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  5. Supplementary Service Manual

Suzuki Liana RH418 Supplementary Service Manual

Summary of Liana RH418

  • 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 2: Foreword

    Foreword this supplementary service manual is a supplement to liana (rh413/rh416) service manual. It has been prepared exclusively for the following applicable model. Applicable model: liana (rh418) vehicles on and after the following vehicle identification numbers (vins). This supplementary service...

  • Page 3: Table of Contents

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

  • Page 5: Section 0

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

  • Page 6: General Information

    0a-1 general information: general information general description transmission identification number s3rh0b0101008 the automatic transmission identification number is located on transmission case. I3rh01010004-01.

  • Page 7: Maintenance and Lubrication

    Maintenance and lubrication: 0b-1 maintenance and lubrication repair instructions automatic transaxle fluid inspection s3rh0b0206030 1) inspect transaxle case for evidence of fluid leakage. Repair leaky point, if any. 2) make sure that vehicle is placed level for fluid level check. 3) pull out dipst...

  • Page 8

    0b-2 maintenance and lubrication: transfer oil (4wd a/t) and rear differential oil (4wd) inspection s3rh0b0206033 1) check transfer case or differential for evidence of oil leakage. Repair leaky point if any. 2) make sure that vehicle is placed level for oil level check. 3) remove level plug of tran...

  • Page 9: 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 10

    1-ii table of contents radiator fan control system check.................1a-99 radiator fan control circuit check ................1a-101 power steering pressure (psp) switch signal circuit check.................................................1a-104 generator control signal circuit check ..........1...

  • Page 11

    Table of contents 1-iii pistons, piston rings and connecting rods components....................................................1d-45 pistons, piston rings and connecting rods removal and installation.................................1d-46 pistons, piston rings, connecting rods and cylinders disassem...

  • Page 12

    1-iv table of contents fuel tank inlet valve inspection ......................... 1g-* fuel pump on-vehicle inspection....................... 1g-* fuel pump assembly components..................... 1g-* fuel pump assembly removal and installation.........................................................

  • Page 13: Precautions

    Precautions: 1-1 precautions precautions precautions for engine s3rh0b1000001 air bag warning refer to “air bag warning in section 00 in related manual”. Precautions on engine service refer to “precautions on engine service in section 1a”. Precautions in diagnosing trouble refer to “precautions in d...

  • Page 14

    1a-1 engine general information and diagnosis: engine general information and diagnosis precautions precautions on engine service s3rh0b1100001 caution ! The following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reliable en...

  • Page 15

    Engine general information and diagnosis: 1a-2 general description statement on cleanliness and care s3rh0b1101001 an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch...

  • Page 16

    1a-3 engine general information and diagnosis: note when a trouble occurs in the above areas and disappears soon while the diagnosis switch terminal is ungrounded and the engine is running, malfunction indicator lamp (1) lights and remains on as long as the trouble exists but it turns off when the n...

  • Page 17

    Engine general information and diagnosis: 1a-4 air intake system description s3rh0b1101005 the main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air control valve (4) and intake manifold (5). The air (by the amount corresponding to man...

  • Page 18

    1a-5 engine general information and diagnosis: engine and emission control system flow diagram ev ap canister purge va lv e air cleaner ia t sensor fuel t ank fuel pump tp sensor ia c va lv e thr o ttle bod y map sensor int ake manifold exha ust manifold exha ust gas air fuel v apor three-w a y ca t...

  • Page 19

    Engine general information and diagnosis: 1a-6 ecm input / output circuit diagram blk c41-13 17 1 5v 12v 2 +b 1 6 5 ig1 c41-9 c41-11 c41-23 c41-22 c41-16 c41-26 c41-14 c41-15 c41-10 c41-25 c41-13 c41-7 g04-14 c41-10 g03-13 c41-21 c41-31 c41-8 c41-6 c41-4 c41-24 g04-18 g04-3 g04-10 g04-6 g04-5 c41-30...

  • Page 20

    1a-7 engine general information and diagnosis: terminal arrangement of ecm coupler (viewed from harness side) 1. Ckp sensor 21. A/c compressor relay 41. Ignition coil assembly (for no.1 and no.4 spark plugs) 2. Cmp sensor 22. A/c compressor magnet clutch 42. Ignition coil assembly (for no.2 and no.3...

  • Page 21

    Engine general information and diagnosis: 1a-8 connector: c41 connector: g04 connector: g03 terminal wire color circuit terminal wire color circuit 1 blk/orn ground 17 — — 2 blk ground 18 — — 3 blk ground 19 grn/wht ignition coil no.2 4 blu/blk evap canister purge valve 20 grn/yel ignition coil no.1...

  • Page 22

    1a-9 engine general information and diagnosis: engine and emission control input / output table s3rh0b1101007 input output electric control device diagnosis switch barometric pressure sensor stop lamp switch start switch ignition switch lighting switch rear defogger switch blower switch a/c switch (...

  • Page 23

    Engine general information and diagnosis: 1a-10 schematic and routing diagram engine and emission control system diagram s3rh0b1102001 10 9 7 14 13 11 15 12 2 6 5 1 3 25 42 26 20 27 40 33 32 16 17 18 41 34 24 23 21 31 22 30 29-1 29-2 29-3 33 28 39 38 36 4 35 37 19 8 gen i3rh0b110003-01 1. Air cleane...

  • Page 24

    1a-11 engine general information and diagnosis: 3. Iat sensor 18. Vss 30. Stop lamp 4. Tp sensor 19. Power steering pressure switch (if equipped) 31. Stop lamp switch 5. Iac valve 20. Radiator fan 32. Ecm 6. Map sensor 21. Malfunction indicator lamp in combination meter 33. Barometric pressure senso...

  • Page 25

    Engine general information and diagnosis: 1a-12 component location electronic control system components location s3rh0b1103001 12 5 8 i g i c h b h 7 4 a* d* g* j f* c e* k e 11* k* 10 9 13 1 2 f b 6 3 a d j i3rh0b110004-01 information sensors control devices others 1. Map sensor a: fuel injector a:...

  • Page 26

    1a-13 engine general information and diagnosis: diagnostic information and procedures engine and emission control system check s3rh0b1104001 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 27

    Engine general information and diagnosis: 1a-14 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 28

    1a-15 engine general information and diagnosis: step 2: dtc(s) check, record and clearance first, check dtc (including pending dtc), referring to “dtc check”. If dtc is indicated, print or write it down and then clear it by referring to “dtc clearance”. Dtc indicates malfunction that occurred in the...

  • Page 29

    Engine general information and diagnosis: 1a-16 2) with ignition switch off, connect it 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 on and confirm that mil lights. 4) read dtc and pending ...

  • Page 30

    1a-17 engine general information and diagnosis: dtc table s3rh0b1104005 note • for parenthetic no. In dtc column, dtc which is displayed by flashing malfunction indicator lamp. • dtc no.12 appears when none of the other codes is identified. Dtc no. Detecting item detecting condition (dtc will set wh...

  • Page 31

    Engine general information and diagnosis: 1a-18 fail-safe table s3rh0b1104006 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. Trouble area fail-safe operati...

  • Page 32

    1a-19 engine general information and diagnosis: scan tool data s3rh0b1104007 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 33

    Engine general information and diagnosis: 1a-20 ) vvt (camshaft position) gap (target- actual position) at specified idle speed after warning up 0 – 3 ° ) tp sensor volt (throttle position sensor output voltage) ignition switch on / engine stopped throttle valve fully closed 0.5 – 1.0 v throttle val...

  • Page 34

    1a-21 engine general information and diagnosis: scan tool data definitions fuel system (fuel system status) air / fuel ratio feedback loop status displayed as either open or closed loop. Open indicates that ecm ignores feedback from the exhaust oxygen sensor. Closed indicates final injection duratio...

  • Page 35

    Engine general information and diagnosis: 1a-22 vvt (camshaft position) gap [target-actual position] ( °) it is calculated using the formula: target valve timing advance – actual valve timing advance. Tp sensor volt (throttle position sensor output voltage, v) the throttle position sensor reading pr...

  • Page 36

    1a-23 engine general information and diagnosis: visual inspection s3rh0b1104008 visually check the following parts and systems. Engine basic inspection s3rh0b1104009 this check is very important for troubleshooting when ecm has detected no dtc and no abnormality has been found in visual inspection. ...

  • Page 37

    Engine general information and diagnosis: 1a-24 5 check idle speed as follows: 1) warm up engine to normal operating temp. 2) shift transmission to neutral position for m/t (“p” position for a/t). 3) all of electrical loads are switched off. 4) check engine idle speed with scan tool. Is it 610 – 710...

  • Page 38

    1a-25 engine general information and diagnosis: 8 check ignition timing as follows: 1) select “misc” mode on suzuki scan tool and fix ignition timing to initial one. 2) using timing light, check initial ignition timing. Is it 5 °± 3 ° btdc at specified idle speed? Go to “engine symptom diagnosis”. C...

  • Page 39

    Engine general information and diagnosis: 1a-26 13 check ignition spark as follows: 1) disconnect injector couplers. 2) remove spark plugs and connect them to high tension cords. 3) ground spark plugs. 4) crank engine and check if each spark plug sparks. Is it in good condition? Go to step 14. Go to...

  • Page 40

    1a-27 engine general information and diagnosis: engine symptom diagnosis s3rh0b1104010 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 41

    Engine general information and diagnosis: 1a-28 engine noise – valve noise note before checking mechanical noise, make sure that: • specified spark plug is used. • specified fuel is used. Improper valve lash “camshaft, tappet and shim inspection in section 1d” worn valve stem and guide “valves and v...

  • Page 42

    1a-29 engine general information and diagnosis: engine overheating inoperative thermostat “thermostat inspection in section 1f in related manual” poor water pump performance “water pump inspection in section 1f in related manual” clogged or leaky radiator “radiator on-vehicle inspection and cleaning...

  • Page 43

    Engine general information and diagnosis: 1a-30 poor gasoline mileage leaks or loose connection of high- tension cord “high-tension cord inspection in section 1h in related manual” faulty spark plug (improper gap, heavy deposits and burned electrodes, etc.) “spark plug inspection in section 1h in re...

  • Page 44

    1a-31 engine general information and diagnosis: excessive engine oil consumption – oil entering combustion chamber sticky piston ring “cylinders, pistons and piston rings inspection in section 1d” worn piston and cylinder “cylinders, pistons and piston rings inspection in section 1d” worn piston rin...

  • Page 45

    Engine general information and diagnosis: 1a-32 surge – engine power variation under steady throttle or cruise. Feels like vehicle speeds up and down with no change in accelerator pedal. Leaky or loosely connected high-tension cord “high-tension cord inspection in section 1h in related manual” fault...

  • Page 46

    1a-33 engine general information and diagnosis: engine has no power faulty spark plug “spark plug inspection in section 1h in related manual” faulty ignition coil with ignitor “ignition coil assembly (including igniter) inspection in section 1h in related manual” leaks, loose connection or disconnec...

  • Page 47

    Engine general information and diagnosis: 1a-34 improper engine idling or engine fails to idle faulty spark plug “spark plug inspection in section 1h in related manual” leaky or disconnected high-tension cord “high-tension cord inspection in section 1h in related manual” faulty ignition coil with ig...

  • Page 48

    1a-35 engine general information and diagnosis: excessive hydrocarbon (hc) emission or carbon monoxide (co) faulty spark plug “spark plug inspection in section 1h in related manual” leaky or disconnected high-tension cord “high-tension cord inspection in section 1h in related manual” faulty ignition...

  • Page 49

    Engine general information and diagnosis: 1a-36 malfunction indicator lamp does not come on at ignition switch on (but engine at stop) s3rh0b1104011 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 bei...

  • Page 50

    1a-37 engine general information and diagnosis: troubleshooting step action yes no 1 mil power supply check 1) turn ignition switch to on position. Do other warning lights come on? Go to step 4. Go to step 2. 2 meter fuse check 1) turn ignition switch to off position. 2) check for fuse blow at “mete...

  • Page 51

    Engine general information and diagnosis: 1a-38 malfunction indicator lamp remains on after engine starts s3rh0b1104012 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 being supplied with the main pow...

  • Page 52

    1a-39 engine general information and diagnosis: mil flashes at ignition switch on s3rh0b1104013 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 being supplied with the main power, turns on the malfunc...

