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Suzuki SX4 SEDAN 2008 Service Manual

Other manuals for SX4 SEDAN 2008: Owner's Manual, Owner's Manual, Owner's Manual, Owner's Manual

Summary of SX4 SEDAN 2008

  • Page 1

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

  • Page 3: Foreword

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

  • Page 4

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

  • Page 5: Table of Contents

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

  • Page 7: Section 00

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

  • Page 8: Precautions

    00-1 precautions: precautions precautions precautions precautions for vehicles equipped with a supplemental restraint (air bag) system s7rw0a0000001 warning ! • the configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these...

  • Page 9

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

  • Page 10

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

  • Page 11

    Precautions: 00-4 general precautions s7rw0a0000002 the warning and caution describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures, and they will not necessarily be repeated with each procedure to which th...

  • Page 12

    00-5 precautions: • when performing service to electrical parts that does not require use of battery power, disconnect the negative cable of the battery. • when disconnecting the negative cable from the battery, be careful to the following. – check and record dtcs in ecm if necessary before disconne...

  • Page 13

    Precautions: 00-6 • be sure to use special tools when instructed. Special tool (a): 09917–98221 (b): 09916–58210 • when disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly. • after servicing fuel, oil, coolant, vacuum,...

  • Page 14

    00-7 precautions: precautions in servicing 4wd model s7rw0a0000004 caution ! • never perform any of the following [a], [b] and [c] types of service work. If it is performed while 4wd-auto mode or 4wd-lock mode is selected, front wheels (or rear wheels) drive rear wheels (or front wheels) and vehicle...

  • Page 15

    Precautions: 00-8 precautions for installing mobile communication equipment s7rw0a0000006 when installing mobile communication equipment such as cb (citizens-band)-radio or cellular-telephone, be sure to observe the following precautions. Failure to follow cautions may adversely affect electronic co...

  • Page 16

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

  • Page 17

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

  • Page 18

    00-11 precautions: fastener caution s7rw0a0000011 caution ! When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not a...

  • Page 19

    Precautions: 00-12 repair instructions electrical circuit inspection procedure s7rw0a0006001 while there are various electrical circuit inspection methods, described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. Open circuit check possible causes ...

  • Page 20

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

  • Page 21

    Precautions: 00-14 intermittent and poor connection inspection s7rw0a0006002 most intermittent are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits ...

  • Page 22

    00-15 precautions:.

  • Page 23: Section 0

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

  • Page 24: General Information

    0a-1 general information: general information general information general description abbreviations s7rw0a0101001 a: abdc: after bottom dead center abs: anti-lock brake system ac: alternating current a/c: air conditioning a-elr: automatic-emergency locking retractor a/f: air fuel mixture ratio alr: ...

  • Page 25

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

  • Page 26

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

  • Page 27

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

  • Page 28

    0a-5 general information: vehicle lifting points s7rw0a0101005 warning ! • before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • before lifting up the vehicle, check to be sur...

  • Page 29

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

  • Page 30

    0a-7 general information: component location warning, caution and information labels location s7rw0a0103001 the figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to warning / caution instructions printed on labels. If any war...

  • Page 31

    General information: 0a-8 5 1 2 4 8 8 6 7 [c] [b] [a] 3 5 i7rw0a010001-01 1. Air bag label on driver air bag (inflator) module 7. Pretensioner label on seat belt retractor 2. Air bag label on contact coil assembly 8. Side/curtain air bag label on pillar (both right and left sides) (if equipped) 3. A...

  • Page 32: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance and lubrication s7rw0a0200001 air bag warning refer to “air bag warning in section 00”. Scheduled maintenance maintenance schedule under normal driving conditions s7rw0a0205001 n...

  • Page 33

    Maintenance and lubrication: 0b-2 note • “r”: replace or change • “i”: inspect and correct, replace or lubricate if necessary • for nickel 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) • pe...

  • Page 34

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

  • Page 35

    Maintenance and lubrication: 0b-4 accessory drive belt replacement s7rw0a0206002 water pump and generator drive belt replace belt with new one referring to “water pump / generator drive belt removal and installation in section 1j”. A/c compressor drive belt (if equipped) replace belt with new one re...

  • Page 36

    0b-5 maintenance and lubrication: 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 identify the position at which filter o-ring first contacts mounting surface. 5) tighten the fi...

  • Page 37

    Maintenance and lubrication: 0b-6 exhaust system inspection s7rw0a0206006 warning ! To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance, or the vehicle is raised f...

  • Page 38

    0b-7 maintenance and lubrication: fuel tank inspection s7rw0a0206012 check fuel tank damage, cracks, fuel leakage, corrosion and tank bolts looseness. If a problem is found, repair or replace. Pcv valve inspection s7rw0a0206013 check crankcase ventilation hose and pcv hose for leaks, cracks or clog,...

  • Page 39

    Maintenance and lubrication: 0b-8 brake hoses and pipes inspection s7rw0a0206017 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 40

    0b-9 maintenance and lubrication: tires inspection s7rw0a0206021 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 pressur...

  • Page 41

    Maintenance and lubrication: 0b-10 2) check bolts and nuts for tightness and retighten them as necessary. Repair or replace defective parts, if any. 3) check steering linkage for looseness and damage. Repair or replace defective parts, if any. 4) check boots (1) and (2) of steering linkage and steer...

  • Page 42

    0b-11 maintenance and lubrication: transfer oil inspection (4wd) s7rw0a0206033 check transfer oil for leakage, contamination and level referring to “transfer oil level check in section 3c”. Transfer oil replacement (4wd) s7rw0a0206034 change transfer oil with new specified oil referring to “transfer...

  • Page 43

    Maintenance and lubrication: 0b-12 clutch (for manual transaxle) check for the following. • clutch is completely released when depressing clutch pedal, • no slipping clutch occurs when releasing pedal and accelerating. • clutch itself is free from any abnormal condition. Gearshift or select lever ch...

  • Page 44

    0b-13 maintenance and lubrication: special tools and equipment recommended fluids and lubricants s7rw0a0208001 special tool s7rw0a0208002 engine oil sg, sh, sj, sl or sm grade (refer to “engine oil and filter change” for engine oil viscosity.) engine coolant (ethylene glycol base coolant) “antifreez...

  • Page 45: Section 1

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

  • Page 46

    1-ii table of contents dtc p0118: engine coolant temperature circuit high .....................................................1a-84 dtc p0122: throttle position sensor (main) circuit low ......................................................1a-87 dtc p0123: throttle position sensor (main) circuit h...

  • Page 47

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

  • Page 48

    1-iv table of contents main bearings, crankshaft and cylinder block removal and installation .......................1d-59 crankshaft inspection .......................................1d-62 main bearings inspection..................................1d-64 sensor plate inspection ..........................

  • Page 49

    Table of contents 1-v ignition system wiring circuit diagram...............1h-2 component location ...........................................1h-3 ignition system components location ...............1h-3 diagnostic information and procedures............1h-4 ignition system symptom diagnosis.............

  • Page 50: Precautions

    1-1 precautions: engine precautions precautions precautions for engine s7rw0a1000001 air bag warning refer to “air bag warning in section 00”. Precautions on engine service refer to “precautions on engine service in section 1a”. Precautions in diagnosing trouble refer to “precautions in diagnosing t...

  • Page 51

    Engine general information and diagnosis: 1a-1 engine engine general information and diagnosis precautions precautions on engine service s7rw0a1100001 caution ! The following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reli...

  • Page 52

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

  • Page 53

    Engine general information and diagnosis: 1a-3 precaution on can troubleshooting s7rw0a1100007 can schematic and routing diagram 6 1 2 3 7 11 4 10 5 : [c] : [e] : [d] [a] [b] 6 1 2 3 7 11 4 10 5 8 9 i7rw0a110001-03 [a]: non-taiwan model [c]: can high line (red) [e]: k-line [b]: taiwan model [d]: can...

  • Page 54

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

  • Page 55

    Engine general information and diagnosis: 1a-5 general description statement on cleanliness and care s7rw0a1101001 an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch...

  • Page 56

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

  • Page 57

    Engine general information and diagnosis: 1a-7 in the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as each malfunction is detected. These data are not updated. Shown in the table are examples of how freeze frame data are stored when two or more malfunc...

  • Page 58

    1a-8 engine general information and diagnosis: for information about the following items, refer to “euro obd model: ”. • warm-up cycle • driving cycle • 2 driving cycle detection logic • pending dtc data link connector (dlc) description s7rw0a1101004 note there are two types of obd system depending ...

  • Page 59

    Engine general information and diagnosis: 1a-9 can communication system description s7rw0a1101006 ecm (1), abs / esp ® control module (2), bcm (3), combination meter (4), keyless start control module (if equipped with keyless start control system) (5), 4wd control module (for 4wd model) (6), steerin...

  • Page 60

    1a-10 engine general information and diagnosis: ecm transmission data ecm reception data ecm-keyless start control module code odometer signal mil control signal immobilizer indicator light control signal fuel level signal fuel consumption signal a/c refrigerant pressure signal engine type signal ve...

  • Page 61

    Engine general information and diagnosis: 1a-11 air intake system description s7rw0a1101007 the main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “electric throttle body system description”.), and intake m...

  • Page 62

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

  • Page 63

    Engine general information and diagnosis: 1a-13 engine and emission control input / output table s7rw0a1101010 input output electric control device barometric pressure sensor brake light switch start switch ignition switch a/c refrigerant pressure sensor (if equipped with a/c) blower switch a/c swit...

  • Page 64

    1a-14 engine general information and diagnosis: schematic and routing diagram ecm input / output circuit diagram s7rw0a1102003 51 50 +b 54 ig1 +bb st 64 65 67 blk/wht wht/red brn/wht blk/red blk/red 57 : 71 : 72 : 5v : 12v 68 ig1 blk wht gry yel/grn wht 66 58 61 62 63 55 70 60 59 53 wht 4 +b 5 pnk r...

  • Page 65

    Engine general information and diagnosis: 1a-15 terminal arrangement of ecm coupler (viewed from harness side) 4. Cmp sensor 28. Electric throttle body assembly 52. To abs / esp ® control module 5. Ckp sensor 29. Throttle actuator 53. “stop” fuse 6. Ho2s-1 30. Tp sensor 54. Main relay 7. Ho2s-2 (if ...

  • Page 66

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

  • Page 67

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

  • Page 68

    1a-18 engine general information and diagnosis: engine and emission control system flow diagram s7rw0a1102002 intak e manif old exhaust manif old exhaust gas air fuel v apor wa rm u p catalyst exhaust pipe ev ap canister purge v alv e fuel injector ect sensor ecm heater control heater control (if eq...

  • Page 69

    Engine general information and diagnosis: 1a-19 engine and emission control system diagram s7rw0a1102001 43 42 37 26 9 8 6 7 13 12 23 10 14 11 2 5 1 3 17 18 24 39 35 30 29 38 15 16 36 31 22 21 40 27 25 41 32 20 19 4 34 33 28 44 45 46 i5rw0c110009-02.

  • Page 70

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

  • Page 71

    Engine general information and diagnosis: 1a-21 component location electronic control system components location s7rw0a1103001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. H* e* 10 d g* c 6 a b* e 3* 12* a 8 13 ...

  • Page 72

    1a-22 engine general information and diagnosis: diagnostic information and procedures engine and emission control system check s7rw0a1104001 refer to the following items for the details of each step. Step action yes no 1 ) customer complaint analysis 1) perform customer complaint analysis referring ...

  • Page 73

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

  • Page 74

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

  • Page 75

    Engine general information and diagnosis: 1a-25 step 2: dtc / freeze frame data check, record and clearance first, check dtc (including pending dtc), referring to “dtc check”. If dtc is indicated, print it and freeze frame data or write them down and then clear them by referring to “dtc clearance”. ...

  • Page 76

    1a-26 engine general information and diagnosis: 1) prepare can communication obd generic scan tool or suzuki scan tool. Special tool (a): suzuki scan tool (suzuki-sdt) 2) with ignition switch off, connect it to dlc (1) located on underside of instrument panel at driver’s seat side. 3) turn ignition ...

  • Page 77

    Engine general information and diagnosis: 1a-27 wiring diagram [a] 4 5 10 8 9 6 3 1 7 2 11 red wht c06-17 c06-7 red wht e01-3 e01-18 red wht red wht e08-1 e08-12 e08-2 e08-13 red wht red wht e04-1 e04-2 g04-4 g04-2 red wht g04-3 g04-1 red wht red wht g26-23 g26-22 red wht red wht g241-9 g241-7 g241-...

  • Page 78

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

  • Page 79

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

  • Page 80

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

  • Page 81

    Engine general information and diagnosis: 1a-31 7 can line check 1) turn ignition switch to off position. 2) disconnect connectors of all control module / sensor communicated by can. 3) check all the following can lines for open, short to power circuit, short to ground circuit, short to other can li...

  • Page 82

    1a-32 engine general information and diagnosis: dtc table s7rw0a1104006 note • there are two types of obd system depending on the vehicle specification. For identification, refer to “precaution on on-board diagnostic (obd) system”. • for non-euro-obd model, some of dtc no. With delta (u) mark in the...

  • Page 83

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

  • Page 84

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

  • Page 85

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

  • Page 86

    1a-36 engine general information and diagnosis: for vehicle equipped with a/t note there are two types of obd system depending on the vehicle specification. For identification, refer to “precaution on on-board diagnostic (obd) system”. When using can communication obd generic scan tool, not only the...

  • Page 87

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

  • Page 88

    1a-38 engine general information and diagnosis: scan tool data s7rw0a1104009 as the data values are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may...

  • Page 89

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

  • Page 90

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

  • Page 91

    Engine general information and diagnosis: 1a-41 scan tool data definitions coolant temp (engine coolant temperature, °c, °f) it is detected by engine coolant temp. Sensor. Intake air temp. ( °c, °f) it is detected by intake air temp. Sensor. Engine speed (rpm) it is computed by reference pulses from...

  • Page 92

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

  • Page 93

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

  • Page 94

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

  • Page 95

    Engine general information and diagnosis: 1a-45 engine symptom diagnosis s7rw0a1104012 perform troubleshooting referring to the followings when ecm has detected no dtc and no abnormality has been found in “visual inspection” and “engine basic inspection”. Condition possible cause correction / refere...

  • Page 96

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

  • Page 97

    Engine general information and diagnosis: 1a-47 engine overheating inoperative thermostat “thermostat inspection in section 1f” poor water pump performance “water pump inspection in section 1f” clogged or leaky radiator “radiator on-vehicle inspection and cleaning in section 1f” improper engine oil ...

  • Page 98

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

  • Page 99

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

  • Page 100

    1a-50 engine general information and diagnosis: improper engine idling or engine fails to idle faulty spark plug “spark plug inspection in section 1h” leaky or disconnected high-tension cord “high-tension cord removal and installation in section 1h” faulty ignition coil with ignitor “ignition coil a...

  • Page 101

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

  • Page 102

    1a-52 engine general information and diagnosis: malfunction indicator lamp does not come on with ignition switch on and engine stop (but engine can be started) s7rw0a1104013 wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn on (close the cont...

  • Page 103

    Engine general information and diagnosis: 1a-53 troubleshooting note • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm con...

