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Suzuki SWIFT RS415 2017 Service Manual

Summary of SWIFT RS415 2017

  • Page 1

    Important warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the words warning, caution and note have special meanings. Pay special attention to the messages highlighted by these signal words. The circle with a slash in this manual m...

  • Page 3: Foreword

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

  • Page 5: Table Of Contents

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

  • Page 7: Section 00

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

  • Page 8: Precautions

    00-1 precautions: precautions precautions precautions for vehicles equipped with a supplemental restraint (air bag) system s4rs0a0000001 warning: • the configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be su...

  • Page 9

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

  • Page 10

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

  • Page 11

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

  • Page 12

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

  • Page 13

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

  • Page 14

    00-7 precautions: precaution for can communication system s4rs0a0000014 • the loose (1) in the wire harnesses twist of the can lines except around the connector (3) should be within 100 mm (3.9 in.). Refer to the wiring diagram for the can lines discrimination. Excessively-loosed lines may be influe...

  • Page 15

    Precautions: 00-8 • when installing vehicle parts, be careful so that the wiring harness is not interfered with or caught by any other part. • to avoid damage to the harness, protect its part which may contact against a part forming a sharp angle by winding tape or the like around it. • be careful n...

  • Page 16

    00-9 precautions: air bag warning s4rs0a0000008 warning: for vehicles equipped with supplemental restraint (air bag) system: • service on and around the air bag system components or wiring must be performed only by an authorized suzuki dealer. Refer to “air bag system components, wiring and connecto...

  • Page 17

    Precautions: 00-10 brake caution s4rs0a0000013 caution: all brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part i...

  • Page 18

    00-11 precautions: 2) disconnect the connector included in the circuit (connector-b in the figure) and measure resistance between terminals “a-1” and “b-1”. If no continuity is indicated, that means that the circuit is open between terminals “a-1” and “b-1”. If continuity is indicated, there is an o...

  • Page 19

    Precautions: 00-12 4) disconnect the connector included in circuit (connector-b) and measure resistance between “a- 1” and body ground. If continuity is indicated, it means that the circuit is shorted to the ground between terminals “a-1” and “b-1”. Intermittent and poor connection inspection s4rs0a...

  • Page 20

    00-13 precautions: • poor terminal-to-wire connection. Check each wire harness in problem circuits for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. • wire insulation which is rubbed through, causing an intermittent short as the bare area touch...

  • Page 21: Section 0

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

  • Page 22: General Information

    0a-1 general information: general information general description abbreviations s4rs0a0101001 a: abs: anti-lock brake system atdc: after top dead center api: american petroleum institute atf: automatic transmission fluid, automatic transaxle fluid alr: automatic locking retractor ac: alternating cur...

  • Page 23

    General information: 0a-2 tcc: torque converter clutch tcm: transmission control module (a/t controller, a/t control module) tp sensor: throttle position sensor tvv: thermal vacuum valve (thermal vacuum switching valve, tvsv, bimetal vacuum switching valve, bvsv) twc: three way catalytic converter (...

  • Page 24

    0a-3 general information: fasteners information s4rs0a0101004 metric fasteners most of the fasteners used for this vehicle are metric. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. Fastener strength identification mo...

  • Page 25

    General information: 0a-4 *:self-lock nut vehicle lifting points s4rs0a0101005 warning: • before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • before lifting up the vehicle, ...

  • Page 26

    0a-5 general information: when using frame contact hoist when using floor jack warning: if the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands. It is extremely dang...

  • Page 27

    General information: 0a-6 to perform service with either front or rear vehicle end jacked up, be sure to place safety stands (1) under body mounting stay (2) so that vehicle body is securely supported. And then check to ensure that body mounting stay (2) does not slide on safety stands (1) and the v...

  • Page 28

    0a-7 general information: vehicle identification number s4rs0a0101006 the number is punched close by the right side strut support (1) in engine room. Engine identification number s4rs0a0101007 the number is punched on cylinder block. Transmission identification number s4rs0a0101009 the automatic tra...

  • Page 29

    General information: 0a-8 1 4 5 3 2 i4rs0a010007- 1. Air bag label on sun visor (if equipped) 4. Steering shaft joint cover label (if equipped) 2. Radiator cap label 5. Jack label 3. Engine cooling fan label 5 7 4 2 1 6 3 [a] i4rs0a010009- 1. Air bag label on driver air bag (inflator) module 5. Air ...

  • Page 30

    0b-1 maintenance and lubrication: maintenance and lubrication precautions precautions for maintenance and lubrication s4rs0a0200001 air bag warning refer to “air bag warning: in section 00”. Scheduled maintenance maintenance schedule under normal driving conditions s4rs0a0205001 note: • this interva...

  • Page 31

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

  • Page 32

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

  • Page 33

    Maintenance and lubrication: 0b-4 note: when replacing belt with a new one, adjust belt tension to 6 – 7 mm (0.24 – 0.28 in.). 3) connect negative (–) cable to battery accessory drive belt replacement s4rs0a0206002 water pump and generator drive belt replace belt with new one referring to “water pum...

  • Page 34

    0b-5 maintenance and lubrication: note: before fitting new oil filter, be sure to oil its o-ring. Use engine oil for this purpose. 4) screw new filter on oil filter stand by hand until the filter o-ring contacts mounting surface. Caution: to tighten oil filter properly, it is important to accurately...

  • Page 35

    Maintenance and lubrication: 0b-6 exhaust system inspection s4rs0a0206006 warning: to avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance, or the vehicle is raised fo...

  • Page 36

    0b-7 maintenance and lubrication: fuel filter replacement s4rs0a0206042 warning: this work must be performed in a well ventilated area and away from any open flames (such as gas hot water heaters). Fuel filter is installed in fuel pump assembly in fuel tank. Replace fuel filter or fuel pump assembly...

  • Page 37

    Maintenance and lubrication: 0b-8 brake hoses and pipes inspection s4rs0a0206017 perform this inspection where these is enough light and use a mirror as necessary. • check brake hoses and pipes for proper hookup, leaks, cracks, chafing and other damage. • check that hoses and pipes are clear of shar...

  • Page 38

    0b-9 maintenance and lubrication: tires inspection s4rs0a0206021 1) check tires for uneven or excessive wear, or damage. If defective, replace. Refer to “irregular and/or premature wear description: in section 2d” and “wear indicators description: in section 2d” for details. 2) check inflating press...

  • Page 39

    Maintenance and lubrication: 0b-10 4) check boots (1) and (2) of steering linkage and steering gear case for damage (leak, detachment, tear, etc.). If damage is found, replace defective boot with new one. If any dent is found on steering gear case boots, correct it to original shape by turning steer...

  • Page 40

    0b-11 maintenance and lubrication: automatic transaxle fluid level inspection s4rs0a0206039 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 dipstick and check fluid level. For fluid leve...

  • Page 41

    Maintenance and lubrication: 0b-12 air conditioning filter (if equipped) inspection s4rs0a0206036 1) remove the air conditioning filter from the hvac unit referring to “air filter removal and installation: in section 7a”. 2) check for dirt and dust. If the air conditioning filter is excessively dirt...

  • Page 42

    0b-13 maintenance and lubrication: warning: with vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any personal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should start to move. Check to ensure that parking brake is fu...

  • Page 43: 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 44

    1-ii table of contents dtc p0171 / p0172: fuel system too lean / rich .............................................................1a-103 dtc p0300 / p0301 / p0302 / p0303 / p0304: random misfire detected / cylinder 1 / cylinder 2 / cylinder 3 / cylinder 4 misfire detected .............................

  • Page 45

    Table of contents 1-iii vehicle speed sensor (vss) inspection (m/t model).......................................................1c-8 knock sensor removal and installation .............1c-8 main relay, fuel pump relay, starting motor control relay and throttle actuator control relay inspection..........

  • Page 46

    1-iv table of contents engine cooling system ...........................1f-1 general description ............................................. 1f-1 cooling system description ................................ 1f-1 coolant description............................................. 1f-1 schematic and rou...

  • Page 47

    Table of contents 1-v specifications........................................................ 1i-9 cranking system specifications........................... 1i-9 tightening torque specifications......................... 1i-9 special tools and equipment .............................. 1i-9 recommended ...

  • Page 48: Precautions

    1-1 precautions: precautions precautions precautions for engine s4rs0a1000001 air bag warning refer to “air bag warning: in section 00”. Precautions on engine service refer to “precautions on engine service: in section 1a”. Precautions in diagnosing trouble refer to “precautions in diagnosing troubl...

  • Page 49

    Engine general information and diagnosis: 1a-1 engine general information and diagnosis precautions precautions on engine service s4rs0a1100001 caution: the following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reliable eng...

  • Page 50

    1a-2 engine general information and diagnosis: connectors at the harness side, and then measure voltage, resistance and/or pulse signal. Or, ecm and its circuits may be damaged by water. • wire colors of the special tool’s connectors are different from the ones of the ecm connectors. However, the ci...

  • Page 51

    Engine general information and diagnosis: 1a-3 • when a malfunction is detected, engine and driving conditions then are stored in ecm memory as freeze frame data. (for the details, refer to description on “freeze frame data: ”.) • it is possible to communicate by using not only suzuki scan tool (2) ...

  • Page 52

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

  • Page 53

    Engine general information and diagnosis: 1a-5 engine and emission control system description s4rs0a1101004 the engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system in...

  • Page 54

    1a-6 engine general information and diagnosis: note: in communication between ecm and combination meter, data is transmitted only from ecm to combination meter. (combination meter does not transmit data to ecm.) ecm reception data air intake system description s4rs0a1101005 the main components of th...

  • Page 55

    Engine general information and diagnosis: 1a-7 electronic control system description s4rs0a1101006 the electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ecm which controls various devices according to the signals from the sensors and...

  • Page 56

    1a-8 engine general information and diagnosis: engine and emission control system flow diagram air cleaner ia t sensor maf sensor fuel tank fuel level sensor fuel pump tp sensor ia c v al ve egr val ve thr o ttle bod y map sensor int ake manifold exha ust manifold exha ust gas air fuel va p o r thre...

  • Page 57

    Engine general information and diagnosis: 1a-9 ecm input / output circuit diagram 6 35 22 23 24 25 27 +b 43 ig1 +bb st ig2 ig2 42 64 47 52 52 52 4 7 : 50 : 51 blu/yel blu/wht blu/red blu/orn blu/blk blk/wht wht/red brn/wht blk/red blk/red gry/red gry/blu red/blk lt grn 45 : 5v : 12v 2 +b 1 pnk gry o...

  • Page 58

    1a-10 engine general information and diagnosis: terminal arrangement of ecm coupler (viewed from harness side) connector: c37 4. Map sensor 26. Iac valve 48. Barometric pressure sensor 5. Knock sensor 27. Evap canister purge valve 49. Oil control valve (camshaft position control) 6. Tp sensor 28. Fu...

  • Page 59

    Engine general information and diagnosis: 1a-11 connector: e23 16 blu/red fuel injector no.3 output 46 blk/red heater output of heated oxygen sensor-1 17 blu/orn fuel injector no.4 output 47 red/blu heater output of heated oxygen sensor-2 18 brn/yel egr valve (stepper motor coil 4) output 48 yel/grn...

  • Page 60

    1a-12 engine general information and diagnosis: 23 — — 53 — — 24 yel/red fuel level sensor signal 54 orn ground for sensors 25 ppl vehicle speed signal output for eps control module 55 red a/c refrigerant pressure sensor signal 26 red/blu eps signal 56 — — 27 — — 57 wht/blk a/c evaporator outlet air...

  • Page 61

    Engine general information and diagnosis: 1a-13 engine and emission control input / output table s4rs0a1101007 input output electric control device fuel level sensor for detecting fuel level barometric pressure sensor stop lamp switch start switch ignition switch a/c refrigerant pressure sensor blow...

  • Page 62

    1a-14 engine general information and diagnosis: schematic and routing diagram engine and emission control system diagram s4rs0a1102001 26 10 9 7 8 14 13 23 11 15 12 2 6 5 1 3 18 24 39 42 35 30 29 38 16 17 37 36 31 22 21 40 27 25 41 34 32 20 19 4 33 28 i4rs0a110011-.

  • Page 63

    Engine general information and diagnosis: 1a-15 component location electronic control system components location s4rs0a1103001 1. Air cleaner 15. Ect sensor 29. Ecm 2. Evap canister purge valve 16. Cmp sensor 30. Barometric pressure sensor 3. Maf and iat sensor 17. Ckp sensor 31. Battery 4. Tp senso...

  • Page 64

    1a-16 engine general information and diagnosis: diagnostic information and procedures engine and emission control system check s4rs0a1104001 refer to the following items for the details of each step. 6. Vss g: iac valve g: tcm (a/t) 7. Battery h: ignition coil assembly (with ignitor) h: bcm (include...

  • Page 65

    Engine general information and diagnosis: 1a-17 step 1: customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for p...

  • Page 66

    1a-18 engine general information and diagnosis: customer problem inspection form (example) note: the form is a standard sample. It should be modified according to conditions characteristic of each market. I2rh01110010-.

  • Page 67

    Engine general information and diagnosis: 1a-19 step 2: dtc / freeze frame data check, record and clearance first, check dtc (including pending dtc), referring to “dtc check: ”. If dtc is indicated, print it and freeze frame data or write them down and then clear them by referring to “dtc clearance:...

  • Page 68

    1a-20 engine general information and diagnosis: 2) with ignition switch turned 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, pend...

  • Page 69

    Engine general information and diagnosis: 1a-21 *p0037 ho2s heater control circuit low (sensor-2) heater current is less than specification while heater on. 2 driving cycles *p0038 ho2s heater control circuit high (sensor-2) heater current is more than specification while heater on. 2 driving cycles...

  • Page 70

    1a-22 engine general information and diagnosis: *p0172 system too rich total fuel trim is smaller than specification for specified time or longer. (fuel trim toward lean side is large.) 2 driving cycles *p0300 random misfire detected misfire of such level as to cause damage to three way catalyst. *2...

  • Page 71

    Engine general information and diagnosis: 1a-23 for vehicle equipped with a/t when using obd generic scan tool, not only the previous star (*) marked ecm dtc(s) but also the following dtc(s) is displayed on obd generic scan tool simultaneously. *p1674 can communication (buss off error) transmission ...

  • Page 72

    1a-24 engine general information and diagnosis: fail-safe table s4rs0a1104006 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. Scan tool data s4rs0a1104007 as the da...

  • Page 73

    Engine general information and diagnosis: 1a-25 tp sensor volt (throttle position sensor output voltage) ignition switch on / warmed up engine stopped accelerator pedal released 0.5 – 1.0 v accelerator pedal depressed fully less than 4.8 v desired idle (desired idle speed) it idling with radiator co...

  • Page 74

    1a-26 engine general information and diagnosis: a/c pressure (a/c refrigerant absolute pressure) engine running a/c on (a/c is operating) at ambient temperature: 30 c (86 f) and humidity: 50% 1350 – 1650 kpa for more details, refer to pressure of high pressure gage under “a/c system performance insp...

  • Page 75

    Engine general information and diagnosis: 1a-27 scan tool data definitions coolant temp (engine coolant temperature, c, f) it is detected by engine coolant temp. Sensor. Intake air temp. ( c, f) it is detected by intake air temp. Sensor. Engine speed (rpm) it is computed by reference pulses from the...

  • Page 76

    1a-28 engine general information and diagnosis: closed throttle pos (closed throttle position, on/off) this parameter reads on when throttle valve is fully closed, or off when it is not fully closed. Canist prg duty (evap canister purge flow duty, %) this parameter indicates valve on (valve open) ti...

  • Page 77

    Engine general information and diagnosis: 1a-29 engine basic inspection s4rs0a1104009 this check is very important for troubleshooting when ecm has detected no dtc and no abnormality has been found in “visual inspection: ”. Follow the flow carefully. • tachometer – operation • abnormal air being inh...

  • Page 78

    1a-30 engine general information and diagnosis: 6 check ignition timing 1) using suzuki scan tool, select “misc test” mode on suzuki scan tool and fix ignition timing to initial one. 2) using timing light, check initial ignition timing. Special tool (a): 09930–76420 is it 5 3 btdc at specified idle ...

  • Page 79

    Engine general information and diagnosis: 1a-31 9 check fuel pump for operation was fuel pump operating sound heard from fuel filler for about 3 seconds after ignition switch on and stop? Go to “fuel pressure check: ”. Go to “fuel pump and its circuit check: ”. 10 check ignition spark 1) disconnect ...

  • Page 80

    1a-32 engine general information and diagnosis: engine symptom diagnosis s4rs0a1104010 perform troubleshooting referring to the followings when ecm has detected no dtc and no abnormality has been found in “visual inspection: ” and “engine basic inspection: ”. Condition possible cause correction / re...

  • Page 81

    Engine general information and diagnosis: 1a-33 engine noise – piston, ring and cylinder noise note: before checking mechanical noise, make sure that: • specified spark plug is used. • specified fuel is used. Worn piston, ring and cylinder bore “cylinders, pistons and piston rings inspection: in sec...

  • Page 82

    1a-34 engine general information and diagnosis: poor gasoline mileage leaks or loose connection of high- tension cord “high-tension cord removal and installation: in section 1h” faulty spark plug (improper gap, heavy deposits and burned electrodes, etc.) “spark plug inspection: in section 1h” malfun...

  • Page 83

    Engine general information and diagnosis: 1a-35 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 removal and installation: in section 1h” faulty s...

  • Page 84

    1a-36 engine general information and diagnosis: engine has no power faulty spark plug “spark plug inspection: in section 1h” faulty ignition coil with ignitor “ignition coil assembly (including ignitor) inspection: in section 1h” leaks, loose connection or disconnection of high-tension cord “high-te...

  • Page 85

    Engine general information and diagnosis: 1a-37 excessive hydrocarbon (hc) emission or carbon monoxide (co) faulty spark plug “spark plug inspection: in section 1h” leaky or disconnected high-tension cord “high-tension cord removal and installation: in section 1h” faulty ignition coil with ignitor “...

  • Page 86

    1a-38 engine general information and diagnosis: malfunction indicator lamp does not come on with ignition switch on and engine stop (but engine can be started) s4rs0a1104011 wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn on (close the cont...

  • Page 87

    Engine general information and diagnosis: 1a-39 troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm ...

  • Page 88

    1a-40 engine general information and diagnosis: malfunction indicator lamp remains on after engine starts s4rs0a1104012 wiring diagram blk/wht blk/red blk/red blk/red wht 80a blk/yel blk/yel red/blk blk/yel grn brn/wht 12v 5v 2 1 3 8 6 5 7 red wht red wht red wht red wht e23-29 e23-3 e23-1 e23-60 e2...

  • Page 89

    Engine general information and diagnosis: 1a-41 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, transmits indication on signal of malfunction indicator lamp (mil) to combination m...

  • Page 90

    1a-42 engine general information and diagnosis: dtc p0010: camshaft position actuator circuit s4rs0a1104014 system and wiring diagram circuit description actual valve timing fails to become close to target advance level of each function although advance control function or retarded advance control f...

  • Page 91

    Engine general information and diagnosis: 1a-43 dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 92

    1a-44 engine general information and diagnosis: dtc p0011 / p0012: camshaft position - timing over-advanced or system performance / -retarded s4rs0a1104015 system description actual value of advanced valve timing does not reach target value. Valve timing is advanced although ecm command is most reta...

  • Page 93

    Engine general information and diagnosis: 1a-45 11) check dtc. Refer to “dtc check: ”. Dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, conn...

  • Page 94

    1a-46 engine general information and diagnosis: dtc p0031 / p0032: ho2s heater control circuit low / high (sensor-1) s4rs0a1104029 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and ...

  • Page 95

    Engine general information and diagnosis: 1a-47 dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 96

    1a-48 engine general information and diagnosis: dtc p0037 / p0038: ho2s heater control circuit low / high (sensor-2) s4rs0a1104031 wiring diagram dtc detecting condition and trouble area 7 ho2s-1 heater check 1) disconnect ho2s-1 connector with ignition switch turned off. 2) check ho2s-1 heater resi...

  • Page 97

    Engine general information and diagnosis: 1a-49 dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and warm up to normal operating temperature. 4) run engine at idle speed for 1 min. 5) check dtc...

  • Page 98

    1a-50 engine general information and diagnosis: dtc p0101: mass air flow circuit range / performance s4rs0a1104067 wiring diagram 7 ho2s-2 heater check 1) disconnect ho2s-2 connector with ignition switch turned off. 2) check ho2s-2 heater resistance referring to “heated oxygen sensor (ho2s-1 and ho2...

  • Page 99

    Engine general information and diagnosis: 1a-51 dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accid...

  • Page 100

    1a-52 engine general information and diagnosis: 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 visual inspection check maf sensor and air intake system for: • objects which block measuring duct and re...

  • Page 101

    Engine general information and diagnosis: 1a-53 7 ground circuit check 1) measure resistance between “c37-27” terminal of ecm connector and vehicle body ground. Is resistance below 5 ? “gry” wire is open or high resistance circuit. Ecm grounds “c37-58”, “c37-15” and/or “c37- 30” circuit is open or h...

  • Page 102

    1a-54 engine general information and diagnosis: dtc p0102: mass air flow circuit low input s4rs0a1104017 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool....

  • Page 103

    Engine general information and diagnosis: 1a-55 dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 104

    1a-56 engine general information and diagnosis: dtc p0103: mass air flow circuit high input s4rs0a1104018 wiring diagram 8 maf sensor signal circuit check 1) measure resistance between “grn/blk” wire terminal of maf and iat sensor connector and “c37-26” terminal of ecm connector. Is resistance below...

  • Page 105

    Engine general information and diagnosis: 1a-57 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and run it for 10 sec. 4) check dtc and pending dtc. Dt...

  • Page 106

    1a-58 engine general information and diagnosis: dtc p0106: manifold absolute pressure range / performance s4rs0a1104079 wiring diagram dtc detecting condition and trouble area 6 maf sensor signal circuit check 1) disconnect connectors from ecm with ignition switch turned off. 2) measure voltage betw...

  • Page 107

    Engine general information and diagnosis: 1a-59 dtc confirmation procedure note: check to make sure that the following conditions are satisfied when using this “dtc confirmation procedure”. • intake air temperature at engine start: –10 c (14 f) to 80 c (176 f) • intake air temperature: –10 c (14 f) ...

  • Page 108

    1a-60 engine general information and diagnosis: dtc p0107: manifold absolute pressure circuit low input s4rs0a1104050 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear d...

  • Page 109

    Engine general information and diagnosis: 1a-61 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 map sensor and its circuit check 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ...

  • Page 110

    1a-62 engine general information and diagnosis: dtc p0108: manifold absolute pressure circuit high input s4rs0a1104051 wiring diagram dtc detecting condition and trouble area note: when dtc p0113, p0118 and p0123 are indicated together, it is possible that “orn” wire circuit is open. Dtc confirmatio...

  • Page 111

    Engine general information and diagnosis: 1a-63 dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 112

    1a-64 engine general information and diagnosis: dtc p0111: intake air temperature circuit range / performance s4rs0a1104068 wiring diagram 6 ground circuit check 1) measure resistance between “c37-55” terminal of ecm connector and vehicle body ground. Is resistance below 5 ? “orn” wire is open or hi...

  • Page 113

    Engine general information and diagnosis: 1a-65 dtc detecting condition and trouble area dtc confirmation procedure note: check to make sure that following conditions are satisfied when using this “dtc confirmation procedure”. • intake air temperature at engine start: –10 c (14 f) to 80 c (176 f) • ...

  • Page 114

    1a-66 engine general information and diagnosis: 3 wire harness check 1) disconnect maf and iat sensor connector (1) with ignition switch turned off. 2) check for proper connection to maf and iat sensor connector (1) at “blk/yel” and “orn” wire terminals. 3) if ok, then with ignition switch turned on...

  • Page 115

    Engine general information and diagnosis: 1a-67 dtc p0112: intake air temperature sensor circuit low s4rs0a1104019 wiring diagram 8 ground circuit check 1) connect connectors to ecm. 2) check for proper connection of maf and iat sensor connector at “orn” wire terminal. 3) measure resistance between ...

  • Page 116

    1a-68 engine general information and diagnosis: dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and run it for 10 sec. 4) check dtc and pending dtc. Dt...

  • Page 117

    Engine general information and diagnosis: 1a-69 3 ecm voltage check 1) disconnect connector from maf and iat sensor with ignition switch turned off. 2) check for proper connection to maf and iat sensor at “blk/yel” and “orn” wire terminals. 3) if ok, then turn on ignition switch, measure voltage bet...

  • Page 118

    1a-70 engine general information and diagnosis: dtc p0113: intake air temperature sensor circuit high s4rs0a1104020 wiring diagram dtc detecting condition and trouble area note: when dtc p0108, p0118 and p0123 are indicated together, it is possible that “orn” wire circuit open. Dtc confirmation proc...

  • Page 119

    Engine general information and diagnosis: 1a-71 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 iat sensor and its circuit check 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ...

  • Page 120

    1a-72 engine general information and diagnosis: 6 wire circuit check 1) measure resistance between “c37-25” terminal of ecm connector and “blk/yel” wire terminal of maf and iat sensor connector with ignition switch turned off. Is resistance below 5 ? Go to step 7. “blk/yel” wire is high resistance c...

  • Page 121

    Engine general information and diagnosis: 1a-73 dtc p0116: engine coolant temperature circuit range / performance s4rs0a1104069 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 possi...

  • Page 122

    1a-74 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 123

    Engine general information and diagnosis: 1a-75 6 ecm voltage check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) check for proper connection of ecm connector at “c37- 24” terminal. 4) if ok, then turn on ignition switch, measure voltage between “c37-2...

  • Page 124

    1a-76 engine general information and diagnosis: dtc p0117: engine coolant temperature circuit low s4rs0a1104021 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using sca...

  • Page 125

    Engine general information and diagnosis: 1a-77 dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 126

    1a-78 engine general information and diagnosis: dtc p0118: engine coolant temperature circuit high s4rs0a1104022 wiring diagram dtc detecting condition and trouble area note: when dtc p0108, p0113 and p0123 are indicated together, it is possible that “orn” wire circuit open. Dtc confirmation procedu...

  • Page 127

    Engine general information and diagnosis: 1a-79 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 ect sensor and its circuit check 1) connect scan tool with ignition switch turned off. 2) turn on ignitio...

  • Page 128

    1a-80 engine general information and diagnosis: dtc p0121: throttle position sensor circuit range / performance s4rs0a1104023 wiring diagram 7 ect sensor ground circuit check 1) connect connectors to ecm. 2) check for proper connection of ect sensor connector at “orn” wire terminal. 3) measure resis...

  • Page 129

    Engine general information and diagnosis: 1a-81 dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accid...

  • Page 130

    1a-82 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 131

    Engine general information and diagnosis: 1a-83 5 wire harness check 1) turn ignition switch to off position. 2) disconnect connectors from map sensor and a/c refrigerant pressure sensor. 3) turn ignition switch to on position. 4) measure voltage between “gry/red” wire terminal of tp sensor connecto...

  • Page 132

    1a-84 engine general information and diagnosis: 10 wire circuit check 1) measure resistance between “c37-14” terminal of ecm connector and “gry/red” wire terminal of tp sensor connector, between “c37-54” terminal of ecm connector and “gry/blu” wire terminal of tp sensor connector with ignition switc...

  • Page 133

    Engine general information and diagnosis: 1a-85 dtc p0122: throttle position sensor circuit low s4rs0a1104024 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan ...

  • Page 134

    1a-86 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ...

  • Page 135

    Engine general information and diagnosis: 1a-87 4 wire harness check 1) turn ignition switch to off position. 2) disconnect connectors from map sensor and a/c refrigerant pressure sensor. 3) turn ignition switch to on position. 4) measure voltage between “gry/red” wire terminal of tp sensor connecto...

  • Page 136

    1a-88 engine general information and diagnosis: dtc p0123: throttle position sensor circuit high s4rs0a1104025 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure note: when dtc p0108, p0113 and p0118 are indicated together, it is possible that “orn” wire circuit open....

  • Page 137

    Engine general information and diagnosis: 1a-89 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 tp sensor and its circuit check 1) connect scan tool to dlc with ignition switch turned off and then turn...

  • Page 138

    1a-90 engine general information and diagnosis: 6 wire circuit check 1) disconnect connectors from ecm with ignition switch turned off. 2) turn on ignition switch. 3) check for proper connection of ecm connector at “c37- 54” terminal. 4) measure voltage between “gry/blu” wire terminal of tp sensor c...

  • Page 139

    Engine general information and diagnosis: 1a-91 dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-1) s4rs0a1104026 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no ...

  • Page 140

    1a-92 engine general information and diagnosis: note: check to make sure that following conditions are satisfied when using this “dtc confirmation procedure”. • intake air temperature at engine start: –10 c (14 f) to 80 c (176 f) • intake air temperature: –10 c (14 f) to 70 c (158 f) • engine coolan...

  • Page 141

    Engine general information and diagnosis: 1a-93 5 wire circuit check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) measure resistance between “wht” wire terminal of ho2s-1 connector and “c37-10” terminal of ecm connector. Is resistance less than 5 ? Go...

  • Page 142

    1a-94 engine general information and diagnosis: dtc p0133: o2 sensor (ho2s) circuit slow response (sensor-1) s4rs0a1104027 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 143

    Engine general information and diagnosis: 1a-95 5) keep above vehicle speed for 6 min. Or more. (throttle valve opening is kept constant in this step.) 6) release accelerator pedal and with engine brake applied, keep vehicle coasting (with fuel cut for 3 sec. Or more) and then stop vehicle. 7) check...

  • Page 144

    1a-96 engine general information and diagnosis: dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accid...

  • Page 145

    Engine general information and diagnosis: 1a-97 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 ho2s-1 output voltage check 1) connect scan tool to dlc with ignition switch turned off. 2) warm up engin...

  • Page 146

    1a-98 engine general information and diagnosis: dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2) s4rs0a1104070 wiring diagram dtc detecting condition and trouble area 8 air intake system check 1) check air intake system for clog or leak. Is it ok? Check ho2s-1 referr...

  • Page 147

    Engine general information and diagnosis: 1a-99 dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out by...

  • Page 148

    1a-100 engine general information and diagnosis: 4 ho2s-2 ground check 1) disconnect connector from ho2s-2 with ignition switch turned off. 2) check for proper connection to ho2s-2 connector at “red/blu”, “brn”, “yel” and “blk/wht” wire terminals. 3) if connections are ok, measure resistance between...

  • Page 149

    Engine general information and diagnosis: 1a-101 dtc p0140: o2 sensor (ho2s) circuit no activity detected (sensor-2) s4rs0a1104030 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or po...

  • Page 150

    1a-102 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 151

    Engine general information and diagnosis: 1a-103 dtc p0171 / p0172: fuel system too lean / rich s4rs0a1104032 dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and ...

  • Page 152

    1a-104 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 153

    Engine general information and diagnosis: 1a-105 dtc p0300 / p0301 / p0302 / p0303 / p0304: random misfire detected / cylinder 1 / cylinder 2 / cylinder 3 / cylinder 4 misfire detected s4rs0a1104033 system description ecm measures the angle of the crankshaft based on the pulse signal from the ckp se...

  • Page 154

    1a-106 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 155

    Engine general information and diagnosis: 1a-107 dtc p0327 / p0328: knock sensor circuit low / high s4rs0a1104034 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc, ...

  • Page 156

    1a-108 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 157

    Engine general information and diagnosis: 1a-109 dtc p0335: crankshaft position (ckp) sensor circuit s4rs0a1104035 wiring diagram dtc detecting condition and trouble area 7 knock sensor circuit for high resistance check 1) turn off ignition switch, measure resistance between “c37-56” terminal of ecm...

  • Page 158

    1a-110 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) crank engine for 3 – 5 sec. 4) check dtc and pending dtc. Dtc troubleshooting note: • before performed troub...

  • Page 159

    Engine general information and diagnosis: 1a-111 dtc p0340: camshaft position (cmp) sensor circuit s4rs0a1104036 wiring diagram 5 ground circuit check 1) turn ignition switch to off position. 2) measure resistance between “blk/orn” wire terminal of ckp sensor connector and engine ground. Is measured...

  • Page 160

    1a-112 engine general information and diagnosis: system description the cmp sensor located on the transmission side of cylinder head consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion). The signal generator generates reference signal through slits in the sli...

  • Page 161

    Engine general information and diagnosis: 1a-113 3 wire harness and connection check 1) disconnect connector from cmp sensor. 2) check for proper connection to cmp sensor at “blk/ red”, “red/yel” and “blk/orn” wire terminals. 3) if ok, turn on ignition switch and check voltage at “blk/ red”, “red/ye...

  • Page 162

    1a-114 engine general information and diagnosis: dtc p0401 / p0402: exhaust gas recirculation flow insufficient detected / excessive detected s4rs0a1104037 system and wiring diagram i4rs0a110035- 1. Egr valve 4. Sensed information 7. “ig coil” fuse 10. Main relay 2. Intake manifold 5. Fresh air 8. B...

  • Page 163

    Engine general information and diagnosis: 1a-115 dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an acci...

  • Page 164

    1a-116 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 165

    Engine general information and diagnosis: 1a-117 dtc p0403: exhaust gas recirculation control circuit s4rs0a1104071 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a ...

  • Page 166

    1a-118 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 167

    Engine general information and diagnosis: 1a-119 dtc p0420: catalyst system efficiency below threshold s4rs0a1104039 system and wiring diagram circuit description ecm monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by ho2s-2. When the catal...

  • Page 168

    1a-120 engine general information and diagnosis: dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out b...

  • Page 169

    Engine general information and diagnosis: 1a-121 dtc p0443: evaporative emission system purge control valve circuit s4rs0a1104040 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 pos...

  • Page 170

    1a-122 engine general information and diagnosis: dtc troubleshooting warning: in order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas water heater. Note: • before performed trouble shooting, be sure to read ...

  • Page 171

    Engine general information and diagnosis: 1a-123 dtc p0462: fuel level sensor circuit low s4rs0a1104072 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. ...

  • Page 172

    1a-124 engine general information and diagnosis: dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 173

    Engine general information and diagnosis: 1a-125 dtc p0463: fuel level sensor circuit high s4rs0a1104073 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool....

  • Page 174

    1a-126 engine general information and diagnosis: 4 fuel level sensor output signal check with suzuki scan tool 1) connect suzuki scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and check fuel level displayed on suzuki scan tool. Is it 3% or less? Go to step 6. Intermitte...

  • Page 175

    Engine general information and diagnosis: 1a-127 dtc p0480: fan 1 (radiator cooling fan) control circuit s4rs0a1104074 wiring diagram dtc detecting condition and trouble area 11 high resistance circuit check for fuel level sensor circuit 1) disconnect connectors from ecm. 2) measure resistance betwe...

  • Page 176

    1a-128 engine general information and diagnosis: dtc confirmation procedure 1) turn off ignition switch turned. 2) clear dtc with ignition switch turned on. 3) run engine at idle speed. 4) check pending dtc in “on board test” or “pending dtc” mode and dtc in “dtc” mode. Dtc troubleshooting step acti...

  • Page 177

    Engine general information and diagnosis: 1a-129 4 wire circuit check 1) connect radiator cooling fan relay no. 1 to relay box with ignition switch turned off. 2) remove ecm from its bracket with ecm connectors connected. 3) turn on ignition switch, measure voltage between vehicle body ground and “e...

  • Page 178

    1a-130 engine general information and diagnosis: 9 radiator cooling fan control check 1) disconnect radiator cooling fan relay no. 2 (2) and no. 3 (3) from relay box (1) with ignition switch turned off. 2) run engine until ect is over 97.5 c, 207.5 f. 3) measure voltage between vehicle body ground a...

  • Page 179

    Engine general information and diagnosis: 1a-131 dtc p0500: vehicle speed sensor (vss) malfunction s4rs0a1104045 wiring diagram 14 radiator cooling fan relay no. 2 and no. 3 check 1) check radiator cooling fan relay no. 2 and no. 3 referring to “radiator cooling fan relay inspection: in section 1f”....

  • Page 180

    1a-132 engine general information and diagnosis: dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an acci...

  • Page 181

    Engine general information and diagnosis: 1a-133 5 power supply circuit check 1) with ignition switch turned off, disconnect connector from vss. 2) check for proper connection to “blk/red”, “ppl” and “blk/orn” wire terminals of vss connector. 3) if wires are ok, turn on ignition switch, measure volt...

  • Page 182

    1a-134 engine general information and diagnosis: dtc p0505: idle air control system s4rs0a1104046 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) run...

  • Page 183

    Engine general information and diagnosis: 1a-135 dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 184

    1a-136 engine general information and diagnosis: dtc p0532: a/c refrigerant pressure sensor circuit low s4rs0a1104075 wiring diagram 8 idle air control valve circuit check 1) measure resistance between “blk” wire terminal of idle air control valve connector and vehicle body ground with ignition swit...

  • Page 185

    Engine general information and diagnosis: 1a-137 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) check dtc and pending dtc. Troubleshooting note: • before per...

  • Page 186

    1a-138 engine general information and diagnosis: dtc p0533: a/c refrigerant pressure sensor circuit high s4rs0a1104076 wiring diagram dtc detecting condition and trouble area 5 a/c refrigerant pressure sensor signal circuit check 1) connect connectors to ecm. 2) turn on ignition switch, measure volt...

  • Page 187

    Engine general information and diagnosis: 1a-139 dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) check dtc and pending dtc. Troubleshooting note: • before performed trouble shooting, be sure to read ...

  • Page 188

    1a-140 engine general information and diagnosis: dtc p0601 / p0602: internal control module memory check sum error / control module programming error s4rs0a1104052 system description internal control module is installed in ecm. Dtc detecting condition and trouble area dtc confirmation procedure 1) c...

  • Page 189

    Engine general information and diagnosis: 1a-141 dtc p0616: starter relay circuit low s4rs0a1104077 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) s...

  • Page 190

    1a-142 engine general information and diagnosis: dtc p0617: starter relay circuit high s4rs0a1104078 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) ...

  • Page 191

    Engine general information and diagnosis: 1a-143 dtc troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the...

  • Page 192

    1a-144 engine general information and diagnosis: dtc p1510: ecm back-up power supply malfunction s4rs0a1104053 wiring diagram circuit description battery voltage is supplied so that dtc memory, values for engine control learned by ecm, etc. Are kept in ecm even when the ignition switch is turned off...

  • Page 193

    Engine general information and diagnosis: 1a-145 dtc p1603: tcm trouble code detected s4rs0a1104065 wiring diagram dtc detecting condition when ecm receives a trouble code from tcm, which indicates that some problem occurred in sensor circuits and its calculated values used for operations such as id...

  • Page 194

    1a-146 engine general information and diagnosis: dtc p1674: can communication (bus off error) s4rs0a1104080 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by usin...

  • Page 195

    Engine general information and diagnosis: 1a-147 troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm...

  • Page 196

    1a-148 engine general information and diagnosis: 8 dtc check in ecm 1) disconnect connector from combination meter with ignition switch turned off. 2) check ecm for dtc. Is there dtc p1674? Go to step 9. Substitute a known- good combination meter and recheck. 9 can communication line circuit insulat...

  • Page 197

    Engine general information and diagnosis: 1a-149 13 can communication line circuit ground short check 1) measure resistance at following connector terminals. • between “e23-3” terminal of ecm connector and vehicle body ground • between “e23-18” terminal of ecm connector and vehicle body ground • bet...

  • Page 198

    1a-150 engine general information and diagnosis: dtc p1675: can communication (transmission error) s4rs0a1104081 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by...

  • Page 199

    Engine general information and diagnosis: 1a-151 troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm...

  • Page 200

    1a-152 engine general information and diagnosis: 9 combination meter operation check 1) check combination meter operation for seat belt warning lamp (fastening and unfastening driver side seat belt) and shift position indicator lamp (equipped with a/t) with ignition switch turned on. Are they ok? Su...

  • Page 201

    Engine general information and diagnosis: 1a-153 dtc p1676: can communication (reception error for tcm) s4rs0a1104082 wiring diagram 13 check for short circuit of can communication line to power circuit 1) measure voltage at following connector terminals with ignition switch turned on. • between “e2...

  • Page 202

    1a-154 engine general information and diagnosis: dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan tool. 3) start engine and run it for 1 min. Or more. 4) check dtc a...

  • Page 203

    Engine general information and diagnosis: 1a-155 8 can communication line circuit continuity check 1) disconnect connectors from ecm and tcm with ignition switch turned off. 2) measure resistance at following connector terminals. • between “c37-13” terminal of ecm connector and “c34-17” terminal of ...