  • Page 53

    Engine general information and diagnosis: 1a-40 mil does not flash or just remains on even with grounding diagnosis switch terminal s3rh0b1104014 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 being ...

  • Page 54

    1a-41 engine general information and diagnosis: mil does not light at ignition switch on and engine does not start through it is cranked up s3rh0b1104015 wiring diagram circuit description when the ignition switch turned on, the main relay turns on (the contact point closes) and the main power is su...

  • Page 55

    Engine general information and diagnosis: 1a-42 troubleshooting step action yes no 1 fuse check 1) check for fuse blow at “ig” fuse and “fi” fuse (1). Are fuses in good condition? Go to step 2. Replace fuse and check for short in circuits connected to this fuse. 2 main relay circuit check 1) turn ig...

  • Page 56

    1a-43 engine general information and diagnosis: 5 main relay circuit check 1) turn ignition switch to off position. 2) install main relay to main fuse box. 3) measure voltage between “g04-10” wire terminal of ecm connector and body ground. Is voltage 10 – 14 v? Go to step 6. Go to step 8. 6 main rel...

  • Page 57

    Engine general information and diagnosis: 1a-44 dtc p0011 (no. 32) / p0012 (no. 32): camshaft position-timing over-advanced or system performance / timing over-retarded s3rh0b1104055 wiring diagram description actual value of advanced valve timing does not reach target value. Valve timing is advance...

  • Page 58

    1a-45 engine general information and diagnosis: dtc confirmation procedure 1) clear dtc. Refer to “dtc clearance”. 2) start engine and drive vehicle under usual driving condition for 5 minutes or longer until engine is warmed up to normal operating temperature. 3) stop vehicle. 4) run engine at idle...

  • Page 59

    Engine general information and diagnosis: 1a-46 note upon completion of inspection and repair work, perform “dtc confirmation procedure” and confirm that the trouble has been corrected. Dtc p0105 (no. 11): manifold absolute pressure (map) circuit malfunction s3rh0b1104016 wiring diagram dtc detectin...

  • Page 60

    1a-47 engine general information and diagnosis: dtc confirmation procedure 1) clear dtc, start engine and keep it at idle for 1 min. 2) select “dtc” mode on scan tool and check dtc. Dtc troubleshooting note when battery voltage is applied to “gry/red” wire, it is possible that map sensor is also fau...

  • Page 61

    Engine general information and diagnosis: 1a-48 dtc p0110 (no. 18): intake air temp. (iat) circuit malfunction s3rh0b1104017 wiring diagram dtc detecting condition and possible cause note • when dtc p0105 (no. 11), p0110 (no. 18), p0115 (no. 19) and p0120 (no. 13) are indicated together, it is possi...

  • Page 62

    1a-49 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 check iat sensor and its circuit 1) connect scan tool to dlc with ignition switch off. ...

  • Page 63

    Engine general information and diagnosis: 1a-50 dtc p0115 (no. 19): engine coolant temp. (ect) circuit malfunction s3rh0b1104018 wiring diagram dtc detecting condition and possible cause note • before inspecting, be sure to check that coolant temp. Meter in combination meter indicates normal operati...

  • Page 64

    1a-51 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 check ect sensor and its circuit 1) connect scan tool with ignition switch off. 2) turn...

  • Page 65

    Engine general information and diagnosis: 1a-52 dtc p0120 (no. 13): throttle position circuit malfunction s3rh0b1104019 wiring diagram dtc detecting condition and possible cause note • when dtc p0105 (no. 11), p0110 (no. 18), p0115 (no. 19) and p0120 (no. 13) are indicated together, it is possible t...

  • Page 66

    1a-53 engine general information and diagnosis: 2 check tp sensor and its circuit 1) connect scan tool to dlc with ignition switch off and then turn ignition switch on. 2) check throttle valve opening percentage displayed on scan tool. 3) check throttle valve opening percentage displayed on scan too...

  • Page 67

    Engine general information and diagnosis: 1a-54 dtc p0130 (no. 14): heated oxygen sensor (ho2s) circuit malfunction (sensor-1) s3rh0b1104021 wiring diagram dtc detecting condition and possible cause dtc confirmation procedure warning ! • when performing a road test, select a place where there is no ...

  • Page 68

    1a-55 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 ho2s-1 (dtc p0130)? Go to applicable dtc diag. Flow. Go to s...

  • Page 69

    Engine general information and diagnosis: 1a-56 dtc p0135 (no. 14): heated oxygen sensor (ho2s) heater circuit malfunction (sensor-1) s3rh0b1104024 wiring diagram dtc detecting condition and possible cause dtc confirmation procedure warning ! • when performing a road test, select a place where there...

  • Page 70

    1a-57 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 check heater for operation 1) check voltage at terminal “c41-7”. 2) warm up engine to n...

  • Page 71

    Engine general information and diagnosis: 1a-58 dtc p0325 (no. 17): knock sensor circuit malfunction s3rh0b1104029 wiring diagram dtc detecting condition and possible cause dtc confirmation procedure 1) clear dtc, start engine and keep it at idle for 1 min. 2) select “dtc” mode on scan tool and chec...

  • Page 72

    1a-59 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 check knock sensor signal 1) with engine running, check voltage from “c41-25” terminal ...

  • Page 73

    Engine general information and diagnosis: 1a-60 dtc p0335 (no. 23): crankshaft position (ckp) sensor circuit malfunction s3rh0b1104030 wiring diagram dtc detecting condition and possible cause reference connect oscilloscope between terminals “c41-23” of ecm connector connected to ecm and ground and ...

  • Page 74

    1a-61 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 check ckp sensor and connector for proper installation is ckp sensor installed properly...

  • Page 75

    Engine general information and diagnosis: 1a-62 6 check ckp sensor for operation 1) remove ckp sensor from cylinder block. 2) remove metal particles on end face of ckp sensor, if any. 3) connect each connector to ecm and ckp sensor. 4) turn ignition switch on. 5) check for voltage at terminal “c41-2...

  • Page 76

    1a-63 engine general information and diagnosis: dtc p0340 (no. 15): camshaft position (cmp) sensor circuit malfunction s3rh0b1104031 wiring diagram dtc detecting condition and possible cause reference connect oscilloscope between terminals “c41-11” of ecm connector connected to ecm and body ground a...

  • Page 77

    Engine general information and diagnosis: 1a-64 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 check cmp sensor and connector for proper installation is cmp sensor installed properly...

  • Page 78

    1a-65 engine general information and diagnosis: 6 check cmp sensor for operation 1) remove cmp sensor from timing chain cover. 2) remove metal particles on end face of cmp sensor, if any. 3) connect each connector to ecm and cmp sensor. 4) turn ignition switch on. 5) check for voltage at terminal “c...

  • Page 79

    Engine general information and diagnosis: 1a-66 dtc p0500 (no. 16): vehicle speed sensor (vss) malfunction s3rh0b1104036 wiring diagram dtc detecting condition and possible cause dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibili...

  • Page 80

    1a-67 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 vehicle equipped a/t? Go to step 10. Go to step 3. 3 does speedometer indicate vehic...

  • Page 81

    Engine general information and diagnosis: 1a-68 7 check vss signal circuit 1) measure voltage from terminal “a” of vss connector to ground. Is voltage more than 4 v? Go to step 8. “ppl” wire open or short. Poor connection of ecm connector terminal. If ok, substitute a known-good ecm and recheck. 8 c...

  • Page 82

    1a-69 engine general information and diagnosis: 12 check vehicle speed signal circuit 1) turn ignition switch off position. 2) disconnect connector from tcm. 3) turn ignition switch to on position, without running engine. 4) measure voltage from terminal “ppl” wire of tcm connector to ground. Is vol...

  • Page 83

    Engine general information and diagnosis: 1a-70 dtc p0601: internal control module memory check sum error s3rh0b1104038 system description internal control module is installed in ecm. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch...

  • Page 84

    1a-71 engine general information and diagnosis: dtc p1915 (no. 33): oil control valve circuit s3rh0b1104056 wiring diagram circuit description actual valve timing fails to become close to target advance level of each function although advance control function or retarded advance control function is ...

  • Page 85

    Engine general information and diagnosis: 1a-72 troubleshooting inspection of ecm and its circuits s3rh0b1104044 ecm and its circuits can be checked at ecm wiring couplers by measuring voltage, pulse signal and resistance. Caution ! Ecm cannot be checked by itself. It is strictly prohibited to conne...

  • Page 86

    1a-73 engine general information and diagnosis: voltage check 1) remove ecm (1) from vehicle body referring to “engine control module (ecm) removal and installation in section 1c in related manual”. 2) check voltage and/or pulse signal at each terminal of couplers (2) connected, using voltmeter (3) ...

  • Page 87

    Engine general information and diagnosis: 1a-74 terminal no. Circuit normal voltage condition c41-1 ground below 0.3 v ignition switch turned on c41-2 ground below 0.3 v ignition switch turned on c41-3 ground below 0.3 v ignition switch turned on c41-4 evap canister purge valve 10 – 14 v ignition sw...

  • Page 88

    1a-75 engine general information and diagnosis: c41-18 — — — c41-19 ignition coil no.2 0 – 1 v ignition switch turned on *0 – 0.6 v ↑↓ 4 – 6 v (reference waveform no.6) engine running. (output signal is active high pulse. Pulse frequency varies depending on engine speed.) c41-20 ignition coil no.1 0...

  • Page 89

    Engine general information and diagnosis: 1a-76 g04-5 power source 10 – 14 v ignition switch on g04-6 power source 10 – 14 v ignition switch on g04-7 a/c pressure switch (if equipped) 0 – 1 v a/c refrigerant pressure below 1500 kpa, 15 kg/ cm 2 , 23 psi. 10 – 14 v a/c refrigerant pressure 1500 kpa, ...

  • Page 90

    1a-77 engine general information and diagnosis: terminal no. Circuit normal voltage condition g03-1 tachometer 0 – 1 v ignition switch on *0 – 1 v ↑↓ 8 – 14 v (reference waveform no.19 and no.20) while engine running. Output signal is pulse. (pulse frequency varies depending on engine speed. (3000 r...

  • Page 91

    Engine general information and diagnosis: 1a-78 1. Reference waveform no.1 oil control valve signal at ignition switch on 2. Reference waveform no.2 oil control valve signal at vehicle driving 3. Reference waveform no.3 heated oxygen sensor-1 signal at engine idling 4. Reference waveform no.4 heated...

  • Page 92

    1a-79 engine general information and diagnosis: 5. Reference waveform no.5 iac valve signal 6. Reference waveform no.6 ignition coil no.2 and no.3 signal at engine idling 7. Reference waveform no.7 ignition coil no.1 and no.4 signal at engine idling 8. Reference waveform no.8 fuel injector signal at...

  • Page 93

    Engine general information and diagnosis: 1a-80 9. Reference waveform no.9 no.4 fuel injector signal at engine idling 10. Reference waveform no.10 no.3 fuel injector signal at engine idling 11. Reference waveform no.11 no.2 fuel injector signal at engine idling 12. Reference waveform no.12 no.1 fuel...

  • Page 94

    1a-81 engine general information and diagnosis: 13. Reference waveform no.13 knock sensor signal at engine speed 4000 r/min. 14. Reference waveform no.14 knock sensor signal at engine speed 4000 r/min. 15. Reference waveform no.15 cmp sensor signal at engine idling 16. Reference waveform no.16 manif...

  • Page 95

    Engine general information and diagnosis: 1a-82 17. Reference waveform no.17 manifold absolute pressure sensor signal at engine racing 18. Reference waveform no.18 vss signal at 30 km/h (19 mil/h) 19. Reference waveform no.19 tachometer (ignition pulse) signal at engine idling 20. Reference waveform...

  • Page 96

    1a-83 engine general information and diagnosis: 21. Reference waveform no.21 engine coolant temperature signal at engine idling 22. Reference waveform no.22 evap canister purge valve signal 23. Reference waveform no.23 ignition coil signal and fuel injector signal at engine cranking 24. Reference wa...

  • Page 97

    Engine general information and diagnosis: 1a-84 resistance check 1) disconnect ecm couplers (1) from ecm with ignition switch off. Caution ! Never touch terminals of ecm itself or connect voltmeter or ohmmeter (2). 2) check resistance between each pair of terminals of disconnected couplers as listed...