  • Page 104

    1a-54 engine general information and diagnosis: malfunction indicator lamp remains on after engine starts s7rw0a1104014 wiring diagram refer to “malfunction indicator lamp does not come on with ignition switch on and engine stop (but engine can be started)”. Circuit description when the ignition swi...

  • Page 105

    Engine general information and diagnosis: 1a-55 dtc p0010: camshaft position actuator circuit (for engine with vvt system) s7rw0a1104015 system and wiring diagram circuit description actual valve timing fails to become close to target advance level of each function although advance control function ...

  • Page 106

    1a-56 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to ste...

  • Page 107

    Engine general information and diagnosis: 1a-57 dtc p0011 / p0012: camshaft position - timing over-advanced or system performance / retarded (for engine with vvt system) s7rw0a1104016 system description actual value of advanced valve timing does not reach target value. Valve timing is advanced altho...

  • Page 108

    1a-58 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to ste...

  • Page 109

    Engine general information and diagnosis: 1a-59 dtc p0031 / p0032: ho2s heater control circuit low / high (sensor-1) s7rw0a1104017 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and ...

  • Page 110

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

  • Page 111

    Engine general information and diagnosis: 1a-61 dtc p0037 / p0038: ho2s heater control circuit low / high (sensor-2) s7rw0a1104018 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and ...

  • Page 112

    1a-62 engine general information and diagnosis: 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-2 heater power circuit check 1) disconnect connector from ho2s-2 with ignition switch turned off. 2) c...

  • Page 113

    Engine general information and diagnosis: 1a-63 dtc p0101: mass air flow circuit range / performance s7rw0a1104019 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 114

    1a-64 engine general information and diagnosis: 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) to 70 °c (158 °f) • eng...

  • Page 115

    Engine general information and diagnosis: 1a-65 5 maf sensor power supply voltage check 1) disconnect connector from maf and iat sensor with ignition switch turned off. 2) turn on ignition switch, measure voltage between engine ground and “blk/red” wire terminal (2) of maf and iat sensor connector (...

  • Page 116

    1a-66 engine general information and diagnosis: dtc p0102: mass air flow circuit low input s7rw0a1104020 wiring diagram refer to “dtc p0101: mass air flow circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect sca...

  • Page 117

    Engine general information and diagnosis: 1a-67 dtc p0103: mass air flow circuit high input s7rw0a1104021 wiring diagram refer to “dtc p0101: mass air flow circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect sc...

  • Page 118

    1a-68 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to ste...

  • Page 119

    Engine general information and diagnosis: 1a-69 dtc p0106: manifold absolute pressure range / performance s7rw0a1104022 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure note check to make sure that the following conditions are satisfied when using this “dtc confirma...

  • Page 120

    1a-70 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p0107: manifold absolute pressure circuit low input s7rw0a1104023 wiring diagram ref...

  • Page 121

    Engine general information and diagnosis: 1a-71 dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to ste...

  • Page 122

    1a-72 engine general information and diagnosis: dtc p0108: manifold absolute pressure circuit high input s7rw0a1104024 wiring diagram refer to “dtc p0106: manifold absolute pressure range / performance”. Dtc detecting condition and trouble area note when dtc p0113 and p0118 are indicated together, i...

  • Page 123

    Engine general information and diagnosis: 1a-73 3 map sensor power supply voltage check 1) disconnect connector from map sensor with ignition switch turned off. 2) check for proper connection of map sensor at “gry/ red”, “red/blk” and “gry/blu” wire terminals. 3) turn on ignition switch, measure vol...

  • Page 124

    1a-74 engine general information and diagnosis: dtc p0111: intake air temperature circuit range / performance s7rw0a1104025 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure note check to make sure that following conditions are satisfied when using this “dtc confirma...

  • Page 125

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

  • Page 126

    1a-76 engine general information and diagnosis: dtc p0112: intake air temperature sensor circuit low s7rw0a1104026 wiring diagram refer to “dtc p0111: intake air temperature circuit range / performance”. Dtc detecting condition and trouble area 5 wire circuit check 1) disconnect connectors from ecm ...

  • Page 127

    Engine general information and diagnosis: 1a-77 dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and run it for 10 sec. 4) check dtc and pending dtc. Dtc troubleshooting note before this troubl...

  • Page 128

    1a-78 engine general information and diagnosis: dtc p0113: intake air temperature sensor circuit high s7rw0a1104027 wiring diagram refer to “dtc p0111: intake air temperature circuit range / performance”. Dtc detecting condition and trouble area note when dtc p0108 and p0118 are indicated together, ...

  • Page 129

    Engine general information and diagnosis: 1a-79 3 iat sensor voltage check 1) disconnect connector from maf and iat sensor with ignition switch turned off. 2) check for proper connection to maf and iat sensor at “blk/yel” and “gry/blu” wire terminals. 3) if ok, then turn on ignition switch, measure ...

  • Page 130

    1a-80 engine general information and diagnosis: dtc p0116: engine coolant temperature circuit range / performance s7rw0a1104028 wiring diagram dtc detecting condition and trouble area 8 ground circuit check 1) remove ecm from its bracket with ecm connectors connected. 2) measure resistance between “...

  • Page 131

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

  • Page 132

    1a-82 engine general information and diagnosis: 5 wire harness check 1) disconnect ect sensor connector with ignition switch turned off. 2) check for proper connection to ect sensor connector at “gry/blu” and “lt grn” wire terminals. 3) if ok, then with ignition switch on, measure voltage between “l...

  • Page 133

    Engine general information and diagnosis: 1a-83 dtc p0117: engine coolant temperature circuit low s7rw0a1104029 wiring diagram refer to “dtc p0116: engine coolant temperature circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch tur...

  • Page 134

    1a-84 engine general information and diagnosis: dtc p0118: engine coolant temperature circuit high s7rw0a1104030 wiring diagram refer to “dtc p0116: engine coolant temperature circuit range / performance”. Dtc detecting condition and trouble area note when dtc p0108 and p0113 are indicated together,...

  • Page 135

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

  • Page 136

    1a-86 engine general information and diagnosis: 6 ect sensor harness resistance check 1) measure resistance between “c01-24” terminal of ecm connector and “lt grn” wire terminal of ect sensor connector with ignition switch turn off. Is resistance below 5 Ω ? Go to step 7. “lt grn” wire is high resis...

  • Page 137

    Engine general information and diagnosis: 1a-87 dtc p0122: throttle position sensor (main) circuit low s7rw0a1104031 wiring diagram dtc detecting condition and trouble area note when dtc p0122 and p0222 are indicated together, it is possible that “red” wire open circuit. E01 c01 3 4 18 19 5 6 7 10 1...

  • Page 138

    1a-88 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed p...

  • Page 139

    Engine general information and diagnosis: 1a-89 dtc p0123: throttle position sensor (main) circuit high s7rw0a1104032 wiring diagram refer to “dtc p0122: throttle position sensor (main) circuit low”. Dtc detecting condition and trouble area note when dtc p0123 and p0223 are indicated together, it is...

  • Page 140

    1a-90 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed p...

  • Page 141

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

  • Page 142

    1a-92 engine general information and diagnosis: dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-1) s7rw0a1104033 wiring diagram dtc detecting condition and trouble area e01 c01 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 ...

  • Page 143

    Engine general information and diagnosis: 1a-93 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out b...

  • Page 144

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

  • Page 145

    Engine general information and diagnosis: 1a-95 dtc p0133: o2 sensor (ho2s) circuit slow response (sensor-1) s7rw0a1104034 wiring diagram refer to “dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-1)”. Dtc detecting condition and trouble area dtc confirmation procedure ...

  • Page 146

    1a-96 engine general information and diagnosis: dtc p0134: o2 sensor (ho2s) circuit no activity detected (sensor-1) s7rw0a1104035 wiring diagram refer to “dtc p0131 / p0132: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-1)”. Dtc detecting condition and trouble area dtc confirmation pro...

  • Page 147

    Engine general information and diagnosis: 1a-97 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 engine ...

  • Page 148

    1a-98 engine general information and diagnosis: dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2) s7rw0a1104036 wiring diagram dtc detecting condition and trouble area 8 air intake system check 1) check air intake system for clog or leak. Is it ok? Replace ho2s-1 refe...

  • Page 149

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

  • Page 150

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

  • Page 151

    Engine general information and diagnosis: 1a-101 dtc p0140: o2 sensor (ho2s) circuit no activity detected (sensor-2) s7rw0a1104037 wiring diagram refer to “dtc p0137 / p0138: o2 sensor (ho2s) circuit low voltage / high voltage (sensor-2)”. Dtc detecting condition and trouble area dtc confirmation pr...

  • Page 152

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

  • Page 153

    Engine general information and diagnosis: 1a-103 dtc p0171 / p0172: fuel system too lean / rich s7rw0a1104038 dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and...

  • Page 154

    1a-104 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 155

    Engine general information and diagnosis: 1a-105 dtc p0222: throttle position sensor (sub) circuit low s7rw0a1104039 wiring diagram dtc detecting condition and trouble area note when dtc p0122 and p0222 are indicated together, it is possible that “red” wire open circuit. E01 c01 3 4 18 19 5 6 7 10 1...

  • Page 156

    1a-106 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed ...

  • Page 157

    Engine general information and diagnosis: 1a-107 dtc p0223: throttle position sensor (sub) circuit high s7rw0a1104040 wiring diagram refer to “dtc p0222: throttle position sensor (sub) circuit low”. Dtc detecting condition and trouble area note when dtc p0123 and p0223 are indicated together, it is ...

  • Page 158

    1a-108 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed ...

  • Page 159

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

  • Page 160

    1a-110 engine general information and diagnosis: dtc p0300 / p0301 / p0302 / p0303 / p0304: random misfire detected / cylinder 1 / cylinder 2 / cylinder 3 / cylinder 4 misfire detected s7rw0a1104041 system description ecm measures the angle of the crankshaft based on the pulse signal from the ckp se...

  • Page 161

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

  • Page 162

    1a-112 engine general information and diagnosis: dtc p0327 / p0328: knock sensor circuit low / high s7rw0a1104042 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc, ...

  • Page 163

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

  • Page 164

    1a-114 engine general information and diagnosis: dtc p0335: crankshaft position (ckp) sensor circuit s7rw0a1104043 wiring diagram dtc detecting condition and trouble area 7 knock sensor circuit for high resistance check 1) turn off ignition switch, measure resistance between “c01-56” terminal of ecm...

  • Page 165

    Engine general information and diagnosis: 1a-115 dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) crank engine for 3 – 5 sec. 4) check dtc and pending dtc. Dtc troubleshooting note before this troubleshooti...

  • Page 166

    1a-116 engine general information and diagnosis: dtc p0340: camshaft position (cmp) sensor circuit s7rw0a1104044 wiring diagram 5 ground circuit check 1) turn ignition switch to off position. 2) measure resistance between “blk/orn” wire terminal of ckp sensor connector and engine ground. Is measured...

  • Page 167

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

  • Page 168

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

  • Page 169

    Engine general information and diagnosis: 1a-119 dtc p0401 / p0402: exhaust gas recirculation flow insufficient detected / excessive detected s7rw0a1104045 system and wiring diagram 7 cmp sensor check 1) check cmp sensor and signal rotor tooth referring to “camshaft position (cmp) sensor inspection ...

  • Page 170

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

  • Page 171

    Engine general information and diagnosis: 1a-121 dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 172

    1a-122 engine general information and diagnosis: dtc p0403: exhaust gas recirculation control circuit s7rw0a1104046 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a...

  • Page 173

    Engine general information and diagnosis: 1a-123 dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 174

    1a-124 engine general information and diagnosis: dtc p0420: catalyst system efficiency below threshold s7rw0a1104047 system and wiring diagram circuit description ecm monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by ho2s-2. When the catal...

  • Page 175

    Engine general information and diagnosis: 1a-125 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out ...

  • Page 176

    1a-126 engine general information and diagnosis: dtc p0443: evaporative emission system purge control valve circuit s7rw0a1104048 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or po...

  • Page 177

    Engine general information and diagnosis: 1a-127 dtc troubleshooting warning ! In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas water heater. Note before this troubleshooting is performed, read the pr...

  • Page 178

    1a-128 engine general information and diagnosis: dtc p0462 / p0463: fuel level sensor circuit low / high s7rw0a1104049 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc us...

  • Page 179

    Engine general information and diagnosis: 1a-129 dtc p0480: fan 1 (radiator cooling fan) control circuit s7rw0a1104050 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) turn off ignition switch. 2) clear dtc with ignition switch turned on. 3) run engine at idle sp...

  • Page 180

    1a-130 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 181

    Engine general information and diagnosis: 1a-131 dtc p0481: cooling fan 2 (a/c condenser fan) control circuit s7rw0a1104051 wiring diagram circuit description a/c condenser cooling fan motor is turned on and off by its relay which ecm controls. A/c condenser cooling fan motor is turned on when ecm o...

  • Page 182

    1a-132 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and warm up engine to normal operating temperature. 4) run engine at idle and turn both a/c swi...

  • Page 183

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

  • Page 184

    1a-134 engine general information and diagnosis: dtc p0500: vehicle speed sensor (vss) malfunction s7rw0a1104052 wiring diagram 9 check a/c condenser cooling fan control 1) ignition switch turned off. 2) remove ecm from vehicle body referring to “engine control module (ecm) removal and installation ...

  • Page 185

    Engine general information and diagnosis: 1a-135 dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an acc...

  • Page 186

    1a-136 engine general information and diagnosis: dtc p0532: a/c refrigerant pressure sensor circuit low s7rw0a1104053 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear d...

  • Page 187

    Engine general information and diagnosis: 1a-137 step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emission control system check”. 2 a/c refrigerant pressure sensor power supply circuit check 1) disconnect connector from a/c refrigerant pr...

  • Page 188

    1a-138 engine general information and diagnosis: dtc p0533: a/c refrigerant pressure sensor circuit high s7rw0a1104054 wiring diagram refer to “dtc p0532: a/c refrigerant pressure sensor circuit low”. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc wit...

  • Page 189

    Engine general information and diagnosis: 1a-139 dtc p0601 / p0602 / p0607: internal control module memory check sum error / control module programming error / control module performance s7rw0a1104055 system description internal control module is installed in ecm. Dtc detecting condition and trouble...

  • Page 190

    1a-140 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p0616: starter relay circuit low s7rw0a1104056 wiring diagram step action yes no 1 ...

  • Page 191

    Engine general information and diagnosis: 1a-141 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine. 4) check dtc and pending dtc. Dtc troubleshooting not...

  • Page 192

    1a-142 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 193

    Engine general information and diagnosis: 1a-143 dtc p1510: ecm back-up power supply malfunction s7rw0a1104058 wiring diagram circuit description battery voltage is supplied so that dtc memory, values for engine control learned by ecm, etc. Are kept in ecm even when the ignition switch is turned off...

  • Page 194

    1a-144 engine general information and diagnosis: dtc p2101: throttle actuator control motor circuit range / performance s7rw0a1104059 wiring diagram 2 battery voltage supply circuit check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) with engine runnin...

  • Page 195

    Engine general information and diagnosis: 1a-145 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep ...

  • Page 196

    1a-146 engine general information and diagnosis: dtc p2102: throttle actuator control motor circuit low s7rw0a1104060 wiring diagram refer to “dtc p2101: throttle actuator control motor circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition...