  • Page 204

    1a-156 engine general information and diagnosis: dtc p1678: can communication (reception error for bcm) s4rs0a1104083 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear d...

  • Page 205

    Engine general information and diagnosis: 1a-157 2 dtc check 1) connect scan tool to dlc with ignition switch turned off. 2) check ecm, tcm (equipped with a/t) and bcm for dtc. Is there any dtc(s) (other than dtc p1674, p1675, p1676, p1678 in ecm, dtc p1774, p1775, p1777, p1778 in tcm (equipped with...

  • Page 206

    1a-158 engine general information and diagnosis: dtc p2227 / p2228 / p2229: barometric pressure circuit malfunction s4rs0a1104054 dtc p2227: barometric pressure circuit range / performance dtc p2228: barometric pressure circuit low dtc p2229: barometric pressure circuit high system description barom...

  • Page 207

    Engine general information and diagnosis: 1a-159 dtc detecting condition and trouble area dtc confirmation procedure dtc p2227: warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence...

  • Page 208

    1a-160 engine general information and diagnosis: inspection of ecm and its circuits s4rs0a1104055 ecm and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. Caution: ecm cannot be checked by itself. It is strictly prohibited to connect voltmete...

  • Page 209

    Engine general information and diagnosis: 1a-161 terminal no. Wire color circuit normal voltage condition remarks c37-1 blu/ yel fuel injector no.1 output 10 – 14 v ignition switch turned on. — *0 – 0.6 v 10 – 14 v (“reference waveform no.1: ”, “reference waveform no.2: ” and “reference waveform no....

  • Page 210

    1a-162 engine general information and diagnosis: c37-10 wht oxygen signal of heated oxygen sensor-1 0 – 1 v ignition switch turned on. — *deflects between over 0.5 v and under 0.45 v (“reference waveform no.9: ” and “reference waveform no.10: ”) while engine running at 2,000 r/min. For 1 min. Or lon...

  • Page 211

    Engine general information and diagnosis: 1a-163 c37-20 red/ yel cmp sensor signal 0 – 1 v or 4 – 5 v ignition switch turned on. — *0 – 0.6 v 4 – 5 v (“reference waveform no.15: ” and “reference waveform no.16: ”) engine running at idle after warmed up engine. Sensor signal is pulse. Pulse frequency...

  • Page 212

    1a-164 engine general information and diagnosis: c37-43 — — — — — c37-44 — — — — — c37-45 — — — — — c37-46 blk/ red heater output of heated oxygen sensor-1 10 – 14 v ignition switch turned on. — *0 – 2 v 10 – 14 v (“reference waveform no.9: ” and “reference waveform no.10: ”) engine running at idle ...

  • Page 213

    Engine general information and diagnosis: 1a-165 c37-59 yel/ grn oil control valve ground below 1.3 v ignition switch turned on. — c37-60 yel/ red oil control valve output *0 – 0.6 v 10 – 14 v (“reference waveform no.25: ” and “reference waveform no.26: ”) at the moment of ignition switch turned on....

  • Page 214

    1a-166 engine general information and diagnosis: e23-17 — — — — — e23-18 wht can (low) communication line (active low signal) for bcm, combination meter *0.5 – 2.5 v (“reference waveform no.27: ”) ignition switch turned on with engine at stop. Can communication line signal is pulse. Pulse signal dis...

  • Page 215

    Engine general information and diagnosis: 1a-167 e23-43 — — — — — e23-44 — — — — — e23-45 — — — — — e23-46 lt grn radiator cooling fan relay no.1 output 10 – 14 v ignition switch turned on, engine coolant temp.: below 95 c (203 f), or a/c refrigerant pressure: below 600 kpa (87 psi) with a/c switch ...

  • Page 216

    1a-168 engine general information and diagnosis: reference waveform no.1 fuel injector signal (1) with engine idling e23-55 red a/c refrigerant pressure sensor signal 1.38 – 1.52 v engine running, a/c switch off and blower selector at off position, a/c refrigerant pressure: 800 kpa (116 psi) — 2.15 ...

  • Page 217

    Engine general information and diagnosis: 1a-169 reference waveform no.2 no.1 fuel injector signal (2) with engine idling reference waveform no.3 no.2 fuel injector signal (2) with engine idling reference waveform no.4 egr valve signal reference waveform no.5 ignition coil no.2 and no.3 signal (2) w...

  • Page 218

    1a-170 engine general information and diagnosis: reference waveform no.6 ignition coil signal (1) with engine idling reference waveform no.7 ignition coil no.1 and no.4 signal (2) with engine idling reference waveform no.8 vss signal at 30 km/h (19 mph) (for m/t model) reference waveform no.9 heated...

  • Page 219

    Engine general information and diagnosis: 1a-171 reference waveform no.10 heated oxygen sensor-1 heater signal (2) with engine idling reference waveform no.11 heated oxygen sensor-2 heater signal (4) with engine idling reference waveform no.12 can communication line signal from tcm (for a/t or amt m...

  • Page 220

    1a-172 engine general information and diagnosis: reference waveform no.14 no.4 fuel injector signal (2) with engine idling reference waveform no.15 cmp sensor signal with engine idling reference waveform no.16 cmp sensor signal with engine idling reference waveform no.17 mass air flow sensor signal ...

  • Page 221

    Engine general information and diagnosis: 1a-173 reference waveform no.18 evap canister purge valve signal reference waveform no.19 iac valve signal with ignition switch turned on reference waveform no.20 iac valve signal reference waveform no.21 manifold absolute pressure sensor signal (1) with ign...

  • Page 222

    1a-174 engine general information and diagnosis: reference waveform no.22 manifold absolute pressure sensor signal (1) with engine racing reference waveform no.23 knock sensor signal at engine speed 4000 r/min. Reference waveform no.24 knock sensor signal at engine speed 4000 r/min. Reference wavefo...

  • Page 223

    Engine general information and diagnosis: 1a-175 reference waveform no.26 oil control valve signal with engine racing (for m15 engine model) reference waveform no.27 can communication line signal from bcm with ignition switch turned on reference waveform no.28 ignition pulse (engine revolution) sign...

  • Page 224

    1a-176 engine general information and diagnosis: reference waveform no.30 ignition coil signal and fuel injector signal with engine cranking resistance check 1) remove ecm from its bracket referring to “engine control module (ecm) removal and installation: in section 1c”. Caution: never touch termin...

  • Page 225

    Engine general information and diagnosis: 1a-177 ecm power and ground circuit check s4rs0a1104066 wiring diagram circuit description when the ignition switch is turned on, the main relay turns on (the contact point closes) and the main power is supplied to ecm. C37-4 to e23-1/16 egr valve (stepping ...

  • Page 226

    1a-178 engine general information and diagnosis: troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm...

  • Page 227

    Engine general information and diagnosis: 1a-179 6 ecm ground circuit check 1) turn ignition switch to off position. 2) disconnect connectors from ecm. 3) measure resistance between each “c37-58”, “c37-15” and “c37-30” terminals of ecm connector and body ground. Is resistance 1 or less? Substitute a...

  • Page 228

    1a-180 engine general information and diagnosis: fuel injector circuit check s4rs0a1104056 wiring diagram 11 sensor power source circuit check 1) connect connectors to ecm with ignition switch turned off. 2) turn on ignition switch, measure each voltage between “c37-14” terminal of ecm connector and...

  • Page 229

    Engine general information and diagnosis: 1a-181 troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm...

  • Page 230

    1a-182 engine general information and diagnosis: fuel pump and its circuit check s4rs0a1104057 wiring diagram troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ...

  • Page 231

    Engine general information and diagnosis: 1a-183 step action yes no 1 fuel pump control system check for operation is fuel pump heard to operate 3 sec. After ignition switch is turned on? Fuel pump circuit is in good condition. Go to step 2. 2 fuel pump relay power supply check 1) disconnect fuel pu...

  • Page 232

    1a-184 engine general information and diagnosis: 7 wire circuit check 1) turn off ignition switch. 2) detach fuel tank referring to “fuel tank removal and installation: in section 1g”. 3) disconnect connector from fuel pump. 4) measure resistance between “pnk” wire terminal of fuel pump connector an...

  • Page 233

    Engine general information and diagnosis: 1a-185 fuel pressure check s4rs0a1104058 system diagram special tool (a): 09912–58442 (b): 09912–58432 (c): 09912–58490 troubleshooting note: before using the following flow, check to make sure that battery voltage is higher than 11 v. If battery voltage is ...

  • Page 234

    1a-186 engine general information and diagnosis: idle air control system check s4rs0a1104059 wiring diagram 4 fuel line check 1) check fuel pipe, fuel hose and joint for damage or deform. Are they in good condition? Faulty fuel pressure regulator. Repair or replace damaged or deformed part. 5 was fu...

  • Page 235

    Engine general information and diagnosis: 1a-187 troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm...

  • Page 236

    1a-188 engine general information and diagnosis: a/c system circuits check s4rs0a1104060 wiring diagram 8 idle air control valve circuit check 1) check idle air control valve circuit referring to step 4 to 10 of “dtc p0505: idle air control system: ”. Is circuit in good condition? Replace iac valve....

  • Page 237

    Engine general information and diagnosis: 1a-189 troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm...

  • Page 238

    1a-190 engine general information and diagnosis: 6 a/c evaporator outlet air temp. Sensor check 1) disconnect connectors from ecm with ignition switch turned off. 2) check for proper connection to “e23-57” and “e23-54” wire terminals of ecm connector. 3) if ok, measure resistance between “e23-57” an...

  • Page 239

    Engine general information and diagnosis: 1a-191 note: when a/c evaporator outlet air temp. Is below 2.5 c (36.5 f), a/c remains off (“e23-47” terminal voltage becomes 10 – 14 v). This condition is not abnormal. 11 a/c compressor relay circuit check 1) measure voltage between “e23-47” wire terminal ...

  • Page 240

    1a-192 engine general information and diagnosis: electric load signal circuit check s4rs0a1104061 wiring diagram troubleshooting note: • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection: ”. • when measuring circuit voltage, resistance and/or pulse signal ...

  • Page 241

    Engine general information and diagnosis: 1a-193 radiator cooling fan low speed control system check s4rs0a1104062 wiring diagram 3 electric load signal circuit check 1) turn on ignition switch. 2) check voltage at terminal “e23-19” of ecm connector connected, under following conditions respectively...

  • Page 242

    1a-194 engine general information and diagnosis: troubleshooting warning: keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ect se...

  • Page 243

    Engine general information and diagnosis: 1a-195 radiator cooling fan high speed control system check s4rs0a1104084 wiring diagram troubleshooting warning: keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or no...

  • Page 244

    1a-196 engine general information and diagnosis: step action yes no 1 is there dtc(s) of ect sensor circuit (dtc p0116 / p0117 / p0118) and/or radiator cooling fan circuit (dtc p0480)? Go to corresponding dtc flow. Go to step 2. 2 low speed radiator cooling fan control circuit check 1) connect scan ...

  • Page 245

    Engine general information and diagnosis: 1a-197 8 radiator cooling fan control no. 2 check 1) connect radiator cooling fan control relay no. 2 to relay box with ignition switch turned off. 2) run engine when ect is over 102.5 c, 216.5 f. 3) measure voltage between vehicle body ground and “blu/blk” ...

  • Page 246

    1a-198 engine general information and diagnosis: repair instructions idle speed / idle air control (iac) duty inspection s4rs0a1106001 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 247

    Engine general information and diagnosis: 1a-199 special tools and equipment special tool s4rs0a1108001 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- 58413...

  • Page 248

    1b-1 aux. Emission control devices: aux. Emission control devices diagnostic information and procedures egr system inspection s4rs0a1204001 1) connect suzuki scan tool to data link connector (dlc) with ignition switch turned off. 2) turn on ignition switch and erase dtc using “clear dtc” in “trouble...

  • Page 249

    Aux. Emission control devices: 1b-2 ii) turn on ignition switch, clear dtc and select “misc test” mode on suzuki scan tool. Special tool (a): suzuki scan tool b) when not using suzuki scan tool: note: before performed this check, be sure to read the “precautions of ecm circuit inspection: in section...

  • Page 250

    1b-3 aux. Emission control devices: vacuum hose inspection s4rs0a1206004 check hoses for connection, leakage, clog and deterioration. Replace as necessary. Evap canister purge valve inspection s4rs0a1206005 warning: do not apply vacuum by mouth; otherwise harmful fuel vapor can be breathed in. Cauti...

  • Page 251

    Aux. Emission control devices: 1b-4 egr valve removal and installation s4rs0a1206007 removal 1) disconnect negative cable at battery. 2) remove air intake pipe. 3) remove egr pipe. 4) disconnect egr valve connector. 5) remove egr valve and gasket from cylinder head. Installation reverse removal proc...

  • Page 252

    1b-5 aux. Emission control devices: special tools and equipment special tool s4rs0a1208001 09917–47011 suzuki scan tool vacuum pump gauge — / this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loopback adapter, 7. Battery powe...

  • Page 253: Engine Electrical Devices

    Engine electrical devices: 1c-1 engine electrical devices repair instructions idle air control (iac) valve operation inspection s4rs0a1306001 using suzuki scan tool 1) connect suzuki scan tool to dlc (1) with ignition switch turned off. Special tool (a): suzuki scan tool 2) warm up engine to normal ...

  • Page 254

    1c-2 engine electrical devices: idle air control (iac) valve removal and installation s4rs0a1306003 removal 1) remove throttle body referring to “throttle body removal and installation: in section 1d”. 2) remove lac valve from throttle body. Installation 1) install new gasket (2) to throttle body (1...

  • Page 255

    Engine electrical devices: 1c-3 manifold absolute pressure (map) sensor inspection s4rs0a1306005 1) remove air cleaner assembly. 2) disconnect connector from map sensor. 3) remove map sensor. 4) arrange 3 new 1.5 v batteries (2) in series (check that total voltage is 4.5 – 5.0 v) and connect its pos...

  • Page 256

    1c-4 engine electrical devices: throttle position (tp) sensor removal and installation s4rs0a1306007 removal 1) disconnect negative cable at battery. 2) disconnect tp sensor connector and remove tp sensor from throttle body. Installation 1) install tp sensor (1) to throttle body. Fit tp sensor to th...

  • Page 257

    Engine electrical devices: 1c-5 engine coolant temperature (ect) sensor inspection s4rs0a1306009 immerse temperature sensing part of ect sensor (1) in water (or ice) and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t show such characteristic...

  • Page 258

    1c-6 engine electrical devices: installation reverse removal procedure noting the following. • tighten heated oxygen sensor (1) to specified torque. Tightening torque heated oxygen sensor (a): 45 n·m (4.5 kg-m, 32.5 lb-ft) • install exhaust manifold referring to “exhaust manifold removal and install...

  • Page 259

    Engine electrical devices: 1c-7 crankshaft position (ckp) sensor removal and installation s4rs0a1306015 removal 1) disconnect negative cable at battery. 2) remove generator drive belt, loosen pivot bolt and move generator rearward. 3) disconnect connector from crankshaft position sensor. 4) remove c...

  • Page 260

    1c-8 engine electrical devices: performance check 1) remove metal particles on end face of ckp sensor, if any. 2) arrange 12 v battery (1) and connect its positive terminal to “vin” terminal (2) and negative terminal to “ground” terminal (3) of sensor. Then using ohmmeter, measure resistance between...

  • Page 261

    Engine electrical devices: 1c-9 main relay, fuel pump relay, starting motor control relay and throttle actuator control relay inspection s4rs0a1306019 1) disconnect negative cable at battery. 2) remove main relay (1), fuel pump relay (3) and starting motor control relay (2) from relay box. 3) check ...

  • Page 262

    1c-10 engine electrical devices: mass air flow (maf) and intake air temperature (iat) sensor removal and installation s4rs0a1306021 caution: • do not disassemble maf and iat sensor. • do not expose maf and iat sensor to any shock. • do not clean maf and iat sensor. • if maf and iat sensor has been d...

  • Page 263

    Engine electrical devices: 1c-11 specifications tightening torque specifications s4rs0a1307001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information: in section 0a”. Special tools and equipment special tool s4rs0a1308001 fastening part tighte...

  • Page 264: Engine Mechanical

    1d-1 engine mechanical: engine mechanical general description engine construction description s4rs0a1401001 the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration and 16 valves (...

  • Page 265

    Engine mechanical: 1d-2 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 266

    1d-3 engine mechanical: cam timing sprocket the cam timing sprocket is equipped with the chambers for timing advancing (2) and retarding (3) which are separated by the rotor (5). The rotor rotates receiving the hydraulic pressure applied to both the chambers. The sprocket (1) is installed on the hou...

  • Page 267

    Engine mechanical: 1d-4 diagnostic information and procedures compression check s4rs0a1404001 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 ...

  • Page 268

    1d-5 engine mechanical: note: • for measuring compression pressure, crank engine at least 250 r/min. By using fully charged battery. • if measured compression pressure is lower than limit value, check installation condition of special tool. If it is properly installed, possibility is compression pre...

  • Page 269

    Engine mechanical: 1d-6 valve lash (clearance) inspection s4rs0a1404003 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 pull...

  • Page 270

    1d-7 engine mechanical: 2) lift down the valve by turning crankshaft to 360 . 3) hold tappet at that position using special tool as follows. A) remove its housing bolts. B) check housing no. And select special tool corresponding to housing no., referring to “special tool selection table”. Special to...

  • Page 271

    Engine mechanical: 1d-8 6) select new shim no. (1) with a thickness as close as possible to calculated value. Available new shims no. 7) install new shim facing shim no. Side with tappet. 8) lift valve by turning crankshaft counterclockwise (in opposite direction against above step 4)) and remove sp...

  • Page 272

    1d-9 engine mechanical: air cleaner element inspection and cleaning s4rs0a1406002 inspection check air cleaner element for dirt. Replace excessive dirty element. Cleaning blow off dust by compressed air from air outlet side of element. Cylinder head cover removal and installation s4rs0a1406011 remov...

  • Page 273

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

  • Page 274

    1d-11 engine mechanical: accelerator cable adjustment s4rs0a1406003 with accelerator pedal depressed fully (1), check clearance between throttle lever (2) and lever stopper (3) of throttle body. If measured value is out of specification, adjust it to specification with cable adjusting nut (4), and t...

  • Page 275

    Engine mechanical: 1d-12 throttle body on-vehicle inspection s4rs0a1406005 check that throttle lever (1) moves smoothly. Throttle body removal and installation s4rs0a1406006 removal 1) disconnect negative cable at battery. 2) drain coolant referring to “cooling system draining: in section 1f”. 3) di...

  • Page 276

    1d-13 engine mechanical: throttle body cleaning s4rs0a1406008 clean throttle body bore (1) and idle air passage (2) by blowing compressed air. Note: tp sensor, idle air control valve or other components containing rubber must not be placed in a solvent or cleaner both. A chemical reaction will cause...

  • Page 277

    Engine mechanical: 1d-14 throttle body and intake manifold components s4rs0a1406009 i4rs0a140003- 1. Intake manifold 7. Egr pipe 13. Evap canister purge valve 19. To pcv valve 2. Intake manifold o-ring 8. O-ring 14. Evap canister purge valve hose 20. To cylinder head cover 3. Throttle body 9. Gasket...

  • Page 278

    1d-15 engine mechanical: intake manifold removal and installation s4rs0a1406010 removal 1) remove throttle body referring to “throttle body removal and installation: ”. 2) disconnect map sensor coupler (1). 3) disconnect the following hoses: • brake booster hose (2) from cylinder head cover • pcv ho...

  • Page 279

    Engine mechanical: 1d-16 engine mountings components s4rs0a1406012 i4rs0a140006- [a]: a/t model 10. Engine right mounting bolt 21. Engine rear mounting body bracket bolt [b]: m/t model 11. Engine left mounting bush bolt 22. Engine rear mounting no.3 bracket bolt 1. Engine right mounting bracket 12. ...

  • Page 280

    1d-17 engine mechanical: engine assembly removal and installation s4rs0a1406013 removal 1) relieve fuel pressure according to “fuel pressure relief procedure: in section 1g”. 2) disconnect negative and positive cable at battery. 3) remove battery and tray. 4) remove engine hood after disconnecting w...

  • Page 281

    Engine mechanical: 1d-18 20) disconnect right and left drive shaft joints from differential gear referring to “front drive shaft assembly removal and installation: in section 3a”. Note: for engine and transaxle removal, it is not necessary to remove drive shafts from steering knuckle. 21) remove exh...

  • Page 282

    1d-19 engine mechanical: 28) lower engine with transaxle from engine compartment. Caution: before lowering engine, to avoid damage to a/c compressor and clutch operating cylinder, make clearance by rising them. Be sure not to damage suspended a/c compressor and clutch operating cylinder. 29) disconn...

  • Page 283

    Engine mechanical: 1d-20 15) adjust a/c compressor belt tension (if equipped) referring to “compressor drive belt inspection and adjustment: in section 7b”. 16) adjust accelerator cable play referring to “accelerator cable adjustment: ” in this section. 17) check to ensure that all removed parts are...

  • Page 284

    1d-21 engine mechanical: timing chain cover removal and installation s4rs0a1406015 caution: • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to damage them. • do not expose removed parts to dust. Keep them always clean. Removal 1) r...

  • Page 285

    Engine mechanical: 1d-22 3) install oil control valve to timing chain cover referring to “oil control valve removal and installation: ”. 4) apply sealant “a” to mating surface of cylinder and cylinder head and “b” to mating surface of timing chain cover as shown in the figure. “a”: sealant 99000–311...

  • Page 286

    1d-23 engine mechanical: 13) install crankshaft pulley (1). Tighten bolt (2) to specified torque. To lock crankshaft pulley, use special tool with it as shown in the figure. Special tool (a): 09917–68221 tightening torque crankshaft pulley bolt (a): 150 n·m (15.0 kg-m, 108.5 lb-ft) 14) install engin...

  • Page 287

    Engine mechanical: 1d-24 oil control valve inspection s4rs0a1406044 oil control valve 1) inspect strainer (1) and mating surface (2) of oil control valve for clog or damage. Clean oil control valve if clog or foreign matter is present on strainer or mating surface of oil control valve. Replace oil c...

  • Page 288

    1d-25 engine mechanical: timing chain and chain tensioner removal and installation s4rs0a1406018 removal caution: after timing chain is removed, never turn crankshaft and camshafts independently more than its allowable turning range described in “installation”. If turned, interference may occur betw...

  • Page 289

    Engine mechanical: 1d-26 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 290

    1d-27 engine mechanical: 8) screw in plunger (1) by turning body (2) in arrow direction and install a retainer (3) (wire) to hold plunger in place. 9) install timing chain tensioner adjuster assembly (1) with a retainer (2). Tighten adjuster bolts to specified torque and then remove a retainer from ...

  • Page 291

    Engine mechanical: 1d-28 crankshaft timing sprocket check teeth of sprocket for wear or damage. Timing chain check timing chain for wear or damage. Timing chain tensioner adjuster check that tooth surface (1) are free from damage. Camshaft, tappet and shim components s4rs0a1406020 i2rh0b140070- i2rh...

  • Page 292

    1d-29 engine mechanical: camshaft, tappet and shim removal and installation s4rs0a1406021 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. Remov...

  • Page 293

    Engine mechanical: 1d-30 3) install intake camshaft (1) and exhaust camshaft (2). Align knock pin (3) and match mark (4) with notches (5) as shown in the figure. Note: before installing camshafts, turn crankshaft until key position faces upward. Refer to “timing chain and chain tensioner removal and...

  • Page 294

    1d-31 engine mechanical: 12) perform steps 3) to 8) of “installation” of “timing chain cover removal and installation: ”. Camshaft, tappet and shim inspection s4rs0a1406022 intake cam timing sprocket assembly fit intake cam timing sprocket assembly to camshaft (2) and hold hexagonal section of camsh...

  • Page 295

    Engine mechanical: 1d-32 6) tighten camshaft housing bolts in such order as indicated in the figure a little at a time till they are tightened to specified torque. Note: do not rotate camshaft while gauging plastic is installed. Tightening torque camshaft housing bolt (a): 11 n·m (1.1 kg-m, 8.0 lb-f...

  • Page 296

    1d-33 engine mechanical: measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head. Cylinder head to tappet clearance standard: 0.025 – 0.066 mm (0.0010 – 0.026 in.) limit: 0.15 mm (0.0059 in.) t...

  • Page 297

    Engine mechanical: 1d-34 valves and cylinder head components s4rs0a1406023 i4rs0a140015- 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (m8) : be sure to tighten cylinder head bolt (m8) after securing the other cylinder head bolt (m10). 2. Valve spring retainer 8. Valve guide : tighten 20 ...

  • Page 298

    1d-35 engine mechanical: valves and cylinder head removal and installation s4rs0a1406024 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation: ”. 2) remove oil pan referring to “oil pan and oil pump strainer removal and installation: in section 1e”. 3...

  • Page 299

    Engine mechanical: 1d-36 note: be sure to tighten m8 bolt “a” after securing the other bolts. Tightening torque cylinder head bolt for m8 (a): 25 n·m (2.5 kg- m, 18.0 lb-ft) cylinder head bolt for m10 (b): 20 n m (2.0 kg-m, 14.5 lb-ft), 40 n m (4.0 kg-m, 29.0 lb-ft) and then retighten by turning thr...

  • Page 300

    1d-37 engine mechanical: valves and cylinder head disassembly and assembly s4rs0a1406025 disassembly 1) for ease in servicing cylinder head, remove intake manifold, injectors, exhaust manifold from cylinder head. 2) using special tools (valve lifter), compress valve spring and then remove valve cott...

  • Page 301

    Engine mechanical: 1d-38 2) install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100 c (176 to 212 f) so that head will not be distorted, and drive new valve guide into hole with special tools. Drive in new valve guide until special tool (valve guide installer...

  • Page 302

    1d-39 engine mechanical: 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 sure to position spring in place with its bottom end (small- pitch end) facing the bottom (valve spring seat side). 8) using special tool...

  • Page 303

    Engine mechanical: 1d-40 valve stem end deflection 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 defl...

  • Page 304

    1d-41 engine mechanical: valve head radial runout check each valve for radial runout with a dial gauge and “v” block. To check runout, rotate valve slowly. If runout exceeds its limit, replace valve. Valve head radial runout limit: 0.08 mm (0.003 in.) seating contact width create contact pattern on ...

  • Page 305

    Engine mechanical: 1d-42 cylinder head inspection s4rs0a1406027 • remove all carbon deposits from combustion chambers. Note: do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to valves and valve seats, t...

  • Page 306

    1d-43 engine mechanical: valve spring preload standard: 107 – 125 n (10.7 – 12.5 kg) for 31.50 mm (23.6 – 27.6 lb/1.240 in.) limit: 102 n (10.2 kg) for 31.50 mm (22.5 lb/1.240 in.) spring squareness use a square and surface plate to check each spring for squareness in terms of clearance between end ...

  • Page 307

    Engine mechanical: 1d-44 pistons, piston rings, connecting rods and cylinders removal and installation s4rs0a1406030 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 in...

  • Page 308

    1d-45 engine mechanical: note: before installing bearing cap, make sure that checking for connecting rod bolt deformation. Refer to “piston pins and connecting rods inspection: ”. Tightening torque connecting rod bearing cap nut (a): 15 n m (1.5 kg-m, 11.0 lb-ft) and then retighten by turning throug...

  • Page 309

    Engine mechanical: 1d-46 4) after installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure. Cylinders, pistons and piston rings inspection s4rs0a1406032 cylinder visual inspection inspect cylinder walls for scratches, roughness or ridges which indicate excess...

  • Page 310

    1d-47 engine mechanical: piston clearance measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston. Note: cylinder bore dia...

  • Page 311

    Engine mechanical: 1d-48 piston pins and connecting rods inspection s4rs0a1406033 piston pin visual inspection check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular attention to condition of small end bore bush. If pin, connecting rod small end bore or...

  • Page 312

    1d-49 engine mechanical: connecting rod bolt deformation (plastic deformation tightening bolt) measure each thread diameter of connecting rod bolt (2) at “a” on 32 mm (1.25 in.) from bolt mounting surface and “b” on 40 mm (1.57 in.) from bolt mounting surface by using a micrometer (3). Calculate dif...

  • Page 313

    Engine mechanical: 1d-50 connecting rod bearing general information service connecting rod bearings are available in standard size and 0.25 mm (0.0098 in.) undersize bearing, and standard size bearing has 5 kinds of bearings differing in tolerance. For identification of undersize bearing, it is pain...

  • Page 314

    1d-51 engine mechanical: selection of connecting rod bearings note: • if bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. • when replacing crankshaft or connecting rod and its bearing due to a...

  • Page 315

    Engine mechanical: 1d-52 4) from number stamped on connecting rod and its cap and alphabets stamped on crank web no.3, determine new standard bearing to be installed to connecting rod big end inside, by referring to the table. For example, if number stamped on connecting rod and its cap is “1” and a...

  • Page 316

    1d-53 engine mechanical: main bearings, crankshaft and cylinder block components s4rs0a1406035 i4rs0a140016-.

  • Page 317

    Engine mechanical: 1d-54 main bearings, crankshaft and cylinder block removal and installation s4rs0a1406036 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 speci...

  • Page 318

    1d-55 engine mechanical: 1) install sensor plate (1) to crankshaft (2) and tighten bolts to specified torque. Note: when installing sensor plate, align spring pin (3) on crankshaft and hole of sensor plate. Tightening torque sensor plate bolt (a): 11 n·m (1.1 kg-m, 8.0 lb-ft) 2) install main bearing...

  • Page 319

    Engine mechanical: 1d-56 8) apply sealant to mating surface of rear oil seal housing (1). “a”: water tight sealant 99000–31250 sealant amount for rear oil seal housing width: “a”: 3 mm (0.12 in.) height “b”: 2 mm (0.08 in.) 9) install rear oil seal housing (1) and tighten bolts to specified torque b...

  • Page 320

    1d-57 engine mechanical: crankshaft thrust play 1) measure this play with crankshaft set in cylinder block in the normal manner, that is with thrust bearing (1) and journal bearing caps installed. Thickness of crankshaft thrust bearing standard: 2.500 mm (0.0984 in.) oversize (0.125 mm (0.0049 in.))...

  • Page 321

    Engine mechanical: 1d-58 main bearings inspection s4rs0a1406038 general information • service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. • upper half of bearing (1) has oil groove (2) as shown in t...

  • Page 322

    1d-59 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 323

    Engine mechanical: 1d-60 4) from number stamped on crank web no.2 and alphabets stamped on cylinder block, determine new standard bearing to be installed to journal, by referring to the table shown. For example, if number stamped on crank web no.2 is “1” and alphabet stamped on cylinder block is “b”...

  • Page 324

    1d-61 engine mechanical: 6) when replacing crankshaft or cylinder block due to any reason, select new standard bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new cylinder block. Undersize bearing (0.25 mm (0.0098 in.)) • 0.25 mm (0.0098 in.) undersi...

  • Page 325

    Engine mechanical: 1d-62 new undersize crankshaft main bearing specification main bearing cap no.1 bolt measure each thread diameter main bearing cap no.1 bolts (1) at “a” on 60 mm (2.36 in.) from seat side of flange bolt and “b” on 90 mm (3.54 in.) from seat side of flange bolt by using a micromete...

  • Page 326

    1d-63 engine mechanical: sensor plate inspection s4rs0a1406039 check sensor plate for crack damage. If malcondition is found, replace it. Rear oil seal inspection s4rs0a1406040 carefully inspect oil seal (1) for wear or damage. If its lip is worn or damaged, replace it. Flywheel inspection s4rs0a140...

  • Page 327

    Engine mechanical: 1d-64 specifications tightening torque specifications s4rs0a1407001 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 component...

  • Page 328

    1d-65 engine mechanical: special tools and equipment recommended service material s4rs0a1408001 note: required service material is also described in the following. “timing chain cover components: ” “timing chain and chain tensioner components: ” “camshaft, tappet and shim components: ” “valves and c...

  • Page 329

    Engine mechanical: 1d-66 09916–34550 09916–37320 reamer handle valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 valve guide installer & remover valve guide installer attachment (protrusion: 11.5 mm) 09916–58210 09916–67020 valve guide installer handle tappet holder (overseas) / / 09916–670...

  • Page 330: Engine Lubrication System

    1e-1 engine lubrication system: engine lubrication system general description engine lubrication description s4rs0a1501001 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 331

    Engine lubrication system: 1e-2 i3rh0b150001-.

  • Page 332

    1e-3 engine lubrication system: diagnostic information and procedures oil pressure check s4rs0a1504001 note: prior to checking oil pressure, check the following. • oil level in oil pan if oil level is low, add oil up to full level mark (hole) (1) on oil level gauge referring to “engine oil and filte...

  • Page 333

    Engine lubrication system: 1e-4 9) before reinstalling oil pressure switch (2), be sure to wrap its screw threads with sealing tape (1) and tighten switch to specified torque. Note: if sealing tape edge is bulged out from screw threads of switch, cut it off. Tightening torque oil pressure switch (a)...

  • Page 334

    1e-5 engine lubrication system: oil pan and oil pump strainer removal and installation s4rs0a1506002 removal 1) remove oil level gauge. 2) drain engine oil by removing drain plug. 3) remove exhaust no.1 pipe (1), exhaust manifold stiffener (2) and heated oxygen sensor no.1 (connector color: green) (...

  • Page 335

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

  • Page 336

    1e-7 engine lubrication system: oil pump components s4rs0a1506004 oil pump removal and installation s4rs0a1506005 oil pump is incorporated with timing chain cover. For removal and installation, refer to “timing chain cover removal and installation: in section 1d”. Oil pump disassembly and reassembly...

  • Page 337

    Engine lubrication system: 1e-8 reassembly 1) wash, clean and then dry all disassembled parts. 2) apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case and plate. 3) install outer (1) and inner rotors (2) to oil pump case. 4) apply engine oil...

  • Page 338

    1e-9 engine lubrication system: radial clearance check radial clearance between outer rotor (1) and case (2) using thickness gauge (3). If clearance exceeds its limit, replace outer rotor or case. Radial clearance between outer rotor and case for oil pump limit: 0.310 mm (0.0122 in.) side clearance ...

  • Page 339

    Engine lubrication system: 1e-10 specifications tightening torque specifications s4rs0a1507001 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...

  • Page 340: Engine Cooling System

    1f-1 engine cooling system: engine cooling system general description cooling system description s4rs0a1601001 the cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. Coolant description s4rs0a...

  • Page 341

    Engine cooling system: 1f-2 schematic and routing diagram coolant circulation s4rs0a1602001 while the engine is warmed up (thermostat closed), coolant circulates as follows. When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be coole...

  • Page 342

    1f-3 engine cooling system: diagnostic information and procedures engine cooling symptom diagnosis s4rs0a1604001 condition possible cause correction / reference item engine overheats (radiator fan operates) loose or broken water pump belt adjust or replace. Not enough coolant check coolant level and...

  • Page 343

    Engine cooling system: 1f-4 repair instructions cooling system components s4rs0a1606001 i4rs0a160001- 1. Radiator 13. Thermostat case 25. Heater outlet no.1 hose 2. Reservoir 14. Thermostat 26. Engine cooling fan assembly 3. Radiator cap 15. Thermostat cap 27. Water bypass no.2 hose 4. Drain plug 16...

  • Page 344

    1f-5 engine cooling system: coolant level check s4rs0a1606002 warning: to help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if radiator cap is taken off too soon. To check level, lift hood a...

  • Page 345

    Engine cooling system: 1f-6 cooling system flush and refill s4rs0a1606004 warning: to help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon. Note: for detail of cool...

  • Page 346

    1f-7 engine cooling system: cooling water pipes or hoses removal and installation s4rs0a1606005 removal 1) drain coolant referring to “cooling system draining: ”. 2) to remove these pipes or hoses, loosen clamp on each hose and pull hose end off. Installation install removed parts in reverse order o...

  • Page 347

    Engine cooling system: 1f-8 thermostat inspection s4rs0a1606007 • make sure that air bleed valve (1) of thermostat is clean. Should this valve be clogged, engine would tend to overheat. • check to make sure that valve seat (2) is free from foreign matters which would prevent valve from seating tight...

  • Page 348

    1f-9 engine cooling system: radiator cooling fan relay inspection s4rs0a1606020 1) disconnect negative (–) cable at battery. 2) remove radiator cooling fan relay no.1 (1), no.2 (2) and/or no.3 (3) from relay box. 3) check that there is no continuity between terminal “c” and “b”. If there is continui...

  • Page 349

    Engine cooling system: 1f-10 radiator removal and installation s4rs0a1606014 removal 1) disconnect negative cable at battery. 2) drain a/t fluid. 3) drain coolant. 4) remove cooling fan assembly referring to “radiator cooling fan removal and installation: ”. 5) remove a/t fluid cooler inlet and outl...

  • Page 350

    1f-11 engine cooling system: water pump / generator drive belt removal and installation s4rs0a1606016 removal 1) disconnect negative cable at battery. 2) if vehicle equipped with a/c, remove compressor drive belt (4) before removing water pump belt (1). Refer to “compressor drive belt removal and in...

  • Page 351

    Engine cooling system: 1f-12 3) install water pump pulley. 4) install water pump / generator drive belt referring to “water pump / generator drive belt removal and installation: ”. 5) install a/c compressor belt (if equipped) referring to “compressor drive belt removal and installation: in section 7...

  • Page 352: Fuel System

    1g-1 fuel system: fuel system precautions precautions on fuel system service s4rs0a1700001 warning: before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. • disconnect negative cable at battery. • do not ...

  • Page 353

    Fuel system: 1g-2 fuel pump description s4rs0a1701003 the fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) and a fuel pressure regulator (3) are included and a fuel level gauge (4) is attached. Addition of the fuel pressure regulator to the fue...

  • Page 354

    1g-3 fuel system: 3) connect special tools and hose between fuel feed hose (1) and fuel delivery pipe as shown in the figure, and clamp hoses securely in order to ensure that no leaks occur during checking. Special tool (a): 09912–58442 (b): 09912–58432 (c): 09912–58490 4) check that battery voltage...

  • Page 355

    Fuel system: 1g-4 repair instructions fuel system components s4rs0a1706001 i4rs0a170003- 1. Fuel tank 10. Fuel tank belt 19. Fuel delivery pipe insulator 2. Fuel pump assembly 11. Fuel pump gasket 20. Wire harness for fuel pump 3. Breather hose 12. Fuel tank bolt 21. To canister 4. Fuel tank filler ...

  • Page 356

    1g-5 fuel system: fuel hose disconnecting and reconnecting s4rs0a1706023 warning: before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in f...

  • Page 357

    Fuel system: 1g-6 the other than fuel tank system for quick joint disconnecting 1) remove mud, dust and/or foreign material between pipe (1) and quick joint (2) by blowing compressed air. 2) unlock joint lock by inserting special tool between pipe and quick joint. Special tool (a): 09919–47020 3) di...

  • Page 358

    1g-7 fuel system: fuel pressure relief procedure s4rs0a1706002 caution: this work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. Note: if ecm detects dtc(s) after servicing, clear dtc(s) referring to “dtc clearance: in section 1a”. 1) make sure that engine ...

  • Page 359

    Fuel system: 1g-8 installation 1) install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with new one. 2) install pipes with pipe clamps to vehicle. 3) connect fuel hoses and pipes to each pipe referring to “fuel hose disconnecting and reconnecting: ...

  • Page 360

    1g-9 fuel system: installation reverse removal procedure for installation noting the following. • replace injector o-ring (1) with new one using care not to damage it. • check if cushion (2) is scored or damaged. If it is, replace with new one. • apply thin coat of fuel to o-rings (1) and then insta...

  • Page 361

    Fuel system: 1g-10 6) operate fuel pump and apply fuel pressure to injector as follows: a) when using scan tool: i) connect scan tool to dlc with ignition switch off. Ii) turn ignition switch on, clear dtc and select “misc test” mode on scan tool. Iii) turn fuel pump on by using scan tool. Special t...

  • Page 362

    1g-11 fuel system: fuel tank inlet valve removal and installation s4rs0a1706015 warning: before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Removal 1) remove fuel filler cap. 2) insert hose of a ...

  • Page 363

    Fuel system: 1g-12 fuel tank inlet valve inspection s4rs0a1706016 warning: before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Check fuel tank inlet valve for the following. If any damage or malfu...

  • Page 364

    1g-13 fuel system: installation caution: • when connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur. • never let the fuel hoses touch the abs sensor h...