  • Page 98

    1a-85 engine general information and diagnosis: fuel injector circuit check s3rh0b1104045 wiring diagram troubleshooting ecm 1 2 3 4 +b c41-9 c41-21 c41-8 c41-31 blu/yel blu/wht blu/red blu/grn blk/red c41 (31p) g04 (24p) g03 (17p) 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...

  • Page 99

    Engine general information and diagnosis: 1a-86 fuel pump and its circuit check s3rh0b1104046 wiring diagram troubleshooting caution ! Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ecm, wire harness, etc. +b m brn pnk blk blk/red blk/red c...

  • Page 100

    1a-87 engine general information and diagnosis: 2 check fuel pump for operation 1) remove fuel pump relay from relay box with ignition switch turned off. 2) check for proper connection to fuel pump relay at each terminals. 3) if it is ok, using service wire (1), connect terminals “blk/red” wire and ...

  • Page 101

    Engine general information and diagnosis: 1a-88 fuel pressure check s3rh0b1104047 system diagram special tool (a): 09912–58442 (b): 09912–58432 (c): 09912–58490 troubleshooting i2rh0b110082-01 1. Injector 3. Fuel pressure regulator 2. Delivery pipe 4. Fuel pump step action yes no 1 check fuel pressu...

  • Page 102

    1a-89 engine general information and diagnosis: idle air control system check s3rh0b1104048 system / wiring diagram 8 with fuel pump operated and fuel return hose blocked by pinching it, is fuel pressure applied? Faulty fuel pressure regulator. Shortage of fuel or fuel pump or its circuit malfunctio...

  • Page 103

    Engine general information and diagnosis: 1a-90 troubleshooting step action yes no 1 engine idle speed and iac duty check 1) check idle speed / idle air control duty referring to “idle speed / idle air control (iac) duty inspection”. Is idle speed within specification? Go to step 2. Go to step 4. 2 ...

  • Page 104

    1a-91 engine general information and diagnosis: 10 check pnp signal (“d” range signal) 1) connect suzuki scan tool to dlc with ignition switch off. 2) turn ignition switch on and check pnp signal (“p/n” and “d” range) on display when shifting selector lever to each range. Pnp signal “p” and “n” rang...

  • Page 105

    Engine general information and diagnosis: 1a-92 idle air control circuit check s3rh0b1104057 system / wiring diagram dtc troubleshooting c41 (31p) g04 (24p) g03 (17p) 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 28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16...

  • Page 106

    1a-93 engine general information and diagnosis: throttle valve opening signal inspection s3rh0b1104049 check throttle valve opening (throttle position) signal referring to step 3 to 5 of “dtc p1700 (no.32 / no.33): throttle position signal input malfunction in section 5a”. If check result is not sat...

  • Page 107

    Engine general information and diagnosis: 1a-94 troubleshooting warning ! Keep hands, tools, and clothing away from a/c condenser 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 sen...

  • Page 108

    1a-95 engine general information and diagnosis: 4 check a/c condenser fan control relay and its circuit 1) check voltage at terminal “g04-9” under each condition given as follows. Voltage at terminal “g04-9” ignition switch on, a/c switch off: 10 – 14 v ignition switch on, a/c switch on and blower m...

  • Page 109

    Engine general information and diagnosis: 1a-96 6 check a/c condenser fan 1) turn ignition switch off. 2) disconnect a/c condenser fan motor connector (1). 3) check for proper connection to motor at “red/blu” and “blk” terminals. 4) if ok, connect battery to motor and check for operation. Is it in g...

  • Page 110

    1a-97 engine general information and diagnosis: 9 check a/c compressor control relay 1) turn ignition switch off and remove a/c compressor control relay (1). 2) check for proper connection to relay at terminals “c” and “d”. 3) if ok, check that there is continuity between “c” and “d” when battery is...

  • Page 111

    Engine general information and diagnosis: 1a-98 electric load signal circuit check s3rh0b1104051 wiring diagram troubleshooting ig2 m ecm blu/blk g03-10 c41 (31p) g04 (24p) g03 (17p) 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 28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 1...

  • Page 112

    1a-99 engine general information and diagnosis: radiator fan control system check s3rh0b1104052 wiring diagram 3 check electric load signal circuit 1) turn ignition switch on. 2) check voltage at each terminals “g04-17” and “g03-10” of ecm connector connected, under above each condition. Voltage at ...

  • Page 113

    Engine general information and diagnosis: 1a-100 troubleshooting step action yes no 1 is there dtc(s) ect sensor circuit (dtc p0115)? Go to corresponding dtc flow. Go to step 2. 2 check low speed radiator fan control circuit 1) connect scan tool to dlc with ignition switch off. 2) start engine and s...

  • Page 114

    1a-101 engine general information and diagnosis: radiator fan control circuit check s3rh0b1104058 wiring diagram 9 check radiator fan control no.3 1) connect radiator fan control relay no.3 to relay box with ignition switch turn off. 2) run engine until ect is over 102 °c, 216 °f. 3) measure resista...

  • Page 115

    Engine general information and diagnosis: 1a-102 step action yes no 1 check wire circuit 1) disconnect radiator fan control relay no.1 (1) from relay box with ignition switch turned off. 2) turn on ignition switch, measure voltage between each engine ground to “blk/wht” and “blu/wht” wire terminal. ...

  • Page 116

    1a-103 engine general information and diagnosis: 5 check radiator fan control relay no.1 1) check radiator fan control relay no.1, referring to “radiator fan relay no.1, no.2 and no.3 inspection in section 1c in related manual”. Is result in good condition? “brn” wire open circuit. Replace relay. 6 ...

  • Page 117

    Engine general information and diagnosis: 1a-104 power steering pressure (psp) switch signal circuit check s3rh0b1104053 wiring diagram 11 check wire circuit 1) turn on ignition switch. 2) check voltage between “g04-3” terminal wire and vehicle body ground. Is voltage 0 v? Go to step 12. “grn/red” w...

  • Page 118

    1a-105 engine general information and diagnosis: troubleshooting step action yes no 1 do you have suzuki scan tool? Go to step 2. Go to step 3. 2 psp switch signal circuit check 1) connect suzuki scan tool to dlc with ignition switch off. 2) start engine and select “data list” mode on scan tool. 3) ...

  • Page 119

    Engine general information and diagnosis: 1a-106 generator control signal circuit check s3rh0b1104054 wiring diagram circuit description ecm sends signal (0 – 1 v) to generator terminal c to suspend charging during vehicle take off or fast acceleration. Troubleshooting ecm red/blu 12v c41 (31p) g04 ...

  • Page 120

    1a-107 engine general information and diagnosis: repair instructions idle speed / idle air control (iac) duty inspection s3rh0b1106001 before idle speed / iac duty check, make sure of the following. • lead wires and hoses of electronic fuel injection and engine and emission control systems are conne...

  • Page 121

    Engine general information and diagnosis: 1a-108 2) warm up engine to normal operating temperature. 3) check engine idle speed and iac duty as follows: a) when using suzuki scan tool: i) select “data list” mode on scan tool to check iac duty. B) when without using suzuki scan tool: note iac duty can...

  • Page 122

    1a-109 engine general information and diagnosis: special tools and equipment special tool s3rh0b1108001 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 123

    Aux. Emission control devices: 1b-1 aux. Emission control devices repair instructions vacuum passage inspection s3rh0b1206005 start engine and run it at idle speed. Disconnect vacuum hose (1) from evap canister purge valve (2). With finger placed against hose disconnected, check that vacuum is appli...

  • Page 124: Engine Electrical Devices

    1c-1 engine electrical devices: engine electrical devices repair instructions idle air control (iac) valve removal and installation s3rh0b1306001 removal 1) remove throttle body from intake manifold referring to “throttle body removal and installation in section 1d”. 2) remove lac valve from throttl...

  • Page 125

    Engine electrical devices: 1c-2 oil control valve removal and installation s3rh0b1306020 removal remove oil gallery pipe no.1 (1) and oil control valve (2) from timing chain cover (3). Installation 1) install new o-ring (4) to oil control valve. 2) install oil control valve to timing chain cover. Ti...

  • Page 126

    1c-3 engine electrical devices: oxygen sensor heater inspection s3rh0b1306012 1) disconnect sensor connector. 2) using ohmmeter, measure resistance between terminals “v b ” and “gnd” of sensor connector. If found faulty, replace oxygen sensor. Note temperature of sensor affects resistance value larg...

  • Page 127: Engine Mechanical

    Engine mechanical: 1d-1 engine mechanical general description engine construction description s3rh0b1401001 the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration consisting of 1...

  • Page 128

    1d-2 engine mechanical: variable valve timing (vvt) system description s3rh0b1401002 system description the vvt system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce...

  • Page 129

    Engine mechanical: 1d-3 oil control valve the oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ecm. By this operation, the intake valve timing is varied continuously. Sig...

  • Page 130

    1d-4 engine mechanical: timing retarding when the duty ratio of the signal output from the ecm is light, the spool valve of the oil control valve moves to the right (head for the coil). By this spool valve movement, the pressurized oil is led into the chambers for timing retarding and the oil in the...

  • Page 131

    Engine mechanical: 1d-5 diagnostic information and procedures compression check s3rh0b1404001 check compression pressure on all 4 cylinders as follows: 1) warm up engine to normal operating temperature. 2) stop engine after warming up. Note after warming up engine, place transaxle gear shift lever i...

  • Page 132

    1d-6 engine mechanical: 11) carry out steps 8) through 10) on each cylinder to obtain 4 readings. 12) after checking, install spark plugs and ignition coil assembles (1) with high-tension cord (2). 13) connect ignition coil couplers (3). 14) connect fuel injector wires (4) at the coupler. 15) instal...

  • Page 133

    Engine mechanical: 1d-7 valve lash (clearance) inspection s3rh0b1404003 1) remove negative cable at battery. 2) remove cylinder head cover referring to “cylinder head cover removal and installation”. 3) remove right side engine under cover, if necessary. 4) using 17 mm wrench, turn crankshaft pulley...

  • Page 134

    1d-8 engine mechanical: replacement of shim 1) close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut section (1) faces inside as shown in the figure. 2) lift down the valve by turning crankshaft to 360 ° 3) hold tappet at that position using specia...

  • Page 135

    Engine mechanical: 1d-9 5) using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table. Shim thickness specification intake side: a = b + c – 0.20 mm (0.008 in.) exhaust side: a = ...

  • Page 136

    1d-10 engine mechanical: repair instructions air cleaner element removal and installation s3rh0b1406001 removal 1) disconnect air cleaner outlet no.1 hose (1) from air cleaner case (2). 2) open air cleaner case by unhooking its clamps. 3) remove air cleaner element from case. Installation reverse re...

  • Page 137

    Engine mechanical: 1d-11 throttle body components s3rh0b1406004 throttle body on-vehicle inspection s3rh0b1406005 check that throttle valve lever (1) moves smoothly. Throttle body removal and installation s3rh0b1406006 removal 1) disconnect negative cable at battery. 2) drain cooling system referrin...

  • Page 138

    1d-12 engine mechanical: installation 1) clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket. 2) connect engine coolant hoses. 3) install throttle body to intake manifold. 4) connect connector to tp sensor (1) and iac valve (2) securely. 5) connect accelerator c...

  • Page 139

    Engine mechanical: 1d-13 throttle body and intake manifold components s3rh0b1406009 i3rh0b140015-01 1. Intake manifold 7. Evap canister purge valve 13. Intake manifold mounting bolt (short) 19. Cushion 2. Intake manifold gasket 8. Tp sensor 14. Intake manifold mounting bolt (long) 20. Fuel delivery ...

  • Page 140

    1d-14 engine mechanical: throttle body and intake manifold removal and installation s3rh0b1406010 removal 1) relieve fuel pressure according to “fuel pressure relief procedure in section 1g in related manual”. 2) disconnect negative cable at battery. 3) drain coolant referring to “cooling system flu...

  • Page 141

    Engine mechanical: 1d-15 installation reverse removal procedure for installation noting the followings. • use new intake manifold gasket and egr pipe gasket (if equipped). • tighten bolts (1) and nuts (2) to specified torque. Tightening torque intake manifold bolt and nut (a): 25 n·m (2.5 kgf- m, 18...