  • Page 197

    Engine general information and diagnosis: 1a-147 dtc p2103: throttle actuator control motor circuit high s7rw0a1104061 wiring diagram refer to “dtc p2101: throttle actuator control motor circuit range / performance”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignitio...

  • Page 198

    1a-148 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p2111: throttle actuator control system - stuck open s7rw0a1104062 wiring diagram r...

  • Page 199

    Engine general information and diagnosis: 1a-149 dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Dtc p2119: throttle actuator control throttle body range / performance s7rw0a1104063 wi...

  • Page 200

    1a-150 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 201

    Engine general information and diagnosis: 1a-151 dtc p2122: pedal position sensor (main) circuit low input s7rw0a1104064 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc ...

  • Page 202

    1a-152 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 203

    Engine general information and diagnosis: 1a-153 dtc p2123: pedal position sensor (main) circuit high input s7rw0a1104065 wiring diagram refer to “dtc p2122: pedal position sensor (main) circuit low input”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch t...

  • Page 204

    1a-154 engine general information and diagnosis: dtc troubleshooting note before this troubleshooting is performed, read the precautions for dtc troubleshooting referring to “precautions for dtc troubleshooting”. Step action yes no 1 was “engine and emission control system check” performed? Go to st...

  • Page 205

    Engine general information and diagnosis: 1a-155 dtc p2127: pedal position sensor (sub) circuit low input s7rw0a1104066 wiring diagram refer to “dtc p2122: pedal position sensor (main) circuit low input”. Dtc detecting condition and trouble area 6 wire harness check 1) disconnect connectors from ecm...

  • Page 206

    1a-156 engine general information and diagnosis: dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep the accelerator pedal at fully depressed ...

  • Page 207

    Engine general information and diagnosis: 1a-157 5 ecm voltage check 1) turn off ignition switch. 2) remove ecm from its bracket with ecm connectors connected. 3) check for proper connection of ecm connector at “e01- 34” terminal. 4) if ok, measure voltage between “e01-34” terminal of ecm connector ...

  • Page 208

    1a-158 engine general information and diagnosis: dtc p2128: pedal position sensor (sub) circuit high input s7rw0a1104067 wiring diagram refer to “dtc p2122: pedal position sensor (main) circuit low input”. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch tu...

  • Page 209

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

  • Page 210

    1a-160 engine general information and diagnosis: dtc p2135: throttle position sensor (main / sub) voltage correlation s7rw0a1104068 wiring diagram 9 ground circuit check 1) remove ecm from its bracket with ecm connectors connected. 2) check for proper connection of ecm connector at “e01- 51” termina...

  • Page 211

    Engine general information and diagnosis: 1a-161 dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) keep the accelerator pedal at idle position for 2 seconds. 4) keep ...

  • Page 212

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

  • Page 213

    Engine general information and diagnosis: 1a-163 dtc p2138: pedal position sensor (main / sub) voltage correlation s7rw0a1104069 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and cl...

  • Page 214

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

  • Page 215

    Engine general information and diagnosis: 1a-165 dtc p2227 / p2228 / p2229: barometric pressure circuit malfunction s7rw0a1104070 dtc p2227: barometric pressure circuit range / performance dtc p2228: barometric pressure circuit low dtc p2229: barometric pressure circuit high system description barom...

  • Page 216

    1a-166 engine general information and diagnosis: dtc confirmation procedure dtc p2227: warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be c...

  • Page 217

    Engine general information and diagnosis: 1a-167 troubleshooting for can-dtc s7rw0a1104075 perform this troubleshooting when can-dtc is detected. Note • when performing this troubleshooting, be sure to have full understanding of “precaution on can troubleshooting” and observe it. • it may be possibl...

  • Page 218

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

  • Page 219

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

  • Page 220

    1a-170 engine general information and diagnosis: 5 can communication check of bcm, ecm, abs / esp ® control module and combination meter 1) turn ignition switch to off position. 2) connect bcm, ecm, abs / esp ® control module and combination meter connectors. 3) perform “communication bus check” und...

  • Page 221

    Engine general information and diagnosis: 1a-171 10 internal circuit check in abs / esp ® control module 1) make sure that ignition switch is off position and battery negative (–) cable is disconnected. 2) connect abs / esp ® control module connector and disconnect ecm connector. 3) measure resistan...

  • Page 222

    1a-172 engine general information and diagnosis: inspection of ecm and its circuits s7rw0a1104076 ecm and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. Caution ! Ecm cannot be checked by itself. It is strictly prohibited to connect voltmet...

  • Page 223

    Engine general information and diagnosis: 1a-173 viewed from harness side 1 2 3 (a) i5jb0a110073-01 e01 c01 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11...

  • Page 224

    1a-174 engine general information and diagnosis: c01-5 grn/ wht ignition coil no.2 and no.3 output 0 – 0.6 v ignition switch turned on. — *0 – 0.6 v ↑↓ 3 – 5 v (“reference waveform no.5: ” and “reference waveform no.6: ”) engine running at idle after warmed up engine. Output signal is active high pu...

  • Page 225

    Engine general information and diagnosis: 1a-175 c01-16 blu/ red fuel injector no.3 output 10 – 14 v ignition switch turned on. — *0 – 0.6 v ↑↓ 10 – 14 v (“reference waveform no.1: ” and “reference waveform no.11: ”) engine running at idle after warmed up engine. Output signal is active low pulse. P...

  • Page 226

    1a-176 engine general information and diagnosis: c01-26 grn/ blk mass air flow (maf) sensor signal 0.5 – 1.5 v ignition switch turned on with engine at stop. — 1.5 – 2.0 v (“reference waveform no.15: ”) when engine running at specified idle speed after warmed up. C01-27 gry ground for maf sensor bel...

  • Page 227

    Engine general information and diagnosis: 1a-177 c01-45 blu output of throttle actuator 0 – 1 v ignition switch turned on and accelerator pedal at full depressed position after warmed up engine. Output signal is pulse. Duty ratio varies depending on throttle valve and accelerator pedal position. *0 ...

  • Page 228

    1a-178 engine general information and diagnosis: c01-59 grn/ wht oil control valve ground (for engine with vvt system) below 1.3 v ignition switch turned on. — c01-60 grn/ red oil control valve output (for engine with vvt system) *0 – 0.6 v ↑↓ 10 – 14 v (“reference waveform no.21: ” and “reference w...

  • Page 229

    Engine general information and diagnosis: 1a-179 e01-18 wht can (low) communication line (active low signal) to abs / esp ® control module *0.5 – 2.5 v (“reference waveform no.23: ”) ignition switch turned on with engine at stop. Can communication line signal is pulse. Pulse signal displayed with a ...

  • Page 230

    1a-180 engine general information and diagnosis: e01-36 yel app sensor (sub) signal 0.37 – 0.38 v ignition switch turned on and accelerator pedal at idle position after warmed up engine. — 1.70 – 2.00 v (“reference waveform no.30: ”) ignition switch turned on and accelerator pedal at full depressed ...

  • Page 231

    Engine general information and diagnosis: 1a-181 e01-55 red / blu a/c refrigerant pressure sensor signal (if equipped with a/ c) 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 – 2.38 v engine running, a/c switch on...

  • Page 232

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

  • Page 233

    Engine general information and diagnosis: 1a-183 reference waveform no.3 no.2 fuel injector signal (2) with engine idling reference waveform no.4 egr valve signal measurement terminal ch1: “c01-20” to “c01-58” ch2: “c01-2” to “c01-58” oscilloscope setting ch1: 5 v/div, ch2: 20 v/div time: 40 ms/div ...

  • Page 234

    1a-184 engine general information and diagnosis: reference waveform no.5 ignition coil no.2 and no.3 signal (2) with engine idling reference waveform no.6 ignition coil signal (1) with engine idling reference waveform no.7 ignition coil no.1 and no.4 signal (2) with engine idling measurement termina...

  • Page 235

    Engine general information and diagnosis: 1a-185 reference waveform no.8 heated oxygen sensor-1 signal (1) with engine idling reference waveform no.9 heated oxygen sensor-1 heater signal (2) with engine idling reference waveform no.10 heated oxygen sensor-2 heater signal (4) with engine idling measu...

  • Page 236

    1a-186 engine general information and diagnosis: reference waveform no.11 no.3 fuel injector signal (2) with engine idling reference waveform no.12 no.4 fuel injector signal (2) with engine idling measurement terminal ch1: “c01-20” to “c01-58” ch2: “c01-16” to “c01-58” oscilloscope setting ch1: 5 v/...

  • Page 237

    Engine general information and diagnosis: 1a-187 reference waveform no.13 cmp sensor signal with engine idling reference waveform no.14 cmp sensor signal with engine idling measurement terminal ch1: “c01-20” to “c01-58” ch2: “c01-21” to “c01-58” oscilloscope setting ch1: 2 v/div, ch2: 2 v/div time: ...

  • Page 238

    1a-188 engine general information and diagnosis: reference waveform no.15 mass air flow sensor signal (1) with engine racing reference waveform no.16 evap canister purge valve signal reference waveform no.17 manifold absolute pressure sensor signal (1) with ignition switch turned on reference wavefo...

  • Page 239

    Engine general information and diagnosis: 1a-189 reference waveform no.19 knock sensor signal at engine speed 4000 r/min. Reference waveform no.20 knock sensor signal at engine speed 4000 r/min. Reference waveform no.21 oil control valve signal with engine idling (for engine with vvt system) referen...

  • Page 240

    1a-190 engine general information and diagnosis: reference waveform no.23 can communication line signal from abs / esp ® control module assembly or tcm with ignition switch turned on reference waveform no.24 ignition pulse (engine revolution) signal (2) with engine idling measurement terminal ch1: “...

  • Page 241

    Engine general information and diagnosis: 1a-191 reference waveform no.25 ignition pulse (engine revolution) signal (2) with engine idling reference waveform no.26 throttle actuator output signal with ignition switch turned on reference waveform no.27 throttle actuator output signal with ignition sw...

  • Page 242

    1a-192 engine general information and diagnosis: reference waveform no.28 ignition coil signal and fuel injector signal with engine cranking reference waveform no.29 throttle position sensor main (1) and sub (2) signal reference waveform no.30 pedal position sensor main (1) and sub (2) signal measur...

  • Page 243

    Engine general information and diagnosis: 1a-193 resistance check 1) remove ecm from its bracket referring to “engine control module (ecm) removal and installation in section 1c”. Caution ! Never touch terminals of ecm itself or connect voltmeter or ohmmeter (2). 2) connect special tool to ecm conne...

  • Page 244

    1a-194 engine general information and diagnosis: ecm power and ground circuit check s7rw0a1104077 wiring diagram circuit description when the ignition switch is turned on, the main relay turns on (the contact point closes) and the main power is supplied to ecm. E01 c01 3 4 18 19 5 6 7 10 11 17 20 47...

  • Page 245

    Engine general information and diagnosis: 1a-195 troubleshooting note • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm co...

  • Page 246

    1a-196 engine general information and diagnosis: 6 ecm ground circuit check 1) turn ignition switch to off position. 2) disconnect connectors from ecm. 3) measure resistance between each “e01-31”, “c01-58”, “c01-15” and “c01-30” terminals of ecm connector and body ground. Is resistance 1 Ω or less? ...

  • Page 247

    Engine general information and diagnosis: 1a-197 fuel injector circuit check s7rw0a1104078 wiring diagram 11 sensor power source circuit check 1) connect connectors to ecm with ignition switch turned off. 2) turn on ignition switch, measure each voltage between “c01-14”, “e01-35”, “e01-34” and “c01-...

  • Page 248

    1a-198 engine general information and diagnosis: troubleshooting note • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm co...

  • Page 249

    Engine general information and diagnosis: 1a-199 fuel pump and its circuit check s7rw0a1104079 wiring diagram e01-1 e01-15 blk/red blk/yel blk/yel blk/red e01-29 blk/wht grn/wht blk/wht blk/wht pnk blk wht grn c01-58 c01-15 c01-30 blk/orn blk blk 7 8 9 6 4 3 2 5 e01 c01 3 4 18 19 5 6 7 10 11 17 20 4...

  • Page 250

    1a-200 engine general information and diagnosis: troubleshooting note • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm co...

  • Page 251

    Engine general information and diagnosis: 1a-201 6 fuel pump relay drive signal check 1) measure voltage within 2 second after ignition switch is turned on. Is voltage 0 – 1 v? Go to step 7. Substitute a known- good ecm and recheck. 7 wire circuit check 1) turn off ignition switch. 2) detach fuel ta...

  • Page 252

    1a-202 engine general information and diagnosis: fuel pressure check s7rw0a1104080 system diagram special tool (a): 09912–58442 (b): 09912–58432 (c): 09912–58490 troubleshooting note before using following flow, check to make sure that battery voltage is higher than 11 v. If battery voltage is low, ...

  • Page 253

    Engine general information and diagnosis: 1a-203 a/c condenser cooling fan control system inspection s7rw0a1104081 wiring diagram 4 fuel line check 1) check fuel pipe, fuel hose and joint for damage or deform. Are they in good condition? Faulty fuel pressure regulator. Repair or replace damaged or d...

  • Page 254

    1a-204 engine general information and diagnosis: troubleshooting step action yes no 1 check a/c condenser fan control system is a/c condenser fan started when a/c is operating? Intermittent trouble. Check for intermittent referring to “intermittent and poor connection inspection in section 00”. Go t...

  • Page 255

    Engine general information and diagnosis: 1a-205 9 check wire circuit 1) install “a/c” fuse “20 a” to individual circuit fuse box no.1. 2) connect a/c condenser cooling fan control relay to individual circuit fuse box no.1 with ignition switch turn off. 3) start engine then turn on a/c switch and bl...

  • Page 256

    1a-206 engine general information and diagnosis: a/c system circuits check s7rw0a1104082 wiring diagram blu/wht blu/wht e01-19 e01-19 21 e01 c01 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 ...

  • Page 257

    Engine general information and diagnosis: 1a-207 troubleshooting note • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm co...

  • Page 258

    1a-208 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 “e01-57” and “e01-54” wire terminals of ecm connector. 3) if ok, measure resistance between “e01-57” an...

  • Page 259

    Engine general information and diagnosis: 1a-209 11 a/c compressor relay circuit check 1) measure voltage between “e01-47” wire terminal of ecm connector and vehicle body ground under following conditions respectively. Voltage between “e01-47” terminal of ecm connector and ground while engine runnin...

  • Page 260

    1a-210 engine general information and diagnosis: electric load signal circuit check s7rw0a1104083 wiring diagram e01 c01 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 1...

  • Page 261

    Engine general information and diagnosis: 1a-211 troubleshooting note • before performed trouble shooting, be sure to read the “precautions of ecm circuit inspection”. • when measuring circuit voltage, resistance and/or pulse signal at ecm connector, connect the special tool to ecm and/or the ecm co...

  • Page 262

    1a-212 engine general information and diagnosis: radiator cooling fan control system check s7rw0a1104084 wiring diagram troubleshooting warning ! Keep hands, tools, and clothing away from radiator cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the en...

  • Page 263

    Engine general information and diagnosis: 1a-213 repair instructions idle speed and iac throttle valve opening inspection s7rw0a1106001 before idle speed check, make sure of the following. • lead wires and hoses of electronic fuel injection and engine and emission control systems are connected secur...