  • Page 365

    Fuel system: 1g-14 fuel pump on-vehicle inspection s4rs0a1706017 warning: before starting the following procedure, be sure to observe “precautions on fuel system service: ” in order to reduce the risk or fire and personal injury. Note: the fuel pressure regulator is incorporated with the fuel pump a...

  • Page 366

    1g-15 fuel system: 3) install new gasket (2) and fuel pump assembly (1) with plate (3) to fuel tank (4). Tightening torque fuel pump assembly bolt (a): 11 n·m (1.1 kg-m, 8.0 lb-ft) 4) connect fuel feed line (1) (pipe joint) to fuel pump assembly (2). 5) install fuel tank to vehicle. Refer to “fuel t...

  • Page 367

    Fuel system: 1g-16 fuel pump inspection s4rs0a1706021 • check fuel pump assembly for damage. • check fuel suction filter (1) for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank. • for electrical circuit, refer to “fuel pressure check: in s...

  • Page 368

    1g-17 fuel system: special tools and equipment special tool s4rs0a1708001 09912–57610 09912–58421 injector checking tool plate checking tool set this kit includes the following items. 1. Tool body and washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose and clamp, 6. Body attachment...

  • Page 369: Ignition System

    1h-1 ignition system: ignition system general description ignition system construction s4rs0a1801001 the ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below. • ecm it detects the engine and vehicle conditions through the signals from the se...

  • Page 370

    Ignition system: 1h-2 schematic and routing diagram ignition system wiring circuit diagram s4rs0a1802001 e23-60 e23-29 12v 5v 5v e23-1 e23-16 blk/wht blk/red blk/red blk/red 80a blk/yel blk/yel blk/yel grn blk wht wht brn/wht blk/orn blk blk c37-20 blk/red pnk blk/orn 5v c37-21 blk/wht 7 3 4 1 12 5 ...

  • Page 371

    1h-3 ignition system: component location ignition system components location s4rs0a1803001 1 7 5 12 11 2 4 10 6 8 3 9 13 14 15 16 i4rs0a180002- 1. Ecm 7. Ect sensor 13. Data link connector 2. Ignition coil assembly for no.1 and no.4 spark plugs 8. Maf and iat sensor 14. Main relay box 3. Ignition co...

  • Page 372

    Ignition system: 1h-4 diagnostic information and procedures ignition system symptom diagnosis s4rs0a1804001 reference waveform of ignition system s4rs0a1804002 1) remove ecm from its bracket with ecm connectors connected referring to “engine control module (ecm) removal and installation: in section ...

  • Page 373

    1h-5 ignition system: ignition system check s4rs0a1804003 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: in section 1a”. 2 ignition spark test 1) check all spark plugs for condition and type referring to “...

  • Page 374

    Ignition system: 1h-6 ignition spark test s4rs0a1804004 1) remove air cleaner assembly with air intake pipe. 2) disconnect all injector couplers from injectors. Warning: without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignite...

  • Page 375

    1h-7 ignition system: repair instructions high-tension cord removal and installation s4rs0a1806001 removal 1) remove air cleaner assembly with air intake pipe and cylinder head upper cover. 2) disconnect no.1 cylinder (2) and no.3 cylinder (3) high-tension cords from ignition coil assemblies (1) whi...

  • Page 376

    Ignition system: 1h-8 spark plug removal and installation s4rs0a1806003 removal 1) remove air cleaner assembly with air intake pipe and cylinder head upper cover. 2) pull out high-tension cords by gripping their caps and then remove ignition coil assemblies referring to “ignition coil assembly (incl...

  • Page 377

    1h-9 ignition system: ignition coil assembly (including ignitor) inspection s4rs0a1806006 measure secondary coil for resistance. If resistance is out of specification, replace ignition coil assembly. Secondary coil resistance 7.6 – 10.2 k at 20 c, 68 f ignition timing inspection s4rs0a1806007 note: ...

  • Page 378

    Ignition system: 1h-10 specifications tightening torque specifications s4rs0a1807001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information: in section 0a”. Special tools and equipment special tool s4rs0a1808001 fastening part tightening torqu...

  • Page 379: Starting System

    1i-1 starting system: starting system schematic and routing diagram cranking system circuit diagram s4rs0a1902001 diagnostic information and procedures cranking system symptom diagnosis s4rs0a1904001 possible symptoms due to starting system trouble would be as follows: • starting motor does not run ...

  • Page 380

    Starting system: 1i-2 condition possible cause correction / reference item motor not running (no operating sound of magnetic switch) shift lever switch is not in p or n, or not adjusted (a/t) shift in p or n, or adjust switch. (a/t) battery run down recharge battery. Battery voltage too low due to b...

  • Page 381

    1i-3 starting system: cranking system test s4rs0a1904002 caution: each test must be performed within 3 – 5 seconds to avoid coil from burning. Pull-in test connect battery to the magnetic switch as shown. Check that plunger and pinion move outward. If plunger and pinion don’t move, replace the magne...

  • Page 382

    Starting system: 1i-4 repair instructions starting motor dismounting and remounting s4rs0a1906001 dismounting 1) disconnect negative (–) battery lead at battery. 2) disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) detach shift & select control cable br...

  • Page 383

    1i-5 starting system: starting motor components s4rs0a1906002 i4rs0a190003- 1. Front housing 8. Seal rubber 15. Yoke : do not reuse. 2. Bush 9. Magnetic switch 16. Armature : apply grease 99000-25010 to sliding surface of each part. 3. Pinion stop ring 10. Ball 17. Brush assembly 4. Over-running clu...

  • Page 384

    Starting system: 1i-6 starting motor inspection s4rs0a1906003 plunger inspect plunger for wear. Replace if necessary. Magnetic switch push in plunger and release it. The plunger should return quickly to its original position. Replace if necessary. Pull-in coil open circuit test check for continuity ...

  • Page 385

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

  • Page 386

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

  • Page 387

    1i-9 starting system: specifications cranking system specifications s4rs0a1907002 tightening torque specifications s4rs0a1907001 note: the specified tightening torque is also described in the following. “starting motor dismounting and remounting: ” “starting motor components: ” reference: for the ti...

  • Page 388: Charging System

    Charging system: 1j-1 charging system general description battery description s4rs0a1a01001 the battery has three major functions in the electrical system. • it is a source of electrical energy for cranking the engine. • it acts as a voltage stabilizer for the electrical system. • it can, for a limi...

  • Page 389

    1j-2 charging system: • when keeping battery on vehicle over a long period of time, follow instructions given below. – weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2000 to 3000 rpm. Make sure all electric switches are off before storing the v...

  • Page 390

    Charging system: 1j-3 diagnostic information and procedures battery inspection s4rs0a1a04001 visual inspection check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious damage is noted, replace battery. Determine cause of damage and correct ...

  • Page 391

    1j-4 charging system: charging indicator lamp operation generator test (undercharged battery check) s4rs0a1a04003 this condition, as evidenced by slow cranking or low specific gravity can be caused by one or more of the following conditions even though indicator lamp may be operating normal. The fol...

  • Page 392

    Charging system: 1j-5 3) ground “f” terminal and start engine, then measure voltage at “b” terminal as shown in the figure. • voltage is higher than standard value. It is considered that generator itself is good but ic regulator has been damaged, replace ic regulator. • voltage is lower than standar...

  • Page 393

    1j-6 charging system: repair instructions jump starting in case of emergency s4rs0a1a06001 with auxiliary (booster) battery caution: if vehicle is manual transaxle model and has a catalytic converter, do not push or tow it to start. Damage to its emission system and/or to other parts may result. Bot...

  • Page 394

    Charging system: 1j-7 generator dismounting and remounting s4rs0a1a06003 1) disconnect negative cable at battery. 2) remove right side drive shaft referring to “front drive shaft assembly removal and installation: in section 3a” 3) dismount in numerical order as shown in the figure. 4) reverse dismo...

  • Page 395

    1j-8 charging system: generator components s4rs0a1a06004 i4rs0a1a0004- 1. Pulley nut 7. Bearing retainer 13. Seal plate 19. Brush holder cover : 3.6 n m (0.36 kg-m, 3.0 lb-ft) 2. Pulley 8. Rotor 14. Rectifier 20. Rear end cover : 2.0 n m (0.2 kg-m, 1.5 lb-ft) 3. Drive end frame 9. End housing bearin...

  • Page 396

    Charging system: 1j-9 generator inspection s4rs0a1a06005 rotor 1) using an ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace the rotor. Standard resistance between slip rings of rotor 2.7 – 3.1 at 20 c (68 f) 2) using an ohmmeter, check that there is no c...

  • Page 397

    1j-10 charging system: rectifier 1) using an ohmmeter, connect one tester probe to the “b” terminal (1) and the other to each rectifier terminal (2). 2) reverse the polarity of the tester probes and repeat step 1). 3) check that one shows continuity and the other shows no continuity. If there is con...

  • Page 398

    Charging system: 1j-11 specifications charging system specifications s4rs0a1a07002 battery generator tightening torque specifications s4rs0a1a07001 note: the specified tightening torque is also described in the following. “generator dismounting and remounting: ” “generator components: ” reference: f...

  • Page 399: Exhaust System

    Exhaust system: 1k-1 exhaust system general description exhaust system description s4rs0a1b01001 the exhaust system consists of an exhaust manifold, three-way catalytic converter (twc) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emiss...

  • Page 400

    1k-2 exhaust system: repair instructions exhaust system components s4rs0a1b06001 warning: to avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I4rs0a1b0001- [a]: installing location...

  • Page 401

    Exhaust system: 1k-3 exhaust manifold removal and installation s4rs0a1b06003 removal warning: to avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. 1) disconnect negative cable at battery. 2) remove front bumper wit...

  • Page 402

    1k-4 exhaust system: 4) install new seal ring and connect exhaust no.1 pipe (1) to exhaust no.2 pipe. Tighten pipe fasteners to specified torque. Tightening torque exhaust no.2 pipe bolt (c): 43 n·m (4.3 kg-m, 31.0 lb-ft) 5) install heated oxygen sensors (3) referring to “exhaust system components: ...

  • Page 403

    Exhaust system: 1k-5 specifications tightening torque specifications s4rs0a1b07001 note: the specified tightening torque is also described in the following. “exhaust system components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information: ...

  • Page 404

    1k-6 exhaust system:.

  • Page 405: Section 2

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

  • Page 406

    2-ii table of contents tire rotation........................................................2d-5 wheel removal and installation..........................2d-6 tire mounting and dismounting ..........................2d-6 tire repair ..........................................................2d-6 specif...

  • Page 407: Precautions

    Precautions: 2-1 precautions precautions precautions on suspension s4rs0a2000001 suspension caution refer to “suspension caution: in section 00”. Wheels and tires caution refer to “wheels and tires caution: in section 00”. General precautions refer to “general precautions: in section 00”. Vehicle li...

  • Page 408

    2a-1 suspension general diagnosis: suspension general diagnosis diagnostic information and procedures suspension, wheels and tires symptom diagnosis s4rs0a2104001 condition possible cause correction / reference item vehicle pulls (leads) mismatched or uneven tires replace tire. Tires not adequately ...

  • Page 409

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

  • Page 410

    2a-3 suspension general diagnosis: specifications wheel alignment specifications s4rs0a2107001 wheel alignment specifications note: toe value in the specifications table was measured by using a toe-in gauge. Item front rear front toe (“b” – “a”) (total) rear toe (non adjustable, for reference only) ...

  • Page 411: Front Suspension

    Front suspension: 2b-1 front suspension general description front suspension construction s4rs0a2201001 i4rs0a220001- 1. Strut assembly 7. Drive shaft : 50 n m (5.0 kg-m, 36.5 lb-ft) : 23 n m (2.3 kg-m, 17.0 lb-ft) 2. Stabilizer bar 8. Tie-rod : 105 n m (10.5 kg-m, 76.0 lb-ft) : 85 n m (8.5 kg-m, 61...

  • Page 412

    2b-2 front suspension: front wheel alignment construction s4rs0a2201002 among factors for front wheel alignment, only toe setting can be adjusted. Camber and caster can be adjusted. Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or co...

  • Page 413

    Front suspension: 2b-3 3) after adjustment, tighten lock nuts (1) to specified torque. Tightening torque tie-rod end lock nut (a): 45 n·m (4.5 kg-m, 32.5 lb-ft) note: make sure that rack boots are not twisted. Steering angle check and adjustment when tie-rod or tie-rod end was replaced, check toe an...

  • Page 414

    2b-4 front suspension: front strut assembly components s4rs0a2206005 front strut assembly removal and installation s4rs0a2206006 removal 1) remove hood rear seal (1), and then remove left side cowl top garnish (2) and right side cover cap (3) from vehicle. I4rs0a220002- 1. Strut assembly 6. Strut be...

  • Page 415

    Front suspension: 2b-5 note: when servicing component parts of strut assembly, remove strut rod cap and then loosen strut nut a little before removing strut assembly. This will make service work easier. Note, however, nut must not be removed at this point. 2) hoist vehicle, allowing front suspension...

  • Page 416

    2b-6 front suspension: • tighten wheel nuts to specified torque. Tightening torque wheel nut: 85 n·m (8.5 kg-m, 61.5 lb-ft) • after installation, confirm front wheel alignment. Front strut assembly disassembly and assembly s4rs0a2206007 disassembly 1) with special tool (a) placed to spring as shown,...

  • Page 417

    Front suspension: 2b-7 2) install compressing coil spring, and mate spring end (2) with stepped part of spring lower seat (1) as shown. Caution: end of coil spring must not interfere with step of spring lower seat. 3) install bump stopper onto strut rod. For installing direction, refer to the figure...

  • Page 418

    2b-8 front suspension: 5) compare strut resistance and number of rebalance on the right with those on the left. And they must be equal in both. With proper strut, vehicle body should come to stop the moments hands are off or after only one or two small rebalances. If conditions of struts are in doub...

  • Page 419

    Front suspension: 2b-9 6) pull brake disc (2) off by using two 8 mm bolts. 7) pull out wheel hub (1) with special tools. Special tool (a): 09943-17912 (b): 09942-15511 caution: when wheel hub is removed, replace wheel bearing with new one. 8) disconnect tie-rod end (1) from steering knuckle (2) with...

  • Page 420

    2b-10 front suspension: 15) remove wheel bearing outside inner race (1). Special tool (c): 09913-65810 (d): 09913-85230 16) remove hub bolts (1) with copper hammer or hydraulic press. Caution: never remove bolt unless replacement is necessary. Be sure to use a new bolt for replacement. Installation ...

  • Page 421

    Front suspension: 2b-11 5) install ball joint bolt (1) and nut (2) from the direction as shown in figure. 6) tighten new suspension arm ball joint nut (2) to specified torque. Tightening torque suspension arm ball joint nut (a): 60 n·m (6.0 kg-m, 43.5 lb-ft) caution: never reuse the removed suspensi...

  • Page 422

    2b-12 front suspension: front wheel hub, disc, nut and bearing check s4rs0a2206012 • inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. • check installation face inside of wheel disc for rust. As rust affects adversely, remove it thoroughly....

  • Page 423

    Front suspension: 2b-13 2) install suspension control arm ball joint to steering knuckle. Align ball stud groove with steering knuckle bolt hole. Then install ball joint bolt (1) from the direction as shown in figure. Tighten new suspension arm ball joint nut (2) to specified torque. Tightening torq...

  • Page 424

    2b-14 front suspension: note: • before installing bushing, apply soap water on its circumference to facilitate installation. 2) press-fit bushing (1) so that dimensions and in figure become equal. Suspension control arm / steering knuckle check s4rs0a2206015 inspect for cracks, deformation or damage...

  • Page 425

    Front suspension: 2b-15 front suspension frame, stabilizer bar and/or bushings components s4rs0a2206018 front suspension frame, stabilizer bar and/or bushings removal and installation s4rs0a2206019 removal 1) hoist vehicle and remove wheels (right & left). 2) remove suspension control arm referring ...

  • Page 426

    2b-16 front suspension: 6) disconnect muffler no.1 mounting (1) from suspension frame (2). Warning: to avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. 7) remove engine rear mounting bolts (1) from engi...

  • Page 427

    Front suspension: 2b-17 note: for correct installation of stabilizer bar, side- to-side, be sure that stopper ring (4) on stabilizer bar aligns with mount bush, both right and left, as shown in figure. 3) tighten stabilizer bar mounting bracket bolts to specified torque. Tightening torque stabilizer...

  • Page 428

    2b-18 front suspension: 9) connect muffler no.1 mounting (1) to suspension frame (2). 10) install steering gear case no.1 bolts (a) and no.2 bolts (b) to specified torque tightening torque steering gear case no.1 bolt (a): 55 n·m (5.5 kg- m, 40.0 lb-ft) steering gear case no.2 bolt (b): 55 n·m (5.5 ...

  • Page 429

    Front suspension: 2b-19 front stabilizer bar, bushing and/or joint check s4rs0a2206022 stabilizer bar inspect for damage or deformation. If defective, replace. Stabilizer bushing inspect for damage, wear or deterioration. If defective, replace. Stabilizer joint 1) check for smooth rotation. 2) inspe...

  • Page 430

    2b-20 front suspension: note: the specified tightening torque is also described in the following. “front suspension construction: ” “front strut assembly components: ” “front wheel hub and steering knuckle components: ” “front suspension frame, stabilizer bar and/or bushings components: ” reference:...

  • Page 431: Rear Suspension

    Rear suspension: 2c-1 rear suspension general description rear suspension construction s4rs0a2301001 2wd vehicle 15 14 13 10 17 16 17 9 5 12 11 17 8 6 7 3 1 2 4 i4rs0a230001- 1. Rear coil spring 6. Wheel bearing 11. Rear shock absorber lower nut 16. Rear spindle 2. Rear spring lower seat 7. Brake dr...

  • Page 432

    2c-2 rear suspension: component location rear suspension component location s4rs0a2303001 2wd vehicle i4rs0a230002- 1. Rear coil spring 8. Circlip 15. Spindle cap : 90 n m (9.0 kg-m, 65.0 lb-ft) 2. Blank 9. Rear trailing arm bolt 16. Brake back plate : 75 n m (7.5 kg-m, 54.0 lb-ft) 3. Rear spring up...

  • Page 433

    Rear suspension: 2c-3 repair instructions rear shock absorber removal and installation s4rs0a2306028 removal 1) hoist vehicle. 2) remove tail end member trim (1) and quarter inner trim (2). 3) support rear axle by using floor jack to prevent it from lowering. 4) remove absorber lower nut. 5) remove ...

  • Page 434

    2c-4 rear suspension: rear shock absorber inspection s4rs0a2306029 • inspect for deformation or damage. • inspect bushings for wear or damage. • inspect for evidence of oil leakage. Replace any defective part. Warning: when handling rear shock absorber (1) in which high-pressure gas is sealed, make ...

  • Page 435

    Rear suspension: 2c-5 rear shock absorber bush inspection s4rs0a2306041 inspect for cracks, deformation or damage. Replace any defective part. Coil spring removal and installation s4rs0a2306030 removal 1) hoist vehicle and remove rear wheels. 2) support rear axle (1) by using two floor jacks (2) to ...

  • Page 436

    2c-6 rear suspension: 4) install wheels and tighten wheel nuts to specified torque. Tightening torque wheel nut (a): 85 n·m (8.5 kg-m, 61.5 lb-ft) 5) lower hoist and vehicle in non-loaded condition, tighten absorber lower nuts (a) to specified torque. Tightening torque rear shock absorber lower nut ...

  • Page 437

    Rear suspension: 2c-7 2) install coil spring referring to “coil spring removal and installation: ”. Rear axle removal and installation s4rs0a2306035 removal 1) hoist vehicle and remove rear wheels (right & left) referring to “wheel removal and installation: in section 2d”. 2) remove rear brake drums...

  • Page 438

    2c-8 rear suspension: 9) lower rear axle gradually as far down as where coil springs (1) (right & left) can be removed. Caution: be careful not to let rear axle down too much. It may cause damage to brake flexible hose, wheel speed sensor lead wire and parking brake cable. 10) remove coil springs (1...

  • Page 439

    Rear suspension: 2c-9 6) install brake back plates (1), spindles (2) and new spindle bolts (a) and then tighten spindle bolts (a) to specified torque. Caution: do not reuse (reinstall) removed rear spindle bolts (a). Tightening torque rear spindle bolt (a): 75 n·m (7.5 kg-m, 54.0 lb- ft) 7) connect ...

  • Page 440

    2c-10 rear suspension: 13) install wheel and tighten wheel nuts to specified torque. Tightening torque wheel nut (a): 85 n·m (8.5 kg-m, 61.5 lb-ft) 14) upon completion of all jobs, depress brake pedal with about 300 n (30 kg, 66 ibs) load three to five times so as to obtain proper drum-to-shoe clear...

  • Page 441

    Rear suspension: 2c-11 wheel bearing and wheel stud bolt removal and installation s4rs0a2306036 removal 1) remove rear brake drum referring to “rear brake drum removal and installation: in section 4c”. 2) remove circlip (1). Special tool (a): 09900–06108 3) remove wheel bearing by using special tool...

  • Page 442

    2c-12 rear suspension: rear wheel disc, nut and bearing inspection s4rs0a2306021 • check wheel nuts for tightness and, as necessary, retighten to specification. • check wheel bolt press-fitted into brake drum for wear, damage, poor thread condition, and looseness. Replace defective bolt with a new o...

  • Page 443

    Rear suspension: 2c-13 tightening torque rear spindle bolt (a): 75 n·m (7.5 kg-m, 54.0 lb- ft) 2) connect wheel speed sensor (1) and tighten wheel speed sensor bolt (a) to specified torque. Tightening torque wheel speed sensor bolt (a): 11 n·m (1.1 kg-m, 8.0 lb-ft) 3) connect brake pipes to wheel cy...

  • Page 444

    2c-14 rear suspension: specifications tightening torque specifications s4rs0a2307001 note: the specified tightening torque is also described in the following. “rear suspension component location: ” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners in...

  • Page 445: Wheels And Tires

    Wheels and tires: 2d-1 wheels and tires general description tires description s4rs0a2401001 the tire is of tubeless type. The tire is designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressures. Correct tire pressures and driv...

  • Page 446

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

  • Page 447

    Wheels and tires: 2d-3 • front tire treads have scuffed appearance with “feather” edges on one side of tread ribs or blocks. Wear indicators description s4rs0a2401004 original equipment tires have built-in tread wear indicators (1) to show when they need replacement. These indicators (1) will appear...

  • Page 448

    2d-4 wheels and tires: equipment manufacture’s recommendations radial tire lead / pull description s4rs0a2401006 “lead / pull” is the deviation of the vehicle from a straight path on a level road even with no pressure on the steering wheel. Lead is usually caused by the following conditions. • impro...

  • Page 449

    Wheels and tires: 2d-5 repair instructions general balance procedures s4rs0a2406001 deposits of mud, etc. Must be cleaned from inside of rim. Warning: stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain good balance. Each tire should be inspe...

  • Page 450

    2d-6 wheels and tires: wheel removal and installation s4rs0a2406003 removal 1) loosen wheel nuts by approximately 180 (half a rotation). 2) hoist vehicle. 3) remove wheel. Caution: never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel be...

  • Page 451

    Wheels and tires: 2d-7 specifications wheels and tires specifications s4rs0a2407001 tire size (standard) 185/60r15 84h wheel size (standard) 15 x 5 1/2 jj (for 185/60r15) tightening torque wheel nut: 85 n·m (8.5 kg-m, 61.5 lb-ft) note: • tire inflation pressure should be checked when tires are cool....

  • Page 452

    2d-8 wheels and tires:.

  • Page 453: Section 3

    Table of contents 3- i 3 section 3 contents driveline / axle drive shaft / axle ..................................... 3a-1 general description .............................................3a-1 front drive shaft construction............................ 3a-1 component location ...........................

  • Page 454: Drive Shaft / Axle

    3a-1 drive shaft / axle: drive shaft / axle general description front drive shaft construction s4rs0a3101001 a constant velocity tripod joint is used on the differential side of both right and left side drive shaft assemblies. A constant velocity ball joint is used on the wheel side of both right an...

  • Page 455

    Drive shaft / axle: 3a-2 diagnostic information and procedures front drive shaft symptom diagnosis s4rs0a3104001 repair instructions front drive shaft components s4rs0a3106001 condition possible cause correction / reference item abnormal noise worn or breakage of the drive shaft joint replace. Worn ...

  • Page 456

    3a-3 drive shaft / axle: front drive shaft assembly on-vehicle inspection s4rs0a3106002 • check boots for breakage or deterioration. • check wheel side joint for rattle or smooth rotation. • check differential side (or center shaft side) joint for smooth rotation. If any abnormality is found, replac...

  • Page 457

    Drive shaft / axle: 3a-4 10) remove drive shaft assembly. 11) remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from differential side gear. Installation caution: • be careful not to damage oil seals and boots when installing drive shaft. • do not hi...

  • Page 458

    3a-5 drive shaft / axle: 3) remove tripod joint spider (1) using 3 arms puller (2). Caution: to prevent any problem caused by washing solution, do not wash tripod joint except its housing. Degreasing of tripod joint with cloth is allowed. 4) remove differential side (or center shaft side) boot small...

  • Page 459

    Drive shaft / axle: 3a-6 7) fasten boot band (1) securely using special tool. Caution: do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability. Special tool (a): 09943–57010 8) set new differential side (or center shaft side) smal...

  • Page 460

    3a-7 drive shaft / axle: caution: • bend each boot band against forward rotation. • do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability. Center shaft and center bearing support disassembly and assembly s4rs0a3106006 note: be s...

  • Page 461

    Drive shaft / axle: 3a-8 • press-fit center shaft (1) from left oil seal (2) side. Type b disassembly 1) remove wheel side oil seal and circlip from center bearing support (3). 2) by using hydraulic press (1), draw out center shaft (2) from center bearing. 3) remove oil seal from center bearing supp...

  • Page 462

    3a-9 drive shaft / axle: 4) install right oil seal (1) to center bearing support (2) until it become flush with bearing support using special tool, and then apply grease to oil seal lip. “a”: grease 99000–25010 special tool (a): 09913–85210 front drive shaft inspection s4rs0a3106005 • check shaft an...

  • Page 463

    Drive shaft / axle: 3a-10 special tools and equipment recommended service material s4rs0a3108001 note: required service material is also described in the following. “front drive shaft assembly components location: ” “front drive shaft components: ” special tool s4rs0a3108002 material suzuki recommen...

  • Page 464

    3a-11 drive shaft / axle:.

  • Page 465: Section 4

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

  • Page 466

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

  • Page 467: Precautions

    Precautions: 4-1 precautions precautions precautions for brakes s4rs0a4000001 suspension caution refer to “suspension caution: in section 00”. Wheels and tires caution refer to “wheels and tires caution: in section 00”. Brake caution refer to “brake caution: in section 00”. General precautions refer...

  • Page 468

    4a-1 brake control system and diagnosis: brake control system and diagnosis precautions precautions on brake s4rs0a4100001 air bag warning refer to “air bag system service warning: in section 00”. Brakes diagnosis note refer to “brakes diagnosis note: ”. General description brakes construction s4rs0...

  • Page 469

    Brake control system and diagnosis: 4a-2 front brake hose / pipe construction s4rs0a4101002 for vehicle with abs i4rs0a410002- [a]: for rh steering vehicle 5. Abs hydraulic unit 10. 4-way joint to left rear brake hose 1. From master cylinder primary to abs hydraulic unit 6. Master cylinder 11. 4-way...

  • Page 470

    4a-3 brake control system and diagnosis: rear brake hose / pipe construction s4rs0a4101003 diagnostic information and procedures brakes diagnosis note s4rs0a4104001 road testing brakes brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road test brakes b...

  • Page 471

    Brake control system and diagnosis: 4a-4 brakes symptom diagnosis s4rs0a4104002 condition possible cause correction / reference item not enough braking force brake oil leakage from brake lines locate leaking point and repair. Brake disc or pads stained with oil clean or replace. Overheated brakes de...

  • Page 472

    4a-5 brake control system and diagnosis: dragging brakes (a very light drag is present in all brakes immediately after pedal is released) master cylinder pistons not returning correctly replace master cylinder. Restricted brake pipes or hoses check for soft hoses or damaged pipes and replace with ne...

  • Page 473

    Brake control system and diagnosis: 4a-6 repair instructions brake pedal free height inspection s4rs0a4106001 1) check brake pedal free height. If it is not within specification, check and adjust following item 2) and 6). Brake pedal free height “a” from floor panel 130 – 150 mm (5.1 – 5.9 in.) 2) c...

  • Page 474

    4a-7 brake control system and diagnosis: master cylinder and brake fluid level inspection s4rs0a4106004 1) check master cylinder, reservoir and reservoir hose (if equipped) for crack, damage and brake fluid leakage. If any faulty condition exists, correct or replace. 2) check that brake fluid level ...

  • Page 475

    Brake control system and diagnosis: 4a-8 2) remove bleeder plug cap. Attach a vinyl tube (1) to bleeder plug, and insert the other end into container (2). 3) depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one- third to one-half turn. 4) when fluid p...

  • Page 476

    4a-9 brake control system and diagnosis: • perform brake test and check installed part for fluid leakage. Rear brake hose / pipe removal and installation s4rs0a4106008 removal 1) raise and support vehicle properly. Remove tire and wheel. 2) clean dirt and foreign material from both flexible hose end...

  • Page 477

    Brake control system and diagnosis: 4a-10 master cylinder reservoir removal and installation s4rs0a4106011 removal caution: brake fluid is extremely damaging to paint. Do not allow brake fluid to get on painted surfaces. 1) disconnect fluid level switch coupler on reservoir. 2) clean outside of rese...

  • Page 478

    4a-11 brake control system and diagnosis: master cylinder assembly removal and installation s4rs0a4106012 removal caution: do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid, flush it with water immediately if any fluid is spilled. 1) clean outside o...

  • Page 479

    Brake control system and diagnosis: 4a-12 6) fill reservoir with specified brake fluid up to its max mark. 7) after completing the work, bleed air referring to “air bleeding of brake system: ”. 8) check each installed parts for fluid leakage. 9) check brake pedal for play referring to “brake pedal p...

  • Page 480

    4a-13 brake control system and diagnosis: 5) apply small amount of rubber grease (included in spare parts) to mating surface of “a” (piston cup (3) and piston guide (1)) and “b” (piston guide (1) and o- ring (2)). 6) apply small amount of silicon grease (included in spare parts) to mating surfaces o...

  • Page 481

    Brake control system and diagnosis: 4a-14 booster operation inspection s4rs0a4106016 there are two ways to perform this inspection, with and without a tester. Ordinarily, it is possible to roughly determine its condition without using a tester. Note: for this check, make sure that no air is in hydra...

  • Page 482

    4a-15 brake control system and diagnosis: brake booster removal and installation s4rs0a4106017 removal 1) recover refrigerant from a/c system by using recovery and recycling equipment referring to “operation procedure for refrigerant charge: in section 7b”. 2) remove master cylinder assembly from bo...

  • Page 483

    Brake control system and diagnosis: 4a-16 brake booster inspection and adjustment s4rs0a4106018 installation position of push rod if push rod clevis (1) has been removed, adjust distance between booster installation surface (without including packing) and the center of clevis pin hole to standard va...

  • Page 484: Front Brakes

    4b-1 front brakes: front brakes repair instructions front disc brake components s4rs0a4206001 i4rs0a420001- 1. Caliper 9. Piston seal : apply small amount of rubber grease (included in repair kit) to all around part of piston seal. 17. Hose washer 2. Caliper pin bolt 10. Cylinder boot : apply small ...

  • Page 485

    Front brakes: 4b-2 front disc brake pad on-vehicle inspection s4rs0a4206002 inspect pad linings (1) periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end (or hole) of caliper and check lining thickness of outside ...

  • Page 486

    4b-3 front brakes: 3) install caliper and tighten caliper pin bolts (a) to specified torque. Tightening torque caliper pin bolt (a): 26 n·m (2.6 kg-m, 19.0 lb-ft) 4) install wheel and lower lift. 5) tighten wheel nuts to specified torque. Tightening torque wheel nut (a): 85 n·m (8.5 kg-m, 61.5 lb-ft...

  • Page 487

    Front brakes: 4b-4 4) remove caliper from caliper carrier. 5) disconnect flexible hose from caliper using care not to twist it. As this will allow brake fluid to flow out of flexible hose, have a container ready beforehand. Installation 1) apply grease to slide pin, then install caliper to caliper c...

  • Page 488

    4b-5 front brakes: 3) remove piston seal using a thin blade like a thickness gauge, etc. Caution: be careful not to damage inside (bore side) of cylinder. 4) remove bleeder plug and cap from caliper. Assembly assemble parts in reverse order of disassembly, observing the following instructions. Cauti...

  • Page 489

    Front brakes: 4b-6 note: check that boot is fitted in boot groove securely all around piston and cylinder. 5) to confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out. Note: boot’s face (1) should be at the same level from cyl...

  • Page 490

    4b-7 front brakes: installation 1) install disc to wheel hub. 2) install caliper assembly to steering knuckle. Caution: make sure that flexible hose is not twisted when installing caliper assembly. If it is twisted, reinstall it using care not to twist it. 3) torque caliper carrier bolts to specific...

  • Page 491

    Front brakes: 4b-8 specifications tightening torque specifications s4rs0a4207001 note: the specified tightening torque is also described in the following. “front disc brake components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information: ...

  • Page 492: Rear Brakes

    4c-1 rear brakes: rear brakes repair instructions rear drum brake components s4rs0a4306001 rear brake drum removal and installation s4rs0a4306002 removal 1) hoist vehicle and remove wheel. 2) remove spindle cap (1) as shown (by hammering lightly at 3 locations around it so as not to deform or cause ...

  • Page 493

    Rear brakes: 4c-2 6) remove wheel bearing from brake drum referring to “wheel bearing and wheel stud bolt removal and installation: in section 2c” if necessary. Installation 1) install wheel bearing to brake drum referring to “wheel bearing and wheel stud bolt removal and installation: in section 2c...

  • Page 494

    4c-3 rear brakes: 9) install wheel and tighten wheel nuts to specified torque. Tightening torque wheel nut (a): 85 n·m (8.5 kg-m, 61.5 lb-ft) 10) check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and perform brake test (foot brake an...

  • Page 495

    Rear brakes: 4c-4 installation 1) install new sensor ring (1) to brake drum (2) by using special tool and hydraulic press (3). Caution: used sensor ring can not be press-fitted securely. Special tool (a): 09926–68310 2) install brake drum referring to “rear brake drum removal and installation: ”. Ab...

  • Page 496

    4c-5 rear brakes: 5) remove push nut (1). 6) remove parking brake shoe lever (2) from shoe rim (3). Installation install parts in reverse order of removal, noting the following. • install shoe hold down springs (1) by pushing them down in place and turning hold down pins (2). • install brake drum re...

  • Page 497

    Rear brakes: 4c-6 4) install bleeder plug cap (4) taken off from pipe back to bleeder plug. 5) install brake shoes. Refer to “rear brake shoe removal and installation: ”. 6) install brake drum. Refer to “rear brake drum removal and installation: ”. 7) fill reservoir with brake fluid and bleed brake ...

  • Page 498

    4c-7 rear brakes: installation 1) install brake back plate (1) and spindle (2), and tighten spindle bolts (3) by hand. 2) install rear wheel speed sensor (1) to brake back plate (2). Tightening torque rear wheel speed sensor bolt (a): 11 n·m (1.1 kg-m, 8.0 lb-ft) 3) tighten spindle bolts (b) to spec...

  • Page 499

    Rear brakes: 4c-8 specifications tightening torque specifications s4rs0a4307001 note: the specified tightening torque is also described in the following. “rear drum brake components: ” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information: in...

  • Page 500: Parking Brake

    4d-1 parking brake: parking brake general description parking brake cable construction s4rs0a4401001 i4rs0a440001- t: top side 4. Parking cable bracket 10. Parking cable clamp bolt [d]: view [d] f: front side 5. Parking cable bracket bolt 11. Rear wheel speed sensor bolt [e]: view [e] r: right side ...

  • Page 501

    Parking brake: 4d-2 repair instructions parking brake inspection and adjustment s4rs0a4406001 inspection hold center of parking brake lever grip and pull it up with 200 n (20 kg, 44 lbs) force. With parking brake lever pulled up as shown, count ratchet notches. There should be 4 to 9 notches. Also, ...

  • Page 502

    4d-3 parking brake: parking brake cable removal and installation s4rs0a4406002 removal note: when it is necessary to remove both right and left parking brake cables, repeat below steps 2) and 6) on right and left wheels. 1) raise, suitably support vehicle. 2) remove wheel. 3) disconnect parking brak...

  • Page 503

    Parking brake: 4d-4 installation 1) install in reverse order of removal procedure. Check equalizer inclined angle. Tightening torque parking brake lever bolt (a): 25 n·m (2.5 kg-m, 18.0 lb-ft) 2) after all parts are installed, parking brake lever needs to be adjusted. Refer to “parking brake inspect...

  • Page 504: Abs

    4e-1 abs: abs precautions precautions in diagnosing troubles s4rs0a4500001 to ensure that the trouble diagnosis is done accurately and smoothly, observe the following and follow “abs check: ”. • if the vehicles was operated in any of the following ways, abs warning lamp may light momentarily but thi...

  • Page 505

    Abs: 4e-2 general description abs description s4rs0a4501001 the abs (antilock brake system) controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This abs has also the following function. W...

  • Page 506

    4e-3 abs: schematic and routing diagram abs schematic s4rs0a4502001 input output abs control module wheel speed sensor (lf) wheel speed sensor (lr) wheel speed sensor (rf) battery voltage pump motor driver (transistor) solenoid valve power supply driver (transistor) solenoid valve driver (transistor...

  • Page 507

    Abs: 4e-4 abs wiring circuit diagram s4rs0a4502002 1. Abs hydraulic unit / control module assembly 8. Pump motor 15. Wheel speed sensor (right-front) 2. Abs control module 9. Stop lamp switch 16. Wheel speed sensor (left-front) 3. Abs hydraulic unit 10. Abs warning lamp 17. Wheel speed sensor (right...

  • Page 508

    4e-5 abs: component location abs components location s4rs0a4503001 terminal wire color circuit e03 1 wht/red abs pump motor driver (transistor) 2 — — 3 grn/wht brake light switch 4 — — 5 blu dark link connector 6 — — 7 grn/orn ignition switch 8 — — 9 — — 10 — — 11 — — 12 — — 13 blk ground 14 wht/blu...

  • Page 509

    Abs: 4e-6 front wheel speed sensor components location s4rs0a4503002 rear wheel speed sensor components location s4rs0a4503003 [a] [b] 1 1 2 3 4 1 (a) (b) i4rs0a450005- [a]: ok 1. Front wheel speed sensor 3. Connector 25 n m (2.5 kg-m, 18.0 lb-ft) [b]: ng 2. Grommet 4. Sensor ring 11 n m (1.1 kg-m, ...

  • Page 510

    4e-7 abs: diagnostic information and procedures abs check s4rs0a4504001 refer to the following items for the details of each step. Step 1: malfunction analysis customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this pu...

  • Page 511

    Abs: 4e-8 customer questionnaire (example) problem symptom confirmation check if what the customer claimed in “customer questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (this step should be shared with the customer if possible.) che...

  • Page 512

    4e-9 abs: step 3: dtc check recheck dtc referring to “dtc check: ”. Step 4: abs check according to abs check for the dtc confirmation in step 3, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator assembly or other part and repair or replace faulty parts. S...

  • Page 513

    Abs: 4e-10 note: if suzuki scan tool can not communicate abs hydraulic unit / control module, perform “serial data link circuit check: ”. 5) after completing the check, turn ignition switch off and disconnect suzuki scan tool from dlc. Dtc table s4rs0a4504005 caution: be sure to perform “abs check: ...

  • Page 514

    4e-11 abs: scan tool data definition battery volt (v): battery voltage is an analog input signal read by the abs control module. Certain abs control module functions will be modified if the battery voltage falls below or rises above programmed thresholds. Pump motor driver (v): this parameter indica...

  • Page 515

    Abs: 4e-12 abs warning lamp comes on steady s4rs0a4504009 wiring diagram circuit description operation (on/off) of abs warning lamp is controlled by abs control module through lamp driver module in combination meter. If the antilock brake system is in good condition, abs control module turns abs war...