  • Page 142

    1d-16 engine mechanical: installation 1) install new spark plug hole gaskets (1) and new cylinder head cover gasket (2) to cylinder head cover (3) as shown in the figure. 2) remove oil, old sealant and dust from sealing surface on cylinder head and cover. After cleaning, apply sealant “a” to the fol...

  • Page 143

    Engine mechanical: 1d-17 engine mountings components s3rh0b1406012 i3rh0b140017-01 [a]: a/t model 3. Engine left mounting 7. Engine front torque bush [b]: m/t model 4. Engine left mounting bracket no.1 8. Mounting member 1. Engine right mounting 5. Engine left mounting bracket no.2 9. Suspension fra...

  • Page 144

    1d-18 engine mechanical: engine assembly removal and installation s3rh0b1406013 removal 1) relieve fuel pressure according to “fuel pressure relief procedure in section 1g in related manual”. 2) disconnect negative and positive cable at battery. 3) remove engine hood after disconnecting windshield w...

  • Page 145

    Engine mechanical: 1d-19 14) disconnect the following hoses: 15) remove suspension frame (1) with stabilizer bar and suspension control arms referring to “front suspension frame removal and installation in section 2b in related manual”. 16) remove exhaust no.1 and no.2 pipes referring to “exhaust pi...

  • Page 146

    1d-20 engine mechanical: installation 1) install clutch cover and clutch disk referring to “clutch cover, clutch disc and flywheel removal and installation in section 5c in related manual”. 2) connect transaxle to engine referring to “manual transaxle unit dismounting and remounting in section 5b in...

  • Page 147

    Engine mechanical: 1d-21 18) check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled. 19) refill cooling system with coolant referring to “cooling system flush and refill in section 1f in related manual”. 20) refill engine with engine o...

  • Page 148

    1d-22 engine mechanical: timing chain cover removal and installation s3rh0b1406015 removal 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. 1) ...

  • Page 149

    Engine mechanical: 1d-23 installation 1) install oil seal (1) to timing chain cover, if removed. Note when installing new oil seal (1), press fit to timing chain cover (2) by using special tool (bearing installer) as shown in the figure. Special tool (a): 09913–75810 oil seal installation depth “a”:...

  • Page 150

    1d-24 engine mechanical: 8) install cap (3) to timing chain cover (1). Tighten bolts to specified torque. Tightening torque cap bolt (c): 25 n·m (2.5 kgf-m, 18.0 lb-ft) 9) install new o-ring (1) to oil gallery pipes no.2 (2) and no.3 (3). 10) install oil gallery pipes no.2 and no.3 to cylinder head ...

  • Page 151

    Engine mechanical: 1d-25 oil control valve inspect strainer (1) and mating surface (2) of oil control valve. Clean oil control valve. Oil gallery pipe inspect oil gallery pipes no.1 (1), no.2 (2) and no.3 (3). Replace if crack, deformation or clog exists. Timing chain and chain tensioner components ...

  • Page 152

    1d-26 engine mechanical: timing chain and chain tensioner removal and installation s3rh0b1406018 removal 1) remove timing chain cover referring to “timing chain cover removal and installation”. 2) by turing crankshaft, align both intake and exhaust camshaft timing sprocket marks (1) with notches (2)...

  • Page 153

    Engine mechanical: 1d-27 3) install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft timing sprocket as shown in the figure. 4) fit crankshaft timing sprocket to timing chain by aligning gold plate (3) of timing chain and circle mark (4) on crankshaft ti...

  • Page 154

    1d-28 engine mechanical: 8) screw in plunger (1) by turning timing chain tensioner adjuster (2) in arrow direction and install a retainer (3) (wire) to hold plunger in place. 9) install timing chain tensioner adjuster assembly (1) with a retainer (2). Tighten adjuster bolts to specified torque and t...

  • Page 155

    Engine mechanical: 1d-29 timing chain and chain tensioner inspection s3rh0b1406019 timing chain no.1 guide check shoe (1) for wear or damage. Timing chain tensioner check shoe (1) for wear or damage. Crankshaft timing sprocket check teeth of sprocket for wear or damage. Timing chain check timing cha...

  • Page 156

    1d-30 engine mechanical: camshaft, tappet and shim components s3rh0b1406020 camshaft, tappet and shim removal and installation s3rh0b1406021 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 ...

  • Page 157

    Engine mechanical: 1d-31 4) loosen camshaft housing bolts in such order as indicated in the figure and remove them. 5) remove camshaft housings. 6) remove intake and exhaust camshafts. 7) remove camshaft bearing (1). 8) remove tappets (2) with shims (1). Installation 1) install tappets and shims to ...

  • Page 158

    1d-32 engine mechanical: 4) apply engine oil to sliding surface of each camshaft and camshaft journal then install them as shown in figure. 5) install camshaft housing pins (1) as shown in the figure. 6) check position of camshaft housings. Embossed marks are provided on each camshaft housing, indic...

  • Page 159

    Engine mechanical: 1d-33 camshaft, tappet and shim inspection s3rh0b1406022 intake cam timing sprocket assembly fit intake cam timing sprocket assembly to camshaft (2) and hold hexagonal section of camshaft by using spanner or the like. Check if sprocket (1) is not turned by hand. If moved, replace ...

  • Page 160

    1d-34 engine mechanical: 6) tighten camshaft housing bolts in such order as indicated in the figure a little at a time till they are tightened to specified torque. Note do not rotate camshaft while gauging plastic is installed. Tightening torque camshaft housing bolt (a): tighten 11 n ⋅m (1.1 kgf-m,...

  • Page 161

    Engine mechanical: 1d-35 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 cylinde...

  • Page 162

    1d-36 engine mechanical: valves and cylinder head components s3rh0b1406023 i3rh0b140044-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt for m8 : tighten 25 n ⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified procedure. 2. Valve spring retainer 8. Valve guide : tightening torque 3. Valve spring...

  • Page 163

    Engine mechanical: 1d-37 valves and cylinder head removal and installation s3rh0b1406024 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2) remove intake manifold rear stiffener (1). 3) remove oil pan referring to “oil pan and oil pump strainer...

  • Page 164

    1d-38 engine mechanical: 5) install cylinder head to cylinder block. Apply engine oil to cylinder head bolts and tighten them gradually as follows. A) tighten cylinder head bolts (“1” – “10”) to 20 n ⋅m (2.0 kgf-m, 14.5 lb-ft) according to numerical order as shown by using a 12 corner socket wrenche...

  • Page 165

    Engine mechanical: 1d-39 valves and cylinder head disassembly and assembly s3rh0b1406025 disassembly 1) for ease in servicing cylinder head, remove intake manifold, injectors and exhaust manifold from cylinder head. 2) using special tools (valve lifter), compress valve spring and then remove valve c...

  • Page 166

    1d-40 engine mechanical: assembly 1) before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as to remove burrs and make it truly round. Special tool (a): 09916–34542 (b): 09916–37320 2) install valve guide to cylinder head. Heat cylinder head uniforml...

  • Page 167

    Engine mechanical: 1d-41 6) install valve to valve guide. Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem. 7) install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Be...

  • Page 168

    1d-42 engine mechanical: if bore gauge is not available, check end deflection of valve stem with a dial gauge instead. Move stem end in directions (1) and (2) to measure end deflection. If deflection exceeds its limit, replace valve stem and valve guide. Valve stem end deflection limit in: 0.14 mm (...

  • Page 169

    Engine mechanical: 1d-43 • seating contact width: create contact pattern on each valve in the usual manner, i.E., by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used. Pattern produced on seati...

  • Page 170

    1d-44 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 171

    Engine mechanical: 1d-45 • 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: 1.6 mm (0.063 i...

  • Page 172

    1d-46 engine mechanical: pistons, piston rings and connecting rods removal and installation s3rh0b1406030 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2) remove cylinder head referring to “valves and cylinder head removal and installation”. ...

  • Page 173

    Engine mechanical: 1d-47 5) install bearing cap (1) as follows a) point arrow mark (2) on cap to crankshaft pulley side. Tighten connecting rod bearing cap nut to specified procedure as follows. I) tighten all cap nuts to 15 n ⋅m (1.5 kgf-m, 11.0 lb-ft). Ii) retighten them to 45 ° iii) repeat step i...

  • Page 174

    1d-48 engine mechanical: 2) install piston rings to piston: • as indicated in the figure, 1st and 2nd rings have “t” mark respectively. When installing these piston rings to piston, direct marked side of each ring toward top of piston. • 1st ring (1) differs from 2nd ring (2) in thickness, shape and...

  • Page 175

    Engine mechanical: 1d-49 pistons • inspect piston for faults, cracks or damage. Damaged or faulty piston should be replaced. • piston diameter: as indicated in the figure, piston diameter should be measured at a position “a” from piston skirt end in the direction perpendicular to piston pin. Piston ...

  • Page 176

    1d-50 engine mechanical: piston rings to measure end gap, insert piston ring (1) into cylinder bore and then measure the gap by using thickness gauge (2). If measured gap is out of specification, replace ring. Note decarbonize and clean top of cylinder bore before inserting piston ring. Piston ring ...

  • Page 177

    Engine mechanical: 1d-51 • connecting rod alignment: mount connecting rod on aligner to check it for bow and twist. If limit is exceeded, replace it. Connecting rod alignment limit on bow: 0.05 mm (0.0020 in.) limit on twist: 0.10 mm (0.0039 in.) crank pin and connecting rod bearings inspection s3rh...

  • Page 178

    1d-52 engine mechanical: connecting rod bearing general information service connecting rod bearings are available in standard size and 0.25 mm (0.0098 in.) undersize bearing. For identification of undersize bearing, it is painted red at the position as indicated in the figure, undersize bearing thic...

  • Page 179

    Engine mechanical: 1d-53 selection of connecting rod bearings note • if bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. • when replacing crankshaft or connecting rod and its bearing due to an...

  • Page 180

    1d-54 engine mechanical: 3) there are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing. Standard size of connecting rod b...

  • Page 181

    Engine mechanical: 1d-55 main bearings, crankshaft and cylinder block components s3rh0b1406035 i3rh0b140048-01 [a]: sealant application amount 7. Crankshaft timing sprocket key 16. Rear oil seal housing mounting bolt “a”: 3 mm (0.12 in.) 8. Crankshaft 17. Main bearing mounting no.2 bolt : tighten 25...

  • Page 182

    1d-56 engine mechanical: main bearings, crankshaft and cylinder block removal and installation s3rh0b1406036 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2) remove clutch cover, clutch disc and flywheel (drive plate for a/t) by using special...

  • Page 183

    Engine mechanical: 1d-57 installation caution ! • use new bearing cap no.1 bolts. If they are reused, check thread diameters of bearing cap no.1 bolt for deformation according to previous mentioned “bearing cap bolt” under “main bearings inspection”, check and replace them with new ones if thread di...

  • Page 184

    1d-58 engine mechanical: d) tighten bolts (11) – (20) to 25 n ⋅m (2.5 kgf-m, 18.0 lb-ft) according to numerical order as shown. Tightening torque crankshaft bearing cap no.1 bolt (1) – (10): tighten 30 n ⋅m (3.0 kgf-m, 22.0 lb-ft), 50 n⋅m (5.0 kgf-m, 36.5 lb-ft) and 60 ° by the specified procedure c...

  • Page 185

    Engine mechanical: 1d-59 10) install pistons and connecting rods. Refer to “pistons, piston rings and connecting rods removal and installation”. 11) install cylinder head assembly to cylinder. Refer to “valves and cylinder head removal and installation”. 12) install camshafts, tappets and shims refe...

  • Page 186

    1d-60 engine mechanical: use a dial gauge to read displacement in axial (thrust) direction of crankshaft. If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard thrust play. Crankshaft thrust play standard: 0.11 – 0.31 mm (0.0044 – 0.0122 in.) limit...

  • Page 187

    Engine mechanical: 1d-61 4) tighten bearing cap no.1 bolts (1) – (10) and no.2 bolts (11) – (20) gradually as follows. A) tighten bolts (1) – (10) to 30 n ⋅m (3.0 kgf-m, 22.0 lb-ft) according to numerical order in the figure. B) in the same manner as in step a), tighten them to 50 n ⋅m (5.0 kgf-m, 3...

  • Page 188

    1d-62 engine mechanical: selection of main bearings standard bearing if bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. 1) first check journal diameter. As shown in the figure, crank web no.2...

  • Page 189

    Engine mechanical: 1d-63 3) there are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in the figure. Each color indicated the following thickness at the center of bearing. Standard size of crankshaft main...