  • Page 264

    1a-214 engine general information and diagnosis: 1) connect suzuki scan tool to dlc (1) with ignition switch turned off. Special tool (a): suzuki scan tool (suzuki-sdt) 2) warm up engine to normal operating temperature. 3) check engine idle speed and “iac throttle opening” by using “data list” mode ...

  • Page 265

    Aux. Emission control devices: 1b-1 engine aux. Emission control devices diagnostic information and procedures egr system inspection (if equipped) s7rw0a1204001 1) connect suzuki scan tool to data link connector (dlc) (1) with ignition switch turned off. 2) turn on ignition switch and erase dtc usin...

  • Page 266

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

  • Page 267

    Aux. Emission control devices: 1b-3 vacuum hose inspection s7rw0a1206004 check hoses for connection, leakage, clog and deterioration. Replace as necessary. Evap canister purge valve inspection s7rw0a1206005 warning ! Do not apply vacuum by mouth; otherwise harmful fuel vapor can be breathed in. Caut...

  • Page 268

    1b-4 aux. Emission control devices: evap canister inspection s7rw0a1206006 warning ! Do not suck nozzles on evap canister. Fuel vapor inside evap canister is harmful. 1) check outside of evap canister visually. 2) disconnect vacuum hoses from evap canister. 3) check that there is no restriction of f...

  • Page 269

    Aux. Emission control devices: 1b-5 pcv hose inspection s7rw0a1206009 note be sure to check that there is no obstruction in pcv valve or its hoses before checking iac throttle valve opening, for obstructed pcv valve or hose hampers its accurate adjustment. Check hoses for connection, leakage, clog a...

  • Page 270: Engine Electrical Devices

    1c-1 engine electrical devices: engine engine electrical devices repair instructions engine control module (ecm) removal and installation s7rw0a1306001 caution ! As ecm consists of precision parts, be careful not to expose it to excessive shock. Removal 1) disconnect negative cable at battery. 2) di...

  • Page 271

    Engine electrical devices: 1c-2 manifold absolute pressure (map) sensor inspection (if equipped) s7rw0a1306002 1) remove air cleaner assembly. 2) disconnect connector from map sensor. 3) remove map sensor. 4) arrange 3 new 1.5 v batteries (2) in series (check that total voltage is 4.5 – 5.0 v) and c...

  • Page 272

    1c-3 engine electrical devices: 4) take off finger from opened throttle valve (1) which is at full open position and check that it moves smoothly by its return spring and open spring force back to default position (position where throttle valve is open by 7 ° (2) from completely closed position). 5)...

  • Page 273

    Engine electrical devices: 1c-4 b) for throttle position sensor (sub), arrange 3 new 1.5 v batteries (1) in series (check that total voltage is 4.5 – 5.0 v) and connect its positive terminal to “vin” terminal (2) and negative terminal to “ground” terminal (3) of sensor. Then using voltmeter, connect...

  • Page 274

    1c-5 engine electrical devices: accelerator pedal position (app) sensor assembly on-vehicle inspection s7rw0a1306005 1) check that app sensor assembly has been mounted to vehicle body properly (no pinched floor carpet, etc.). If mounting is not properly, reinstall app sensor assembly properly referr...

  • Page 275

    Engine electrical devices: 1c-6 2) for app sensor (sub), arrange 3 new 1.5 v batteries (1) in series (check that total voltage is 4.5 – 5.0 v) and connect its positive terminal to “vin 2” terminal (2) and negative terminal to “ground 2” terminal (3) of sensor. Then using voltmeter, connect positive ...

  • Page 276

    1c-7 engine electrical devices: engine coolant temperature (ect) sensor inspection s7rw0a1306009 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 277

    Engine electrical devices: 1c-8 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 kgf-m, 32.5 lb-ft) • install exhaust manifold referring to “exhaust manifold removal and instal...

  • Page 278

    1c-9 engine electrical devices: camshaft position (cmp) sensor inspection s7rw0a1306013 visual check • check that o-ring is free from damage. • check that end face of sensor and signal rotor tooth are free from any metal particles and damage. Performance check 1) remove metal particles on end face o...

  • Page 279

    Engine electrical devices: 1c-10 installation 1) install crankshaft position sensor to cylinder block. Tighten ckp sensor bolt to specified torque. Tightening torque ckp sensor bolt (a): 11 n·m (1.1 kgf-m, 8.0 lb-ft) 2) connect connector to ckp sensor securely. 3) adjust generator drive belt tension...

  • Page 280

    1c-11 engine electrical devices: main relay, fuel pump relay, starting motor control relay, throttle actuator control relay and radiator cooling fan relay inspection s7rw0a1306017 1) disconnect negative cable at battery. 2) remove main relay (1), fuel pump relay (3), starting motor control relay (2)...

  • Page 281

    Engine electrical devices: 1c-12 mass air flow (maf) and intake air temperature (iat) sensor removal and installation s7rw0a1306019 caution ! • do not disassemble maf and iat sensor. • do not expose maf and iat sensor to any shock. • do not clean maf and iat sensor. • if maf and iat sensor has been ...

  • Page 282

    1c-13 engine electrical devices: specifications tightening torque specifications s7rw0a1307001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. Fastening part tightening torque note n ⋅m kgf-m lb-ft ecm mounting bolt 8 0....

  • Page 283: Engine Mechanical

    Engine mechanical: 1d-1 engine engine mechanical general description engine construction description s7rw0a1401001 the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration and 16 v...

  • Page 284

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

  • Page 285

    Engine mechanical: 1d-3 camshaft position control (vvt variable valve timing) system description s7rw0a1401002 system description the vvt system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized i...

  • Page 286

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

  • Page 287

    Engine mechanical: 1d-5 targeted timing varying operation diagnostic information and procedures compression check s7rw0a1404001 check compression pressure on all 4 cylinders as follows: 1) warm up engine to normal operating temperature. 2) stop engine after warming up. Note after warming up engine, ...

  • Page 288

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

  • Page 289

    Engine mechanical: 1d-7 7) install air cleaner assembly with air suction hose referring to “air cleaner assembly removal and installation”. 8) run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification. Vacuum specification (at sea level) 59 – 73 kpa (45 – 55 cmh...

  • Page 290

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

  • Page 291

    Engine mechanical: 1d-9 6) select new shim no. (1) with a thickness as close as possible to calculated value. Available new shims no. 7) install new shim facing shim no. Side with tappet. 8) lift valve by turning crankshaft counterclockwise (in opposite direction against above step 4)) and remove sp...

  • Page 292

    1d-10 engine mechanical: repair instructions air intake system components s7rw0a1406001 air cleaner filter removal and installation s7rw0a1406002 removal 1) open air cleaner case (1) by unhooking its clamps (2). 2) remove air cleaner filter from case. Installation reverse removal procedure for insta...

  • Page 293

    Engine mechanical: 1d-11 air cleaner assembly removal and installation s7rw0a1406004 removal 1) disconnect negative cable at battery. 2) disconnect maf sensor connector (1). 3) remove evap canister purge valve (2). 4) remove air cleaner assembly (3) with air suction hose (4). Installation reverse re...

  • Page 294

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

  • Page 295

    Engine mechanical: 1d-13 throttle body and intake manifold components s7rw0a1406006 i6rw0d140001-01 1. Intake manifold 8. To cylinder head cover 15. Brake booster hose 22. Throttle body outlet water hose no.2 2. O-ring 9. Gasket (with egr) 16. To brake booster 23. Egr pipe plate (without egr) 3. Thr...

  • Page 296

    1d-14 engine mechanical: throttle body on-vehicle inspection s7rw0a1406007 check electric throttle body assembly referring to “throttle valve operation check” and “electric throttle body assembly operation check” under “electric throttle body assembly on-vehicle inspection in section 1c”. Electric t...

  • Page 297

    Engine mechanical: 1d-15 intake manifold removal and installation s7rw0a1406010 removal 1) remove throttle body referring to “electric throttle body assembly removal and installation”. 2) disconnect map sensor connector (1). 3) disconnect the following hoses: • brake booster hose (2) from cylinder h...

  • Page 298

    1d-16 engine mechanical: engine mountings components s7rw0a1406011 i6rw0d140002-01 [a]: for 4wd model 4. Engine left mounting : be sure to direct paint mark to forward. 12. Dynamic damper [b]: for 2wd model 5. Engine rear mounting : be sure to direct paint mark to forward. 13. Mounting member cushio...

  • Page 299

    Engine mechanical: 1d-17 engine assembly removal and installation s7rw0a1406012 removal 1) relieve fuel pressure according to “fuel pressure relief procedure in section 1g”. 2) disconnect negative and positive cable at battery. 3) disconnect ecm connectors. 4) remove battery and battery tray with ec...

  • Page 300

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

  • Page 301

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

  • Page 302

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

  • Page 303

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

  • Page 304

    1d-22 engine mechanical: timing chain cover components s7rw0a1406013 i5rw0c140041-01 [a]: for engine with vvt 8. Timing chain cover mounting nut 17. Oil control valve [b]: for engine without vvt 9. Oil gallery pipe no.1 18. Oil control valve mounting nut 1. Crankshaft pulley bolt 10. Copper washer 1...

  • Page 305

    Engine mechanical: 1d-23 timing chain cover removal and installation s7rw0a1406014 caution ! • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to damage them. • do not expose removed parts to dust. Keep them always clean. Removal 1) ...

  • Page 306

    1d-24 engine mechanical: installation 1) clean sealing surface on timing chain cover, cylinder block and cylinder head. Remove oil, old sealant and dust from sealing surface. 2) install oil seal (1) to timing chain cover, if removed. Note when installing new oil seal, press fit to timing chain cover...

  • Page 307

    Engine mechanical: 1d-25 8) for engine with vvt, install new o-ring (1) to oil gallery pipes no.2 (2) and no.3 (3). 9) for engine with vvt, install oil gallery pipes no.2 and no.3 to cylinder head (4) and timing chain cover (5). Tighten bolts to specified torque. Tightening torque oil gallery pipe n...

  • Page 308

    1d-26 engine mechanical: oil control valve removal and installation (for engine with vvt) s7rw0a1406016 removal remove oil gallery pipe no.1 and oil control valve from timing chain cover. Installation 1) install new o-ring (4) to oil control valve (2). 2) install oil control valve to timing chain co...

  • Page 309

    Engine mechanical: 1d-27 timing chain and chain tensioner components s7rw0a1406018 timing chain and chain tensioner removal and installation s7rw0a1406019 removal caution ! After timing chain is removed, never turn crankshaft and camshafts independently more than its allowable turning range describe...

  • Page 310

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

  • Page 311

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

  • Page 312

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

  • Page 313

    Engine mechanical: 1d-31 timing chain and chain tensioner inspection s7rw0a1406020 timing chain no.1 guide check shoe (1) for wear or damage. Timing chain tensioner check shoe (1) for wear or damage. Crankshaft timing sprocket check teeth of sprocket for wear or damage. Timing chain check timing cha...

  • Page 314

    1d-32 engine mechanical: camshaft, tappet and shim components s7rw0a1406021 i4rs0b140014-03 [a]: for engine with vvt 4. Exhaust camshaft 9. Camshaft bearing : install a bearing half with some holes to upper side of intake camshaft no.1 bearing. [b]: for engine without vvt 5. Shim : shim no. On it fa...

  • Page 315

    Engine mechanical: 1d-33 camshaft, tappet and shim removal and installation s7rw0a1406022 caution ! • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to damage them. • do not expose removed parts to dust. Keep them always clean. Remo...

  • Page 316

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

  • Page 317

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

  • Page 318

    1d-36 engine mechanical: camshaft, tappet and shim inspection s7rw0a1406023 intake cam timing sprocket assembly (for engine with vvt) fit intake cam timing sprocket assembly to camshaft (2) and hold hexagonal section of camshaft by using spanner or the like. Check if sprocket (1) is not turned by ha...

  • Page 319

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

  • Page 320

    1d-38 engine mechanical: camshaft bearing thickness (for engine with vvt) : 1.5120 – 1.5180 mm (0.0596 – 0.0597 in.) wear of tappet and shim check tappet and shim for pitting, scratches, or damage. If any malcondition is found, replace. Measure cylinder head bore and tappet outside diameter to deter...

  • Page 321

    Engine mechanical: 1d-39 valves and cylinder head components s7rw0a1406024 i4rs0a140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (m8) : be sure to tighten cylinder head bolt (m8) after securing the other cylinder head bolt (m10). 2. Valve spring retainer 8. Valve guide : tighten 2...

  • Page 322

    1d-40 engine mechanical: valves and cylinder head removal and installation s7rw0a1406025 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2) remove oil pan referring to “oil pan and oil pump strainer removal and installation in section 1e”. 3) r...

  • Page 323

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

  • Page 324

    1d-42 engine mechanical: valves and cylinder head disassembly and assembly s7rw0a1406026 disassembly 1) for ease in servicing cylinder head, remove intake manifold, injectors, exhaust manifold from cylinder head. 2) using special tools (valve lifter), compress valve spring and then remove valve cott...

  • Page 325

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

  • Page 326

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

  • Page 327

    Engine mechanical: 1d-45 valves and valve guides inspection s7rw0a1406027 valve guide valve stem-to-guide clearance using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of...

  • Page 328

    1d-46 engine mechanical: valve head radial runout check each valve for radial runout with a dial gauge and “v” block. To check runout, rotate valve slowly. If runout exceeds its limit, replace valve. Valve head radial runout limit: 0.08 mm (0.003 in.) seating contact width create contact pattern on ...

  • Page 329

    Engine mechanical: 1d-47 cylinder head inspection s7rw0a1406028 • remove all carbon deposits from combustion chambers. Note do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to valves and valve seats, to...

  • Page 330

    1d-48 engine mechanical: valve spring inspection s7rw0a1406029 valve spring free length and preload referring to data, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibilit...

  • Page 331

    Engine mechanical: 1d-49 pistons, piston rings, connecting rods and cylinders removal and installation s7rw0a1406031 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 inst...

  • Page 332

    1d-50 engine mechanical: 5) install bearing cap (1): point arrow mark (2) on cap to crankshaft pulley side. After applying engine oil to rod bolts and tighten cap nuts (3) gradually as follows. A) tighten all cap nuts to 15 n ⋅m (1.5 kgf-m, 11.0 lb- ft). B) retighten them to 45 °. C) repeat step b) ...

  • Page 333

    Engine mechanical: 1d-51 3) install piston rings to piston: • as indicated in figure, 1st and 2nd rings have “t” mark (4) respectively. When installing these piston rings to piston, direct marked side of each ring toward top of piston. • 1st ring (1) differs from 2nd ring (2) in thickness, shape and...

  • Page 334

    1d-52 engine mechanical: piston visual inspection inspect piston for faults, cracks or other damages. Damaged or faulty piston should be replaced. Piston diameter as indicated in figure, piston diameter should be measured at a position 19.5 mm (0.77 in.) (“a”) from piston skirt end in the direction ...

  • Page 335

    Engine mechanical: 1d-53 piston ring piston ring end gap to measure end gap, insert piston ring (2) into cylinder bore and then measure the gap by using thickness gauge (1). If measured gap exceeds limit, replace ring. Note decarbonize and clean top of cylinder bore before inserting piston ring. Pis...