  • Page 516

    4e-13 abs: troubleshooting step action yes no 1 1) perform diagnostic trouble code check. Is there any dtc(s)? Go to step 7 of “abs check: ”. Go to step 2. 2 are main fuses for abs pump motor and abs solenoid in good condition? Go to step 3. Replace fuse and check circuit for short to ground. 3 1) t...

  • Page 517

    Abs: 4e-14 abs warning lamp flashes continuously while ignition switch is on s4rs0a4504010 wiring diagram troubleshooting i4rs0a450011- [a]: abs hydraulic unit / control module connector e03 5. Combination meter 1. Battery 6. Abs warning lamp 2. Main fuse box 7. Ebd warning lamp (brake warning lamp)...

  • Page 518

    4e-15 abs: ebd warning lamp (brake warning lamp) comes on steady s4rs0a4504012 wiring diagram circuit description ebd warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and abs hydraulic unit / control module assembly through lamp driver module in combi...

  • Page 519

    Abs: 4e-16 serial data link circuit check s4rs0a4504013 inspection i4rs0a450012- [a]: abs hydraulic unit / control module connector e03 1. Battery 4. Circuit fuse box 7. Lamp driver module 10. Abs hydraulic unit / control module assembly 2. Main fuse box 5. Combination meter 8. Data link connector (...

  • Page 520

    4e-17 abs: 5 1) turn ignition switch to off position. 2) check for proper connection to abs hydraulic unit / control module connector at terminals “e03-13” and “e03-26”. 3) if ok, measure resistance between each terminal of “e03-13”, “e03-26” and vehicle body ground. Are resistance less than 2 ? Go ...

  • Page 521

    Abs: 4e-18 dtc c1021, c1022 / c1025, c1026 / c1031, c1032 / c1035, c1036: right-front / left-front / right- rear / left-rear wheel speed sensor circuit or sensor ring s4rs0a4504015 wiring diagram dtc detecting condition the abs control module monitors the voltage at the terminal of each sensor while...

  • Page 522

    4e-19 abs: 3 1) turn ignition switch off. 2) connect applicable abs wheel speed sensor coupler. 3) disconnect abs hydraulic unit / control module connector. 4) check for proper connection to abs control module at each sensor terminal. 5) if ok, then turn ignition switch on and measure voltage betwee...

  • Page 523

    Abs: 4e-20 dtc c1041 / c1045 / c1051 / c1055, dtc c1042 / c1046 / c1052 / c1056: right-front / left-front / right-rear / left-rear inlet solenoid circuit, right-front / left-front / right-rear / left-rear outlet solenoid circuit s4rs0a4504016 wiring diagram dtc detecting condition the abs control mo...

  • Page 524

    4e-21 abs: dtc c1057: power source circuit s4rs0a4504017 wiring diagram dtc detecting condition the abs control module monitors the power source voltage at terminal “e03-14”. When the power source voltage becomes extremely high or low while vehicle is running at more than 20 km/h (13 mph), this dtc ...

  • Page 525

    Abs: 4e-22 dtc c1061: abs pump motor and/or motor driver circuit s4rs0a4504018 wiring diagram dtc detecting condition the abs control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition switch turned on. It sets this dtc when the voltage at the monitor ...

  • Page 526

    4e-23 abs: dtc c1063: solenoid valve power supply driver circuit s4rs0a4504019 wiring diagram dtc detecting condition abs control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned on. Also, immediately after ignition switch is turned on, perform i...

  • Page 527

    Abs: 4e-24 dtc c1071: abs control module s4rs0a4504020 wiring diagram dtc detecting condition this dtc will be set when an internal malfunction is detected in the abs control module. Dtc troubleshooting i4rs0a450019- [a]: abs hydraulic unit / control module connector e03 2. Main fuse box 4. Abs hydr...

  • Page 528

    4e-25 abs: repair instructions abs hydraulic unit operation check s4rs0a4506001 1) check that basic brake system other than abs is in good condition. 2) check that battery voltage is 11 v or higher. 3) lift up vehicle. 4) set transmission to neutral and release parking brake. 5) turn each wheel grad...

  • Page 529

    Abs: 4e-26 abs hydraulic unit / control module assembly on-vehicle inspection s4rs0a4506003 caution: never disassemble abs hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of abs hydraulic unit /...

  • Page 530

    4e-27 abs: 3) using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from abs hydraulic unit / control module assembly (3). Special tool (a): 09950-78220 note: put bleeder plug cap or the like onto pipe to prevent fluid from spilling. Do not allow brake fluid to get on painted surf...

  • Page 531

    Abs: 4e-28 2) bleed air from brake system referring to “air bleeding of brake system: in section 4a”. 3) check each installed part for fluid leakage and perform “abs hydraulic unit operation check: ”. Note: for new abs hydraulic unit / control module assembly, if “abs hydraulic unit operation check:...

  • Page 532

    4e-29 abs: installation 1) check that no foreign material is attached to sensor (1) and sensor ring (2). 2) install it by reversing removal procedure. Tightening torque front wheel speed sensor bolt (a): 25 n·m (2.5 kg-m, 18.0 lb-ft) front wheel speed sensor harness clamp bolt (b): 11 n·m (1.1 kg-m,...

  • Page 533

    Abs: 4e-30 reference when using oscilloscope for this check, check if peak-to- peak voltage (1) meets specification and waveform is complete. Peak-to-peak voltage at 1/2 to 1 rotation per second 140 mv or more at 15 hz rear wheel speed sensor removal and installation s4rs0a4506009 removal 1) disconn...

  • Page 534

    4e-31 abs: • be sure to install wheel speed sensor (2) and its bolt at the correct (upper) position as shown in figure. Tighten sensor bolt (1) and harness clamp bolts to specified torque. Tightening torque rear wheel speed sensor bolt (a): 11 n·m (1.1 kg- m, 8.0 lb-ft) rear wheel speed sensor harne...

  • Page 535

    Abs: 4e-32 front wheel speed sensor ring removal and installation s4rs0a4506012 note: the front wheel sensor ring can not be removed or replaced alone. If front wheel sensor ring needs to be replaced, replace it as a wheel side joint assembly of drive shaft. For removal and installation of wheel sid...

  • Page 536

    4e-33 abs: special tools and equipment special tool s4rs0a4508001 09950–78220 suzuki scan tool flare nut wrench (10 mm) — this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loopback adapter, 7. Battery power cable, 8. Rs232 ca...

  • Page 537: 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............

  • Page 538

    5-ii table of contents inspection of tcm and its circuits ....................5a-86 tcm power and ground circuit check.............5a-90 brake interlock system inspection....................5a-91 repair instructions ............................................5a-92 learning control initialization......

  • Page 539

    Table of contents 5-iii vehicle speed sensor (vss) removal and installation.................................................. 5b-7 back up lamp switch removal and installation......................................................... 5b-7 back up lamp switch inspection ....................... 5b-8 ma...

  • Page 540: Precautions

    5-1 precautions: precautions precautions precautions on transmission / transaxle s4rs0a5000001 air bag warning refer to “air bag system service warning: in section 00”..

  • Page 541: Automatic Transmission

    Automatic transmission: 5a-1 automatic transmission precautions precautions in diagnosing trouble s4rs0a5100001 • do not disconnect couplers from tcm, battery cable from battery, tcm ground wire harness from engine or main fuse before checking the diagnostic information (dtc, freeze frame data, etc....

  • Page 542

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

  • Page 543

    Automatic transmission: 5a-3 general description a/t description s4rs0a5101001 this automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (o/d) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an a...

  • Page 544

    5a-4 automatic transmission: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 i3rm0b510001- 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (tcc) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23. Short plan...

  • Page 545

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

  • Page 546

    5a-6 automatic transmission: clutch / brake / planetary gear function of automatic transaxle s4rs0a5101002 functions table of component operation s4rs0a5101003 1 2 4 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 i4rs0a510001- 1. Input shaft and intermediate shaft 8: one-way no.2 clutch 15. Front sun gea...

  • Page 547

    Automatic transmission: 5a-7 : on : off : on only when tcc is operating a/t diagnosis general description s4rs0a5101005 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 c...

  • Page 548

    5a-8 automatic transmission: driving cycle a “driving cycle” consists of engine startup, driving mode where a malfunction would be detected if present, and engine shutoff. 2 driving cycles detection logic the malfunction detected in the first driving cycle is stored in tcm memory (in the form of pen...

  • Page 549

    Automatic transmission: 5a-9 schematic and routing diagram transmission control module (tcm) wiring diagram s4rs0a5102001 ig1 11 5 5 5 8 9 10 7 6 p r n d 2 l 12 12v 2.5v 5v 12v 5v 12v 12v 12v 12v wht blk blk blk blk ppl blk/red yel/blk ig11 red/blk yel/blk yel/blu lt grn/blk +bb wht/red 14 20 15 16 ...

  • Page 550

    5a-10 automatic transmission: operation of shift solenoid valves, timing solenoid valve and tcc solenoid valve : on (turn power on) : off (turn power off) : on only when tcc is operating selector position gear position solenoid condition shift solenoid valve-a (no.1) shift solenoid valve-b (no. 2) t...

  • Page 551

    Automatic transmission: 5a-11 automatic gear shift table s4rs0a5102002 automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the d position. 1.Shift point in d, 3 and/or 2 position 2. Lock-up point in d and/or 3 position 3. Slip lock-up point in d an...

  • Page 552

    5a-12 automatic transmission: component location electronic shift control system components location s4rs0a5103001 3 4 5 1 2 6 7 8 9 10 11 12 13 14 15 16 17 18 19 i4rs0a510006- 1. Engine 8. Tcc pressure control solenoid valve 15. Ecm 2. Transaxle 9. Transmission fluid temperature sensor 16. Tcm 3. M...

  • Page 553

    Automatic transmission: 5a-13 engine torque converter with torque converter clutch oil pump regulator valves in valve body planetary gear unit clutches and brakes control valves in valve body shift solenoid valves, tcc pressure control solenoid valve and timing solenoid valve pressure control soleno...

  • Page 554

    5a-14 automatic transmission: diagnostic information and procedures a/t system check s4rs0a5104001 refer to the following items for the details of each step. Step 1. Customer complaint analysis record details of the problem such as failure, complaint and how it occurred as described by the customer....

  • Page 555

    Automatic transmission: 5a-15 customer problem inspection form (example) note: the form is a standard sample. It should be modified according to conditions characteristic of each market. I2rh01510008-.

  • Page 556

    5a-16 automatic transmission: step 2. Dtc / freeze frame data check, record and clearance first, referring to “dtc check: ”, check dtc and pending dtc. If dtc exists, print or write down dtc and freeze frame data and then clear malfunction dtc(s) by referring to “dtc clearance: ”. Malfunction dtc in...

  • Page 557

    Automatic transmission: 5a-17 visual inspection s4rs0a5104002 visually check the following parts and systems. Malfunction indicator lamp (mil) check s4rs0a5104003 refer to the same item in “malfunction indicator lamp (mil) check: in section 1a” for checking procedure. Dtc table s4rs0a5104005 inspect...

  • Page 558

    5a-18 automatic transmission: p0717 input / turbine speed sensor circuit no signal no sensor signal is detected although output speed sensor signal is inputted. 1 driving cycle p0722 output speed sensor circuit no signal no sensor signal is inputted although input speed sensor signal is inputted. 1 ...

  • Page 559

    Automatic transmission: 5a-19 note: *1: tcm does not desire turning on malfunction indicator lamp to ecm but dtc is stored in tcm memory. This item can not be read generic scan tool. Dtc check s4rs0a5104006 note: the mil is turned on when the ecm and/or tcm detect malfunction(s). Each control module...

  • Page 560

    5a-20 automatic transmission: fail-safe table s4rs0a5104008 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 or its ci...

  • Page 561

    Automatic transmission: 5a-21 p1703 can invalid data - tcm in case of throttle position signal malfunction: • throttle opening used for line pressure control is assumed to be 100%. • throttle opening used for gear shifting control is assumed to be 0%. • upshifting to 4th gear is inhibited. • lock-up...

  • Page 562

    5a-22 automatic transmission: scan tool data s4rs0a5104009 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 condition...

  • Page 563

    Automatic transmission: 5a-23 atf temperature after driving at 60 km/h (37.5 mile/h) for 15 minutes or more, and a/t fluid temperature around sensor reaches 70 – 80 c (158 – 176 f) 70 – 80 c (158 – 176 f) shift solenoid- a command at vehicle stop on at 60 km/h (37.5 mile/h) constant speed, o/d off s...

  • Page 564

    5a-24 automatic transmission: scan tool data definitions: gear position current gear position computed by throttle position coming from ecm and vehicle speed. Engine speed (rpm) engine speed computed by reference pulses from crankshaft position sensor. Input shaft revolution (rpm) input shaft revolu...

  • Page 565

    Automatic transmission: 5a-25 torque reduction signal on: signal which tcm require ecm to reduce output torque at shifting gear off: signal which tcm does not require ecm to reduce output torque engine coolant temperature ( c, f) engine coolant temperature computed by duty signal from ecm. Air condi...

  • Page 566

    5a-26 automatic transmission: road test s4rs0a5104011 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 persons, a driv...

  • Page 567

    Automatic transmission: 5a-27 3 4 upshift fails to occur malfunction of shift solenoid valve-b inspect. If ng, replace. Malfunction of “3” position switch inspect. If ng, replace. Malfunction of engine coolant temperature sensor inspect. If ng, replace. Malfunction of output shaft speed sensor (vss)...

  • Page 568

    5a-28 automatic transmission: manual road test s4rs0a5104012 this test checks the gears being used in “l”, “2” “3” or “d” range when driven with unoperated gear shift control system. Test drive vehicle on a level road. Note: before this test, check dtc. 1) with select lever in “p”, start engine and ...

  • Page 569

    Automatic transmission: 5a-29 troubleshooting engine brake test s4rs0a5104016 warning: before test, make sure that there is no vehicle behind so as to prevent rear-end collision. 1) while driving vehicle in 3rd gear of “d” range, shift select lever down to “2” range and check if engine brake operate...

  • Page 570

    5a-30 automatic transmission: troubleshooting condition possible cause correction / reference item lower than standard level in both “d” and “r” range engine output torque failure inspect and repair engine. Faulty one-way clutch of torque converter replace torque converter. Higher than standard leve...

  • Page 571

    Automatic transmission: 5a-31 time lag test s4rs0a5104014 this test is to check conditions of clutch, brake and fluid pressure. “time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) with chocks placed before and behind front and rear wheels respectivel...

  • Page 572

    5a-32 automatic transmission: line pressure test s4rs0a5104015 purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires the following conditions. • automatic fluid is at normal operating temperature (70 – 80 c ...

  • Page 573

    Automatic transmission: 5a-33 “p” range test s4rs0a5104017 1) stop vehicle on a slope of 5 degrees or more, shift select lever to “p” range and at the same time apply parking brake. 2) after stopping engine, depress brake pedal and release parking brake. 3) then, release brake pedal gradually and ch...

  • Page 574

    5a-34 automatic transmission: poor 1 2 shift shift solenoid valve-b circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Output shaft speed sensor (vss) circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Transmission range sensor circuit faulty...

  • Page 575

    Automatic transmission: 5a-35 poor 3 4 shift shift solenoid valve-b circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Pressure control solenoid valve circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Timing solenoid valve circuit faulty ins...

  • Page 576

    5a-36 automatic transmission: poor 3 2 shift shift solenoid valve-a circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Output shaft speed sensor (vss) circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Can communication circuit faulty inspect...

  • Page 577

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

  • Page 578

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

  • Page 579

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

  • Page 580

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

  • Page 581

    Automatic transmission: 5a-41 no gear shift to 4th gear s4rs0a5104019 system description tcm does not shift to 4th gear under any of the following condition. • “3” position switch is turned on. • engine coolant temperature is less than 50 c (122 f). • a/t fluid temperature is less than 20 c (68 f). ...

  • Page 582

    5a-42 automatic transmission: no lock-up occurs s4rs0a5104020 system description tcm turns tcc solenoid off under any of the following conditions. • brake light switch is turned on (brake pedal is depressed). • transmission fluid temperature is less than 60 c (140 f). • throttle opening is as much a...

  • Page 583

    Automatic transmission: 5a-43 dtc p0705: transmission range sensor circuit malfunction s4rs0a5104021 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm memory by using scan tool. 3) start engin...

  • Page 584

    5a-44 automatic transmission: table for step 4 3 check transmission range sensor (switch) circuit for operation check by using suzuki scan tool: 1) connect suzuki scan tool to dlc with ignition switch off. 2) turn ignition switch on and check transmission range signal (“p”, “r”, “n”, “d”, “2” or “l”...

  • Page 585

    Automatic transmission: 5a-45 dtc p0707: transmission range sensor circuit low s4rs0a5104045 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be...

  • Page 586

    5a-46 automatic transmission: table for step 4 3 check transmission range sensor (switch) circuit for operation check by using suzuki scan tool: 1) connect suzuki scan tool to dlc with ignition switch off. 2) turn ignition switch on and check transmission range signal (p, r, n, d, 2 or l) on display...

  • Page 587

    Automatic transmission: 5a-47 dtc p0712: transmission fluid temperature sensor circuit low s4rs0a5104046 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic acc...

  • Page 588

    5a-48 automatic transmission: dtc p0713: transmission fluid temperature sensor circuit high s4rs0a5104023 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic ac...

  • Page 589

    Automatic transmission: 5a-49 dtc p0717: input / turbine speed sensor circuit malfunction s4rs0a5104024 wiring diagram dtc detecting condition and trouble area 3 check transmission fluid temperature circuit for ig short 1) cool down a/t fluid temperature under ambient temperature. 2) connect tcm con...

  • Page 590

    5a-50 automatic transmission: dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out with 2 persons, a dr...

  • Page 591

    Automatic transmission: 5a-51 dtc p0722: output speed sensor (vss) circuit no signal s4rs0a5104025 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident ...

  • Page 592

    5a-52 automatic transmission: 3 check output shaft speed sensor (vss) ground circuit 1) turn ignition switch off. 2) check continuity between “yel/blk” wire terminal of disconnected output shaft speed sensor harness side connector and ground. Is continuity indicated? Go to step 4. “yel/blk” wire ope...

  • Page 593

    Automatic transmission: 5a-53 dtc p0741 / p0742: tcc circuit performance or stuck off / tcc circuit stuck on s4rs0a5104027 dtc detecting condition and trouble area dtc p0741 dtc p0742 dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possi...

  • Page 594

    5a-54 automatic transmission: dtc p0751 / p0752 / p0756 / p0757: shift solenoid malfunction s4rs0a5104030 dtc p0751: shift solenoid-a (no.1) performance or stuck off dtc p0752: shift solenoid-a (no.1) stuck on dtc p0756: shift solenoid-b (no.2) performance or stuck off dtc p0757: shift solenoid-b (n...

  • Page 595

    Automatic transmission: 5a-55 4) shift select lever to “n” and “d” range for 10 seconds. 5) start vehicle and increase vehicle speed to 65 km/h (40 mile/h) with throttle position 10% or more. 6) stop vehicle and turn ignition switch off. 7) repeat step 3) to 5) one time. 8) stop vehicle and check dt...

  • Page 596

    5a-56 automatic transmission: 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 timing solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on transaxle. 3) check for prop...

  • Page 597

    Automatic transmission: 5a-57 dtc p0788: shift / timing solenoid control circuit high s4rs0a5104050 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine and s...

  • Page 598

    5a-58 automatic transmission: 4 check timing solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on transaxle. 3) check for proper connection to solenoid valve at “blu/ blk” circuit. 4) check resistance of solenoid valve. Timing solenoid valve r...

  • Page 599

    Automatic transmission: 5a-59 dtc p0962: pressure control solenoid control circuit low s4rs0a5104032 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine. 4) ...

  • Page 600

    5a-60 automatic transmission: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check: ”. 2 check pressure control solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transaxl...

  • Page 601

    Automatic transmission: 5a-61 dtc p0963: pressure control solenoid control circuit high s4rs0a5104047 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine. 4)...

  • Page 602

    5a-62 automatic transmission: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check: ”. 2 check pressure control solenoid circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper connect...

  • Page 603

    Automatic transmission: 5a-63 dtc p0973 / p0976: shift solenoid-a (no.1) control circuit low / shift solenoid-b (no.2) control circuit low s4rs0a5104051 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where the...

  • Page 604

    5a-64 automatic transmission: dtc troubleshooting step action yes no 1 was “automatic transaxle diagnostic flow table” performed? Go to step 2. Go to “a/t system check: ”. 2 check shift solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on auto...

  • Page 605

    Automatic transmission: 5a-65 dtc p0974 / p0977: shift solenoid-a (no.1) / shift solenoid-b (no.2) control circuit high s4rs0a5104048 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 606

    5a-66 automatic transmission: dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check: ”. 2 check shift solenoid valve circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper connection t...

  • Page 607

    Automatic transmission: 5a-67 dtc p1702: internal control module memory check sum error s4rs0a5104033 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtc in tcm memory. 3) after 10 seconds passed from turning ignition...

  • Page 608

    5a-68 automatic transmission: dtc p1723: range select switch malfunction s4rs0a5104052 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool and turn ignition s...

  • Page 609

    Automatic transmission: 5a-69 dtc p1774: control module communication bus off s4rs0a5104053 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start engi...

  • Page 610

    5a-70 automatic transmission: 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 dtc 1) connect scan tool to dlc with ignition switch turned off. 2) check dtc in ecm, tcm and bcm. Is there any dtc(s) (other than dtc p1674, p16...

  • Page 611

    Automatic transmission: 5a-71 9 check can communication line circuit insulation 1) disconnect connectors from ecm, bcm, tcm and combination meter with ignition switch off. 2) measure resistance at the following connector terminals. • between “e23-3” and “e23-18” terminals of ecm connector • between ...

  • Page 612

    5a-72 automatic transmission: dtc p1775: high speed can communication bus off (transmission error) s4rs0a5104054 wiring diagram 12 check can communication line circuit power supply short 1) measure voltage at the following connector terminals with ignition switch turned on. • between “e23-3” termina...

  • Page 613

    Automatic transmission: 5a-73 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. 3) start engine and run it for 1 min. Or more. 4) check dtc, pending dtc and freeze-frame ...

  • Page 614

    5a-74 automatic transmission: 8 check can communication line circuit insulation 1) measure resistance between “c34-17” and “c34-7” terminals of tcm connector. Is resistance infinity? Go to step 9. Repair insulation of can communication line circuit referring to “precaution for can communication syst...

  • Page 615

    Automatic transmission: 5a-75 dtc p1777: tcm lost communication with ecm (reception error) s4rs0a5104055 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. ...

  • Page 616

    5a-76 automatic transmission: 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 dtc 1) connect scan tool to dlc with ignition switch turned off. 2) check dtc in ecm, tcm and bcm. Is there any dtc(s) (other than dtc p1674, p16...

  • Page 617

    Automatic transmission: 5a-77 10 check can communication line circuit power supply short 1) measure voltage at the following connector terminals with ignition switch turned on. • between “c34-17” terminal of tcm connector and vehicle body ground • between “c34-7” terminal of tcm connector and vehicl...

  • Page 618

    5a-78 automatic transmission: dtc p1778: tcm lost communication with bcm (reception error) s4rs0a5104056 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm and ecm memories by using scan tool. ...

  • Page 619

    Automatic transmission: 5a-79 3 check tcm for can communication error 1) check dtc in tcm. Is there dtc p1774? Go to “dtc p1774: control module communication bus off: ”. Go to step 4. 4 check ecm, tcm and bcm connectors 1) check for proper connection at each ecm, tcm and bcm connector terminals with...

  • Page 620

    5a-80 automatic transmission: 10 check can communication line circuit ground short 1) measure resistance at the following connector terminals. • between “e23-3” terminal of ecm connector and vehicle body ground • between “e23-18” terminal of ecm connector and vehicle body ground • between “c37-13” t...

  • Page 621

    Automatic transmission: 5a-81 dtc p1878: torque converter clutch shudder s4rs0a5104057 dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during ...

  • Page 622

    5a-82 automatic transmission: dtc p2763: torque converter clutch (tcc) pressure control solenoid control circuit high s4rs0a5104037 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 p...

  • Page 623

    Automatic transmission: 5a-83 2 check tcc solenoid valve circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper connection to tcm at terminal “c34-3” and “c34-5”. 4) if connection is ok, turn ignition switch on and measure voltage between term...

  • Page 624

    5a-84 automatic transmission: dtc p2764: torque converter clutch (tcc) circuit pressure control solenoid control circuit low s4rs0a5104036 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning: • when performing a road test, select a place where there is no traff...

  • Page 625

    Automatic transmission: 5a-85 2 check tcc lock-up pressure control solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transaxle. 3) check for proper connection to solenoid at “wht/blu” and “wht/blk” circuits. 4) check resistance of...

  • Page 626

    5a-86 automatic transmission: inspection of tcm and its circuits s4rs0a5104038 tcm and its circuits can be checked at tcm wiring connectors by measuring voltage, pulse signal and resistance. Caution: tcm cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to tcm w...

  • Page 627

    Automatic transmission: 5a-87 connector “c35” 5 wht/blu tcc pressure control solenoid valve (+) *0 – 0.6 v 10 – 14 v (“reference waveform no. 2: ”) engine running at idling (output signal is duty pulse. Duty ratio varies depending on torque converter clutch operating condition). 6 yel/blk power sour...

  • Page 628

    5a-88 automatic transmission: reference waveform no. 1 pressure control solenoid valve signal at engine idling. 7 grn transmission range sensor (“d” range) 8 – 14 v ignition switch on, selector lever at “d” range 0 – 1 v ignition switch on, selector lever at other than “d” range 8 grn/orn transmissi...

  • Page 629

    Automatic transmission: 5a-89 reference waveform no. 2 tcc pressure control solenoid valve signal at engine idling. Reference waveform no. 3 can communication line (high & low) signal at engine idling. Reference waveform no. 4 input shaft speed sensor signal at engine idling. Reference waveform no. ...

  • Page 630

    5a-90 automatic transmission: tcm power and ground circuit check s4rs0a5104039 wiring diagram troubleshooting blk blk blk c34-1 c34-23 c34-6 yel/blk yel/blu lt grn/blk +bb c34-24 wht/red 1 2 3 6 24 23 1 c34 c35 [a] i4rs0a510023- 1. Tcm 3. Ignition switch 2. A/t relay [a]: terminal arrangement of tcm...

  • Page 631

    Automatic transmission: 5a-91 brake interlock system inspection s4rs0a5104058 1) check that selector lever cannot be moved to any other range from “p” range position when ignition switch key is at acc position, at lock position or it is removed from keyhole of ignition switch, or brake pedal is not ...

  • Page 632

    5a-92 automatic transmission: repair instructions learning control initialization s4rs0a5106067 1) connect san tool to dlc (1) with ignition switch off. Special tool (a): suzuki scan tool 2) start engine and shift selector lever to “p” range. 3) select “misc test” mode on scan tool. 4) perform “at l...

  • Page 633

    Automatic transmission: 5a-93 a/t fluid change s4rs0a5106002 caution: do not use any fluid other than the specified atf. Use of any fluid other than the specified atf may cause juddering or some other faulty condition to occur. 1) lift up vehicle. 2) when engine is cool, remove drain plug (1) from t...

  • Page 634

    5a-94 automatic transmission: select lever assembly installation s4rs0a5106068 note the following when installing select lever assembly: • after installing select lever assembly, adjust select cable referring to “select cable adjustment: ”. Select lever knob installation s4rs0a5106069 screw select l...

  • Page 635

    Automatic transmission: 5a-95 select cable removal and installation s4rs0a5106003 removal 1) remove parking brake lever cover. 2) remove console box. 3) disconnect select cable from selector lever and then detach from bracket. 4) remove clip and disconnect select cable from manual select lever. 5) r...

  • Page 636

    5a-96 automatic transmission: transmission range sensor (shift switch) inspection and adjustment s4rs0a5106008 1) shift manual select lever (4) to “n” range. 2) check that needle direction shaped on lock washer (2) and “n” reference line (1) on transmission range sensor are aligned. If not, loosen s...

  • Page 637

    Automatic transmission: 5a-97 output shaft speed sensor (vss) inspection s4rs0a5106010 1) connect positive cable of 12 volt battery to “a” terminal of sensor and ground cable to “c” terminal. Then using voltmeter, check voltage between “b” terminal and “c” terminal with output shaft speed sensor (vs...

  • Page 638

    5a-98 automatic transmission: transmission fluid temperature sensor removal and installation s4rs0a5106059 removal 1) disconnect negative cable at battery. 2) lift up vehicle. 3) with engine is cool, remove drain plug and drain a/t fluid. 4) install drain plug. Refer to “a/t fluid change: ”. 5) remo...

  • Page 639

    Automatic transmission: 5a-99 “3” position switch inspection s4rs0a5106014 1) remove console box referring to “console box components: in section 9h”. 2) disconnect “3” position switch connector (1). 3) check continuity between “3” position switch terminals. “3” position switch specification shift s...

  • Page 640

    5a-100 automatic transmission: installation 1) install shift solenoid valve-a (no.1) (1), shift solenoid valve-b (no.2) (2) and timing solenoid valve (3). Tightening torque shift solenoid bolt (a): 11 n·m (1.1 kg-m, 8.0 lb- ft) 2) connect solenoid connectors identifying their installing positions by...

  • Page 641

    Automatic transmission: 5a-101 operation check shift solenoid valve-a (no.1) and -b (no.2) caution: • do not insert air gun against strainer installed on inlet of solenoid valve too deeply, when blowing air into solenoid valve. If not, the strainer will be damaged. • be very careful as dust etc. Doe...

  • Page 642

    5a-102 automatic transmission: pressure control solenoid valves (pressure control solenoid and tcc pressure control solenoid) removal and installation s4rs0a5106060 removal 1) disconnect negative cable at battery. 2) lift up vehicle. 3) remove drain plug and drain a/t fluid. 4) install drain plug. T...

  • Page 643

    Automatic transmission: 5a-103 using regulated dc power supply 1) connect pressure control solenoid valve (1) with regulated dc power supply (2) as shown in figure. 2) turn regulated dc power supply switch on and increase voltage of power supply keeping current within 1.0 a. 3) check for gradual mov...

  • Page 644

    5a-104 automatic transmission: installation reverse removal procedure noting the following. • connect tcm connectors securely. • if the vehicle is equipped with air bag system, be sure to enable air bag system after tcm is back in place. Refer to “enabling air bag system: in section 8b”. A/t relay i...

  • Page 645

    Automatic transmission: 5a-105 6) install drive shaft referring to “front drive shaft assembly removal and installation: in section 3a”. 7) pour a/t fluid referring to “a/t fluid change: ”. Shift lock solenoid inspection s4rs0a5106064 check that shift lock solenoid (1) actuate when battery voltage i...

  • Page 646

    5a-106 automatic transmission: key interlock cable removal and installation s4rs0a5106066 note: don’t bend interlock cable excessively when removing and installing it, or system will not operate correctly. Removal 1) if the vehicle is equipped with air bag system, disconnect negative cable at batter...

  • Page 647

    Automatic transmission: 5a-107 11) if the vehicle is equipped with air bag system, connect negative cable at battery and enable air bag system, referring to “enabling air bag system: in section 8b”. A/t fluid cooler hoses replacement s4rs0a5106022 the rubber hoses for the a/t fluid cooler should be ...

  • Page 648

    5a-108 automatic transmission: automatic transaxle unit dismounting and remounting s4rs0a5106024 dismounting 1) take down transaxle with engine. For its procedure, refer to “engine assembly removal and installation: in section 1d”. 2) remove transaxle housing lower plates (1). 3) remove drive plate ...

  • Page 649

    Automatic transmission: 5a-109 3) tighten drive plate to torque converter bolts. Align bolt hole of drive plate and torque converter then tighten bolts through torque converter housing lower plate opening. Lock drive plate (1) by engaging flat head rod or the like (2) with drive plate gear. Tighteni...

  • Page 650

    5a-110 automatic transmission: automatic transaxle assembly components s4rs0a5106025 i3rm0b510053-.

  • Page 651

    Automatic transmission: 5a-111 1. Torque converter 33. Oil pan 65. 2nd brake retaining plate 2. Torque converter housing : apply sealant 99000-31230 to mating surface to transaxle case. 34. A/t fluid drain plug 66. 2nd brake disc 3. Oil strainer assembly : replace oil strainer when overhauling. 35. ...

  • Page 652

    5a-112 automatic transmission: automatic transaxle unit disassembly s4rs0a5106026 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 not expose...

  • Page 653

    Automatic transmission: 5a-113 10) remove oil pan (1) and oil pan gasket (2). Note: • for removal of oil pan, do not turn transaxle over as this will contaminate valve body with foreign materials in bottom of oil pan. • when removing oil pan, tap around it lightly with plastic hammer. Do not force i...

  • Page 654

    5a-114 automatic transmission: 15) remove valve body harness (1). Caution: when pulling valve body harness out of transaxle case, take care not to damage transmission fluid temperature sensor (2) at narrow exit of case. Careless sensor treatment might cause sensor malfunction. 16) remove governor ap...

  • Page 655

    Automatic transmission: 5a-115 19) remove transaxle case plug (1). 20) remove torque converter housing bolts. 21) remove torque converter housing (1) while tapping around it lightly with plastic hammer. 22) remove breather hose (1). 23) remove breather union (2). 24) measure input shaft thrust play....

  • Page 656

    5a-116 automatic transmission: 28) remove input shaft rear thrust bearing (1) and thrust bearing race (2). Note: if input shaft rear thrust bearing is not found, it may have been taken out with direct clutch assembly. 29) remove direct clutch hub (1). 30) remove differential assembly (1) and counter...

  • Page 657

    Automatic transmission: 5a-117 35) remove 2nd brake gasket (1). 36) measure o/d and 2nd coast brake piston stroke. If piston stroke exceeds specification, inspect and replace plates and discs. • measure dimension “a” from mating surface of transaxle case to o/d and 2nd coast brake rear plate (1) usi...

  • Page 658

    5a-118 automatic transmission: 40) remove forward clutch hub (1). 41) remove rear sun gear thrust bearing (1) from forward clutch hub (2). Note: if rear sun gear thrust bearing is not found on forward clutch hub, it may have been left in transaxle. 42) remove rear sun gear thrust bearing race (1). 4...

  • Page 659

    Automatic transmission: 5a-119 48) remove front planetary sun gear (1). 49) remove front sun gear thrust bearing race (2) from front planetary sun gear (1). 50) using special tool and hydraulic press, remove 2nd brake piston snap ring (1). Caution: do not press 2nd brake piston assembly in over 0.4 ...

  • Page 660

    5a-120 automatic transmission: 55) remove one-way clutch outer race retainer (1). 56) check one-way clutch no.2 as follows. • ensure planetary carrier (1) rotates only in counterclockwise direction “a”, never in clockwise direction “b”. • if the planetary carrier rotates both ways or does not rotate...

  • Page 661

    Automatic transmission: 5a-121 61) remove 1st and reverse brake retaining plate, discs and separator plates. 62) remove 1st and reverse brake return spring subassembly (1). 63) turn over transaxle and uncaulk reduction drive gear nut (1). 64) secure reduction drive gear (1) with parking lock pawl, t...

  • Page 662

    5a-122 automatic transmission: 67) screwing 3 bolts (1), remove reduction drive gear (2). Caution: screw 3 bolts into reduction drive gear uniformly, or reduction drive gear, bearing and transaxle case may be damaged. Bolt length 30 mm (1.20 in.) 68) blowing compressed air from oil hole (1) of oil p...

  • Page 663

    Automatic transmission: 5a-123 75) remove manual shift shaft oil seal (1). Oil pump assembly components s4rs0a5106027 i2rh0b510146- i2rh0b510147- i2rh0b510148- 1. Oil seal : apply grease 99000-25030 to oil seal lip. 5. Oil pump drive gear : apply automatic transaxle fluid. 2. O-ring 6. Stator shaft ...

  • Page 664

    5a-124 automatic transmission: oil pump assembly disassembly and reassembly s4rs0a5106028 disassembly 1) remove o-ring from pump body. 2) remove 8 oil pump subassembly bolts (1) and stator shaft assembly (2). 3) remove oil seal (1) using special tool. Special tool (a): 09913–50121 reassembly 1) inst...

  • Page 665

    Automatic transmission: 5a-125 2) check tip clearance of both drive and driven gears. Using a feeler gauge, measure clearance between drive and driven gear tips. If clearance exceeds its standard value, replace oil pump assembly. Tip clearance between oil pump drive gear and oil pump driven gear sta...

  • Page 666

    5a-126 automatic transmission: direct clutch assembly components s4rs0a5106030 direct clutch assembly preliminary check s4rs0a5106031 install direct clutch assembly (1) to oil pump assembly (2) blow in air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (3) of oil pump assembly with s...

  • Page 667

    Automatic transmission: 5a-127 direct clutch assembly disassembly and reassembly s4rs0a5106032 disassembly 1) remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates. 2) using special tool and hydraulic press, remove shaft snap ring (1). Special tool (a): 099...

  • Page 668

    5a-128 automatic transmission: reassembly reverse disassembly procedure for assembly, noting the following points. • use new seal ring and o-ring. Apply a/t fluid before installation. • do not damage direct clutch return spring subassembly (1) and piston by pressing in direct clutch return spring su...

  • Page 669

    Automatic transmission: 5a-129 direct clutch assembly inspection s4rs0a5106033 clutch discs, plates and retaining plate check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt. If necessary, replace. Note: • if disc lining is exfoliated, discolored, repl...

  • Page 670

    5a-130 automatic transmission: forward and reverse clutch assembly components s4rs0a5106034 forward and reverse clutch assembly preliminary check s4rs0a5106035 1) install forward and reverse clutch assembly (1) to transaxle rear cover (2), blow in compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – ...

  • Page 671

    Automatic transmission: 5a-131 2) blow compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (1) of transaxle rear cover with the special tool attached on the upper surface of forward clutch retaining plate, and measure forward clutch piston stroke. If piston stroke exceeds s...

  • Page 672

    5a-132 automatic transmission: 5) remove forward clutch return spring subassembly (1). 6) install intermediate shaft subassembly (1) to transaxle rear cover (2). Apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole (3) of transaxle rear cover to remove forward clutch piston...

  • Page 673

    Automatic transmission: 5a-133 • • apply a/t fluid to forward clutch separator plates (1), discs (2) and retaining plate (3). • install forward clutch separator plates (1), discs (2) and retaining plate (3), then snap ring (4) to forward clutch drum. • install forward clutch plate snap ring so that ...

  • Page 674

    5a-134 automatic transmission: • install reverse clutch plate snap ring so that its both ends would be positioned in correct locations as shown in figure. • measure reverse clutch piston stroke in the same manner as “forward and reverse clutch assembly preliminary check: ”. When piston stroke is out...

  • Page 675

    Automatic transmission: 5a-135 forward clutch drum lip check each lip for wear, deformation, cut and/or hardening. If necessary, replace. 2nd brake piston assembly components s4rs0a5106038 2nd brake piston assembly disassembly and reassembly s4rs0a5106040 disassembly 1) apply compressed air (400 – 8...

  • Page 676

    5a-136 automatic transmission: 2) remove inner o-ring (1) and outer o-ring (2). Reassembly reverse disassembly procedure for assembly, noting the following points. • use new o-rings. Apply a/t fluid to the o-rings, before installation. • install 2nd brake piston (1) to which a/t fluid is applied to ...

  • Page 677

    Automatic transmission: 5a-137 transaxle rear cover (o/d and 2nd coast brake piston) assembly disassembly and reassembly s4rs0a5106044 disassembly 1) remove snap ring by using special tools and hydraulic press. Special tool (a): 09926–96030 (b): 09946–06710 caution: do not press o/d and 2nd coast br...

  • Page 678

    5a-138 automatic transmission: • do not open rear cover seal ring too wide to attach. • do not damage o/d and 2nd coast brake return spring subassembly and piston by pressing in o/d and 2nd coast brake return spring subassembly passing through its original installing position over 1.0 mm (0.039 in.)...

  • Page 679

    Automatic transmission: 5a-139 countershaft assembly components s4rs0a5106048 countershaft assembly disassembly and reassembly s4rs0a5106049 disassembly 1) remove countershaft lh bearing (1) and reduction driven gear (2) at once by using special tool and hydraulic press. Special tool (a): 09925–9822...

  • Page 680

    5a-140 automatic transmission: 3) install countershaft lh bearing (1) with special tools and hydraulic press. Special tool (a): 09913–84510 (b): 09925–88210 valve body assembly components s4rs0a5106050 i2rh0b510214- i4rs0a510044- 1. Pressure control solenoid valve 6. Temperature sensor clamp : apply...