  • Page 190

    1d-64 engine mechanical: • if necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. A. Regrind journal to the following finished diameter. Finished journal diameter 51.7320 – 51.7500 mm (2.0367 – 2.0374 in.) b. Using micrometer, measure reground journal diamet...

  • Page 191

    Engine mechanical: 1d-65 rear oil seal inspection s3rh0b1406040 carefully inspect oil seal (1) for wear or damage. If its lip is worn or damaged, replace it. For oil seal installation, press-fit rear oil seal (1) to oil seal housing (2) by using special tool as shown in the figure. Special tool (a):...

  • Page 192

    1d-66 engine mechanical: specifications tightening torque specifications s3rh0b1407001 note the specified tightening torque is also described in the following. “throttle body components” “throttle body and intake manifold components” “engine mountings components” “timing chain cover components” “tim...

  • Page 193

    Engine mechanical: 1d-67 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a in related manual”. Special tools and equipment recommended service material s3rh0b1408001 note required service material is also described in the fo...

  • Page 194

    1d-68 engine mechanical: 09916–14910 09916–34542 valve spring compressor attachment reamer handle ) / ) ) / ) 09916–34550 09916–37320 reamer handle valve guide outer reamer (10.5 mm) ) ) 09916–44910 09916–56011 valve guide installer & remover valve guide installer attachment (protrusion: 11.5 mm) ) ...

  • Page 195: Engine Lubrication System

    Engine lubrication system: 1e-1 engine lubrication system general description engine lubrication description s3rh0b1501001 the oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil ...

  • Page 196

    1e-2 engine lubrication system: repair instructions oil pan and oil pump strainer components s3rh0b1506001 oil pan and oil pump strainer removal and installation s3rh0b1506002 removal 1) remove oil level gauge. 2) remove exhaust no.1 pipe and exhaust manifold stiffener referring to “exhaust pipe rem...

  • Page 197

    Engine lubrication system: 1e-3 8) remove oil pump strainer (1) from cylinder block. Installation 1) apply sealant to oil pan mating surface continuously as shown in the figure. “a”: water tight sealant 99000–31250 sealant amount for oil pan width “a”: 3 mm (0.12 in.) height “b”: 2 mm (0.08 in.) 2) ...

  • Page 198

    1e-4 engine lubrication system: oil pump components s3rh0b1506004 oil pump disassembly and assembly s3rh0b1506006 disassembly 1) remove rotor plate (1) by removing its mounting bolts. 2) remove outer rotor (1) and inner rotor (2). 3) remove relief valve (1), spring (2) and retainer (3) by removing c...

  • Page 199

    Engine lubrication system: 1e-5 assembly 1) wash, clean and then dry all disassembled parts. 2) apply thin coat of engine oil to inner and outer rotors, oil seal lip portion and inside surfaces of oil pump case. 3) install outer (1) and inner rotors (2) to oil pump case. 4) apply engine oil to relie...

  • Page 200

    1e-6 engine lubrication system: specifications tightening torque specifications s3rh0b1507001 note the specified tightening torque is also described in the following. “oil pan and oil pump strainer components” “oil pump components” reference: for the tightening torque of fastener not specified in th...

  • Page 201: Fuel System

    Fuel system: 1g-1 fuel system repair instructions fuel pipe removal and installation s3rh0b1706005 warning ! Before servicing fuel system, be sure to observe “precautions on fuel system service in related manual”. Removal 1) relieve fuel pressure in fuel feed line according to “fuel pressure relief ...

  • Page 202

    1g-2 fuel system: fuel injector removal and installation s3rh0b1706007 warning ! Before servicing fuel system, be sure to observe “precautions on fuel system service in related manual”. Removal caution ! A small amount of fuel may come out after removal of fuel injectors, cover them with shop cloth....

  • Page 203

    Fuel system: 1g-3 fuel injector inspection s3rh0b1706008 warning ! • before servicing fuel system, be sure to observe “precautions on fuel system service in related manual”. • as fuel is injected in this inspection, perform in a well ventilated area and away from open flames. Use special care to pre...

  • Page 204

    1g-4 fuel system: 7) apply battery voltage to injector (2) for 15 seconds and measure injected fuel volume with graduated cylinder. Test each injector two or three times. If not within specification, replace injector. Injected fuel volume 56 – 60 cc/15 sec. (1.90/1.98 – 2.02/2.11 us/lmp oz/15 sec.) ...

  • Page 205

    Fuel system: 1g-5 installation for installation, reverse removal procedure and note the following precautions. • use new o-ring (1). • apply thin coat of gasoline to o-ring to facilitate installation. • tighten fuel pressure regulator bolts to specified torque. Tightening torque fuel pressure regula...

  • Page 206

    1g-6 fuel system: 8) disconnect fuel filler hose (1) and breather hose (2) from filler neck (3). Caution ! Never disconnect fuel filler hose (1) from fuel tank inlet. If half or more of fuel is remaining to fuel tank, fuel over flows in this case and come out. 9) due to absence of fuel tank drain pl...

  • Page 207

    Fuel system: 1g-7 installation 1) if parts have been removed from fuel tank, install them before installing fuel tank to vehicle. 2) raise fuel tank (1) with jack and connect fuel pump connector and ground wire harness and clamp wire harness. 3) install fuel tank to vehicle. Tightening torque fuel t...

  • Page 208

    1g-8 fuel system: specifications tightening torque specifications s3rh0b1707001 note the specified tightening torque is also described in the following. “fuel system components in related manual” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners info...

  • Page 209: Section 3

    Table of contents 3- i 3 section 3 contents driveline / axle drive shaft / axle ..................................... 3a-1 general description ............................................. 3a-* front drive shaft construction.............................3a-* diagnostic information and procedures........

  • Page 210: Drive Shaft / Axle

    3a-1 drive shaft / axle: drive shaft / axle repair instructions front drive shaft components s3rh0b3106001 i3rh0b311009-02 [a]: tripod joint type 10. Damper.

  • Page 211

    Drive shaft / axle: 3a-2 front drive shaft assembly removal and installation s3rh0b3106003 removal 1) undo caulking (“a”) and remove drive shaft nut (1) and washer. 2) hoist vehicle. 3) remove wheel. 4) remove engine undercovers. 5) drain transaxle oil referring to “manual transaxle oil change in se...

  • Page 212

    3a-3 drive shaft / axle: 10) disconnect front suspension control arm ball stud (1) from steering knuckle (2) after removing ball stud bolt (3) and nut. 11) remove drive shaft assembly. Caution ! To prevent damage of boots, be careful not to bring them into contact with other parts, when removing dri...

  • Page 213

    Drive shaft / axle: 3a-4 front drive shaft disassembly and assembly s3rh0b3106004 disassembly for tripod joint type 1) remove differential side boot big band, and then take out joint housing (1). 2) wipe off grease from shaft and take off snap ring (1) using special tool. Special tool (a): 09900-061...

  • Page 214

    3a-5 drive shaft / axle: 2) slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out of outer race (3). 3) wipe off grease and remove circlip (1) used to fix cage (2) using special tool. Special tool (a): 09900-06107 4) draw away cage (1) using bear...

  • Page 215

    Drive shaft / axle: 3a-6 2) remove o-ring from center shaft. (for m/t model) 3) remove oil seals from center bearing support, if equipped. 4) remove circlip (1) using special tool. Special tool (a): 09900-06108 5) remove center bearing from center bearing support. Assembly for tripod joint type judg...

  • Page 216

    3a-7 drive shaft / axle: 4) fasten wheel side boot small band using special tool. Note • boot small band must not come out of its installed position. • be sure to fasten boot small band securely until complete contact “a” is obtained. Special tool (a): 09943–57010 5) apply grease to wheel side joint...

  • Page 217

    Drive shaft / axle: 3a-8 12) apply grease to inside of tripod joint housing (1), joint it with tripod joint and fit boot (2) to tripod joint housing. After fitting boot, insert screwdriver into boot on tripod joint housing side and allow air to enter boot so that air pressure in boot at the joint po...

  • Page 218

    3a-9 drive shaft / axle: 1) install new wheel side boot big band and small band in the same manner as step 1) to 8) of tripod joint type. 2) install damper (1) on left drive shaft according to dimension specified as follows. Drive shaft damper installing position (distance “a” between reference posi...

  • Page 219

    Drive shaft / axle: 3a-10 6) apply grease to entire surface of cage. Use specified grease in tube included in spare parts. 7) insert cage into joint housing (2) and fit snap ring (1) into groove of joint housing (2). Caution ! Position opening of snap ring “c” so that it will not be lined up with a ...

  • Page 220

    3a-11 drive shaft / axle: for center shaft install center shaft by reversing the removal procedure and noting the following points. For m/t model • when installing circlip (1), make sure that if fits in circlip groove in center bearing support (2) securely as shown. • press-fit center shaft (1) from...

  • Page 221

    Drive shaft / axle: 3a-12 specifications tightening torque specifications s3rh0b3107001 note the specified tightening torque is also described in the following. “front drive shaft components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners informat...

  • Page 222

    3a-13 drive shaft / axle:.

  • Page 223: 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 224

    5-ii table of contents input shaft speed sensor removal and installation.......................................................5a-70 input shaft speed sensor inspection................5a-70 transmission fluid temperature sensor inspection........................................................5a-70 ...

  • Page 225

    Table of contents 5-iii clutch ........................................................5c-* general description ............................................. 5c-* clutch construction............................................. 5c-* diagnostic information and procedures............ 5c-* clutch syste...

  • Page 226: Precautions

    5-1 precautions: precautions precautions precautions on transmission / transaxle s3rh0b5000001 air bag warning refer to “air bag warning in section 00 in related manual”. Precautions in diagnosing trouble refer to “precautions in diagnosing trouble in section 5a”. Precautions for disassembly and rea...

  • Page 227

    Automatic transmission/transaxle: 5a-1 automatic transmission/transaxle precautions precautions in diagnosing trouble s3rh0b5100002 • don’t disconnect couplers from tcm and/or ecm, battery cable from battery, tcm and/or ecm ground wire harness from engine or main fuse before checking the diagnosis i...

  • Page 228

    5a-2 automatic transmission/transaxle: general description a/t description s3rh0b5101001 this automatic transaxle is a full automatic type with 3-speed plus overdrive (o/d). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up mechani...

  • Page 229

    Automatic transmission/transaxle: 5a-3 i2rh01510002-01 1. Torque converter clutch (tcc) 9. One-way clutch no.0 17. Parking lock gear 2. 2nd and 4th brake band 10. Forward clutch 18. Counter driven gear (reduction gear) 3. Reverse clutch 11. Coast clutch 19. Oil pump 4. One-way clutch no.1 12. Overdr...

  • Page 230

    5a-4 automatic transmission/transaxle: specifications clutch / brake / planetary gear function of automatic transaxle s3rh0b5101002 item specifications torque converter type stall torque ratio 3-element, 1-step, 2-phase type (with tcc (lock-up) mechanism) 1.90 – 2.05 oil pump type drive system inter...

  • Page 231

    Automatic transmission/transaxle: 5a-5 functions table of component operation s3rh0b5101003 { : on ×: off u: on only when tcc is operating 4. Overdrive clutch 10. Front large planetary pinion gear 16. Input shaft 5. Rear planetary ring gear 11. Planetary sun gear 17. Reverse clutch 6. Rear planetary...

  • Page 232

    5a-6 automatic transmission/transaxle: a/t diagnosis general description s3rh0b5101005 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 233

    Automatic transmission/transaxle: 5a-7 schematic and routing diagram transmission control module (tcm) wiring diagram s3rh0b5102001 the tcm is an electronic circuit component that controls gear shift and idle-up according to the signal from each sensor. It is a microcomputer of an ic, transistor, di...

  • Page 234

    5a-8 automatic transmission/transaxle: operation of shift solenoid valves and tcc solenoid valve { : on (turn power on) ×: off (turn power off) u: power is turned off after passing 3 seconds from shifting with vehicle stopped ({): on only when lock-up function operates (—): gear is neutral position ...

  • Page 235

    Automatic transmission/transaxle: 5a-9 automatic gear shift diagram s3rh0b5102003 automatic shift schedule as a result of shift control is shown in the following. In case that selector lever is shifted to l at a higher than 55 km/h (34 mile/h) speed, 2nd gear is operated and then down shifts to 1st ...

