification. For identification, refer to “precaution on on-board diagnostic (obd) system”. • the mil is turned on when the ecm and/or tcm detect malfunction(s)...

  • Page 74

    1a-30 engine general information and diagnosis: wiring diagram 5 2 3 4 red wht red wht red wht red wht red wht e01-4 e01-19 e08-1 e08-12 e08-2 e08-13 e04-1 e04-2 g04-4 g04-2 red wht red wht g16-19 g16-18 7 red wht g04-3 g04-1 8 9 red wht g26-23 g26-22 6 red wht g241-9 g241-7 g241-10 g241-6 1 red wht...

  • Page 75

    Engine general information and diagnosis: 1a-31 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 76

    1a-32 engine general information and diagnosis: 4 dtc check 1) turn ignition switch to off position. 2) connect scan tool to dlc. 3) check dtc in the following control modules that communicate with scan tool by k-line. • bcm • keyless start control module • 4wd control module is there any dtc other ...

  • Page 77

    Engine general information and diagnosis: 1a-33 7 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 hi...

  • Page 78

    1a-34 engine general information and diagnosis: dtc table s6rw0c1104006 note • there are two types of obd system depending on the vehicle specification. For non-euro-obd model, refer to “precaution on on-board diagnostic (obd) system”. • for non-euro-obd model, some of dtc no. With delta (u) mark in...

  • Page 79

    Engine general information and diagnosis: 1a-35 ) *p0122 throttle/pedal position sensor/switch “a” (main) circuit low output voltage of tp sensor (main) is lower than 0.3 v. 1 driving cycle 1 driving cycle ) *p0123 throttle/pedal position sensor/switch “a” (main) circuit high output voltage of tp se...

  • Page 80

    1a-36 engine general information and diagnosis: ) *p0335 crankshaft position (ckp) sensor “a” circuit ckp sensor signal is not detected for 2 sec. Even though starter is operated. 1 driving cycle 1 driving cycle ) *p0340 camshaft position (cmp) sensor “a” circuit if either of the following condition...

  • Page 81

    Engine general information and diagnosis: 1a-37 ) p0660 intake manifold tuning valve control circuit/ open monitor signal of imt valve is different from command signal for 5 sec. 1 driving cycle not applicable ) p0662 intake manifold tuning valve control circuit high circuit voltage of imt valve is ...

  • Page 82

    1a-38 engine general information and diagnosis: ) u0073 control module communication bus off transmission error that is inconsistent between transmission data and transmission monitor (can bus monitor) data is detected more than 30 times continuously. 1 driving cycle not applicable ) *u0101 ecm lost...

  • Page 83

    Engine general information and diagnosis: 1a-39 for vehicle equipped with a/t 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, not only the...

  • Page 84

    1a-40 engine general information and diagnosis: fail-safe table s6rw0c1104007 when any of the following dtcs is detected, ecm enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ecm detects normal condition after that. Dtc no. Detected item fail-safe operat...

  • Page 85

    Engine general information and diagnosis: 1a-41 ) p0327 knock sensor 1 circuit low • ecm stops knock control. • ecm controls fuel cut at specified engine speed. ) p0328 knock sensor 1 circuit high ) p0335 crankshaft position (ckp) sensor “a” circuit • ecm controls ignition timing. • ecm controls fue...

  • Page 86

    1a-42 engine general information and diagnosis: scan tool data s6rw0c1104008 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 87

    Engine general information and diagnosis: 1a-43 * ) long ft b1 (long term fuel trim) at specified idle speed after warming up –20 – +20% ) total ft b1 (total fuel trim) at specified idle speed after warming up –35 – +35% * ) a/f b1 s1 current (a/f sensor output current) at specified idle speed after...

  • Page 88

    1a-44 engine general information and diagnosis: 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 89

    Engine general information and diagnosis: 1a-45 maf (mass air flow rate, g/s, lb/min.) it represents total mass of air entering intake manifold which is measured by mass air flow sensor. Calc load (calculated load value, %) engine load displayed as a percentage of maximum possible load. Value is cal...

  • Page 90

    1a-46 engine general information and diagnosis: starter sw (starter switch, on / off) this parameter indicates condition of starting motor relay output. On: starting motor relay is on off: starting motor relay is off a/c pressure (a/c refrigerant absolute pressure, kpa) this parameter indicates a/c ...

  • Page 91

    Engine general information and diagnosis: 1a-47 visual inspection s6rw0c1104009 visually check the following parts and systems. Engine basic inspection s6rw0c1104010 this check is very important for troubleshooting when ecm has detected no dtc and no abnormality has been found in “visual inspection”...

  • Page 92

    1a-48 engine general information and diagnosis: 5 is engine cranked? Go to step 6. Go to “cranking system symptom diagnosis in section 1i”. 6 does engine start? Go to step 7. Go to step 9. 7 check idle speed 1) check engine idle speed referring to “idle speed and iac throttle valve opening inspectio...

  • Page 93

    Engine general information and diagnosis: 1a-49 engine symptom diagnosis s6rw0c1104011 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 94

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

  • Page 95

    Engine general information and diagnosis: 1a-51 poor gasoline mileage faulty spark plug (improper gap, heavy deposits and burned electrodes, etc.) “spark plug inspection in section 1h” high idle speed condition “improper engine idling or engine fails to idle” poor performance of ect sensor or maf se...

  • Page 96

    1a-52 engine general information and diagnosis: surge – engine power variation under steady throttle or cruise. Feels like vehicle speeds up and down with no change in accelerator pedal faulty spark plug (excess carbon deposits, improper gap, burned electrodes, etc.) “spark plug inspection in sectio...

  • Page 97

    Engine general information and diagnosis: 1a-53 engine has no power faulty spark plug “spark plug inspection in section 1h” faulty ignition coil with ignitor “ignition coil assembly (including ignitor) inspection in section 1h” faulty knock sensor “dtc p0327 / p0328: knock sensor circuit low / high”...

  • Page 98

    1a-54 engine general information and diagnosis: excessive hydrocarbon (hc) emission or carbon monoxide (co) faulty spark plug “spark plug inspection in section 1h” faulty ignition coil with ignitor “ignition coil assembly (including ignitor) inspection in section 1h” low compression “compression che...

  • Page 99

    Engine general information and diagnosis: 1a-55 mil does not come on with ignition switch on and engine stop (but engine can be started) s6rw0c1104012 wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn on (close the contact point). Then, ecm b...

  • Page 100

    1a-56 engine general information and diagnosis: troubleshooting note when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm connectors referring to “inspection of ecm and its circuits”. Step action yes no 1 mil power supply che...

  • Page 101

    Engine general information and diagnosis: 1a-57 mil remains on after engine starts s6rw0c1104013 wiring diagram refer to “mil does not come on with ignition switch on and engine stop (but engine can be started)”. Circuit description when the ignition switch is turned on, ecm causes the main relay to...

  • Page 102

    1a-58 engine general information and diagnosis: dtc p0030: ho2s heater control circuit (sensor-1, bank-1) s6rw0c1104014 wiring diagram a/f sensor description refer to “a/f sensor description”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, con...

  • Page 103

    Engine general information and diagnosis: 1a-59 dtc troubleshooting dtc p0031 / p0032: ho2s heater control circuit low / high (sensor-1, bank-1) s6rw0c1104015 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. A/f sensor description refer to “a/f sensor description”...

  • Page 104

    1a-60 engine general information and diagnosis: dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 a/f sensor heater circuit check 1) disconnect connector from a/f sensor with ignition s...

  • Page 105

    Engine general information and diagnosis: 1a-61 dtc p0037 / p0038: ho2s heater control circuit low / high (sensor-2, bank-1) s6rw0c1104016 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ...

  • Page 106

    1a-62 engine general information and diagnosis: dtc p0101: mass or volume air flow circuit range / performance s6rw0c1104017 wiring diagram 4 ho2s heater circuit check 1) disconnect connectors from ecm and check for proper terminal connection to ecm connector. 2) if connections are ok, check that ho...

  • Page 107

    Engine general information and diagnosis: 1a-63 dtc detecting condition and trouble area dtc confirmation procedure note check to make sure that the following conditions are satisfied when using this “dtc confirmation procedure”. • intake air temperature at engine start: –10 °c (14 °f) to 80 °c (176...

  • Page 108

    1a-64 engine general information and diagnosis: dtc p0102 / p0103: mass or volume air flow circuit low / high input s6rw0c1104018 wiring diagram refer to “dtc p0101: mass or volume air flow circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with igni...

  • Page 109

    Engine general information and diagnosis: 1a-65 3 maf sensor power supply voltage check 1) disconnect connector from maf sensor with ignition switch turned off. 2) check for proper terminal connection to maf sensor and ecm connectors. 3) if connections are ok, turn ignition switch to on position. 4)...

  • Page 110

    1a-66 engine general information and diagnosis: dtc p0111: intake air temperature sensor 1 circuit range / performance s6rw0c1104019 wiring diagram refer to “dtc p0101: mass or volume air flow circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure note chec...

  • Page 111

    Engine general information and diagnosis: 1a-67 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 10 sec. 4) check dtc. Dtc troubleshooting no...

  • Page 112

    1a-68 engine general information and diagnosis: dtc p0116: engine coolant temperature circuit range / performance s6rw0c1104021 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 poss...

  • Page 113

    Engine general information and diagnosis: 1a-69 dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 dtc check is there dtc(s) other than p0116? Go to applicable dtc diag.Flow. Go to step ...

  • Page 114

    1a-70 engine general information and diagnosis: dtc p0117 / p0118: engine coolant temperature circuit low / high s6rw0c1104022 wiring diagram refer to “dtc p0116: engine coolant temperature circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with igni...

  • Page 115

    Engine general information and diagnosis: 1a-71 dtc p0122 / p0123: throttle / pedal position sensor / switch “a” circuit low / high s6rw0c1104023 wiring diagram 4 ect sensor check 1) check ect sensor for performance referring to “engine coolant temperature (ect) sensor inspection in section 1c”. Is ...

  • Page 116

    1a-72 engine general information and diagnosis: dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 10 sec. 4) check dtc. Dtc troubleshooting no...

  • Page 117

    Engine general information and diagnosis: 1a-73 3 wire harness check 1) turn ignition switch off position. 2) disconnect connectors from tp sensor and ecm. 3) check for proper terminal connection to electric throttle body assembly and ecm connectors. 4) if connections are ok, check that tp sensor (m...

  • Page 118

    1a-74 engine general information and diagnosis: dtc p0131 / p0132: o2 sensor circuit low voltage / high voltage (sensor-1, bank-1) s6rw0c1104026 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. Dtc detecting condition and trouble area dtc confirmation procedure no...

  • Page 119

    Engine general information and diagnosis: 1a-75 dtc p0133: o2 sensor circuit slow response / performance (sensor-1, bank-1) s6rw0c1104027 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. A/f sensor description refer to “a/f sensor description”. Dtc detecting condi...

  • Page 120

    1a-76 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 121

    Engine general information and diagnosis: 1a-77 dtc p0134: o2 sensor circuit no activity detected (sensor-1, bank-1) s6rw0c1104028 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. A/f sensor description refer to “a/f sensor description”. Dtc detecting condition an...

  • Page 122

    1a-78 engine general information and diagnosis: dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2, bank-1) s6rw0c1104030 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. Dtc detecting condition and trouble area dtc confirmation proce...

  • Page 123

    Engine general information and diagnosis: 1a-79 6) repeat step 4). 7) keep above vehicle speed for 8 min. Or more. (throttle valve opening is kept constant in this step.) 8) repeat step 5). 9) check dtc and pending dtc. Dtc troubleshooting step action yes no 1 was “engine and emission control system...

  • Page 124

    1a-80 engine general information and diagnosis: dtc p0140: o2 sensor (ho2s) circuit no activity detected (sensor-2, bank-1) s6rw0c1104032 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. Dtc detecting condition and trouble area dtc confirmation procedure note chec...

  • Page 125

    Engine general information and diagnosis: 1a-81 dtc p0171 / p0172: system too lean / too rich (sensor-1, bank-1) s6rw0c1104033 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. A/f sensor description refer to “a/f sensor description”. Dtc detecting condition and tr...

  • Page 126

    1a-82 engine general information and diagnosis: dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 is there dtc(s) other than fuel system (dtc p0171 / p0172 / 2195 / 2196)? Go to applica...

  • Page 127

    Engine general information and diagnosis: 1a-83 dtc p0222 / p0223: throttle position sensor (sub) circuit low / high s6rw0c1104034 wiring diagram refer to “dtc p0122 / p0123: throttle / pedal position sensor / switch “a” circuit low / high”. Dtc detecting condition and trouble area dtc confirmation ...

  • Page 128

    1a-84 engine general information and diagnosis: 3 wire harness check 1) turn ignition switch off position. 2) disconnect connectors from tp sensor and ecm. 3) check for proper terminal connection to electric throttle body assembly and ecm connectors. 4) if connections are ok, check that tp sensor (s...

  • Page 129

    Engine general information and diagnosis: 1a-85 dtc p0300 / p0301 / p0302 / p0303 / p0304: random misfire detected / cylinder 1 / cylinder 2 / cylinder 3 / cylinder 4 misfire detected s6rw0c1104035 system description ecm measure the angle of the crankshaft based on the pulse signal from the ckp sens...

  • Page 130

    1a-86 engine general information and diagnosis: dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 does fuel level meter indicate “e” level (empty)? Add fuel and recheck. Go to step 3. 3...

  • Page 131

    Engine general information and diagnosis: 1a-87 dtc p0327 / p0328: knock sensor circuit low / high s6rw0c1104036 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 pe...

  • Page 132

    1a-88 engine general information and diagnosis: dtc p0335: crankshaft position sensor “a” circuit s6rw0c1104037 wiring diagram dtc detecting condition and trouble area 3 wire harness check 1) disconnect connector from ecm with ignition switch turned off. 2) check that knock sensor signal circuit is ...

  • Page 133

    Engine general information and diagnosis: 1a-89 dtc confirmation procedure note check to make sure that the following conditions are satisfied when using this “dtc confirmation procedure”. • the following dtcs are not detected: dtcs related to starter relay 1) with ignition switch off, connect scan ...

  • Page 134

    1a-90 engine general information and diagnosis: dtc p0340: camshaft position sensor “a” circuit s6rw0c1104038 wiring diagram system description the cmp sensor located on the cylinder head cover consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion). The signal ...

  • Page 135

    Engine general information and diagnosis: 1a-91 dtc confirmation procedure note check to make sure that the following conditions are satisfied when using this “dtc confirmation procedure”. • the following dtcs are not detected: dtcs related to ckp sensor 1) with ignition switch off, connect scan too...

  • Page 136

    1a-92 engine general information and diagnosis: dtc p0420: catalyst system efficiency below threshold (bank-1) s6rw0c1104039 system and wiring diagram system description ecm monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by ho2s. When the ...

  • Page 137

    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 very careful during testing to avoid occurrence of an accident. • road test should be carried out with...

  • Page 138

    1a-94 engine general information and diagnosis: dtc p0443: evap emission system purge control valve circuit s6rw0c1104041 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 possibilit...

  • Page 139

    Engine general information and diagnosis: 1a-95 dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 evap canister purge valve power supply voltage check 1) disconnect connector from evap ...

  • Page 140

    1a-96 engine general information and diagnosis: dtc p0462 / p0463: fuel level sensor circuit low / high s6rw0c1104045 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...

  • Page 141

    Engine general information and diagnosis: 1a-97 dtc confirmation procedure 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 10 sec. 4) check dtc and pending dtc. Dtc troubleshooting step action yes no 1 was “e...

  • Page 142

    1a-98 engine general information and diagnosis: dtc p0480: fan 1 control circuit s6rw0c1104046 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 by using scan tool. 3) sta...

  • Page 143

    Engine general information and diagnosis: 1a-99 dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 wire harness check 1) turn ignition switch to off position. 2) check for proper termina...

  • Page 144

    1a-100 engine general information and diagnosis: 5 radiator cooling fan control circuit voltage check 1) turn ignition switch to off position. 2) remove radiator cooling fan relay no.1 (1), no.2 (2) or no.3 (3). 3) turn ignition switch on position. 4) check that radiator cooling fan relay (no.1, no....

  • Page 145

    Engine general information and diagnosis: 1a-101 dtc p0481: fan 2 control circuit s6rw0c1104048 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 by using scan tool. 3) st...

  • Page 146

    1a-102 engine general information and diagnosis: dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 wire harness check 1) turn ignition switch to off position. 2) check for proper termin...

  • Page 147

    Engine general information and diagnosis: 1a-103 dtc p0500: vehicle speed sensor “a” s6rw0c1104050 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 traffic accident...

  • Page 148

    1a-104 engine general information and diagnosis: dtc troubleshooting note make sure that dtc of can communication is not detected by ecm. Dtc p0504: brake switch “a”/“b” correlation s6rw0c1104051 wiring diagram step action yes no 1 was “engine and emission control system check” performed? Go to step...

  • Page 149

    Engine general information and diagnosis: 1a-105 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 150

    1a-106 engine general information and diagnosis: dtc p0532 / p0533: a/c refrigerant pressure sensor circuit low / high s6rw0c1104053 wiring diagram 4 brake switch signal circuit check 1) disconnect connectors from ecm with ignition switch turned off. 2) check for proper connection of each switch cir...

  • Page 151

    Engine general information and diagnosis: 1a-107 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 by using scan tool. 3) check dtc. Dtc troubleshooting dtc p0601 / p0602 / p0607: intern...

  • Page 152

    1a-108 engine general information and diagnosis: dtc troubleshooting dtc p0616 / p0617: starter relay circuit low / high s6rw0c1104055 wiring diagram circuit description engine start signal is sent from engine starter circuit while engine cranking. Step action yes no 1 dtc recheck 1) clear dtc refer...

  • Page 153

    Engine general information and diagnosis: 1a-109 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 1 minute. 4) check dtc and pending dtc. Dtc...

  • Page 154

    1a-110 engine general information and diagnosis: dtc p0660 / p0662: intake manifold tuning valve control circuit open / high s6rw0c1104057 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure note check to make sure that the following conditions are satisfied when using...

  • Page 155

    Engine general information and diagnosis: 1a-111 dtc troubleshooting dtc p1510: ecm back-up power supply malfunction s6rw0c1104063 wiring diagram step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 imt valve...

  • Page 156

    1a-112 engine general information and diagnosis: 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. Dtc detecting condition and trouble area dtc confirmation procedure 1) with...

  • Page 157

    Engine general information and diagnosis: 1a-113 dtc troubleshooting dtc p2102: throttle actuator control motor circuit low s6rw0c1104066 wiring diagram refer to “dtc p0122 / p0123: throttle / pedal position sensor / switch “a” circuit low / high”. Dtc detecting condition and trouble area dtc confir...

  • Page 158

    1a-114 engine general information and diagnosis: dtc troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 throttle actuator control relay circuit check 1) remove throttle actuator control rela...

  • Page 159

    Engine general information and diagnosis: 1a-115 dtc p2103: throttle actuator control motor circuit high s6rw0c1104067 wiring diagram refer to “dtc p0122 / p0123: throttle / pedal position sensor / switch “a” circuit low / high”. Dtc detecting condition and trouble area dtc confirmation procedure 1)...

  • Page 160

    1a-116 engine general information and diagnosis: dtc troubleshooting dtc p2119: throttle actuator control throttle body range / performance s6rw0c1104069 wiring diagram refer to “dtc p0122 / p0123: throttle / pedal position sensor / switch “a” circuit low / high”. Dtc detecting condition and trouble...

  • Page 161

    Engine general information and diagnosis: 1a-117 dtc p2122 / p2123: throttle / pedal position sensor / switch “d” circuit low / high s6rw0c1104070 wiring diagram 3 wire harness check 1) disconnect connectors from electric throttle body assembly and ecm with ignition switch turned off. 2) check for p...

  • Page 162

    1a-118 engine general information and diagnosis: 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 by using scan tool. 3) keep the accelerator pedal at idle position for 2 sec. 4) keep t...

  • Page 163

    Engine general information and diagnosis: 1a-119 dtc p2127 / p2128: throttle / pedal position sensor / switch “e” circuit low / high input s6rw0c1104071 wiring diagram refer to “dtc p2122 / p2123: throttle / pedal position sensor / switch “d” circuit low / high”. Dtc detecting condition and trouble ...

  • Page 164

    1a-120 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 by using scan tool. 3) keep the accelerator pedal at idle position for 2 sec. 4) keep the accelerator pedal at fully depressed p...

  • Page 165

    Engine general information and diagnosis: 1a-121 dtc p2135: throttle / pedal position sensor / switch “a” / “b” voltage correction s6rw0c1104072 wiring diagram refer to “dtc p0122 / p0123: throttle / pedal position sensor / switch “a” circuit low / high”. Dtc detecting condition and trouble area dtc...

  • Page 166

    1a-122 engine general information and diagnosis: dtc p2138: pedal position sensor (main / sub) voltage correction s6rw0c1104073 wiring diagram refer to “dtc p0122 / p0123: throttle / pedal position sensor / switch “a” circuit low / high”. Dtc detecting condition and trouble area dtc confirmation pro...

  • Page 167

    Engine general information and diagnosis: 1a-123 dtc p2195 / p2196: o2 sensor signal stuck lean / stuck rich (sensor-1, bank-1) s6rw0c1104074 wiring diagram refer to “dtc p0030: ho2s heater control circuit (sensor-1, bank-1)”. A/f sensor description refer to “a/f sensor description”. Dtc detecting c...

  • Page 168

    1a-124 engine general information and diagnosis: dtc troubleshooting dtc p2227 / p2228 / p2229: barometric pressure circuit performance / low / high s6rw0c1104077 system description barometric pressure sensor is installed in ecm. Dtc detecting condition and trouble area dtc confirmation procedure dt...

  • Page 169

    Engine general information and diagnosis: 1a-125 dtc u0073: control module communication bus off s6rw0c1104081 refer to “troubleshooting for can-dtc”. Dtc u0101: lost communication with tcm s6rw0c1104082 refer to “troubleshooting for can-dtc”. Dtc u0121: lost communication with abs / esp ® control m...

  • Page 170

    1a-126 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 171

    Engine general information and diagnosis: 1a-127 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 172

    1a-128 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 173

    Engine general information and diagnosis: 1a-129 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 174

    1a-130 engine general information and diagnosis: inspection of ecm and its circuits s6rw0c1104086 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 175

    Engine general information and diagnosis: 1a-131 terminal no. Wire color circuit normal voltage condition remarks c01-1 blu/ yel fuel injector no.1 10 – 14 v ig switch: on — *0 – 0.6 v ↑↓ 10 – 14 v (“reference waveform no.1: ”, “reference waveform no.2: ” and “reference waveform no.24: ”) engine: id...

  • Page 176

    1a-132 engine general information and diagnosis: c01-15 blk ground for ecm below 0.3 v ig switch: on — c01-16 blu/ red fuel injector no.3 10 – 14 v ig switch: on — *0 – 0.6 v ↑↓ 10 – 14 v (“reference waveform no.1: ” and “reference waveform no.7: ”) engine: idle speed after warming up output signal ...

  • Page 177

    Engine general information and diagnosis: 1a-133 c01-24 lt grn ect sensor signal 3.3 – 3.8 v ig switch: on ect: 0 °c (32 °f) — 1.38 – 1.72 v ig switch: on ect: 50 °c (122 °f) 0.40 – 0.53 v ig switch: on ect: 100 °c (212 °f) c01-25 lt grn/ blk iat sensor signal 3.18 – 3.67 v ig switch: on iat: 0 °c (...

  • Page 178

    1a-134 engine general information and diagnosis: c01-40 wht tp sensor (sub) signal 1.33 – 1.63 v ig switch: on engine: after warmed up accelerator pedal: released — 3.67 – 4.67 v ig switch: on engine: after warmed up accelerator pedal: depressed fully c01-41 blk ground for tp sensor below 0.3 v ig s...

  • Page 179

    Engine general information and diagnosis: 1a-135 c01-49 wht can (low) communication line (active low signal) to tcm 1.5 – 2.5 v (“reference waveform no.25: ”) engine: stop ig switch: on can communication signal is serial communication signal pulse. Pulse signal displayed with a regular frequency var...

  • Page 180

    1a-136 engine general information and diagnosis: terminal no. Wire color circuit normal voltage condition remarks e01-1 blk/ red main power supply 10 – 14 v ig switch: on — e01-2 wht/ red power source for ecm internal memory 10 – 14 v ig switch: on — e01-3 — — — — — e01-4 red can (high) communicatio...

  • Page 181

    Engine general information and diagnosis: 1a-137 e01-22 lt grn cruise control command switch signal 4 – 6 v ig switch: on — e01-23 — — — — — e01-24 yel/ red fuel level sensor signal 0 – 6 v ig switch: on voltage varies depends on fuel level e01-25 — — — — — e01-26 — — — — — e01-27 red/ blu eps activ...

  • Page 182

    1a-138 engine general information and diagnosis: e01-44 brn engine speed signal output for p/ s control module *0 – 1 v ↑ ↓ 8 – 14 v (“reference waveform no.26: ” and “reference waveform no.27: ”) while engine running. Output signal is pulse. Pulse frequency varies depending on engine speed. (2 puls...

  • Page 183

    Engine general information and diagnosis: 1a-139 reference waveform no.1 fuel injector signal (1) with engine idling reference waveform no.2 no.1 fuel injector signal (2) with engine idling e01-52 yel app sensor (sub) signal 0.17 – 0.58 v ig switch: on engine: after warmed up accelerator pedal: rele...

  • Page 184

    1a-140 engine general information and diagnosis: reference waveform no.3 no.2 fuel injector signal (2) with engine idling reference waveform no.4 ho2s signal (1) with engine idling reference waveform no.5 ho2s signal (1) with engine racing reference waveform no.6 evap canister purge valve signal mea...

  • Page 185

    Engine general information and diagnosis: 1a-141 reference waveform no.7 no.3 fuel injector signal (2) with engine idling reference waveform no.8 no.4 fuel injector signal (2) with engine idling reference waveform no.9 ignition coil signal (1) with engine idling reference waveform no.10 ignition coi...

  • Page 186

    1a-142 engine general information and diagnosis: reference waveform no.11 ignition coil no.3 signal (2) with engine idling reference waveform no.12 ignition coil no.2 signal (1) with engine idling reference waveform no.13 ignition coil no.1 signal (1) with engine idling reference waveform no.14 maf ...

  • Page 187

    Engine general information and diagnosis: 1a-143 reference waveform no.15 a/f sensor signal with engine idling reference waveform no.16 imt valve actuator signal with engine racing reference waveform no.17 cmp sensor signal with engine idling reference waveform no.18 cmp sensor signal with engine id...

  • Page 188

    1a-144 engine general information and diagnosis: reference waveform no.19 throttle actuator output signal with ignition switch turned on reference waveform no.20 throttle actuator output signal with ignition switch turned on reference waveform no.21 knock sensor signal at engine speed 4000 r/min. Me...

  • Page 189

    Engine general information and diagnosis: 1a-145 reference waveform no.22 knock sensor signal at engine speed 4000 r/min. Reference waveform no.23 can communication line signal from abs / esp ® control module with ignition switch turned on reference waveform no.24 ignition coil signal and fuel injec...

  • Page 190

    1a-146 engine general information and diagnosis: reference waveform no.26 ignition pulse (engine revolution) signal (2) with engine idling reference waveform no.27 ignition pulse (engine revolution) signal (2) with engine idling measurement terminal ch1: “c01-52” to “c01-58” ch2: “e01-44” to “c01-58...

  • Page 191

    Engine general information and diagnosis: 1a-147 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 192

    1a-148 engine general information and diagnosis: ecm power and ground circuit check s6rw0c1104087 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 193

    Engine general information and diagnosis: 1a-149 circuit description when the ignition switch is turned on, the main relay turns on (the contact point closes) and the main power is supplied to ecm. And then ecm supplies 5 v power to each sensor (a/c refrigerant pressure sensor, app sensor and tp sen...

  • Page 194

    1a-150 engine general information and diagnosis: 5 main relay circuit check 1) connect connectors to ecm with ignition switch turned off. 2) turn ignition switch to on position. 3) measure voltage between “e01-60” terminal of ecm connector and body ground. Is voltage 0 – 1 v? Go to step 7. Go to ste...

  • Page 195

    Engine general information and diagnosis: 1a-151 fuel injector circuit check s6rw0c1104088 wiring diagram 10 main relay check 1) check main relay referring to “engine and emission control system relay inspection in section 1c”. Is main relay in good condition? “brn/wht” wire is open or high resistan...

  • Page 196

    1a-152 engine general information and diagnosis: troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm con...

  • Page 197

    Engine general information and diagnosis: 1a-153 fuel pump and its circuit check s6rw0c1104089 wiring diagram e01-1 e01-60 e01-15 brn/wht blk/yel blk/yel e01-29 blk/wht grn/wht blk/wht blk/wht pnk blk wht grn 7 6 4 3 2 5 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...

  • Page 198

    1a-154 engine general information and diagnosis: troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm con...

  • Page 199

    Engine general information and diagnosis: 1a-155 6 fuel pump relay drive signal check 1) measure voltage within 2 sec. 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 tank...

  • Page 200

    1a-156 engine general information and diagnosis: fuel pressure check s6rw0c1104090 system diagram special tool (a): 09912–58442 (b): 09912–58432 (c): 09912–58490 i7rw01110038-01 1. Injector 2. Delivery pipe 3. Fuel pump 4. Fuel filter 5. Fuel pressure regulator.

  • Page 201

    Engine general information and diagnosis: 1a-157 troubleshooting note before using the following flow chart, chart check to make sure that battery voltage is higher than 11 v. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition. Step ...

  • Page 202

    1a-158 engine general information and diagnosis: a/c condenser cooling fan control system inspection s6rw0c1104091 wiring diagram troubleshooting 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 ...