  • Page 336

    1d-54 engine mechanical: connecting rod big-end side clearance check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod. Big-end side clearance standard: 0.25 – ...

  • Page 337

    Engine mechanical: 1d-55 crank pin and connecting rod bearings inspection s7rw0a1406035 crank pin diameter inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged or out-of round or taper is out of limit, replace crankshaft ...

  • Page 338

    1d-56 engine mechanical: 4) install rod bearing cap (1) to connecting rod. When installing cap, be sure to point arrow mark (2) on cap to crankshaft pulley side, as shown in figure. After applying engine oil to rod bolts, tighten cap nuts (3) gradually as follows. A) tighten all cap nuts to 15 n ⋅m ...

  • Page 339

    Engine mechanical: 1d-57 2) next, check crankshaft pin diameter. On crank web no.3, four alphabets are stamped as shown in figure. Three kinds of alphabet (“a”, “b” and “c”) represent the following crankshaft pin diameter respectively. For example, stamped “a” indicates that corresponding crankshaft...

  • Page 340

    1d-58 engine mechanical: main bearings, crankshaft and cylinder block components s7rw0a1406036 i6rw0d140003-01 1. Ckp sensor : see “a” 11. Rear oil seal 21. Oil filter adapter bolt 2. Knock sensor 12. Input shaft bearing 22. Spring pin 3. Cylinder block 13. Flywheel or drive plate 23. Sensor plate b...

  • Page 341

    Engine mechanical: 1d-59 main bearings, crankshaft and cylinder block removal and installation s7rw0a1406037 removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation”. 2) remove clutch cover, clutch disc and flywheel (drive plate for a/t) by using special...

  • Page 342

    1d-60 engine mechanical: installation note • use new bearing cap no.1 bolts. They are deformed once they are used because they are plastic deformation tightening bolts. • all parts to be installed must be perfectly clean. • be sure to oil crankshaft journals, journal bearings, thrust bearings, crank...

  • Page 343

    Engine mechanical: 1d-61 6) install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side. After applying engine oil to main bearing cap no.1 bolts ((1) – (10)) and...

  • Page 344

    1d-62 engine mechanical: 9) install rear oil seal housing (1) and tighten new bolts to specified torque by using special tool. Special tool (a): 09911–97720 tightening torque rear oil seal housing bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) 10) install flywheel (drive plate for a/t). Using special tool, loc...

  • Page 345

    Engine mechanical: 1d-63 2) tighten main bearing cap no.1 bolts (1) – (10) and main bearing cap no.2 bolts (11) – (20) gradually as follows. A) tighten bolts (1) – (10) to 30 n ⋅m (3.0 kgf-m, 22.0 lb-ft) according to numerical order in figure. B) in the same manner as in step a), tighten them to 50 ...

  • Page 346

    1d-64 engine mechanical: main bearings inspection s7rw0a1406039 general information • service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. • upper half of bearing (1) has oil groove (2) as shown in f...

  • Page 347

    Engine mechanical: 1d-65 selection of main bearings standard bearing if bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. 1) first check journal diameter. As shown in figure, crank web no.2 has...

  • Page 348

    1d-66 engine mechanical: 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 349

    Engine mechanical: 1d-67 • if necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. A. Regrind journal to the following finished diameter. Finished journal diameter 51.7320 – 51.7500 mm (2.0367 – 2.0374 in.) b. Using micrometer, measure regrind journal diamete...

  • Page 350

    1d-68 engine mechanical: sensor plate inspection s7rw0a1406040 check sensor plate for crack damage. If malcondition is found, replace it. Rear oil seal inspection s7rw0a1406041 carefully inspect oil seal (1) for wear or damage. If its lip is worn or damaged, replace it. Flywheel inspection s7rw0a140...

  • Page 351

    Engine mechanical: 1d-69 specifications tightening torque specifications s7rw0a1407001 note the specified tightening torque is also described in the following. “air intake system components” “engine mountings components” “timing chain cover components” “timing chain and chain tensioner components” “...

  • Page 352

    1d-70 engine mechanical: reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. Special tools and equipment recommended service material s7rw0a1408001 note required service material is also described in the following. “timing c...

  • Page 353

    Engine mechanical: 1d-71 09916–14521 09916–34542 valve spring compressor attachment reamer handle ) / ) ) / ) 09916–34550 09916–37320 reamer handle valve guide outer reamer (10.5 mm) ) ) 09916–44910 09916–56011 valve guide installer & remover valve guide installer attachment (protrusion: 11.5 mm) ) ...

  • Page 354: Engine Lubrication System

    1e-1 engine lubrication system: engine engine lubrication system general description engine lubrication description s7rw0a1501001 the oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filter...

  • Page 355

    Engine lubrication system: 1e-2 diagnostic information and procedures oil pressure check s7rw0a1504001 warning ! To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Note prior to c...

  • Page 356

    1e-3 engine lubrication system: 8) start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) connect oil pressure switch coupler (1). Repair instructions oil pan and oil pump strainer components s7rw0a1506001 i2rh0b150006-01 1 2 3 4 (a) 5 (b) 6 (b) 8 (b) 9 (b...

  • Page 357

    Engine lubrication system: 1e-4 oil pan and oil pump strainer removal and installation s7rw0a1506002 removal 1) remove oil level gauge. 2) drain engine oil by removing drain plug. 3) for 4wd model, dismount transfer referring to “transfer dismounting and remounting in section 3c”. 4) remove clutch h...

  • Page 358

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

  • Page 359

    Engine lubrication system: 1e-6 oil pump components s7rw0a1506004 oil pump removal and installation s7rw0a1506005 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 360

    1e-7 engine lubrication system: 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 361

    Engine lubrication system: 1e-8 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 362

    1e-9 engine lubrication system: specifications tightening torque specifications s7rw0a1507001 note the specified tightening torque is also described in the following. “oil pan and oil pump strainer components” “oil pump components” reference: for the tightening torque of fastener not specified in th...

  • Page 363: Engine Cooling System

    Engine cooling system: 1f-1 engine engine cooling system general description cooling system description s7rw0a1601001 the cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. Coolant description...

  • Page 364

    1f-2 engine cooling system: schematic and routing diagram coolant circulation s7rw0a1602001 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 365

    Engine cooling system: 1f-3 diagnostic information and procedures engine cooling symptom diagnosis s7rw0a1604001 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 366

    1f-4 engine cooling system: repair instructions cooling system components s7rw0a1606001 i5rw0c160012-01 1. Radiator 11. Thermostat case water outlet pipe 21. Heater outlet no.1 hose 2. Reservoir 12. Thermostat case 22. Radiator cooling fan assembly for disassembly and reassembly, refer to “radiator ...

  • Page 367

    Engine cooling system: 1f-5 coolant level check s7rw0a1606002 warning ! To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if radiator cap is taken off too soon. To check level, lift hood ...

  • Page 368

    1f-6 engine cooling system: cooling system flush and refill s7rw0a1606005 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 369

    Engine cooling system: 1f-7 thermostat removal and installation s7rw0a1606007 removal 1) drain coolant referring to “cooling system draining”. 2) remove intake manifold referring to “intake manifold removal and installation in section 1d”. 3) disconnect water hose (1) and heater hose (2) from each p...

  • Page 370

    1f-8 engine cooling system: radiator cooling fan assembly on-vehicle inspection s7rw0a1606009 1) check continuity between terminals. If there is no continuity, replace radiator fan assembly. 2) connect battery to radiator fan motor coupler as shown in figure, then check that the radiator fan motor o...

  • Page 371

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

  • Page 372

    1f-10 engine cooling system: water pump / generator drive belt tension inspection and adjustment s7rw0a1606015 warning ! • disconnect negative cable at battery before checking and adjusting belt tension. • to help avoid danger of being burned, do not remove radiator cap while engine and radiator are...

  • Page 373

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

  • Page 374

    1f-12 engine cooling system: water pump inspection s7rw0a1606018 caution ! Do not disassemble water pump. If any repair is required on pump, replace it as assembly. Rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, replace it. Specific...

  • Page 375: Fuel System

    Fuel system: 1g-1 engine fuel system precautions precautions on fuel system service s7rw0a1700001 warning ! Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. • disconnect negative cable at battery. •...

  • Page 376

    1g-2 fuel system: general description fuel system description s7rw0a1701001 caution ! This engine requires the unleaded fuel only. The leaded and/or low lead fuel can result in engine damage and reduce the effectiveness of the emission control system. The main components of the fuel system are fuel ...

  • Page 377

    Fuel system: 1g-3 schematic and routing diagram fuel delivery system diagram s7rw0a1702001 diagnostic information and procedures fuel pressure inspection s7rw0a1704001 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the ri...

  • Page 378

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

  • Page 379

    Fuel system: 1g-5 repair instructions fuel system components s7rw0a1706001 i6rw0d170001-01 1. Fuel tank 11. Fuel vapor line 21. Fuel pump bolt 2. Fuel pump assembly 12. Fuel tank protector 22. Fuel tank inlet valve 3. Fuel tank filler hose 13. Insulator 23. Fuel pump gasket 4. Fuel tank filler neck ...

  • Page 380

    1g-6 fuel system: fuel hose disconnecting and reconnecting s7rw0a1706002 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. For connection other than quick joint • clamp around fuel tank ...

  • Page 381

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

  • Page 382

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

  • Page 383

    Fuel system: 1g-9 fuel injector on-vehicle inspection s7rw0a1706007 1) using sound scope (1) or such, check operating sound of injector (2) when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, check injector cir...

  • Page 384

    1g-10 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 ins...

  • Page 385

    Fuel system: 1g-11 4) install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting. 5) put graduated cylinder under injector. 6) operate fuel pump and apply fuel pressure to injector as follows: a) when using scan tool: i) connect scan tool to dlc with ignition ...

  • Page 386

    1g-12 fuel system: fuel filler cap inspection s7rw0a1706010 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. Remove cap (1), and check gasket for even filler neck imprint, and deteriora...

  • Page 387

    Fuel system: 1g-13 fuel tank removal and installation s7rw0a1706013 warning ! Before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. Removal 1) relieve fuel pressure in fuel feed line according to “fue...

  • Page 388

    1g-14 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 ...

  • Page 389

    Fuel system: 1g-15 fuel tank purging procedure s7rw0a1706015 warning ! • before starting the following procedure, be sure to observe “precautions on fuel system service” in order to reduce the risk of fire and personal injury. • this purging procedure will not remove all fuel vapor. Do not attempt a...

  • Page 390

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

  • Page 391

    Fuel system: 1g-17 fuel pump inspection s7rw0a1706019 • check fuel pump assembly for damage. • check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank. • for electrical circuit, refer to “fuel pump and its circuit che...

  • Page 392

    1g-18 fuel system: special tools and equipment special tool s7rw0a1708001 09912–57610 09912–58421 injector checking tool plate checking tool set ) this kit includes the following items. 1. Tool body and washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose and clamp, 6. Body attachme...

  • Page 393: Ignition System

    Ignition system: 1h-1 engine ignition system general description ignition system construction s7rw0a1801001 the ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below. • ecm it detects the engine and vehicle conditions through the signals from...

  • Page 394

    1h-2 ignition system: schematic and routing diagram ignition system wiring circuit diagram s7rw0a1802001 e01-60 e01-29 12v 5v 5v e01-1 e01-16 blk/wht blk/red blk/red blk/red 80a blk/yel blk/yel blk/yel grn blk wht brn/wht blk/orn blk blk blk c01-20 blk/red pnk blk/orn 5v c01-21 blk/wht 7 3 4 1 12 5 ...

  • Page 395

    Ignition system: 1h-3 component location ignition system components location s7rw0a1803001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 12* 15* 13 1 6 8 9 11 10 7 4 5 14 2 3 16 i5rw0c180002-01 1. Ecm 7. Ect sens...

  • Page 396

    1h-4 ignition system: diagnostic information and procedures ignition system symptom diagnosis s7rw0a1804001 reference waveform of ignition system s7rw0a1804002 refer to “reference waveform no.5”, “reference waveform no.6” and “reference waveform no.7” under “inspection of ecm and its circuits in sec...

  • Page 397

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

  • Page 398

    1h-6 ignition system: ignition spark test s7rw0a1804004 1) remove air cleaner assembly with air intake pipe. 2) disconnect all injector couplers from injectors. Warning ! Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignit...

  • Page 399

    Ignition system: 1h-7 high-tension cord inspection s7rw0a1806002 measure resistance of high-tension cord (1) by using ohmmeter. If resistance exceeds specification, replace high-tension cord(s). High-tension cord resistance no.1 cylinder high-tension cord resistance: 1.4 – 4.0 k Ω no.3 cylinder high...

  • Page 400

    1h-8 ignition system: ignition coil assembly (including ignitor) removal and installation s7rw0a1806005 removal 1) disconnect negative cable at battery. 2) remove air cleaner assembly with air intake pipe and cylinder head upper cover. 3) disconnect ignition coil coupler. 4) disconnect high-tension ...

  • Page 401

    Ignition system: 1h-9 initial ignition timing fixed with suzuki scan tool: 5 ± 3° btdc (at specified idle speed) ignition order 1 – 3 – 4 – 2 special tool (a): 09930–76420 7) if ignition timing is out of specification, check the followings. • ckp sensor • ckp sensor plate • tp sensor • cmp sensor • ...

  • Page 402: Starting System

    1i-1 starting system: engine starting system schematic and routing diagram cranking system circuit diagram s7rw0a1902001 diagnostic information and procedures cranking system symptom diagnosis s7rw0a1904001 possible symptoms due to starting system trouble would be as follows: • starting motor does n...

  • Page 403

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

  • Page 404

    1i-3 starting system: cranking system test s7rw0a1904002 caution ! Each test must be performed within 3 – 5 seconds to avoid coil from burning. Pull-in test connect battery to the magnetic switch as shown. Check that plunger and pinion move outward. If plunger and pinion don’t move, replace the magn...

  • Page 405

    Starting system: 1i-4 repair instructions starting motor dismounting and remounting s7rw0a1906001 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 406

    1i-5 starting system: starting motor components s7rw0a1906002 i4rs0a190003-01 1. Front housing 7. Plate 13. Planetary gear 19. Rear bush 2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut 3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 n ⋅m (0.98 kgf-m, 7.0 lb-ft) 4. Over-...

  • Page 407

    Starting system: 1i-6 starting motor inspection s7rw0a1906003 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 408

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

  • Page 409

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

  • Page 410

    1i-9 starting system: front housing bush inspect the bush for wear or damage. Replace if necessary. Specifications cranking system specifications s7rw0a1907001 tightening torque specifications s7rw0a1907002 note the specified tightening torque is also described in the following. “starting motor dism...

  • Page 411: Charging System

    Charging system: 1j-1 engine charging system general description battery description s7rw0a1a01001 the battery has three major functions in the electrical system. • it is a source of electrical energy for cranking the engine. • it acts as a voltage stabilizer for the electrical system. • it can, for...

  • Page 412

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

  • Page 413

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

  • Page 414

    1j-4 charging system: generator symptom diagnosis s7rw0a1a04002 caution ! • do not mistake polarities of “ig” terminal and “l” terminal. • do not create short circuit between “ig” and “l” terminals. Always connect these terminals through a lamp. • do not connect any load between “l” and “e” terminal...