  • Page 681

    Automatic transmission: 5a-141 valve body assembly disassembly and reassembly s4rs0a5106051 caution: when replacing pressure control solenoid valve and/or tcc pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing pressure control...

  • Page 682

    5a-142 automatic transmission: reassembly reverse disassembly procedure for assembly, noting the following points. • shift solenoid valve-a and -b are identical • after applying a/t fluid to new o-rings, fit them to solenoid valves, then install solenoid valves to valve body. • tighten solenoid valv...

  • Page 683

    Automatic transmission: 5a-143 differential assembly disassembly and reassembly s4rs0a5106053 disassembly 1) remove final gear bolts (1), and then final gear (2). 2) remove differential side rh bearing by using special tools. Special tool (a): 09926–37610 (b): 09926–37610–001 (c): 09926–37610–003 (d...

  • Page 684

    5a-144 automatic transmission: 2) as shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. 3) tighten final gear bolts (1) to specified torque. Note: to avoid rust, apply a/t fluid to final driven gear after installation. Tightening torque final gear bol...

  • Page 685

    Automatic transmission: 5a-145 torque converter housing disassembly and reassembly s4rs0a5106055 disassembly 1) remove fluid reservoir rh plate (1) and lubrication tube clamp (2). 2) remove lubrication lh tube (1) and rh tube (2). Note: do not bend lubrication tube with excessive force. 3) remove di...

  • Page 686

    5a-146 automatic transmission: reassembly 1) after applying a/t fluid to new o-rings, fit them to housing plugs. Finally install plugs to torque converter housing. Tightening torque torque converter housing plug (a): 7.5 n·m (0.75 kg-m, 5.5 lb-ft) 2) using special tools, assemble differential side r...

  • Page 687

    Automatic transmission: 5a-147 transaxle case disassembly and reassembly s4rs0a5106057 disassembly 1) remove differential side oil seal (1). 2) remove countershaft lh bearing cup and shim with special tools. Special tool (a): 09944–96011 (b): 09942–15511 3) remove differential side lh bearing cup an...

  • Page 688

    5a-148 automatic transmission: 4) apply grease to oil seal lip. : grease 99000–25030 automatic transaxle unit inspection and adjustment s4rs0a5106063 inspection brake discs dry and inspect them for pitting, burn flaking, significant wear, glazing, cracking, charring and chips or metal particles imbe...

  • Page 689

    Automatic transmission: 5a-149 adjustment differential side bearing preload 1) after applying a/t fluid to differential assembly, fit it to transaxle case. 2) install torque converter housing to transaxle case, then tighten bolts (1) to specified torque. Tightening torque torque converter housing bo...

  • Page 690

    5a-150 automatic transmission: 3) measure bearing preload (b) by using special tool. Special tool (a): 09928–06050 countershaft bearing preload (b) measured as starting torque in the case of new bearing: 0.33 – 0.76 n m (3.3 – 7.6 kg-cm, 0.24 – 0.55 lb-ft) in the case of reused bearing: 0.17 – 0.38 ...

  • Page 691

    Automatic transmission: 5a-151 tightening torque manual detent spring bolt (a): 10 n·m (1.0 kg-m, 7.5 lb-ft) 3) install parking lock pawl rod (2) to manual valve lever (1). 4) after applying a/t fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3) and manual valve ...

  • Page 692

    5a-152 automatic transmission: 9) install 1st and reverse brake return spring subassembly (1) to transaxle case (2). 10) apply a/t fluid to 1st and reverse brake discs (2), separator plates (3) and retaining plate (1), then install them to transaxle case. 11) compress 1st and reverse brake return sp...

  • Page 693

    Automatic transmission: 5a-153 note: when replacing reduction drive gear, replace it together with reduction driven gear as a set. Special tool (a): 09951–18210 (b): 09944–78210 15) install parking lock pawl (1) and spring (2). Apply a/t fluid to parking lock pawl shaft, then insert it into transaxl...

  • Page 694

    5a-154 automatic transmission: 18) caulk reduction drive gear nut (1). 19) apply a/t fluid to planetary gear assembly (1), then fit it to planetary ring gear assembly. 20) check for correct installation of planetary gear assembly as follows. Measure the distance “a” by using micrometer caliper (1) a...

  • Page 695

    Automatic transmission: 5a-155 23) apply a/t fluid to new brake drum gasket (1), then install it to transaxle case. 24) apply a/t fluid to 2nd brake retaining plate (1), discs (2) and separator plates (3), then install them to transaxle case. 25) install 2nd brake return spring subassembly (1) to tr...

  • Page 696

    5a-156 automatic transmission: 30) install o/d and 2nd coast brake retaining plate snap ring (1). Caution: be sure to install o/d and 2nd coast brake retaining plate snap ring correctly in groove of transaxle case. 31) after applying grease to slide contact face of planetary carrier thrust washer (1...

  • Page 697

    Automatic transmission: 5a-157 bearing race dimension 39) apply a/t fluid to forward and reverse clutch assembly (1). Install forward and reverse clutch assembly while rotating clockwise and counterclockwise frequently to fit clutch discs to mating hubs. Note: before installation, align teeth of for...

  • Page 698

    5a-158 automatic transmission: available o/d and 2nd coast brake rear plate thickness 43) after applying a/t fluid to new 2nd brake gaskets (1), install them to transaxle case (2). 44) after applying a/t fluid to reverse clutch drum thrust bearing (1), install it to forward and reverse clutch assemb...

  • Page 699

    Automatic transmission: 5a-159 52) after applying a/t fluid to differential assembly (1) and countershaft assembly (2), install them to transaxle case. 53) after applying a/t fluid to direct clutch hub (1), install it to planetary gear assembly. 54) after applying a/t fluid to input shaft rear thrus...

  • Page 700

    5a-160 automatic transmission: 57) check for correct installation of direct clutch assembly as follows. Measure distance “a” by using micrometer caliper (1) and straightedge (2). If out of specification, remove direct clutch assembly, direct clutch hub and reinstall them properly. Distance between d...

  • Page 701

    Automatic transmission: 5a-161 63) wipe off and clean mating surface between transaxle case (1) and torque converter housing. 64) apply sealant to torque converter housing by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “a”: sealant 99000–3...

  • Page 702

    5a-162 automatic transmission: 69) after applying a/t fluid to cooler check valve (1) and spring (2), install them to transaxle case (3). 70) after applying a/t fluid to new governor apply no.1 gasket (1), install it to transaxle case. 71) after applying a/t fluid to new o-ring, fit it to valve body...

  • Page 703

    Automatic transmission: 5a-163 74) connect solenoid connectors to solenoid valves identifying their installing positions by wire colors, and install transmission fluid temperature sensor to its clamp. Solenoid valve coupler specification 75) install oil strainer assembly (1). Tightening torque oil s...

  • Page 704

    5a-164 automatic transmission: 80) install new gaskets (2) and then install fluid cooler pipes. Tightening torque fluid cooler pipe union bolt (b): 22 n·m (2.2 kg- m, 16.0 lb-ft) fluid cooler pipe bracket bolt (c): 10 n·m (1.0 kg-m, 7.5 lb-ft) 81) after applying a/t fluid to new o-ring, fit it to fl...

  • Page 705

    Automatic transmission: 5a-165 91) bend dents of lock washer (1) in order to prevent displacement of lock washer. 92) install manual select lever (1). Tightening torque manual select lever nut (a): 13 n·m (1.3 kg-m, 9.5 lb-ft) 93) install engine mounting lh bracket (1). Tightening torque engine moun...

  • Page 706

    5a-166 automatic transmission: specifications tightening torque specifications s4rs0a5107001 note: the specified tightening torque is also described in the following. “select cable components: ” “automatic transaxle unit components: ” “automatic transaxle assembly components: ” “oil pump assembly co...

  • Page 707

    Automatic transmission: 5a-167 special tools and equipment recommended service material s4rs0a5108001 note: required service material is also described in the following. “select cable components: ” “automatic transaxle unit components: ” “automatic transaxle assembly components: ” “oil pump assembly...

  • Page 708

    5a-168 automatic transmission: 09923–78210 09924–74510 bearing installer bearing and oil seal handle / / / / / / 09925–37811–001 09925–88210 oil pressure gauge bearing puller attachment / 09925–98210 09925–98221 input shaft bearing installer bearing installer 09926–37610–001 09926–37610–002 bearing ...

  • Page 709

    Automatic transmission: 5a-169 09928–06050 09942–15511 differential preload adapter sliding hammer / / / / 09944–78210 09944–88220 bearing installer support oil seal installer / / / / / / / 09944–96011 09946–06710 bearing outer race remover transfer bearing dummy / / / / 09951–18210 09952–06020 oil ...

  • Page 710: Manual Transmission

    5b-1 manual transmission: manual transmission general description manual transaxle construction and servicing s4rs0a5201001 the transaxle provides five forward speeds and one reverse speed by means of three synchromeshs and three shafts (input shaft, countershaft and reverse gear shaft). All forward...

  • Page 711

    Manual transmission: 5b-2 i3rm0b521001- 1. 5th speed sleeve & hub 8. Reverse idler gear 15. Countershaft 3rd gear 2. Input shaft 5th gear 9. Input shaft 16. Countershaft 2nd gear 3. Input shaft 4th gear 10. Right case 17. Low speed synchronizer sleeve & hub 4. High speed synchronizer sleeve & hub 11...

  • Page 712

    5b-3 manual transmission: diagnostic information and procedures manual transaxle symptom diagnosis s4rs0a5204001 repair instructions manual transaxle oil change s4rs0a5206001 1) before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) with vehicle lifted up, check ...

  • Page 713

    Manual transmission: 5b-4 differential side oil seal replacement s4rs0a5206002 1) lift up vehicle and drain transaxle oil. 2) remove front drive shaft and/or center shaft referring to “front drive shaft assembly removal and installation: in section 3a”. 3) remove oil seal (1) using special tool. Spe...

  • Page 714

    5b-5 manual transmission: gear shift control lever and cable components s4rs0a5206003 1 7 3 4 (a) 6 a 8 (b) 2 (c) 5 9 a i4rs0a520002- 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut : 10 n m (1.0 kg-m, 7.5 lb-ft) 2. Cable bracket bolt 7. Gear shift control lever as...

  • Page 715

    Manual transmission: 5b-6 gear shift control lever and cable removal and installation s4rs0a5206004 removal 1) remove console box. 2) disconnect cable ends (5) from pivot (6) of gear shift control lever assembly. 3) disconnect gear shift and select control cables (1) from gear shift control lever as...

  • Page 716

    5b-7 manual transmission: vehicle speed sensor (vss) removal and installation s4rs0a5206027 removal 1) remove battery and tray with coolant reservoir. 2) disconnect gear shift and select control cables (1) from transaxle. 3) remove cable bracket (1) from transaxle. 4) disconnect vss coupler (2). 5) ...

  • Page 717

    Manual transmission: 5b-8 installation 1) apply oil to new o-ring (1) and tighten back up lamp switch (2) to specified torque. Tightening torque back up lamp switch (a): 23 n·m (2.3 kg-m, 17.0 lb-ft) 2) connect back up lamp switch coupler. 3) install battery and tray, and then install coolant reserv...

  • Page 718

    5b-9 manual transmission: manual transaxle unit dismounting and remounting s4rs0a5206033 dismounting 1) drain coolant. 2) remove coolant reservoir with reservoir hose. 3) remove battery and tray. 4) remove air cleaner case and resonator. 5) disconnect gear shift and gear select control cables (1) fr...

  • Page 719

    Manual transmission: 5b-10 16) remove engine under covers. 17) support transaxle with transmission jack. 18) remove transaxle to engine bolts and nut of lower side. 19) remove engine left mounting (1) with bracket (2). 20) remove engine rear mounting bracket bolts (1). 21) remove other attached part...

  • Page 720

    5b-11 manual transmission: gear shift and select shaft assembly components s4rs0a5206029 gear shift and select shaft assembly removal and installation s4rs0a5206016 removal 1) remove gear shift interlock bolt (1) and 5th to reverse interlock guide bolt (2) from transaxle case. 2) remove gear shift &...

  • Page 721

    Manual transmission: 5b-12 4) install washer and gear shift interlock bolt (2) to which sealant have been applied and then tighten it to specified torque. “b”: sealant 99000–31260 tightening torque gear shift interlock bolt (b): 50 n·m (5.0 kg-m, 36.5 lb-ft) 5) install washer and 5th to reverse inte...

  • Page 722

    5b-13 manual transmission: manual transaxle assembly components s4rs0a5206028 i4rs0a520013-.

  • Page 723

    Manual transmission: 5b-14 fifth gear disassembly and assembly s4rs0a5206018 disassembly 1) remove 9 bolts and take off transaxle side cover (1). Caution: care should be taken not to distort side cover when it is removed from left case. 2) using special tool, remove circlip (1). Special tool : 09900...

  • Page 724

    5b-15 manual transmission: 6) remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would be necessary if spline fitting of countershaft 5th gear is tight. Assembly 1) assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and...

  • Page 725

    Manual transmission: 5b-16 5) fit 5th gear shift fork (1) to synchronizer sleeve (2) and hub (3) assembly and install them into input shaft and gear shift shaft aligning punch mark (4) with matching mark (5) on input shaft. 6) tighten shift fork bolt (2) to which thread lock cement has been applied....

  • Page 726

    5b-17 manual transmission: manual transaxle assembly disassembly and reassembly s4rs0a5206034 disassembly 1) remove gear shift and select shaft assembly referring to “gear shift and select shaft assembly removal and installation: ”. 2) remove fifth gear referring to “fifth gear disassembly and assem...

  • Page 727

    Manual transmission: 5b-18 15) remove side bearing retainer bolts. 16) turn side bearing retainer (1) counterclockwise until it stops, and remove side bearing retainer using 2 flat end rods (2) or the like. 17) remove o-ring from side bearing retainer. 18) remove differential bearing shim. 19) remov...

  • Page 728

    5b-19 manual transmission: 3) install 5th & reverse gear shift shaft (1) with 5th & reverse gear shift guide shaft (2) into right case (5). Reverse gear shift arm (4) has to be joined with reverse gear shift lever (3) at the same time. 4) make reverse idler gear (1) with reverse gear shift lever (2)...

  • Page 729

    Manual transmission: 5b-20 b) select a shim of differential side bearing as follows. I) measure depth “a” from left case (1) face to side bearing outer race (2) using depth gauge. Ii) measure height “b” of side bearing retainer with depth gauge. Iii) calculate clearance a – b, and select differentia...

  • Page 730

    5b-21 manual transmission: c) install differential side bearing shim to left case (4). D) apply oil to new o-ring of side bearing retainer (3), and install side bearing retainer with new o- ring to left case. E) tighten side bearing retainer bolts (1) to specified torque. Note: install side bearing ...

  • Page 731

    Manual transmission: 5b-22 15) by repeating step 14), select a suitable shim which adjusts clearance “a” to specification and put it on bearing outer race. Note: insert 0.15 mm (0.0059 in.) feeler to know whether or not a shim fulfills specification quickly. Available shim thickness 16) place left c...

  • Page 732

    5b-23 manual transmission: 3) remove input shaft oil seal (1) using special tools, if necessary. Special tool (a): 09930–30104 (b): 09923–74510 4) pull out countershaft right bearing outer race (2) using special tools, if necessary. Special tool (a): 09930–30104 (c): 09941–64511 5) replace different...

  • Page 733

    Manual transmission: 5b-24 assembly 1) if input oil gutter (1) has been removed, install it with bolt to which thread lock cement has been applied. “a”: thread lock cement 99000–32110 tightening torque oil gutter bolt (a): 10 n·m (1.0 kg-m, 7.5 lb-ft) 2) if differential side oil seal is removed, ins...

  • Page 734

    5b-25 manual transmission: input shaft assembly disassembly and reassembly s4rs0a5206021 disassembly 1) remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and hydraulic press. 2) drive out 5th gear spacer (2) and left bearing (3) from input shaft (1) using bearing pul...

  • Page 735

    Manual transmission: 5b-26 3) fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in the figure. Note: • no specific direction is assigned to each key but it is assigned as sleeve & hub assembly. • size of high speed synchronizer sleeve, hub, ...

  • Page 736

    5b-27 manual transmission: 8) press-fit left bearing (2) using special tool and hammer. Special tool (a): 09913–70123 9) using the same special tool at step 8), drive in 5th gear spacer (1). Caution: to prevent 5th gear spacer from being distorted because of excessive compression, do not press-fit i...

  • Page 737

    Manual transmission: 5b-28 6) disassemble low speed synchronizer sleeve & hub assembly. 7) take out 1st gear needle bearing of resin cage type from shaft. 8) remove right bearing cone (2) using bearing puller (3), metal stick (1) and hydraulic press. Assembly 1) clean all components thoroughly, insp...

  • Page 738

    5b-29 manual transmission: note: • support shaft with special tool as shown in the figure so that retainer of bearing cone (4) will be free from compression. • make sure that synchronizer ring (2) key slots are aligned with keys while press- fitting sleeve & hub assembly. • check free rotation of 1s...

  • Page 739

    Manual transmission: 5b-30 synchronizer parts inspection s4rs0a5206036 check clearance “a” between synchronizer ring (2) and gear (1), each chamfered tooth of gear, synchronizer ring and sleeve, then determine parts replacement. Clearance “a” between synchronizer ring and gear standard: 1.0 – 1.4 mm...

  • Page 740

    5b-31 manual transmission: 5th and reverse gear shift shafts disassembly and assembly s4rs0a5206024 disassembly disassemble component parts using special tool and hammer. Special tool (a): 09922–85811 assembly replace or correct parts as required and assemble shafts making sure that component parts ...

  • Page 741

    Manual transmission: 5b-32 differential components s4rs0a5206032 differential disassembly and assembly s4rs0a5206025 disassembly 1) using special tools, remove right bearing (1) and sensor rotor (2). Special tool (a): 09913–60910 (b): 09925–88210 2) remove left bearing in the same manner at step 1)....

  • Page 742

    5b-33 manual transmission: assembly judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that all parts are clean. 1) assemble differential gear and measure thrust p...

  • Page 743

    Manual transmission: 5b-34 7) hold differential assembly with soft jawed vise (3), install final gear (2) as shown in the figure and then tighten bolts (1) to specified torque. Caution: use of any other bolts than specified ones is prohibited. Tightening torque final gear bolt (a): 90 n·m (9.0 kg-m,...

  • Page 744

    5b-35 manual transmission: note: the specified tightening torque is also described in the following. “gear shift control lever and cable components: ” “manual transaxle unit components: ” “gear shift and select shaft assembly components: ” “manual transaxle assembly components: ” “gear shift shaft c...

  • Page 745

    Manual transmission: 5b-36 09913–76010 09913–80113 bearing installer bearing installer / / 09913–84510 09913–85210 bearing installer bearing installer / / / 09922–85811 09923–74510 spring pin remover (4.5 mm) bearing puller (20-35 mm) / / 09923–78210 09924–07710 bearing installer synchronizer hub in...

  • Page 746

    5b-37 manual transmission: 09927–76060 09930–30104 gear holder sliding shaft / / 09940–51710 09940–54910 bearing installer front fork oil seal install driver 09941–64511 09951–16060 bearing and oil seal remover (30 mm min.) control arm bush remover 09951–16080 bearing installer.

  • Page 747: Clutch

    Clutch: 5c-1 clutch general description clutch construction s4rs0a5301001 the clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc...

  • Page 748

    5c-2 clutch: diagnostic information and procedures clutch system symptom diagnosis s4rs0a5304001 condition possible cause correction / reference item slipping improper clutch pedal free travel replace master cylinder or clutch pedal arm. Worn or oily clutch disc facing replace disc. Warped disc, pre...

  • Page 749

    Clutch: 5c-3 repair instructions clutch pedal inspection s4rs0a5306019 clutch pedal free travel “a” 1) depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has moved (clutch pedal free travel) as represented by “a” in the figure. Then check its conformance ...

  • Page 750

    5c-4 clutch: clutch fluid level inspection s4rs0a5306020 refer to “master cylinder and brake fluid level inspection: in section 4a”. Air bleeding of clutch system s4rs0a5306021 caution: brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe f...

  • Page 751

    Clutch: 5c-5 clutch fluid pipe and hose components s4rs0a5306022 clutch fluid pipe removal and installation s4rs0a5306023 removal caution: do not allow fluid to get on painted surface. It may cause painted surface damage. 1) remove dust and dirt from each joint of pipe to be disconnected and clean a...

  • Page 752

    5c-6 clutch: installation reverse removal procedure for installation noting the following. Caution: • do not allow fluid to get on painted surface. • do not allow pipe to contact hard against vehicle body or other parts. • install each clamp securely. • after installation, check clutch pedal free tr...

  • Page 753

    Clutch: 5c-7 installation reverse removal procedure for installation noting the following. • apply grease to push rod tip. “a”: grease 99000–25100 • tighten clutch operating cylinder bolt to specified torque. Tightening torque clutch operating cylinder bolt: 23 n·m (2.3 kg-m, 17.0 lb-ft) clutch peda...

  • Page 754

    5c-8 clutch: clutch cover, clutch disc and flywheel components s4rs0a5306014 clutch cover, clutch disc and flywheel removal and installation s4rs0a5306015 removal 1) dismount manual transaxle assembly referring to “manual transaxle unit dismounting and remounting: in section 5b”. 2) hold flywheel wi...

  • Page 755

    Clutch: 5c-9 4) remove flywheel (1) from crank shaft using special tool. Special tool (a): 09924–17810 installation note: before assembling, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly. 1) install flywheel (2) to crankshaft and tighten bolts (1) ...

  • Page 756

    5c-10 clutch: note: when inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the splines. Clutch cover, clutch disc and flywheel inspection s4rs0a5306016 input shaft bearing check bearing (1) for smooth rotation and replace it if abnormality is found. Clutch dis...

  • Page 757

    Clutch: 5c-11 5) install tap (m16 x 1.5) (1) to clutch release shaft no.1 bush. 6) pull no.1 bush out using tap (1) and special tools. Special tool (b): 09923–46020 (c): 09930-30104 installation 1) drive in a new no.1 bush using special tools and hammer, and then apply grease to bush inside. Special...

  • Page 758

    5c-12 clutch: 8) set release arm (1) to release shaft (2) aligning punch mark (4) of release arm and punch mark (3) of release shaft, then tighten bolt to specified torque. Tightening torque release lever bolt (a): 23 n·m (2.3 kg-m, 17.0 lb- ft) clutch release system inspection s4rs0a5306018 clutch ...

  • Page 759

    Clutch: 5c-13 special tools and equipment recommended service material s4rs0a5308001 note: required service material is also described in the following. “clutch fluid pipe and hose components: ” “clutch pedal and clutch pedal bracket components: ” “clutch cover, clutch disc and flywheel components: ...

  • Page 760

    5c-14 clutch:.

  • Page 761: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions on steering........................................ 6-1 steering general diagnosis..............

  • Page 762

    6-ii table of contents special tool ......................................................6c-38.

  • Page 763: Precautions

    Precautions: 6-1 precautions precautions precautions on steering s4rs0a6000001 air bag warning refer to “air bag warning: in section 00”. Air bag system service warning refer to “air bag system service warning: in section 00”. Precautions for steering diagnosis refer to “precautions for steering dia...

  • Page 764: Steering General Diagnosis

    6a-1 steering general diagnosis: steering general diagnosis precautions precautions for steering diagnosis s4rs0a6100001 since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle fir...

  • Page 765

    Steering general diagnosis: 6a-2 diagnostic information and procedures steering symptom diagnosis s4rs0a6104001 condition possible cause correction / reference item hard steering tire not adequately inflated inflate tires to proper pressure. Malfunction of power steering system check and correct. Bi...

  • Page 766: Steering Wheel And Column

    6b-1 steering wheel and column: steering wheel and column precautions service precautions of steering wheel and column s4rs0a6200001 for service precautions, refer to “precautions on service and diagnosis of air bag system: in section 8b”. Service and diagnosis for diagnosis and servicing, refer to ...

  • Page 767

    Steering wheel and column: 6b-2 4) check steering shaft for smooth rotation. If found defective, replace as steering column assembly. 5) check steering shaft and steering column for bend, cracks or deformation. If found defective, replace. Repair instructions steering wheel and column construction s...

  • Page 768

    6b-3 steering wheel and column: 3) remove driver air bag (inflator) module from steering wheel. Refer to “driver air bag (inflator) module removal and installation: in section 8b”. 4) disconnect horn connector and audio control switch connector, if equipped. 5) remove steering shaft nut and then mak...

  • Page 769

    Steering wheel and column: 6b-4 5) remove contact coil cable assembly (1) from steering column. Installation 1) check to make sure that vehicle’s front tires are set at straight-ahead position and then ignition switch is at lock position. 2) install contact coil cable assembly (1) to steering column...

  • Page 770

    6b-5 steering wheel and column: 4) from the position where contact coil became unable to turn any further (it stopped), turn it back clockwise about two and a half rotations and align center mark with alignment mark (1). Contact coil cable assembly inspection s4rs0a6206004 check contact coil cable a...

  • Page 771

    Steering wheel and column: 6b-6 13) remove steering column mounting nuts (1). 14) remove steering column from vehicle. Installation caution: after tightening steering column mounting nuts, shaft joint bolts should be tightened. Wrong tightening order could cause a damage to shaft joint. 1) be sure t...

  • Page 772

    6b-7 steering wheel and column: steering column inspection s4rs0a6206006 check steering column for damage and operation referring to “checking steering column for accident damage: ”. Steering lower shaft removal and installation s4rs0a6206008 caution: never turn steering wheel while steering lower s...

  • Page 773

    Steering wheel and column: 6b-8 specifications tightening torque specifications s4rs0a6207001 note: the specified tightening torque is also described in the following. “steering wheel and column construction: ” reference: for the tightening torque of fastener not specified in this section, refer to ...

  • Page 774

    6c-1 power assisted steering system: power assisted steering system precautions steering system note s4rs0a6300001 note: all steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/ or could result in major repair expense. They ...

  • Page 775

    Power assisted steering system: 6c-2 eps diagnosis general description s4rs0a6301003 the p/s system in this vehicle is controlled by the p/s control module. The p/s control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have ...

  • Page 776

    6c-3 power assisted steering system: schematic and routing diagram eps system wiring circuit diagram s4rs0a6302001 12v 5v m 12v 5v brn red/blu gry lt grn/blk blk red wht blu grn red brn yel e52-1 e52-5 e52-11 e52-14 e52-12 e51-1 e51-2 e52-18 e52-6 e52-8 e52-20 e52-9 e52-16 e52-19 e49-2 e49-1 blk grn...

  • Page 777

    Power assisted steering system: 6c-4 diagnostic information and procedures eps system check s4rs0a6304006 warning: carry out test drive in light traffic area to prevent an accident. [a]: connector “e52” (viewed from harness side) 3. Junction block assembly 11. P/s control module [b]: connector “e49”...

  • Page 778

    6c-5 power assisted steering system: note: • as execution of “dtc clearance: ” will clear all dtcs, be sure to record all dtcs before service. • dtc c1122 is indicated when ignition switch is at on position and engine is not running, it means that nothing is abnormal. • current dtc and history dtc c...

  • Page 779

    Power assisted steering system: 6c-6 dtc check s4rs0a6304008 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel at driver’s seat side. Special tool (a): suzuki scan tool 3) turn ignition switch to on position...

  • Page 780

    6c-7 power assisted steering system: c1118 torque sensor failure (signal voltage low) voltage at “e52-16” terminal is higher than upper limit voltage for p/s control module diagnosis for specified period or longer 1 driving cycle c1119 torque sensor 12 v power supply circuit failure voltage at “e52-...

  • Page 781

    Power assisted steering system: 6c-8 scan tool data s4rs0a6304011 scan tool data definitions battery volt battery voltage is an analog input signal read by the ecu. Tqs (torque sensor) power suppl this parameter indicates the power supply voltage which the eps controller supplies to the torque senso...

  • Page 782

    6c-9 power assisted steering system: p/s system symptom diagnosis s4rs0a6304001 this section describes trouble diagnosis of the p/s system parts whose trouble is not indicated by the on-board diagnostic system (self-diagnostic function). When no malfunction is indicated by the on-board diagnostic sy...

  • Page 783

    Power assisted steering system: 6c-10 troubleshooting step action yes no 1 was “eps system check” performed? Go to step 2. Go to “eps system check: ”. 2 1) make sure that suzuki scan tool is free from malfunction and that correct program card (software) for p/s system is used. 2) turn ignition switc...

  • Page 784

    6c-11 power assisted steering system: “eps” warning lamp does not come on at ignition switch on but engine stop s4rs0a6304013 wiring diagram circuit description operation (on/off) of “eps” warning lamp is controlled by p/s control module through combination meter. If the p/s system is in good condit...

  • Page 785

    Power assisted steering system: 6c-12 4 1) check for proper connection to p/s control module at “e49-1” terminal. 2) if ok, check for voltage between “e49-1” (“grn” wire) terminal and body ground with ignition switch on. Is it 10 – 14 v? Go to step 5. “blk” or “grn” wire circuit open or short to gro...

  • Page 786

    6c-13 power assisted steering system: “eps” warning lamp come on steady and engine start s4rs0a6304014 wiring diagram circuit description operation (on/off) of “eps” warning lamp is controlled by p/s control module through combination meter. If the p/s system is in good condition, p/s control module...

  • Page 787

    Power assisted steering system: 6c-14 dtc c1113 / c1117 /c1118: torque sensor circuit failure s4rs0a6304015 dtc c1113: torque sensor main and sub circuit voltage difference high dtc c1117: torque sensor failure (signal voltage high) dtc c1118: torque sensor failure (signal voltage low) wiring diagra...

  • Page 788

    6c-15 power assisted steering system: dtc troubleshooting dtc c1114: torque sensor 5 v power supply circuit failure s4rs0a6304016 wiring diagram step action yes no 1 was “eps system check” performed? Go to step 2. Go to “eps system check: ”. 2 is dtc c1114 and/or dtc c1119 indicated, too? Go to “dtc...

  • Page 789

    Power assisted steering system: 6c-16 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area voltage at “e52-20” terminal (5 v) differs from specified voltage for p/s control module diagnosis for specified period or longer (1 driving cycle detection logic) ...

  • Page 790

    6c-17 power assisted steering system: dtc c1119: torque sensor 12 v power supply circuit failure s4rs0a6304020 wiring diagram dtc detecting condition and trouble area dtc troubleshooting lt grn/blk wht blu grn red brn yel e52-1 e52-18 e52-6 e52-8 e52-20 e52-9 e52-16 e52-19 e49-2 e49-1 blk grn gry gr...

  • Page 791

    Power assisted steering system: 6c-18 3 1) remove console box. 2) check p/s control module connector (“e52”) for proper connection. 3) if ok, turn ignition switch on. 4) check for voltage between “e52-8” (“grn” wire) terminal and body ground with connector (“e52”) connected to the p/s control module...

  • Page 792

    6c-19 power assisted steering system: dtc c1121 / c1123 / c1124: vss circuit failure s4rs0a6304017 dtc c1121: vss circuit signal not input (60 seconds or more) dtc c1123: vss circuit signal not input (30 seconds or more) dtc c1124: vss circuit failure (abnormal deceleration) wiring diagram 12v ppl g...

  • Page 793

    Power assisted steering system: 6c-20 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area dtc c1121: no vehicle speed signal is inputted to p/s control module in either one of the following two conditions (1 driving cycle detection logic) 1. More than 60...

  • Page 794

    6c-21 power assisted steering system: dtc c1122: engine speed signal circuit failure s4rs0a6304018 wiring diagram dtc detecting condition and trouble area dtc troubleshooting 5v red/blu e52-14 e49-2 blk 5v lt grn/blk e52-1 e49-1 grn grn blk 1 2 [b] [a] 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19...

  • Page 795

    Power assisted steering system: 6c-22 dtc c1141 / c1142 / c1143 / c1145: motor circuit failure s4rs0a6304019 dtc c1141: motor circuit voltage abnormal dtc c1142: motor circuit current high command with p/s control module target current dtc c1143: motor circuit current excessive dtc c1145: motor circ...

  • Page 796

    6c-23 power assisted steering system: dtc troubleshooting dtc c1153: p/s control module power supply circuit failure s4rs0a6304021 wiring diagram step action yes no 1 was “eps system check” performed? Go to step 2. Go to “eps system check: ”. 2 is dtc c1153 and/or dtc c1155 indicated, too? Go to “dt...

  • Page 797

    Power assisted steering system: 6c-24 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area battery voltage is lower than lower limit voltage for p/s control module diagnosis (1 driving cycle detection logic) • high resistance, open or short in p/s control...

  • Page 798

    6c-25 power assisted steering system: dtc c1155: p/s control module failure s4rs0a6304022 wiring diagram dtc detecting condition and trouble area dtc troubleshooting inspection of p/s control module and its circuits s4rs0a6304023 the p/s control module (1) and its circuits can be checked at the p/s ...

  • Page 799

    Power assisted steering system: 6c-26 voltage check 1) remove console box. 2) check for voltage at each terminal with connectors connected to the p/s control module. Note: as each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 v or more when ignition switch...

  • Page 800

    6c-27 power assisted steering system: note: *: the voltage of this circuit may not be checked by voltmeter. If so, use oscilloscope. E52-6 blu torque sensor (sub) about 2.5 v • ignition switch on and steering wheel at straight position • check voltage between “e52-6” and “e52-9” terminals e52-7 — — ...

  • Page 801

    Power assisted steering system: 6c-28 steering wheel play check s4rs0a6304002 • check steering wheel for looseness or rattle by moving it in its shaft direction and lateral direction. If found defective, repair or replace. • check steering wheel for play, holding vehicle in straight forward conditio...

  • Page 802

    6c-29 power assisted steering system: repair instructions steering gear case assembly components s4rs0a6306020 (g) (e) (a) (c) (b) (d) 8 11 1 6 7 (b) 7 8 3 (a) 3 10 19 (g) 19 18 4 4 5 6 2 2 (b) 9 (b) 9 5 17 (f) 12 16 13 15 14 i4rs0a630025- 1. Steering gear case 10. Steering gear case mounting no.1 b...

  • Page 803

    Power assisted steering system: 6c-30 tie-rod end boot on-vehicle inspection s4rs0a6306008 inspect each boot for tear. If evan a small tear is noted, replace it with a new one. Tie-rod end removal and installation s4rs0a6306009 removal 1) hoist vehicle, and then remove wheel referring to “wheel remo...

  • Page 804

    6c-31 power assisted steering system: 4) after confirming proper toe, tighten tie-rod end lock nut to specified torque. Tightening torque tie-rod end lock nut (a): 45 n·m (4.5 kg-m, 32.5 lb-ft) 5) tighten wheel bolts to specified torque and lower hoist. Tightening torque wheel bolt: 85 n·m (8.5 kg-m...

  • Page 805

    Power assisted steering system: 6c-32 7) to remove the steering gear case assembly easily, lower the engine with transmission, but don’t remove. 8) support engine with transaxle by supporting device and then remove engine rear mounting bolt (1). 9) remove front suspension frame with steering gear ca...

  • Page 806

    6c-33 power assisted steering system: 7) tighten steering shaft joint lower bolt (1) and upper bolt (2) to specified torque (lower side first and then upper side). Tightening torque steering shaft joint bolt (a): 25 n·m (2.5 kg-m, 18.5 lb-ft) 8) install both wheels and tighten wheel bolts to specifi...

  • Page 807

    Power assisted steering system: 6c-34 7) hold rack with soft jawed vise (3) and remove tie-rod from rack (2). Installation 1) install tie-rod (1) to rack (2). 2) hold rack with soft jawed vise and tighten tie-rod to specified torque. Tightening torque tie-rod (a): 93 n·m (9.3 kg-m, 67.5 lb-ft) 3) be...

  • Page 808

    6c-35 power assisted steering system: steering rack plunger removal and installation s4rs0a6306030 removal 1) remove gear case assembly referring to “steering gear case assembly removal and installation: ”. 2) loosen lock nut (1) with holding damper screw (2). 3) remove lock nut (1), rack damper scr...

  • Page 809

    Power assisted steering system: 6c-36 torque sensor inspection s4rs0a6306028 1) remove console box. 2) turn ignition switch to on position. 3) check for voltage between terminals of connector (“e52”) with connecting it to p/s control module and not running engine. If check result is not satisfactory...

  • Page 810

    6c-37 power assisted steering system: specifications tightening torque specifications s4rs0a6307001 note: the specified tightening torque is also described in the following. “steering gear case assembly components: ” reference: for the tightening torque of fastener not specified in this section, ref...

  • Page 811

    Power assisted steering system: 6c-38 special tools and equipment recommended service material s4rs0a6308001 note: required service material is also described in the following. “steering gear case assembly components: ” special tool s4rs0a6308002 material suzuki recommended product or specification ...

  • Page 812

    6c-39 power assisted steering system:.

  • Page 813: Section 7

    Table of contents 7- i 7 section 7 contents hvac precautions .................................................7-1 precautions............................................................. 7-1 precautions on hvac ........................................... 7-1 heater and ventilation......................

  • Page 814: Precautions

    7-1 precautions: precautions precautions precautions on hvac s4rs0a7000001 air bag warning refer to “air bag warning: in section 00”. A/c system caution refer to “a/c system caution: in section 7b”. Precautions on servicing a/c system refer to “precautions on servicing a/c system: in section 7b”..

  • Page 815: Heater And Ventilation

    Heater and ventilation: 7a-1 heater and ventilation general description heater and ventilation construction s4rs0a7101001 i4rs0a710001- 1. Hvac unit 6. Foot air 11. Center ventilation air 2. Ventilator duct 7. Front defroster air 12. Air intake door 3. Defroster nozzle 8. Side defroster air 13. Blow...

  • Page 816

    7a-2 heater and ventilation: schematic and routing diagram heater and ventilation wiring circuit diagram s4rs0a7102001 10a 80a blk red/blk 3 1 5 7 blk 2 m 12v blu/wht e23-19 g18-3 g18-4 g18-7 g18-8 g18-10 g18-13 g19-2 g19-3 g19-7 g19-6 g19-1 g18-9 g18-14 blk/wht yel blu/wht red red/blk red grn brn b...

  • Page 817

    Heater and ventilation: 7a-3 diagnostic information and procedures heater and ventilation symptom diagnosis s4rs0a7104001 condition possible cause correction / reference item blower motor does not operate with blower speed selector on. Fuse blown check related fuses, and then check for short circuit...

  • Page 818

    7a-4 heater and ventilation: repair instructions hvac unit components s4rs0a7106001 1 2 3 4 5 7 8 5 15 15 15 14 14 6 13 12 11 10 2 9 8 7 6 17 18 19 17 16 i4rs0a710003- 1. Fresh air inlet duct 6. Foot duct 11. Blower motor 16. Drain hose 2. Blower upper case 7. Airflow control door assembly 12. Heate...

  • Page 819

    Heater and ventilation: 7a-5 hvac unit removal and installation s4rs0a7106002 removal 1) disconnect negative (–) cable from battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove cowl top panel from vehicle body referring to “cowl top components: in sect...

  • Page 820

    7a-6 heater and ventilation: blower motor resistor removal and installation s4rs0a7106005 removal 1) disconnect negative (–) cable from battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove glove box from instrument panel. 4) remove passenger air bag mo...

  • Page 821

    Heater and ventilation: 7a-7 hvac control unit components s4rs0a7106008 hvac control unit removal and installation s4rs0a7106010 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove passenger air bag module f...

  • Page 822

    7a-8 heater and ventilation: installation reverse removal procedure noting the following instructions. • connect temperature control cable and airflow control cable of hvac control unit to links of hvac unit. A. Set airflow selector (1) to “vent” position and temperature selector (2) to “max cool” p...

  • Page 823

    Heater and ventilation: 7a-9 air intake switch inspection s4rs0a7106018 • check that there is continuity between terminal (1) and terminal (2) when air intake switch is at fresh position. • check that there is no continuity between terminal (1) and terminal (2) and there is continuity between termin...

  • Page 824

    7a-10 heater and ventilation: center ventilation louver removal and installation s4rs0a7106014 removal 1) disconnect negative (–) cable from battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove passenger air bag module from instrument panel referring t...

  • Page 825

    Heater and ventilation: 7a-11 4) remove passenger air bag module from instrument panel referring to “passenger air bag (inflator) module removal and installation: in section 8b”. 5) separate left side ventilation louver (1) and passenger air bag module (2). Installation reverse removal procedure not...