  • Page 203

    Engine general information and diagnosis: 1a-159 4 check wire circuit 1) disconnect a/c condenser cooling fan relay from fuse box no.2 with ignition switch turned off. 2) turn on ignition switch, measure voltage between engine ground and “blu/yel” wire terminal of a/c condenser cooling fan relay con...

  • Page 204

    1a-160 engine general information and diagnosis: a/c system circuits check s6rw0c1104092 wiring diagram blk/wht blk/red wht blu brn/wht 12v 5v 14 17 10 8 e01-29 e01-1 e01-60 c01-15 c01-29 c01-48 c01-58 c01-30 blk/yel blk/yel blk blk blk blk/orn blk/orn red blk 11 wht 9 3 4 blk/red red/blk blk/red bl...

  • Page 205

    Engine general information and diagnosis: 1a-161 troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm con...

  • Page 206

    1a-162 engine general information and diagnosis: 9 a/c evaporator temperature sensor check 1) check a/c evaporator temperature sensor referring to “evaporator temperature sensor inspection in section 7b”. Is resistance within specification? Go to step 10. Faulty a/c evaporator temperature sensor. 10...

  • Page 207

    Engine general information and diagnosis: 1a-163 electric load signal circuit check s6rw0c1104093 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 208

    1a-164 engine general information and diagnosis: troubleshooting note • before performed troubleshooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm con...

  • Page 209

    Engine general information and diagnosis: 1a-165 radiator cooling fan low speed control system check s6rw0c1104094 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...

  • Page 210

    1a-166 engine general information and diagnosis: 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 engine is running. The fan can start automatically in response to the ect...

  • Page 211

    Engine general information and diagnosis: 1a-167 radiator cooling fan high speed control system check s6rw0c1104095 wiring diagram refer to “radiator cooling fan low speed control system check”. Troubleshooting warning ! Keep hands, tools, and clothing away from radiator cooling fan to help prevent ...

  • Page 212

    1a-168 engine general information and diagnosis: repair instructions idle speed and iac throttle valve opening inspection s6rw0c1106001 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 213

    Engine general information and diagnosis: 1a-169 special tools and equipment special tool s6rw0c1108001 09912–58432 09912–58442 fuel pressure gauge hose fuel pressure gauge this tool is included in fuel pressure gauge set (09912- 58413). ) this tool is included in fuel pressure gauge set (09912- 584...

  • Page 214

    1b-1 aux. Emission control devices: engine aux. Emission control devices diagnostic information and procedures evap canister purge system inspection s6rw0c1204003 1) warm up engine to normal operating temperature. 2) hoist vehicle so that all wheels rotate freely. 3) set m/t in “neutral” or a/t in “...

  • Page 215

    Aux. Emission control devices: 1b-2 repair instructions evap system components s6rw0c1206001 evap canister purge inspection s6rw0c1206002 note before inspection, check to make sure that gear shift lever is in neutral position (with a/t model, selector lever in “p” range) and that parking brake lever...

  • Page 216

    1b-3 aux. Emission control devices: evap canister purge valve and its circuit inspection s6rw0c1206003 warning ! Do not apply vacuum by mouth; otherwise harmful fuel vapor can be breathed in. Caution ! Do not apply vacuum more than –86 kpa (– 12.47 psi); otherwise evap canister purge valve could be ...

  • Page 217

    Aux. Emission control devices: 1b-4 vacuum passage inspection s6rw0c1206004 start engine and run it at idle speed. Disconnect purge hose no.3 (1) from evap canister purge valve (2). With finger placed against disconnected hose, check that vacuum is applied. If it is not applied, clean vacuum passage...

  • Page 218

    1b-5 aux. Emission control devices: evap canister removal and installation s6rw0c1206010 removal 1) disconnect negative cable at battery. 2) hoist vehicle. 3) remove evap canister as follows. A) disconnect hoses (1) from evap canister (2). B) remove evap canister bracket (3) with evap canister from ...

  • Page 219

    Aux. Emission control devices: 1b-6 pcv valve inspection s6rw0c1206016 1) remove pcv valve referring to “pcv valve removal and installation”. 2) connect pcv valve to hose and install plug to cylinder head cover hole. 3) run engine at idle. 4) place your finger over end of pcv valve (1) to check for ...

  • Page 220: Engine Electrical Devices

    1c-1 engine electrical devices: engine engine electrical devices repair instructions engine control module (ecm) removal and installation s6rw0c1306001 caution ! As ecm consists of precision parts, be careful not to expose it to excessive shock. Note for vehicle equipped with immobilizer control sys...

  • Page 221

    Engine electrical devices: 1c-2 electric throttle body assembly on-vehicle inspection s6rw0c1306004 warning ! Never touch throttle valve with finger while ignition switch is turned on and accelerator pedal is depressed. Otherwise, injury may result by pinching the finger between throttle valve and t...

  • Page 222

    1c-3 engine electrical devices: electric throttle body assembly operation check 1) remove air cleaner outlet hose. 2) turn on ignition switch. 3) depress accelerator pedal gradually and check that throttle valve moves smoothly until it opens fully. 4) release accelerator pedal depressed in step 3) a...

  • Page 223

    Engine electrical devices: 1c-4 tp sensor (sub) [b]: 1.33 – 5.007 v, varying according to throttle valve opening by finger (voltage should vary by about 0.032 v for each 1 ° valve opening) electric throttle body system calibration s6rw0c1306005 note if the service described under the “precautions of...

  • Page 224

    1c-5 engine electrical devices: accelerator pedal position (app) sensor assembly removal and installation s6rw0c1306007 caution ! • do not expose app sensor assembly to excessive shock like a dropping it. If app sensor assembly has been exposed to excessive shock, it should be replaced. • be careful...

  • Page 225

    Engine electrical devices: 1c-6 3) measure output voltage variation while accelerator pedal is released and fully depressed as the following graph. If sensor voltage is out of specified value or does not vary linearly as the following graph, replace app sensor assembly. Engine coolant temperature (e...

  • Page 226

    1c-7 engine electrical devices: air fuel ratio (a/f) sensor on-vehicle inspection s6rw0c1306011 heater 1) disconnect a/f sensor connector. 2) using ohmmeter, measure resistance of sensor heater between terminals “v b ” and “gnd” at sensor connector. If found faulty, replace a/f sensor. Note temperat...

  • Page 227

    Engine electrical devices: 1c-8 camshaft position (cmp) sensor removal and installation s6rw0c1306014 removal 1) disconnect negative cable at battery. 2) remove air cleaner case referring to “air cleaner assembly removal and installation in section 1d”. 3) disconnect connector from cmp sensor. 4) re...

  • Page 228

    1c-9 engine electrical devices: installation reverse removal procedure noting the following. • apply engine oil to o-ring of sensor. • tighten ckp sensor bolt to specified torque. Tightening torque ckp sensor bolt (a): 11 n·m (1.1 kgf-m, 8.0 lb-ft) • connect connector and fix wire harness with clamp...

  • Page 229

    Engine electrical devices: 1c-10 engine and emission control system relay inspection s6rw0c1306019 main, fuel pump, starting motor control, throttle actuator control and radiator cooling fan relays 1) disconnect negative cable at battery. 2) remove main relay (1), fuel pump relay (3), starting motor...

  • Page 230

    1c-11 engine electrical devices: mass air flow (maf) and intake air temperature (iat) sensor removal and installation s6rw0c1306021 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 231

    Engine electrical devices: 1c-12 imt valve actuator inspection s6rw0c1306023 caution ! Be sure not to apply battery voltage to imt valve actuator for 10 seconds or more. 1) connect battery positive (+) and negative (–) terminals to imt valve actuator (1) as shown in table below. If it does not opera...

  • Page 232: Engine Mechanical

    1d-1 engine mechanical: engine engine mechanical general description engine construction s6rw0c1401001 the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double over head camshaft) valve mechanism arranged for “v” type valve configuration consisting of 16 va...

  • Page 233

    Engine mechanical: 1d-2 imt (intake manifold tuning) system s6rw0c1401002 imt (intake manifold tuning) system varies effective length of intake pipe by opening and closing imt valve in order to improve air volumetric efficiency. As intake valve in cylinder head is opened and closed repeatedly, intak...

  • Page 234

    1d-3 engine mechanical: diagnostic information and procedures compression check s6rw0c1404001 check compression pressure on all 4 cylinders as follows: 1) warm up engine. 2) stop engine after warming up. Note after warming up engine, place transmission gear shift lever in “neutral” (shift selector l...

  • Page 235

    Engine mechanical: 1d-4 engine vacuum check s6rw0c1404002 the engine vacuum that develops in the intake line is a good indicator of the condition of the engine. The vacuum checking procedure is as follows: 1) warm up engine to normal operating temperature. Note after warming up engine, be sure to pl...

  • Page 236

    1d-5 engine mechanical: 5) check valve lashes with thickness gauge (1) according to the following procedure. A) check valve lashes of cylinder no.1. B) turn crankshaft pulley by 180 ° clockwise. C) check valve lashes of cylinder no.3. D) in the same manner as b) – c), check valve lashes of cylinder ...

  • Page 237

    Engine mechanical: 1d-6 4) turn camshaft by approximately 90 ° clockwise and remove shim (3). Warning ! Never put in the hand between camshaft and tappet. 5) using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim...

  • Page 238

    1d-7 engine mechanical: 9) install camshaft housing (1) and tighten bolts to specified torque. Tightening torque camshaft housing bolt (a): 11 n·m (1.1 kgf-m, 8.0 lb-ft) 10) turn crankshaft pulley more than 4 rotations. 11) check valve clearance again. 12) after checking and adjusting all valves, in...

  • Page 239

    Engine mechanical: 1d-8 air cleaner assembly removal and installation s6rw0c1406002 removal 1) remove air cleaner inlet hose (2) and outlet hose. 2) disconnect maf sensor connector (3). 3) remove air cleaner case (1). Installation 1) install air cleaner case (1). 2) connect maf sensor connector (3),...

  • Page 240

    1d-9 engine mechanical: electric throttle body and intake manifold components s6rw0c1406005 (a) 4 2 2 2 1 3 i7rw01140021-03 1. Intake manifold : never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is found, replace it with new one. 4. Electric thro...

  • Page 241

    Engine mechanical: 1d-10 electric throttle body on-vehicle inspection s6rw0c1406006 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”. E...

  • Page 242

    1d-11 engine mechanical: intake manifold removal and installation s6rw0c1406009 caution ! Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is found, replace it with new one. Removal 1) disconnect negative (–) cable at battery. 2) drain cooling. ...

  • Page 243

    Engine mechanical: 1d-12 imt valve actuator removal and installation s6rw0c1406010 removal 1) disconnect negative (–) cable at battery. 2) disconnect imt valve actuator connector. 3) remove imt valve actuator (1) and o-ring (2) from intake manifold (3). Installation reverse removal procedure noting ...

  • Page 244

    1d-13 engine mechanical: installation 1) install pcv valve to cylinder head cover referring to “pcv valve removal and installation in section 1b”. 2) remove oil, old sealant and dust from sealing surfaces on cylinder head and cover. 3) install new cylinder head side seals (1) to cylinder head. 4) ap...

  • Page 245

    Engine mechanical: 1d-14 engine mountings components s6rw0c1406013 i7rw01140031-02 [a]: 2wd model 6. Engine left mounting :be sure to direct paint mark to forward. 16. Yellow mark [b]: 4wd model 7. Engine rear mounting :be sure to direct paint mark to forward. 17. Mounting member [c]: m/t model 8. E...

  • Page 246

    1d-15 engine mechanical: engine assembly removal and installation s6rw0c1406014 removal 1) relieve fuel pressure according to “fuel pressure relief procedure in section 1g”. 2) disconnect negative and positive cables at battery. 3) disconnect ecm connectors. 4) remove battery and battery tray with e...

  • Page 247

    Engine mechanical: 1d-16 16) disconnect the following hoses. • brake booster hose (29) from intake manifold • radiator inlet and outlet hoses from radiator • heater inlet and outlet hoses (31) from heater core • fuel feed hose (32) from fuel feed pipe • purge hose (33) from purge valve • clutch hose...

  • Page 248

    1d-17 engine mechanical: 24) remove engine right mounting (1), engine right mounting no.1 bracket (2) and engine left mounting bracket bolt and nuts(3). 25) remove suspension frame mounting bolts (1) and front lower cross member bolts (2). 26) lower engine with transaxle, front suspension frame, fro...

  • Page 249

    Engine mechanical: 1d-18 7) install engine right mounting, engine right mounting no.1 bracket and engine left mounting bracket, and then tighten bolts and nuts to specified torque referring to “engine mountings components”. 8) remove jack. 9) connect steering lower shaft to pinion shaft referring to...

  • Page 250

    1d-19 engine mechanical: timing chain cover components s6rw0c1406015 timing chain cover removal and installation s6rw0c1406016 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...

  • Page 251

    Engine mechanical: 1d-20 5) remove crankshaft pulley (1). To remove crankshaft pulley, use special tools (steering wheel remover, bearing puller attachment) with it as shown in figure. Special tool (a): 09944–36011 (b): 09926–58010 6) remove idler pulley (1), water pump pulley (2) and belt tensioner...

  • Page 252

    1d-21 engine mechanical: 3) apply sealant “a” and “b” to specific area as shown in figure. “a”: sealant 99000–31260 (suzuki bond no.1217g) “b”: water tight sealant 99000–31140 (suzuki bond no.1207b) sealant amount for timing chain cover “a”: 3 mm (0.12 in.) “b”: 2 mm (0.08 in.) “c”: 4 mm (0.16 in.) ...

  • Page 253

    Engine mechanical: 1d-22 8) install cylinder head cover referring to “cylinder head cover removal and installation”. 9) install oil pan. Refer to “oil pan and oil pump strainer removal and installation in section 1e” for installation. 10) install crankshaft pulley. To lock crankshaft pulley (1), use...

  • Page 254

    1d-23 engine mechanical: 2nd timing chain and chain tensioner removal and installation s6rw0c1406019 caution ! After 2nd timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may occur between pis...

  • Page 255

    Engine mechanical: 1d-24 4) remove intake and exhaust camshaft timing sprocket bolts (1). To remove them, fit a spanner (4) to hexagonal part (3) at the center of camshaft to hold it stationary. 5) remove camshaft timing sprockets and 2nd timing chain (2). Installation 1) check that match mark (1) o...

  • Page 256

    1d-25 engine mechanical: 6) tighten intake and exhaust camshaft timing sprocket bolts (1) to specified torque. To tighten it, fit a spanner (2) to hexagonal part (3) at the center of camshaft to hold it stationary. Tightening torque camshaft timing sprocket bolt (a): 80 n·m (8.0 kgf-m, 57.5 lb-ft) 7...

  • Page 257

    Engine mechanical: 1d-26 2nd timing chain and chain tensioner inspection s6rw0c1406020 timing chain guide no.2 check shoe (2) for wear or damage. Camshaft sprocket check teeth of sprocket for wear or damage. Timing chain check timing chain for wear or damage. Tensioner adjuster no.2 check shoe (1) f...

  • Page 258

    1d-27 engine mechanical: 1st timing chain and chain tensioner components s6rw0c1406021 1st timing chain and chain tensioner removal and installation s6rw0c1406022 caution ! After timing chain is removed, never turn crankshaft and camshafts independently more than its allowable turning range describe...

  • Page 259

    Engine mechanical: 1d-28 2) check that match mark (1) on crankshaft timing sprocket is in match with timing mark (2) on lower crankcase. 3) apply engine oil to idler sprocket shaft and bush of idler sprocket (1). 4) install idler sprocket and idler sprocket shaft. 5) install 1st timing chain by alig...

  • Page 260

    1d-29 engine mechanical: 11) apply engine oil to sliding surface of timing chain guide no.1 (1) and then install it. Tighten guide bolts to specified torque. Tightening torque timing chain guide no.1 bolt (a): 9 n·m (0.9 kgf- m, 6.5 lb-ft) 12) check that dark blue and gold plates of 1st timing chain...

  • Page 261

    Engine mechanical: 1d-30 idler sprocket check teeth and bush (1) of sprocket for wear or damage. 1st timing chain check timing chain for wear or damage. Timing chain tensioner adjuster no.1 check that latch (1) and tooth surface (2) are free from damage and latch functions properly. Camshafts, tappe...

  • Page 262

    1d-31 engine mechanical: camshafts, tappet and shim removal and installation s6rw0c1406025 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. Rem...

  • Page 263

    Engine mechanical: 1d-32 5) 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. 6) after applying oil to housing bolts, tighten them temporarily first. Then tighte...

  • Page 264

    1d-33 engine mechanical: camshaft journal wear check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing housings. Check clearance by using gauging ...

  • Page 265

    Engine mechanical: 1d-34 wear of tappet and shim check tappet and shim for pitting, scratches, or damage. If any malcondition is found, replace. Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylind...

  • Page 266

    1d-35 engine mechanical: valves and cylinder head components s6rw0c1406027 valves and cylinder head removal and installation s6rw0c1406028 removal 1) remove camshafts, tappets and shims. Refer to “camshafts, tappet and shim removal and installation” for removal. 2) loosen cylinder head bolts in such...

  • Page 267

    Engine mechanical: 1d-36 3) check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary. 4) remove cylinder head with intake manifold, exhaust manifold and water outlet cap. Use lifting device, if necessary. Installation 1) ma...

  • Page 268

    1d-37 engine mechanical: d) tighten cylinder head bolts (m10) to 52 n ⋅m (5.2 kgf-m, 38.0 lb-ft) according to numerical order in figure. E) in the same manner as in step b), retighten cylinder head bolts (m10) to 103 n ⋅m (10.3 kgf- m, 74.5 lb-ft). F) tighten cylinder head bolt (m6) to specified tor...

  • Page 269

    Engine mechanical: 1d-38 3) release special tool, and remove spring retainers and valve springs. 4) remove valve from combustion chamber side. 5) remove valve stem seal (1) from valve guide, and then valve spring seat (2). Note do not reuse seal once disassembled. Be sure to use new seal when assemb...

  • Page 270

    1d-39 engine mechanical: 3) ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore. Special tool (a): 09916–34542 (b): 09916–37810 4) install valve spring seat to cylinder head. 5) install new valve stem seal (1) to valve guide. After applying engine oil to seal and spind...

  • Page 271

    Engine mechanical: 1d-40 valves and valve guides inspection s6rw0c1406030 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 272

    1d-41 engine mechanical: valve visual inspection • remove all carbon from valves. • inspect each valve for wear, burn or distortion at its face and stem end, as necessary, replace it. • inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfa...

  • Page 273

    Engine mechanical: 1d-42 valve seat repair a valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping. 1) exhaust valve seat: use valve seat cutters...

  • Page 274

    1d-43 engine mechanical: • check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using a straightedge and thickness gauge, check flatness of gasketed surface at a total of 6 locations. If distortion limit is exceeded, correct gasketed surface with a surfa...

  • Page 275

    Engine mechanical: 1d-44 spring squareness use a square and surface plate to check each spring for squareness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit must be replaced. Valve spring squareness limit: 2.2 mm (0.087 in.)...

  • Page 276

    1d-45 engine mechanical: pistons, piston rings, connecting rods and cylinders removal and installation s6rw0c1406034 removal 1) remove oil pump with oil pump strainer. Refer to “oil pump removal and installation in section 1e” for removal. 2) remove cylinder head. Refer to “valves and cylinder head ...

  • Page 277

    Engine mechanical: 1d-46 5) install cylinder head. Refer to “valves and cylinder head removal and installation” for installation. 6) install oil pan. Refer to “oil pan and oil pump strainer removal and installation in section 1e” for installation. 7) install camshafts and tappets and shims. Refer to...

  • Page 278

    1d-47 engine mechanical: reassembly note two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. 1) each piston (1) has stamped number (2) as shown. ...

  • Page 279

    Engine mechanical: 1d-48 4) install piston pin to piston (1) and connecting rod (3): after applying engine oil to piston pin, piston pin holes in piston and inner surface of connecting rod small end, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, ...

  • Page 280

    1d-49 engine mechanical: note if any one of four cylinders has to be rebored, rebore all four to the same next oversize. This is necessary for the sake of uniformity and balance. Pistons • inspect piston for faults, cracks or other damages. Damaged or faulty piston should be replaced. • piston diame...

  • Page 281

    Engine mechanical: 1d-50 piston pin • check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly worn or damaged, replace pin, connecting rod or pis...

  • Page 282

    1d-51 engine mechanical: connecting rod • big-end side clearance: check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod. Big-end side clearance • connecting r...

  • Page 283

    Engine mechanical: 1d-52 • connecting rod bearing clearance: a. Before checking bearing clearance, clean bearing and crank pin. B. Install bearing in connecting rod and bearing cap. C. Place a piece of gauging plastic (1) to full width of crank pin as contacted by bearing (parallel to crankshaft), a...

  • Page 284

    1d-53 engine mechanical: • 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 ...

  • Page 285

    Engine mechanical: 1d-54 c. 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 the figure. Each color indicated the following thickness at the center of bearing. Standard size of connecting rod ...

  • Page 286

    1d-55 engine mechanical: main bearings, crankshaft and cylinder block components s6rw0c1406039 i7rw01140065-01 1. Cylinder block 10. Flywheel : tighten 40 n ⋅m (4.0 kgf-m, 29.0 lb-ft), 0 n ⋅m (0 kgf-m, 0 lb-ft), 40 n⋅m (4.0 kgf-m, 29.0 lb-ft) and 58 n ⋅m (5.8 kgf-m, 42.0 lb-ft) by the specified proc...

  • Page 287

    Engine mechanical: 1d-56 main bearings, crankshaft and cylinder block removal and installation s6rw0c1406040 removal 1) remove engine assembly from vehicle. Refer to “engine assembly removal and installation”. 2) remove flywheel (drive plate for a/t) by using special tool. Special tool (a): 09924–17...

  • Page 288

    1d-57 engine mechanical: 1) fit main bearings to cylinder block (1). One of two halves of main bearing (4) has oil groove (3). Install this half with oil groove to cylinder block and another half without oil groove to lower crankcase. Make sure that two halves are painted in the same color. 2) insta...

  • Page 289

    Engine mechanical: 1d-58 c) tighten bolts ((1) – (10)) to 40 n ⋅m (4.0 kgf-m, 29.0 lb-ft) according to numerical order in figure. D) in the same manner as in step c), retighten bolts ((1) – (10)) to 58 n ⋅m (5.8 kgf-m, 42.0 lb-ft). E) tighten bolts ((11) – (22)) to specified torque according to nume...

  • Page 290

    1d-59 engine mechanical: 11) install flywheel (drive plate for a/t). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) to specified torque. Note use new flywheel or drive plate bolt. Special tool (a): 09924–17811 tightening torque flywheel or drive plate...

  • Page 291

    Engine mechanical: 1d-60 crankshaft thrust play measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and lower crankcase installed. Tighten crankcase bolts referring to “main bearings, crankshaft and cylinder block removal and installation”. Use ...

  • Page 292

    1d-61 engine mechanical: main bearing clearance check clearance by using gauging plastic according to the following procedure. 1) remove lower crankcase. 2) clean bearings and main journals. 3) place a piece of gauging plastic (1) to full width of bearing (parallel to crankshaft) on journal, avoidin...

  • Page 293

    Engine mechanical: 1d-62 stamped alphabets on lower crankcase represent journal diameter marked with an arrow in figure respectively. For example, stamped alphabet “a” at no.2 journal indicates that (journal) bore diameter of no.2 journal is 61.9940 – 62.0000 mm (2.44070 – 2.44094 in.). 3) there are...

  • Page 294

    1d-63 engine mechanical: 5) check main bearing clearance with newly selected standard bearing referring to “main bearing clearance”. If clearance still exceeds its limit, use next thicker bearing and recheck clearance. Undersize bearing (0.25 mm): • 0.25 mm undersize bearing is available, in five ki...

  • Page 295

    Engine mechanical: 1d-64 crankshaft position sensor plate check teeth of plate for damage. If any damage is found, replace crankshaft (1). Oil pump sprocket check teeth of sprocket for wear or damage. If any damage or wear is found, replace crankshaft (1). Oil pump chain check oil pump chain for wea...

  • Page 296

    1d-65 engine mechanical: honing or reboring cylinders 1) when any cylinder needs reboring, all other cylinders must also be rebored at the same time. Oversize piston specification 2) using micrometer, measure piston diameter. 3) calculate cylinder bore diameter to be rebored as follows. D = a + b – ...

  • Page 297

    Engine mechanical: 1d-66 note the specified tightening torque is also described in the following. “air cleaner components” “electric throttle body and intake manifold components” “cylinder head cover components” “engine mountings components” “timing chain cover components” “2nd timing chain and chai...

  • Page 298

    1d-67 engine mechanical: special tools and equipment recommended service material s6rw0c1408001 note required service material is also described in the following. “timing chain cover components” “2nd timing chain and chain tensioner components” “1st timing chain and chain tensioner components” “cams...

  • Page 299

    Engine mechanical: 1d-68 09916–37810 09916–38210 valve guide reamer (6 mm) valve guide reamer (11 mm) ) ) 09916–46020 09916–57340 valve guide remover valve guide installer attachment ) ) 09916–57350 09916–66510 valve guide installer handle (6 mm) tappet holder ) / ) ) / ) 09916–77310 09916–84511 pis...

  • Page 300: Engine Lubrication System

    1e-1 engine lubrication system: engine engine lubrication system general description engine lubrication description s6rw0c1501001 the oil pump is trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered...

  • Page 301

    Engine lubrication system: 1e-2 diagnostic information and procedures oil pressure check s6rw0c1504001 warning ! To avoid danger of being burned, do not touch exhaust manifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has cooled down. Note prior to checki...

  • Page 302

    1e-3 engine lubrication system: repair instructions engine oil and filter change s6rw0c1506008 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 wit...

  • Page 303

    Engine lubrication system: 1e-4 5) screw new filter on oil filter stand by hand until the filter o-ring contacts mounting surface. Caution ! To tighten oil filter properly, it is important to accurately identify the position at which filter o-ring first contacts mounting surface. 6) tighten the filt...

  • Page 304

    1e-5 engine lubrication system: oil pan and oil pump strainer components s6rw0c1506001 (a) (d) 9 12 10 3 (b) 2 6 (a) (a) 4 1217g 8 5 (a) (a) 1 (c) 7 5 11 (e) i7rw01150005-01 1. Oil pan : apply sealant 99000-31260 to mating surface. 10. Clutch housing plate upper bolt : tighten upper bolt first, then...

  • Page 305

    Engine lubrication system: 1e-6 oil pan and oil pump strainer removal and installation s6rw0c1506002 removal 1) remove oil level gauge. 2) raise vehicle. 3) remove engine under cover. 4) remove exhaust no.1 pipe referring to “exhaust system components in section 1k”. 5) remove transfer referring to ...

  • Page 306

    1e-7 engine lubrication system: installation 1) install new o-rings (2) to oil pump strainer (1) securely as shown in figure. Tighten strainer bolts to specified torque. Tightening torque oil pump strainer bolt (a): 11 n·m (1.1 kgf-m, 8.0 lb-ft) 2) apply sealant to oil pan (1) mating surface continu...

  • Page 307

    Engine lubrication system: 1e-8 oil pump components s6rw0c1506004 i7rw01150011-01 1. Cylinder block 8. Oil pump relief valve retainer 15. Baffle plate bolt (m6 bolt) 2. Oil pump relief valve set : replace as a set. 9. Oil pump chain guide 16. Oil pump sprocket cover 3. Baffle plate 10. Oil pump chai...

  • Page 308

    1e-9 engine lubrication system: oil pump removal and installation s6rw0c1506005 caution ! Don’t remove sprocket and inner rotor from oil pump, otherwise damage of oil pump center shaft and abnormal operation of oil pump could result. Removal 1) disconnect negative (–) cable at battery. 2) drain engi...

  • Page 309

    Engine lubrication system: 1e-10 oil pump disassembly and reassembly s6rw0c1506006 caution ! Don’t remove sprocket and inner rotor from oil pump, otherwise damage of oil pump center shaft and abnormal operation of oil pump could result. Disassembly • disassemble oil pump referring to “oil pump compo...

  • Page 310

    1e-11 engine lubrication system: radial clearance check radial clearance between outer rotor (2) and case no.1 (1), using thickness gauge (4). If clearance exceeds its limit, replace oil pump assembly. Limit on radial clearance between outer rotor and case 0.20 mm (0.0079 in.) side clearance using s...

  • Page 311

    Engine lubrication system: 1e-12 special tools and equipment recommended service material s6rw0c1508001 note required service material is also described in the following. “oil pan and oil pump strainer components” special tool s6rw0c1508002 material suzuki recommended product or specification note s...

  • Page 312: Engine Cooling System

    1f-1 engine cooling system: engine engine cooling system general description cooling system s6rw0c1601001 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 s6rw0c1601002 warning !...

  • Page 313

    Engine cooling system: 1f-2 schematic and routing diagram coolant circulation s6rw0c1602001 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 314

    1f-3 engine cooling system: diagnostic information and procedures engine cooling symptom diagnosis s6rw0c1604001 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 315

    Engine cooling system: 1f-4 repair instructions cooling system components s6rw0c1606001 i7rw01160001-03 1. Radiator 9. Water outlet cap gasket 17. Radiator cooling fan assembly for disassembly and reassembly, refer to “radiator cooling fan disassembly and reassembly”. 2. Reservoir 10. O-ring 18. To ...

  • Page 316

    1f-5 engine cooling system: coolant level check s6rw0c1606002 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 317

    Engine cooling system: 1f-6 cooling system flush and refill s6rw0c1606005 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 318

    1f-7 engine cooling system: thermostat removal and installation s6rw0c1606007 removal 1) drain coolant. 2) disconnect radiator outlet hose from thermostat cap (1). 3) remove thermostat cap (1) from water pump (2). 4) remove thermostat from water pump (2). Installation reverse removal procedure for i...