  • Page 415

    Charging system: 1j-5 2) run engine from idling up to 2,000 rpm with all accessories turned off and read meters. If voltage is higher than standard value, check ground of brushes. If brushes are not grounded, replace ic regulator. If voltage is lower than standard value, proceed to the following che...

  • Page 416

    1j-6 charging system: repair instructions jump starting in case of emergency s7rw0a1a06001 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. Bo...

  • Page 417

    Charging system: 1j-7 remounting 1) reverse removal procedure. 2) tighten battery cables securely. Note check to be sure that ground cable has enough clearance to hood panel by terminal. Water pump / generator drive belt tension inspection and adjustment s7rw0a1a06003 warning ! • disconnect negative...

  • Page 418

    1j-8 charging system: water pump / generator drive belt removal and installation s7rw0a1a06004 removal 1) disconnect negative cable at battery. 2) if vehicle equipped with a/c, remove compressor drive belt before removing water pump belt (1). Refer to “compressor drive belt removal and installation:...

  • Page 419

    Charging system: 1j-9 generator components s7rw0a1a06006 i4rs0a1a0004-01 1. Pulley nut 8. Rotor 15. Insulator : 111 n ⋅m (11.1 kgf-m, 80.5 lb-ft) 2. Pulley 9. End housing bearing 16. Regulator : 9.8 n ⋅m (0.98 kgf-m, 7.0 lb-ft) 3. Drive end frame 10. Bearing cover 17. Brush : 3.0 n ⋅m (0.3 kgf-m, 2....

  • Page 420

    1j-10 charging system: generator inspection s7rw0a1a06007 rotor 1) using ohmmeter, connect positive terminal to “fr” terminal and connect negative terminal to “b” terminal of generator, check that continuity between “b” terminal and “fr” terminal. If there is no continuity, replace rotor or regulato...

  • Page 421

    Charging system: 1j-11 4) check slip rings for roughness or scoring. If rough or scored, replace the rotor. Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace the rotor. Slip ring diameter standard: 14.2 – 14.4 mm (0.560 – 0.566 in.) limit: 12.8 mm...

  • Page 422

    1j-12 charging system: specifications charging system specifications s7rw0a1a07001 battery note the battery used in each vehicle is one of the following two types, depending on specification. Battery : 46b24r (40.6ah/5hr), 55b24r (42.5ah/5hr) 12v generator tightening torque specifications s7rw0a1a07...

  • Page 423: Exhaust System

    Exhaust system: 1k-1 engine exhaust system general description exhaust system description s7rw0a1b01001 the exhaust system consists of an exhaust manifold, three-way catalytic converter (twc) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is a...

  • Page 424

    1k-2 exhaust system: repair instructions exhaust system components s7rw0a1b06001 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. 1 2 3 5 6 7 8 9 10 12 12 16 17 18 18 ...

  • Page 425

    Exhaust system: 1k-3 exhaust manifold removal and installation s7rw0a1b06002 removal warning ! To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. 1) disconnect negative cable at battery. 2) disconnect ho2s-1 conn...

  • Page 426

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

  • Page 427: 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 428

    2-ii table of contents wheels and tires specifications .........................2d-6 tightening torque specifications........................2d-6.

  • Page 429: Precautions

    Precautions: 2-1 suspension precautions precautions precautions on suspension s7rw0a2000001 suspension caution refer to “suspension caution in section 00”. Wheels and tires caution refer to “wheels and tires caution in section 00”. General precautions refer to “general precautions in section 00”. Ve...

  • Page 430: Suspension General Diagnosis

    2a-1 suspension general diagnosis: suspension suspension general diagnosis diagnostic information and procedures suspension, wheels and tires symptom diagnosis s7rw0a2104001 condition possible cause correction / reference item vehicle pulls (leads) mismatched or uneven tires replace tires. Tires not...

  • Page 431

    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.) suspension bottoms overloaded check loading. Faulty strut (shock absorber) replace strut (shock absorber). Incorrect, broken or sagging coi...

  • Page 432: Front Suspension

    2b-1 front suspension: suspension front suspension general description front suspension construction s7rw0a2201001 caution ! There are two types of front suspension mounting bolt. One is pre-coated with friction stabilizer. The other is not. Never reuse pre-coated bolt to prevent it from loosening. ...

  • Page 433

    Front suspension: 2b-2 front wheel alignment construction s7rw0a2201002 among factors for front wheel alignment, only toe setting can be adjusted. Camber and caster are not adjustable. Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or...

  • Page 434

    2b-3 front suspension: toe (total) (“b” – “a”) front: in 1.0 ± 1.0 mm (0.0394 ± 0.0394 in.) adjustment caution ! • never adjust only right or left tie-rod, be sure to adjust both tie-rods by same amount. • make sure that rack boot is not twisted. Otherwise, rack boot may be broken. 1) check tie-rod ...

  • Page 435

    Front suspension: 2b-4 steering angle check and adjustment s7rw0a2206020 when tie-rod or tie-rod end was replaced, check toe and then also steering angle with turning radius gauge. If measured value is out of specified value, perform inspection and adjustment of toe. Steering angle inside: 36 °± 2° ...

  • Page 436

    2b-5 front suspension: front strut assembly removal and installation s7rw0a2206003 caution ! When rebound stopper and strut assembly were removed, check strut support lower nut for specified torque before installing strut assembly. Removal 1) remove hood rear seal (1), and then remove cowl top garni...

  • Page 437

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

  • Page 438

    2b-7 front suspension: 2) install compressed coil spring to strut, and place coil spring end (2) onto spring lower seat (1) as shown. Note end of coil spring must not interfere with step of spring lower seat. 3) install bump stopper and strut dust cover onto strut rod. For installing direction, refe...

  • Page 439

    Front suspension: 2b-8 front wheel hub and steering knuckle components s7rw0a2206006 front wheel hub, steering knuckle and wheel bearing removal and installation s7rw0a2206007 caution ! When removing and installing steering knuckle assembly, be careful not to damage dust boots of control arm joint b...

  • Page 440

    2b-9 front suspension: 6) pull out wheel hub (1) with special tools. Special tool (a): 09943–17912 (b): 09942–15511 caution ! When wheel hub is removed, replace wheel bearing with new one. 7) disconnect tie-rod end from steering knuckle referring to “tie-rod end removal and installation in section 6...

  • Page 441

    Front suspension: 2b-10 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 caution ! • never reuse wheel bearing and circlip. Otherwise, abnormal noise and abnormal vibra...

  • Page 442

    2b-11 front suspension: 6) using special tool and hydraulic press, press fit wheel hub (1) into wheel bearing (2) (face grooved rubber seal side to wheel hub). Special tool (a): 09913–75510 7) apply grease lightly to end face of inner ring (1). “a”: grease 99000–25121 (suzuki super grease h) note do...

  • Page 443

    Front suspension: 2b-12 13) connect tie-rod end to steering knuckle, referring to “tie-rod end removal and installation in section 6c”. 14) install brake disc (2) and brake caliper (3). 15) tighten caliper carrier bolt to specified torque. Tightening torque caliper carrier bolt: 85 n·m (8.5 kgf-m, 6...

  • Page 444

    2b-13 front suspension: suspension control arm removal and installation s7rw0a2206009 caution ! When removing and installing steering knuckle assembly, be careful not to damage dust boots of control arm joint by drive shaft dust cover and brake dust cover. Removal 1) hoist vehicle and remove wheel. ...

  • Page 445

    Front suspension: 2b-14 assembly caution ! Be sure to use new bush. 1) front bush press-fit front bush (1) by using special tools and press (2). Special tool (a): 09943–76310 (b): 09913–75821 note • before installing bush, apply soap water on its circumference to facilitate bush installation. 2) pre...

  • Page 446

    2b-15 front suspension: front suspension frame, stabilizer bar and/or bush components s7rw0a2206014 front suspension frame, stabilizer bar and/or bush removal and installation s7rw0a2206015 warning ! When supporting and installing front suspension frame, be sure to apply some supporting equipment (s...

  • Page 447

    Front suspension: 2b-16 10) remove engine rear mounting nut and mounting member nut referring to “engine mountings components in section 1d”. 11) support front suspension frame (2) with mission jack (1). 12) remove engine rear mounting, mounting member bolt and front suspension frame mounting bolts ...

  • Page 448

    2b-17 front suspension: 3) support front suspension frame (2) with mission jack (1) and jack up it. 4) align lugs (1) (right and left) of front suspension frame with whole (2) in vehicle body. 5) tighten front suspension frame bolts to specified torque. Tightening torque front suspension frame mount...

  • Page 449

    Front suspension: 2b-18 front suspension frame check s7rw0a2206016 inspect for cracks, deformation or damage. If defective, replace. Front stabilizer bar, bush and/or joint check s7rw0a2206017 stabilizer bar inspect for damage or deformation. If defective, replace. Stabilizer bush inspect for damage...

  • Page 450

    2b-19 front suspension: specifications tightening torque specifications s7rw0a2207001 note the specified tightening torque is also described in the following. “front suspension construction” “front strut assembly components” “front wheel hub and steering knuckle components” “front suspension frame, ...

  • Page 451

    Front suspension: 2b-20 special tools and equipment recommended service material s7rw0a2208001 special tool s7rw0a2208002 material suzuki recommended product or specification note grease suzuki super grease h p/no.: 99000–25121 ) 09913–65810 09913–75510 crankshaft bearing puller bearing installer ) ...

  • Page 452: Rear Suspension

    2c-1 rear suspension: suspension rear suspension repair instructions rear suspension components s7rw0a2306001 i7rw0a230001-01 f: forward 7. Vehicle body 16. Rear drive shaft nut [a]: 2wd model 8. Rear shock absorber 17. Rear wheel hub assembly [b]: 4wd model 9. Lower washer : 73 n ⋅m (7.3 kgf-m, 53....

  • Page 453

    Rear suspension: 2c-2 rear wheel alignment inspection s7rw0a2306012 measure toe and camber referring to “inspection” under “front wheel alignment inspection and adjustment in section 2b”. Note rear suspension is not adjustable structure. Toe (total) rear: in 5.0 ± 5.0 mm (in 0.1969 ± 0.1969 in.) cam...

  • Page 454

    2c-3 rear suspension: installation 1) install absorber upper bushes (1). Note for proper installing direction of absorber upper bushes (1), refer to the figure. 2) install shock absorber (1), upper washers (2). Tighten new rear shock absorber upper nut (4) and lower nut (5) temporarily at this step....

  • Page 455

    Rear suspension: 2c-4 rear shock absorber inspection s7rw0a2306003 • inspect for deformation or damage. • inspect bushes for wear or damage. • inspect for evidence of oil leakage. Replace any defective parts. Warning ! When handling rear shock absorber (1) in which high-pressure gas is sealed, make ...

  • Page 456

    2c-5 rear suspension: 5) detach each lower end (2) of shock absorbers (1) (right and left) from rear axle. 6) lower rear axle gradually as far down as the coil spring can be removed. Caution ! Be careful not to lower rear axle down too much. It may cause damage to brake flexible hose, wheel speed se...

  • Page 457

    Rear suspension: 2c-6 4) remove floor jacks from rear axle. 5) remount rear differential (4wd model) referring to “rear differential dismounting and remounting in section 3b”. 6) install wheel and tighten wheel nuts to specified torque. Tightening torque wheel nut: 85 n·m (8.5 kgf-m, 61.5 lb-ft) 7) ...

  • Page 458

    2c-7 rear suspension: installation caution ! Never reuse rear axle bolts and rear hub bolts. 1) install brake pipes to rear axle, if removed. 2) using floor jacks, install rear axle and new rear axle bolts (1) and tighten bolts temporarily. 3) install coil spring referring to “rear coil spring remov...

  • Page 459

    Rear suspension: 2c-8 rear wheel hub assembly inspection s7rw0a2306013 • check noise and smooth rotation of wheel by rotating wheel. If it is defective, replace wheel hub assembly. • measure thrust play of wheel hub using dial gauge as shown in figure. When the thrust play exceeds limit, replace whe...

  • Page 460

    2c-9 rear suspension: 8) if necessary, remove wheel stud 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 caution ! Rear hub bolt is pre-coated with friction stabilizer. Never reuse t...

  • Page 461

    Rear suspension: 2c-10 6) install brake drum referring to step 1) and 2) of “installation” under “rear brake drum removal and installation in section 4c”. 7) pull up parking brake lever. Install new rear drive shaft nut (1) to specified torque, and then caulk drive shaft nut (1) (4wd model). Caution...

  • Page 462: Wheels and Tires

    2d-1 wheels and tires: suspension wheels and tires precautions precautions in wheels and tires servicing s7rw0a2400001 • wheel repairs that use welding, heating, or peeling are not approved. All damaged wheels should be replaced. Studs if a broken stud is found, replace it referring to “front wheel ...

  • Page 463

    Wheels and tires: 2d-2 whenever a tire is dismounted from its wheel, it should be remounted so that the tire and wheel are matched. If the tire’s paint dot cannot be located, a line should be scribed on the tire and wheel before dismounting to assure that it is remounted in the same position. Replac...

  • Page 464

    2d-3 wheels and tires: irregular and/or premature wear description s7rw0a2401003 irregular and premature wear has many causes. Some of them are as follows: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, tire rotation i...

  • Page 465

    Wheels and tires: 2d-4 equipment manufacture’s recommendations radial tire lead / pull description s7rw0a2401006 “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 466

    2d-5 wheels and tires: repair instructions wheel discs inspection s7rw0a2406001 inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Wheel balance inspection and adjustment s7rw0a2406002 refer to “balancing wheels description”. Deposits of mud...

  • Page 467

    Wheels and tires: 2d-6 tightening order “1” – “2” – “3” – “4” – “5” tightening torque wheel nut (a): 85 n·m (8.5 kgf-m, 61.5 lb-ft) tire mounting and dismounting s7rw0a2406005 warning ! Do not stand over tire when inflating. Bead may break when bead snaps over rim’s safety hump and cause serious per...

  • Page 468

    2d-7 wheels and tires:.

  • Page 469: Section 3

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

  • Page 470

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

  • Page 471: Precautions

    Precautions: 3-1 driveline / axle precautions precautions precautions on driveline / axle s7rw0a3000001 precaution for rear differential oil leakage refer to “precaution for rear differential oil leakage in section 3b”. Precaution in diagnosing trouble refer to “precautions in diagnosing trouble in ...

  • Page 472: Drive Shaft / Axle

    3a-1 drive shaft / axle: front driveline / axle drive shaft / axle front general description front drive shaft construction s7rw0a3111001 a constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For a/t vehicle, a tripod type constant velocity join...

  • Page 473

    Drive shaft / axle: front 3a-2 diagnostic information and procedures front drive shaft symptom diagnosis s7rw0a3114001 repair instructions front drive shaft components s7rw0a3116001 condition possible cause correction / reference item abnormal noise worn or breakage of the drive shaft joint replace....

  • Page 474

    3a-3 drive shaft / axle: front front drive shaft assembly on-vehicle inspection s7rw0a3116002 • check boots for breakage or deterioration. • check wheel side joint for rattle or smooth rotation. • check differential side (or center shaft side) joint for smooth rotation. If any abnormality is found, ...