  • Page 236

    5a-10 automatic transmission/transaxle: component location electronic shift control system components location s3rh0b5103001 i3rh0b510003-01 1. Engine 15. Tcc solenoid valve h: brake signal 2. Transaxle 16. Transmission fluid temperature sensor (a/t fluid temp. Sensor) i: shift indicator, “o/d off” ...

  • Page 237

    Automatic transmission/transaxle: 5a-11 diagnostic information and procedures a/t system check s3rh0b5104001 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 238

    5a-12 automatic transmission/transaxle: 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 an...

  • Page 239

    Automatic transmission/transaxle: 5a-13 note the form is a standard sample. It should be modified according to conditions characteristic of each market. Step 2. Dtc check, record and clearance first, referring to “dtc check”, check dtc. If dtc exists, print or write down dtc and then clear malfuncti...

  • Page 240

    5a-14 automatic transmission/transaxle: visual inspection s3rh0b5104002 visually check the following parts and systems. “o/d off” lamp check s3rh0b5104053 1) turn ignition switch on. 2) check that “o/d off” lamp (1) lights for about 2 sec. And then goes off. If anything faulty is found, advance to “...

  • Page 241

    Automatic transmission/transaxle: 5a-15 • a: driving cycles when “o/d off” light flashing and storing dtc in tcm memory. • *1: “o/d off” lamp does not flash although dtc is detected and stored in tcm memory. Dtc no. Detecting item detecting condition (dtc will set when detecting:) a type i type ii p...

  • Page 242

    5a-16 automatic transmission/transaxle: dtc check s3rh0b5104006 automatic transaxle dtc can be checked using any one of the following 2 methods. Reading dtc using suzuki scan tool 1) prepare suzuki scan tool. 2) with ignition switch off, connect it to data link connector (dlc) (1) located on undersi...

  • Page 243

    Automatic transmission/transaxle: 5a-17 dtc clearance s3rh0b5104007 as automatic transaxle dtc can be cleared using any one of the following 2 methods. Dtc clearance using suzuki scan tool 1) turn ignition switch off. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside ...

  • Page 244

    5a-18 automatic transmission/transaxle: fail safe table s3rh0b5104008 this function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The following table shows the fail safe function for each fail condition of sensor, solenoid...

  • Page 245

    Automatic transmission/transaxle: 5a-19 scan tool data s3rh0b5104009 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 246

    5a-20 automatic transmission/transaxle: scan tool data definitions: gear position (p/n or r/1/2/3/4) current gear position computed by throttle position coming from ecm and vehicle speed. Engine speed (rpm) engine speed computed by reference pulses from crankshaft position sensor. Input shaft rev (i...

  • Page 247

    Automatic transmission/transaxle: 5a-21 press cont sol (pressure control solenoid, %) electric current value ratio between electric current value being outputted from tcm to solenoid and maximum value can be outputted by tcm. Vehicle speed (kph/mph) vehicle speed computed by reference pulses coming ...

  • Page 248

    5a-22 automatic transmission/transaxle: road test s3rh0b5104011 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 249

    Automatic transmission/transaxle: 5a-23 manual road test s3rh0b5104012 this test checks the gears being used in “l”, “2” or “d” range when driven with unoperated gear shift control system. Test drive vehicle on a level road. Note before this test, check dtc. 1) with select lever in “p”, start engine...

  • Page 250

    5a-24 automatic transmission/transaxle: stall test s3rh0b5104013 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 251

    Automatic transmission/transaxle: 5a-25 time lag test s3rh0b5104014 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 252

    5a-26 automatic transmission/transaxle: line pressure test s3rh0b5104015 purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following conditions. • automatic fluid is at normal operating temperature (70 –...

  • Page 253

    Automatic transmission/transaxle: 5a-27 troubleshooting engine brake test s3rh0b5104016 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 br...

  • Page 254

    5a-28 automatic transmission/transaxle: a/t symptom diagnosis s3rh0b5104018 trouble diagnosis 1 electrical repair condition possible cause correction / reference item poor 1 → 2 shift shift solenoid valve-b circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Output shaft ...

  • Page 255

    Automatic transmission/transaxle: 5a-29 incorrect gear shift point output shaft speed sensor circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Throttle position sensor signal circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Throttle positi...

  • Page 256

    5a-30 automatic transmission/transaxle: trouble diagnosis 2 on-vehicle repair condition possible cause correction / reference item unable to run in all range faulty valve body component replace valve body assembly. Poor 1 → 2 shift, excessive shock or slippage engine abnormal condition inspect and r...

  • Page 257

    Automatic transmission/transaxle: 5a-31 poor 3 → o/d shift, excessive shock or slippage engine abnormal condition inspect and repair engine. Malfunction of tcc solenoid valve inspect. If ng, replace. Malfunction of input shaft speed sensor inspect. If ng, replace. Malfunction of output shaft speed s...

  • Page 258

    5a-32 automatic transmission/transaxle: trouble diagnosis 3 off-vehicle repair condition possible cause correction / reference item unable to run in all range faulty oil pump inspection. If ng, replace. Seized or broken planetary gear inspection. If ng, replace. Faulty one-way clutch no.2 inspection...

  • Page 259

    Automatic transmission/transaxle: 5a-33 no gear shift to o/d s3rh0b5104019 system description tcm does not shift to o/d gear under any of the following condition. • o/d off switch is turned on. (“o/d off” lamp on.) • engine coolant temperature is lower than 50 °c (122 °f) • tcm detects dtc p0743. Tr...

  • Page 260

    5a-34 automatic transmission/transaxle: no lock-up occurs s3rh0b5104020 system description tcm turns tcc solenoid off under any of the following conditions. • engine coolant temperature is lower than 50 °c (122 °f). • tcm detects the following dtcs. P0715 / p0720 / p0743 / p0748 / p0753 / p0758 / p1...

  • Page 261

    Automatic transmission/transaxle: 5a-35 dtc p0705 (no.34): transmission range sensor circuit malfunction (prndl input) s3rh0b5104022 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...

  • Page 262

    5a-36 automatic transmission/transaxle: dtc troubleshooting table for step 4 step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 do you have suzuki scan tool? Go to step 3. Go to step 4. 3 check transmission range sensor (switch) circuit for operation. Ch...

  • Page 263

    Automatic transmission/transaxle: 5a-37 dtc p0710 (no.36 / no.38): transmission fluid temperature sensor circuit malfunction s3rh0b5104043 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traf...

  • Page 264

    5a-38 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check transmission fluid temperature sensor circuit for open 1) turn ignition switch off. 2) disconnect tcm connectors from tcm. 3) check for p...

  • Page 265

    Automatic transmission/transaxle: 5a-39 dtc p0715 (no.37): input / turbine speed sensor circuit malfunction s3rh0b5104024 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 266

    5a-40 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check input shaft speed sensor circuit 1) disconnect tcm connectors with ignition switch off. 2) check for proper connection to input shaft spe...

  • Page 267

    Automatic transmission/transaxle: 5a-41 dtc p0720 (no.31): output shaft speed sensor circuit malfunction s3rh0b5104025 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 o...

  • Page 268

    5a-42 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check output shaft speed sensor circuit 1) disconnect tcm connectors with ignition switch off. 2) check for proper connection to output shaft s...

  • Page 269

    Automatic transmission/transaxle: 5a-43 dtc p0725 (no.35): engine speed input circuit malfunction s3rh0b5104026 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtcs in tcm memory. 2) start engine and keep engine running for 30 seconds. 3) check dtc. 15 g08...

  • Page 270

    5a-44 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check engine speed input signal circuit for open 1) turn ignition switch off. 2) disconnect tcm and ecm connectors from tcm and ecm. 3) check f...

  • Page 271

    Automatic transmission/transaxle: 5a-45 dtc p0743 (no.25 / no.26) torque converter clutch circuit electrical s3rh0b5104027 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 possibili...

  • Page 272

    5a-46 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check tcc solenoid valve circuit for ig short 1) turn ignition switch on and measure voltage between terminal “g08-12” of harness side tcm conn...

  • Page 273

    Automatic transmission/transaxle: 5a-47 dtc p0748 (no.41 / no.42): pressure control solenoid-a electrical s3rh0b5104045 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtcs in tcm memory. 2) start engine and keep engine running for 1 minute. 3) check dtc. ...

  • Page 274

    5a-48 automatic transmission/transaxle: 3 check pressure control solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1) on transaxle (2). 3) check for proper connection to solenoid at “gry/red” and “gry/blk” circuits. 4) check resistance of solenoid. Re...

  • Page 275

    Automatic transmission/transaxle: 5a-49 dtc p0753 / p0758 (no.21 / no.22 / no.23 / no.24): shift solenoid-a (no.1) electrical / shift solenoid- b (no.2) electrical s3rh0b5104047 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test...

  • Page 276

    5a-50 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check shift solenoid valve circuit for ig short 1) turn ignition switch off and disconnect tcm connectors. 2) check for proper connection to tc...

  • Page 277

    Automatic transmission/transaxle: 5a-51 dtc p1700 (no.32 / no.33): throttle position signal input malfunction s3rh0b5104048 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtcs in tcm memory. 2) turn ignition switch on. 3) depress accelerator pedal fully a...

  • Page 278

    5a-52 automatic transmission/transaxle: dtc troubleshooting dtc p1702 (no.52): internal malfunction of tcm s3rh0b5104033 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtcs in tcm memory. 2) after passing 10 seconds from turning ignition switch on, check dtc. Dtc troubl...

  • Page 279

    Automatic transmission/transaxle: 5a-53 dtc p1705 (no.51): engine coolant temperature signal circuit malfunction s3rh0b5104049 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtcs in tcm memory. 2) start engine and run it for 25 minutes or more. 3) check d...

  • Page 280

    5a-54 automatic transmission/transaxle: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 is there dtc related to engine coolant temperature sensor (p0115)? Go to dtc p0115 flow. Go to step 3. 3 check engine coolant temperature signa...

  • Page 281

    Automatic transmission/transaxle: 5a-55 dtc p1730 (no.64) engine torque signal circuit malfunction s3rh0b5104050 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtcs in tcm memory. 2) start engine and run it for 10 seconds. 3) check dtc. 23 g08 g07 3 1 2 1...

  • Page 282

    5a-56 automatic transmission/transaxle: dtc troubleshooting dtc p1895 (no.27): torque control signal malfunction s3rh0b5104037 wiring diagram step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check engine torque signal circuit for ig short 1) turn ignit...

  • Page 283

    Automatic transmission/transaxle: 5a-57 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtcs in tcm memory. 2) start engine and run it for 1 minute. 3) check dtc. Dtc troubleshooting dtc detecting condition trouble area voltage of torque reduction signal circuit tcm term...

  • Page 284

    5a-58 automatic transmission/transaxle: inspection of tcm and its circuits s3rh0b5104038 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 285

    Automatic transmission/transaxle: 5a-59 terminal circuit standard voltage condition g07 1 transmission range sensor (“r” range) 8 – 14 v ignition switch on, selector lever at “r” range 0 – 1 v ignition switch on, selector lever at other than “r” range 2 transmission range sensor (“p” range) 8 – 14 v...

  • Page 286

    5a-60 automatic transmission/transaxle: g08 1 — — — 2 — — — 3 shift solenoid valve-b (no.2) 0 – 1 v ignition switch on, selector lever at “p” range 4 shift solenoid valve-a (no.1) 9 – 14 v ignition switch on, selector lever at “p” range 5 transmission fluid temperature sensor (+) 3.3 – 3.7 v ignitio...

  • Page 287

    Automatic transmission/transaxle: 5a-61 tcm power and ground circuit check s3rh0b5104039 wiring diagram troubleshooting 15 19 20 g08 g07 5 bb ig11 g08-20 g08-15 g08-19 blk/wht blk blk 3 2 4 1 i2rh01510018-01 1. Tcm 3. Ignition switch 5. Terminal arrangement of tcm connector (viewed from harness side...

  • Page 288

    5a-62 automatic transmission/transaxle: “o/d off” lamp circuit check s3rh0b5104040 wiring diagram circuit description operation (on/off) of the “o/d off” lamp is controlled by transmission control module (tcm) and combination meter. When ignition switch is turned on and malfunction is not detected, ...