  • Page 319

    Engine cooling system: 1f-8 radiator cooling fan assembly inspection s6rw0c1606009 1) check continuity between each terminals. If there is no continuity, replace radiator fan assembly. 2) connect battery to radiator fan motor connector as shown in figure, then check that the radiator fan motor opera...

  • Page 320

    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 9) to 17) of “cooling system flush and refill”. • after installat...

  • Page 321

    Engine cooling system: 1f-10 water pump removal and installation s6rw0c1606015 removal 1) disconnect negative (–) cable at battery. 2) drain coolant referring to “cooling system draining”. 3) remove water pump and generator drive belt referring to “water pump and generator drive belt removal and ins...

  • Page 322: Fuel System

    1g-1 fuel system: engine fuel system precautions precautions on fuel system service s6rw0c1700001 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 323

    Fuel system: 1g-2 general description fuel system s6rw0c1701001 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 tank, fuel p...

  • Page 324

    1g-3 fuel system: schematic and routing diagram fuel delivery system diagram s6rw0c1702001 diagnostic information and procedures fuel pressure inspection s6rw0c1704001 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the ri...

  • Page 325

    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 326

    1g-5 fuel system: repair instructions fuel system components s6rw0c1706001 i6rw0c170001-01 1. Fuel tank 10. Fuel tank belt 20. O-ring 2. Fuel pump assembly 11. Fuel vapor line 21. Fuel pump bolt 3. Fuel tank filler hose 12. Fuel tank protector 22. Fuel tank inlet valve 4. Fuel tank filler neck 13. I...

  • Page 327

    Fuel system: 1g-6 fuel hose disconnecting and reconnecting s6rw0c1706002 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. Connection other than quick joint • clamp around fuel tank note...

  • Page 328

    1g-7 fuel system: clamp other than around fuel tank quick joint disconnecting 1) remove mud, dust and/or foreign material between pipe (1) and quick joint (2) by blowing compressed air. 2) unlock joint lock by inserting special tool between pipe and quick joint. Special tool (a): 09919–47020 3) disc...

  • Page 329

    Fuel system: 1g-8 fuel pressure relief procedure s6rw0c1706003 caution ! This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. Note if ecm detects dtc(s) after servicing, clear dtc(s) referring to “dtc clearance in section 1a”. 1) make sure that engine i...

  • Page 330

    1g-9 fuel system: fuel pipe removal and installation s6rw0c1706006 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 “fuel...

  • Page 331

    Fuel system: 1g-10 fuel injector removal and installation s6rw0c1706008 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 according to “fuel pressure rel...

  • Page 332

    1g-11 fuel system: fuel injector inspection s6rw0c1706009 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. • put injector and battery as far away as possible in order to reduce risk o...

  • Page 333

    Fuel system: 1g-12 7) apply battery voltage to injector (1) for 15 seconds and measure injected fuel volume with graduated cylinder. Test each injector two or three times. If injected volume is out of reference value greatly, replace injector. Reference injected fuel volume approx. 65 cc/15 sec. (2....

  • Page 334

    1g-13 fuel system: fuel tank inlet valve removal and installation s6rw0c1706011 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk or fire and personal injury. Removal 1) remove fuel tank referring to “fuel tank remo...

  • Page 335

    Fuel system: 1g-14 5) hoist vehicle, and remove clamp (2), fuel filler hose (1) and breather hose (3) from fuel filler neck. 6) remove evap canister referring to “evap canister removal and installation in section 1b”. 7) remove exhaust center pipe referring to “exhaust pipe and muffler removal and i...

  • Page 336

    1g-15 fuel system: 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 wheel speed...

  • Page 337

    Fuel system: 1g-16 fuel tank inspection s6rw0c1706014 after removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Also check fuel pump assembly gaskets for leaks, visually inspect fuel tank for leaks and damage. Replace any damaged or...

  • Page 338

    1g-17 fuel system: fuel filter replacement s6rw0c1706020 warning ! This work must be performed in a well ventilated area and away from any open flames (such as gas hot water heaters). Fuel filter (1) is installed in fuel pump assembly (2) in fuel tank. Replace fuel pump assembly with new one periodi...

  • Page 339

    Fuel system: 1g-18 main fuel level sensor removal and installation s6rw0c1706018 caution ! • do not touch resister plate (1) and deform arm (2). It may cause main fuel level sensor to fail. • be very careful not to cause damage to fuel tube installed section (sealed section in bore). If it be damage...

  • Page 340

    1g-19 fuel system: specifications tightening torque specifications s6rw0c1707001 note the specified tightening torque is also described in the following. “fuel system components” “fuel hose disconnecting and reconnecting” reference: for the tightening torque of fastener not specified in this section...

  • Page 341: Ignition System

    Ignition system: 1h-1 engine ignition system general description ignition system construction s6rw0c1801001 the ignition system is an electronic (distributor less) ignition system. Especially, a direct ignition system is adopted. They consists of the parts as described below. • ecm it detects the en...

  • Page 342

    1h-2 ignition system: schematic and routing diagram ignition system wiring circuit diagram s6rw0c1802001 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 19 5 6 7 ...

  • Page 343

    Ignition system: 1h-3 component location ignition system components location s6rw0c1803001 diagnostic information and procedures ignition system check s6rw0c1804001 7 5 6 3 4 2 1 10 9 11 8 12 13 14 15 i7rw01180002-01 1. Ecm 6. Electric throttle body assembly 11. Ignition coil assembly for no.1 2. Cm...

  • Page 344

    1h-4 ignition system: 4 electrical connection check 1) check ignition coil assemblies for electrical connection. Are they connected securely? Go to step 5. Connect securely. 5 ignition coil assembly power supply and ground circuit check 1) check ignition coil assembly power supply and ground circuit...

  • Page 345

    Ignition system: 1h-5 ignition system symptom diagnosis s6rw0c1804002 reference waveform of ignition system s6rw0c1804003 refer to “reference waveform no.11 to 15” and “reference waveform no.19 and 20” under “inspection of ecm and its circuits in section 1a” for waveform of ignition trigger signal. ...

  • Page 346

    1h-6 ignition system: repair instructions spark plug removal and installation s6rw0c1806001 removal 1) remove ignition coil assemblies referring to “ignition coil assembly (including ignitor) removal and installation”. 2) remove spark plugs. Installation 1) install spark plugs and tighten them to sp...

  • Page 347

    Ignition system: 1h-7 ignition timing inspection s6rw0c1806005 note • ignition timing is not adjustable. If ignition timing is out of specification, check system related parts. • before starting engine, place transmission gear shift lever in “neutral” (shift selector lever to “p” range for a/t model...

  • Page 348

    1h-8 ignition system: specifications tightening torque specifications s6rw0c1807001 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 s6rw0c1808001 fastening part tightening torque ...

  • Page 349: Starting System

    Starting system: 1i-1 engine starting system schematic and routing diagram cranking system circuit diagram s6rw0c1902001 diagnostic information and procedures cranking system symptom diagnosis s6rw0c1904001 possible symptoms due to starting system trouble would be as follows: • starting motor does n...

  • Page 350

    1i-2 starting system: 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. Battery run down recharge battery. Battery voltage too low d...

  • Page 351

    Starting system: 1i-3 cranking system test s6rw0c1904002 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 352

    1i-4 starting system: repair instructions starting motor unit components s6rw0c1906001 starting motor dismounting and remounting s6rw0c1906002 dismounting 1) remove battery and battery tray with ecm. 2) remove magnetic switch lead wire (1) and battery cable (2). 3) remove starting motor mount bolt (...

  • Page 353

    Starting system: 1i-5 starting motor components s6rw0c1906003 i7rw01190004-01 1. Front housing 7. Lever 13. Internal gear 19. Brush 2. Bush 8. Plunger 14. Planetary carrier shaft 20. Brush holder 3. Snap ring 9. Plate 15. Planetary gear 21. Rear bracket 4. Pinion stop ring 10. Seal rubber 16. Packin...

  • Page 354

    1i-6 starting system: starting motor inspection s6rw0c1906004 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 355

    Starting system: 1i-7 brush holder • check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for contamination. Clean or correct as necessary. • check for continuity across insulated brush holder (positive side) ...

  • Page 356

    1i-8 starting system: • check the commutator and armature core. If there is continuity, the armature is grounded and must be replaced. • check for continuity between segments. If there is no continuity at any test point, there is an open circuit and the armature must be replaced. Gears inspect the i...

  • Page 357

    Starting system: 1i-9 specifications cranking system specifications s6rw0c1907001 tightening torque specifications s6rw0c1907002 note the specified tightening torque is also described in the following. “starting motor unit components” reference: for the tightening torque of fastener not specified in...

  • Page 358: Charging System

    1j-1 charging system: engine charging system general description battery description s6rw0c1a01001 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 359

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

  • Page 360

    1j-3 charging system: i7rw011a0006-02 1. Generator with regulator assembly 6. Charge indicator light 11. Combination meter 2. I.C. Regulator 7. Main switch 12. Can driver 3. Stator coil 8. Battery 13. Ig fuse 4. Diode 9. Ecm 14. Meter fuse 5. Field coil (rotor coil) 10. Bcm i5jb0a1a0004-01 1. Pulley...

  • Page 361

    Charging system: 1j-4 diagnostic information and procedures battery inspection s6rw0c1a04001 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 but fails to oper...

  • Page 362

    1j-5 charging system: generator test (undercharged battery check) s6rw0c1a04003 this condition, as evidenced by slow cranking or indicator clear with dark or light yellow dot can be caused by one or more of the following conditions even though indicator light may be operating normal. The following p...

  • Page 363

    Charging system: 1j-6 generator test (overcharged battery check) s6rw0c1a04004 1) to determine battery condition, refer to “battery description”. 2) if obvious overcharge condition exists as evidenced by excessive spewing of electrolyte, measure generator “b” terminal voltage at engine 2000 rpm. 3) ...

  • Page 364

    1j-7 charging system: 6) start engine of vehicle with booster battery and turn off electrical accessories. Then start engine of the vehicle with discharged battery. 7) disconnect jumper cable in the exact reverse order. With charging equipment caution ! When jump starting engine with charging equipm...

  • Page 365

    Charging system: 1j-8 water pump and generator drive belt on-vehicle inspection s6rw0c1a06003 • inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of these conditions are found, replace belt, referring to “water pump and generator drive belt removal and installation”. • check t...

  • Page 366

    1j-9 charging system: installation 1) loosen tensioner by turning the tensioner pulley (2) clockwise. 2) while holding the tensioner, install generator belt (1). 3) install right side engine under cover. Note • make sure that the belt fits each pulley’s groove properly. • after installing generator ...

  • Page 367

    Charging system: 1j-10 generator dismounting and remounting s6rw0c1a06006 dismounting 1) disconnect negative (–) cable at battery. 2) remove water pump and generator drive belt referring to “water pump and generator drive belt removal and installation”. 3) remove air cleaner case referring to “air c...

  • Page 368

    1j-11 charging system: generator components s6rw0c1a06007 12 11 13 14 (a) (b) (c) (d) 1 2 3 4 5 6 7 8 9 10 15 16 i4rs0b1a0007-01 1. Pulley nut 6. Drive end bearing 11. Rear housing 16. “b” terminal nut 2. Pulley 7. Bearing retainer 12. Rectifier : 118 n ⋅m (11.8 kgf-m, 85.5 lb-ft) 3. Front housing 8...

  • Page 369

    Charging system: 1j-12 generator inspection s6rw0c1a06008 rotor • using ohmmeter, connect positive terminal to “fr” terminal and connect negative terminal to “b” terminal of generator, check that continuity between “b” terminal and “fr” terminal. If there is no continuity, replace rotor or regulator...

  • Page 370

    1j-13 charging system: stator • using ohmmeter, check all leads for continuity. If there is no continuity, replace stator (1). • using ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator. Brush and brush holder check each bru...

  • Page 371

    Charging system: 1j-14 rectifier 1) using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace ...

  • Page 372

    1j-15 charging system: specifications charging system specifications s6rw0c1a07001 battery battery : 55b24r (42.5ah/5hr) 12v generator tightening torque specifications s6rw0c1a07002 note the specified tightening torque is also described in the following. “generator unit components” “generator compon...

  • Page 373: Exhaust System

    Exhaust system: 1k-1 engine exhaust system general description exhaust system s6rw0c1b01001 the exhaust system consists of the exhaust manifold, exhaust no.1 pipe with wu-twc (warm up three way catalytic converter), exhaust no.2 pipe and exhaust center pipe with twc (three way catalytic converter), ...

  • Page 374

    1k-2 exhaust system: repair instructions exhaust system components s6rw0c1b06001 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. I7rw011b0001-04.

  • Page 375

    Exhaust system: 1k-3 exhaust manifold removal and installation s6rw0c1b06002 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) remove engine hood...

  • Page 376

    1k-4 exhaust system: installation 1) install new exhaust manifold gasket (1) to cylinder head. 2) install exhaust manifold (1) and engine hook (2), and tighten exhaust manifold bolts and nuts to specified torque according to numerical order (“1” through “9”) as shown as in figure. Tightening torque ...

  • Page 377

    Exhaust system: 1k-5 specifications tightening torque specifications s6rw0c1b07001 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 378

    1k-6 exhaust system:.

  • Page 379: 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 380

    2-ii table of contents repair instructions ..............................................2d-5 wheel discs inspection.......................................2d-5 tires inspection...................................................2d-5 wheel balance inspection and adjustment.........2d-5 tire rotation.....

  • Page 381: Precautions

    Precautions: 2-1 suspension precautions precautions precautions on suspension s6rw0c2000001 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 382: Suspension General Diagnosis

    2a-1 suspension general diagnosis: suspension suspension general diagnosis diagnostic information and procedures suspension, wheels and tires symptom diagnosis s6rw0c2104001 condition possible cause correction / reference item vehicle pulls (leads) mismatched or uneven tires replace tires. Tires not...

  • Page 383

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

  • Page 384

    2a-3 suspension general diagnosis: repair instructions suspension system inspection s6rw0c2106001 • 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 fro...

  • Page 385

    Suspension general diagnosis: 2a-4 specifications wheel alignment specifications s6rw0c2107001 toe “b” – “a” 2wd: • front: in 1 ± 1 (mm) in 0.0393 ± 0.0393 (in.) • rear: in 5 ± 5 (mm) in 0.1969 ± 0.1969 (in.) 4wd: • front: in 2 ± 1 (mm) in 0.0787 ± 0.0393 (in.) • rear: in 5 ± 5 (mm) in 0.1969 ± 0.19...

  • Page 386: Front Suspension

    2b-1 front suspension: suspension front suspension general description front suspension construction s6rw0c2201001 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 387

    Front suspension: 2b-2 front wheel alignment construction s6rw0c2201002 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 388

    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 389

    Front suspension: 2b-4 front strut assembly components s6rw0c2206002 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 390

    2b-5 front suspension: front strut assembly removal and installation s6rw0c2206003 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 391

    Front suspension: 2b-6 • lower hoist and vehicle in unloaded condition, tighten strut nut (b) to specified torque. Tightening torque strut nut (b): 50 n·m (5.0 kgf-m, 36.5 lb-ft) note don’t twist brake hose and wheel speed sensor harness when installing them. • tighten wheel nut to specified torque....

  • Page 392

    2b-7 front suspension: reassembly for assembly, reverse disassembly procedure, noting the following instructions. 1) compress coil spring with special tool (a) until total length becomes about 280 mm (11.0 in.) as shown. Length “a”: 280 mm (11.0 in.) 2) install compressed coil spring to strut, and p...

  • Page 393

    Front suspension: 2b-8 if conditions of struts are in doubt, compare them with known-good vehicle or strut. • inspect bearing for wear, abnormal noise or gripping. If defective, replace. • inspect coil spring seat for cracks or deformation. If defective, replace. • inspect bump stopper for deteriora...

  • Page 394

    2b-9 front suspension: 4) remove caliper carrier bolts and then caliper (1) with carrier. Note hang removed caliper with a wire hook or the like (3) so as to prevent brake hose (4) from bending, twisting or tension. Do not depress brake pedal during caliper removal. Don’t operate brake pedal with ca...

  • Page 395

    Front suspension: 2b-10 13) remove circlip from knuckle. 14) using hydraulic press (1) and special tool, remove wheel bearing. Special tool (a): 09913–75510 (b): 09943–37910 15) remove wheel bearing outside inner race (1). Special tool (a): 09913–65810 (b): 09913–85230 16) remove hub bolts (1) with ...

  • Page 396

    2b-11 front suspension: 3) insert new hub bolt (1) in hub hole. Rotate hub bolt slowly to assure that serrations are aligned with those made by original bolt. 4) drive in dust cover so that dimensions “a” and “b” become equal as shown in figure. Caution ! When drive in dust cover, be careful not to ...

  • Page 397

    Front suspension: 2b-12 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 398

    2b-13 front suspension: front wheel hub, disc, bolt and bearing check s6rw0c2206008 • 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 399

    Front suspension: 2b-14 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 400

    2b-15 front suspension: 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 401

    Front suspension: 2b-16 front suspension frame, stabilizer bar and/or bushing components s6rw0c2206014 1 2 3 4 5 6 7 8 8 (c) (a) 6 (b) (b) (c) (c) i6rw0c220001-01 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 402

    2b-17 front suspension: front suspension frame, stabilizer bar and/or bushing removal and installation (2wd model) s6rw0c2206015 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 ...

  • Page 403

    Front suspension: 2b-18 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 404

    2b-19 front suspension: 6) tighten front suspension frame bolts to specified torque. Tightening torque front suspension frame mounting bolt: 150 n·m (15.0 kgf-m, 108.5 lb-ft) 7) remove mission jack from front suspension frame. 8) install engine rear mounting and tighten mounting member bolts referri...

  • Page 405

    Front suspension: 2b-20 front suspension frame check s6rw0c2206017 inspect for cracks, deformation or damage. If defective, replace. Front stabilizer bar, bushing and/or joint check s6rw0c2206018 stabilizer bar inspect for damage or deformation. If defective, replace. Stabilizer bushing inspect for ...

  • Page 406

    2b-21 front suspension: specifications tightening torque specifications s6rw0c2207001 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 407

    Front suspension: 2b-22 special tools and equipment recommended service material s6rw0c2208001 special tool s6rw0c2208002 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 408: Rear Suspension

    2c-1 rear suspension: suspension rear suspension repair instructions rear suspension components s6rw0c2306001 i6rw0c230004-01 f: forward 7. Vehicle body 16. Brake dust cover [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, 53.0 lb...

  • Page 409

    Rear suspension: 2c-2 rear shock absorber removal and installation s6rw0c2306002 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 410

    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 411

    Rear suspension: 2c-4 rear coil spring removal and installation s6rw0c2306005 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 412

    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 413

    Rear suspension: 2c-6 rear axle removal and installation s6rw0c2306008 caution ! Do not drop brake fluid onto painted surface. Painted surfaces will be damaged. Removal 1) hoist vehicle and remove rear wheels, exhaust center pipe and muffler. 2) dismount rear differential (4wd model) referring to “r...

  • Page 414

    2c-7 rear suspension: 6) remount rear differential (4wd model) referring to “rear differential dismounting and remounting in section 3b”. 7) install exhaust center pipe and muffler. 8) after installing removed parts, bleed air from brake system referring to “air bleeding of brake system in section 4...

  • Page 415

    Rear suspension: 2c-8 rear wheel hub assembly removal and installation s6rw0c2306013 removal 1) hoist vehicle and remove rear wheel. 2) remove rear drive shaft (4wd model) referring to “rear drive shaft assembly removal and installation in section 3a”. 3) remove rear brake caliper assembly and rear ...

  • Page 416

    2c-9 rear suspension: 3) connect wheel speed sensor (3) and tighten wheel speed sensor bolt (2wd model) to specified torque. Tightening torque wheel speed sensor bolt (b): 11 n·m (1.1 kgf-m, 8.0 lb-ft) 4) install rear brake disc and rear brake caliper assembly referring to “rear brake disc removal a...

  • Page 417: Wheels and Tires

    Wheels and tires: 2d-1 suspension wheels and tires general description tires description s6rw0c2401001 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 418

    2d-2 wheels and tires: 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 419

    Wheels and tires: 2d-3 irregular and/or premature wear description s6rw0c2401003 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 420

    2d-4 wheels and tires: equipment manufacture’s recommendations radial tire lead / pull description s6rw0c2401006 “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 421

    Wheels and tires: 2d-5 repair instructions wheel discs inspection s6rw0c2406006 inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Tires inspection s6rw0c2406007 1) check tires for uneven or excessive wear, or damage referring to “irregular ...

  • Page 422

    2d-6 wheels and tires: installation for installation, reverse removal procedure, noting the following. • wheel nuts must be tightened in sequence and to specified torque to avoid bending wheel or brake disc or drum as shown in the figure. Note before installing wheels, remove any build- up of corros...

  • Page 423: 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 424

    3-ii table of contents dtc u0100: lost communication with ecm ....3b-26 dtc u0121: lost communication with abs / esp ® control module.....................................3b-26 dtc u0155: lost communication with instrument panel cluster (ipc) control module ..............................................

  • Page 425: Precautions

    Precautions: 3-1 driveline / axle precautions precautions precautions on driveline / axle s6rw0c3000001 precaution for rear differential oil leakage refer to “precaution for rear differential oil leakage in section 3b”. Precautions in diagnosing trouble refer to “precautions in diagnosing trouble in...

  • Page 426: Drive Shaft / Axle

    3a-1 drive shaft / axle: front driveline / axle drive shaft / axle front general description front drive shaft construction s6rw0c3111001 a constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. A tripod type constant velocity joint is used on the ...

  • Page 427

    Drive shaft / axle: front 3a-2 diagnostic information and procedures front drive shaft symptom diagnosis s6rw0c3114001 repair instructions front drive shaft components s6rw0c3116001 front drive shaft assembly on-vehicle inspection s6rw0c3116002 • check boots for breakage or deterioration. • check wh...

  • Page 428

    3a-3 drive shaft / axle: front 3) drain transaxle oil and transfer oil (4wd model). 4) disconnect tie-rod end (1) from steering knuckle (2) using puller (3). 5) remove brake hose mounting bolt (1) and brake hose (2) from bracket and then detach wheel speed sensor harness (3) from strut bracket. 6) r...

  • Page 429

    Drive shaft / axle: front 3a-4 front drive shaft disassembly and reassembly s6rw0c3116004 disassembly 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,...

  • Page 430

    3a-5 drive shaft / axle: front reassembly 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 housing (2) are wa...

  • Page 431

    Drive shaft / axle: front 3a-6 8) install damper (1) to specified position on drive shaft, if equipped. Drive shaft damper installing position (right side) “a”: 359 mm (14.1 in.) (2wd model) “a”: 362 mm (14.3 in.) (4wd model) drive shaft damper installing position (left side) “a”: 252 mm (9.9 in.) (...

  • Page 432

    3a-7 drive shaft / axle: front 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 reassembly...

  • Page 433

    Drive shaft / axle: front 3a-8 • 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 figure. Special tool : 09925–15410 distance a/t model “a”: 0 – 1 mm (0 – 0.04 in.) “b”: 11 – 12 mm (0.43 – 0.47 in.) m...

  • Page 434

    3a-9 drive shaft / axle: front special tools and equipment recommended service material s6rw0c3118001 note required service material is also described in the following. “front drive shaft components” special tool s6rw0c3118002 material suzuki recommended product or specification note grease suzuki s...

  • Page 435: Rear

    Drive shaft / axle: rear 3a-10 rear general description rear drive shaft construction s6rw0c3121001 refer to “front drive shaft construction”. Repair instructions rear drive shaft components s6rw0c3126001 i5rw0a312001-01 1. Differential side joint (constant velocity doj) : apply dark gray grease inc...

  • Page 436

    3a-11 drive shaft / axle: rear rear drive shaft assembly removal and installation s6rw0c3126002 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 437

    Drive shaft / axle: rear 3a-12 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 438

    3a-13 drive shaft / axle: rear specifications tightening torque specifications s6rw0c3127001 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 439: Differential

    Differential: 3b-1 driveline / axle differential precautions precaution for rear differential oil leakage s6rw0c3200001 whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage. Precautions in diagnosing trouble s6rw0c3200002 • do not disconnect t...

  • Page 440

    3b-2 differential: general description rear differential description s6rw0c3201001 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 441

    Differential: 3b-3 4wd control system components s6rw0c3201003 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 442

    3b-4 differential: 4wd control system description s6rw0c3201004 4wd shift control the 4wd control module operates the coupling assembly according to the 2wd/4wd switch operation to obtain the selected position (2wd, 4wd-auto or 4wd-lock). Also, the 4wd control system has 4wd auto indicator and 4wd l...

  • Page 443

    Differential: 3b-5 4wd control system wiring circuit diagram s6rw0c3201006 terminal arrangement of 4wd control module s6rw0c3201007 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 444

    3b-6 differential: input / output signal table of 4wd control module s6rw0c3201008 4wd control module outputs the following signals to coupling assembly, indicators, according to the 2wd/4wd switch operation. On-board diagnostic system description s6rw0c3201009 for 4wd control system, 4wd control mo...

  • Page 445

    Differential: 3b-7 can communication system description s6rw0c3201010 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 446

    3b-8 differential: diagnostic information and procedures 4wd control system check s6rw0c3204001 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 447

    Differential: 3b-9 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 448

    3b-10 differential: step 5. Trouble symptom confirmation check trouble symptoms based on information obtained in “step 1. Customer complaint analysis: ” and “step 2. Dtc check, record and clearance: ”. Also, reconfirm dtc according to “dtc confirmation procedure” described in each dtc flow. Step 6 a...

  • Page 449

    Differential: 3b-11 dtc check s6rw0c3204005 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel. Special tool (a): suzuki scan tool 3) turn ignition switch to on position. 4) read dtc according to instructions...

  • Page 450

    3b-12 differential: dtc table s6rw0c3204007 note “o” in transfer position indicator column of the above table means indicator lights up when dtc is detected. Fail-safe table s6rw0c3204008 this function is provided by the safe mechanism that assures safe driveability even when the coupling assembly, ...

  • Page 451

    Differential: 3b-13 scan tool data s6rw0c3204009 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 452

    3b-14 differential: rear differential symptom diagnosis s6rw0c3204010 4wd control symptom diagnosis s6rw0c3204011 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 453

    Differential: 3b-15 4wd position indicator does not come on at ignition switch on but engine stops s6rw0c3204012 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 454

    3b-16 differential: 4wd position indicator remains on steady at ignition switch on s6rw0c3204013 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 455

    Differential: 3b-17 dtc c1240: 4wd control module power supply circuit malfunction s6rw0c3204014 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 456

    3b-18 differential: dtc c1243: internal circuit malfunction of 4wd control module s6rw0c3204015 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 457

    Differential: 3b-19 dtc confirmation procedure 1) clear dtc using scan tool. 2) turn ignition switch to on position for 10 seconds. 3) check dtc. 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 ...

  • Page 458

    3b-20 differential: dtc c1251: coupling air temperature sensor circuit short s6rw0c3204017 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 459

    Differential: 3b-21 dtc c1252: coupling assembly circuit open s6rw0c3204018 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 460

    3b-22 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 461

    Differential: 3b-23 dtc c1253: coupling assembly circuit short s6rw0c3204019 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 462

    3b-24 differential: dtc c1254: 2wd/4wd switch malfunction s6rw0c3204020 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 463

    Differential: 3b-25 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 464

    3b-26 differential: dtc u0073: control module communication bus off s6rw0c3204021 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0100: lost communication with ecm s6rw0c3204022 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0121: lost communication with abs / esp ® control mo...

  • Page 465

    Differential: 3b-27 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 466

    3b-28 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 467

    Differential: 3b-29 repair instructions rear differential oil level check s6rw0c3206001 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 468

    3b-30 differential: 2wd/4wd switch removal and installation s6rw0c3206003 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 s6rw0c3206004 check ...

  • Page 469

    Differential: 3b-31 coupling air temperature sensor inspection s6rw0c3206007 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 470

    3b-32 differential: rear differential mountings components s6rw0c3206009 1 8 10 10 3 2 4 5 4 6 (a) 11 (a) (b) 9 (b) 7 (b) 13 12 13 12 14 i7rw01320010-01 1. Rear differential 6. Front mounting to body bolt 11. Rear mounting bolt : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Front mounting arm 7. Front mountin...

  • Page 471

    Differential: 3b-33 front mounting arm and/or rear mounting bracket assembly removal and installation s6rw0c3206010 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 472

    3b-34 differential: rear differential components s6rw0c3206013 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 473

    Differential: 3b-35 rear differential disassembly and reassembly s6rw0c3206014 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 474

    3b-36 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 475

    Differential: 3b-37 13) remove rear bearing (2) from drive bevel pinion (1) by using bearing puller (3) and hydraulic press. 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 f...

  • Page 476

    3b-38 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 477

    Differential: 3b-39 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 478

    3b-40 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 479

    Differential: 3b-41 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 480

    3b-42 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 481

    Differential: 3b-43 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 482

    3b-44 differential: 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 483

    Differential: 3b-45 b) install snap ring using snap ring pliers. C) apply grease to oil seal lip, install oil seal (2) to coupling case (1) using special tool as shown in figure. Note install oil seal horizontally to surface of coupling case. “a”: grease 99000–25010 (suzuki super grease a) distance ...

  • Page 484

    3b-46 differential: 32) apply grease to oil seal lip, and then install oil seals (1) to rear differential (2) using special tool as shown in figure. Note install oil seal horizontally to surface of rear differential case. “a”: grease 99000–25010 (suzuki super grease a) distance between rear differen...

  • Page 485

    Differential: 3b-47 special tools and equipment recommended service material s6rw0c3208001 note required service material is also described in the following. “rear differential components” special tool s6rw0c3208002 material suzuki recommended product or specification note grease suzuki super grease...

  • Page 486

    3b-48 differential: 09922–76120 09922–76140 mounting dummy shaft bevel pinion shaft ) / ) ) / ) / ) 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...