  • Page 475

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

  • Page 476

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

  • Page 477

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

  • Page 478

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

  • Page 479

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

  • Page 480

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

  • Page 481

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

  • Page 482

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

  • Page 483

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

  • Page 484

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

  • Page 485

    Drive shaft / axle: front 3a-14 special tools and equipment recommended service material s7rw0a3118001 note required service material is also described in the following. “front drive shaft components: front” special tool s7rw0a3118002 material suzuki recommended product or specification note grease ...

  • Page 486: Rear

    3a-15 drive shaft / axle: rear rear general description rear drive shaft construction s7rw0a3121001 refer to “front drive shaft construction: front”. Repair instructions rear drive shaft components s7rw0a3126001 i5rw0a312001-01 1. Differential side joint (constant velocity doj joint) : apply dark gr...

  • Page 487

    Drive shaft / axle: rear 3a-16 rear drive shaft assembly removal and installation s7rw0a3126002 removal 1) hoist vehicle and remove rear wheel. 2) undo caulking of drive shaft nut (1) and then remove drive shaft nut with pull up parking brake lever. 3) remove rear drive shaft flange nuts (1), and th...

  • Page 488

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

  • Page 489

    Drive shaft / axle: rear 3a-18 specifications tightening torque specifications s7rw0a3127001 note the specified tightening torque is also described in the following. “rear drive shaft components: rear” reference: for the tightening torque of fastener not specified in this section, refer to “fastener...

  • Page 490: Differential

    3b-1 differential: driveline / axle differential precautions precaution for rear differential oil leakage s7rw0a3200001 whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage. Precautions in diagnosing trouble s7rw0a3200002 • do not disconnect t...

  • Page 491

    Differential: 3b-2 general description rear differential description s7rw0a3201001 the differential assembly uses a hypoid bevel pinion and gear. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory. F...

  • Page 492

    3b-3 differential: 4wd control system description s7rw0a3201004 4wd shift control the 4wd control module operates the coupling assembly according to the 2wd/4wd switch operation to the selected position (2wd, 4wd-auto or 4wd-lock). Also, the 4wd control system has 4wd auto indicator and 4wd lock ind...

  • Page 493

    Differential: 3b-4 input / output signal table of 4wd control module s7rw0a3201008 4wd control module outputs the following signals to coupling assembly, indicators, according to the 2wd/4wd switch operation. On-board diagnostic system description s7rw0a3201009 for 4wd control system, 4wd control mo...

  • Page 494

    3b-5 differential: can communication system description s7rw0a3201010 refer to “can communication system description in section 1a” for can communication system description. When 4wd control module receive the signal of abnormal as following information, vehicle is not changed to 4wd- auto and 4wd-l...

  • Page 495

    Differential: 3b-6 schematic and routing diagram 4wd control system wiring circuit diagram s7rw0a3202007 5v 5v 12v g26-3 yel gry g26-2 g26-22 g26-23 red wht g26-13 g26-14 g26-12 g26-11 g26-10 blk wht/red red/blk gry/yel red/wht 12v l102-1 l102-4 1 3 7 9 10 12 13 14 12v g26-21 blu g26-25 g26-24 orn b...

  • Page 496

    3b-7 differential: terminal arrangement of 4wd control module 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 [a] i4ja01332038-01 [a]: connector “g26” viewed from harness side terminal circuit terminal circuit g26-2 coupling assembly (power) g26-14 “4wd lock” switch g26-3 coupli...

  • Page 497

    Differential: 3b-8 component location 4wd control system components location s7rw0a3203004 2 1 3 6 5 4 i5rw0a320002-04 1. 4wd control module 3. 4wd lock indicator 5. Coupling assembly 2. 4wd auto indicator 4. 2wd/4wd switch 6. Coupling air temperature sensor.

  • Page 498

    3b-9 differential: diagnostic information and procedures 4wd control system check s7rw0a3204001 refer to the following items for the details of each step. Step action yes no 1 ) customer complaint analysis 1) perform customer complaint analysis. Was customer complaint analysis performed? Go to step ...

  • Page 499

    Differential: 3b-10 detail of 4wd control system check step 1. Customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting info...

  • Page 500

    3b-11 differential: step 2. Dtc check, record and clearance first, referring to “dtc check”, check dtc and pending dtc. If dtc exists, print or write down dtc and then clear malfunction dtc(s) by referring to “dtc clearance”. Malfunction dtc indicates malfunction in the system but it is not possible...

  • Page 501

    Differential: 3b-12 visual inspection s7rw0a3204004 check the following parts and systems visually. Dtc check s7rw0a3204005 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel. Special tool (a): suzuki scan to...

  • Page 502

    3b-13 differential: dtc table s7rw0a3204007 note “o” in transfer position indicator column of the above table means indicator lights up when dtc is detected. Fail-safe table s7rw0a3204008 this function is provided by the safe mechanism that assures safe driveability even when the coupling assembly, ...

  • Page 503

    Differential: 3b-14 scan tool data s7rw0a3204009 scan tool data definitions accel pedal pos (accelerator pedal position) (%) accelerator pedal opening ratio detected by signal on can communication line fed from ecm. Engine speed (rpm) this parameter indicates engine revolution calculated by 4wd cont...

  • Page 504

    3b-15 differential: rear differential symptom diagnosis s7rw0a3204010 4wd control symptom diagnosis s7rw0a3204011 diagnose 4wd system after performing the following inspections. • perform 4wd control system check referring to “4wd control system check”. Condition possible cause correction / referenc...

  • Page 505

    Differential: 3b-16 4wd position indicator does not come on at ignition switch on but engine stops s7rw0a3204012 wiring diagram circuit description 4wd position indicator operates according to the signal from 4wd control module. If the 4wd control system is in good condition, 4wd position indicator ...

  • Page 506

    3b-17 differential: 4wd position indicator remains on steady at ignition switch on s7rw0a3204013 wiring diagram refer to “4wd position indicator does not come on at ignition switch on but engine stops”. Circuit description transfer position indicator operates according to the signal from 4wd control...

  • Page 507

    Differential: 3b-18 dtc c1240: 4wd control module power supply circuit malfunction s7rw0a3204014 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) turn ignition switch to on position for 10 seconds. 3) check dtc. Troubleshooting [a]: ...

  • Page 508

    3b-19 differential: dtc c1243: internal circuit malfunction of 4wd control module s7rw0a3204015 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and run it for 10 seconds. Or more. 3) stop vehicle and check dtc. Troubleshooting substit...

  • Page 509

    Differential: 3b-20 dtc confirmation procedure 1) clear dtc using scan tool. 2) turn ignition switch to on position for 10 seconds. 3) check dtc. Troubleshooting step action yes no 1 was “4wd control system check” performed? Go to step 2. Go to “4wd control system check”. 2 coupling air temperature ...

  • Page 510

    3b-21 differential: dtc c1251: coupling air temperature sensor circuit short s7rw0a3204017 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) turn ignition switch to on position for 10 seconds. 3) check dtc. Troubleshooting [a]: 4wd co...

  • Page 511

    Differential: 3b-22 dtc c1252: coupling assembly circuit open s7rw0a3204018 wiring diagram dtc detecting condition and trouble area 3 coupling assembly ground circuit check 1) disconnect connector from 4wd control module with ignition switch turned off. 2) measure resistance between “orn” terminal o...

  • Page 512

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

  • Page 513

    Differential: 3b-24 dtc c1253: coupling assembly circuit short s7rw0a3204019 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc using scan tool. 2) start engine and select 2wd/4wd switch to “lock” position. 3) keep engine running at 2000 rpm for 10 second...

  • Page 514

    3b-25 differential: dtc c1254: 2wd/4wd switch malfunction s7rw0a3204020 wiring diagram 4 coupling assembly check 1) check coupling assembly referring to “coupling assembly inspection”. Is it in good condition? Substitute a known- good 4wd control module and recheck. Replace coupling assembly. 5 coup...

  • Page 515

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

  • Page 516

    3b-27 differential: dtc u0073: control module communication bus off s7rw0a3204021 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0100: lost communication with ecm s7rw0a3204022 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0121: lost communication with abs / esp ® control mo...

  • Page 517

    Differential: 3b-28 terminal arrangement of 4wd control module connector (viewed from harness side) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 i4ja01332054-01 terminal number wire color circuit normal voltage condition g26-1 — — — — g26-2 grn coupling assembly (ground) abou...

  • Page 518

    3b-29 differential: reference waveform no.1 coupling assembly signal reference waveform no.2 can communication signal g26-24 orn coupling air temperature sensor (ground) 0 – 1 v ignition switch turned on position g26-25 brn coupling air temperature sensor (power) about 2.5 v ignition switch turned o...

  • Page 519

    Differential: 3b-30 repair instructions rear differential oil level check s7rw0a3206001 1) lift up vehicle and check oil leakage. Repair leaky point, if any. 2) remove oil level / filler plug (1) and check oil contamination and oil level is lower end of oil level / filler plug hole (2). If oil is ex...

  • Page 520

    3b-31 differential: 2wd/4wd switch removal and installation s7rw0a3206003 removal 1) disconnect negative cable at battery. 2) remove console box (2). 3) remove 2wd/4wd switch (1) from console box. Installation reverse removal procedure for installation. 2wd/4wd switch inspection s7rw0a3206004 check ...

  • Page 521

    Differential: 3b-32 coupling air temperature sensor inspection s7rw0a3206007 caution ! Do not heat up coupling air temperature sensor more than 100 °c (212 °f). Otherwise, coupling air temperature sensor will be damaged. • blow hot air to temperature sensing part (2) of coupling air temperature sens...

  • Page 522

    3b-33 differential: rear differential mountings components s7rw0a3206009 1 8 10 10 3 2 4 5 4 6 (a) 11 (a) (b) 9 (b) 7 (b) i5rw0a320022-04 1. Rear differential 6. Front mounting to body bolt 11. Rear mounting bolt 2. Front mounting arm 7. Front mounting to body nut : 80 n ⋅m (8.0 kgf-m, 58.0 lb-ft) 3...

  • Page 523

    Differential: 3b-34 front mounting arm and/or rear mounting bracket assembly removal and installation s7rw0a3206010 remove and install front mounting arm and/or rear mounting bracket after rear differential removed. For tightening torque of each bolt and nut, refer to “rear differential mountings co...

  • Page 524

    3b-35 differential: rear differential components s7rw0a3206013 4 5 9 2 30 6 (a) 13 12 (a) 3 a 3 a 14 16 17 21 18 29 3 a 1 (b) 22 1217g 10 1217g 11 8 oil 15 oil 19 20 oil 23 oil 25 oil 27 oil 27 oil 25 oil 19 oil 18 26 28 oil 26 oil 23 oil 24 oil (c) 14 7 i5rw0a320026-02 1. Flange nut 13. Differentia...

  • Page 525

    Differential: 3b-36 rear differential disassembly and reassembly s7rw0a3206014 disassembly 1) remove rear mounting bracket from rear differential referring to “front mounting arm and/or rear mounting bracket assembly removal and installation”. 2) remove drive shaft flanges. 3) separate coupling case...

  • Page 526

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

  • Page 527

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

  • Page 528

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

  • Page 529

    Differential: 3b-40 8) to engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting...

  • Page 530

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

  • Page 531

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

  • Page 532

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

  • Page 533

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

  • Page 534

    3b-45 differential: tooth contact pattern diagnosis and remedy normal high contact pinion is positioned too far from the center of drive bevel gear (1). • increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. • adjust drive bevel gear backlash to specifica...

  • Page 535

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

  • Page 536

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

  • Page 537

    Differential: 3b-48 specifications tightening torque specifications s7rw0a3207001 note the specified tightening torque is also described in the following. “rear differential mountings components” “rear differential components” reference: for the tightening torque of fastener not specified in this se...

  • Page 538

    3b-49 differential: special tool s7rw0a3208002 09900–20607 09900–20701 dial gauge magnetic stand ) ) 09912–34510 09913–50121 case separator oil seal remover ) / ) ) / ) 09913–60910 09913–65135 bearing and gear puller (40- 60mm) bearing puller ) ) 09913–70123 09913–75510 bearing installing tool beari...

  • Page 539

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

  • Page 540: Transfer

    3c-1 transfer: driveline / axle transfer general description transfer description s7rw0a3301001 the transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in transaxle coupled by involute spline. Driving force from transaxle is transmitted...

  • Page 541

    Transfer: 3c-2 repair instructions transfer oil level check s7rw0a3306001 1) lift up vehicle and check oil leakage. Repair leaky point, if any. 2) remove oil level / filler plug (1) and check oil contamination and oil level is lower end of oil level / filler plug hole (2). If oil is excessive dirty ...

  • Page 542

    3c-3 transfer: transfer dismounting and remounting s7rw0a3306003 dismounting 1) disconnect negative cable at battery. 2) drain transaxle oil and transfer oil. 3) remove drive shafts assembly referring to “front drive shaft assembly removal and installation: front in section 3a”. 4) remove exhaust no...

  • Page 543

    Transfer: 3c-4 • pour transaxle oil and transfer oil referring to “manual transaxle oil change in section 5b” and “transfer oil change”. Transfer assembly components s7rw0a3306004 1 2 6 9 11 10 8 7 3 a 4 5 36 oil (a) 5 (a) oil 28 18 30 27 25 21 28 13 12 22 oil oil 32 a 31 a 1322 (d) 34 a 33 23 a 20 ...

  • Page 544

    3c-5 transfer: transfer assembly disassembly and reassembly s7rw0a3306005 disassembly note it is possible to disassemble transfer assembly without removing intermediate shaft with step 1) to 4) performed if not necessary. 1) remove right case oil seal no.1 (1) from transfer right case using special ...

  • Page 545

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

  • Page 546

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

  • Page 547

    Transfer: 3c-8 reduction driven gear assembly disassembly and reassembly s7rw0a3306007 disassembly 1) remove left bearing (1) and bevel gear (2) using special tool, bearing puller (3) and hydraulic press (4). Special tool (a): 09925–98221 2) in order to remove right bearing (1) from reduction driven...

  • Page 548

    3c-9 transfer: 3) install left bearing (1) to reduction driven gear (2) using special tools and hydraulic press. Special tool (a): 09913–84510 (b): 09924–84510–005 transfer right case and left case disassembly and reassembly s7rw0a3306008 disassembly 1) remove oil seals from right case (1) using spe...

  • Page 549

    Transfer: 3c-10 transfer output retainer assembly disassembly and reassembly s7rw0a3306009 disassembly 1) uncaulk transfer output flange nut. 2) remove transfer output flange nut while holding flange (1) by using special tool. Special tool (a): 09930–40113 3) remove transfer output flange (1) by bea...

  • Page 550

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

  • Page 551

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

  • Page 552

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

  • Page 553

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

  • Page 554

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

  • Page 555

    Transfer: 3c-16 specifications tightening torque specifications s7rw0a3307001 note the specified tightening torque is also described in the following. “transfer assembly components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in sec...

  • Page 556

    3c-17 transfer: special tools and equipment recommended service material s7rw0a3308001 note required service material is also described in the following. “transfer assembly components” special tool s7rw0a3308002 material suzuki recommended product or specification note grease suzuki super grease a p...

  • Page 557

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

  • Page 558: Propeller Shaft

    3d-1 propeller shaft: driveline / axle propeller shaft precautions propeller shaft caution s7rw0a3400001 caution ! • all propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They mus...