  • Page 826: Air Conditioning System

    7b-1 air conditioning system: air conditioning system precautions a/c system caution s4rs0a7200001 caution: the air conditioning system of this vehicle uses refrigerant hfc-134a (r-134a). None of refrigerant, compressor oil and component parts is interchangeable between two types of a/ c: one using ...

  • Page 827

    Air conditioning system: 7b-2 • never use heat for bending pipes. When bending a pipe, try to make its bending angle as smooth as possible. • keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immed...

  • Page 828

    7b-3 air conditioning system: general description refrigerant type construction s4rs0a7201002 whether the a/c system in the vehicle uses hfc-134a (r-134a) or cfc-12 (r-12) is indicated on label (1) on the compressor. Also, it can be checked by the shape of the service (charge) valve (2). Sub-cool a/...

  • Page 829

    Air conditioning system: 7b-4 10 11 12 9 8 13 7 6 2 5 3 4 1 : [a] : [b] : [c] i4rs0a720051- [a]: liquid 2. Magnet clutch 6. Expansion valve 10. Desiccant [b]: vapor 3. Condenser 7. A/c evaporator 11. Filter [c]: superheated vapor 4. Receiver/dryer 8. Condensation part 12. Vapor refrigerant 1. Compre...

  • Page 830

    7b-5 air conditioning system: schematic and routing diagram major components of a/c system s4rs0a7202001 airflow diagram major components of a/c system i4rs0a720003- 7 2 3 4 1 8 6 5 i4rs0a720004- 1. Hvac 5. Discharge hose 9. Side ventilation air 13. Side defroster air 2. Compressor 6. Suction hose 1...

  • Page 831

    Air conditioning system: 7b-6 a/c system wiring diagram s4rs0a7202002 10a blk/red blk/red 80a blk/yel blk/yel blk/yel brn/wht 12v 5v 5v 5v 5v 11 e23-1 e23-60 blk/red blk/red e23-16 e23-57 e23-54 orn wht/blk 9 13 e23-55 c37-14 c37-57 gry/red red blk orn e23-47 gry wht blu/yel red/blk 14 3 1 15 5 7 bl...

  • Page 832

    7b-7 air conditioning system: diagnostic information and procedures a/c system symptom diagnosis s4rs0a7204001 condition possible cause correction / reference item no cool air comes out (a/ c system does not operate) no refrigerant perform recovery, evacuation and charge referring to “operation proc...

  • Page 833

    Air conditioning system: 7b-8 cool air does not come out or insufficient cooling (a/c system normal operation) insufficient or excessive charge of refrigerant check the amount of refrigerant and system for leaks. Condenser clogged check condenser referring to “condenser assembly on-vehicle inspectio...

  • Page 834

    7b-9 air conditioning system: abnormal noise symptom diagnosis of a/c system s4rs0a7204002 abnormal noise from compressor abnormal noise from magnetic clutch abnormal noise from tubing abnormal noise from condenser assembly abnormal noise from crankshaft pulley insufficient airflow of cooled air a/c...

  • Page 835

    Air conditioning system: 7b-10 abnormal noise from tension pulley abnormal noise from a/c evaporator abnormal noise from blower motor a/c system performance inspection s4rs0a7204003 1) confirm that vehicle and environmental conditions are as follows. • vehicle is put indoors. • ambient temperature i...

  • Page 836

    7b-11 air conditioning system: 8) open front windows, front doors and engine food. 9) with about 20 mm (0.8 in.) of dry bulb thermometer (1) put right in front of center ventilation louver and a wet and dry bulb thermometer (2) near air inlet of hvac unit. 10) check for each pressure of low side and...

  • Page 837

    Air conditioning system: 7b-12 high pressure gauge low pressure gauge 11) check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature near air inlet of hvac unit is 30 c (86 f) and the one at air outlet of center ventilation louver is 17 c (62.6 ...

  • Page 838

    7b-13 air conditioning system: thermometer at center duct note: if ambient temperature is approximately 30 c (86 f), it is possible to diagnose a/c system in detail referring to the following table. Condition possible cause correction crossing point is higher than acceptable range (“e” area) insuffi...

  • Page 839

    Air conditioning system: 7b-14 normal: 0.23 – 0.36 (2.3 – 3.6) (33 – 51) abnormal: negative pressure normal: 1.24 – 1.52 (12.4 – 15.2) (176 – 216) abnormal: 0.7 – 1.0 (7 – 10) (100 – 142) during a/c operation, the low pressure side sometimes indicates negative pressure, and sometimes normal pressure...

  • Page 840

    7b-15 air conditioning system: a/c system inspection at ecm s4rs0a7204004 voltage check ecm and its circuits can be checked at ecm wiring couplers by measuring voltage. Caution: • ecm connectors are waterproofed. Each terminal of the ecm connectors is sealed up with the grommet. Therefore, do not me...

  • Page 841

    Air conditioning system: 7b-16 ecm voltage values table for relation of a/c control terminal wire color circuit normal value condition c37-14 gry/red output of 5 v power source 4.5 – 5.5 v ignition switch turned on c37-24 lt grn engine coolant temp. (ect) sensor signal 3.3 – 3.6 v ignition switch tu...

  • Page 842

    7b-17 air conditioning system: repair instructions operation procedure for refrigerant charge s4rs0a7206002 warning: • your eyes should not be exposed to refrigerant (liquid). Any liquid hfc-134a (r-134a) escaping by accident shows a temperature as low as approximately – 6 c (21.2 f) below freezing ...

  • Page 843

    Air conditioning system: 7b-18 recovery when discharging refrigerant out of a/c system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant hfc-134a (r-134a) into atmosphere would cause adverse effect to environments. Note: • after recovering refri...

  • Page 844

    7b-19 air conditioning system: evacuation caution: do not evacuate before recovering refrigerant in a/c system. Note: once air conditioning system circuit is opened (exposed) to atmospheric air, system must be evacuated by using a vacuum pump. The a/c system should be attached with a manifold gauge ...

  • Page 845

    Air conditioning system: 7b-20 charge caution: • because the sight glass is not used for this a/c system, do not perform an additional charge to the a/c system. To charge the proper amount of refrigerant, recover and evacuate the a/c system first. And then, charge the proper amount of refrigerant in...

  • Page 846

    7b-21 air conditioning system: b) replace empty container with a refrigerant container which has been charged with refrigerant. When using refrigerant container tap valve (2), use the following procedure for replacement. I) retract needle (3) and remove refrigerant container tap valve by loosening i...

  • Page 847

    Air conditioning system: 7b-22 check a/c system for refrigerant leaks whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result in malfunction of lines and connections, it is advisable to check for leaks. Common sense should be used during re...

  • Page 848

    7b-23 air conditioning system: installation reverse the removal procedure to install condenser noting the following instructions. • replenish specified amount of compressor oil to compressor suction side referring to “replenishing compressor oil” in “operation procedure for refrigerant charge: ”. • ...

  • Page 849

    Air conditioning system: 7b-24 hvac unit components s4rs0a7206003 10 2 6 7 1 3 4 2 5 7 8 8 17 16 18 19 15 15 15 14 6 14 12 13 11 21 20 23 20 22 9 i4rs0a720021- 1. Fresh air inlet duct 7. Airflow control door assembly 13. Heater core 19. Evaporator thermistor (evaporator temperature sensor) 2. Blower...

  • Page 850

    7b-25 air conditioning system: hvac unit removal and installation s4rs0a7206012 removal 1) disconnect negative (–) cable from battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) recover refrigerant from a/c system with recovery and recycling equipment referr...

  • Page 851

    Air conditioning system: 7b-26 installation reverse the removal procedure noting the following instruction. • install evaporator thermistor (evaporator temperature sensor) (1) onto evaporator (2) as shown. Evaporator thermistor (evaporator temperature sensor) inspection s4rs0a7206014 check resistanc...

  • Page 852

    7b-27 air conditioning system: installation reverse removal procedure noting the following instructions. • apply compressor oil to o-ring of expansion valve and pipes. • evacuate and charge the a/c system referring to “evacuation” and “charge” in “operation procedure for refrigerant charge: ”. Expan...

  • Page 853

    Air conditioning system: 7b-28 compressor relay inspection s4rs0a7206019 1) disconnect negative (–) cable from battery. 2) remove compressor relay (1) from main fuse box. 3) check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay. 4) connect battery posi...

  • Page 854

    7b-29 air conditioning system: compressor drive belt removal and installation s4rs0a7206036 removal 1) loosen tension pulley nut (1). 2) loosen belt tension by loosening tension pulley adjusting bolt (2). 3) remove compressor drive belt (3). Installation reverse removal procedure noting the followin...

  • Page 855

    Air conditioning system: 7b-30 compressor assembly components s4rs0a7206024 magnet clutch inspection s4rs0a7206023 • check armature plate and magnet clutch pulley for wear and oil soak respectively. • check magnet clutch pulley bearing for noise, wear and grease leakage. • measure magnet clutch coil...

  • Page 856

    7b-31 air conditioning system: 4) remove shims from shaft. 5) remove circlip (1) using special tool. Special tool (b): 09900–06107 6) remove magnet clutch pulley (2). Note: • if it is difficult to remove magnet clutch pulley by hand, use puller (1). • do not damage magnet clutch pulley when using pu...

  • Page 857

    Air conditioning system: 7b-32 8) adjust clearance between magnet clutch plate (1) and magnet clutch pulley by putting shim(s) on compressor shaft. To measure the clearance, perform the following steps. A) put compressor in a vise (2). B) set dial gauge (3) on magnet clutch plate, and then adjust it...

  • Page 858

    7b-33 air conditioning system: installation reverse removal procedure noting the following instructions. • use new o-ring. • apply compressor oil to o-ring. • tighten relive valve to the specified torque. Tightening torque relief valve (a): 8 n·m (0.8 kg-m, 6.0 lb-ft) • evacuate and charge the a/c s...

  • Page 859

    Air conditioning system: 7b-34 special tools and equipment recommended service material s4rs0a7208001 note: required service material is also described in the following. “precautions on servicing a/c system: ” special tool s4rs0a7208002 material suzuki recommended product or specification note compr...

  • Page 860

    7b-35 air conditioning system:.

  • Page 861: Section 8

    Table of contents 8- i 8 section 8 contents restraint precautions .................................................8-1 precautions............................................................. 8-1 precautions on restraint....................................... 8-1 seat belts ............................

  • Page 862

    8-ii table of contents dtc b1064 / b1068: driver / passenger side-air bag initiator circuit short to power circuit..............................................................8b-82 dtc b1071: forward-sensor performance problem...........................................................8b-85 dtc b107...

  • Page 863: Precautions

    Precautions: 8-1 precautions precautions precautions on restraint s4rs0a8000001 air bag system service warning refer to “air bag system service warning: in section 00”. Fastener caution refer to “fastener caution: in section 00”. Precautions on service and diagnosis of seat belt refer to “precaution...

  • Page 864: Seat Belts

    8a-1 seat belts: seat belts precautions precautions on service and diagnosis of seat belt s4rs0a8100001 warning: if replacing seat belt is necessary, replace buckle and seat belt assembly together as a set. This is for the reason of ensuring locking of tongue plate with buckle. If these parts are re...

  • Page 865

    Seat belts: 8a-2 seat belt with elr the seat belt with emergency locking retractor (elr) is designed so that it locks immediately (to prevent the webbing from being pulled out of the retractor any further) when any of the following items is detected as exceeding each set value; • speed at which the ...

  • Page 866

    8a-3 seat belts: repair instructions front seat belt components s4rs0a8106001 warning: • never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service a...

  • Page 867

    Seat belts: 8a-4 5) remove front seat belts from the vehicle. Installation install in reverse order of removal, noting the following. • seat belt anchor bolts should have an unified fine thread (7/16-20 unf). Under no circumstances should any different sized or metric screw threads be used. • connec...

  • Page 868

    8a-5 seat belts: seat belt • the seat belt webbing or strap should be free from damage. Retractor assembly (with seat belt pretensioner) 1) let the seat belt retract fully to confirm its easy retraction. • the retractor assembly should lock webbing when pulled quickly. • the front seat belt retracto...

  • Page 869

    Seat belts: 8a-6 rear seat belt components s4rs0a8106006 warning: be sure to read “precautions on service and diagnosis of seat belt: ” before starting to work and observe every precaution during work. (b) (a) (a) (a) (a) (a) 3 4 3 6 5 2 1 7 i4rs0a810003- 1. Upper anchor 4. Rear center seat belt 7. ...

  • Page 870

    8a-7 seat belts: rear seat belt removal and installation s4rs0a8106004 warning: be sure to read “precautions on service and diagnosis of seat belt: ” before starting to work and observe every precaution during work. Removal 1) fold rear seats referring to “folding rear seats” in owners manual. 2) re...

  • Page 871: Air Bag System

    Air bag system: 8b-1 air bag system precautions precautions on service and diagnosis of air bag system s4rs0a8200001 warning: • if the air bag system and another vehicle system both need repair, suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system acti...

  • Page 872

    8b-2 air bag system: • if sdm has been dropped, replace it with a new one. • if sdm installation part of floor was damaged, repair that part completely before reinstallation. • all sdm and mounting bracket fasteners must be carefully torqued and the arrow must be pointed toward the front of the vehi...

  • Page 873

    Air bag system: 8b-3 warning: • for handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 c (150 f), without high humidity and away from electric noise. • when carrying a live air bag (inflator) module, make sure the bag opening is pointed aw...

  • Page 874

    8b-4 air bag system: warning: never attempt to measure the resistance of the seat belt pretensioners. It is very dangerous as the electric current from the tester may activate pretensioner. • never attempt to disassemble the seat belt pretensioners (retractor assembly). • if any abnormality is found...

  • Page 875

    Air bag system: 8b-5 • make sure air bag system grounding point (2) is clean and ground is securely fastened for optimum metal-to- metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Precautions on disposal of air bag and seat belt pretensioner s4rs0a8200003...

  • Page 876

    8b-6 air bag system: the air bag system is designed to activate only in severe frontal and sideward collisions. It is not designed to activate in rear impacts, rollovers, or minor frontal and sideward collisions, since it would offer no protection in those types of accidents. Air bag system input / ...

  • Page 877

    Air bag system: 8b-7 schematic and routing diagram air bag system wiring circuit diagram s4rs0a8202001 [a] [b] “e13” “e44”, “g04” “g35” and "l03" "l41" 1 2 grn yel grn yel yel/red yel/grn yel/red yel/grn pnk wht red 13 blu 9 7 8 5 6 10 “l10” “l11” “l04” “g35” “g34” “g33” “g28” “g32” “l35” l29-1 l29-...

  • Page 878

    8b-8 air bag system: terminal arrangement of sdm (viewed from harness side) connector “l29” (sdm connector) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1 i5rh01820003- 1. Sdm connector “l29” terminal ter...

  • Page 879

    Air bag system: 8b-9 component location air bag system components, wiring and connectors location s4rs0a8203001 5 2 10 (a) (b) (b) (b) (b) (c) (d) 1 1 2 3 4 5 6 7 8 8 8 9 10 11 11 12 12 11 12 13 13 13 15 14 i4rs0a820007-.

  • Page 880

    8b-10 air bag system: diagnostic information and procedures air bag diagnostic system check s4rs0a8204001 warning: to avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or ac powered voltmeter, ohmmeter, etc., or any type of elect...

  • Page 881

    Air bag system: 8b-11 dtc table s4rs0a8204004 sdm dtc 4 1) check dtc using suzuki scan tool referring to “dtc check: ”. Is “no codes” displayed on suzuki scan tool? Air bag system is in good condition. An intermittent trouble has occurred at some place. Check the connector harness, etc. Related to t...

  • Page 882

    8b-12 air bag system: dtc check s4rs0a8204005 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) located on underside of instrument panel at driver’s seat side. Special tool (a): suzuki scan tool 3) turn ignition switch to on position. 4) read dtc accor...

  • Page 883

    Air bag system: 8b-13 scan tool data s4rs0a8204068 data list of sdm scan tool data definition back up volt (v): this parameter indicates the capacity of the backup condenser installed to maintain the ignition current (as much as possible) even when the power supply to sdm that ignites the inflator i...

  • Page 884

    8b-14 air bag system: caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correct terminal adapter from special tool (connector test adapter kit)...

  • Page 885

    Air bag system: 8b-15 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • repeat “air bag diagnostic system check: ” to confirm that the trouble has been corrected. “air bag” war...

  • Page 886

    8b-16 air bag system: caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correct terminal adapter from special tool (connector test adapter kit)...

  • Page 887

    Air bag system: 8b-17 “air bag” warning lamp flashes s4rs0a8204009 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correct ter...

  • Page 888

    8b-18 air bag system: dtc b1013: sdm fault s4rs0a8204030 dtc will set when an internal sdm fault is detected by sdm. Note: dtc b1013 can never be cleared once it has been set. Dtc troubleshooting 1) turn ignition switch off. 2) replace sdm. 3) repeat “air bag diagnostic system check: ”. Dtc b1014: “...

  • Page 889

    Air bag system: 8b-19 dtc troubleshooting note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic syst...

  • Page 890

    8b-20 air bag system: dtc will set when the power source voltage to sdm is above an approx. 21 v for specified time. Flow test description step 1: check if voltage applied to sdm is within normal range. Step 2: check if dtc b1016 still exists. Dtc troubleshooting note: upon completion of inspection ...

  • Page 891

    Air bag system: 8b-21 dtc b1017: power source voltage low s4rs0a8204021 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correc...

  • Page 892

    8b-22 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 893

    Air bag system: 8b-23 dtc b1021: front air bag module deployed s4rs0a8204028 dtc will set when the sdm detects a frontal crash of sufficient force to warrant activation of the air bag system. (sdm outputs a deployment command.) flow test description step 1: check that dtc b1021 has been set although...

  • Page 894

    8b-24 air bag system: dtc troubleshooting note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • repeat “air bag diagnostic system check: ” to confirm that the trouble has been corr...

  • Page 895

    Air bag system: 8b-25 dtc b1027: reusable number exceeded s4rs0a8204071 dtc will set when the sdm has not been replaced though the side-air bag developed several times in the past. Note: dtc b1027 can never be cleared once it has been set. Dtc trouble shooting 1) turn ignition switch off. 2) replace...

  • Page 896

    8b-26 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect contact coil connector located under of the steering column. 2) check proper connection to contact coil at terminal in “g26” connector. 3) if ok, then connect special tools (b) and (c) to “g26” con...

  • Page 897

    Air bag system: 8b-27 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-1” and “l32-2”. 3) if ok, then connect special tools (b) and (d) to “l32” connector. Special tool (b): 09932–75010 (d): 0...

  • Page 898

    8b-28 air bag system: 3 1) with ignition switch off, disconnect sdm connector “l29”. 2) check proper connection to sdm at terminals “l29-2” and “l29-3”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure resistance between “l29-2” and ...

  • Page 899

    Air bag system: 8b-29 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 900

    8b-30 air bag system: dtc b1032: driver air bag initiator circuit resistance low s4rs0a8204017 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tes...

  • Page 901

    Air bag system: 8b-31 dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect contact coil connector located under of the steering column. 2) check proper connection to contact coil at terminal in “g26” connector. 3) if ok, then connect special tools (b) and (c) to “g26” con...

  • Page 902

    8b-32 air bag system: 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-1” and “l32-2”. 3) if ok, then connect special tools (b) and (d) to “l32” connector. Special tool (b): 09932–75010 (d): 0...

  • Page 903

    Air bag system: 8b-33 3 1) with ignition switch off, disconnect sdm connector “l29”. 2) check proper connection to sdm at terminals “l29-2” and “l29-3”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure resistance between “l29-2” and ...

  • Page 904

    8b-34 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 905

    Air bag system: 8b-35 dtc b1033: driver air bag initiator circuit short to ground s4rs0a8204018 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a te...

  • Page 906

    8b-36 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect contact coil connector located under of the steering column. 2) check proper connection to contact coil at terminal in “g26” connector. 3) if ok, then connect special tools (b) and (c) to “g26” con...

  • Page 907

    Air bag system: 8b-37 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-1” and “l32-2”. 3) if ok, then connect special tools (b) and (d) to “l32” connector. Special tool (b): 09932–75010 (d): 0...

  • Page 908

    8b-38 air bag system: 3 1) with ignition switch off, disconnect special tools (b) and (d) from “l32” connector and sdm connector “l29” from sdm respectively. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure resistance between “l29-2” termin...

  • Page 909

    Air bag system: 8b-39 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 910

    8b-40 air bag system: dtc b1034: driver air bag initiator circuit short to power circuit s4rs0a8204019 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, u...

  • Page 911

    Air bag system: 8b-41 dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect contact coil connector located under of the steering column. 2) check proper connection to contact coil at terminal in “g26” connector. 3) if ok, then connect special tools (b) and (c) to “g26” con...

  • Page 912

    8b-42 air bag system: 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-1” and “l32-2”. 3) if ok, then connect special tools (b) and (d) to “l32” connector. Special tool (b): 09932–75010 (d): 0...

  • Page 913

    Air bag system: 8b-43 3 1) with ignition switch off, disconnect special tools (b) and (d) from “l32” connector and sdm connector “l29” from sdm respectively. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure voltage from “l29-2” terminal to ...

  • Page 914

    8b-44 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 915

    Air bag system: 8b-45 dtc b1041: passenger air bag initiator circuit resistance high s4rs0a8204012 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a...

  • Page 916

    8b-46 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect passenger air bag (inflator) module connector. 2) check proper connection to passenger air bag (inflator) module at terminals in “g10” connector. 3) if ok, then connect special tools (a), (b) and (...

  • Page 917

    Air bag system: 8b-47 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-3” and “l32-4”. 3) if ok, then connect special tools (b) and (c) to “l32” connector disconnected in step 1). Special tool...

  • Page 918

    8b-48 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 919

    Air bag system: 8b-49 dtc b1042: passenger air bag initiator circuit resistance low s4rs0a8204013 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a ...

  • Page 920

    8b-50 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect passenger air bag (inflator) module connector. 2) check proper connection to passenger air bag (inflator) module at terminals in “g10” connector. 3) if ok, then connect special tools (a), (b) and (...

  • Page 921

    Air bag system: 8b-51 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-3” and “l32-4”. 3) if ok, then connect special tools (b) and (c) to “l32” connector disconnected in step 1). Special tool...

  • Page 922

    8b-52 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 923

    Air bag system: 8b-53 dtc b1043: passenger air bag initiator circuit short to ground s4rs0a8204014 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a...

  • Page 924

    8b-54 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect passenger air bag (inflator) module connector. 2) check proper connection to passenger air bag (inflator) module at terminals in “g10” connector. 3) if ok, then connect special tools (a), (b) and (...

  • Page 925

    Air bag system: 8b-55 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-3” and “l32-4”. 3) if ok, then connect special tools (b) and (c) to “l32” connector disconnected in step 1). Special tool...

  • Page 926

    8b-56 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 927

    Air bag system: 8b-57 dtc b1044: passenger air bag initiator circuit short to power circuit s4rs0a8204015 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow...

  • Page 928

    8b-58 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect passenger air bag (inflator) module connector. 2) check proper connection to passenger air bag (inflator) module at terminals in “g10” connector. 3) if ok, then connect special tools (a), (b) and (...

  • Page 929

    Air bag system: 8b-59 2 1) with ignition switch off, disconnect “l32” connector located near the glove box. 2) check proper connection to floor harness connector at terminal “l32-3” and “l32-4”. 3) if ok, then connect special tools (b) and (c) to “l32” connector disconnected in step 1). Special tool...

  • Page 930

    8b-60 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 931

    Air bag system: 8b-61 dtc b1051 / b1055: driver / passenger pretensioner initiator circuit resistance high s4rs0a8204024 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is requir...

  • Page 932

    8b-62 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, remove center pillar lower trim of driver or passenger side and disconnect seat belt pretensioner connector “l10” or “l36” (1). 2) check proper connection to seat belt pretensioner at terminals in “l10” or “l...

  • Page 933

    Air bag system: 8b-63 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 934

    8b-64 air bag system: dtc b1052 / b1056: driver / passenger pretensioner initiator circuit resistance low s4rs0a8204025 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is require...

  • Page 935

    Air bag system: 8b-65 dtc troubleshooting step action yes no 1 1) with ignition switch off, remove center pillar lower trim of driver or passenger side and disconnect seat belt pretensioner connector “l10” or “l36” (1). 2) check proper connection to seat belt pretensioner at terminals in “l10” or “l...

  • Page 936

    8b-66 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 937

    Air bag system: 8b-67 dtc b1053 / b1057: driver / passenger pretensioner initiator circuit short to ground s4rs0a8204026 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is requir...

  • Page 938

    8b-68 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, remove center pillar lower trim of driver or passenger side and disconnect seat belt pretensioner connector “l10” or “l36” (1). 2) check proper connection to seat belt pretensioner at terminals in “l10” or “l...

  • Page 939

    Air bag system: 8b-69 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 940

    8b-70 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, remove center pillar lower trim of driver or passenger side and disconnect seat belt pretensioner connector “l10” and “l36” (1). 2) check proper connection to seat belt pretensioner at terminals in “l10” or “...

  • Page 941

    Air bag system: 8b-71 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 942

    8b-72 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect side-air bag (inflator) module connector under front seat cushion. 2) check proper connection to driver or passenger side-air bag (inflator) module at terminals in “l25” or “l30” connector. 3) if o...

  • Page 943

    Air bag system: 8b-73 2 1) with ignition switch off, disconnect sdm connector “l29”. 2) check proper connection to sdm at terminals “l29-10” and “l29-11” or “l29-12” and “l29-13”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure resi...

  • Page 944

    8b-74 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm ...

  • Page 945

    Air bag system: 8b-75 dtc b1062 / b1066: driver / passenger side-air bag initiator circuit resistance low s4rs0a8204073 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is require...

  • Page 946

    8b-76 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect side-air bag (inflator) module connector under front seat cushion. 2) check proper connection to driver or passenger side-air bag (inflator) module at terminals in “l25” or “l30” connector. 3) if o...

  • Page 947

    Air bag system: 8b-77 2 1) with ignition switch off, disconnect sdm connector “l29”. 2) check proper connection to sdm at terminals “l29-10” and “l29-11” or “l29-12” and “l29-13”. 3) if ok, release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 4) measure resi...

  • Page 948

    8b-78 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm ...

  • Page 949

    Air bag system: 8b-79 dtc b1063 / b1067: driver / passenger side-air bag initiator circuit short to ground s4rs0a8204074 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is requir...

  • Page 950

    8b-80 air bag system: dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect side-air bag (inflator) module connector under front seat cushion. 2) check proper connection to driver or passenger side-air bag (inflator) module at terminals in “l25” or “l30” connector. 3) if o...

  • Page 951

    Air bag system: 8b-81 2 1) with ignition switch off, disconnect special tools and sdm connector “l29”. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure resistance between “l29-10” and body ground, and between “l29-11” and body ground (for d...

  • Page 952

    8b-82 air bag system: note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm ...

  • Page 953

    Air bag system: 8b-83 dtc troubleshooting step action yes no 1 1) with ignition switch off, disconnect side-air bag (inflator) module connector under front seat cushion. 2) check proper connection to driver or passenger side-air bag (inflator) module at terminals in “l25” or “l30” connector. 3) if o...

  • Page 954

    8b-84 air bag system: 2 1) with ignition switch off, disconnect special tools (b), (c) and sdm connector “l29”. 2) release shorting bar in sdm connector inserting release tool (1) included in special tool (a). 3) measure voltage between “l29-10” and body ground, and between “l29-11” and ground (for ...

  • Page 955

    Air bag system: 8b-85 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm ...

  • Page 956

    8b-86 air bag system: caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correct terminal adapter from special tool (connector test adapter kit)...

  • Page 957

    Air bag system: 8b-87 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 958

    8b-88 air bag system: dtc troubleshooting step action yes no 1 1) disconnect forward-sensor connector “e13”. 2) disconnect sdm connector “l29”. 3) check proper connection to sdm connector at terminals “l29-49” and “l29-50” or terminals. 4) check proper connection to forward-sensor connector at termi...

  • Page 959

    Air bag system: 8b-89 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 960

    8b-90 air bag system: dtc will set when the resistance measured between side-sensor circuit and ground circuit is below a specified value for specified time. Flow test description step 1: check for short circuit between side-sensor circuit and ground. Step 2: check if malfunction is in side-sensor. ...

  • Page 961

    Air bag system: 8b-91 dtc b1084 / b1094: driver / passenger side-sensor circuit short to power circuit or open s4rs0a8204081 wiring diagram caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is re...

  • Page 962

    8b-92 air bag system: dtc troubleshooting step action yes no 1 1) disconnect side-sensor connector “l11” or “l35”. 2) disconnect sdm connector “l29”. 3) check proper connection to sdm connector at terminals “l29-45” and “l29-46” or terminals “l29-43” and “l29- 44”. 4) check proper connection to side...

  • Page 963

    Air bag system: 8b-93 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confi...

  • Page 964

    8b-94 air bag system: dtc will set when the combined resistance of the side curtain-air bag (inflator) module (driver or passenger), harness wiring and connector terminal contact is above a specified value for specified time. Flow test description step 1: check whether malfunction is in side curtain...

  • Page 965

    Air bag system: 8b-95 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm ...

  • Page 966

    8b-96 air bag system: caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correct terminal adapter from special tool (connector test adapter kit)...

  • Page 967

    Air bag system: 8b-97 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm ...

  • Page 968

    8b-98 air bag system: caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correct terminal adapter from special tool (connector test adapter kit)...

  • Page 969

    Air bag system: 8b-99 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm ...

  • Page 970

    8b-100 air bag system: caution: • be sure to perform “air bag diagnostic system check: ” before starting diagnosis according to flow. • when measurement of resistance or voltage is required in this flow, use a tester along with a correct terminal adapter from special tool (connector test adapter kit...

  • Page 971

    Air bag system: 8b-101 note: upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance: ”, if any. • repeat “air bag diagnostic system check: ” to confirm...

  • Page 972

    8b-102 air bag system: • poor terminal-to-wire connection. Check each wire harness in problem circuits for poor connection by shaking it by hand lightly. If any abnormal condition is found, change the wire harness assembly or component parts with new ones. • wire insulation which is rubbed through, ...

  • Page 973

    Air bag system: 8b-103 when side-air bag and side curtain-air bag are deployed, the following components must be replaced. • deployed side-air bag (inflator) module • deployed side curtain-air bag (inflator) module • side-sensor • sdm accident with or without deployment / activation – component insp...

  • Page 974

    8b-104 air bag system: – check wire harness clamps for tightness. – for air bag harness including in instrument panel harness replacement, refer to “passenger air bag (inflator) module repair harness installation: ”. • forward-sensor – check sensor (1) and front panel (2) for damage, bend or rust. –...

  • Page 975

    Air bag system: 8b-105 repair instructions disabling air bag system s4rs0a8206001 1) turn steering wheel so that vehicle’s wheels (front tires) are pointing straight ahead. 2) disconnect negative (–) cable at battery. 3) turn ignition switch to “lock” position and remove key. 4) remove “a/bag” fuse ...

  • Page 976

    8b-106 air bag system: 4) install glove box. 5) if equipped with side-air bag (inflator) module, connect yellow connector (1) of side-air bag (inflator) module by pushing connector till click is heard from it. 6) if equipped with side curtain-air bag (inflator) module, connect black connector (1) se...

  • Page 977

    Air bag system: 8b-107 installation 1) check that none of the following faulty conditions exists. • bend, scratch, deformity in vehicle body where sdm is mounted. • foreign matter or rust on mating surface of vehicle body where sdm is mounted. 2) install sdm (2) to vehicle. Caution: ensure that arro...

  • Page 978

    8b-108 air bag system: warning: special care is necessary when handling and storing a live (undeployed) air bag (inflator) module. Observe “precautions on handling and storage of air bag system components: ”. Otherwise, personal injury may result. Installation 1) connect horn connector (1) securely....

  • Page 979

    Air bag system: 8b-109 passenger air bag (inflator) module removal and installation s4rs0a8206007 warning: • never attempt to disassemble or repair the passenger air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions ...

  • Page 980

    8b-110 air bag system: installation 1) install passenger air bag (inflator) module to air bag hole cover (2). Caution: confirm claw (1) of passenger air bag (inflator) module hangs in air bag hole cover (2). 2) install passenger air bag (inflator) module with air bag hole cover (1) to instrument pan...

  • Page 981

    Air bag system: 8b-111 caution: if air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module appearance visually for the following symptoms and if any one of them is found, replace with a new one. • air bag has deployed. • wir...

  • Page 982

    8b-112 air bag system: installation 1) confirm sleeve (1) is surely installed in side-air bag (inflator) module. 2) tighten sleeve lock nut (2) to specified torque. Tightening torque sleeve lock nut (a): 2.5 n·m (0.25 kg-m, 2.0 lb-ft) 3) install new clip to seat back. 4) connect side-air bag (inflat...

  • Page 983

    Air bag system: 8b-113 side curtain-air bag (inflator) module removal and installation s4rs0a8206025 warning: • never attempt to disassemble or repair the side curtain-air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precau...

  • Page 984

    8b-114 air bag system: 4) install head lining referring to “head lining removal and installation: in section 9h”. 5) enable air bag system. Refer to “enabling air bag system: ”. Side curtain-air bag (inflator) module inspection s4rs0a8206026 warning: • never measure resistance of side curtain- air b...

  • Page 985

    Air bag system: 8b-115 4) remove forward-sensor bolt (1) and forward-sensor (2). Installation caution: proper operation of forward-sensor requires sensor be rigidly attached to vehicle structure and that the arrow on sensor be pointing toward the front of the vehicle. 1) check that none of the follo...

  • Page 986

    8b-116 air bag system: 6) disconnect side-sensor connector sliding connector outer (1) as shown. Installation caution: proper operation of side-sensor requires sensor be rigidly attached to specified position. 1) check that none of following faulty conditions exists. • bend, deformity or rust of und...

  • Page 987

    Air bag system: 8b-117 • check sensor (1) for dents, crack, deformation. • check sensor connector (sensor side and harness side), lock mechanism or sensor lead wire for damage, crack, scorching or melting. • check connector terminals for bent, corrosion or rust. If any faulty condition is found in a...

  • Page 988

    8b-118 air bag system: air bag (inflator) module and seat belt pretensioner disposal s4rs0a8206013 warning: failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury. ...

  • Page 989

    Air bag system: 8b-119 deployment / activation outside of vehicle when you intend to return the vehicle to service, deploy the air bag (inflator) module(s) or activate seat belt pretensioner(s) outside of the vehicle. 1) turn ignition switch to lock position and remove key. 2) wear safety glasses du...

  • Page 990

    8b-120 air bag system: warning: • for handling and storage of seat belt pretensioner, select place where ambient temperature is below 65 c (150 f), without high humidity and away from electric noise. • never carry seat belt pretensioner by webbing. • when placing seat belt pretensioner on workbench ...

  • Page 991

    Air bag system: 8b-121 c. Fill plastic reservoir in deployment fixture (a) with water or sand. This is necessary to provide sufficient stabilization of fixture during deployment. D. Attach passenger air bag (inflator) module (1) in deployment fixture (a) securely using m8 bolt (2). Caution: be sure ...

  • Page 992

    8b-122 air bag system: paved, outdoor location where there is no activity is preferred. If outdoor location is not available, use space on shop floor where there is no activity and sufficient ventilation is provided. Ensure no loose or flammable object exists within activation area. D. Pile tire wit...

  • Page 993

    Air bag system: 8b-123 • for passenger air bag (inflator) module [b] check that passenger air bag (inflator) module is firmly and properly secured on deployment fixture (special tool), and connect adapter cable (b) to passenger air bag (inflator) module. • for side-air bag (inflator) module [c] veri...

  • Page 994

    8b-124 air bag system: 12) notify all people in immediate area that you intend to deploy / activate air bag (inflator) module or seat belt pretensioner. Note: • when air bag (inflator) module deploys and seat belt pretensioner activates, rapid gas expansion will create substantial report. Wear suita...

  • Page 995

    Air bag system: 8b-125 21) wash your hands with mild soap and water afterward. Note: remaining steps are to be followed in the unlikely event that air bag (inflator) module did not deploy or seat belt pretensioner did not activate. 22) ensure that deployment harness has been disconnected from 12 vol...

  • Page 996

    8b-126 air bag system: 5) check that there is no open, short or damage in special tools (deployment harness (a), adapter cable (b) and (c)). If any faulty condition is found, do not use it and be sure to use new special tool. And connect adapter cable (b), (c) or (d) to deployment harness (a) and lo...

  • Page 997

    Air bag system: 8b-127 12) completely cover windshield area and front door window openings with drop cloth, a blanket or any similar item. This reduces possibility of injury due to possible fragmentation of vehicle’s glass or interior. 13) notify all people in immediate area that you intend to deplo...

  • Page 998

    8b-128 air bag system: note: remaining steps are to be followed in the unlikely event that air bag (inflator) module did not deploy or seat belt pretensioner did not activate. 24) remove undeployed air bag (inflator) module(s) and/ or inactivated seat belt pretensioner(s) from vehicle. For driver ai...

  • Page 999

    Air bag system: 8b-129 specifications tightening torque specifications s4rs0a8207001 note: the specified tightening torque is also described in the following. “air bag system components, wiring and connectors location: ” reference: for the tightening torque of fastener not specified in this section,...

  • Page 1000

    8b-130 air bag system: special tool (b): 09932-75010 (air bag driver / passenger load tool) this tool is used as a diagnostic aid and safety device to prevent inadvertent air bag (inflator) module deployment. The load tool has three connectors attached to its case which are electrically functional a...

  • Page 1001

    Air bag system: 8b-131 special tool s4rs0a8208005 09932–75010 09932–75031 air bag load tool air bag deployment harness / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / 09932–75041 09932–76010 passenger air bag (inflator) module deploymen...

  • Page 1002

    8b-132 air bag system: suzuki scan tool — this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loopback adapter, 7. Battery power cable, 8. Rs232 cable, 9. Rs232 adapter, 10. Rs232 loop back connector, 11. Storage case, 12. Powe...

  • Page 1003: Section 9

    Table of contents 9- i 9 section 9 contents body, cab and accessories precautions .................................................9-1 precautions............................................................. 9-1 precautions on body, cab and accessories......... 9-1 precautions for body service.........

  • Page 1004

    9-ii table of contents c connector ......................................................9a-82 e connector ......................................................9a-83 g connector......................................................9a-84 j connector......................................................

  • Page 1005

    Table of contents 9-iii horn inspection.................................................9c-17 horn relay inspection.......................................9c-17 antenna amplifier removal and installation .....9c-17 remote audio control switch inspection..........9c-17 specifications.....................

  • Page 1006

    9-iv table of contents keyless entry receiver removal and installation....................................................... 9f-12 keyless entry receiver and its circuit inspection........................................................ 9f-13 specifications.............................................

  • Page 1007: Precautions

    Precautions: 9-1 precautions precautions precautions on body, cab and accessories s4rs0a9000001 air bag warning refer to “air bag warning: in section 00”. Fastener caution refer to “fastener caution: in section 00”. Precautions for body service refer to “precautions for body service: ”. Fastener cau...

  • Page 1008: Wiring Systems

    9a-1 wiring systems: wiring systems precautions cautions in body electrical system servicing s4rs0a9100001 when performing works related to electric systems, observe the cautions described in “precautions for electrical circuit service: in section 00” for the purpose of protection of electrical part...

  • Page 1009

    Wiring systems: 9a-2 general description applicable model s4rs0a9101001 abbreviations s4rs0a9101002 vin vin (m15a engine) jsaezc2100100001~ i4rs0a910901- abbreviation full term abbreviation full term 2wd 2 wheel drive vehicles ill illumination 4wd 4 wheel drive vehicles ind indicator a/b air bag int...

  • Page 1010

    9a-3 wiring systems: wire / connector color symbols s4rs0a9101003 symbols and marks s4rs0a9101004 symbol wire / connector color symbol wire / connector color blk black orn orange blu blue red red brn brown wht white grn green yel yellow gry gray pnk pink lt blu light blue ppl purple lt grn light gre...

  • Page 1011

    Wiring systems: 9a-4 photo transistor diode zener diode light emitting diode photo diode piezoelectric element harness ring terminal connector connected not connected relay normal open normal closed switch open switch closed switch ignition switch keyless entry immobilizer system combination meter l...