  • Page 487

    Differential: 3b-49 09951–26020 suzuki scan tool bush remover & installer support — ) / ) this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loop back adapter, 7. Battery power cable, 8. Rs232 cable, 9. Rs232 adapter, 10. Rs23...

  • Page 488: Transfer

    3c-1 transfer: driveline / axle transfer general description transfer description s6rw0c3301001 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 489

    Transfer: 3c-2 repair instructions transfer oil level check s6rw0c3306001 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 490

    3c-3 transfer: transfer dismounting and remounting s6rw0c3306003 dismounting 1) disconnect negative (–) cable at battery. 2) drain transaxle oil and transfer oil. 3) remove drive shaft assembly referring to “front drive shaft assembly removal and installation in section 3a”. 4) remove exhaust no.1, ...

  • Page 491

    Transfer: 3c-4 remounting reverse dismounting procedure for remounting of transfer, noting the following points. • apply grease to left case (1) and new o-ring (2) as shown in figure. • use new o-ring. • apply grease to o-ring (2). “a”: grease 99000–25010 (suzuki super grease a) • tighten front susp...

  • Page 492

    3c-5 transfer: transfer assembly components s6rw0c3306004 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 19 (c) 1217g 29 1217g (b) 35 15 a 26 26 14 24 17 16 1217g (b) a i5rw0a330007-05 1. Transfer output flange nut : after tigh...

  • Page 493

    Transfer: 3c-6 transfer assembly disassembly and reassembly s6rw0c3306005 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 494

    3c-7 transfer: 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 495

    Transfer: 3c-8 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 496

    3c-9 transfer: reduction driven gear assembly disassembly and reassembly s6rw0c3306007 disassembly 1) remove left bearing (1) and bevel gear (2) using special tool, bearing puller (3) and hydraulic press (4). Special tool (a): 09925–98220 2) in order to remove right bearing (1) from reduction driven...

  • Page 497

    Transfer: 3c-10 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 s6rw0c3306008 disassembly 1) remove oil seals from right case (1) using sp...

  • Page 498

    3c-11 transfer: transfer output retainer assembly disassembly and reassembly s6rw0c3306009 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 499

    Transfer: 3c-12 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 500

    3c-13 transfer: d) measure height “b” in figure by using vernier caliper. Calculate “c” by using measured value. E) obtain adjusting shim thickness by the following equation. F) select a shim closest to the calculated value (necessary shim thickness) from among the available shims or combine shims t...

  • Page 501

    Transfer: 3c-14 4) install bevel pinion with new pinion shaft spacers (1) and new pump seal (2) to transfer output retainer (3). 5) drive in rear taper roller bearing by using special tool and tapping lightly with plastic hammer. Special tool (a): 09913–84510 6) apply grease to new oil seal lip. “a”...

  • Page 502

    3c-15 transfer: transfer assembly inspection s6rw0c3306010 • check each bearing for smooth rotation, wear or discoloration if found abnormal, replace. • check oil seal for leakage and its lip for excessive hardness if either is found, replace. • check transfer case for cracks. • check bevel pinion a...

  • Page 503

    Transfer: 3c-16 gear tooth contact table tooth contact pattern diagnosis and remedy normal high contact pinion is positioned too far from the center of drive bevel gear. • decrease thickness of bevel pinion shim and position pinion closer to gear center. • adjust drive bevel gear backlash to specifi...

  • Page 504

    3c-17 transfer: specifications tightening torque specifications s6rw0c3307001 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 505

    Transfer: 3c-18 special tools and equipment recommended service material s6rw0c3308001 note required service material is also described in the following. “transfer assembly components” special tool s6rw0c3308002 material suzuki recommended product or specification note grease suzuki super grease a p...

  • Page 506

    3c-19 transfer: 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 09925–98220 t...

  • Page 507: Propeller Shafts

    Propeller shafts: 3d-1 driveline / axle propeller shafts general description propeller shaft construction s6rw0c3401001 universal joints and ball joint require no maintenance. They are lubricated for life and can not be lubricated on the vehicle. If a universal joint becomes noisy or worn, it must b...

  • Page 508

    3d-2 propeller shafts: propeller shaft assembly removal and installation s6rw0c3406002 removal 1) hoist vehicle. 2) before removing propeller shaft assembly, give match marks (2) on joint flange and propeller shaft as shown. 3) separate propeller shaft assembly (1) from transfer output flange and re...

  • Page 509: 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 510

    4-ii table of contents parking brake lever and cable inspection and adjustment .................................................4d-1 parking brake cable removal and installation.........................................................4d-3 parking brake lever removal and installation ....4d-3 specifi...

  • Page 511: Precautions

    Precautions: 4-1 brakes precautions precautions precautions for brakes s6rw0c4000001 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 512

    4a-1 brake control system and diagnosis: brakes brake control system and diagnosis precautions precautions on brake s6rw0c4100001 air bag warning refer to “air bag warning in section 00”. Brakes diagnosis note refer to “brakes diagnosis note”. General description brakes construction s6rw0c4101001 wh...

  • Page 513

    Brake control system and diagnosis: 4a-2 brake pedal foot protection system construction (if equipped) s6rw0c4101004 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 514

    4a-3 brake control system and diagnosis: front brake hose / pipe construction s6rw0c4101002 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 515

    Brake control system and diagnosis: 4a-4 rear brake hose / pipe construction s6rw0c4101003 i6rw0c410003-01 1. To left rear brake hose 5. Left rear brake hose to left brake 2. To right rear brake hose 6. Right rear brake hose to right brake 3. Left rear brake hose : 16 n ⋅m (1.6 kgf-m, 12.0 lb-ft) 4....

  • Page 516

    4a-5 brake control system and diagnosis: diagnostic information and procedures brakes diagnosis note s6rw0c4104001 road testing brakes brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road test brakes by making brake applications with both light and he...

  • Page 517

    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 518

    4a-7 brake control system and diagnosis: repair instructions brake pedal components s6rw0c4106018 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 519

    Brake control system and diagnosis: 4a-8 brake fluid level inspection s6rw0c4106004 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 520

    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 521

    Brake control system and diagnosis: 4a-10 installation reverse brake flexible hose removal procedure, noting the following. • make sure that steering wheel is in straight-forward position and flexible hose has not twist or kink. • install clamps and tighten nuts referring to “front brake hose / pipe...

  • Page 522

    4a-11 brake control system and diagnosis: master cylinder and brake booster components s6rw0c4106010 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 523

    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 524

    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 525

    Brake control system and diagnosis: 4a-14 booster operation inspection s6rw0c4106014 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 526

    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 s6rw0c4106015 removal 1) remove master cylinder assembly from booster referring to “master c...

  • Page 527

    Brake control system and diagnosis: 4a-16 booster push clevis rod adjustment s6rw0c4106017 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 528: Front Brakes

    4b-1 front brakes: brakes front brakes repair instructions front disc brake components s6rw0c4206001 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 529

    Front brakes: 4b-2 front disc brake pad on-vehicle inspection s6rw0c4206002 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 530

    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 531

    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 532

    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 533

    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 534

    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 535

    Front brakes: 4b-8 specifications tightening torque specifications s6rw0c4207001 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 536: Rear Brakes

    4c-1 rear brakes: brakes rear brakes repair instructions rear disc brake components s6rw0c4306001 (d) (c) (a) (a) (a) 16 17 14 13 2 1 15 2 19 12 11 7 7 3 7 4 20 20 5 10 9 8 (b) 18 6 24 23 22 21 i7rw01432001-02 1. Caliper 11. Brake caliper carrier 21. Shaft cover : apply rubber grease. 2. Caliper pin...

  • Page 537

    Rear brakes: 4c-2 rear disc brake pad removal and installation s6rw0c4306002 note when replacing brake pad, replace it on the right and left. Removal 1) hoist vehicle and remove wheel. 2) release parking brake lever. 3) remove caliper pin bolts (1). 4) remove caliper (2) from caliper carrier. Note h...

  • Page 538

    4c-3 rear brakes: 8) install rear wheel referring to “wheel (with tire) removal and installation in section 2d”. 9) after completion of installation, check for brake effectiveness. Rear disc brake caliper removal and installation s6rw0c4306003 caution ! Do not allow brake fluid to get on painted sur...

  • Page 539

    Rear brakes: 4c-4 2) install new slide pin boots (1) to brake caliper carrier. 3) apply rubber grease to slide pins, then install slide pin (2) to front side and slide pin (3) to rear side of brake caliper carrier. Note be sure not to install wrongly because the shape of slide pins are different as ...

  • Page 540

    4c-5 rear brakes: 10) after reassembling brake lines, bleed air from them referring to “air bleeding of brake system in section 4a”. 11) check to make sure that system is free from fluid leakage. 12) start engine and then depress brake pedal with about 300 n (30 kg, 66 lbs) load 3 times or more so a...

  • Page 541

    Rear brakes: 4c-6 assembly 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 caliper to brake caliper carrier, install slide pins with grease applied into carrier hole and che...

  • Page 542

    4c-7 rear brakes: rear disc brake caliper inspection s6rw0c4306006 pin boot and cylinder boot check boots (1) for breakage, crack and damage. If defective, replace. Disc brake piston check all around piston for rust, corrosion and any other damage. If it is found faulty, replace. Caliper push in adj...

  • Page 543

    Rear brakes: 4c-8 installation install in reverse order of removal nothing the following. • tighten caliper carrier bolts to specified torque. Tightening torque caliper carrier bolt (a): 60 n·m (6.0 kgf-m, 43.5 lb- ft) • install rear wheel referring to “wheel (with tire) removal and installation in ...

  • Page 544

    4c-9 rear brakes: special tools and equipment recommended service material s6rw0c4308001 note required service material is also described in the following. “rear disc brake components” special tool s6rw0c4308002 material suzuki recommended product or specification note thread lock cement thread lock...

  • Page 545: Parking Brake

    Parking brake: 4d-1 brakes parking brake general description parking brake cable construction s6rw0c4401001 repair instructions parking brake lever and cable inspection and adjustment s6rw0c4406001 inspection • inspect brake cable for damage and smooth movement. Replace cable if it is in deteriorate...

  • Page 546

    4d-2 parking brake: • check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking brake lever. • 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 sh...

  • Page 547

    Parking brake: 4d-3 parking brake cable removal and installation s6rw0c4406002 removal note when it is necessary to remove both right and left parking brake cables, repeat below steps 2) and 6) on right and left wheels. 1) hoist vehicle. 2) remove wheel. 3) disconnect parking brake cable from equali...

  • Page 548

    4d-4 parking brake: specifications tightening torque specifications s6rw0c4407001 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 549: Abs

    Abs: 4e-1 brakes abs precautions precautions in diagnosing troubles s6rw0c4500001 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 550

    4e-2 abs: general description abs description s6rw0c4501001 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 551

    Abs: 4e-3 abs hydraulic unit / control module assembly description s6rw0c4501002 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 552

    4e-4 abs: schematic and routing diagram abs schematic s6rw0c4502001 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 553

    Abs: 4e-5 abs wiring circuit diagram s6rw0c4502002 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 554

    4e-6 abs: 5. Combination meter 17. Data link connector (dlc) 29. Pump motor driver (transistor) 6. Abs warning light 18. To bcm, 4wd control module, p/s control module, hvac control module (auto a/c model) and sdm 30. Pump motor 7. Ebd warning light (brake warning light) 19. Ecm 31. Solenoid valve p...

  • Page 555

    Abs: 4e-7 component location abs components location s6rw0c4503001 diagnostic information and procedures abs check s6rw0c4504001 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 556

    4e-8 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 557

    Abs: 4e-9 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 brak...

  • Page 558

    4e-10 abs: dtc check s6rw0c4504004 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 559

    Abs: 4e-11 scan tool data s6rw0c4504007 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 560

    4e-12 abs: abs warning light does not come on at ignition switch on s6rw0c4504008 wiring diagram 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 ...

  • Page 561

    Abs: 4e-13 troubleshooting abs warning light comes on steady s6rw0c4504009 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”. ...

  • Page 562

    4e-14 abs: ebd warning light (brake warning light) comes on steady s6rw0c4504010 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 563

    Abs: 4e-15 serial data link circuit check s6rw0c4504011 wiring diagram 4 dtc check of bcm 1) connect scan tool to data link connector with ignition switch turned off. 2) turn ignition switch to on position and check dtc of bcm. Is there dtc u0073? Go to “dtc u0073 (no. 0073): control module communic...

  • Page 564

    4e-16 abs: trouble shooting 2. Main fuse box 8. Light driver module 14. To bcm, 4wd control module, p/s control module, hvac control module (auto a/c model) and sdm 3. Ignition switch 9. Can driver step action yes no 1 scan tool communication check can scan tool communicate with bcm? Go to step 2. G...

  • Page 565

    Abs: 4e-17 dtc c1013: control module mismatch s6rw0c4504012 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 566

    4e-18 abs: dtc c1015: g sensor circuit (4wd model) s6rw0c4504013 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 567

    Abs: 4e-19 dtc 1016: brake light switch s6rw0c4504014 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 568

    4e-20 abs: dtc c1021 / c1022 / c1025 / c1026 / c1031 / c1032 / c1035 / c1036: wheel speed sensor circuit / sensor or encoder s6rw0c4504015 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 569

    Abs: 4e-21 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 570

    4e-22 abs: dtc c1033: wheel speed sensor deviation s6rw0c4504016 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 571

    Abs: 4e-23 dtc c1041 / c1042 / c1045 / c1046 / c1051 / c1052 / c1055 / c1056: inlet / outlet solenoid s6rw0c4504017 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 572

    4e-24 abs: dtc c1057: power supply voltage too high / too low s6rw0c4504018 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 573

    Abs: 4e-25 dtc c1061: pump motor circuit s6rw0c4504019 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 574

    4e-26 abs: dtc c1063: solenoid valve power supply driver circuit s6rw0c4504020 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 575

    Abs: 4e-27 dtc c1071: control module internal defect s6rw0c4504021 dtc detecting condition and trouble area dtc troubleshooting abs hydraulic unit / control module assembly power and ground circuit check s6rw0c4504022 wiring diagram circuit description when the ignition switch is turned on, power su...

  • Page 576

    4e-28 abs: troubleshooting repair instructions abs hydraulic unit operation check s6rw0c4506001 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 577

    Abs: 4e-29 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 578

    4e-30 abs: abs hydraulic unit / control module assembly on-vehicle inspection s6rw0c4506003 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 579

    Abs: 4e-31 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 580

    4e-32 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 581

    Abs: 4e-33 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 582

    4e-34 abs: front wheel speed sensor encoder on-vehicle inspection s6rw0c4506010 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 583

    Abs: 4e-35 g sensor removal and installation (4wd model) s6rw0c4506014 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 584

    4e-36 abs: specifications tightening torque specifications s6rw0c4507001 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 585: 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 586

    5-ii table of contents dtc p0602 / p1702: control module programming error / internal control module check sum error ............................................5a-55 dtc p1723: range select switch malfunction ..5a-56 dtc p2763: torque converter clutch pressure control solenoid control circuit high....

  • Page 587

    Table of contents 5-iii specifications...................................................5a-142 tightening torque specifications.................... 5a-142 special tools and equipment .........................5a-143 recommended service material..................... 5a-143 special tool .................

  • Page 588: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions on transmission / transaxle s6rw0c5000001 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 589

    Automatic transmission/transaxle: 5a-1 transmission / transaxle automatic transmission/transaxle precautions precautions in diagnosing trouble s6rw0c5100001 • don’t disconnect couplers from tcm, battery cable from battery, tcm ground wire harness from engine or main fuse before checking the diagnosi...

  • Page 590

    5a-2 automatic transmission/transaxle: part inspection and correction table general description a/t description s6rw0c5101001 this automatic transaxle is a full automatic type with 4-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled...

  • Page 591

    Automatic transmission/transaxle: 5a-3 2wd i4rh01510001-01 1. Torque converter clutch (tcc) 7. 1st / reverse brake 13. Countershaft 19. Torque converter 2. One-way no. 1 clutch 8. Rear planetary gear 14. One-way no. 3 clutch 20. Oil pump 3. 2nd coast brake 9. Forward clutch 15. U/d clutch 21. Drive ...

  • Page 592

    5a-4 automatic transmission/transaxle: 4wd i7rw01510061-01 1. Torque converter clutch (tcc) 7. 1st / reverse brake 13. Countershaft 19. Torque converter 2. One-way no. 1 clutch 8. Rear planetary gear 14. One-way no. 3 clutch 20. Oil pump 3. 2nd coast brake 9. Forward clutch 15. U/d clutch 21. Drive ...

  • Page 593

    Automatic transmission/transaxle: 5a-5 specifications item specifications torque converter type 3-element, 1-step, 2-phase type (with tcc (lock-up) mechanism) oil pump type drive system internal gear type oil pump engine driven gear change device type forward 4-step, reverse 1-step planetary gear ty...

  • Page 594

    5a-6 automatic transmission/transaxle: clutch / brake / planetary gear function of automatic transaxle s6rw0c5101002 functions 17 16 11 12 14 13 10 9 8 7 6 5 4 2 3 1 15 i4rh01510003-01 1. 2nd coast brake 6. One-way no. 2 clutch 11. U/d planetary gear 16. Countershaft 2. 2nd brake 7. Front planetary ...

  • Page 595

    Automatic transmission/transaxle: 5a-7 table of component operation s6rw0c5101003 { : on ×: off brake interlock system construction s6rw0c5101004 shift lock solenoid control this system consists of shift lock solenoid control system and interlock cable control system. The shift lock solenoid control...

  • Page 596

    5a-8 automatic transmission/transaxle: a/t diagnosis general description s6rw0c5101005 this vehicle is equipped with an electronic transaxle control system, which controls the automatic shift up and shift down timing, tcc operation, etc. Suitably to vehicle driving conditions. Tcm has an on-board di...

  • Page 597

    Automatic transmission/transaxle: 5a-9 can communication system description s6rw0c5101007 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 598

    5a-10 automatic transmission/transaxle: electronic shift control input / output table s6rw0c5101008 input output tcm ecm gear shift control 4th gear inhibit control slope shift control cruise shift control lock up control torque control line pressure control overrun control reverse control squat con...

  • Page 599

    Automatic transmission/transaxle: 5a-11 schematic and routing diagram transmission control module (tcm) wiring diagram s6rw0c5102001 p r n d 2 l 2.5v 5v 5v 12v ig11 red/blk +bb 6 5 16 15 14 13 12 11 4 3 24 23 21 22 10 9 8 7 2 1 19 20 18 17 c06 17 16 26 25 15 14 6 5 3 4 2 13 12 23 22 24 11 10 9 21 20...

  • Page 600

    5a-12 automatic transmission/transaxle: operation of shift solenoid valves and tcc solenoid valve { : on (turn power on) ×: off (turn power off) ({): on only when lock-up function operates automatic gear shift table s6rw0c5102002 automatic gear shift schedule is shown in the following table. Test-dr...

  • Page 601

    Automatic transmission/transaxle: 5a-13 non-euro-obd model 1. Shift point in “d”, “3” and/or “2” range 2. Lock-up point in “d” and/or “3” range note the gear change is done at the shift point different from the above while any of the following control functions is working. Bear this in mind when per...

  • Page 602

    5a-14 automatic transmission/transaxle: bearing and race installation diagram s6rw0c5102003 bearing and race dimensions i4rh01510243-01 diameter a mm (in.) b mm (in.) c mm (in.) d mm (in.) e mm (in.) f mm (in.) g mm (in.) h mm (in.) i mm (in.) front race outer 58 (2.3) — 54 (2.1) 74 (2.9) — 41 (1.6)...

  • Page 603

    Automatic transmission/transaxle: 5a-15 component location electronic shift control system components location s6rw0c5103001 note below figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 6 7 1 10* 8 15 16 17 14 18 13 2 9* 12 1...

  • Page 604

    5a-16 automatic transmission/transaxle: diagnostic information and procedures a/t system check s6rw0c5104001 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 605

    Automatic transmission/transaxle: 5a-17 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 as shown in the following page as an example will facilitate collecting in...

  • Page 606

    5a-18 automatic transmission/transaxle: step 2. Dtc / freeze frame data check, record and clearance first, referring to “dtc check”, check dtc (including 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”. Malf...

  • Page 607

    Automatic transmission/transaxle: 5a-19 visual inspection s6rw0c5104002 visually check the following parts and systems. Malfunction indicator lamp (mil) check s6rw0c5104003 refer to the same item in “malfunction indicator lamp (mil) check in section 1a” for checking procedure. Transmission warning l...

  • Page 608

    5a-20 automatic transmission/transaxle: dtc table s6rw0c5104004 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”. • with the can communication obd generic scan tool, dtc no. Wi...

  • Page 609

    Automatic transmission/transaxle: 5a-21 ) p0756 shift solenoid “b” performance or stuck off actual gear position is different from commanded gear position of tcm (shift solenoid valve – b does not turn on). 2 driving cycles 2 driving cycles* ) p0757 shift solenoid “b” stuck on actual gear position i...

  • Page 610

    5a-22 automatic transmission/transaxle: dtc check s6rw0c5104005 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 611

    Automatic transmission/transaxle: 5a-23 ) p0712 transmission fluid temperature sensor “a” circuit low tcm assumes transmission fluid temperature to be 200 °c (392 °f) and controls transaxle. ) p0713 transmission fluid temperature sensor “a” circuit high ) p0717 input speed sensor “a” circuit no sign...

  • Page 612

    5a-24 automatic transmission/transaxle: scan tool data s6rw0c5104008 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 613

    Automatic transmission/transaxle: 5a-25 scan tool data definitions: input shaft revolution (rpm) it indicates input shaft revolution computed by reference pulses coming from input shaft speed sensor on transmission case. Output shaft revolution (rpm) it indicates output shaft revolution computed by ...

  • Page 614

    5a-26 automatic transmission/transaxle: shift solenoid b (com) (command signal of shift solenoid valve - b) (on, off) on: on command being outputted to shift solenoid valve-b. Off: on command not being outputted to shift solenoid valve-b. Tcc solenoid (com) (command signal of torque converter clutch...

  • Page 615

    Automatic transmission/transaxle: 5a-27 road test s6rw0c5104010 this test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a level road. Warning ! • carry out test in very little traffic area to prevent an accident. • test requires 2 pers...

  • Page 616

    5a-28 automatic transmission/transaxle: manual road test s6rw0c5104011 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 tr...

  • Page 617

    Automatic transmission/transaxle: 5a-29 stall test s6rw0c5104012 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 618

    5a-30 automatic transmission/transaxle: time lag test s6rw0c5104013 this test is to check conditions of clutch, reverse brake and fluid pressure. “time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) with chocks placed before and behind front and rear ...

  • Page 619

    Automatic transmission/transaxle: 5a-31 1) apply parking brake securely and place chocks against wheels. 2) remove fluid pressure check hole plug bolt. 3) attach oil pressure gauge to fluid pressure check hole in transaxle case. Special tool (a): 09925–37811–001 caution ! After attaching oil pressur...

  • Page 620

    5a-32 automatic transmission/transaxle: engine brake test s6rw0c5104015 warning ! Before test, make sure that there is no vehicle behind so as to prevent rear-end collision. 1) while driving vehicle in 3rd gear of “d” range, shift select lever down to “2” range and check if engine brake operates. 2)...

  • Page 621

    Automatic transmission/transaxle: 5a-33 a/t symptom diagnosis s6rw0c5104017 trouble diagnosis 1 electrical repair condition possible cause correction / reference item no up-shift (fixed gear position) battery voltage abnormality inspect charging system referring to “generator test (undercharged batt...

  • Page 622

    5a-34 automatic transmission/transaxle: non operate tcc (lock- up) system tcc solenoid valve circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Transmission range sensor circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Transmission fluid te...

  • Page 623

    Automatic transmission/transaxle: 5a-35 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. Poor 1 → 2 shift, excessive shock or slippage engine abnormal condition inspect and r...

  • Page 624

    5a-36 automatic transmission/transaxle: trouble diagnosis 3 off-vehicle repair transmission warning light circuit check – light does not come “on” at ignition switch on (non- euro-obd model) s6rw0c5104043 troubleshooting condition possible cause correction / reference item unable to run in any forwa...

  • Page 625

    Automatic transmission/transaxle: 5a-37 transmission warning light circuit check – light remains “on” at ignition switch on (non-euro- obd model) s6rw0c5104044 troubleshooting dtc p0705: transmission range sensor circuit malfunction (p r n d l input) s6rw0c5104018 wiring diagram dtc detecting condit...

  • Page 626

    5a-38 automatic transmission/transaxle: dtc troubleshooting table for step 4 dtc p0707: transmission range sensor circuit low s6rw0c5104019 wiring diagram refer to “dtc p0705: transmission range sensor circuit malfunction (p r n d l input)”. Dtc detecting condition and trouble area step action yes n...

  • Page 627

    Automatic transmission/transaxle: 5a-39 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 628

    5a-40 automatic transmission/transaxle: table for step 4 dtc p0711: transmission fluid temperature sensor “a” circuit range / performance s6rw0c5104020 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where the...

  • Page 629

    Automatic transmission/transaxle: 5a-41 dtc troubleshooting dtc p0712: transmission fluid temperature sensor “a” circuit low s6rw0c5104021 wiring diagram refer to “dtc p0711: transmission fluid temperature sensor “a” circuit range / performance”. Dtc detecting condition and trouble area dtc confirma...

  • Page 630

    5a-42 automatic transmission/transaxle: dtc p0713: transmission fluid temperature sensor “a” circuit high s6rw0c5104022 wiring diagram refer to “dtc p0711: transmission fluid temperature sensor “a” circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure warn...

  • Page 631

    Automatic transmission/transaxle: 5a-43 dtc p0717: input speed sensor “a” circuit no signal s6rw0c5104023 wiring diagram dtc detecting condition and trouble area 3 check transmission fluid temperature sensor circuit for ig short 1) cool down a/t fluid temperature under ambient temperature. 2) connec...

  • Page 632

    5a-44 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 633

    Automatic transmission/transaxle: 5a-45 dtc p0722: output speed sensor circuit no signal s6rw0c5104024 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 traffic acci...

  • Page 634

    5a-46 automatic transmission/transaxle: dtc troubleshooting dtc p0741 / p0742: torque converter clutch circuit performance or stuck off / stuck on s6rw0c5104025 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 c...

  • Page 635

    Automatic transmission/transaxle: 5a-47 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 636

    5a-48 automatic transmission/transaxle: dtc troubleshooting dtc p0756 / p0757: shift solenoid “b” performance or stuck off / shift solenoid “b” stuck on s6rw0c5104027 dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where the...

  • Page 637

    Automatic transmission/transaxle: 5a-49 dtc p0961: pressure control solenoid “a” control circuit range / performance s6rw0c5104028 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc. 2) start engine at idle speed for 15 seconds or more. 3) check dtc. Dtc ...

  • Page 638

    5a-50 automatic transmission/transaxle: dtc p0962: pressure control solenoid “a” control circuit low s6rw0c5104029 wiring diagram refer to “dtc p0961: pressure control solenoid “a” control circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc....

  • Page 639

    Automatic transmission/transaxle: 5a-51 dtc p0963: pressure control solenoid “a” control circuit high s6rw0c5104030 wiring diagram refer to “dtc p0961: pressure control solenoid “a” control circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc...

  • Page 640

    5a-52 automatic transmission/transaxle: dtc p0973 / p0976: shift solenoid “a” control circuit low / shift solenoid “b” control circuit low s6rw0c5104031 wiring diagram 3 check pressure control solenoid valve resistance 1) turn ignition switch to off position. 2) disconnect valve body harness connect...

  • Page 641

    Automatic transmission/transaxle: 5a-53 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc. 2) start engine and run it for 30 seconds. 3) check dtc. Dtc troubleshooting dtc detecting condition trouble area dtc p0973: difference between command signal and monitor signal ...

  • Page 642

    5a-54 automatic transmission/transaxle: dtc p0974 / p0977: shift solenoid “a” control circuit high / shift solenoid “b” control circuit high s6rw0c5104032 wiring diagram refer to “dtc p0973 / p0976: shift solenoid “a” control circuit low / shift solenoid “b” control circuit low”. Dtc detecting condi...

  • Page 643

    Automatic transmission/transaxle: 5a-55 dtc p0602 / p1702: control module programming error / internal control module check sum error s6rw0c5104033 system description internal control module is installed in ecm. Dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc. 2) sta...

  • Page 644

    5a-56 automatic transmission/transaxle: dtc troubleshooting dtc p1723: range select switch malfunction s6rw0c5104034 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc. 2) start engine and then shift select lever to each of “p”, “r”, “n” or “l” ranges for...

  • Page 645

    Automatic transmission/transaxle: 5a-57 dtc p2763: torque converter clutch pressure control solenoid control circuit high s6rw0c5104035 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc. 2) start engine and run it for 30 seconds. 3) check dtc. Dtc troubl...

  • Page 646

    5a-58 automatic transmission/transaxle: dtc p2764: torque converter clutch pressure control solenoid control circuit low s6rw0c5104036 wiring diagram refer to “dtc p2763: torque converter clutch pressure control solenoid control circuit high”. Dtc detecting condition and trouble area dtc confirmatio...

  • Page 647

    Automatic transmission/transaxle: 5a-59 dtc troubleshooting dtc u0073: control module communication bus off s6rw0c5104037 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0100: lost communication with ecm s6rw0c5104038 refer to “troubleshooting for can-dtc in section 1a”. Step action yes n...

  • Page 648

    5a-60 automatic transmission/transaxle: inspection of tcm and its circuits s6rw0c5104039 tcm and its circuits can be checked at tcm wiring connectors by measuring voltage and resistance. Caution ! Tcm cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to tcm with...

  • Page 649

    Automatic transmission/transaxle: 5a-61 connector “c06” terminal wire color circuit standard voltage condition c06-1 blk ground for tcm 0 – 1 v ignition switch is at on position. C06-2 lt grn/ blk ground for pressure control solenoid valve 0.6 – 1.0 v ignition switch is at on position. C06-3 — — — —...