  • Page 289

    Automatic transmission/transaxle: 5a-63 troubleshooting step action yes no 1 does “o/d off” lamp light steady? Go to step 2. Go to step 4. 2 check o/d off switch circuit 1) turn ignition switch off and disconnect tcm connectors. 2) check resistance between terminal “g07-3” of disconnected harness si...

  • Page 290

    5a-64 automatic transmission/transaxle: 5 does “o/d off” lamp blink for 10 seconds and then go out? “red/yel” circuit open or shorted to ground. If circuit is ok, faulty combination meter or tcm. Inspect combination meter referring to “o/d off indicator lamp (a/t vehicle only) symptom diagnosis in s...

  • Page 291

    Automatic transmission/transaxle: 5a-65 repair instructions a/t fluid level check s3rh0b5106001 level check at normal operation temperature 1) stop vehicle and place it level. 2) apply parking brake and place chocks against wheels. 3) with selector at “p” position, start engine. 4) warm up engine ti...

  • Page 292

    5a-66 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 hole...

  • Page 293

    Automatic transmission/transaxle: 5a-67 select cable components s3rh0b5106006 selector cable adjustment s3rh0b5106007 1) remove adjuster (cable end) from selector lever pin of selector lever assembly. 2) shift manual shift lever to “n” range (transmission range sensor “n” range). 3) release lock pla...

  • Page 294

    5a-68 automatic transmission/transaxle: 5) shift selector lever to “n” position. 6) apply grease to selector lever pin and install adjuster (cable end) to it. : grease 99000–25010 7) with both selector lever and transmission range sensor kept each “n” position, drive cable end holder (1) in until it...

  • Page 295

    Automatic transmission/transaxle: 5a-69 5) check that engine starts in “n” and “p” ranges but it doesn’t start in “d”, “2”, “l” or “r” range. Also, check that back-up lamp turn on in “r” range. Output shaft speed sensor removal and installation s3rh0b5106009 removal 1) disconnect negative cable at b...

  • Page 296

    5a-70 automatic transmission/transaxle: input shaft speed sensor removal and installation s3rh0b5106011 removal 1) disconnect negative cable at battery. 2) disconnect input shaft speed sensor connector (2). 3) remove input shaft speed sensor (1) by removing its bolt. Installation 1) apply a/t fluid ...

  • Page 297

    Automatic transmission/transaxle: 5a-71 7) warm up transmission fluid temperature sensor (2). Check resistance between terminals of a/t side valve body connector. Thus make sure its resistance decrease with the increase of temperature. After inspection, install transmission fluid temp. Sensor and co...

  • Page 298

    5a-72 automatic transmission/transaxle: “o/d off” switch inspection s3rh0b5106014 1) remove console box. 2) disconnect o/d off switch connector (1). 3) check continuity between o/d off switch (2) terminals. “o/d off” switch specification with o/d off switch under being pressed (3): continuity with o...

  • Page 299

    Automatic transmission/transaxle: 5a-73 installation 1) install shift solenoid valve-a (no.1) (1), shift solenoid valve-b (no.2) (2) and tcc solenoid valve (3) in that order. Tightening torque shift solenoid bolt (a): 7.0 n·m (0.7 kgf-m, 5.0 lb- ft) valve body bolt (b): 10 n·m (1.0 kgf-m, 7.5 lb-ft)...

  • Page 300

    5a-74 automatic transmission/transaxle: 8) install a/t fluid cooler pipe (1). Tightening torque a/t fluid pipe union bolt (color: green) (a): 27 n·m (2.7 kgf-m, 19.5 lb-ft) a/t fluid pipe union bolt (color: silver) (a): 35 n·m (3.5 kgf-m, 25.5 lb-ft) a/t fluid pipe nut (b): 18 n·m (1.8 kgf-m, 13.0 l...

  • Page 301

    Automatic transmission/transaxle: 5a-75 tcc solenoid valve • 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 transaxle fluid from oiler does not come out of ...

  • Page 302

    5a-76 automatic transmission/transaxle: not using regulated dc power supply 1) connect pressure control solenoid valve (1) to battery (2) setting the 8 – 10 w bulb (4) on the way as shown in the figure. 2) check for movement of valve (3) in the direction of arrow “a”. 3) disconnect pressure control ...

  • Page 303

    Automatic transmission/transaxle: 5a-77 differential side oil seal replacement s3rh0b5106019 1) lift up vehicle and drain automatic transaxle fluid. 2) remove drive shaft joints from differential gear of transaxle. Refer to “front drive shaft assembly removal and installation in section 3a” for proc...

  • Page 304

    5a-78 automatic transmission/transaxle: automatic transaxle unit components s3rh0b5106023 3 85 n·m (8.5 kg-m) 2 85 n·m (8.5 kg-m) 7 70 n·m (7.0 kg-m) 5 25 n·m (2.5 kg-m) 8 50 n·m (5.0 kg-m) 3 85 n·m (8.5 kg-m) 3 85 n·m (8.5 kg-m) 1 6 4 i3rh0b510012-01 1. Lower stiffener 4. Torque converter 7. Drive ...

  • Page 305

    Automatic transmission/transaxle: 5a-79 automatic transaxle unit dismounting and remounting s3rh0b5106024 dismounting 1) take down transaxle with engine. For its procedure, refer to “engine assembly removal and installation in section 1d”. 2) remove engine rear mounting no.1 bracket and engine rear ...

  • Page 306

    5a-80 automatic transmission/transaxle: remounting 1) make sure that torque converter is installed correctly to transaxle. Refer to “automatic transaxle unit assembly”. 2) attach transaxle to engine. Tightening torque transaxle to engine bolts and nut (a): 85 n·m ( 8.5 kgf-m, 61.5 lb-ft) warning ! B...

  • Page 307

    Automatic transmission/transaxle: 5a-81 automatic transaxle assembly components s3rh0b5106025 i3rh0b510036-01 1. Torque converter 22. Gasket 43. Manual valve lever 2. A/t fluid drain plug 23. 1st / reverse brake piston 44. Spacer 3. Transaxle housing 24. O-ring 45. Output shaft speed sensor 4. A/t f...

  • Page 308

    5a-82 automatic transmission/transaxle: automatic transaxle unit disassembly s3rh0b5106026 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 309

    Automatic transmission/transaxle: 5a-83 3) remove fluid cooler pipes (1). Note never reuse gaskets (2) after removal. 4) pull out transmission range sensor assembly (1). A) remove manual shift lever (2). B) pry off lock washer (4). C) remove lock nut (3). D) remove lock washer (4) and rubber plate. ...

  • Page 310

    5a-84 automatic transmission/transaxle: 7) pull out differential gear assembly. 8) clean and wipe off gasket sealant on mating surface between transaxle housing and transaxle case. 9) remove three gaskets at transaxle case side. Note never reuse removed gaskets. 10) remove 6 bolts of oil pump body (...

  • Page 311

    Automatic transmission/transaxle: 5a-85 19) remove valve body connector mounting bolt and remove valve body connector and its harness. 20) remove 2 gaskets (1). Note never reuse removed gaskets. 21) remove snap ring (1) using special tool. Special tool (a): 09900-06108 22) pull out 2nd and 4th brake...

  • Page 312

    5a-86 automatic transmission/transaxle: 27) apply valve lifter as illustrated and push in brake inner cover. Special tool (a): 09916-14510 (b): 09916-48210 28) remove snap ring by using snap ring pliers (special tool). Special tool (c): 09900-06108 29) remove tools and take out 2nd and 4th brake pis...

  • Page 313

    Automatic transmission/transaxle: 5a-87 36) remove 5 gaskets (1). Note never reuse removed gaskets. 37) remove planetary carrier (2), planetary ring gear (3) and sun gear assembly (1) with the following sun gear thrust roller bearing (4) installed. Sun gear thrust roller bearing dimension outside di...

  • Page 314

    5a-88 automatic transmission/transaxle: 42) remove retainer ring (1) and 1st and reverse brake piston return spring (2). 43) remove 1st and reverse brake piston with o-ring installed while applying and releasing compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole section (3...

  • Page 315

    Automatic transmission/transaxle: 5a-89 51) remove snap ring. 52) press counter drive gear subassembly (1) using special tool. Special tool (b): 09925-86010 53) remove slotted spring pin (3) using pin punch or the like. Note never reuse removed spacer (2) and slotted spring pin (3). 54) remove manua...

  • Page 316

    5a-90 automatic transmission/transaxle: oil pump disassembly and reassembly s3rh0b5106028 disassembly 1) remove two seal rings (1) and clutch drum thrust washer (2) from stator shaft subassembly back side. Note never reuse seal rings after removal. 2) remove oil pump cover (1) by removing eight torx...

  • Page 317

    Automatic transmission/transaxle: 5a-91 oil pump inspection s3rh0b5106029 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 exceeds standard value, replace gear...

  • Page 318

    5a-92 automatic transmission/transaxle: forward clutch components s3rh0b5106030 forward clutch preliminary check s3rh0b5106031 1) measure piston stroke before disassembly. A) install forward clutch assembly (2) to transaxle rear cover (1). B) measure piston stroke while applying and releasing compre...

  • Page 319

    Automatic transmission/transaxle: 5a-93 forward clutch disassembly and reassembly s3rh0b5106032 disassembly 1) remove snap ring (1). 2) remove retaining plate “r”, friction plates “f” and separator plates “s” in the following order. R → f → s → f → s → f → s 3) remove clutch drum thrust washer. 4) u...

  • Page 320

    5a-94 automatic transmission/transaxle: reassembly 1) coat new oil seal rings (3, 4) with a/t fluid. 2) install them to transaxle rear case (2) and forward clutch drum subassembly (1). Note • do not spread ring ends excessively. • make sure that opening ends of oil seal rings are not lined up so as ...

  • Page 321

    Automatic transmission/transaxle: 5a-95 11) apply a/t fluid to ring gear thrust roller bearing, race (1) and clutch drum thrust washer (2). Ring gear thrust roller bearing dimension outside diameter: 32.5 mm (1.28 in.) inside diameter: 18.8 mm (0.74 in.) thickness: 2.7 mm (0.11 in.) ring gear thrust...

  • Page 322

    5a-96 automatic transmission/transaxle: overdrive clutch and coast clutch components s3rh0b5106034 overdrive clutch and coast clutch preliminary check s3rh0b5106035 1) measure piston stroke. Install forward clutch assembly and overdrive / coast clutch assembly (2) to transaxle rear cover (1). 2) mea...

  • Page 323

    Automatic transmission/transaxle: 5a-97 3) measure coast clutch 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. Special tool (a): 09900–20607 (b): 09900-20701 coast clutch piston stroke standard: 2.6...

  • Page 324

    5a-98 automatic transmission/transaxle: 5) using special tool and hydraulic press (2), compress overdrive clutch return spring and remove snap ring (1). Special tool (a): 09926-98310 caution ! Be careful when applying pressure, for overpressure will cause plate section of overdrive clutch return spr...

  • Page 325

    Automatic transmission/transaxle: 5a-99 5) using special tool and hydraulic press (2), compress overdrive clutch return spring and install snap ring (1). Special tool (a): 09926-98310 note • when installing return spring, be careful so that return spring will not fall or tilt. • do not align opening...

  • Page 326

    5a-100 automatic transmission/transaxle: 12) install forward clutch assembly and overdrive and coast clutch assembly to transaxle rear cover. 13) measure overdrive clutch piston stroke again, using special tools. Special tool (a): 09900–20607 (b): 09900-20701 overdrive clutch piston stroke standard:...

  • Page 327

    Automatic transmission/transaxle: 5a-101 planetary gear components s3rh0b5106038 i2rh01510164-01 1. Snap ring 12. Carrier front thrust roller bearing 23. Rear ring gear flange 2. Front planetary ring gear 13. Carrier front thrust roller bearing race 24. One-way clutch no.0 3. One-way clutch no.1 14....

  • Page 328

    5a-102 automatic transmission/transaxle: planetary gear operation check s3rh0b5106039 one-way clutches 1) install forward clutch assembly and overdrive / coast clutch assembly to transaxle rear cover. 2) install rear planetary ring gear assembly to overdrive and coast clutch assembly. 3) make sure t...

  • Page 329

    Automatic transmission/transaxle: 5a-103 4) remove front ring gear thrust washer (1). Front ring gear thrust washer dimension outside diameter: 85.5 mm (3.67 in.) inside diameter: 70.0 mm (2.76 in.) thickness: 2.0 mm (0.08 in.) 5) remove front ring gear thrust roller bearing race (1). Front ring gea...