  • Page 1012

    9a-5 wiring systems: how to read connector layout diagram s4rs0a9101005 [a-1]: harness symbol and corresponding harness name a: battery harness b: a/c harness c: engine harness d: injector harness e: main harness, oil pressure switch wire, console wire g: instrument panel harness j: side door wire (...

  • Page 1013

    Wiring systems: 9a-6 how to read connector codes and terminal nos. S4rs0a9101006 1) connector code/terminal no./terminal layout • the connector shape and terminal layout shown in this manual are those when viewed from “z” in the illustration. Refer to “list of connectors: ”. 2) connector type 3) ter...

  • Page 1014

    9a-7 wiring systems: 4) joint connector (j/c) • the joint connector (j/c) connects several different wires with the same wire color at one place instead of connecting them by welding or caulking one by one. It is not an ordinary connector but a part of the continuous wire in the harness. 5) junction...

  • Page 1015: Cross-Reference

    Wiring systems: 9a-8 6) connector location, shape and terminal no. Refer to “connector layout diagram: ”. Refer to “system circuit diagram: ”. Refer to “list of connectors: ”. How to read ground point s4rs0a9101007 refer to “system circuit diagram: ”. Refer to “ground (earth) point: ”. "system circu...

  • Page 1016

    9a-9 wiring systems: how to read power supply diagram s4rs0a9101008 refer to “power supply diagram: ”. Refer to “system circuit diagram: ”. How to read system circuit diagram s4rs0a9101009 the circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom o...

  • Page 1017

    Wiring systems: 9a-10 [m]: terminal no. [n]: symbol mark [o]: “see” mark switch blu blu grn/blk grn/red grn/blk 1 2 grn grn c26 2 1 blk 5 blk 2 1 c40 grn/blk "xx" solenoid fuse fuse 3 15a main relay on off 1 15a 6 20a 1 sensor 1 2 8 brn/red e52 1 2 e52 1 brn/red red 2 brn/red brn/red motor m m 6 5 5...

  • Page 1018

    9a-11 wiring systems: connector layout diagram connector layout diagram s4rs0a910a001 refer to “engine compartment: ”. Refer to “instrument panel: ”. Refer to “door, roof: ”. Refer to “floor: ”. Refer to “rear: ”. Engine compartment s4rs0a910a002 a: battery cable / c: engine harness c: engine harnes...

  • Page 1019

    Wiring systems: 9a-12 e: main harness e: main harness c09/grn ect sensor c29/gry (a/t) shift solenoid c10/gry egr stepper motor c30/blk (m/t) back-up light switch c11/blk throttle position sensor c31/- main fuse box c12/blk map sensor c33/- main fuse box c13/blk maf sensor c34/n (a/t) tcm c14/blk ev...

  • Page 1020

    9a-13 wiring systems: instrument panel s4rs0a910a003 e: main harness and power steering wire e: main harness e08/blk head light (r) e27/blk main fuse box e09/gry front turn signal light (r) e28/n radiator fan relay #1 e10/grn rear washer motor e29/n radiator fan relay #2 e11/blu windshield washer mo...

  • Page 1021

    Wiring systems: 9a-14 e: power steering wire g: instrument panel harness g: instrument panel harness no./color connective position no./color connective position e50/blu main harness (to e48) e53/blk p/s torque sensor e51/blu p/s control module e54/gry p/s motor e52/blk p/s control module j/b 9 10 g3...

  • Page 1022

    9a-15 wiring systems: door, roof s4rs0a910a004 j: front and rear door wire and rear door joint wire / k: roof wire j: front door wire (drive side) j: front door wire (passenger side) j: rear door wire k02 k k01 j/b j04 j21 (to l37) j02 j03 j06 j07 j08 j25 j23 j24 j j01 (to l06) j22 j09 (to l31) j12 ...

  • Page 1023

    Wiring systems: 9a-16 k: roof wire floor s4rs0a910a005 l: floor harness, acc socket wire, license plate wire / r: fuel pump wire no./color connective position no./color connective position k01/n j/b k02/gry interior light l48 14 l43 l42 (to o01) l40 l41 l33 (to g03) l32 (to g04) l46 acc socket wire ...

  • Page 1024

    9a-17 wiring systems: l: floor harness l: acc socket wire l: license plate wire r: fuel pump wire no./color connective position no./color connective position l01/blu bcm l24/gry j/c l02/n main harness (to e44) l25/yel side air-bag inflator (driver side) l03/yel main harness (to e45) l26/n seat belt ...

  • Page 1025

    Wiring systems: 9a-18 rear s4rs0a910a006 o: rear end door harness, rear defogger wire o: rear end door harness o: rear defogger wire o rear defogger wire o01 (to l42) o02 o03 19 o04 o05 o06 20 i4rs0a910970- no./color connective position no./color connective position o01/n floor harness (to l42) o04/...

  • Page 1026

    9a-19 wiring systems: ground point ground (earth) point s4rs0a910c001 refer to “connector layout diagram: ”. 20 19 13 lhd shown (lh) 14 (rh) 7 3 4 1 2 fwd 5 6 17 8 9 10 fwd fwd (rh) 11 12 (lh) 15 16 fwd 18 fwd i4rs0a910971-.

  • Page 1027

    Wiring systems: 9a-20 power supply diagram power supply diagram s4rs0a910d001 refer to “fuses and the protected parts: ”. Refer to “fuses in main fuse box: ”. Refer to “individual circuit fuse box no. 1: ”. Refer to “individual circuit fuse box no. 2 (in j/b): ”. Refer to “junction block (j/b) conne...

  • Page 1028

    9a-21 wiring systems: fuses and the protected parts s4rs0a910d002 the chart below describes what parts each fuse protects. G32 j/b 3 wht/blu 4 g21 3 1 2 10 blk 2 1 blk/gry 10a 15a 30a 5 6 4 7 8 9 10 12 1 e27 2 wht 13 14 16 19 20 21 blu blu/yel 6 blk/yel 5 yel/blu 7 pnk 8 9 wht/red red grn 12 wht gry...

  • Page 1029

    Wiring systems: 9a-22 fuses in main fuse box s4rs0a910d003 individual circuit fuse box no. 1 s4rs0a910d004 no. Fuse protected circuit 80 a all electric circuit battery generator 50 a lamp 50 a ig switch supplementary fuse box no.2 (in j/b) 1 3 2 i4rs0a910905- 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1...

  • Page 1030

    9a-23 wiring systems: individual circuit fuse box no. 2 (in j/b) s4rs0a910d005 30 a ig acc ig switch 30 a rdtr fan radiator fan relay #1 radiator fan relay #2 blank blank blank 30 a abs sol abs control module blank blank blank 15 a thr mot blank 15 a fr fog front fog light relay 15 a h/l l headlight...

  • Page 1031

    Wiring systems: 9a-24 15 a wiper comb switch rear washer motor rear wiper motor rear wiper relay windshield washer motor windshield wiper motor 10 a ig1 sig a/t relay (a/t) power steering control module 15 a a/bag a/b sdm 10 a abs abs control module 10 a tail comb switch blank blank blank 20 a d/l b...

  • Page 1032

    9a-25 wiring systems: junction block (j/b) connector / fuse layout s4rs0a910d006 bcm side 2 1 6 5 3 4 4 3 2 12 1 11 14 13 15 5 9 8 7 17 6 16 19 18 20 10 6 5 4 3 2 8 1 7 10 9 12 11 3 4 6 5 2 1 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 g34 g33 g32 bcm (j/b side connector) 3 4 1 2 5 15 14 1213...

  • Page 1033

    Wiring systems: 9a-26 fuse side 1 2 3 4 5 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 heater relay relay 2 3 4 1 2 1 1 2 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 1 2 3 4 5 6 7 8 9 10 4 3 2 1 10 9 8 7 6 5 6 5 4 3 2 1 7 11 10 9 8 15 14 13 12 16 9 8 7 6 5 4 3 2 1 13 12 11...

  • Page 1034

    9a-27 wiring systems: junction block inner circuit (overview) s4rs0a910d007 1 ig2fl 2 6 lamp fl (fl box) 1 a/b cont 4 a/b sig 3 k-line 2 a/b signal 9 a/b signal 8 k-line 23 * 11 bcm ;ig1 22 d/ul-in 21 d/l-in 18 security in 6 serial out 14 tail bcm wng, etc 12 answer back 17 rr def control 1 d/l (+b)...

  • Page 1035

    Wiring systems: 9a-28 junction block inner circuit (detail) s4rs0a910d008 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g33 g32 g34 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 k01 2 3 4 1 4 3 5 6 12 14 1...

  • Page 1036

    9a-29 wiring systems: bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g33 g32 g34 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 k01 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 15 1...

  • Page 1037

    Wiring systems: 9a-30 e39 e41 e40 bcm g34 g33 g32 k01 l04 l05 l06 j/b 7 17 8 5 4 14 2 6 3 (continued) def lp rr def rr def control rr-def rly epi a/c panel luggage lamp bcm dome lp power rr fog sw deicer lp deicer deicer control deicer rly rr def rr fog mta radio haz-horn 20a 10a 10a 15a 15a immobi ...

  • Page 1038

    9a-31 wiring systems: (continued) bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g33 g32 g34 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 k01 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11...

  • Page 1039

    Wiring systems: 9a-32 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g33 g32 g34 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 k01 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 15 1...

  • Page 1040

    9a-33 wiring systems: system circuit diagram system circuit diagram s4rs0a910e001 refer to “a-1 cranking system circuit diagram: ”. Refer to “a-2 charging system circuit diagram: ”. Refer to “a-3 ignition system circuit diagram: ”. Refer to “a-4 cooling system circuit diagram: ”. Refer to “a-5 engin...

  • Page 1041

    Wiring systems: 9a-34 a-1 cranking system circuit diagram s4rs0a910e002 starting motor relay w "a-5" ecm p r n d 2 l transaxle range sensor c28 1 4 e31 c23 1 c24 1 starting motor m off on blk 1 blk/gry c31 1 battery e24 c36 1 red individual circuit fuse box (no.1) 10 30a 36 10a wht wht m/t e24 c36 1...

  • Page 1042

    9a-35 wiring systems: a-2 charging system circuit diagram s4rs0a910e003 4 e24 c36 blk/wht blk/wht blk/wht 80a main fuse box c22 j/b 1 c33 ig coil 1 15a 23 generator ic regulator 1 e41 5 c21 2 1 wht/blu wb bcm "a-8" 16 wht/blu blk weld splice c39 i4rs0a910916-.

  • Page 1043

    Wiring systems: 9a-36 a-3 ignition system circuit diagram s4rs0a910e004 15a 4 e24 c36 2 c02 1 3 ig coil #1 c03 blk blk/wht grn/yel blk/wht j/b ecm gy gw 23 ig coil blk blk ig coil #2 e41 5 3 grn/wht 1 3 2 c37 5 6 weld splice c39 blk/wht blk/wht i4rs0a910917-.

  • Page 1044

    9a-37 wiring systems: a-4 cooling system circuit diagram s4rs0a910e005 e17 m 1 3 2 1 7 "a-5" g lt grn "a-5" lg brn/wht bw blk/yel blk/yel br relay #1 e28 3 5 blu/red relay #2 e29 3 2 1 relay #3 e30 5 3 1 2 2 4 gry grn blu/red blu/wht blu/red blu/red blu/blk grn gry 30a rdtr fan 14 e32 4 3 15a fi 5 2...

  • Page 1045

    Wiring systems: 9a-38 a-5 engine and a/c control system circuit diagram s4rs0a910e006 1 yel/red e45 l02 5 9 l15 r01 4 2 pnk yel/red p pnk yel/red 3 1 3 3 1 e24 c36 blk/orn blk/orn blk/orn blk/orn 3 15 blk 4 2 r02 3 2 and fuel gauge main relay 1 1 blk/wht blk/wht c39 weld splice weld splice e55 grn/w...

  • Page 1046

    9a-39 wiring systems: 2 c09 lt grn 1 c12 c13 c11 e23 c37 c37 knock sensor c19 ecm c04 2 1 c05 2 1 c06 2 1 c07 2 1 #2 #1 #3 #4 blu/red blu/wht blu/yel blu/grn blk/red blu/blk evap canister purge valve c14 ect sensor orn maf sensor 4 4 map sensor throttle position sensor weld splice c41 orn orn orn lt...

  • Page 1047

    Wiring systems: 9a-40 "e-1" egr stepper motor ppl p "a-6" m/t a/t a b a b a b ecm 2 3 red orn gry/red evap thermistor 1 2 g09 13 orn e38 g36 bw heater fan switch a/c pressure sensor e04 c10 brn/yel wht/red grn/red 6 4 3 1 2 5 ckp sensor cmp sensor vehicle speed sensor blk/orn blk/orn tcm c37 blk 3 1...

  • Page 1048

    9a-41 wiring systems: j/c e43 j/c g16 dlc g20 g37 5 e46 9 e38 g36 14 c36 e24 15 blk/orn blk/orn blk/orn 4 blk 11 j/c g15 5 4 5 16 wht/red 8 wht/red wht/red c37 grn/yel grn/wht 5 6 yg brn b p/s cont.M 4 "f-3" 25 a a d e a a ppl/wht ppl/wht ppl/wht ppl/wht yel/grn wht/red blk 9 a ppl e42 ppl j/c ecm e...

  • Page 1049

    Wiring systems: 9a-42 ecm wht wht w starting motor relay "a-1" grn bcm relay #2 relay #3 g "a-4" e23 48 red e46 3 18 30 tcm wht red 12 13 c34 c37 e23 1 2 7 17 r w e23 i4rs0a910923-.

  • Page 1050

    9a-43 wiring systems: a-6 a/t control system circuit diagram s4rs0a910e007 grn/yel brake light switch e47 grn/yel c35 20 8 7 19 18 e24 c36 9 8 5 3 6 2 grn/yel back-up light 20 red "d-8" r transaxle range sensor tcm l23 4 a/t select switch a/t shift lever blk/orn 16 off on red 1 red blk pnk/blk grn/o...

  • Page 1051

    Wiring systems: 9a-44 orn gry 2 tcm lock up solenoid a/t fluid temperature sensor shift solenoid no.2 shift solenoid no.1 11 12 c29 1 6 blk/yel 3 2 brn 10 15 4 2 14 5 4 9 timing solenoid wht/blk wht/blu pressure control solenoid lt grn/blk 3 8 shift solenoid lt grn blu/blk 5 ecm wht red wht/red wht/...

  • Page 1052

    9a-45 wiring systems: a-7 immobilizer system circuit diagram s4rs0a910e008 ecm icm dlc g20 4 10 j/c g15 5 5 7 11 3 ig coil g34 6 j/b 29 15a 23 blk/wht 13 28 yel/blk yb yr e38 g36 14 c36 e24 15 blk/orn blk/orn blk/orn blk j/c e43 j/c g16 bcm g37 5 e46 9 16 wht/red e23 3 g24 1 4 blk/orn 2 e38 g36 5 15...

  • Page 1053

    Wiring systems: 9a-46 a-8 body control system circuit diagram s4rs0a910e009 1 e46 2 wht red 4 g37 2 wht red 3 g20 1 6 14 wht/blk red/blk pnk lt grn g37 dlc 4 11 blk blk a a j/c g15 13 14 12 receiver 5 ppl/wht ppl/wht a a j/c g16 "a-5" "f-2" "f-3" 9 e46 ppl/wht ecm e d j/c e d e43 ppl/wht ppl/wht p/s...

  • Page 1054

    9a-47 wiring systems: 9 15 7 "d-5" "a-6" a/t gry/red red/blu 16 a a b b g37 blu/yel blu/yel j/c g17 j/c g17 g22 g22 1 4 main switch (key switch) radio g33 5 15a 40 wht/red yel/red yel/blk 1 e14 2 ambient temperature sensor "b-5" switch 6 l01 14 16 17 12 5 red/blk brn/yel lt grn/blk brn gry/wht gry p...

  • Page 1055

    Wiring systems: 9a-48 18 17 grn/wht brn "e-1" mode control switch g37 flasher relay relay relay h 12 "junction block inner circuit" j/b (bcm- 12 ) j/b (bcm- 18 ) 16 18 j/b (bcm- 16 ) j/b "b-5" "b-5" "b-5" "b-5" 11 9 l06 l08 22 10 21 b e e rear j/b grn grn red/blu b l09 red/blu grn red/blu grn red/bl...

  • Page 1056

    9a-49 wiring systems: 50a 3 j/b 15a radio 40 2 15a acc 1 26 10 1 20a d/l 34 11 10a meter 25 main fuse box wht e40 2 20 heater relay "junction block inner circuit" relay j/b (bcm- 20 ) j/b (bcm- 17 ) 17 2 l04 9 3 8 3 b b g33 3 4 l05 10 j/c g15 blk/orn blk/orn 16 blk/orn "f-1" yel ppl/wht a/b sdm 14 3...

  • Page 1057

    Wiring systems: 9a-50 b-1 windshield wiper and washer circuit diagram s4rs0a910e010 j/b lo hi e01 3 4 6 blk e39 3 9 g23 8 switch 1 13 blu/wht blu/wht 5 3 2 blu/red blu/red blu/yel blu/yel blu/yel 3 2 4 6 wiper 15a 28 2 e11 1 g33 1 yel m m yel blu/orn 10 5 blk off on wf ew p t mist off int lo hi +b +...

  • Page 1058

    9a-51 wiring systems: b-2 rear wiper and washer circuit diagram s4rs0a910e011 j/b o03 4 2 3 blk l05 5 g34 9 a g23 9 8 1 8 g37 l42 o01 6 e39 9 m wash off int on on+wash wr ew +1r p t blk blk blk 2 e10 1 yel yel m yel/red orn orn yel 20a wiper j/c g15 28 11 12 e37 g35 yel/red 4 2 3 1 relay r.Int 10 9 ...

  • Page 1059

    Wiring systems: 9a-52 b-3 rear defogger circuit diagram s4rs0a910e012 l42 o01 3 blk/red o02 1 o06 1 20 1 2 4 3 20a rr def 41 relay 17 brn g37 17 g33 7 blk/red blk/red l05 8 rear def mode control switch blk/orn 10 blk/orn g15 9 j/c b b blk g18 7 8 j/b b a br j/b side connector (bcm) a bcm i4rs0a91093...

  • Page 1060

    9a-53 wiring systems: b-4 power window circuit diagram s4rs0a910e013 1 2 j15 l31 j09 j01 l07 6 6 34 7 2 7 16 2 3 5 6 7 3 2 10 11 17 16 1 4 30a p/w 45 sub switch main switch j14 2 1 grn red red 15 l05 j/b 18 blk blk 2 13 wht/blu wht/blu 1 2 3 4 5 6 red/wht wht/blu grn/wht red/wht grn/wht red/wht grn/...

  • Page 1061

    Wiring systems: 9a-54 j24 l37 j21 j19 2 3 5 2 2 1 3 3 5 c c a a l13 j16 2 1 3 5 j23 j18 red/blk blu/yel wht/blu grn/yel wht/blu wht/blu wht/grn 4 12 11 j/c l08 l09 j01 l07 1 4 2 1 m grn red 1 4 2 1 grn red 1 2 3 4 5 6 unlock up off down up off down lock ig e rlu rld rear (l) sub switch m unlock up o...

  • Page 1062

    9a-55 wiring systems: b-5 power door lock circuit diagram s4rs0a910e014 8 7 6 17 16 10 9 switch j06 l07 j01 brn blk lt grn/blk main switch l01 34 14 9 5 12 22 21 j08 gry blk blk gry/wht brn lt grn/blk gry gry/wht 18 up off down lock unlock e receiver g02 g37 lt grn pnk 14 13 12 3 1 4 up off down loc...

  • Page 1063

    Wiring systems: 9a-56 11 4 10 l06 l08 21 9 22 1 8 4 2 l13 j16 7 b e e 8 l37 j21 7 7 l42 o01 o04 rear (r) j/b j/c grn grn red/blu b j20 red/blu grn red/blu grn red/blu d/l 20a 34 3 m 4 2 b 1 j13 l09 l01 m 1 3 rear (l) j25 m b e 25 l31 j09 23 m grn red/blu grn red/blu grn red/blu blu/yel blu/yel bcm 1...

  • Page 1064

    9a-57 wiring systems: b-6 power mirror circuit diagram s4rs0a910e015 13 5 12 10 13 5 4 9 r l 3 32 7 7 j07 l06 l07 j01 6 j03 j11 34 j01 l07 blk blk 18 switch motor m m down up 5 r l 6 motor m m down up blu/wht blu/wht 1 j/b acc 1 15a 26 31 30 27 31 30 27 l31 j09 lt grn orn lt grn/blk lt grn lt grn lt...

  • Page 1065

    Wiring systems: 9a-58 b-7 horn circuit diagram s4rs0a910e016 bcm 14 a 8 3 +b 7 ig 3 3 flasher relay 10a meter j/b 25 grn blu 1 1 combination switch (horn) h 9 a a blk j/c 1 2 4 3 relay h e15 g27 g15 e41 g34 9 a 11 blk blk j/b side connector (bcm) a i4rs0a910939-.

  • Page 1066

    9a-59 wiring systems: c-1 combination meter circuit diagram (meter) s4rs0a910e017 radio j/b 15a 40 meter 10a 25 wht/red g28 32 31 5 stepper motor and led output driver voltage regulator micro controller ill (dial) ill (display) ill (pointer) g33 6 red/blk 16 b b blk /orn blk /orn j/c g15 fuel temp t...

  • Page 1067

    Wiring systems: 9a-60 c-2 combination meter circuit diagram (indicator) s4rs0a910e018 radio 15a 40 meter 10a 25 wht/red 32 31 5 stepper motor and led output driver voltage regulator micro controller smart key g33 6 red/blk "d-1" beam 22 a/t red (dimmer / passing) j/b l 2 3 d n r p 16 b b blk /orn bl...

  • Page 1068

    9a-61 wiring systems: c-3 combination meter circuit diagram (warning light) s4rs0a910e019 j/b meter 10a 25 g28 g35 e37 31 3 14 1 9 stepper motor and led output driver voltage regulator interface circuit micro controller eps g33 6 red/blk 14 5 25 pnk/blk gry gry red/blu pnk/blk red/blu p/s cont m "f-...

  • Page 1069

    Wiring systems: 9a-62 gear abs belt door charge immobi brake fuel radio 15a 40 32 5 wht/red j/b g33 g28 1 2 i4rs0a910943-.

  • Page 1070

    9a-63 wiring systems: d-1 headlight system circuit diagram s4rs0a910e020 1 headlight (r) headlight (l) wht/blu red dimmer / passing switch light switch 2 2 b a b c b c 3 3 15 1 22 g28 e08 g34 e21 g33 6 31 red/blk wht/red 10a 25 meter wht/red 7 10 9 blk 11 g25 15a 21 15a 20 h/l,r h/l,l 5 8 red/wht re...

  • Page 1071

    Wiring systems: 9a-64 d-2 position, tail and licence plate light system circuit diagram s4rs0a910e021 3 5 l43 1 2 l47 (l) (r) (r) (l) blk red/yel red/yel red/yel 7 j/c l08 l09 e42 15 g34 7 blk g25 5 10a tail 32 1 2 e07 1 c c a 2 e d e e22 blk blk red/yel j/b l05 3 e41 16 blk blk e43 j/c licence plat...

  • Page 1072

    9a-65 wiring systems: d-3 front fog light system circuit diagram s4rs0a910e022 fr fog (r) (l) 1 e18 2 a a 1 e12 2 15a 19 relay switch 2 e34 3 4 1 wht/grn gry/red gry/red lt grn blk blk blk blk lt grn lt grn 7 d d e37 g35 free ig load e il ile terminal position push 6 7 4 8 g15 g31 g29 red/yel red/ye...

  • Page 1073

    Wiring systems: 9a-66 d-4 illumination light system circuit diagram s4rs0a910e023 wht/red a/t shift lever l23 2 5 blk blk 10a tail 32 j/b 15 g34 7 blk g25 8 5 11 17 a/t b b j/c l24 red/yel red/yel red/yel j/c l08 c a l05 3 "d-3" if eqpd ry switch j/c g31 red/yel ry red/yel switch ry red/yel mode con...

  • Page 1074

    9a-67 wiring systems: d-5 interior light system circuit diagram s4rs0a910e024 15a 40 radio j/b off door on k02 k01 2 6 3 1 interior light 15 7 off on off on l12 1 1 gry/red blk off on off on l16 l34 1 l40 1 rear door switch front door switch blk/red blk blk blk l05 14 wht/red g15 j/c a a 5 7 g34 k01...

  • Page 1075

    Wiring systems: 9a-68 d-6 turn signal and hazard warning light system circuit diagram s4rs0a910e025 4 d d g11 g31 2 switch blk/orn blk wht rear turn signal light 6 l43 blk 11 2 haz lp-l lp-r flasher relay g34 red/yel red/yel turn signal switch 12 g25 13 11 10a meter 25 red/blu blu/red j/b l n r turn...

  • Page 1076

    9a-69 wiring systems: d e e j/c e43 e42 j/c grn/red 9 (turn (l)) (turn (r)) e06 12 g33 6 blu/yel grn/red blu/yel "c-2" gr by fr turn signal light (r) side turn signal light (r) e09 2 e19 fr turn signal light (l) side turn signal light (l) blk 5 e39 5 blk blk blk blk 1 2 1 2 1 2 1 e20 1 2 j/b i4rs0a9...

  • Page 1077

    Wiring systems: 9a-70 d-7 brake light system circuit diagram s4rs0a910e026 brake light switch (r) brake light pnk blk (l) 15a 8 stop lamp e47 l43 grn/wht grn/wht grn/wht 5 4 1 l06 2 8 e41 1 j/b "f-2" abs cont.M grn/wht 2 "a-5" ecm 13 gw gw gw tcm pb pnk/blk "a-6" grn/yel a/t shift lever gy "a-6" 2 3...

  • Page 1078

    9a-71 wiring systems: d-8 back-up light system circuit diagram s4rs0a910e027 blk blk 14 13 f f d j/c l08 l09 j/c d l28 back-up light switch back-up light (r) red red red/blk red/blk on off j/b 10a 24 back e24 c36 19 c30 2 1 20 l43 1 l20 1 red red red a/t m/t l06 3 e41 11 j/b p r n d 2 l transaxle ra...

  • Page 1079

    Wiring systems: 9a-72 e-1 heater system circuit diagram s4rs0a910e028 brn/wht grn/wht 10a back 24 m blk/red relay blk/orn blk/orn g15 j/c g01 fresh / recircle actuator 3 7 1 grn red 9 g18 7 8 g31 j/c 4 g34 bcm "a-8" gw bcm "b-3" b brn 8 red/yel red/yel red/blk red/blk red/blk 10 13 14 5 6 rear def r...

  • Page 1080

    9a-73 wiring systems: red m yel blu/wht blk/wht g19 5 brn/wht j/b blk/wht blk/yew 1 2 g05 12 blk g06 heater resister 1 3 4 2 blower fan g32 6 1 7 2 3 6 fan ecm "a-5" bw heater fan switch 1 2 5 3 30a htr fan 4 10a 38 ig2 sig heater relay e39 7 g34 9 g15 j/c 11 a a blk blk blu 1 individual circuit fus...

  • Page 1081

    Wiring systems: 9a-74 f-1 air-bag system circuit diagram s4rs0a910e029 3 orn y pw a/b sdm l29 j/b 15a a/bag 30 red l04 bcm 15 blk 1 e44 l03 1 pnk/blk e13 forward sensor (r) 1 2 contact coil g26 1 2 l32 g04 2 1 l10 2 1 yel/red grn/red g10 1 2 4 3 yel/red l36 1 2 3 4 7 8 5 6 9 10 28 27 37 32 50 51 "a-...

  • Page 1082

    9a-75 wiring systems: l30 l25 l18 l41 1 2 1 2 a/b sdm l29 l11 l35 1 2 1 2 12 11 13 14 20 19 21 22 46 47 45 44 if eqpd sensor sensor lt grn/blk yel/grn blk/yel brn/yel side curtain side curtain l04 4 g34 13 j/b "c-3" yb 2 yel/blk yel/blk wht/red wht/grn lt grn gry/red gry 1 2 brn/wht brn yel/blu 1 2 ...

  • Page 1083

    Wiring systems: 9a-76 f-2 anti-lock brake system circuit diagram s4rs0a910e030 13 26 14 1 3 23 17 e03 abs cont.M blk 30a abs sol 16 30a abs mot 9 wht/red wht/blu grn/wht 6 blk pnk/blk pb pnk/blk rb red/blu red/blu 14 9 g35 e37 "c-3" j/b 10a abs 31 e41 9 grn/orn 7 gw "d-7" brake light switch (abs) gr...

  • Page 1084

    9a-77 wiring systems: yel abs cont.M l38 lt grn/blk lt grn lt grn/blk lt grn l02 e45 1 6 wheel speed sensor (rl) brn yel brn 7 2 l14 wheel speed sensor (rr) wht/blk e05 wheel speed sensor (fr) wht red e25 wheel speed sensor (fl) red/blk 18 19 22 21 25 24 16 15 e03 2 1 2 1 2 1 2 1 5 dlc ppl/wht ppl/w...

  • Page 1085

    Wiring systems: 9a-78 f-3 power steering system circuit diagram s4rs0a910e031 p/s cont.M 50a eps 12 e41 12 j/b 10a ig1 sig 29 red 6 20 e48 e50 e50 e48 torque sensor blk e49 8 grn lt grn/blk yel 1 16 grn 2 8 brn 4 9 wht 5 18 blu 7 6 19 1 2 1 lt grn/blk 3 e53 e49 e52 e52 rb 5 ecm "a-5" red/blu red/blu...

  • Page 1086

    9a-79 wiring systems: b p/s cont.M 6 j/c e42 e48 e50 e d g35 e37 j/c e43 e54 m red blk e51 ecm "a-5" gry brn 1 2 1 2 11 12 5 gry brn 1 4 e52 ppl 2 p 4 ppl/wht ppl/wht eps meter 10a 25 g28 31 g33 6 red/blk 25 ppl g20 dlc 4 blk a a j/c g15 5 ppl/wht ppl/wht a a j/c g16 9 e46 e38 g36 14 e24 c36 15 blk/...

  • Page 1087

    Wiring systems: 9a-80 g-1 audio system circuit diagram s4rs0a910e032 g33 5 gry l31 j09 18 14 l07 j01 18 14 l37 j21 g03 l33 3 13 2 5 15 14 4 5 4 5 11 2 1 1 2 2 1 1 2 2 1 2 1 3 13 4 14 5 15 6 16 11 ry "d-4" ry wht/red g12 1 j/c g17 wht/red j/b 15a radio 40 red/yel j/c g31 bcm "a-8" antenna amplifier w...

  • Page 1088

    9a-81 wiring systems: g-2 multi information display / accessory socket system circuit diagram s4rs0a910e033 11 blu/wht blu/wht 15a acc 2 27 j/c g17 l28 l44 y g multi information display j/b bcm j/b g34 7 14 red/yel 10 blk/orn 2 blk/orn 15a radio 40 g33 5 wht/red g14 1 3 j/c yel yel g16 4 5 7 g15 j/c...

  • Page 1089

    Wiring systems: 9a-82 list of connectors list of connectors s4rs0a910f001 refer to “c connector: ”. Refer to “e connector: ”. Refer to “g connector: ”. Refer to “j connector: ”. Refer to “k connector: ”. Refer to “l connector: ”. Refer to “o connector: ”. Refer to “r connector: ”. C connector s4rs0a...

  • Page 1090

    9a-83 wiring systems: e connector s4rs0a910f003 c36 (to e24) c37 c38 c39 c40 c41 e01 e02 e03 e04 e05 e06 e07 e08 e09 e10 e11 e12 e13 e14 e15 e17 e18 if eqpd if eqpd e19 e20 e21 e22 e23 e24 (to c36) e25 e26 2 1 8 3 9 7 6 5 13 12 11 18 19 4 10 14 20 17 16 15 mconf200011-01 1 2 3 4 5 6 20 21 16 17 18 1...

  • Page 1091

    Wiring systems: 9a-84 g connector s4rs0a910f004 e27 e28 e29 e30 e31 e32 e33 e34 e35 e36 e37 (to g35) e38 (to g36) e39 e40 e41 e42 e43 e44 (to l03) e45 (to l02) e46 e47 e48 (to e50) e49 e50 (to e48) e51 e52 e53 e54 e55 g01 g02 g03 (to l33) g04 (to l32) g05 2 1 mconf020201-01 1 2 3 4 5 mconf050015-01 ...

  • Page 1092

    9a-85 wiring systems: g06 g09 g10 g11 g12 g14 g15 g16 g17 g18 g19 g20 g21 g22 g23 g24 g25 g26 g27 g28 g29 g31 if eqpd g32 g33 g34 g35 (to e37) g36 (to e38) g37 1 2 3 4 mconf040097-01 1 2 mconf020112-01 2 1 mconf020207-01 1 2 3 4 mconf040098-01 1 2 5 6 7 8 9 11 12 13 14 15 16 17 18 19 10 20 3 4 mconf...

  • Page 1093

    Wiring systems: 9a-86 j connector s4rs0a910f005 j01 (to l06) j02 j03 j04 j05 j06 j07 j08 j09 (to l31) j10 j11 j12 j13 j14 j15 j16 (to l13) j17 j18 j19 j20 j21 (to l37) j22 j23 j24 j25 31 32 34 33 30 29 24 28 23 27 22 26 21 25 16 20 19 15 12 11 10 14 18 13 17 8 7 6 2 4 1 3 5 9 mconm340002-01 2 1 mcon...

  • Page 1094

    9a-87 wiring systems: k connector s4rs0a910f006 l connector s4rs0a910f007 k01 k02 l01 l02 (to e45) l03 (to e44) l04 l05 l06 l07 (to j01) l08 l09 l10 l11 if eqpd l12 l13 (to j16) l14 l15 (to r01) l16 l17 l18 l19 l20 l21 (to l22) l22 (to l21) l23 if eqpd a/t 3 4 5 6 1 2 mconf060065-01 1 2 3 mconf03010...

  • Page 1095

    Wiring systems: 9a-88 o connector s4rs0a910f008 r connector s4rs0a910f009 l24 l25 l26 l27 l28 (to l44) if eqpd l29 l30 l31 (to j09) if eqpd l32 (to g04) l33 (to g03) l34 l35 l36 if eqpd l37 (to j21) l38 l39 l40 l41 l42 (to o01) if eqpd l43 l44 (to l28) l46 l47 l48 o01 (to l42) o02 o03 o04 o05 o06 r0...

  • Page 1096: Lighting Systems

    9b-1 lighting systems: lighting systems component location lighting system location s4rs0a9203001 11 2 1 3 4 6 9 15 [a] 15 15 10 8 12 13 14 5 7 i4rs0a920001- 1. Headlight bulb 7. Headlight unit 13. Turn signal / hazard warning relay 2. Socket cover 8. Lighting switch 14. Rear combination light 3. Cl...

  • Page 1097

    Lighting systems: 9b-2 interior light system location s4rs0a9203002 diagnostic information and procedures headlight symptom diagnosis s4rs0a9204001 1 3 2 4 i4rs0a920002- 1. Dome light 3. Door switches (both sides) 2. Luggage compartment light 4. Rear end door switch (included in lock assembly) condi...

  • Page 1098

    9b-3 lighting systems: turn signal and hazard warning light symptom diagnosis s4rs0a9204003 clearance, tail and license plate light symptom diagnosis s4rs0a9204004 condition possible cause correction / reference item flash rate high or one side only flashes bulb blown on “flash rate high”-side repla...

  • Page 1099

    Lighting systems: 9b-4 back-up light symptom diagnosis s4rs0a9204005 stop (brake) lamp symptom diagnosis s4rs0a9204006 front fog light symptom diagnosis (if equipped) s4rs0a9204007 condition possible cause correction / reference item back-up lights do not light up bulb(s) blown replace bulb(s). Circ...

  • Page 1100

    9b-5 lighting systems: interior light symptom diagnosis s4rs0a9204009 note: • use suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of suzuki scan tool” under “scan too...

  • Page 1101

    Lighting systems: 9b-6 headlight bulb replacement s4rs0a9206002 warning: • to avoid danger of being burned, don’t touch when the bulb is hot. • don’t touch glass surface of bulb, to avoid deteriorate as the case may be unclear when bulb light on at dirty condition. 1) disconnect negative (–) cable a...

  • Page 1102

    9b-7 lighting systems: 3) align headlight aiming to specification by adjusting aiming gear if it is not set properly. Headlight switch (in lighting switch) removal and installation s4rs0a9206004 removal 1) disconnect negative cable at battery. 2) remove steering column hole cover (1). 3) remove stee...

  • Page 1103

    Lighting systems: 9b-8 headlight switch (in lighting switch) inspection s4rs0a9206005 check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Hazard warning switch removal and installation s4rs0a9206019 removal 1) disconnect negative (–) c...

  • Page 1104

    9b-9 lighting systems: stop (brake) lamp switch inspection s4rs0a9206011 check stop (brake) lamp switch for continuity between terminals at each switch position. If check result is not as specified, replace switch. Turn signal light switch (in lighting switch) removal and installation s4rs0a9206012 ...

  • Page 1105

    Lighting systems: 9b-10 3) check turn r circuit connect terminal “6” and battery negative (–) terminal by a jumper wire. Check right side bulbs (1) for flashing cycle. If check result is not as specified, replace turn signal and hazard warning relay. Reference flashing cycle 60 – 120 cycle/minute 4)...

  • Page 1106

    9b-11 lighting systems: front fog light bulb replacement s4rs0a9206017 warning: • to avoid danger of being burned, don’t touch when the bulb is hot. • don’t touch glass surface of bulb to avoid deteriorate as the case may be unclear when bulb light on at dirty condition. 1) remove fog light referrin...

  • Page 1107

    Lighting systems: 9b-12 front fog light aiming adjustment with screen s4rs0a9206023 basic aiming note: • unless otherwise obligated by local regulations, adjust front fog light aiming according to the following procedure. • an example in case that the light-to-wall distance 10 m is shown in the illu...

  • Page 1108

    9c-1 instrumentation / driver info. / horn: instrumentation / driver info. / horn general description can communication data of combination meter s4rs0a9301001 communication of ecm (3), tcm (if equipped) (4), bcm (2) and combination meter (1) is established by can (controller area network). Can comm...

  • Page 1109

    Instrumentation / driver info. / horn: 9c-2 schematic and routing diagram combination meter circuit diagram s4rs0a9302001 g28-32 g28-5 g28-14 g28-3 13 g28-8 g28-10 g28-1 g28-22 4 5 6 7 8 1 2 11 9 9 10 10 19 3 3 12 14 15 16 17 g28-16 3 l 2 d n r p 18 g28-31 g28-26 g28-25 i4rs0a930002- 1. Main fuse 6....

  • Page 1110

    9c-3 instrumentation / driver info. / horn: terminal arrangement of coupler viewed from combination meter side note: molded numbers (1) have no relation to the terminal numbers. Component location audio system component location s4rs0a9303001 terminal circuit terminal circuit g28-1 to turn signal li...

  • Page 1111

    Instrumentation / driver info. / horn: 9c-4 diagnostic information and procedures speedometer and vss symptom diagnosis s4rs0a9304001 note: make sure that any dtc is not detected by both ecm and tcm before starting the troubleshooting by using the following table. If any dtc is detected, troubleshoo...

  • Page 1112

    9c-5 instrumentation / driver info. / horn: low fuel warning light symptom diagnosis s4rs0a9304018 note: • make sure that any dtc is not detected by ecm an before starting the troubleshooting by using the following table. If any dtc is detected, troubleshoot the dtc advance. • confirm that fuel mete...

  • Page 1113

    Instrumentation / driver info. / horn: 9c-6 brake and parking brake warning light symptom diagnosis s4rs0a9304020 note: make sure that any dtc is not detected by bcm before starting the troubleshooting by using the following table. If any dtc is detected, troubleshoot the dtc advance. Seat belt remi...

  • Page 1114

    9c-7 instrumentation / driver info. / horn: charge warning light symptom diagnosis s4rs0a9304023 note: make sure that any dtc is not detected by bcm before starting the troubleshooting by using the following table. If any dtc is detected, troubleshoot the dtc advance. Main beam (high beam) indicator...

  • Page 1115

    Instrumentation / driver info. / horn: 9c-8 horn symptom diagnosis s4rs0a9304011 information display symptom diagnosis (if equipped) s4rs0a9304012 note: this thermometer indicates the ambient temperature in back of front bumper member. Under any one of the following listed conditions, however, even ...