  • Page 650

    5a-62 automatic transmission/transaxle: connector “c07” terminal wire color circuit standard voltage condition c07-1 red “r” range signal for transmission range sensor 10 – 14 v ignition switch is at on position and select lever is at “r” range. 0 – 1 v ignition switch is at on position and select l...

  • Page 651

    Automatic transmission/transaxle: 5a-63 reference waveform no. 1 signal of pressure control solenoid valve. Reference waveform no. 2 signal of tcc pressure control solenoid valve. Reference waveform no. 3 high and low of can communication signals. Reference waveform no. 4 signal of output shaft spee...

  • Page 652

    5a-64 automatic transmission/transaxle: reference waveform no. 5 signal of input shaft speed sensor. Tcm power and ground circuit check s6rw0c5104040 wiring diagram measurement terminal ch1: “c07-6” to “c06-1” oscilloscope setting ch1: 1 v/div time: 4 ms/div measurement condition engine running at s...

  • Page 653

    Automatic transmission/transaxle: 5a-65 troubleshooting step action yes no 1 check tcm back-up power supply circuit 1) disconnect connectors from tcm with ignition switch turned off. 2) check for proper connection to “c06-6” and “c06-24” terminals of tcm connector. 3) if ok, measure voltage between ...

  • Page 654

    5a-66 automatic transmission/transaxle: brake interlock system inspection s6rw0c5104041 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, or brake pedal...

  • Page 655

    Automatic transmission/transaxle: 5a-67 repair instructions a/t fluid level check s6rw0c5106001 level check at normal operation temperature 1) stop vehicle and place it level. 2) apply parking brake and place chocks against wheels. 3) with select lever at “p” position, start engine. 4) warm up engin...

  • Page 656

    5a-68 automatic transmission/transaxle: 5) lower vehicle and fill proper amount of an equivalent of dexron ® -iii 6) check fluid level referring to “a/t fluid level check”. Automatic transaxle fluid : an equivalent of dexron ® -iii automatic transaxle fluid capacity when draining from drain plug hol...

  • Page 657

    Automatic transmission/transaxle: 5a-69 “3” position switch inspection s6rw0c5106007 1) remove console box referring to “console box components in section 9h”. 2) disconnect “3” position switch connector (1). 3) check continuity between “3” position switch terminals. If check result is not as satisf...

  • Page 658

    5a-70 automatic transmission/transaxle: select cable components s6rw0c5106010 select cable removal and installation s6rw0c5106011 removal 1) remove parking brake lever cover. 2) remove console box. 3) disconnect select cable from select lever and then detach from bracket. 4) remove clip and disconne...

  • Page 659

    Automatic transmission/transaxle: 5a-71 3) release lock plate (1) which restricts moving of cable end holder (2). 4) push cable end holder (1) out from eye-end (2) using an appropriate tool (3) to disengage cable. 5) shift select lever to “n” position. 6) apply grease to select lever pin and install...

  • Page 660

    5a-72 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 661

    Automatic transmission/transaxle: 5a-73 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 662

    5a-74 automatic transmission/transaxle: adjustment 1) shift manual shift lever (1) to “n” range. 2) connect ohmmeter between 6 and 10 terminals of disconnected transmission range sensor connector (3). 3) turn transmission range sensor (2) gradually to find position where ohmmeter reading indicates c...

  • Page 663

    Automatic transmission/transaxle: 5a-75 output shaft speed sensor inspection s6rw0c5106016 1) disconnect negative cable at battery. 2) disconnect output shaft speed sensor connector (2). 3) check resistance between output shaft speed sensor (1) terminals. If check result is not as specified, replace...

  • Page 664

    5a-76 automatic transmission/transaxle: 3) lift up vehicle. 4) with engine is cool, drain a/t fluid referring to “a/t fluid change”. 5) remove transmission fluid temperature sensor (1) with o-ring. Installation 1) apply a/t fluid to new o-ring. 2) install new o-ring to transmission fluid temperature...

  • Page 665

    Automatic transmission/transaxle: 5a-77 4) remove solenoid harness from clamp. 5) disconnect solenoid connectors (1). 6) remove pressure control solenoid valve (2) after removing bolt (1). 7) remove tcc solenoid valve (1), shift solenoid valve–b (no. 2) (2) and shift solenoid valve–a (no. 1) (3) by ...

  • Page 666

    5a-78 automatic transmission/transaxle: 6) clean mating surface transaxle case. 7) apply sealant to mating surface of transaxle side cover and transaxle case by using a nozzle (1) as shown in figure by such amount that its section is 1.5 mm (0.059 in) in diameter. “a”: sealant 99000–31230 (suzuki bo...

  • Page 667

    Automatic transmission/transaxle: 5a-79 operation check shift solenoid valve-a (no. 1) and -b (no. 2) • check that solenoid valve (1) actuate with click sound when battery voltage is conducted. • apply oiler (2) to solenoid valve (1) and give compression by hands and then check to be sure that trans...

  • Page 668

    5a-80 automatic transmission/transaxle: pressure control solenoid valve inspection s6rw0c5106023 resistance check check resistance between pressure control solenoid valve (1) terminals. If check result is not as specified, replace solenoid valve. Pressure control solenoid valve resistance standard: ...

  • Page 669

    Automatic transmission/transaxle: 5a-81 transmission control module (tcm) removal and installation s6rw0c5106024 caution ! Tcm consists of highly precise parts, therefore when handling it, be careful not to expose to excessive shock. Removal 1) disconnect negative cable at battery. 2) if the vehicle...

  • Page 670

    5a-82 automatic transmission/transaxle: a/t fluid cooler hoses inspection s6rw0c5106072 check automatic transaxle fluid cooler hoses (1) for fluid leakage, cracks, damage and deterioration. Replace hose and/or clamp if any faulty condition is found. A/t fluid cooler hoses replacement s6rw0c5106026 t...

  • Page 671

    Automatic transmission/transaxle: 5a-83 automatic transaxle unit components s6rw0c5106028 automatic transaxle unit dismounting and remounting s6rw0c5106029 dismounting 1) take down transaxle with engine. For its procedure, refer to “engine assembly removal and installation in section 1d”. 2) remove ...

  • Page 672

    5a-84 automatic transmission/transaxle: 7) remove starting motor. 8) remove bolts and nut fastening engine and transaxle, then detach transaxle from engine. Note when detaching transaxle from engine, move it in parallel with crankshaft and use care so as not to apply excessive force to drive plate a...

  • Page 673

    Automatic transmission/transaxle: 5a-85 automatic transaxle assembly components s6rw0c5106030 2 1 25 n·m(2.5 kg-m) 7.0 n·m(0.7 kg-m) 10 n·m(1.0 kg-m) 5.5 n·m(0.55 kg-m) 10 n·m(1.0 kg-m) 10 n·m(1.0 kg-m) 3 4 5 13 14 15 10 9 12 11 8 7 5.5 n·m(0.55 kg-m) 6 i7rw01510050-02 1. Torque converter 6. Input s...

  • Page 674

    5a-86 automatic transmission/transaxle: 5. Transmission fluid temperature sensor 10. Underdrive brake accumulator piston 15. Manual detent spring 24 n·m(2.4 kg-m) 10 n·m(1.0 kg-m) 10 n·m(1.0 kg-m) 1 3 2 5 15 17 27 18 21 22 6 8 10 12 13 4 7 9 11 14 16 19 20 23 24 25 25 n·m(2.5 kg-m) 26 28 30 29 40 37...

  • Page 675

    Automatic transmission/transaxle: 5a-87 6. Bearing race 19. Snap ring 32. Bearing race 45. Differential side right bearing race 7. Input shaft 20. Retaining plate 33. Underdrive gear assembly 46. Differential gear 8. Thrust bearing 21. Friction plate 34. Thrust bearing 47. Differential side left bea...

  • Page 676

    5a-88 automatic transmission/transaxle: automatic transaxle unit disassembly s6rw0c5106031 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 677

    Automatic transmission/transaxle: 5a-89 5) remove transaxle side cover (1) by removing bolts. 6) remove solenoid harness from clamp. 7) disconnect pressure control solenoid, shift solenoid– a, shift solenoid–b and tcc solenoid connectors (1, 2, 3, 4). 8) remove solenoid harness (5) with o-ring. 9) r...

  • Page 678

    5a-90 automatic transmission/transaxle: 13) remove transaxle housing with oil pump (1), using special tool, and then remove oil pump body (2) by hand. Special tool (a): 09912–34510 14) clean and wipe off gasket sealant on mating surface between transaxle housing and transaxle case. 15) remove oil re...

  • Page 679

    Automatic transmission/transaxle: 5a-91 21) loosen 11 bolts of transaxle rear cover. 22) lightly and uniformly tap two rib sections of transaxle rear cover (1), using plastic hammer. 23) pull out transaxle rear cover (1) and input shaft rear thrust bearing rear race (2). 24) remove 4 gaskets (1) fro...

  • Page 680

    5a-92 automatic transmission/transaxle: 31) remove front thrust bearing (2) and bearing race (1) of front planetary ring gear. 32) remove retainer ring (3) and 1st / reverse brake piston return spring (4). 33) remove 1st / reverse brake piston (1) with o-ring installed while applying and releasing c...

  • Page 681

    Automatic transmission/transaxle: 5a-93 39) remove underdrive gear assembly (1) with bearing (2) and bearing race (3). 40) remove torsion spring (1), spacer (2) and underdrive brake accumulator bracket (3). 41) remove underdrive brake accumulator cover (1), piston (2) and spring (3) while applying a...

  • Page 682

    5a-94 automatic transmission/transaxle: 46) remove underdrive brake piston as follows. A) using special tool, compress underdrive brake piston cover (2) and remove snap ring using pliers or the like. B) remove cover (2), piston (3) and spring (4) by applying compressed air (400 – 800 kpa, 4 – 8 kg/c...

  • Page 683

    Automatic transmission/transaxle: 5a-95 oil pump 2nd coast brake and 2nd brake components s6rw0c5106032 23 20 18 16 24 19 21 22 17 15 14 13 11 10 9 8 12 7 6 4 3 2 5 1 i4rh01510087-01 1. Oil pump oil seal 8. O-ring 15. Snap ring 22. Friction plate 2. Oil pump body 9. 2nd brake piston 16. 2nd coast br...

  • Page 684

    5a-96 automatic transmission/transaxle: 2nd coast brake and 2nd brake preliminary check s6rw0c5106033 1) measure 2nd brake piston stroke while applying and releasing compressed air (400 – 800 kpa, 4 – 8 kg/ cm 2 , 57 – 113 psi) through oil hole (1) by using special tools. If measured piston stroke e...

  • Page 685

    Automatic transmission/transaxle: 5a-97 4) using special tool and hydraulic press (1), compress 2nd coast brake piston return spring (2) until spring seat is pushed down to 1 – 2 mm (0.039 – 0.078 in.) lower than snap ring groove and remove snap ring (3). Special tool (a): 09926–98350 caution ! Be c...

  • Page 686

    5a-98 automatic transmission/transaxle: 12) remove oil pump plate (1), driven gear (2) and drive gear (3). 13) remove o-ring. 14) remove oil pump oil seal (1), using special tool. Special tool (a): 09913–50121 note never reuse removed oil seal. Reassembly 1) press-fit new oil pump oil seal (1) using...

  • Page 687

    Automatic transmission/transaxle: 5a-99 8) install 2nd brake piston return spring. 9) install cushion plate “c”, separator plates “s”, friction plates “f” and retaining plate “r” with flat end facing to friction plates side in the following order. C → s → f → s → f → s → f → s → f → r 10) install sn...

  • Page 688

    5a-100 automatic transmission/transaxle: 15) install separator plates “s”, friction plates “f” and retaining plate “r” in the following order. S → f → s → f → r note make sure that 2nd brake piston return spring is inserted in 2nd coast brake retaining plate boss. 16) using special tool and hydrauli...

  • Page 689

    Automatic transmission/transaxle: 5a-101 oil pump, 2nd brake and 2nd coast brake inspection s6rw0c5106035 1) check body clearance of driven gear (1). Push driven gear (2) to one side of oil pump body (3). Using a feeler gauge, measure clearance between driven gear (2) and body (3). If clearance exce...

  • Page 690

    5a-102 automatic transmission/transaxle: 5) measure inside diameter of starter shaft bushing, using special tools. If inside diameter exceeds limit, replace starter shaft. Starter shaft bushing inside diameter limit: 21.57 mm (0.849 in.) special tool (a): 09900–20607 (b): 09900–22403 note perform me...

  • Page 691

    Automatic transmission/transaxle: 5a-103 one-way no. 1 clutch components s6rw0c5106036 one-way no. 1 clutch operation check s6rw0c5106037 1) check that one-way no. 1 clutch (1) turns freely when turned counterclockwise [a] and locks when turned clockwise [b]. One-way no. 1 clutch disassembly and rea...

  • Page 692

    5a-104 automatic transmission/transaxle: 2) remove one-way no. 1 clutch inner race (1) and one-way no. 1 clutch front thrust washer (2). 3) remove one-way no. 1 clutch (3) from one-way no. 1 clutch outer race (4). Reassembly 1) install one-way no. 1 clutch (3) into one-way clutch outer race (4). 2) ...

  • Page 693

    Automatic transmission/transaxle: 5a-105 forward and direct clutch components s6rw0c5106040 15 14 18 13 17 16 12 10 8 5 9 6 7 11 3 4 2 1 i4rh01510119-01 1. Snap ring 6. Retaining plate 11. O-ring 16. Input shaft rear thrust bearing front race 2. Retaining plate 7. Friction plate 12. Direct clutch pi...

  • Page 694

    5a-106 automatic transmission/transaxle: forward and direct clutch preliminary check s6rw0c5106041 1) install forward and direct clutch assembly (1) to transaxle rear cover (2). 2) measure forward clutch piston stroke while applying and releasing compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 1...

  • Page 695

    Automatic transmission/transaxle: 5a-107 5) using special tool and hydraulic press, compress direct clutch piston return spring and remove snap ring (1). Special tool (a): 09926–95420 (b): 09940–51710 caution ! Be careful when applying pressure, for overpressure will cause plate section of direct cl...

  • Page 696

    5a-108 automatic transmission/transaxle: 2) apply a/t fluid to new o-rings and install new o- rings to forward clutch piston. 3) press forward clutch piston to input shaft. Note do not twist or deviate o-rings during installation. 4) apply a/t fluid to new o-rings and install o-rings to direct clutc...

  • Page 697

    Automatic transmission/transaxle: 5a-109 12) measure forward clutch piston stroke again, using special tools. If measured piston stroke exceeds specified value, replace forward clutch retaining plate with new one so that piston stroke is within standard value. Special tool (a): 09900–20607 (b): 0990...

  • Page 698

    5a-110 automatic transmission/transaxle: forward and direct clutch inspection s6rw0c5106043 1) check that sliding surfaces of friction, separator and retaining plates are not worn or burnt. If necessary, replace. Note • if friction plate lining is exfoliated, discolored or worn hardly, replace all f...

  • Page 699

    Automatic transmission/transaxle: 5a-111 1st / reverse brake and one-way no. 2 clutch components s6rw0c5106044 16 15 18 17 13 11 10 9 14 8 7 6 3 1 4 2 12 5 i7rw01510054-01 1. O-ring 6. Friction plate 11. One-way no. 2 clutch inner race 16. Front planetary ring gear flange 2. 1st / reverse brake pist...

  • Page 700

    5a-112 automatic transmission/transaxle: 1st / reverse brake and one-way no. 2 clutch operation check s6rw0c5106045 one-way no. 2 clutch 1) check that one-way no. 2 clutch (1) turns freely when turned counterclockwise [a] and looks when turned clockwise [b]. 1st / reverse brake and one-way no. 2 clu...

  • Page 701

    Automatic transmission/transaxle: 5a-113 4) fit flat surface of thrust washer (1) to front planetary ring gear with petroleum jelly so as not to fall washer off when reassembling. 5) install one-way no. 2 clutch (1). 6) install snap ring, using flat head rod or the like. 7) apply a/t fluid to outer ...

  • Page 702

    5a-114 automatic transmission/transaxle: underdrive clutch and one-way no. 3 clutch components s6rw0c5106048 12 10 9 8 7 11 3 2 4 6 5 1 13 i7rw01510055-01 1. Snap ring 5. Snap ring 9. Underdrive clutch drum 13. Cushion plate 2. Separator plate 6. Underdrive clutch piston return spring 10. Underdrive...

  • Page 703

    Automatic transmission/transaxle: 5a-115 underdrive clutch and one-way no. 3 clutch preliminary check s6rw0c5106049 1) install underdrive clutch (1) to transaxle case (2). 2) measure underdrive clutch piston stroke while applying and releasing compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 ...

  • Page 704

    5a-116 automatic transmission/transaxle: 3) using special tool and hydraulic press (2), compress underdrive clutch piston return spring (1) until spring seat is pushed down to 1 – 2 mm (0.039 – 0.078 in.) lower than snap ring groove and remove snap ring (3). Special tool (a): 09926–98350 caution ! B...

  • Page 705

    Automatic transmission/transaxle: 5a-117 3) using special tool and hydraulic press (2), compress underdrive clutch piston return spring (1) until spring seat is pushed down to 1 – 2 mm (0.039 – 0.078 in.) lower than snap ring groove and install snap ring (3). Special tool (a): 09926–98350 note • whe...

  • Page 706

    5a-118 automatic transmission/transaxle: underdrive clutch and one-way no. 3 clutch inspection s6rw0c5106052 1) check that sliding surfaces of friction, separator and retaining cushion plates are not worn or burnt. If necessary, replace. Note • if friction plate lining is exfoliated, discolored or w...

  • Page 707

    Automatic transmission/transaxle: 5a-119 planetary gear components s6rw0c5106053 8 10 3 2 4 5 7 1 9 6 i4rh01510150-01 1. Planetary front gear 5. Rear planetary ring gear flange 9. Planetary sun gear 2. Front planetary carrier rear thrust bearing race 6. Snap ring 10. Input shaft front thrust bearing...

  • Page 708

    5a-120 automatic transmission/transaxle: planetary gear disassembly and reassembly s6rw0c5106054 disassembly rear planetary ring gear assembly 1) remove snap ring (1) using flat end rod or the like. 2) remove rear planetary ring gear flange (2) from rear planetary ring gear (3). Reassembly rear plan...

  • Page 709

    Automatic transmission/transaxle: 5a-121 underdrive brake components s6rw0c5106056 underdrive brake disassembly and reassembly s6rw0c5106057 disassembly 1) remove e-ring (1) from underdrive brake piston (2), using flat end rod or the like. 2) remove underdrive brake piston rod, underdrive brake pist...

  • Page 710

    5a-122 automatic transmission/transaxle: 4) remove o-rings (1) from underdrive brake piston cover (2). Note never reuse removed o-rings. Reassembly 1) apply a/t fluid to new o-rings. 2) install new o-rings (1) to underdrive brake piston cover (2). 3) install underdrive brake piston rod spring (1), u...

  • Page 711

    Automatic transmission/transaxle: 5a-123 underdrive gear assembly components s6rw0c5106060 underdrive gear preliminary check s6rw0c5106061 measure starting torque of underdrive gear, using spring force gauge, attach cord at gear of underdrive gear. If starting torque is out of specification, replace...

  • Page 712

    5a-124 automatic transmission/transaxle: valve body assembly components s6rw0c5106062 caution ! When replacing pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. 7 n·m(0.7 kg-m) 7 n·m(0.7 kg-m) 7 n·m(0.7 kg-m) 7 n·m(0.7 kg-m) 7 n·m(0.7 ...

  • Page 713

    Automatic transmission/transaxle: 5a-125 valve body assembly disassembly and reassembly s6rw0c5106063 disassembly 1) pull out manual valve. 2) remove solenoid valves with o-ring by removing bolts. Note never reuse removed o-ring. Reassembly 1) apply a/t fluid to new o-rings and install o-rings to ea...

  • Page 714

    5a-126 automatic transmission/transaxle: differential components s6rw0c5106064 differential preliminary check s6rw0c5106065 differential assembly starting torque 1) install differential assembly (1) to transaxle case and tighten case bolts to specified torque. Tightening torque transaxle housing bol...

  • Page 715

    Automatic transmission/transaxle: 5a-127 available differential side bearing shim thickness (thickness: identification) differential gear thrust play 1) hold differential assembly with soft jawed vice and set special tools as shown. Special tool (a): 09900–20607 (b): 09900–20701 2) measure different...

  • Page 716

    5a-128 automatic transmission/transaxle: 2) install differential side left bearing race (1) to transaxle housing (2), using special tool. Special tool (a): 09924–07710 final gear 1) heat final gear to about 100 °c (212 °f) in oil bath. 2) clean mating surfaces of final gear and differential case. 3)...

  • Page 717

    Automatic transmission/transaxle: 5a-129 transaxle rear cover components s6rw0c5106067 transaxle rear cover disassembly and reassembly s6rw0c5106068 disassembly 1) remove oil seal rings (1). 2) remove forward clutch accumulator (1), forward clutch accumulator spring (2) and forward clutch accumulato...

  • Page 718

    5a-130 automatic transmission/transaxle: reassembly 1) apply a/t fluid to new o-ring and install o-ring (1) to forward clutch accumulator piston (2). 2) press forward clutch accumulator piston (2) into transaxle rear cover. Note do not twist or deviate o-rings during installation. 3) install forward...

  • Page 719

    Automatic transmission/transaxle: 5a-131 4) install one-way no. 3 clutch (1) to transaxle case. Note make sure that groove section of one-way no. 3 clutch faces (2) toward upper side. 5) install snap ring (3), using flat end rod or the like. Note make sure that opening end of snap ring should be ali...

  • Page 720

    5a-132 automatic transmission/transaxle: 11) apply special tools and push in underdrive brake piston cover (1). Special tool (a): 09916–14510 (b): 09916–14910 12) install snap ring (2), using pliers or the like. 13) install underdrive brake band (1). 14) apply a/t fluid to new o-ring (1) and install...

  • Page 721

    Automatic transmission/transaxle: 5a-133 20) apply petroleum jelly to underdrive clutch thrust bearing (1) and countershaft rear thrust bearing race (2). 21) install underdrive clutch thrust bearing (1) and countershaft rear thrust bearing race (2) to underdrive clutch assembly (3). 22) install unde...

  • Page 722

    5a-134 automatic transmission/transaxle: 32) apply a/t fluid to new o-rings and install o-rings to 1st / reverse brake piston (1). 33) place 1st / reverse brake piston (1) into transaxle case. Note do not twist or deviate o-rings during installation. 34) mount 1st / reverse brake piston return sprin...

  • Page 723

    Automatic transmission/transaxle: 5a-135 44) measure 1st / reverse brake piston stroke while applying and releasing compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (1) by using special tools. If measured piston stroke exceeds specified value, check for an important inst...

  • Page 724

    5a-136 automatic transmission/transaxle: 55) apply a/t fluid to 4 new gaskets (1). 56) install 4 new gaskets (1) to transaxle case. 57) apply a/t fluid to transaxle lubrication tubes (2). 58) install tube clamp (3) and tighten the torx ® bolt to specified torque. Tightening torque tube clamp torx ® ...

  • Page 725

    Automatic transmission/transaxle: 5a-137 65) apply a/t fluid to new oil seal ring (1) and install oil seal ring (1) to transaxle housing. Note do not spread oil seal ring ends excessively. 66) apply a/t fluid to transaxle rubrication tube (2). 67) install tube clamp (3) and tighten the bolt to speci...

  • Page 726

    5a-138 automatic transmission/transaxle: 73) install transaxle housing to transaxle case by 15 tightening bolts to specified torque. Tightening torque transaxle case bolt: 29 n·m (2.9 kgf-m, 20.98 lb- ft) note make sure to use new transaxle housing bolts b and c. 74) install one-way no. 1 clutch ass...

  • Page 727

    Automatic transmission/transaxle: 5a-139 77) measure end play of input shaft (1), using special tool. If end play is out of specification, replace input shaft rear thrust bearing front race in the following so as end play to be in standard value. Special tool (a): 09900–20607 (b): 09900–20701 end pl...

  • Page 728

    5a-140 automatic transmission/transaxle: 85) apply sealant to mating surface of transaxle case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter. “a”: sealant 99000–31230 (suzuki bond no.1216b) 86) install transaxle side cover (1) by tightening ne...

  • Page 729

    Automatic transmission/transaxle: 5a-141 91) install transmission range sensor assembly. A) install transmission range sensor plate (1) to groove of solenoid harness. B) install transmission range sensor (2) to manual valve lever shaft (3). C) place lock washer (4). D) insert transmission range sens...

  • Page 730

    5a-142 automatic transmission/transaxle: specifications tightening torque specifications s6rw0c5107001 note the specified tightening torque is also described in the following. “select cable components” “automatic transaxle unit components” “automatic transaxle assembly components” “valve body assemb...

  • Page 731

    Automatic transmission/transaxle: 5a-143 special tools and equipment recommended service material s6rw0c5108001 note required service material is also described in the following. “select cable components” “automatic transaxle assembly components” “oil pump 2nd coast brake and 2nd brake components” “...

  • Page 732

    5a-144 automatic transmission/transaxle: 09916–14510 09916–14910 valve lifter valve spring compressor attachment ) ) 09924–07710 09924–07730 synchronizer hub installer bearing installer ) / ) ) 09924–84510–005 09925–37811–001 bearing installer attachment (d) oil pressure gauge ) ) 09926–95420 09926–...

  • Page 733

    Manual transmission/transaxle: 5b-1 transmission / transaxle manual transmission/transaxle general description manual transaxle construction s6rw0c5201001 the transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts-input shaft, countershaft...

  • Page 734

    5b-2 manual transmission/transaxle: 2wd i5rw0a520001-01 1. Input shaft 6. Input shaft 3rd gear 11. Countershaft 16. Countershaft 2nd gear 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. Count...

  • Page 735

    Manual transmission/transaxle: 5b-3 4wd i5rw0a520002-05 1. Input shaft 8. Reverse gear shaft 15. Countershaft 3rd gear 22. Transfer driven gear 2. 5th speed sleeve & hub 9. Reverse idler gear 16. Countershaft 2nd gear 23. Transfer bevel gear 3. Input shaft 5th gear 10. Right case 17. Low speed sleev...

  • Page 736

    5b-4 manual transmission/transaxle: 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. I7rw01520011-01 1. Gear shift control cable 7. R...

  • Page 737

    Manual transmission/transaxle: 5b-5 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 738

    5b-6 manual transmission/transaxle: diagnostic information and procedures manual transaxle symptom diagnosis s6rw0c5204001 repair instructions manual transaxle oil level check s6rw0c5206001 1) lift up vehicle and check oil leakage. Repair leaky point, if any. 2) remove oil level / filler plug (1) an...

  • Page 739

    Manual transmission/transaxle: 5b-7 manual transaxle oil change s6rw0c5206002 1) before changing 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 work than oil ch...

  • Page 740

    5b-8 manual transmission/transaxle: differential side oil seal replacement s6rw0c5206003 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 741

    Manual transmission/transaxle: 5b-9 gear shift control lever and cable components s6rw0c5206004 1 7 3 4 (a) 6 a 8 (b) 2 (c) 5 9 a 11 10 i7rw01520009-02 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut 11. Shift cable seal 2. Cable bracket bolt 7. Gear shift control ...

  • Page 742

    5b-10 manual transmission/transaxle: gear shift control lever and cable removal and installation s6rw0c5206005 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 743

    Manual transmission/transaxle: 5b-11 5) slide lock plate (3) in the direction of c, until it gets over the claw (4) of cable end holder. Back up light switch removal and installation s6rw0c5206007 removal 1) remove battery and tray with ecm. 2) disconnect back up light switch coupler (1). 3) remove ...

  • Page 744

    5b-12 manual transmission/transaxle: manual transaxle unit components s6rw0c5206009 3 7 (a) 8 (a) 4 6 5 2 [a] 1 (a) 7 7 (a) 9 (b) i7rw01520001-01 [a]: forward 4. Back up light switch connector 8. Transaxle to engine nut 1. Engine 5. Ground cable bolt 9. Stiffener bolt 2. Transaxle 6. Ground cable : ...

  • Page 745

    Manual transmission/transaxle: 5b-13 manual transaxle unit dismounting and remounting s6rw0c5206010 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 746

    5b-14 manual transmission/transaxle: gear shift and select shaft assembly components s6rw0c5206011 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 747

    Manual transmission/transaxle: 5b-15 gear shift and select shaft assembly removal and installation s6rw0c5206012 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 748

    5b-16 manual transmission/transaxle: gear shift and select shaft assembly disassembly and reassembly s6rw0c5206013 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 749

    Manual transmission/transaxle: 5b-17 manual transaxle assembly components s6rw0c5206014 i7rw01520004-01 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 750

    5b-18 manual transmission/transaxle: fifth gear disassembly and reassembly s6rw0c5206015 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 snap ring pliers, remove circlip (1). 3) ...

  • Page 751

    Manual transmission/transaxle: 5b-19 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 752

    5b-20 manual transmission/transaxle: 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 753

    Manual transmission/transaxle: 5b-21 2) remove bearing set shim. 3) remove snap ring (1) using snap ring pliers (4). 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 bolts (1) from outside ...

  • Page 754

    5b-22 manual transmission/transaxle: 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 755

    Manual transmission/transaxle: 5b-23 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 756

    5b-24 manual transmission/transaxle: 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 200 n (20.0 kgf) and turn countershaft (2) 1...

  • Page 757

    Manual transmission/transaxle: 5b-25 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 758

    5b-26 manual transmission/transaxle: reassembly 1) install input shaft oil seal facing its spring side upward until it becomes flush with case surface. Use special tool and hammer for installation and apply grease to oil seal lip. : grease 99000–25011 (suzuki super grease a) special tool (a): 09913–...