  • Page 330

    5a-104 automatic transmission/transaxle: 4) remove on-way clutch no.0 retainer (1) with rear ring gear thrust roller bearing (2) by removing snap ring (3). Rear ring gear thrust roller bearing dimension outside diameter: 32.5 mm (1.28 in.) inside diameter: 18.8 mm (0.74 in.) thickness: 2.7 mm (0.11 ...

  • Page 331

    Automatic transmission/transaxle: 5a-105 10) install one-way clutch no.1 (1) with snap ring (2). 11) install carrier front thrust roller bearing (1). 12) coat two thrust bearing races (4) with a/t fluid. 13) install planetary pinion gear assembly (3) and overdrive clutch hub (2) with snap ring (1). ...

  • Page 332

    5a-106 automatic transmission/transaxle: planetary gear inspection s3rh0b5106041 rear planetary ring gear assembly visually check the following parts for scratches or discoloration. • outer surface of one-way clutch no.0 roller (1). • inner surface of one-way clutch no.0 outer race (2). • inner surf...

  • Page 333

    Automatic transmission/transaxle: 5a-107 reverse clutch preliminary inspection s3rh0b5106045 1) remove sun gear input flange (1) with thrust washer (2) installed by removing retainer ring (3). 2) remove input shaft (1) with input shaft rear thrust roller bearing race (3), input shaft rear thrust rol...

  • Page 334

    5a-108 automatic transmission/transaxle: reverse clutch disassembly and reassembly s3rh0b5106046 disassembly 1) remove reverse clutch drum with bearing (1) from oil pump body. 2) remove sun gear input flange (2) with thrust washer (3) installed by removing retainer ring (4). 3) remove friction plate...

  • Page 335

    Automatic transmission/transaxle: 5a-109 4) place reverse clutch return spring onto reverse clutch piston. 5) install snap ring (1), using special tool and hydraulic press (2). Special tool (a): 09926-96010 note to prevent spring seat deformation, be sure to keep clearance of 1 – 2 mm between return...

  • Page 336

    5a-110 automatic transmission/transaxle: 17) install input shaft to reverse clutch drum. 18) install sun gear input flange (1) with retainer ring (3). 19) apply a/t fluid to thrust washer. 20) install thrust washer (2) to reverse clutch assembly. 21) apply a/t fluid to input shaft front thrust rolle...

  • Page 337

    Automatic transmission/transaxle: 5a-111 3) make sure that ball (1) makes creaking noise when shaking the reverse clutch piston. (i.E., check that ball is free.) 4) check that there is no leakage by applying low- pressure air onto ball. 5) check that outer surface of reverse clutch with bearing is n...

  • Page 338

    5a-112 automatic transmission/transaxle: 3) remove angular ball bearing from counter drive gear. Note if inner race of angular ball bearing remains on counter drive gear (1), remove it using gear puller and special tools. Special tool (a): 09925-86010 (b): 09925-06010 reassembly 1) press new angular...

  • Page 339

    Automatic transmission/transaxle: 5a-113 counter driven gear components s3rh0b5106050 i2rh01510207-01 1. Counter shaft rh thrust roller bearing race 5. Counter shaft driven gear lock nut (for output shaft speed sensor) : after tightening nut to specified tightening torque, stake nut securely. : appl...

  • Page 340

    5a-114 automatic transmission/transaxle: counter driven gear disassembly and reassembly s3rh0b5106051 disassembly 1) clamp counter driven gear (1) with special tool and a vice (2). Special tool (a): 09921-57810 2) unstake lock section of counter shaft driven gear lock nut. 3) remove counter shaft dr...

  • Page 341

    Automatic transmission/transaxle: 5a-115 5) stake new counter shaft driven gear lock nut (2), using standard punch in combination with hammer. Note when staking counter shaft driven gear lock nut (2), point a suitable staking tool (1) toward differential drive pinion shaft (3) axis center and stake ...

  • Page 342

    5a-116 automatic transmission/transaxle: valve body assembly components s3rh0b5106052 caution ! When replacing pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. 3 2 4 1 7 7 7 6 8 9 10 5 7 n·m(0.7 kg-m) 7 n·m(0.7 kg-m) 7 n·m(0.7 kg-m) 7...

  • Page 343

    Automatic transmission/transaxle: 5a-117 valve body assembly disassembly and reassembly s3rh0b5106053 disassembly 1) pull out manual valve. 2) remove solenoid valves by removing bolts. Reassembly 1) install solenoid valves to valve body and tighten bolts to specified torque. Tightening torque shift ...

  • Page 344

    5a-118 automatic transmission/transaxle: differential components s3rh0b5106054 differential removal and installation s3rh0b5106055 removal final gear 1) unclamp 4 final gear set bolt lock plates (2). 2) remove 8 bolts and 4 final gear set bolt lock plates (2). Note don’t reuse lock plates. 3) remove...

  • Page 345

    Automatic transmission/transaxle: 5a-119 installation bearing outer race 1) install bearing outer race and shim by using special tool and hummer. Special tool (a): 09924-74510 (b): 09944-68210 final gear 1) heat final gear to about 100 °c (212 °f) in oil bath. 2) clean mating surfaces of final gear ...

  • Page 346

    5a-120 automatic transmission/transaxle: differential inspection s3rh0b5106056 1) hold differential assembly with soft jawed vice and set special tools as shown. Special tool (a): 09900–20607 (b): 09900-20701 2) measure differential gear thrust play. Differential gear thrust play standard: 0.06 – 0....

  • Page 347

    Automatic transmission/transaxle: 5a-121 installation 1) apply a/t fluid to counter shaft rh thrust roller bearing (1). Counter shaft rh thrust roller bearing dimension outside diameter: 46.0 mm (1.81 in.) inside diameter: 32.5 mm (1.28 in.) thickness: 3.2 mm (0.13 in.) 2) install counter shaft rh t...

  • Page 348

    5a-122 automatic transmission/transaxle: transaxle housing inspection s3rh0b5106058 check pan for particles. Remove magnets and use them to collect any chips. Inspect oil reservoir plate for any chips and particle collected on magnet. Inspect them carefully to find out the type of wear on transaxle....

  • Page 349

    Automatic transmission/transaxle: 5a-123 6) rotate new spacer approximately 180 degrees. 7) stake small hole of new spacer. 8) press counter drive gear (1), using special tools. Special tool (a): 09924-74510 (b): 09926-68310 9) install new snap ring (1) to angular ball bearing. 10) apply a/t fluid t...

  • Page 350

    5a-124 automatic transmission/transaxle: 16) install special tools on transaxle. Special tool (a): 09900–20607 (b): 09900-20701 measure 1st and reverse brake piston stroke by applying and releasing compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole section (1). 1st and rev...

  • Page 351

    Automatic transmission/transaxle: 5a-125 24) install brake cover (1) to transaxle case with snap ring (2), using snap ring pliers. Special tool (a): 09900-06108 note it is best for the head section of piston rod (1) to protrude from the inner side of transaxle case approx. 2 – 3 mm (0.079 – 0.118 in...

  • Page 352

    5a-126 automatic transmission/transaxle: 33) temporarily tighten transaxle housing to transaxle case with 5 – 6 bolts. 34) stand transaxle up (i.E.: transaxle housing facing down-ward). 35) install front and rear planetary carrier (1) while rotating counter-clockwise and clockwise. 36) install sun g...

  • Page 353

    Automatic transmission/transaxle: 5a-127 43) install five gaskets (1). Note there is no installation direction for new gaskets. 44) apply sealant to thread parts of 2 bolts (3). “a”: sealant 99000–31230 45) tighten transaxle rear cover (1) and engine mounting lh bracket (2) with ten bolts (3, 4). Ti...

  • Page 354

    5a-128 automatic transmission/transaxle: 56) check for correct installation of input shaft as follows. Measure the distance “a” by using vernier (1) and straightedge (2). If out of specification, remove input shaft (3) with reverse clutch assembly and reinstall them properly. Distance between input ...

  • Page 355

    Automatic transmission/transaxle: 5a-129 65) apply sealant to thread parts of 2 bolts (1). “a”: sealant 99000–31230 66) install transaxle housing to transaxle case by tightening bolts to specified torque. Tightening torque transaxle case bolt (a): 30 n·m (3.0 kgf-m, 22.0 lb-ft) 67) insert wiring har...

  • Page 356

    5a-130 automatic transmission/transaxle: 73) wipe off and clean mating surface between case and side cover. 74) apply sealant to 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 75) apply sealant to thr...

  • Page 357

    Automatic transmission/transaxle: 5a-131 80) install transmission range sensor assembly. A) place new rubber plate and new lock washer (3) or transmission range sensor (1). B) tighten transmission range sensor lock nut (4). Tightening torque transmission range sensor lock nut (a): 7.0 n·m (0.7 kgf-m...

  • Page 358

    5a-132 automatic transmission/transaxle: specifications tightening torque specifications s3rh0b5107001 note the specified tightening torque is also described in the following. “select cable components” “automatic transaxle unit components” “automatic transaxle assembly components” “oil pump componen...

  • Page 359

    Automatic transmission/transaxle: 5a-133 special tools and equipment recommended service material s3rh0b5108001 note required service material is also described in the following. “select cable components” “automatic transaxle assembly components” “oil pump components” “forward clutch components” “ov...

  • Page 360

    5a-134 automatic transmission/transaxle: 09924–74590 09924–84510–005 input shaft oil seal installer attachment bearing installer attachment (d) ) ) 09925–06010 09925–37811–001 bearing puller oil pressure gauge ) ) 09925–86010 09926–68310 bearing puller attachment differential bevel pinion bearing in...

  • Page 361

    Automatic transmission/transaxle: 5a-135 09944–68210 09944–88210 bearing & oil seal installer bearing housing installer ) ) / ) 09951–16060 09951–46010 control arm bush remover drive shaft oil seal installer ) ) suzuki scan tool — this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc ...

  • Page 362

    5a-136 automatic transmission/transaxle:.

  • Page 363: Section 9

    Table of contents 9- i 9 section 9 contents body, cab and accessories precautions ................................................. 9-* precautions.............................................................. 9-* precautions on body, cab and accessories.......... 9-* precautions for body service......

  • Page 364

    9-ii table of contents d-3 fog light circuit diagram............................. 9a-* d-4 illumination light circuit diagram................. 9a-* d-5 interior light circuit diagram........................ 9a-* d-6 turn signal and hazard warning light circuit diagram ..................................

  • Page 365

    Table of contents 9-iii engine coolant temperature (ect) sensor inspection.......................................................... 9c-* brake fluid level switch inspection ................... 9c-* parking brake switch inspection ........................ 9c-* door switch (front / rear door) inspect...

  • Page 366

    9-iv table of contents power door lock actuator inspection..................9f-* front door lock assembly inspection .................9f-* rear door lock assembly components ..............9f-* rear door lock assembly removal and installation..........................................................9...

  • Page 367

    Instrumentation / driver info. / horn: 9c-1 instrumentation / driver info. / horn schematic and routing diagram combination meter circuit diagram s3rh0b9302001 terminal arrangement of coupler viewed from harness side lcd l 2 d n r p 12 14 14 15 11 16 16 25 23 22 20 4 17 18 19 16 24 1 2 26 21 *1 g21-...

  • Page 368

    9c-2 instrumentation / driver info. / horn: terminal wire color circuit terminal wire color circuit g20-1 — — g21-1 — — g20-2 blk/orn to engine ground g21-2 — — g20-3 — — g21-3 — — g20-4 red/yel to headlight relay g21-4 — — g20-5 — — g21-5 wht/blu to generator g20-6 pnk to ecm (immobilizer indicator...

  • Page 369: Glass / Windows / Mirrors

    Glass / windows / mirrors: 9e-1 glass / windows / mirrors repair instructions power window main switch inspection s3rh0b9506019 check for continuity between terminals at each switch position. If check result is not as specified, replace switch. I3rh0b950001-01 1. Power window lock switch 4. Rear lh ...

  • Page 370

    Prepared by 1st ed. Feb, 2004 2nd ed. Jul, 2006 367.

  • Page 371: Supplementary Service Manual

    14 mm 99501-54g30-24e 99501-54g30-24e supplementary service manual supplement ar y ser vice manu al.