  • Page 1116

    9c-9 instrumentation / driver info. / horn: audio system symptom diagnosis (if equipped) s4rs0a9304013 radio note: electronic part / system with undiagnosed problem may cause electromagnetic interference. Electromagnetic interference condition may have poor radio reception. To test for presence of e...

  • Page 1117

    Instrumentation / driver info. / horn: 9c-10 remote audio control switch (if equipped) symptom diagnosis s4rs0a9304014 repair instructions ignition switch removal and installation s4rs0a9306001 removal 1) disconnect negative cable at battery. 2) confirm that ignition key is removed. 3) remove steeri...

  • Page 1118

    9c-11 instrumentation / driver info. / horn: ignition switch inspection s4rs0a9306002 • check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Combination meter removal and installation s4rs0a9306003 removal 1) disconnect negative (–) cab...

  • Page 1119

    Instrumentation / driver info. / horn: 9c-12 oil pressure switch removal and installation s4rs0a9306006 for removal and installation, refer to “oil pressure check: in section 1e”. Oil pressure switch inspection s4rs0a9306007 1) disconnect oil pressure switch (1) lead wire. 2) check for continuity be...

  • Page 1120

    9c-13 instrumentation / driver info. / horn: parking brake switch inspection s4rs0a9306012 check for continuity between parking brake switch terminal and body ground as shown in figure. If found defective, replace switch. Parking brake switch specification off position (parking brake released): no c...

  • Page 1121

    Instrumentation / driver info. / horn: 9c-14 outside air temperature sensor inspection s4rs0a9306017 measure resistance of outside air temperature sensor using an ohmmeter. If resistance is out of specification, replace outside air temperature sensor. Outside air temperature sensor resistance 1.62 k...

  • Page 1122

    9c-15 instrumentation / driver info. / horn: 11) remove instrument panel mounting screws (1). 12) detach instrument panel from steering support member (2) and then remove foot duct (3). 13) disconnect instrument panel harness connectors, heater control cables and antenna cable instrument panel remov...

  • Page 1123

    Instrumentation / driver info. / horn: 9c-16 radio assembly removal and installation s4rs0a9306020 removal 1) disconnect negative (–) cable at battery. 2) remove globe box referring to “instrument panel removal and installation: ”. 3) remove 2 mounting bolts (1). 4) disconnect electrical connectors ...

  • Page 1124

    9c-17 instrumentation / driver info. / horn: horn inspection s4rs0a9306029 1) disconnect negative (–) cable at battery. 2) remove front bumper referring to “front bumper and rear bumper components: in section 9k”. 3) disconnect horn connector (1). 4) connect battery positive (+) to terminal of horn ...

  • Page 1125

    Instrumentation / driver info. / horn: 9c-18 4) check switch for resistance between “b” and “c” terminals under each condition below. If check result is not satisfactory, replace remote audio control switch. “mode”, and switch resistance all switches released (off): 4700 – 5600 k “mode” switch (4) p...

  • Page 1126: Wipers / Washers

    9d-1 wipers / washers: wipers / washers diagnostic information and procedures front wiper and washer symptom diagnosis s4rs0a9404001 rear wiper and washer (if equipped) symptom diagnosis s4rs0a9404002 condition possible cause correction / reference item wiper malfunctions circuit fuse blown replace ...

  • Page 1127

    Wipers / washers: 9d-2 repair instructions wipers and washers components s4rs0a9406001 11 5 6 (b) (b) (c) 12 13 14 14 14 [a] (d) 7 9 10 10 10 11 11 8 (a) (a) (b) (b) 3 1 2 1 4 (b) 2 i4rs0a940001-.

  • Page 1128

    9d-3 wipers / washers: washer tank and washer pump removal and installation s4rs0a9406002 removal 1) disconnect negative (–) cable at battery. 2) remove front bumper referring to “front bumper and rear bumper components: in section 9k”. 3) remove grommet (1) and upper part (2) of washer tank. 4) rem...

  • Page 1129

    Wipers / washers: 9d-4 windshield wiper removal and installation s4rs0a9406012 removal 1) disconnect negative (–) cable at battery. 2) remove wiper pivot caps (1) and wiper arm nuts (2), and remove windshield wiper arms with wiper blades (3). 3) remove cowl top garnish referring to “cowl top compone...

  • Page 1130

    9d-5 wipers / washers: • for motor operation in high speed a. Connect battery positive (+) terminal to “2” and its negative (–) terminal to terminal “5”. B. Check if motor revolution speed is as specification. If check result is not as specified, replace motor. Specification 60 – 76 r/min (rpm) • fo...

  • Page 1131

    Wipers / washers: 9d-6 installation 1) install rear wiper motor (1) and tighten rear wiper motor mounting bolts to specified torque. Tightening torque rear wiper motor mounting bolt (a): 8 n·m (0.8 kg-m, 6.0 lb-ft) 2) connect coupler to rear wiper motor 3) install rear end door trim referring to “re...

  • Page 1132

    9d-7 wipers / washers: • for automatic stop operation a. Connect battery positive (+) terminal to terminal “1” and its negative (–) terminal to terminal “2” and let the motor turn. B. Disconnect terminal “2” from battery negative (–) terminal and let the motor stop. C. Observe the motor (4) turns on...

  • Page 1133

    Wipers / washers: 9d-8 intermittent wiper relay circuit 1) turn the windshield wiper switch to “int” position. 2) connect battery positive (+) terminal to terminal “5” and its negative (–) terminal to terminal “2”. 3) connect voltmeter positive lead to terminal “4” and its negative lead to terminal ...

  • Page 1134

    9d-9 wipers / washers: rear wiper and washer switch inspection s4rs0a9406009 check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Rear wiper relay removal and installation s4rs0a9406015 removal 1) disconnect negative (–) cable at batter...

  • Page 1135

    Glass / windows / mirrors: 9e-1 glass / windows / mirrors general description rear end door window defogger system description s4rs0a9501002 the rear end door window defogger is controlled by bcm. For the bcm description refer to “bcm general description: in section 10b”. Windshield construction s4r...

  • Page 1136

    9e-2 glass / windows / mirrors: • windshield knife • brush for primer application (2 pcs) • knife • rubber sucker grip • sealant gun (for filling adhesive) • putty spatula (for correcting adhered parts) diagnostic information and procedures rear end door window defogger symptom diagnosis s4rs0a95040...

  • Page 1137

    Glass / windows / mirrors: 9e-3 power door mirror control system (if equipped) symptom diagnosis s4rs0a9504003 repair instructions windshield removal and installation s4rs0a9506001 removal 1) clean both inside and outside of glass and around it. 2) remove wiper arms and cowl top garnish. 3) remove w...

  • Page 1138

    9e-4 glass / windows / mirrors: note: before using knife (1), clean it with alcohol or the like to remove oil from it. 12) when reusing windshield, remove the adhesive (1) from it, using care not to damage primer coated surface (2). Installation 1) using cleaning solvent, clean windshield edge where...

  • Page 1139

    Glass / windows / mirrors: 9e-5 8) using new brush, apply sufficient amount of primer onto glass along glass edge. Note: • be sure to refer to maker’s instruction for proper handling and drying time. • do not apply primer on outside of ceramic coated surface. • do not touch primer coated surface. Wi...

  • Page 1140

    9e-6 glass / windows / mirrors: note: • do not use high pressure water. • do not blow compressed air directly at adhesive applied part when drying. • do not use infrared lamp or like for drying. Caution: upon completion of installation, note the following. • sudden closing of door before adhesive is...

  • Page 1141

    Glass / windows / mirrors: 9e-7 front door glass removal and installation s4rs0a9506004 removal 1) remove door mirror trim (1). 2) remove door trim mounting screws (2). 3) remove door trim (1) as shown. And disconnect power window switch lead wire at coupler. 4) remove door trim bracket (1). 5) remo...

  • Page 1142

    9e-8 glass / windows / mirrors: front door window regulator removal and installation s4rs0a9506005 removal 1) remove door glass referring to “front door glass removal and installation: ”. 2) disconnect power window motor lead wire at coupler. 3) remove regulator mounting screws (1), and then remove ...

  • Page 1143

    Glass / windows / mirrors: 9e-9 rear door window components s4rs0a9506007 rear door glass removal and installation s4rs0a9506008 removal 1) remove rear door inner garnish (1). 2) remove door trim mounting screws (2). 3) remove door trim (1) as shown. And disconnect power window switch lead wire at c...

  • Page 1144

    9e-10 glass / windows / mirrors: 6) detach rear part of glass run from door sash (1), and remove door sash (1). 7) remove door glass (2) as shown. Installation reverse removal procedure noting the following instructions. • if there is deformity for glass run, replace it with a new one. • tighten doo...

  • Page 1145

    Glass / windows / mirrors: 9e-11 installation reverse removal procedure noting the following. • apply grease to sliding and rotating portions of window regulator. : grease 99000–25010 • tighten rear door window regulator attaching screws. Rear door window regulator screw tightening order (a) (b) rea...

  • Page 1146

    9e-12 glass / windows / mirrors: rear end door window defogger switch inspection s4rs0a9506016 1) check rear end door window defogger switch for operation as follows. A) rear end door window defogger switch is built in hvac control unit. Remove hvac control unit referring to “hvac control unit remov...

  • Page 1147

    Glass / windows / mirrors: 9e-13 rear end door window defogger wire inspection s4rs0a9506017 note: • when cleaning rear end door window glass, use a dry cloth to wipe it along heat wire (1) direction. • when cleaning glass, do not use detergent or abrasive-containing glass cleaner. • when measuring ...

  • Page 1148

    9e-14 glass / windows / mirrors: power window main switch inspection s4rs0a9506019 switch for driver side window 1) remove driver side door trim referring to step 1) to 3) of “front door glass removal and installation: ”. 2) remove power window main switch from door trim. 3) connect 12 v battery pos...

  • Page 1149

    Glass / windows / mirrors: 9e-15 power window sub switch inspection s4rs0a9506020 1) remove door trim from door panel. For front door trim, refer to step 1) to 3) of “front door glass removal and installation: ” for rear door trim, refer to step 1) to 3) of “rear door glass removal and installation:...

  • Page 1150

    9e-16 glass / windows / mirrors: door mirror removal and installation s4rs0a9506022 when removing or installing door mirror, refer to the figure in “door mirror components: ”. Power door mirror switch inspection s4rs0a9506023 1) remove driver side door trim referring to step 1) to 3) of “front door ...

  • Page 1151: Security And Locks

    Security and locks: 9f-1 security and locks general description key coding construction s4rs0a9601001 key usage and identification key is used for ignition and door lock cylinder. Keys are cut on both edges to make them reversible. Key identification is obtained from five character key code stamped ...

  • Page 1152

    9f-2 security and locks: component location power door lock and keyless entry system component location s4rs0a9603001 i4rs0a960001- 1. Keyless entry receiver 3. Power door lock switch 5. Rear door actuator 7. Door switch 2. Transmitter 4. Front door actuator 6. Rear end door actuator 8. Bcm (include...

  • Page 1153

    Security and locks: 9f-3 diagnostic information and procedures power door lock system symptom diagnosis s4rs0a9604001 note: • use suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output te...

  • Page 1154

    9f-4 security and locks: keyless entry system symptom diagnosis s4rs0a9604004 note: • confirm that power door lock system is in good condition before referring to the following possible causes. • check each part in the order from the top of the following list. Keyless entry system operation inspecti...

  • Page 1155

    Security and locks: 9f-5 rear end door opener system symptom diagnosis s4rs0a9604007 note: • use suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of suzuki scan tool” ...

  • Page 1156

    9f-6 security and locks: front door lock assembly removal and installation s4rs0a9606018 removal 1) remove door mirror trim (1). 2) remove door trim (3) after removing screws (2) and clips “a” and “b”. 3) disconnect power window switch and mirror switch lead wire at coupler. 4) remove door trim brac...

  • Page 1157

    Security and locks: 9f-7 • move door latch striker (2) up or down so its center aligns with the center of groove “a” on the door lock assembly (1) as shown. Striker should be moved vertically and placed level. Do not adjust door lock. Tightening torque door latch striker screw (a): 10 n·m (1.0 kg-m,...

  • Page 1158

    9f-8 security and locks: door key cylinder switch inspection s4rs0a9606004 1) remove front door trim referring to step 1) to 3) of “front door glass removal and installation: in section 9e” 2) check for continuity between terminals at each switch position. If check result is not as specified, replac...

  • Page 1159

    Security and locks: 9f-9 rear door lock assembly components s4rs0a9606007 rear door lock assembly removal and installation s4rs0a9606008 removal 1) remove rear door glass referring to “rear door glass removal and installation: in section 9e”. 2) disconnect door lock motor lead wire. 3) remove door l...

  • Page 1160

    9f-10 security and locks: rear end door lock assembly components s4rs0a9606010 rear end door lock assembly removal and installation s4rs0a9606011 removal 1) remove door trim (1) from rear end door panel (2). 2) disconnect door lock motor lead wire. 3) loosen door latch bolts (1) and remove door latc...

  • Page 1161

    Security and locks: 9f-11 installation reverse removal procedure to install rear end door lock assembly noting the following instruction. • tighten rear end door latch bolt to specified torque. Tightening torque rear end door latch bolt (a): 10 n·m (1.0 kg-m, 7.5 lb-ft) • adjust door latch striker s...

  • Page 1162

    9f-12 security and locks: note: • to prevent theft, be sure to break the transmitter before discarding it. • dispose of the used battery properly according to applicable rules or regulations. Do not dispose of lithium batteries with ordinary household trash. Programming transmitter code s4rs0a960601...

  • Page 1163

    Security and locks: 9f-13 keyless entry receiver and its circuit inspection s4rs0a9606022 1) check that the voltage between the following terminals and body ground are specifications under each conditions. If check result is not as specified, check applicable circuit for open or short. If circuit is...

  • Page 1164

    9f-14 security and locks: specifications tightening torque specifications s4rs0a9607001 note: the specified tightening torque is also described in the following. “front door lock assembly components: ” “rear door lock assembly components: ” “rear end door lock assembly components: ” reference: for t...

  • Page 1165: Seats

    Seats: 9g-1 seats repair instructions front seat components s4rs0a9706001 front seat removal and installation s4rs0a9706002 removal 1) disable air bag system referring to“disabling air bag system: in section 8b” 2) disconnect seat harness coupler and side air bag coupler, if equipped. 3) remove 4 mo...

  • Page 1166

    9g-2 seats: rear seat components s4rs0a9706003 rear seat removal and installation s4rs0a9706004 removal 1) fold rear seat back forward. 2) remove seat mounting bolts and nuts to remove seat assembly. 3) disassemble and repair seat as necessary. Installation reverse removal procedure to install rear ...

  • Page 1167: Interior Trim

    Interior trim: 9h-1 interior trim repair instructions floor carpet removal and installation s4rs0a9806001 removal 1) remove front seats and rear seats. 2) remove seat belt lower anchor bolt. 3) remove dash side trims, front side sill scuffs, center pillar inner lower trims, rear side lower trims and...

  • Page 1168

    9h-2 interior trim: 7) remove rear inner trim (1), rear side lower trim (2) and rear pillar trim (3). 8) remove assistant grip (1). 9) remove head lining clips (2) and remove head lining (3). Installation reverse removal procedure noting the following. • apply adhesive (1) to head lining (2) as show...

  • Page 1169

    Interior trim: 9h-3 roof molding components s4rs0a9806004 splash guard (if equipped) components s4rs0a9806005 4 2 3 2 1 i4rs0a980009- 1. Roof molding 3. Roof molding clip (push-in type) 2. Roof side weather-strip 4. Windshield side garnish “a” “a” “a” “a” 1 i4rs0a980010- 1. Side sill splash guard.

  • Page 1170

    9h-4 interior trim: specifications tightening torque specifications s4rs0a9807001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information: in section 0a”. Fastening part tightening torque note n m kg-m lb-ft sun visor screw 4 0.4 3.0

  • Page 1171: Hood / Fenders / Doors

    Hood / fenders / doors: 9j-1 hood / fenders / doors repair instructions hood removal and installation s4rs0a9a06001 removal caution: place cloth to prevent body from any damage. 1) remove hood silencer (4). 2) disconnect window washer hose (1) from hood. 3) remove 4 mounting bolts (3) to detach hood...

  • Page 1172

    9j-2 hood / fenders / doors: front fender components s4rs0a9a06003 front fender removal and installation s4rs0a9a06004 removal 1) remove splash guard (if equipped) referring to “splash guard (if equipped) components: in section 9h”. 2) remove front fender lining. 3) remove front bumper referring to ...

  • Page 1173

    Hood / fenders / doors: 9j-3 front door assembly components s4rs0a9a06005 front door assembly removal and installation s4rs0a9a06006 removal 1) remove front fender referring to “front fender components: ”. 2) disconnect door harness lead wires at each coupler. 3) remove door open stopper (1). 4) sup...

  • Page 1174

    9j-4 hood / fenders / doors: • when replacing door, coat replacement door inside with wax for proper anti-corrosion treatment. Refer to “sealant application areas: in section 9l”. • apply sealant to contact face “a” of hinge (1) and apply grease to rotating part “b” of hinge (1). Specified sealant a...

  • Page 1175

    Hood / fenders / doors: 9j-5 rear door assembly removal and installation s4rs0a9a06008 refer to “front door assembly removal and installation: ” as removal and installation procedures are basically the same. However, note the following. • tighten rear door hinge bolts and nuts to specified torque re...

  • Page 1176

    9j-6 hood / fenders / doors: warning: handling of rear end door balancer (damper) • handle balancer carefully. Do not scar or scratch exposed surface of its piston rod, and never allow any paint or oil to stick to its surface. • do not turn piston rod with balancer fully extended. • do not disassemb...

  • Page 1177

    Hood / fenders / doors: 9j-7 specifications tightening torque specifications s4rs0a9a07001 note: the specified tightening torque is also described in the following. “front door assembly components: ” “rear door assembly components: ” “rear end door assembly components: ” reference: for the tightenin...

  • Page 1178: Body Structure

    9k-1 body structure: body structure repair instructions front bumper and rear bumper components s4rs0a9b06001 1 2 11 3 4 5 6 7 8 9 10 12 14 13 15 i4rs0a9b0001- 1. Front bumper 5. Front fog lamp cap 9. Front bumper lower member 13. Rear bumper holder 2. Radiator upper grill 6. Front bumper upper abso...

  • Page 1179

    Body structure: 9k-2 cowl top components s4rs0a9b06003 3. Radiator lower grill 7. Front bumper lower absorber 11. License plate nut 15. Plastic nut 4. Front air dam skirt 8. Front bumper upper member 12. Rear bumper 1. Cowl top cover 3. Cowl top side garnish 5. Hood rear seal 2. Cowl the cover lid 4...

  • Page 1180

    9k-3 body structure: specifications body dimensions s4rs0a9b07001 engine room hole to hole distance g’ b c k g i a b’ c’ d d’ e e’ f’ f h h’ i’ j k’ j’ i4rs0a9b0003- a. Cowl top installation center hole e (e’). Headlight installation hole i (i’). Front bumper upper member installation hole b (b’). F...

  • Page 1181

    Body structure: 9k-4 rear end door hole to hole distance i4rs0a9b0004- a (a’). Roof back member bolt installation hole c (c’). Back panel bolt installation hole b (b’). Jig hole d. Rear end door striker installation left side hole a-a’: 759 mm (29.88 in.) a’-b: 1037 mm (40.83 in.) b-c’: 985 mm (38.7...

  • Page 1182

    9k-5 body structure: side body hole to hole distance hole to hole distance i4rs0a9b0005- a (a’). Jig hole ( 8 mm) e (e’). Rear door lower hinge installation rear hole i (i’). Jig hole ( 10 mm) b (b’). Front door upper hinge installation upper hole f (f’). Rear door upper hinge installation upper hol...

  • Page 1183

    Body structure: 9k-6 hole to hole distance i4rs0a9b0006- a (a’). Jig hole ( 6.5 mm) b (b’). Panel cross point c. Parking brake cable bracket installation front hole a-b: 638 mm (25.12 in.) a-b’: 1194 mm (47.01 in.) a-c: 1293 mm (50.91 in.) b-c: 1422 mm (55.98 in.) a-a’: 800 mm (31.50 in.) b-b’: 1272...

  • Page 1184

    9k-7 body structure: under body hole to hole distance hole to hole distance a b c d e f g h i j a' b' c' d' e' f' g' i' j' a b c d e f g h i j a' b' c' d' e' f' g' h' i' j' h' i4rs0a9b0007- a (a’). Jig hole ( 20 mm) e (e’). Jig hole ( 15 mm) i (i’). Drain hole ( 10 mm) b (b’). Front suspension frame...

  • Page 1185

    Body structure: 9k-8 hole to hole distance projection dimension from standard line “a” front suspension frame hole to hole distance i g f e d c a b "a" j h i4rs0a9b0008- a. Jig hole ( 20 mm) e. Jig hole ( 15 mm) i. Drain hole ( 10 mm) b. Front suspension frame installation hole f. Jig hole ( 15 mm) ...

  • Page 1186

    9k-9 body structure: hole to hole distance projection dimension from standard line “a” i4rs0a9b0010- a. Stud d. Front suspension frame installation hole b. Front suspension frame installation hole e. Front suspension control arm installation hole c. Front suspension control arm installation hole a-b...

  • Page 1187

    Body structure: 9k-10 panel clearance s4rs0a9b07002 panel to panel distance i4rs0a9b0011- a: 0-1 mm (0-0.039 in.) h: 3.1-5.1 mm (0.122-0.201 in.) o: 8.1 mm (0.319 in.) b: 2.3-4.3 mm (0.091-0.169 in.) i: 4.7-6.7 mm (0.185-0.263 in.) p: 6.1-8.1 mm (0.240-0.319 in.) c: 3.1-5.1 mm (0.122-0.201 in.) j: 1...

  • Page 1188: Paint / Coatings

    9l-1 paint / coatings: paint / coatings general description anti-corrosion treatment construction s4rs0a9c01001 warning: standard shop practices, particularly eye protection, should be followed during the performance of the following operations to avoid personal injury. As rust proof treatment, stee...

  • Page 1189

    Paint / coatings: 9l-2 5) polypropylene must raise no readily distinguishable smoke while burning. Component location sealant application areas s4rs0a9c03001 i4rs0a9c0001- “a”: apply sealant. “c”: smooth out sealant with a brush. “b”: wipe off excess sealant after application. “d”: do not apply seal...

  • Page 1190

    9l-3 paint / coatings: i4rs0a9c0002- “a”: apply sealant. “c”: smooth out sealant with a brush. “b”: fill gap / hole with sealant. “d”: do not apply sealant..

  • Page 1191

    Paint / coatings: 9l-4 i4rs0a9c0003- “a”: apply sealant. “c”: smooth out sealant with a brush. “e”: apply sealant covering flange end (between “c” and “d”). “b”: wipe off excess sealant after application. “d”: do not apply sealant..

  • Page 1192

    9l-5 paint / coatings: i4rs0a9c0004- “a”: apply sealant.

  • Page 1193

    Paint / coatings: 9l-6 i4rs0a9c0005- “a”: apply sealant. “c”: apply sealant covering flange end. “b”: wipe off excess sealant after application. “d”: do not apply sealant..

  • Page 1194

    9l-7 paint / coatings: under coating application areas s4rs0a9c03002 i4rs0a9c0006- “a”: apply undercoating (pvc, 400 m or more). “c”: do not apply undercoating. “b”: apply anti-chip coat (300 m or more). “d”: apply undercoating (pvc, 400 m or more) covering flange end..

  • Page 1195

    Paint / coatings: 9l-8 i4rs0a9c0007- “a”: apply undercoating (pvc, 400 m or more). “c”: do not apply undercoating. “b”: apply undercoating (pvc, 600 m or more)..

  • Page 1196

    9l-9 paint / coatings: anti-corrosion compound application area s4rs0a9c03003 i4rs0a9c0008- “a”: apply rust proof wax (hot wax 50 m or more). “b”: apply rust proof wax (high viscosity wax 50 m or more). “c”: never fill up drain holes with rust proof wax..

  • Page 1197: Exterior Trim

    Exterior trim: 9m-1 exterior trim repair instructions roof molding components s4rs0a9d06005 4 2 3 2 1 i4rs0a980009- 1. Roof molding 3. Roof molding clip (push-in type) 2. Roof side weather-strip 4. Windshield side gamish.

  • Page 1198

    9m-2 exterior trim: splash guard (if equipped) components s4rs0a9d06006 “a” “a” “a” “a” 1 i4rs0a980010- 1. Side sill splash guard.

  • Page 1199: Section 10

    Table of contents 10- i 10 section 10 contents control systems precautions ...............................................10-1 precautions........................................................... 10-1 precautions for control systems......................... 10-1 body electrical control system .......

  • Page 1200: Precautions

    10-1 precautions: precautions precautions precautions for control systems s4rs0aa000001 air bag warning refer to “air bag warning: in section 00”..

  • Page 1201

    Body electrical control system: 10b-1 body electrical control system precautions precautions in diagnosing trouble s4rs0aa200001 • diagnostic information stored in bcm memory can be cleared as well as checked by using suzuki scan tool. Before using scan tool, read its operator’s (instruction) manual...

  • Page 1202

    10b-2 body electrical control system: can communication system description s4rs0aa201002 can communication system uses the serial communication in which data is transmitted at a high speed. It uses a twisted pair of two communication lines for the high-speed data transmission. As one of its characte...

  • Page 1203

    Body electrical control system: 10b-3 alarm indicator lamp the information display (1) of this vehicle includes an alarm indicator lamp (2) for the theft preventive purpose. The bcm makes the alarm indicator lamp flash at certain intervals after the ignition switch is turned off until it is turned o...

  • Page 1204

    10b-4 body electrical control system: l01-7 l01-15 gry/red l01-3 blk/yel blk/red 12v 12v g37-16 +bb blu/yel e46-11 gry 12v e46-4 wht/blu 12v +bb red/yel g34-7 g37-8 gry e46-10 e46-8 yel/red yel/blk 5v g37-11 yel ig1 g37-21 ig1 ig1 wash off int on wash, on wr ew on int blu/blk blu/blk e39-9 g37-22 gr...

  • Page 1205

    Body electrical control system: 10b-5 1. Bcm (included in junction block assembly) 19. Door key cylinder switch (included in door lock actuator) 37. Turn signal and hazard warning relay 2. Rear washer motor 20. Manual door lock switch 38. Hazard warning switch 3. Rear wiper motor 21. Rear end door w...

  • Page 1206

    10b-6 body electrical control system: connector layout diagram of bcm and junction block assembly s4rs0aa202002 bcm and junction block assembly connectors (viewed from harness side) i4rs0aa20004- [a]: junction block assembly (viewed from bcm side) 4. Horn relay [b]: junction block assembly (viewed f...

  • Page 1207

    Body electrical control system: 10b-7 component location bcm and related system component location s4rs0aa203001 3 4 5 7 6 11 13 12 15 17 18 16 29 19 14 20 21 24 25 26 27 28 22 23 22 1 2 8 9 10 i4rs0aa20005- 1. Generator 11. Keyless entry receiver 21. “3” position switch 2. Brake fluid level switch ...

  • Page 1208

    10b-8 body electrical control system: diagnostic information and procedures bcm self-diagnosis function s4rs0aa204001 • bcm monitors conditions of the system components and its circuit with ignition switch turned to on position. When an abnormality in the system occurs, the area where that abnormali...

  • Page 1209

    Body electrical control system: 10b-9 body electrical control system check s4rs0aa204002 combination meter • tail light switch • oil pressure switch • parking brake switch • driver side seat belt switch • brake fluid level switch • generator • ecm (engine speed signal, vehicle speed signal, engine c...

  • Page 1210

    10b-10 body electrical control system: customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the figure will facilitate collecting information to the point requir...

  • Page 1211

    Body electrical control system: 10b-11 final confirmation test confirm that the problem symptom has gone and the body electrical control system is free from any abnormal conditions. If what has been repaired is related to the malfunction dtc, check dtc again and confirm that no dtc is indicated. Sca...

  • Page 1212

    10b-12 body electrical control system: scan tool data definitions vehicle speed (km/h, mph): it is computed based on pulse signals from vehicle speed sensor on transmission. Outside air temp ( c, f): it is detected by outside air temperature sensor. Battery voltage (v): this parameter indicates batt...

  • Page 1213

    Body electrical control system: 10b-13 dtc table s4rs0aa204004 dtc check s4rs0aa204005 using suzuki scan tool 1) prepare suzuki scan tool. 2) with ignition switch turned off, connect it to data link connector (dlc) located on underside of instrument panel of driver’s side. Special tool (a): suzuki s...

  • Page 1214

    10b-14 body electrical control system: 4) read dtc according to instructions displayed on suzuki scan tool and print it or write it down. Refer to suzuki scan tool operator’s manual for further details. If communication between suzuki scan tool and bcm is not possible, check if suzuki scan tool is c...

  • Page 1215

    Body electrical control system: 10b-15 dtc clearance s4rs0aa204006 after repair or replace of malfunction part(s), clear all dtcs by performing the following procedure. Using suzuki scan tool 1) connect suzuki scan tool to data link connector in the same manner as when making this connection for dtc...

  • Page 1216

    10b-16 body electrical control system: troubleshooting step action yes no 1 fuse check 1) turn ignition switch to off position. 2) check circuit fuses for condition. Are circuit fuses in good condition? Go to step 2. Replace fuse and check for short circuit to ground. 2 power supply circuit check 1)...

  • Page 1217

    Body electrical control system: 10b-17 dtc b1133 (dtc no.1133): battery voltage too high s4rs0aa204021 wiring diagram dtc detecting condition and possible cause flow test description step 1: check charging system dtc troubleshooting i4rs0aa20008- [a]: junction block assembly connector viewed from ha...

  • Page 1218

    10b-18 body electrical control system: dtc b1141 / dtc b1142 / dtc b1143 (no.1141 / no. 1142/ no. 1143) outside air temperature (ambient temp.) sensor circuit malfunction s4rs0aa204022 wiring diagram dtc detecting condition and possible cause flow test description step 1: check whether malfunction i...

  • Page 1219

    Body electrical control system: 10b-19 dtc troubleshooting step action yes no 1 check outside air temperature sensor 1) turn ignition switch to off position. 2) disconnect connector from outside air temperature sensor. 3) check outside air temperature sensor for resistance referring to “outside air ...

  • Page 1220

    10b-20 body electrical control system: dtc b1150 (no. 1150): air bag communication circuit malfunction s4rs0aa204014 wiring diagram dtc detecting condition and possible cause flow test description step 1: check air bag communication circuit. Step 2: check air bag communication circuit. Step 3: check...

  • Page 1221

    Body electrical control system: 10b-21 dtc troubleshooting step action yes no 1 check air bag communication circuit 1) turn ignition switch to off position. 2) disconnect connector from sdm referring to “sdm removal and installation: in section 8b”. 3) disconnect connector from junction block assemb...

  • Page 1222

    10b-22 body electrical control system: dtc b1157 (no.1157) air bag deployment signal input s4rs0aa204023 wiring diagram dtc detecting condition and possible cause flow test description step 1: check dtc for sdm. Dtc troubleshooting dtc b1170 (no. 1170): eeprom access error s4rs0aa204012 dtc detectin...

  • Page 1223

    Body electrical control system: 10b-23 dtc u1001 (no. 1001): high speed can communication (transmission error) s4rs0aa204024 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and ...

  • Page 1224

    10b-24 body electrical control system: troubleshooting step action yes no 1 check dtc in bcm is dtc u1001 (no. 1001) and dtc u1073 (no. 1073) detected together? Go to “dtc u1073 (no. 1073): control module communication bus off: ”. Go to step 2. 2 check each control module connectors 1) check connect...

  • Page 1225

    Body electrical control system: 10b-25 dtc u1073 (no. 1073): control module communication bus off s4rs0aa204025 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by ...

  • Page 1226

    10b-26 body electrical control system: troubleshooting step action yes no 1 check each control unit connectors 1) check connection of connectors of all control modules (bcm, ecm, tcm (if equipped) and combination meter) communicating by means of can. 2) recheck dtc. Is dtc u1073 detected? Go to step...

  • Page 1227

    Body electrical control system: 10b-27 dtc u1100 (no.1100): lost communication with ecm s4rs0aa204026 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan...

  • Page 1228

    10b-28 body electrical control system: troubleshooting step action yes no 1 check dtc in bcm is dtc u1100 (no. 1100) and dtc u1073 (no. 1073) detected together? Go to “dtc u1073 (no. 1073): control module communication bus off: ”. Go to step 2. 2 check dtc in ecm 1) check ecm for dtc. Is dtc p1678 d...

  • Page 1229

    Body electrical control system: 10b-29 dtc u1101 (no.1101): lost communication with tcm s4rs0aa204027 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc by using scan...

  • Page 1230

    10b-30 body electrical control system: troubleshooting inspection of bcm and its circuits s4rs0aa204013 bcm and its circuits can be checked at bcm wiring couplers by measuring voltage and resistance. Caution: bcm cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter...

  • Page 1231

    Body electrical control system: 10b-31 note: • as each terminal voltage is affected by the battery voltage, confirm that it is 11 v or more when ignition switch is on. • voltage with asterisk (*) can not be measured by voltmeter because it is pulse signal. Check it with oscilloscope if necessary. Bc...

  • Page 1232

    10b-32 body electrical control system: bcm connector “e46” l01-11 blu/yel rear end door actuator motor 0 v rear end door actuator motor is not in operation 10 – 14 v rear end door actuator motor is in operation l01-12 gry/wht manual door lock switch (lock) 4 – 6 v manual door lock switch is at any p...

  • Page 1233

    Body electrical control system: 10b-33 bcm connector “g37” e46-11 gry oil pressure switch *3 – 14 v (“reference waveform no. 5: ”) engine is running and oil pressure is in normal condition 0 v ignition switch is at on position and engine is at stop e46-12 — — — — e46-13 — — — — e46-14 — — — — termin...

  • Page 1234

    10b-34 body electrical control system: junction block connector “e40” junction block connector “e41” junction block connector “g32” junction block connector “g33” junction block connector “g34” g37-18 gry/wht a/c switch *3 – 14 v (“reference waveform no. 10: ”) ignition switch is at on position and ...

  • Page 1235

    Body electrical control system: 10b-35 junction block connector “k01” junction block connector “l04” junction block connector “l05” junction block connector “l06” g34-11 wht hazard switch 10 – 14 v hazard switch is at on position or lock or unlock button of key less entry transmitter (answer back co...

  • Page 1236

    10b-36 body electrical control system: reference waveform no. 1 parking brake or brake fluid level switch signal (1) reference waveform no. 2 “3” position switch signal (1) for tcm reference waveform no. 3 driver seat belt switch signal (1) reference waveform no. 4 bcm – ecm can communication signal...

  • Page 1237

    Body electrical control system: 10b-37 reference waveform no. 5 oil pressure switch signal (1) reference waveform no. 6 bcm – dlc can communication signal reference waveform no. 7 bcm – combination meter can communication signal reference waveform no. 8 information display serial communication signa...

  • Page 1238

    10b-38 body electrical control system: reference waveform no. 9 keyless entry receiver signal (1) reference waveform no. 10 a/c switch signal (1) reference waveform no. 11 rear wiper int signal (1) reference waveform no. 12 rear wiper low signal (1) measurement terminal ch2: “g37-14” to “g33-3” osci...

  • Page 1239

    Body electrical control system: 10b-39 reference waveform no. 13 sdm communication signal (1) repair instructions bcm (included in junction block assembly) removal and installation s4rs0aa206001 caution: do not attempt removal of bcm from junction block assembly as it may cause contact failure. If t...

  • Page 1240

    10b-40 body electrical control system: special tools and equipment special tool s4rs0aa208001 suzuki scan tool — this kit includes following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loopback adapter, 7. Battery power cable, 8. Rs232 cable, 9. R...

  • Page 1241: Immobilizer Control System

    Immobilizer control system: 10c-1 immobilizer control system precautions precautions in diagnosing troubles s4rs0aa300001 • before confirming the diagnostic trouble code (dtc), do not disconnect connector from ecm, battery cable from battery, ground wire harness, or main fuse. Such disconnection wil...

  • Page 1242

    10c-2 immobilizer control system: general description immobilizer control system introduction s4rs0aa301001 the immobilizer control system is an anti-theft device that immobilizes the vehicle. It stops the engine from working and prevents the vehicle from being stolen. It mainly consists of the foll...

  • Page 1243

    Immobilizer control system: 10c-3 on-board diagnostic system description (self- diagnosis function) s4rs0aa301002 ecm diagnoses if there is any trouble with the immobilizer control system. The diagnostic information is stored as the diagnostic trouble code (dtc) in ecm. To read the diagnostic inform...

  • Page 1244

    10c-4 immobilizer control system: blk/wht blk/orn pll/wht grn wht blk wht/red e23-13 e23-28 g24-3 g24-4 e23-5 e46-9 e46-2 e46-1 g37-4 e23-3 e23-18 g37-2 pll/wht wht wht red red yel/red yel/blk 12v 12v g24-1 g24-2 wht/blu blk/orn 1 2 2 2 3 2 2 5 6 7 8 14 9 4 g28-10 g28-8 12v g37-5 10 g28-32 g28-31 11...

  • Page 1245

    Immobilizer control system: 10c-5 diagnostic information and procedures immobilizer control system check s4rs0aa304001 diagnostic trouble code (dtc) check s4rs0aa304002 note: to know how to use suzuki scan tool in detail, refer to its operator’s manual. 1) turn the ignition switch to off position. 2...

  • Page 1246

    10c-6 immobilizer control system: diagnostic trouble code (dtc) table s4rs0aa304003 ecm note: if any dtc other than the above dtcs is detected, refer to “dtc table: in section 1a”. Scan tool data s4rs0aa304016 the data listed below is the standard data obtained from the normal vehicle by using suzuk...

  • Page 1247

    Immobilizer control system: 10c-7 dtc p1614 transponder response error s4rs0aa304028 possible cause and trouble area troubleshooting possible cause trouble area • temporary error • use of the ignition key without the transponder • corruption of the transponder in the ignition key • immobilizer contr...

  • Page 1248

    10c-8 immobilizer control system: dtc p1621 immobilizer communication line error s4rs0aa304029 possible cause and trouble area troubleshooting possible cause trouble area • temporary error • related fuse(s) blown • poor connection at immobilizer control module connector • “blk/wht” wire open • “blk/...

  • Page 1249

    Immobilizer control system: 10c-9 6 check for open in “blk/orn” wire: 1) with the ignition switch at on position, check voltage between “g24-2” wire terminal at immobilizer control module and body ground. Is voltage 0? Go to step 7. Repair open in “blk/ orn” wire. 7 check for open in “yel/blk” wire:...

  • Page 1250

    10c-10 immobilizer control system: dtc p1622 eeprom error s4rs0aa304030 possible cause and trouble area troubleshooting 1) clear dtc(s) referring to “diagnostic trouble code (dtc) clearance: ”. 2) turn the ignition switch to off position. 3) check if dtc p1622 is still detected referring to “diagnos...

  • Page 1251

    Immobilizer control system: 10c-11 dtc p1625 immobilizer antenna error s4rs0aa304032 possible cause and trouble area troubleshooting 3 registration of the unregistered ignition key with ecm and diagnostic trouble code (dtc) check: 1) register the transponder code in the transponder in the unregister...

  • Page 1252

    10c-12 immobilizer control system: inspection of immobilizer control module and its circuit s4rs0aa304015 immobilizer control module and its circuit can be checked at immobilizer control module wiring connector by measuring voltage. Caution: immobilizer control module cannot be checked by itself. It...

  • Page 1253

    Immobilizer control system: 10c-13 reference waveform note: when ecm cannot read the transponder code at the first try, ecm tries to read the transponder code repeatedly up to 8 times. The second waveform is the example showing that ecm read the transponder code successfully at the second try. [a]: ...

  • Page 1254

    10c-14 immobilizer control system: repair instructions immobilizer control module removal and installation s4rs0aa306005 removal 1) disconnect negative (-) cable at battery. 2) disable air bag system referring to “disabling air bag system: in section 8b”. 3) remove driver air bag (inflator) module r...

  • Page 1255

    Prepared by 1st ed. Dec., 2004.

  • Page 1256: Service Manual

    21 mm 99500-63j00-24e 99500-63j00-24e service manual volume 1 of 2 ser vice manu al vol. 1 of 2.

  • Page 1257: Service Manual

    29 mm 99500-63j00-24e 99 50 0- 63 j0 0- 24 e service manual volume 2 of 2 s e r v ic e m a n u a l vol. 2 of 2.