  • Page 759

    Manual transmission/transaxle: 5b-27 2) select differential side shim as follows. A) keep pushing outer race (4) with the power of 35 n (3.5 kgf) and turn differential case 10 times or more. B) measure distance “a” of differential assembly (1). C) measure depth “b” of left case (2) and “c” of right ...

  • Page 760

    5b-28 manual transmission/transaxle: input shaft and countershaft components s6rw0c5206019 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 761

    Manual transmission/transaxle: 5b-29 input shaft disassembly and reassembly s6rw0c5206020 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 762

    5b-30 manual transmission/transaxle: 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 763

    Manual transmission/transaxle: 5b-31 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 764

    5b-32 manual transmission/transaxle: countershaft disassembly and reassembly s6rw0c5206021 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 765

    Manual transmission/transaxle: 5b-33 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 766

    5b-34 manual transmission/transaxle: 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 767

    Manual transmission/transaxle: 5b-35 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 768

    5b-36 manual transmission/transaxle: gear shift shaft components s6rw0c5206022 5th and reverse gear shift shafts disassembly and reassembly s6rw0c5206023 disassembly disassemble component parts by using special tool and hammer. Special tool : 09922–85811 reassembly replace or correct parts as requir...

  • Page 769

    Manual transmission/transaxle: 5b-37 differential components s6rw0c5206025 differential disassembly and reassembly s6rw0c5206026 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 770

    5b-38 manual transmission/transaxle: 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 771

    Manual transmission/transaxle: 5b-39 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 772

    5b-40 manual transmission/transaxle: special tools and equipment recommended service material s6rw0c5208001 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 773

    Manual transmission/transaxle: 5b-41 09913–80113 09913–84510 bearing installer bearing installer ) / ) / ) ) 09913–85210 09913–85230 bearing installer bearing remover tool ) / ) ) / ) / ) 09922–85811 09923–78210 spring pin remover (4.5 mm) bearing installer ) / ) / ) ) / ) / ) 09924–07710 09924–0772...

  • Page 774

    5b-42 manual transmission/transaxle: 09940–54950 09941–64511 bearing installer attachment bearing and oil seal remover (30 mm min.) ) ) 09942–15511 09944–96011 sliding hammer bearing outer race remover ) ) 09952–06010 dial gauge plate no.1 ).

  • Page 775: Clutch

    Clutch: 5c-1 transmission / transaxle clutch general description clutch (hydraulic type) construction s6rw0c5301001 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 776

    5c-2 clutch: diagnostic information and procedures clutch system symptom diagnosis s6rw0c5304001 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 777

    Clutch: 5c-3 repair instructions clutch pedal inspection s6rw0c5306001 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 778

    5c-4 clutch: air bleeding of clutch system s6rw0c5306003 caution ! • brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. • when operating the pedal stroke for air bleeding of clutch system, after...

  • Page 779

    Clutch: 5c-5 clutch pedal position (cpp) switch inspection and adjustment s6rw0c5306005 inspection check for resistance between terminals under each condition below. If check result is not satisfactory, replace. Cpp switch resistance when switch shaft is pushed (1): continuity when switch shaft is f...

  • Page 780

    5c-6 clutch: clutch fluid pipe removal and installation s6rw0c5306007 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 around brake master cylinder reservoir cap. 2) take ...

  • Page 781

    Clutch: 5c-7 installation reverse removal procedure for installation noting the following. • apply grease to push rod tip. “a”: grease 99000–25100 (suzuki silicone grease) • tighten clutch master cylinder nut to specified torque. Tightening torque clutch master cylinder nut: 13 n·m (1.3 kgf-m, 9.5 l...

  • Page 782

    5c-8 clutch: 4) remount transaxle assembly referring to “manual transaxle unit dismounting and remounting in section 5b”. 5) bleed air from system and check clutch pedal free travel. Refer to “air bleeding of clutch system” and “clutch pedal inspection”. Clutch operating cylinder assembly inspection...

  • Page 783

    Clutch: 5c-9 clutch cover, clutch disc and flywheel removal and installation s6rw0c5306012 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 784

    5c-10 clutch: 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, ...

  • Page 785

    Clutch: 5c-11 clutch cover and clutch disc inspection s6rw0c5306013 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 de...

  • Page 786

    5c-12 clutch: special tools and equipment recommended service material s6rw0c5308001 special tool s6rw0c5308002 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 787: 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 788

    6-ii table of contents tie-rod end removal and installation..............6c-37 tie-rod end inspection.....................................6c-38 steering shaft joint on-vehicle inspection.......6c-38 steering gear case assembly removal and installation....................................................

  • Page 789: Precautions

    Precautions: 6-1 steering precautions precautions precautions on steering s6rw0c6000001 air bag warning refer to “air bag warning in section 00”. Precautions for steering diagnosis refer to “precautions for steering diagnosis in section 6a”. Service precautions of steering wheel and column refer to ...

  • Page 790: Steering General Diagnosis

    6a-1 steering general diagnosis: steering steering general diagnosis precautions precautions for steering diagnosis s6rw0c6100001 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 791

    Steering general diagnosis: 6a-2 steering system inspection s6rw0c6104002 check steering system referring to the following items. If found a defective part, repair or replace it. Steering system operation check s6rw0c6104003 • check that steering wheel can be turned fully to the right and left. • ch...

  • Page 792: Steering Wheel and Column

    6b-1 steering wheel and column: steering steering wheel and column precautions service precautions of steering wheel and column s6rw0c6200001 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 793

    Steering wheel and column: 6b-2 diagnostic information and procedures checking steering column for accident damage s6rw0c6204001 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 794

    6b-3 steering wheel and column: repair instructions steering wheel and column construction s6rw0c6206001 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 795

    Steering wheel and column: 6b-4 steering wheel removal and installation s6rw0c6206002 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 796

    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 797

    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 798

    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 799

    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 800

    6b-9 steering wheel and column: steering lock assembly (ignition switch) removal and installation s6rw0c6206011 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 801

    Steering wheel and column: 6b-10 steering lower shaft removal and installation s6rw0c6206012 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 802

    6b-11 steering wheel and column: specifications tightening torque specifications s6rw0c6207001 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 803

    Power assisted steering system: 6c-1 steering power assisted steering system precautions p/s system note s6rw0c6300001 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 804

    6c-2 power assisted steering system: general description p/s system description s6rw0c6301001 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 805

    Power assisted steering system: 6c-3 eps diagnosis general description s6rw0c6301002 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 806

    6c-4 power assisted steering system: schematic and routing diagram eps system wiring circuit diagram s6rw0c6302001 [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 807

    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 s6rw0c6304001 warning ! Carry out test drive in light traffic area to prevent an accident. Refer to the following items for the de...

  • Page 808

    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 809

    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 810

    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 811

    Power assisted steering system: 6c-9 dtc clearance s6rw0c6304004 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 812

    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 813

    Power assisted steering system: 6c-11 visual inspection s6rw0c6304006 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 drived. • p/s motor ci...

  • Page 814

    6c-12 power assisted steering system: scan tool data s6rw0c6304007 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 815

    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 816

    6c-14 power assisted steering system: dlc and its communication check (no communication to p/s control module) s6rw0c6304009 wiring diagram troubleshooting lt grn/blk e11-1 e11-11 e13-1 grn grn wht 8 13 3 18 19 20 5 6 17 4 1 2 7 12v e13-2 blk 9 g241-31 +bb blu/ wht e04-9 10 11 red/blk g241-25 e11-5 ...

  • Page 817

    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 818

    6c-16 power assisted steering system: “eps” warning light does not come on with ignition switch turned on before engine starts s6rw0c6304010 wiring diagram circuit description operation (on/off) of “eps” warning light is controlled by p/s control module through combination meter. If the p/s system i...

  • Page 819

    Power assisted steering system: 6c-17 troubleshooting step action yes no 1 “eps” warning light power supply check 1) turn ignition switch on. Do the other warning light come on? Go to step 2. “grn”, “red/blk” wire circuit or circuit fuse for combination meter is open or short to ground. 2 fuse check...

  • Page 820

    6c-18 power assisted steering system: “eps” warning light remains on steady after engine starts s6rw0c6304011 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 821

    Power assisted steering system: 6c-19 dtc c1111 / c1113 / c1115: torque sensor circuit failure s6rw0c6304012 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 822

    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 823

    Power assisted steering system: 6c-21 dtc c1116: steering torque sensor power supply circuit s6rw0c6304013 wiring diagram dtc detecting condition and trouble area [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 e11-8 e11-9 e11-19 e13-...

  • Page 824

    6c-22 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 indicated, together? Go to applicable dtc diag. Flow. Go to step 3. 3 torque sensor power supply voltage check 1) with ign...

  • Page 825

    Power assisted steering system: 6c-23 dtc c1121 / c1123 / c1124: vehicle speed signal circuit failure s6rw0c6304014 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 826

    6c-24 power assisted steering system: 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 827

    Power assisted steering system: 6c-25 dtc c1122: engine speed signal s6rw0c6304015 wiring diagram dtc detecting condition and trouble area 5 bcm voltage check 1) with ignition switch turned off, connect bcm connector. 2) check bcm for vehicle speed signal output referring to “inspection of p/s contr...

  • Page 828

    6c-26 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 1) check ecm for dtc referring to “dtc check in section 1a”. Is there any dtc(s) detected? Go to applicable dtc diag. Flow. Go to step ...

  • Page 829

    Power assisted steering system: 6c-27 dtc c1141 / c1142 / c1143 / c1145: motor circuit failure s6rw0c6304016 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 830

    6c-28 power assisted steering system: dtc troubleshooting dtc c1153: p/s control module power supply circuit s6rw0c6304017 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 831

    Power assisted steering system: 6c-29 dtc troubleshooting dtc c1155: p/s control module internal failure s6rw0c6304018 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 832

    6c-30 power assisted steering system: p/s control module power supply and ground circuit check s6rw0c6304019 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 833

    Power assisted steering system: 6c-31 inspection of p/s control module and its circuits s6rw0c6304020 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 834

    6c-32 power assisted steering system: 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.6” under “ins...

  • Page 835

    Power assisted steering system: 6c-33 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 836

    6c-34 power assisted steering system: 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 837

    Power assisted steering system: 6c-35 steering wheel play check s6rw0c6304021 • 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 838

    6c-36 power assisted steering system: repair instructions steering gear case assembly components s6rw0c6306001 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 839

    Power assisted steering system: 6c-37 tie-rod end boot on-vehicle inspection s6rw0c6306002 check boot for crack and damage. If any defect is found, replace it with a new one. Tie-rod end removal and installation s6rw0c6306003 removal 1) hoist vehicle, and then remove front wheel. 2) remove tie-rod e...

  • Page 840

    6c-38 power assisted steering system: 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 841

    Power assisted steering system: 6c-39 2) install steering gear case to suspension frame (3) as follows. A) set member bracket (2) to steering gear case (1). B) install all steering gear case mounting bolts by hand. C) tighten steering mounting bolts in numerical order and specified torque. Tightenin...

  • Page 842

    6c-40 power assisted steering system: 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 843

    Power assisted steering system: 6c-41 steering rack plunger removal and installation s6rw0c6306009 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 844

    6c-42 power assisted steering system: p/s control module removal and installation s6rw0c6306011 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 845

    Power assisted steering system: 6c-43 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 846

    6c-44 power assisted steering system: 5) hoist vehicle 6) check that steering wheel turns to left and right smoothly. If steering wheel does not turn smoothly, inspect and repair defective steering and suspension parts. 7) connect “e12” connector with ignition switch turned off. 8) using ammeter (2)...

  • Page 847

    Power assisted steering system: 6c-45 specifications tightening torque specifications s6rw0c6307001 note the specified tightening torque is also described in the following. “steering gear case assembly components” reference: for the tightening torque of fastener not specified in this section, refer ...

  • Page 848

    6c-46 power assisted steering system:.

  • Page 849: 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 850

    7-ii table of contents compressor drive belt removal and installation.......................................................7b-30 compressor assembly removal and installation.......................................................7b-30 compressor assembly components.................7b-31 magnet clutc...

  • Page 851

    Table of contents 7-iii condenser assembly removal and installation.......................................................7b-87 evaporator inspection ....................................... 7b-87 evaporator temperature sensor removal and installation................................................7b...

  • Page 852: Precautions

    7-1 precautions: hvac precautions precautions precautions on hvac s6rw0c7000001 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 853: Heater and Ventilation

    Heater and ventilation: 7a-1 hvac heater and ventilation general description heater and ventilation construction s6rw0c7101001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6rw0c710001-02.

  • Page 854

    7a-2 heater and ventilation: i6rw0c710011-01 a: air flow 7. Defroster air 15. Rear duct (if equipped) b: water flow 8. Demister air 16. Foot duct 1. Hvac unit 9. Fresh air 17. Engine 2. Ventilator duct 10. Recirculation air 18. Radiator 3. Defroster duct and demister duct 11. Center ventilation air ...

  • Page 855

    Heater and ventilation: 7a-3 schematic and routing diagram heater and ventilation wiring circuit diagram s6rw0c7102001 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 856

    7a-4 heater and ventilation: diagnostic information and procedures heater and ventilation symptom diagnosis s6rw0c7104001 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 857

    Heater and ventilation: 7a-5 repair instructions hvac unit components s6rw0c7106001 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) s6rw0c7106002 for manual a/c and au...

  • Page 858

    7a-6 heater and ventilation: • 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 859

    Heater and ventilation: 7a-7 blower motor relay inspection s6rw0c7106007 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 860

    7a-8 heater and ventilation: hvac control unit removal and installation s6rw0c7106009 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 861

    Heater and ventilation: 7a-9 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 862

    7a-10 heater and ventilation: blower speed selector inspection s6rw0c7106010 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 s6rw0c7106011 • check that there is con...

  • Page 863

    Heater and ventilation: 7a-11 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 s6rw0c7106013 check air intake control actuator as follows: 1) using...

  • Page 864

    7a-12 heater and ventilation: center ventilation louver removal and installation s6rw0c7106014 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 865

    Heater and ventilation: 7a-13 rear duct removal and installation (if equipped) s6rw0c7106016 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 866: Air Conditioning System

    7b-1 air conditioning system: manual type hvac air conditioning system manual type precautions a/c system caution s6rw0c7210001 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 867

    Air conditioning system: manual type 7b-2 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 868

    7b-3 air conditioning system: manual type manual a/c electronic input output table s6rw0c7211002 a/c operation description at ecm s6rw0c7211003 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 869

    Air conditioning system: manual type 7b-4 schematic and routing diagram a/c system air flow diagram s6rw0c7212001 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 870

    7b-5 air conditioning system: manual type a/c system wiring diagram s6rw0c7212002 [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 871

    Air conditioning system: manual type 7b-6 component location a/c system major components location s6rw0c7213001 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 872

    7b-7 air conditioning system: manual type electronic control system components location s6rw0c7213002 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 873

    Air conditioning system: manual type 7b-8 diagnostic information and procedures a/c system performance inspection s6rw0c7214001 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 874

    7b-9 air conditioning system: manual type 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 875

    Air conditioning system: manual type 7b-10 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 876

    7b-11 air conditioning system: manual type thermometer at center ventilation louver trouble diagnosis for abnormal pressure s6rw0c7214002 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 877

    Air conditioning system: manual type 7b-12 a/c system inspection at ecm s6rw0c7214003 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 878

    7b-13 air conditioning system: manual type a/c system symptom diagnosis s6rw0c7214004 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 879

    Air conditioning system: manual type 7b-14 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 880

    7b-15 air conditioning system: manual type abnormal noise symptom diagnosis of a/c system s6rw0c7214005 abnormal noise from compressor abnormal noise from magnetic clutch abnormal noise from tubing insufficient air flow of cooled air a/c evaporator clogged or frosted check a/c evaporator and evapora...

  • Page 881

    Air conditioning system: manual type 7b-16 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 item considerable vibration i...

  • Page 882

    7b-17 air conditioning system: manual type repair instructions operation procedure for refrigerant charge s6rw0c7216001 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 883

    Air conditioning system: manual type 7b-18 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 884

    7b-19 air conditioning system: manual type 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 885

    Air conditioning system: manual type 7b-20 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 886

    7b-21 air conditioning system: manual type 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 887

    Air conditioning system: manual type 7b-22 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 888

    7b-23 air conditioning system: manual type condenser cooling fan inspection s6rw0c7216003 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 889

    Air conditioning system: manual type 7b-24 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 890

    7b-25 air conditioning system: manual type hvac unit components s6rw0c7216007 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 891

    Air conditioning system: manual type 7b-26 hvac unit removal and installation s6rw0c7216008 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 892

    7b-27 air conditioning system: manual type 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 893

    Air conditioning system: manual type 7b-28 evaporator temperature sensor inspection s6rw0c7216011 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 894

    7b-29 air conditioning system: manual type a/c refrigerant pressure sensor and its circuit inspection s6rw0c7216014 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 895

    Air conditioning system: manual type 7b-30 a/c system relay inspection s6rw0c7216017 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 896

    7b-31 air conditioning system: manual type installation reverse removal procedure noting the following instructions. • if compressor is replaced, pour new compressor oil referring to “replenishing compressor oil” in “operation procedure for refrigerant charge”. • tighten compressor mounting bolts to...

  • Page 897

    Air conditioning system: manual type 7b-32 magnet clutch removal and installation s6rw0c7216023 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 898

    7b-33 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 899

    Air conditioning system: manual type 7b-34 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 900

    7b-35 air conditioning system: manual type relief valve inspection s6rw0c7216026 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 s6rw0c7216027 removal 1) reco...

  • Page 901

    Air conditioning system: manual type 7b-36 specifications tightening torque specifications s6rw0c7217001 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 902: Automatic Type

    7b-37 air conditioning system: automatic type automatic type precautions a/c system caution s6rw0c7220001 refer to “a/c system caution”. Precautions in diagnosing trouble s6rw0c7220002 • do not disconnect couplers from hvac control module, battery cable from battery, hvac control module ground wire ...

  • Page 903

    Air conditioning system: automatic type 7b-38 general description auto a/c system description s6rw0c7221001 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 904

    7b-39 air conditioning system: automatic type hvac control description s6rw0c7221002 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 905

    Air conditioning system: automatic type 7b-40 on-board diagnostic system description s6rw0c7221004 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 906

    7b-41 air conditioning system: automatic type a/c system wiring diagram s6rw0c7222002 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 907

    Air conditioning system: automatic type 7b-42 [a]: illumination control model 10. Air intake actuator 22. Compressor 34. “a/c” indicator light [b]: junction block with bcm 11. Air flow control actuator 23. Hvac control module 35. Rear defogger switch [c]: junction block without bcm 12. Temperature c...

  • Page 908

    7b-43 air conditioning system: automatic type component location a/c system major components location s6rw0c7223001 refer to “a/c system major components location”. Electronic control system components location s6rw0c7223002 note the figure shows left-hand steering vehicle. For right-hand steering v...

  • Page 909

    Air conditioning system: automatic type 7b-44 diagnostic information and procedures air conditioning system check s6rw0c7224001 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 910

    7b-45 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 911

    Air conditioning system: automatic type 7b-46 a/c system symptom diagnosis s6rw0c7224002 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 912

    7b-47 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 913

    Air conditioning system: automatic type 7b-48 abnormal noise symptom diagnosis of a/c system s6rw0c7224003 refer to “abnormal noise symptom diagnosis of a/c system”. Insufficient air flow of cooled air a/c evaporator clogged or frosted check a/c evaporator and evaporator temperature sensor referring...

  • Page 914

    7b-49 air conditioning system: automatic type dtc check s6rw0c7224004 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) lig...

  • Page 915

    Air conditioning system: automatic type 7b-50 example: when inside air temperature sensor circuit malfunction (open) is set example: when vss signal failure (data error) is set 6) after completing above check, turn ignition switch to “off” position. Dtc clearance s6rw0c7224005 using suzuki scan tool...

  • Page 916

    7b-51 air conditioning system: automatic type dtc table s6rw0c7224006 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 917

    Air conditioning system: automatic type 7b-52 ) 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 918

    7b-53 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. Dtc no. Detection item detecting condition (dtc will set when detecting) mil p0481...

  • Page 919

    Air conditioning system: automatic type 7b-54 fail-safe table s6rw0c7224007 when any of the following malfunctions (dtcs) is detected, fail-safe mode is activated. However, when hvac control module detects normal operation of a/c system, fail-safe mode is canceled. Dtc no. Trouble area fail-safe ope...

  • Page 920

    7b-55 air conditioning system: automatic type scan tool data s6rw0c7224008 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 921

    Air conditioning system: automatic type 7b-56 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 922

    7b-57 air conditioning system: automatic type visual inspection s6rw0c7224009 check visually the following parts and systems. Dtc b1502: inside air temperature sensor circuit malfunction s6rw0c7224010 wiring diagram dtc detecting condition and trouble area inspection item correction • refrigerant le...

  • Page 923

    Air conditioning system: automatic type 7b-58 dtc troubleshooting note when dtc b1503, b1504, b1511 and b1512 are indicated together, it is possible that sensor ground circuit is open. Step action yes no 1 was “air conditioning system check” performed? Go to step 2. Go to “air conditioning system ch...

  • Page 924

    7b-59 air conditioning system: automatic type dtc b1503: evaporator temperature sensor circuit malfunction s6rw0c7224011 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 925

    Air conditioning system: automatic type 7b-60 dtc b1504: sunload sensor circuit malfunction s6rw0c7224012 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 926

    7b-61 air conditioning system: automatic type dtc troubleshooting dtc b1511: temperature control actuator (position sensor) and/or its circuit malfunction s6rw0c7224013 wiring diagram step action yes no 1 was “air conditioning system check” performed? Go to step 2. Go to “air conditioning system che...

  • Page 927

    Air conditioning system: automatic type 7b-62 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 928

    7b-63 air conditioning system: automatic type dtc b1512: air flow control actuator (position sensor) and/or its circuit malfunction s6rw0c7224014 wiring diagram dtc detecting condition and trouble area 4 temperature control actuator check 1) check position sensor of temperature control actuator for ...

  • Page 929

    Air conditioning system: automatic type 7b-64 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 930

    7b-65 air conditioning system: automatic type dtc b1513: temperature control actuator (motor) and/or its circuit malfunction s6rw0c7224015 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 931

    Air conditioning system: automatic type 7b-66 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 932

    7b-67 air conditioning system: automatic type dtc b1514: air flow control actuator (motor) and/or its circuit malfunction s6rw0c7224016 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 933

    Air conditioning system: automatic type 7b-68 dtc b1520 / b1521 / b1522: temperature / blower speed / air flow selector malfunction s6rw0c7224017 dtc detecting condition and trouble area dtc troubleshooting 5 wire harness check check position sensor circuit of temperature control actuator for condit...

  • Page 934

    7b-69 air conditioning system: automatic type dtc b1541: back-up power supply circuit malfunction s6rw0c7224018 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 935

    Air conditioning system: automatic type 7b-70 dtc b1546: a/c refrigerant pressure malfunction s6rw0c7224019 dtc detecting condition and trouble area dtc troubleshooting dtc b1551: serial communication circuit malfunction s6rw0c7224020 wiring diagram dtc detecting condition trouble area • a/c refrige...

  • Page 936

    7b-71 air conditioning system: automatic type 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 937

    Air conditioning system: automatic type 7b-72 dtc b1552: hvac control module check sum error s6rw0c7224021 dtc detecting condition and trouble area dtc troubleshooting dtc b1553: can communication circuit malfunction s6rw0c7224022 dtc detecting condition and trouble area dtc troubleshooting dtc dete...

  • Page 938

    7b-73 air conditioning system: automatic type dtc b1557: vss signal failure s6rw0c7224023 dtc detecting condition and trouble area dtc troubleshooting dtc b1561: ect signal failure s6rw0c7224024 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area hvac co...

  • Page 939

    Air conditioning system: automatic type 7b-74 dtc b1562: outside air temperature signal failure s6rw0c7224025 dtc detecting condition and trouble area dtc troubleshooting dtc b1563: a/c refrigerant pressure signal failure s6rw0c7224026 dtc detecting condition and trouble area dtc troubleshooting dtc...

  • Page 940

    7b-75 air conditioning system: automatic type dtc b1570: engine type signal failure s6rw0c7224027 dtc detecting condition and trouble area dtc troubleshooting dtc b1571: combination meter spec signal failure s6rw0c7224028 dtc detecting condition and trouble area dtc troubleshooting dtc detecting con...

  • Page 941

    Air conditioning system: automatic type 7b-76 inspection of hvac control module and its circuit s6rw0c7224029 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 942

    7b-77 air conditioning system: automatic type 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 943

    Air conditioning system: automatic type 7b-78 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 944

    7b-79 air conditioning system: automatic type 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 s6rw0c7224030 when checking voltage at ecm terminals related to a/c system, refer to “inspec...

  • Page 945

    Air conditioning system: automatic type 7b-80 repair instructions operation procedure for refrigerant charge s6rw0c7226001 refer to “operation procedure for refrigerant charge”. Hvac unit components s6rw0c7226002 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 ...

  • Page 946

    7b-81 air conditioning system: automatic type hvac unit removal and installation s6rw0c7226003 refer to “hvac unit removal and installation”. Temperature control actuator removal and installation s6rw0c7226004 removal 1) disconnect negative (–) cable at battery. 2) remove steering column hole cover ...

  • Page 947

    Air conditioning system: automatic type 7b-82 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 948

    7b-83 air conditioning system: automatic type air flow control actuator removal and installation s6rw0c7226006 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 949

    Air conditioning system: automatic type 7b-84 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 950

    7b-85 air conditioning system: automatic type blower motor controller inspection s6rw0c7226012 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 951

    Air conditioning system: automatic type 7b-86 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 s6rw0c72260...

  • Page 952

    7b-87 air conditioning system: automatic type condenser cooling fan relay inspection s6rw0c7226020 refer to “a/c system relay inspection”. Condenser cooling fan removal and installation s6rw0c7226021 refer to “condenser cooling fan removal and installation”. Condenser cooling fan inspection s6rw0c72...

  • Page 953

    Air conditioning system: automatic type 7b-88 special tools and equipment recommended service material s6rw0c7228001 note required service material is also described in the following. “hvac unit components” special tool s6rw0c7228002 suzuki scan tool — this kit includes following items. 1. Tech 2, 2...

  • Page 954

    7b-89 air conditioning system: automatic type.

  • Page 955: 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 956

    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 957: Precautions

    Precautions: 8-1 restraint precautions precautions precautions on restraint s6rw0c8000001 air bag warning refer to “air bag warning in section 00”. Fastener caution refer to “fastener caution in section 00”. Precautions on service and diagnosis of seat belt refer to “precautions on service and diagn...

  • Page 958: Seat Belts

    8a-1 seat belts: restraint seat belts precautions precautions on service and diagnosis of seat belt s6rw0c8100001 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 959

    Seat belts: 8a-2 general description seat belt construction s6rw0c8101001 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 960

    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 961

    Seat belts: 8a-4 repair instructions front seat belt components s6rw0c8106001 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 962

    8a-5 seat belts: front seat belt removal and installation s6rw0c8106002 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 963

    Seat belts: 8a-6 front seat belt inspection s6rw0c8106003 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 964

    8a-7 seat belts: rear seat belt components s6rw0c8106004 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 965

    Seat belts: 8a-8 rear seat belt removal and installation s6rw0c8106005 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 966: Air Bag System

    8b-1 air bag system: restraint air bag system precautions precautions on service and diagnosis of air bag system s6rw0c8200004 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 967

    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 968

    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 969

    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 970

    8b-5 air bag system: precautions on disposal of air bag and seat belt pretensioner s6rw0c8200003 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 971

    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 972

    8b-7 air bag system: air bag system input / output table s6rw0c8201002 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 973

    Air bag system: 8b-8 schematic and routing diagram air bag system wiring circuit diagram s6rw0c8202001 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 974

    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 975

    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 976

    8b-11 air bag system: component location air bag system components, wiring and connectors location s6rw0c8203001 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 a: combination meter 6. Side curtain-air bag (inflator) module (8- channel system) 14. “a/b” fuse in ...

  • Page 977

    Air bag system: 8b-12 diagnostic information and procedures air bag diagnostic system check s6rw0c8204001 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 978

    8b-13 air bag system: air bag diagnostic system check flow s6rw0c8204002 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 979

    Air bag system: 8b-14 dtc table s6rw0c8204003 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 980

    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 981

    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 982

    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 983

    Air bag system: 8b-18 dtc check s6rw0c8204004 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 984

    8b-19 air bag system: scan tool data s6rw0c8204006 data list of sdm 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...

  • Page 985

    Air bag system: 8b-20 troubleshooting 4. Individual circuit fuse box no.1 8. “a/b” fuse 12. “air bag” warning light 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) ch...

  • Page 986

    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 987

    Air bag system: 8b-22 “air bag” warning light does not come on s6rw0c8204008 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 988

    8b-23 air bag system: serial data link circuit check s6rw0c8204051 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 989

    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 990

    8b-25 air bag system: dtc b1013: sdm internal failure s6rw0c8204010 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 991

    Air bag system: 8b-26 dtc b1014: “air bag” warning light circuit s6rw0c8204011 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 992

    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 993

    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 994

    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 995

    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 996

    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 997

    Air bag system: 8b-32 2 drive air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector located under the steering column. 2) check for proper connection to contact coil at terminal in “g347” connector. 3) if ok, then connect special tools (a) and (b) to “g347” conn...

  • Page 998

    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 999

    Air bag system: 8b-34 dtc b1032: driver air bag circuit low resistance s6rw0c8204019 wiring diagram refer to “dtc b1031: driver air bag circuit high resistance”. Dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area driver air bag circuit is less than 1.1 ...

  • Page 1000

    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 1001

    Air bag system: 8b-36 dtc b1033: driver air bag circuit shorted to ground s6rw0c8204020 wiring diagram refer to “dtc b1031: driver air bag circuit high resistance”. Dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area driver air bag circuit has been short...

  • Page 1002

    8b-37 air bag system: 3 floor harness circuit check 1) disconnect “l378” connector located near the driver side front pillar lower trim. 2) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). Special tool (a): 09932–76010 3) measure resistance betwee...

  • Page 1003

    Air bag system: 8b-38 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 1004

    8b-39 air bag system: 3 floor harness circuit check 1) disconnect “l378” connector located near the driver side front pillar lower trim. 2) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). Special tool (a): 09932–76010 3) with ignition switch turn...

  • Page 1005

    Air bag system: 8b-40 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 1006

    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 1007

    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 1008

    8b-43 air bag system: dtc b1042: passenger air bag circuit low resistance s6rw0c8204023 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 1009

    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 1010

    8b-45 air bag system: dtc b1043: passenger air bag circuit shorted to ground s6rw0c8204024 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 1011

    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 1012

    8b-47 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 circuit check 1) remove passenger air bag (inflator) module from steering column referring to “passenge...

  • Page 1013

    Air bag system: 8b-48 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 1014

    8b-49 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 seat belt pretensioner circuit check 1) with ignition switch turned off, remove center pillar lower trim of applicable si...

  • Page 1015

    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 1016

    8b-51 air bag system: dtc b1052 / b1056: seat belt pretensioner circuit low resistance s6rw0c8204027 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 1017

    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 1018

    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 1019

    Air bag system: 8b-54 dtc b1054 / b1058: seat belt pretensioner circuit shorted to power supply s6rw0c8204029 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 1020

    8b-55 air bag system: dtc b1061 / b1065: side-air bag circuit high resistance s6rw0c8204053 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 1021

    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 1022

    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 1023

    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 1024

    8b-59 air bag system: dtc b1062 / b1066: side-air bag circuit low resistance s6rw0c8204054 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 1025

    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 1026

    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 1027

    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 1028

    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 1029

    Air bag system: 8b-64 dtc b1064 / b1068: side-air bag circuit shorted to power supply s6rw0c8204056 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 1030

    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 1031

    Air bag system: 8b-66 dtc b1071: driver forward impact-sensor communication data inconsistent s6rw0c8204034 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 1032

    8b-67 air bag system: dtc b1073: driver forward impact-sensor circuit shorted to ground s6rw0c8204036 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 1033

    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 1034

    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 1035

    Air bag system: 8b-70 dtc b1081 / b1091: side impact-sensor no response s6rw0c8204066 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 1036

    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 1037

    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 1038

    8b-73 air bag system: dtc b1084 / b1094: side impact-sensor circuit open s6rw0c8204060 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 1039

    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 1040

    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 1041

    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 1042

    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 1043

    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 1044

    8b-79 air bag system: dtc b1362 / b1366: curtain-air bag circuit low resistance s6rw0c8204063 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 1045

    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 1046

    8b-81 air bag system: dtc b1363 / b1367: curtain-air bag circuit shorted to ground s6rw0c8204064 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 1047

    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 1048

    8b-83 air bag system: dtc b1364 / b1368: curtain-air bag circuit shorted to power supply s6rw0c8204065 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 1049

    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 1050

    8b-85 air bag system: sdm power supply and ground circuit check s6rw0c8204049 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 1051

    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 1052

    8b-87 air bag system: contact coil cable and its circuit check s6rw0c8204050 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 1053

    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 1054

    8b-89 air bag system: inspection of intermittent and poor connections s6rw0c8204047 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 1055

    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 1056

    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 1057

    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 1058

    8b-93 air bag system: repair instructions disabling air bag system s6rw0c8206001 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 1059

    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 1060

    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 1061

    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 1062

    8b-97 air bag system: driver air bag (inflator) module inspection s6rw0c8206006 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 1063

    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 1064

    8b-99 air bag system: passenger air bag (inflator) module inspection s6rw0c8206008 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 1065

    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 1066

    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 1067

    Air bag system: 8b-102 side curtain-air bag (inflator) module removal and installation s6rw0c8206022 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 1068

    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 1069

    Air bag system: 8b-104 5) remove forward impact-sensor bolt (3) and forward impact-sensor (4) from apron-side-member (driver side) (5). Installation caution ! Proper operation of forward impact-sensor requires sensor be rigidly attached to vehicle structure and that the arrow on sensor be pointing t...

  • Page 1070

    8b-105 air bag system: side impact-sensor removal and installation s6rw0c8206024 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 1071

    Air bag system: 8b-106 passenger air bag (inflator) module repair harness installation s6rw0c8206017 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 1072

    8b-107 air bag system: 5) fix passenger air bag (inflator) module repair harness (1) to instrument panel harness (2). Caution ! To avoid interference with other parts, fasten the repair harness to instrument panel harness with a clamp (3) as shown in figure. 6) connect passenger air bag (inflator) m...

  • Page 1073

    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 1074

    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 1075

    Air bag system: 8b-110 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 outdoor location is not available, space on shop floor where there is no activity and provide s...

  • Page 1076

    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 1077

    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 1078

    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 1079

    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 1080

    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 1081

    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 1082

    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 1083

    Air bag system: 8b-118 specifications tightening torque specifications s6rw0c8207001 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 1084

    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 1085

    Air bag system: 8b-120 special tool s6rw0c8208002 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 1086

    8b-121 air bag system:.

  • Page 1087: 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 1088

    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 1089

    Table of contents 9-iii headlight bulb replacement (discharge headlight model).............................................9b-20 ballast removal and installation (discharge headlight model).............................................9b-21 igniter removal and installation (discharge headlight model)...

  • Page 1090

    9-iv table of contents front speaker removal and installation (if equipped)........................................................9c-20 rear speaker removal and installation (if equipped)........................................................9c-20 gps antenna removal and installation (if equipped)...

  • Page 1091

    Table of contents 9-v rear end door opener system operation inspection (if equipped) .................................... 9f-5 repair instructions .............................................. 9f-6 front door lock assembly components ............ 9f-6 front door lock assembly removal and installati...

  • Page 1092: Precautions

    9-1 precautions: body, cab and accessories precautions precautions precautions on body, cab and accessories s6rw0c9000001 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 1093: Wiring Systems

    Wiring systems: 9a-1 body, cab and accessories wiring systems precautions cautions in body electrical system servicing s6rw0c9100001 when servicing the electric systems, observe the cautions described in “precautions for electrical circuit service in section 00” to protect electrical parts and to pr...

  • Page 1094

    9a-2 wiring systems: symbols and marks s6rw0c9101003 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 1095

    Wiring systems: 9a-3 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 1096

    9a-4 wiring systems: how to read connector layout diagram s6rw0c9101004 [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 1097

    Wiring systems: 9a-5 how to read connector codes and terminal nos. S6rw0c9101005 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 1098

    9a-6 wiring systems: 3) terminals in one connector (broken line) (b15)/terminals in different connectors (b14, b16) 4) joint connector (j/c) • the joint connector (j/c) connects several different wires with the same wire color at one place instead of connecting them by welding or caulking one by one...

  • Page 1099: Cross-Reference

    Wiring systems: 9a-7 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 1100: Cross-Reference

    9a-8 wiring systems: how to read ground point s6rw0c9101006 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 1101

    Wiring systems: 9a-9 how to read power supply diagram s6rw0c9101007 refer to “power supply diagram”. Refer to “system circuit diagram”. How to read system circuit diagram s6rw0c9101008 the circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of th...

  • Page 1102

    9a-10 wiring systems: [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 1103

    Wiring systems: 9a-11 connector layout diagram connector layout diagram s6rw0c910a001 refer to “engine compartment”. Refer to “instrument panel”. Refer to “door, roof”. Refer to “floor”. Refer to “rear”. Engine compartment s6rw0c910a002 a: battery cable / c: engine harness (m15a engine rhd) c: engin...

  • Page 1104

    9a-12 wiring systems: 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 1105

    Wiring systems: 9a-13 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 1106

    9a-14 wiring systems: 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 1107

    Wiring systems: 9a-15 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 1108

    9a-16 wiring systems: 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 1109

    Wiring systems: 9a-17 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 1110

    9a-18 wiring systems: 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 1111

    Wiring systems: 9a-19 instrument panel s6rw0c910a003 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 1112

    9a-20 wiring systems: 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 1113

    Wiring systems: 9a-21 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 1114

    9a-22 wiring systems: 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 1115

    Wiring systems: 9a-23 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 1116

    9a-24 wiring systems: 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 1117

    Wiring systems: 9a-25 door, roof s6rw0c910a004 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 1118

    9a-26 wiring systems: 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 1119

    Wiring systems: 9a-27 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 1120

    9a-28 wiring systems: floor s6rw0c910a005 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 1121

    Wiring systems: 9a-29 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 1122

    9a-30 wiring systems: 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 1123

    Wiring systems: 9a-31 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 1124

    9a-32 wiring systems: rear s6rw0c910a006 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 1125

    Wiring systems: 9a-33 ground point ground (earth) point s6rw0c910c001 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 1126

    9a-34 wiring systems: power supply diagram power supply diagram s6rw0c910d001 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 1127

    Wiring systems: 9a-35 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 1128

    9a-36 wiring systems: fuses and the protected parts s6rw0c910d002 the chart below describes what parts each fuse protects. Fuses in main fuse box s6rw0c910d003 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 1129

    Wiring systems: 9a-37 individual circuit fuse box no. 1 s6rw0c910d004 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 1130

    9a-38 wiring systems: individual circuit fuse box no. 2 (in j/b (except taiwan)) s6rw0c910d009 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 1131

    Wiring systems: 9a-39 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 1132

    9a-40 wiring systems: individual circuit fuse box no. 2 (in j/b (taiwan)) s6rw0c910d005 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 1133

    Wiring systems: 9a-41 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 1134

    9a-42 wiring systems: junction block (j/b) connector / fuse layout s6rw0c910d006 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 1135

    Wiring systems: 9a-43 relay side junction block inner circuit (overview (except taiwan)) s6rw0c910d010 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 1136

    9a-44 wiring systems: 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 1137

    Wiring systems: 9a-45 junction block inner circuit (detail (except taiwan)) s6rw0c910d011 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 1138

    9a-46 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 1139

    Wiring systems: 9a-47 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 1140

    9a-48 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 1141

    Wiring systems: 9a-49 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 1142

    9a-50 wiring systems: junction block inner circuit (overview (taiwan)) s6rw0c910d007 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 1143

    Wiring systems: 9a-51 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 1144

    9a-52 wiring systems: junction block inner circuit (detail (taiwan)) s6rw0c910d008 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 1145

    Wiring systems: 9a-53 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 1146

    9a-54 wiring systems: 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 1147

    Wiring systems: 9a-55 (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 1148

    9a-56 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 1149

    Wiring systems: 9a-57 system circuit diagram system circuit diagram s6rw0c910e001 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 1150

    9a-58 wiring systems: a-1 cranking system circuit diagram s6rw0c910e002 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 1151

    Wiring systems: 9a-59 a-2 charging system circuit diagram s6rw0c910e003 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 1152

    9a-60 wiring systems: a-3 ignition system circuit diagram (m15a engine, m16a engine) s6rw0c910e004 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 1153

    Wiring systems: 9a-61 a-3 ignition system circuit diagram (j20a engine) s6rw0c910e039 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 1154

    9a-62 wiring systems: a-4 cooling system circuit diagram (m15a engine, m16a engine) s6rw0c910e005 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 1155

    Wiring systems: 9a-63 a-4 cooling system circuit diagram (j20a engine) s6rw0c910e040 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 1156

    9a-64 wiring systems: a-5 engine and a/c control system circuit diagram (m15a engine) s6rw0c910e006 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 1157

    Wiring systems: 9a-65 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 1158

    9a-66 wiring systems: 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 1159

    Wiring systems: 9a-67 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 1160

    9a-68 wiring systems: a-5 engine and a/c control system circuit diagram (m16a engine) s6rw0c910e041 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 1161

    Wiring systems: 9a-69 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 1162

    9a-70 wiring systems: 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 1163

    Wiring systems: 9a-71 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 1164

    9a-72 wiring systems: a-5 engine and a/c control system circuit diagram (j20a engine) s6rw0c910e042 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 1165

    Wiring systems: 9a-73 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 1166

    9a-74 wiring systems: 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 1167

    Wiring systems: 9a-75 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 1168

    9a-76 wiring systems: a-6 a/t control system circuit diagram s6rw0c910e007 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 1169

    Wiring systems: 9a-77 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 1170

    9a-78 wiring systems: a-7 immobilizer system circuit diagram s6rw0c910e008 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 1171

    Wiring systems: 9a-79 a-8 body control system circuit diagram (except taiwan) s6rw0c910e009 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 1172

    9a-80 wiring systems: 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 1173

    Wiring systems: 9a-81 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 1174

    9a-82 wiring systems: 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 1175

    Wiring systems: 9a-83 a-8 body control system circuit diagram (taiwan) s6rw0c910e043 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 1176

    9a-84 wiring systems: 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 1177

    Wiring systems: 9a-85 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 1178

    9a-86 wiring systems: 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 1179

    Wiring systems: 9a-87 a-10 4wd control system (except taiwan) s6rw0c910e010 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 1180

    9a-88 wiring systems: b-1 windshield wiper and washer circuit diagram s6rw0c910e011 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 1181

    Wiring systems: 9a-89 b-2 rear wiper and washer circuit diagram (except taiwan) s6rw0c910e044 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 1182

    9a-90 wiring systems: b-2 rear wiper and washer circuit diagram (taiwan) s6rw0c910e012 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 1183

    Wiring systems: 9a-91 b-3 rear defogger circuit diagram (except taiwan) s6rw0c910e045 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 1184

    9a-92 wiring systems: b-3 rear defogger circuit diagram (taiwan) s6rw0c910e013 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 1185

    Wiring systems: 9a-93 b-4 power window circuit diagram s6rw0c910e014 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 1186

    9a-94 wiring systems: 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 1187

    Wiring systems: 9a-95 b-5 power door lock circuit diagram (except taiwan) s6rw0c910e047 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 1188

    9a-96 wiring systems: 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 1189

    Wiring systems: 9a-97 b-5 power door lock circuit diagram (taiwan) s6rw0c910e015 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 1190

    9a-98 wiring systems: 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 1191

    Wiring systems: 9a-99 b-6 power mirror circuit diagram (except taiwan) s6rw0c910e048 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 1192

    9a-100 wiring systems: b-6 power mirror circuit diagram (taiwan) s6rw0c910e016 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 1193

    Wiring systems: 9a-101 b-7 horn circuit diagram s6rw0c910e017 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 1194

    9a-102 wiring systems: b-8 seat heater circuit diagram s6rw0c910e060 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 1195

    Wiring systems: 9a-103 b-9 keyless start system circuit diagram s6rw0c910e018 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 1196

    9a-104 wiring systems: c-1 combination meter circuit diagram (meter) s6rw0c910e019 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 1197

    Wiring systems: 9a-105 c-2 combination meter circuit diagram (indicator) s6rw0c910e020 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 1198

    9a-106 wiring systems: c-3 combination meter circuit diagram (warning light) s6rw0c910e021 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 1199

    Wiring systems: 9a-107 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 1200

    9a-108 wiring systems: d-1 headlight system circuit diagram (except taiwan) s6rw0c910e049 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 1201

    Wiring systems: 9a-109 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 1202

    9a-110 wiring systems: d-1 headlight system circuit diagram (taiwan) s6rw0c910e022 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 1203

    Wiring systems: 9a-111 d-2 position, tail and licence plate light system circuit diagram (except taiwan) s6rw0c910e051 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 1204

    9a-112 wiring systems: d-2 position, tail and licence plate light system circuit diagram (taiwan) s6rw0c910e023 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 1205

    Wiring systems: 9a-113 d-3 front fog light system circuit diagram (except taiwan) s6rw0c910e052 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 1206

    9a-114 wiring systems: d-3 front fog light system circuit diagram (taiwan) s6rw0c910e024 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 1207

    Wiring systems: 9a-115 d-4 illumination light system circuit diagram (except taiwan) s6rw0c910e053 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 1208

    9a-116 wiring systems: d-4 illumination light system circuit diagram (taiwan) s6rw0c910e025 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 1209

    Wiring systems: 9a-117 d-5 interior light system circuit diagram (except taiwan) s6rw0c910e054 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 1210

    9a-118 wiring systems: d-5 interior light system circuit diagram (taiwan) s6rw0c910e026 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 1211

    Wiring systems: 9a-119 d-6 turn signal and hazard warning light system circuit diagram (except taiwan) s6rw0c910e055 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 1212

    9a-120 wiring systems: 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 1213

    Wiring systems: 9a-121 d-6 turn signal and hazard warning light system circuit diagram (taiwan) s6rw0c910e027 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 1214

    9a-122 wiring systems: 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 1215

    Wiring systems: 9a-123 d-7 brake light system circuit diagram s6rw0c910e028 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 1216

    9a-124 wiring systems: d-8 back-up light system circuit diagram s6rw0c910e029 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 1217

    Wiring systems: 9a-125 d-9 headlight beam leveling system circuit diagram (manual leveling) s6rw0c910e056 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 1218

    9a-126 wiring systems: d-10 rear fog light circuit diagram s6rw0c910e061 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 1219

    Wiring systems: 9a-127 e-1 heater system circuit diagram s6rw0c910e030 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 1220

    9a-128 wiring systems: 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 1221

    Wiring systems: 9a-129 e-2 auto a/c system circuit diagram s6rw0c910e031 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 1222

    9a-130 wiring systems: 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 1223

    Wiring systems: 9a-131 f-1 air-bag system circuit diagram (4ch) s6rw0c910e032 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 1224

    9a-132 wiring systems: f-1 air-bag system circuit diagram (8ch) s6rw0c910e033 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 1225

    Wiring systems: 9a-133 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 1226

    9a-134 wiring systems: f-2 anti-lock brake system circuit diagram s6rw0c910e034 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 1227

    Wiring systems: 9a-135 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 1228

    9a-136 wiring systems: f-4 power steering system circuit diagram s6rw0c910e036 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 1229

    Wiring systems: 9a-137 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 1230

    9a-138 wiring systems: g-1 audio system circuit diagram s6rw0c910e037 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 1231

    Wiring systems: 9a-139 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 1232

    9a-140 wiring systems: g-2 multi information display / accessory socket system circuit diagram s6rw0c910e038 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 1233

    Wiring systems: 9a-141 g-4 navigation system circuit diagram s6rw0c910e059 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 1234

    9a-142 wiring systems: 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 1235

    Wiring systems: 9a-143 list of connector list of connectors s6rw0c910f001 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 1236

    9a-144 wiring systems: 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 1237

    Wiring systems: 9a-145 e connector s6rw0c910f003 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 1238

    9a-146 wiring systems: g connector s6rw0c910f004 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 1239

    Wiring systems: 9a-147 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 1240

    9a-148 wiring systems: 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 1241

    Wiring systems: 9a-149 j connector s6rw0c910f005 k connector s6rw0c910f006 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 1242

    9a-150 wiring systems: l connector s6rw0c910f007 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 1243

    Wiring systems: 9a-151 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 1244

    9a-152 wiring systems: o connector s6rw0c910f008 q connector (8ch) s6rw0c910f009 r connector s6rw0c910f010 s connector s6rw0c910f011 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 1245: Lighting Systems

    Lighting systems: 9b-1 body, cab and accessories lighting systems precautions precautions for discharge headlight service (if equipped) s6rw0c9200001 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 1246

    9b-2 lighting systems: general description discharge headlight description (if equipped) s6rw0c9201001 discharge headlight provides more brightness and consumes less electricity as compared with the conventional halogen headlight. It consists of a ballast (1), igniter (2) and discharge headlight bul...

  • Page 1247

    Lighting systems: 9b-3 headlight auto leveling system description (if equipped) s6rw0c9201002 headlight auto leveling system adjusts the optical axis of the headlight automatically to be suitable for the varied vehicle position while the headlights are lit. It consists of front height sensor (1), re...

  • Page 1248

    9b-4 lighting systems: front and rear height sensors front height sensor (1) is installed to the front suspension frame (2) respectively and connected to the lower arm (4) with the link (3). Also rear height sensor is installed to the rear floor center cross member (5) respectively and connected to ...

  • Page 1249

    Lighting systems: 9b-5 headlight leveling actuator headlight leveling actuator is (1) located in the headlight housing (2). It moves the reflector (3) in the headlight housing according to the drive signal from the headlight leveling control module so as to adjust the optical axis of the headlight t...

  • Page 1250

    9b-6 lighting systems: schematic and routing diagram headlight auto leveling system wiring circuit diagram s6rw0c9202001 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 1251

    Lighting systems: 9b-7 component location lighting system components location s6rw0c9203001 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 1252

    9b-8 lighting systems: interior light system location s6rw0c9203002 diagnostic information and procedures self-diagnosis function for headlight auto leveling system s6rw0c9204014 the headlight leveling control module has self-diagnosis function to monitor the system components and circuits while the...

  • Page 1253

    Lighting systems: 9b-9 headlight leveling warning light check s6rw0c9204015 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 1254

    9b-10 lighting systems: headlight symptom diagnosis (other than discharge headlight model) s6rw0c9204017 auto-on headlight system symptom diagnosis (if equipped) s6rw0c9204018 condition possible cause correction / reference item only one low beam does not light up circuit fuse blown replace fuse and...

  • Page 1255

    Lighting systems: 9b-11 drl system symptom diagnosis (if equipped) s6rw0c9204002 headlight auto leveling system symptom diagnosis (if equipped) s6rw0c9204019 condition possible cause correction / reference item headlight does not light when lighting switch is in off position and engine is running li...

  • Page 1256

    9b-12 lighting systems: headlight manual leveling system symptom diagnosis (if equipped) s6rw0c9204003 turn signal and hazard warning light symptom diagnosis s6rw0c9204004 condition possible cause correction / reference item optical axes of both headlights do not change circuit fuse blown replace fu...

  • Page 1257

    Lighting systems: 9b-13 clearance, tail and license plate light symptom diagnosis s6rw0c9204005 back-up light symptom diagnosis s6rw0c9204020 brake light symptom diagnosis s6rw0c9204007 front fog light symptom diagnosis (if equipped) s6rw0c9204008 condition possible cause correction / reference item...

  • Page 1258

    9b-14 lighting systems: rear fog light symptom diagnosis (if equipped) s6rw0c9204009 illumination cancel system symptom diagnosis (if equipped) s6rw0c9204010 interior light symptom diagnosis s6rw0c9204011 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the inpu...

  • Page 1259

    Lighting systems: 9b-15 inspection of drl controller and its circuits (if equipped) s6rw0c9204013 1) confirm that lighting switch is in good condition referring to “headlight switch (in lighting switch) inspection”. 2) confirm that oil pressure switch is in good condition referring to “oil pressure ...

  • Page 1260

    9b-16 lighting systems: auto-on headlight operation inspection (if equipped) s6rw0c9204021 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 1261

    Lighting systems: 9b-17 inspection of headlight leveling control module and its circuit (headlight auto leveling system) s6rw0c9204023 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 1262

    9b-18 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 1263

    Lighting systems: 9b-19 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 s6rw0c9206001 warning ! • to avoid danger of being burned, don’t touch when the b...

  • Page 1264

    9b-20 lighting systems: installation reverse removal procedure noting the following. • install headlight mounting bolts and clip (1), and then tighten headlight mounting bolts (“1” – “2”) according to numerical order as shown in figure. • after installation, be sure to inspect and adjust aiming refe...

  • Page 1265

    Lighting systems: 9b-21 ballast removal and installation (discharge headlight model) s6rw0c9206023 warning ! Be sure to read “precautions for discharge headlight service (if equipped)” carefully before working. Neglecting them may result in personal injury. Removal 1) check to ensure that lighting s...

  • Page 1266

    9b-22 lighting systems: headlight aiming adjustment with screen s6rw0c9206003 note • unless otherwise obligated by local regulations, adjust headlight aiming according to the following procedure. • after replacing headlight housing, be sure to adjust aiming. • when inspecting and adjusting headlight...

  • Page 1267

    Lighting systems: 9b-23 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 1268

    9b-24 lighting systems: headlight switch (in lighting switch) removal and installation s6rw0c9206004 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 1269

    Lighting systems: 9b-25 with auto-on headlight switch hazard warning switch removal and installation s6rw0c9206006 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 1270

    9b-26 lighting systems: turn signal light switch (in lighting switch) inspection s6rw0c9206010 check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Turn signal and hazard warning relay removal and installation s6rw0c9206011 removal 1) d...

  • Page 1271

    Lighting systems: 9b-27 turn signal and hazard warning relay inspection s6rw0c9206012 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 1272

    9b-28 lighting systems: front fog light assembly removal and installation (if equipped) s6rw0c9206014 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 1273

    Lighting systems: 9b-29 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 1274

    9b-30 lighting systems: headlight manual levering switch inspection (if equipped) s6rw0c9206019 check for resistance between terminals at each switch position. If check result is not as specified, replace switch. Headlight leveling actuator inspection (if equipped) s6rw0c9206026 headlight auto level...

  • Page 1275

    Lighting systems: 9b-31 height sensor removal and installation (if equipped) s6rw0c9206027 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 1276

    9b-32 lighting systems: height sensor and its circuit inspection (if equipped) s6rw0c9206028 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 1277

    Lighting systems: 9b-33 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 1278

    9b-34 lighting systems: illumination cancel switch inspection (if equipped) s6rw0c9206022 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) s6rw0c92060...

  • Page 1279

    Lighting systems: 9b-35 specifications tightening torque specifications s6rw0c9207001 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 1280

    9c-1 instrumentation / driver info. / horn: body, cab and accessories instrumentation / driver info. / horn precautions precautions in diagnosing troubles for combination meter s6rw0c9300001 combination meter uses signals (information) from each control module by can communication to control speedom...

  • Page 1281

    Instrumentation / driver info. / horn: 9c-2 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 1282

    9c-3 instrumentation / driver info. / horn: auto volume control system description (if equipped) s6rw0c9301002 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 1283

    Instrumentation / driver info. / horn: 9c-4 schematic and routing diagram combination meter circuit diagram s6rw0c9302001 7 6 5 4 g241-9 9 g241-5 1 2 11 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 g241-7 g241-10 10 10 i6rw0c930002-01 1. Dome fuse ...

  • Page 1284

    9c-5 instrumentation / driver info. / horn: 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 s6rw0c9303001 terminal circuit terminal circuit g241-1 to turn signal light switc...

  • Page 1285

    Instrumentation / driver info. / horn: 9c-6 diagnostic information and procedures speedometer and vss symptom diagnosis s6rw0c9304001 tachometer symptom diagnosis s6rw0c9304002 engine coolant temperature (ect) meter symptom diagnosis s6rw0c9304003 fuel meter symptom diagnosis s6rw0c9304004 condition...

  • Page 1286

    9c-7 instrumentation / driver info. / horn: low fuel warning light symptom diagnosis s6rw0c9304005 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 1287

    Instrumentation / driver info. / horn: 9c-8 brake and parking brake warning light symptom diagnosis s6rw0c9304007 seat belt reminder light symptom diagnosis s6rw0c9304008 a/t shift position indicator symptom diagnosis (a/t model) s6rw0c9304009 condition possible cause correction / reference item bra...

  • Page 1288

    9c-9 instrumentation / driver info. / horn: charge warning light symptom diagnosis s6rw0c9304010 main beam (high beam) indicator symptom diagnosis s6rw0c9304011 warning buzzer circuit symptom diagnosis s6rw0c9304012 note • use of suzuki scan tool makes it easy to check whether a faulty condition is ...

  • Page 1289

    Instrumentation / driver info. / horn: 9c-10 cigarette lighter symptom diagnosis (if equipped) s6rw0c9304013 horn symptom diagnosis s6rw0c9304014 information display symptom diagnosis (if equipped) s6rw0c9304015 note this thermometer indicates the ambient temperature in the under side of front bumpe...

  • Page 1290

    9c-11 instrumentation / driver info. / horn: clock system diagnosis (if equipped) s6rw0c9304016 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 1291

    Instrumentation / driver info. / horn: 9c-12 audio system symptom diagnosis (if equipped) s6rw0c9304017 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 1292

    9c-13 instrumentation / driver info. / horn: cd player auto volume control system condition possible cause correction / reference item cd-rom does not insert another cd-rom already inserted eject cd-rom. Circuit fuse blown replace fuse and check for short circuit. Wiring or grounding faulty repair c...

  • Page 1293

    Instrumentation / driver info. / horn: 9c-14 remote audio control switch symptom diagnosis (if equipped) s6rw0c9304018 navigation symptom diagnosis (if equipped) s6rw0c9304019 repair instructions ignition switch removal and installation s6rw0c9306001 removal 1) disconnect negative cable at battery. ...

  • Page 1294

    9c-15 instrumentation / driver info. / horn: installation reverse removal procedure noting the following. Tighten steering column mounting nuts referring to step 2) under “installation” of “steering column removal and installation in section 6b”. Ignition switch inspection s6rw0c9306002 • check for ...

  • Page 1295

    Instrumentation / driver info. / horn: 9c-16 fuel level sensor removal and installation s6rw0c9306004 removal remove fuel pump assembly referring to “fuel pump assembly removal and installation in section 1g”. Installation install fuel pump assembly referring to “fuel pump assembly removal and insta...

  • Page 1296

    9c-17 instrumentation / driver info. / horn: brake fluid level switch inspection s6rw0c9306009 check for continuity between terminals of brake fluid level switch coupler (1). If found defective, replace switch. Brake fluid level switch specification off position (float up): no continuity on position...

  • Page 1297

    Instrumentation / driver info. / horn: 9c-18 outside air temperature sensor removal and installation (if equipped) s6rw0c9306013 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 1298

    9c-19 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 1299

    Instrumentation / driver info. / horn: 9c-20 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) s6rw0c9...

  • Page 1300

    9c-21 instrumentation / driver info. / horn: gps antenna removal and installation (if equipped) s6rw0c9306027 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 1301

    Instrumentation / driver info. / horn: 9c-22 horn relay inspection s6rw0c9306022 1) disconnect negative (–) cable at battery. 2) remove junction block. 3) remove horn relay (1) from junction block (2). 4) check that there is no continuity between terminals “c” and “d”. If there is continuity, replac...

  • Page 1302

    9c-23 instrumentation / driver info. / horn: remote audio control switch inspection (if equipped) s6rw0c9306025 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 1303: Wipers / Washers

    Wipers / washers: 9d-1 body, cab and accessories wipers / washers diagnostic information and procedures front wiper and washer symptom diagnosis s6rw0c9404001 rear wiper and washer symptom diagnosis s6rw0c9404002 condition possible cause correction / reference item wiper malfunctions circuit fuse bl...

  • Page 1304

    9d-2 wipers / washers: repair instructions wipers and washers components s6rw0c9406001 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 1305

    Wipers / washers: 9d-3 washer tank and washer pump removal and installation s6rw0c9406002 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 1306

    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 1307

    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 1308

    9d-6 wipers / washers: rear wiper removal and installation s6rw0c9406006 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 1309

    Wipers / washers: 9d-7 rear wiper motor inspection s6rw0c9406007 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 1310

    9d-8 wipers / washers: windshield wiper and washer switch removal and installation s6rw0c9406008 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 1311

    Wipers / washers: 9d-9 4) check that the voltmeter indicates the battery voltage (10 – 14 v). 5) connect terminal “3” and terminal “5” by a jumper wire. 6) disconnect end of the jumper wire from terminal “5”. 7) connect disconnected jumper wire end to terminal “2”, then check that voltage between te...

  • Page 1312

    9d-10 wipers / washers: rear wiper and washer switch removal and installation s6rw0c9406010 for removal and installation, refer to “windshield wiper and washer switch removal and installation”. Rear wiper and washer switch inspection s6rw0c9406011 check for continuity between terminals at each switc...

  • Page 1313

    Wipers / washers: 9d-11 rear wiper relay inspection s6rw0c9406013 1) check that there is no continuity between terminal “3” and “4”. If there is continuity, replace relay. 2) connect battery positive (+) terminal to terminal “2” of relay. 3) connect battery negative (–) terminal to terminal “1” of r...

  • Page 1314: Glass / Windows / Mirrors

    9e-1 glass / windows / mirrors: body, cab and accessories glass / windows / mirrors general description rear end door window defogger system description s6rw0c9501001 the rear end door window defogger is controlled by bcm. For the bcm description refer to “bcm general description in section 10b”. Di...

  • Page 1315

    Glass / windows / mirrors: 9e-2 power door mirror control system symptom diagnosis s6rw0c9504003 door mirror heater symptom diagnosis (if equipped) s6rw0c9504004 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 ...

  • Page 1316

    9e-3 glass / windows / mirrors: repair instructions windshield components s6rw0c9506001 3 3 1 2 4 4 4 i5rw0a950001-02 1. Windshield glass 3. Windshield glass stopper : do not reuse. 2. Windshield molding 4. Spacer.

  • Page 1317

    Glass / windows / mirrors: 9e-4 windshield removal and installation s6rw0c9506002 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 1318

    9e-5 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 1319

    Glass / windows / mirrors: 9e-6 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 1320

    9e-7 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 1321

    Glass / windows / mirrors: 9e-8 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 do...

  • Page 1322

    9e-9 glass / windows / mirrors: rear quarter window components s6rw0c9506005 rear quarter window removal and installation s6rw0c9506006 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. However, note the following. • observe th...

  • Page 1323

    Glass / windows / mirrors: 9e-10 rear end door window components s6rw0c9506007 rear end door glass removal and installation s6rw0c9506008 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. However, note the following. • observe ...

  • Page 1324

    9e-11 glass / windows / mirrors: front door window components s6rw0c9506009 front door glass removal and installation s6rw0c9506010 removal 1) remove door mirror trim (1). 2) remove door trim mounting screws (2). 3) remove door trim (1) as shown. And disconnect connectors from power window switch, d...

  • Page 1325

    Glass / windows / mirrors: 9e-12 4) remove door inner weather-strip (3). 5) remove door trim bracket (1). 6) remove door sealing cover (2). 7) remove door glass mounting screws (1). 8) remove door glass (2) while tilting it as shown. Installation reverse removal procedure noting the following instru...

  • Page 1326

    9e-13 glass / windows / mirrors: installation reverse removal procedure noting the following instruction. • apply grease to sliding portions of window regulator. : grease 99000–25011 (suzuki super grease a) front door window regulator inspection s6rw0c9506012 check the following parts for wear, dama...

  • Page 1327

    Glass / windows / mirrors: 9e-14 3) remove door trim (1) as shown. 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 ...

  • Page 1328

    9e-15 glass / windows / mirrors: rear door window regulator removal and installation s6rw0c9506015 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 1329

    Glass / windows / mirrors: 9e-16 rear end door window defogger relay inspection s6rw0c9506018 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 1330

    9e-17 glass / windows / mirrors: 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 1331

    Glass / windows / mirrors: 9e-18 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 1332

    9e-19 glass / windows / mirrors: door mirror components s6rw0c9506023 door mirror removal and installation s6rw0c9506024 when removing or installing door mirror, refer to the figure in “door mirror components”. Power door mirror switch inspection s6rw0c9506025 1) remove driver side door trim referri...

  • Page 1333

    Glass / windows / mirrors: 9e-20 power door mirror actuator inspection s6rw0c9506026 1) remove door trim referring to step 1) to 3) of “front door glass removal and installation”. 2) disconnect door mirror coupler (1). 3) check that door mirror operates properly when battery voltage is applied to co...

  • Page 1334: Security and Locks

    9f-1 security and locks: body, cab and accessories security and locks general description key coding construction s6rw0c9601001 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 1335

    Security and locks: 9f-2 component location power door lock and keyless entry system component location (if equipped) s6rw0c9603001 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 1336

    9f-3 security and locks: diagnostic information and procedures power door lock system symptom diagnosis (if equipped) s6rw0c9604001 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 1337

    Security and locks: 9f-4 keyless entry system symptom diagnosis (if equipped) s6rw0c9604003 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 1338

    9f-5 security and locks: keyless entry system operation inspection (if equipped) s6rw0c9604004 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 1339

    Security and locks: 9f-6 repair instructions front door lock assembly components s6rw0c9606001 front door lock assembly removal and installation s6rw0c9606002 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 1340

    9f-7 security and locks: 5) disconnect door opening control rod (1) from outside handle. 6) disconnect door lock motor lead wire at coupler (if equipped). 7) remove door latch screws (2) and remove door lock assembly (3). Installation reverse removal procedure to install front door lock assembly not...

  • Page 1341

    Security and locks: 9f-8 front door lock assembly inspection s6rw0c9606003 • 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 1342

    9f-9 security and locks: power door lock actuator inspection (if equipped) s6rw0c9606006 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 1343

    Security and locks: 9f-10 rear door lock assembly components s6rw0c9606007 rear door lock assembly removal and installation s6rw0c9606008 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 1344

    9f-11 security and locks: rear end door lock assembly components s6rw0c9606010 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 1345

    Security and locks: 9f-12 rear end door lock assembly removal and installation s6rw0c9606011 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 1346

    9f-13 security and locks: rear end door opener switch inspection (if equipped) s6rw0c9606013 1) remove rear end door trim. 2) disconnect rear end door switch coupler. 3) check that there is continuity between terminals “a” and “b” when rear end door opener switch (1) is pushed. 4) check that there i...

  • Page 1347

    Security and locks: 9f-14 programming transmitter code for keyless entry system (other than keyless start model) s6rw0c9606015 note • three transmitter codes can be registered. • when a new transmitter code is registered, the oldest one will be cleared. • as for vehicle equipped with keyless start s...

  • Page 1348

    9f-15 security and locks: keyless entry receiver and its circuit inspection (if equipped) s6rw0c9606017 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 1349

    Security and locks: 9f-16 specifications tightening torque specifications s6rw0c9607001 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 1350: Seats

    9g-1 seats: body, cab and accessories seats repair instructions front seat components s6rw0c9706001 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 gr...

  • Page 1351

    Seats: 9g-2 front seat removal and installation s6rw0c9706002 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 1352

    9g-3 seats: rear seat removal and installation s6rw0c9706004 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 seat. • torque to specifications in...

  • Page 1353: Interior Trim

    Interior trim: 9h-1 body, cab and accessories interior trim repair instructions floor carpet removal and installation s6rw0c9806001 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 1354

    9h-2 interior trim: head lining removal and installation s6rw0c9806002 warning ! Refer to “air bag 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 sill scuffs (2)...

  • Page 1355

    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 1356

    9h-4 interior trim: specifications tightening torque specifications s6rw0c9807001 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 1357: Hood / Fenders / Doors

    Hood / fenders / doors: 9j-1 body, cab and accessories hood / fenders / doors repair instructions hood removal and installation s6rw0c9a06001 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 1358

    9j-2 hood / fenders / doors: front fender components s6rw0c9a06003 front fender removal and installation s6rw0c9a06004 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 1359

    Hood / fenders / doors: 9j-3 front door assembly components s6rw0c9a06005 front door assembly removal and installation s6rw0c9a06006 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 1360

    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 1361

    Hood / fenders / doors: 9j-5 rear door assembly components s6rw0c9a06007 rear door assembly removal and installation s6rw0c9a06008 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 1362

    9j-6 hood / fenders / doors: rear end door assembly components s6rw0c9a06009 b a a b a a a a a a a a a 5 6 1 4 2 (a) (a) [a] 3 7 8 9 i6rw0b9a0006-01 [a]: rear end door spoiler installation position 4. Rear end door balancer 8. Cap 1. Rear end door panel assembly 5. Rear end door trim 9. Clip 2. Rear...

  • Page 1363

    Hood / fenders / doors: 9j-7 rear end door assembly removal and installation s6rw0c9a06010 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. Removal 1) remove rear end door trim (1). 2) rem...

  • Page 1364

    9j-8 hood / fenders / doors: • adjust door latch striker position by referring to “rear end door lock assembly removal and installation in section 9f”. • adjust door cushion so that door contacts body when closed. • apply sealant to contact face “a” of door hinge (1) and apply grease to rotating par...

  • Page 1365: Body Structure

    Body structure: 9k-1 body, cab and accessories body structure repair instructions front bumper and rear bumper components s6rw0c9b06001 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 (i...

  • Page 1366

    9k-2 body structure: cowl top and front lower crossmember components s6rw0c9b06002 4. Front bumper upper member 8. Rear bumper i7rw019b0002-01 1. Cowl top garnish 3. Hood rear seal 5. Damper : 55 n ⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Cowl top panel 4. Front lower crossmember 6. Damper bracket : 25 n ⋅m (2...

  • Page 1367

    Body structure: 9k-3 specifications body dimensions s6rw0c9b07001 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 1368

    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 1369

    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 1370

    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 1371

    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 1372

    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 1373

    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 1374

    9k-10 body structure: panel clearance s6rw0c9b07002 panel to panel distance tightening torque specifications s6rw0c9b07003 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 1375: Paint / Coatings

    Paint / coatings: 9l-1 body, cab and accessories paint / coatings general description anti-corrosion treatment construction s6rw0c9c01001 warning ! Standard shop practices, particularly eye protection, should be followed during the performance of the following operations to avoid personal injury. As...

  • Page 1376

    9l-2 paint / coatings: 5) polypropylene must raise no readily distinguishable smoke while burning. Component location sealant application areas s6rw0c9c03001 i7rw019c0007-01.

  • Page 1377

    Paint / coatings: 9l-3 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 1378

    9l-4 paint / coatings: 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 1379

    Paint / coatings: 9l-5 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 1380

    9l-6 paint / coatings: 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 1381

    Paint / coatings: 9l-7 i5rw0c9c0005-01 “a”: apply sealant. 1. Hole.

  • Page 1382

    9l-8 paint / coatings: i5rw0c9c0006-01 “a”: apply sealant covering flange end..

  • Page 1383

    Paint / coatings: 9l-9 under coating application areas s6rw0c9c03002 i6rw0c9c0005-02 [a]: lh side “c”: do not apply undercoating. [b]: rh side “d”: apply under coating after panting black color..

  • Page 1384

    9l-10 paint / coatings: [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 1385

    Paint / coatings: 9l-11 anti-corrosion compound application area s6rw0c9c03003 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 1386

    9l-12 paint / coatings: i5rw0a9c0010-01 “a”: apply rust proof wax (hot wax 50 µm or more). “b”: never fill up drain holes with rust proof wax..

  • Page 1387: Exterior Trim

    Exterior trim: 9m-1 body, cab and accessories exterior trim repair instructions roof molding removal and installation s6rw0c9d06001 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 1388

    9m-2 exterior trim: splash guard removal and installation (if equipped) s6rw0c9d06002 specifications tightening torque specifications s6rw0c9d07001 note the specified tightening torque is also described in the following. “roof molding removal and installation” reference: for the tightening torque of...

  • Page 1389: Section 10

    Table of contents 10- i 10 section 10 contents control systems precautions ...............................................10-1 precautions........................................................... 10-1 precautions for control systems......................... 10-1 cruise control system.................

  • Page 1390

    10-ii table of contents precaution in replacing ecm ...........................10c-1 precaution in replacing ignition key ................10c-1 precautions in handling immobilizer control system ............................................................10c-1 general description ......................

  • Page 1391: Precautions

    Precautions: 10-1 control systems precautions precautions precautions for control systems s6rw0ca000001 air bag warning refer to “air bag warning in section 00”. Precaution on can troubleshooting refer to “precaution on can troubleshooting in section 1a”..

  • Page 1392: Cruise Control System

    10a-1 cruise control system: control systems cruise control system general description cruise control system construction s6rw0ca101001 the cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.G., on a highway. It allows the driver to drive his ve...

  • Page 1393

    Cruise control system: 10a-2 components and functions of cruise control system s6rw0ca101002 component function ecm and electric throttle body ecm executes centralized control over all functions including setting a constant speed, resuming it, setting coast, cancelling cruise control limiting minimu...

  • Page 1394

    10a-3 cruise control system: cancel conditions of cruise control system s6rw0ca101003 constant cruising is cancelled under the following conditions. • ignition switch is turned off. • main (on/off) switch is turned off. • *vehicle speed becomes lower than minimum operating speed (40 km/h (25 mile/h)...

  • Page 1395

    Cruise control system: 10a-4 schematic and routing diagram cruise control system wiring diagram s6rw0ca102001 ig1 ig1 +bb +bb e01-56 5v 5v 5v 5v 12v 12v brn blu e01-6 e01-8 e01-7 e01-22 e01-21 e01-20 c01-58 c01-15 c01-29 c01-41 c01-40 c01-54 c01-53 c01-44 c01-45 e01-16 e01-60 e01-29 e01-1 c01-48 e01...

  • Page 1396

    10a-5 cruise control system: diagnostic information and procedures cruise control system symptom diagnosis s6rw0ca104001 note • ecm uses tcm, combination meter, abs control module and can communication to transmit and receive data for cruise control. Therefore, check that no dtc is detected from ecm...

  • Page 1397

    Cruise control system: 10a-6 inspection of cruise control system circuit s6rw0ca104002 cruise control system is controlled by ecm. Each switch and circuit can be checked by taking measurement of terminal voltage and terminal to terminal resistance of ecm. When measuring these values, be sure to read...

  • Page 1398

    10a-7 cruise control system: repair instructions cruise control switch removal and installation s6rw0ca106001 for removal and installation, refer to “remote audio control switch removal and installation (if equipped) in section 9c”. Cruise control switch inspection s6rw0ca106002 note never disassemb...

  • Page 1399

    Cruise control system: 10a-8 installation 1) install cpp switch (for cruise control) (2) to pedal bracket. 2) with clutch pedal (1) released, adjust switch position so that clearance between end of thread and clutch pedal bracket is within specification. Clearance between end of thread and clutch pe...

  • Page 1400

    10b-1 body electrical control system: control systems body electrical control system precautions precautions in diagnosing trouble s6rw0ca200001 • 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 1401

    Body electrical control system: 10b-2 bcm reception data theft deterrent light s6rw0ca201003 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 1402

    10b-3 body electrical control system: 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 blk/red g271-7 on door off +b +b ig1 wht l312-5 12v lt gr...

  • Page 1403

    Body electrical control system: 10b-4 1. Bcm (included in junction block) 21. Brake fluid level switch 41. Door lock actuator relay (if equipped) 2. Rear end door opener actuator (if equipped) 22. Parking brake switch 42. Driver side door lock actuator (if equipped) 3. Rear end door opener relay (if...

  • Page 1404

    10b-5 body electrical control system: connector layout diagram of bcm and junction block s6rw0ca202002 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 1405

    Body electrical control system: 10b-6 component location bcm and related system component location s6rw0ca203001 13 12 17 18 21 19 14 24 25 25 26 27 22 23 22 24 7 6 20 11 4 5 1 15 16 15 16 [a] [b] 2 9 10 3 8 i6rw0ca20005-01 [a]: auto a/c 9. Rear end door opener switch (if equipped) 19. Lighting swit...

  • Page 1406

    10b-7 body electrical control system: diagnostic information and procedures bcm self-diagnosis function s6rw0ca204001 • 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 1407

    Body electrical control system: 10b-8 body electrical control system check s6rw0ca204002 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 1408

    10b-9 body electrical control system: 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 1409

    Body electrical control system: 10b-10 scan tool data s6rw0ca204003 scan tool data definitions vehicle speed (km/h, mph): this parameter indicates the vehicle speed computed by ecm. Outside air temp ( °c, °f): it is detected by outside air temperature sensor. Battery voltage (v): this parameter indi...

  • Page 1410

    10b-11 body electrical control system: fuel consumption (km/l): this parameter indicates the fuel consumption computed by ecm. Key reminder sw (key reminder switch) (pulled / key in): this parameter indicates the state of the key reminder switch. Rear wiper sw (rear wiper switch) (on / int / off): t...

  • Page 1411

    Body electrical control system: 10b-12 dtc table s6rw0ca204004 dtc check s6rw0ca204005 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 s...

  • Page 1412

    10b-13 body electrical control system: without using suzuki scan tool 1) turn ignition switch to off position. 2) perform following steps a) to d) within 10 seconds after ignition switch is turned on and engine stops. A) turn headlight switch to “small” position. B) turn headlight switch to “off” po...

  • Page 1413

    Body electrical control system: 10b-14 bcm power circuit and ground circuit check s6rw0ca204007 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 1414

    10b-15 body electrical control system: dtc b1133 (dtc no. 1133): battery voltage too high s6rw0ca204008 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 1415

    Body electrical control system: 10b-16 dtc b1141 / dtc b1142 (no. 1141 / no. 1142) outside air temperature (ambient temp.) sensor circuit malfunction s6rw0ca204009 wiring diagram dtc detecting condition and possible cause flow test description step 1: check whether malfunction is in outside air temp...

  • Page 1416

    10b-17 body electrical control system: dtc b1150 (no. 1150): air bag communication circuit malfunction s6rw0ca204010 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 1417

    Body electrical control system: 10b-18 dtc b1157 (no. 1157) air bag deployment signal input s6rw0ca204011 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 1418

    10b-19 body electrical control system: inspection of bcm and its circuits s6rw0ca204017 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 1419

    Body electrical control system: 10b-20 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 1420

    10b-21 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 1421

    Body electrical control system: 10b-22 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 1422

    10b-23 body electrical control system: junction block connector “l314” junction block connector “l315” reference waveform no. 1 parking brake or brake fluid level switch signal (1) reference waveform no. 2 driver seat belt switch signal (1) terminal circuit normal voltage condition l314-4 ground for...

  • Page 1423

    Body electrical control system: 10b-24 reference waveform no. 3 can communication signal reference waveform no. 4 oil pressure switch signal (1) reference waveform no. 5 information display and hvac control module serial communication signal (1) reference waveform no. 6 keyless entry receiver signal...

  • Page 1424

    10b-25 body electrical control system: reference waveform no. 7 vehicle speed pulse output signal (1) reference waveform no. 8 a/c or rear end door window defogger switch signal (1) reference waveform no. 9 rear wiper switch signal (1) reference waveform no. 10 sdm communication signal (1) measureme...

  • Page 1425

    Body electrical control system: 10b-26 repair instructions bcm (included in junction block) removal and installation s6rw0ca206001 caution ! Do not attempt removal of bcm from junction block as it may cause contact failure. If there is faulty condition in bcm, replace junction block assembly. Remova...

  • Page 1426: Immobilizer Control System

    10c-1 immobilizer control system: control systems immobilizer control system precautions precautions in diagnosing troubles s6rw0ca300001 • 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 1427

    Immobilizer control system: 10c-2 • 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 1428

    10c-3 immobilizer control system: schematic and routing diagram immobilizer control system wiring circuit diagram s6rw0ca302001 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 1429

    Immobilizer control system: 10c-4 component location immobilizer control system components location s6rw0ca303001 diagnostic information and procedures immobilizer control system check s6rw0ca304001 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 1430

    10c-5 immobilizer control system: dtc check s6rw0ca304002 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 1431

    Immobilizer control system: 10c-6 dtc table s6rw0ca304004 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 1432

    10c-7 immobilizer control system: scan tool data s6rw0ca304005 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 1433

    Immobilizer control system: 10c-8 immobilizer indicator light does not come on with ignition switch on and engine stop s6rw0ca304006 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 1434

    10c-9 immobilizer control system: immobilizer indicator light remains on after engine start s6rw0ca304007 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 1435

    Immobilizer control system: 10c-10 dtc p1615: steering lock unit communication error s6rw0ca304009 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 1436

    10c-11 immobilizer control system: dtc p1616: unregistered keyless start control module s6rw0ca304010 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 1437

    Immobilizer control system: 10c-12 dtc p1621: immobilizer communication line error s6rw0ca304012 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Detecting condition and trouble area troubleshooting detecting condition trouble area communication error between icm and ecm....

  • Page 1438

    10c-13 immobilizer control system: dtc p1622: eeprom reading / writing error s6rw0ca304013 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 1439

    Immobilizer control system: 10c-14 troubleshooting dtc p1636: immobilizer information registration failure s6rw0ca304016 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Detecting condition and trouble area troubleshooting step action yes no 1 was “immobilizer control sys...

  • Page 1440

    10c-15 immobilizer control system: dtc p1638: immobilizer information mismatched s6rw0ca304017 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Detecting condition and trouble area troubleshooting 5 replacement of bcm 1) replace bcm with new one referring to “bcm (include...

  • Page 1441

    Immobilizer control system: 10c-16 inspection of icm and its circuit s6rw0ca304018 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 1442

    10c-17 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 1443

    Immobilizer control system: 10c-18 repair instructions icm removal and installation s6rw0ca306001 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 1444

    10c-19 immobilizer control system: special tools and equipment special tool s6rw0ca308001 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 1445: Keyless Start System

    Keyless start system: 10e-1 control systems keyless start system general description keyless start system description s6rw0ca501001 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 1446

    10e-2 keyless start system: parts and functions s6rw0ca501002 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 1447

    Keyless start system: 10e-3 keyless engine start function s6rw0ca501003 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 1448

    10e-4 keyless start system: door lock function of keyless start system s6rw0ca501004 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 1449

    Keyless start system: 10e-5 however, even when the remote controller is within the operation area as shown above, there are cases where the keyless start system doesn’t work under certain conditions as described below. And when the keyless engine start function doesn’t work, the key indicator light ...

  • Page 1450

    10e-6 keyless start system: alarm function s6rw0ca501006 under conditions as described in the table below, the keyless start control module makes the key indicator light flash in red and the buzzer sound to call the driver’s attention. Can communication system description s6rw0ca501007 refer to “can...

  • Page 1451

    Keyless start system: 10e-7 schematic and routing diagram keyless start system electric wiring circuit diagram s6rw0ca502001 diagnostic information and procedures precautions in diagnosing troubles s6rw0ca504001 • the keyless start system executes data transmission/ reception by means of the radio w...

  • Page 1452

    10e-8 keyless start system: • communication of ecm, tcm (a/t model), bcm, abs control module, 4wd control module (if equipped), keyless start control module and combination meter is established by can (controller area network). (for detail of can communication for keyless start control module, refer...

  • Page 1453

    Keyless start system: 10e-9 customer questionnaire (example) s6rw0ca504005 5 1) confirm if the problem is solved and the keyless start system is free from any abnormal conditions. If what has been repaired is related to the dtc, clear the dtc once and then confirm that no dtc is indicated. Is there ...

  • Page 1454

    10e-10 keyless start system: key indicator light check s6rw0ca504006 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 to “key indicator light circuit check (key indic...

  • Page 1455

    Keyless start system: 10e-11 6) read flashing pattern of key indicator light (1) which represents dtc as shown in example below and write it down. When more than 2 dtcs are stored in memory, flashing for each dtc is repeated three times starting with the smallest dtc number in increasing order. Note...

  • Page 1456

    10e-12 keyless start system: dtc clearance s6rw0ca504009 1) perform steps 1) through 5) of dtc check procedure and have dtc indicated. 2) open driver side door. 3) close driver side door and within 10 seconds after that, perform steps a) to c) described below. A) push unlock side (3) of driver side ...

  • Page 1457

    Keyless start system: 10e-13 keyless engine start function note before performing symptom diagnosis procedure for keyless engine start system, check that engine starts by using ignition key. If it cannot be started by using ignition key, go to “engine symptom diagnosis in section 1a”. Keyless start ...

  • Page 1458

    10e-14 keyless start system: door lock operation (keyless start system) s6rw0ca504012 1) check that all door locks are released and all doors are closed. 2) with remote controller of which id code is registered in keyless start control module carried with yourself, check that pushing driver door req...

  • Page 1459

    Keyless start system: 10e-15 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 31 30 29 24 23 37 18 19 20 [a] i5rw0aa50008-03 [a]: keyless start control module connector (viewed from harness side) terminal number circuit normal voltage condition g16-1 driver side door antenna (–) *0 – 5 v refer to “refer...

  • Page 1460

    10e-16 keyless start system: 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) g16-29 signal for steering lock unit 4 – 6 v ignition knob switch is at any position other t...

  • Page 1461

    Keyless start system: 10e-17 reference waveform no. 2 center antenna signal (request signal (1) transmitted by center antenna when each door request switch is pushed) reference waveform no. 3 luggage room antenna signal (request signal (1) transmitted by luggage room antenna when each door request s...

  • Page 1462

    10e-18 keyless start system: reference waveform no. 6 driver and passenger side door lock switch signals. (this signal indicates door lock status.) in case the position of driver and passenger side door lock is changed from the unlock to the lock. In case the position of passenger side door lock is ...

  • Page 1463

    Keyless start system: 10e-19 in case the position of driver and passenger side door lock is changed from the lock to the unlock. No dtc detection after performing dtc check s6rw0ca504014 wiring diagram description the keyless start control module detects dtc by using signals from the key reminder an...

  • Page 1464

    10e-20 keyless start system: troubleshooting step action yes no 1 combination meter power and ground circuit check 1) turn ignition switch to on position. Do warning lights in combination meter other than key indicator light light up? Go to step 2. Check main fuse, circuit fuse, combination meter po...

  • Page 1465

    Keyless start system: 10e-21 key indicator light circuit check (key indicator light doesn’t light when ignition knob switch is pushed) s6rw0ca504015 wiring diagram description when the ignition knob switch is pushed, the key indicator light lights up in blue if you carry the remote controller regist...

  • Page 1466

    10e-22 keyless start system: keyless start control module power and ground circuit check s6rw0ca504016 wiring diagram troubleshooting 4 wire harness check 1) turn ignition switch to off position. 2) disconnect connectors from keyless start control module, steering lock unit and combination meter. 3)...

  • Page 1467

    Keyless start system: 10e-23 dtc no. 11: communication error with steering lock unit s6rw0ca504017 wiring diagram 2 power supply circuit check 1) disconnect connector from keyless start control module. 2) check for proper connection to “power source”, “acc signal” and “ig on signal” terminal of keyl...

  • Page 1468

    10e-24 keyless start system: dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance”. 2) turn ignition knob switch pushing ignition knob switch. 3) check dtc referring to “dtc check”. Dtc troubleshooting dtc detecting condition trouble area no co...

  • Page 1469

    Keyless start system: 10e-25 dtc no. 13 / no. 14: release signal error from steering lock unit / steering lock unit malfunction s6rw0ca504018 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 1470

    10e-26 keyless start system: dtc no. 51 / no. 52 / no. 53: driver side / passenger side / rear end door request switch failure s6rw0ca504022 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance”. 2) push request switch of each do...

  • Page 1471

    Keyless start system: 10e-27 repair instructions antennas and request switches removal and installation s6rw0ca506001 remove and install antennas and request switches referring to the following figures. 3 wire harness check 1) disconnect connector from keyless start control module. 2) check for open...

  • Page 1472

    10e-28 keyless start system: front door (driver and passenger side), rear end door request switch inspection s6rw0ca506002 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 1473

    Keyless start system: 10e-29 keyless start control module removal and installation s6rw0ca506006 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 1474

    10e-30 keyless start system: 5) install printed circuit board and rubber switch to upper case and then fit lower case securely. Note • to prevent theft, be sure to break the remote controller before discarding it. • dispose of the used battery properly according to applicable rules or regulations. D...

  • Page 1475

    Keyless start system: 10e-31 note when 60 seconds elapse after engine is started, the above process to enter registration mode will be cancelled. Therefore, be sure to proceed to the next step within 60 seconds. 5) turn ignition switch to off position. When ignition switch is turned to off position,...

  • Page 1476

    Prepared by 1st ed. Feb., 2007.

  • Page 1477: Service Manual

    31.0 mm 99 50 0- 80 j0 0- 01 e s e r v ic e m a n u a l vol. 1 of 2 99500-80j00-01e service manual volume 1 of 2 rw420

  • Page 1478: Service Manual

    28.0 mm 99 50 0- 80 j0 0- 01 e s e r v ic e m a n u a l vol. 2 of 2 99500-80j00-01e service manual volume 2 of 2 rw420