  • Page 559

    Propeller shaft: 3d-2 repair instructions propeller shaft joint check s7rw0a3406001 if universal joints and ball joint are suspected of producing chattering or rattling noise, inspect them for wear. For universal joint, check to see if cross spider rattles in yokes are worn down and replace defectiv...

  • Page 560

    3d-3 propeller shaft: specifications tightening torque specifications s7rw0a3407001 note the specified tightening torque is also described in the following. “propeller shaft construction” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information ...

  • Page 561: 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 562

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

  • Page 563

    Table of contents 4-iii visual inspection............................................... 4f-22 esp ® warning light does not come on at ignition switch on .......................................... 4f-23 esp ® warning light comes on steady.......... 4f-24 abs warning light does not come on at ignitio...

  • Page 564: Precautions

    4-1 precautions: brakes precautions precautions precautions for brakes s7rw0a4000001 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”. Esp ® system precauti...

  • Page 565

    Brake control system and diagnosis: 4a-1 brakes brake control system and diagnosis precautions precautions on brake s7rw0a4100001 air bag warning refer to“air bag warning in section 00”. Brakes diagnosis note refer to “brakes diagnosis note”. General description brakes construction s7rw0a4101001 whe...

  • Page 566

    4a-2 brake control system and diagnosis: brake pedal foot protection system construction (if equipped) s7rw0a4101002 should a front crash occur and the engine push the dash panel toward the interior side, the brake pedal bracket is also pushed toward the interior side. In this case, the brake pedal ...

  • Page 567

    Brake control system and diagnosis: 4a-3 brakes symptom diagnosis s7rw0a4104002 condition possible cause correction / reference item not enough braking force brake fluid leakage from brake lines locate leaking point and repair. Brake disc or pad stained with fluid, grease or other oil clean or repla...

  • Page 568

    4a-4 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 569

    Brake control system and diagnosis: 4a-5 repair instructions brake pedal components s7rw0a4106001 caution ! If equipped brake pedal foot protection system, never disassemble brake pedal assembly. Disassemble will spoil its original function. If faulty condition is found, replace it with new one. Bra...

  • Page 570

    4a-6 brake control system and diagnosis: excessive pedal travel inspection s7rw0a4106004 1) start engine. 2) depress brake pedal a few times. 3) with brake pedal depressed with approximately 300 n (30 kg, 66 lbs) load, measure brake pedal to wall (dash panel silencer) clearance “a”. If clearance is ...

  • Page 571

    Brake control system and diagnosis: 4a-7 brake light switch adjustment s7rw0a4106006 adjustment should be made as follows. Pull up brake pedal toward you and while holding it there, adjust switch position so that clearance between end of thread and brake pedal is as specified. Then lock it by turnin...

  • Page 572

    4a-8 brake control system and diagnosis: front brake hose / pipe components s7rw0a4106019 i7rw0a410001-01 [a]: lhd 3. From abs (esp ®) hydraulic unit to right front brake 9. Master cylinder fixing nut [b]: rhd 4. From abs hydraulic unit to left front brake : 18 n ⋅m (1.8 kgf-m, 13.0 lb-ft) [c]: abs ...

  • Page 573

    Brake control system and diagnosis: 4a-9 front brake hose and pipe removal and installation s7rw0a4106008 caution ! Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid, flush it with water immediately if any fluid is spilled. Removal 1) hoist vehicle ...

  • Page 574

    4a-10 brake control system and diagnosis: rear brake hose / pipe components s7rw0a4106020 rear brake hose and pipe removal and installation s7rw0a4106009 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...

  • Page 575

    Brake control system and diagnosis: 4a-11 master cylinder and brake booster components s7rw0a4106011 caution ! Never disassemble master cylinder and brake booster. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. 4 2 2 1 (b) 10 9 8 7 11 12 6 3 5 (a...

  • Page 576

    4a-12 brake control system and diagnosis: master cylinder reservoir removal and installation s7rw0a4106012 caution ! Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid, flush it with water immediately if any fluid is spilled. Removal 1) clean outside...

  • Page 577

    Brake control system and diagnosis: 4a-13 6) fill reservoir with specified brake fluid up to its max level. 7) after completing the work, bleed air from brake system referring to “air bleeding of brake system” and bleed air from clutch system referring to“air bleeding of clutch system in section 5c”...

  • Page 578

    4a-14 brake control system and diagnosis: 4) connect brake pipe to master cylinder and tighten flare nuts to specified torque. Tightening torque brake pipe flare nut for m10 (a): 16 n·m (1.6 kgf- m, 12.0 lb-ft) brake pipe flare nut for m12 (a): 19 n·m (1.9 kgf- m, 14.0 lb-ft) 5) connect clutch reser...

  • Page 579

    Brake control system and diagnosis: 4a-15 4) if pedal travel doesn’t change, air tightness isn’t obtained. Note if defective, inspect vacuum lines and sealing parts, and replace any faulty part. When this has been done, repeat the entire test. Check operation 1) with engine stopped, depress brake pe...

  • Page 580

    4a-16 brake control system and diagnosis: brake booster removal and installation s7rw0a4106016 removal 1) remove master cylinder assembly from booster referring to “master cylinder removal and installation”. 2) disconnect vacuum hose from booster referring to “master cylinder and brake booster compo...

  • Page 581

    Brake control system and diagnosis: 4a-17 specifications tightening torque specifications s7rw0a4107001 note the specified tightening torque is also described in the following. “brake pedal components” “front brake hose / pipe components” “rear brake hose / pipe components” “master cylinder and brak...

  • Page 582: Front Brakes

    4b-1 front brakes: brakes front brakes repair instructions front disc brake components s7rw0a4206001 i8rw01420001-01 1. Caliper 9. Disc brake piston : apply rubber grease included in piston seal set or brake fluid to contact surface of cylinder. 17. Brake flexible hose : be sure to direct mark (18) ...

  • Page 583

    Front brakes: 4b-2 front disc brake pad on-vehicle inspection s7rw0a4206002 inspect pad linings periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end and inspection hole of caliper and check lining thickness of ou...

  • Page 584

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

  • Page 585

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

  • Page 586

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

  • Page 587

    Front brakes: 4b-6 4) insert piston into cylinder by hand and fit boot in boot groove in piston. 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 no...

  • Page 588

    4b-7 front brakes: 3) pull brake disc off by using 8 mm bolts (1) (2 pcs). Installation 1) install caliper assembly to steering knuckle. Caution ! Make sure that flexible hose is not twisted when installing caliper assembly. If it is twisted, reinstall it using care not to twist it. 2) tighten calip...

  • Page 589

    Front brakes: 4b-8 specifications tightening torque specifications s7rw0a4207001 note the specified tightening torque is also described in the following. “front disc brake components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in s...

  • Page 590: Rear Brakes

    4c-1 rear brakes: brakes rear brakes repair instructions rear drum brake components s7rw0a4306001 11 2 3 4 5 6 7 12 14 1 13 10 16 19 15 17 9 8 18 f (a) (b) (c) (d) i6rw0d430001-01 1. Brake drum 10. Wheel cylinder 19. Bleeder plug 2. Brake shoe 11. Brake back plate : 73 n ⋅m (7.3 kgf-m, 53 lb-ft) 3. ...

  • Page 591

    Rear brakes: 4c-2 rear brake drum removal and installation s7rw0a4306002 removal 1) hoist vehicle and remove rear wheel. 2) release parking brake lever. 3) remove brake drum (1) by using 8 mm bolts (2) (2 pcs). Installation 1) before installing brake drum, to maximize brake shoe-to-drum clearance, p...

  • Page 592

    4c-3 rear brakes: brake shoe caution ! Never polish lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage drum. When it is required to correct lining, replace it with a new one. Measure thickness of brake shoe (1). Also, c...

  • Page 593

    Rear brakes: 4c-4 installation install parts in reverse order of removal, noting the following. • before installing rear brake shoe to brake back plate, clean brake back plate and apply heat-resistance brake grease to a on which shoe rims rest. • push and rotate 90 ° hold down pin and install hold d...

  • Page 594

    4c-5 rear brakes: 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 system. For bleeding operation refer to “air bleeding of brake system in secti...

  • Page 595

    Rear brakes: 4c-6 specifications tightening torque specifications s7rw0a4307001 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 sec...

  • Page 596: Parking Brake

    4d-1 parking brake: brakes parking brake repair instructions parking brake cable components s7rw0a4406004 4 6 f t t f f r 3 [a] f 9 ( a ) 2 ( a ) 5 1 3 4 [a] ( a ) 10 ( a ) 10 ( b ) 11 ( b ) ( b ) 10 10 11 11 ( a ) ( a ) 11 7 8 ( b ) i6rw0d440001-01 t: top side 3. Equalizer 8. Parking brake cable le...

  • Page 597

    Parking brake: 4d-2 parking brake inspection and adjustment s7rw0a4406001 inspection hold center of parking brake lever grip and pull it up with 200 n (20 kg, 44 lbs) force. With parking brake lever pulled up as shown, count ratchet notches. There should be 4 – 9 notches. Also, check if both right a...

  • Page 598

    4d-3 parking brake: parking brake lever removal and installation s7rw0a4406003 removal 1) remove console box. 2) block vehicle wheels and release parking brake lever. 3) disconnect lead wire of parking brake switch at coupler. 4) loosen parking brake cable adjusting nut (1). 5) remove parking brake ...

  • Page 599

    Parking brake: 4d-4 specifications tightening torque specifications s7rw0a4407001 note the specified tightening torque is also described in the following. “parking brake cable components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information ...

  • Page 600: Abs

    4e-1 abs: brakes abs precautions precautions in diagnosing troubles s7rw0a4500001 to ensure that the trouble diagnosis is done accurately and smoothly, observe the following and follow “abs check”. • diagnostic information stored in abs control module memory can be cleared as well as checked by usin...

  • Page 601

    Abs: 4e-2 general description abs description s7rw0a4501001 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 602

    4e-3 abs: abs hydraulic unit / control module assembly description s7rw0a4501002 abs control module is a component of abs hydraulic unit / control module assembly and has the following functions. Self-diagnosis function abs control module diagnoses conditions of the system component parts (whether o...

  • Page 603

    Abs: 4e-4 schematic and routing diagram abs schematic s7rw0a4502001 1 3 2 8 6 5 7 12 4 15 17 16 14 9 18 19 11 10 20 21 22 13 23 input output abs control module wheel speed sensor (lr) wheel speed sensor (rf) g sensor (4wd model) wheel speed sensor (lf) pump motor driver (transistor) solenoid valve p...

  • Page 604

    4e-5 abs: abs wiring circuit diagram s7rw0a4502002 1. Abs hydraulic unit / control module assembly 9. Brake light switch 17. Wheel speed sensor (left-rear) 2. Abs control module 10. Abs warning light 18. Battery 3. Abs hydraulic unit 11. Ebd warning light (brake warning light) 19. Ignition switch 4....

  • Page 605

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

  • Page 606

    4e-7 abs: component location abs components location s7rw0a4503001 terminal circuit e08 1 can communication line (high) for ecm 2 can communication line (high) for bcm 3 g sensor ground (4wd model) 4 — 5 — 6 g sensor signal (4wd mode) 7 brake light switch 8 — 9 ignition switch 10 left-rear wheel spe...

  • Page 607

    Abs: 4e-8 diagnostic information and procedures abs check s7rw0a4504001 refer to the following items for the details of each step. Step action yes no 1 ) malfunction analysis 1) perform “customer complaint analysis: ”. 2) perform “problem symptom confirmation: ”. 3) perform “dtc check, record and cl...

  • Page 608

    4e-9 abs: step 1: malfunction analysis customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the point req...

  • Page 609

    Abs: 4e-10 problem symptom confirmation check if what the customer claimed in “customer questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (this step should be shared with the customer if possible.) check warning lights related to bra...

  • Page 610

    4e-11 abs: dtc check s7rw0a4504004 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (1). Special tool (a): suzuki scan tool 3) turn ignition switch to on position. 4) read dtc according to instructions displayed on suzuki scan tool and print it or write it ...

  • Page 611

    Abs: 4e-12 scan tool data s7rw0a4504007 the parameter data below are values measured with the scan tool when the normally operating vehicle is under the following conditions. When taking measurements for comparison by using the scan tool, be sure to check that the vehicle is under the following cond...

  • Page 612

    4e-13 abs: abs warning light does not come on at ignition switch on s7rw0a4504008 wiring diagram e08 [c] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 g241 [d] 1 3 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 18 20 2122 23 24 25 26 27 28 29 30 3132 wht grn 3 e08-2 e08-13 red wht 5...

  • Page 613

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

  • Page 614

    4e-15 abs: abs warning light comes on steady s7rw0a4504009 wiring diagram refer to “warning diagram” under “abs warning light does not come on at ignition switch on”. Circuit description refer to “circuit description” under “abs warning light does not come on at ignition switch on”. Troubleshooting ...

  • Page 615

    Abs: 4e-16 ebd warning light (brake warning light) comes on steady s7rw0a4504010 wiring diagram referring to “wiring diagram” under “abs warning light does not come on at ignition switch on”. Circuit description ebd warning light (brake warning light) is controlled by abs control module and bcm thro...

  • Page 616

    4e-17 abs: serial data link circuit check s7rw0a4504011 wiring diagram 5 can communication line circuit check 1) turn ignition switch to off position. 2) disconnect connectors of all control modules communicating by means of can. 3) check for proper connection to can communication line wire. 4) if o...

  • Page 617

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

  • Page 618

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

  • Page 619

    Abs: 4e-20 dtc c1013: control module mismatch s7rw0a4504012 wiring diagram dtc detecting condition and trouble area note when abs hydraulic unit / control module assembly for 4wd model is installed to 2wd model, this dtc is set. Replace to the correct abs hydraulic unit / control module assembly. Tr...

  • Page 620

    4e-21 abs: dtc c1015: g sensor circuit (4wd model) s7rw0a4504013 wiring diagram refer to “wiring diagram” under “dtc c1013: control module mismatch”. Dtc detecting condition and trouble area note when a vehicle is lifted up and its wheel(s) is turned, this dtc is set. In such case, clear the dtc and...

  • Page 621

    Abs: 4e-22 dtc 1016: brake light switch s7rw0a4504014 wiring diagram dtc detecting condition and trouble area note when a vehicle is lifted up and its wheel(s) is turned, this dtc is set. In such case, clear the dtc and check again. Troubleshooting wht grn 3 4 7 12v e08-7 e08-9 grn/orn 2 8 1 12v grn...

  • Page 622

    4e-23 abs: dtc c1021 / c1022 / c1025 / c1026 / c1031 / c1032 / c1035 / c1036: wheel speed sensor circuit / sensor or encoder s7rw0a4504015 dtc c1021 / c1025 / c1031 / c1035: right-front / left-front / right-rear / left-rear wheel speed sensor circuit dtc c1022 / c1026 / c1032 / c1036: right-front / ...

  • Page 623

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

  • Page 624

    4e-25 abs: dtc c1033: wheel speed sensor deviation s7rw0a4504016 wiring diagram refer to “wiring diagram” under “dtc c1021 / c1022 / c1025 / c1026 / c1031 / c1032 / c1035 / c1036: wheel speed sensor circuit / sensor or encoder”. Dtc detecting condition and trouble area dtc troubleshooting dtc detect...

  • Page 625

    Abs: 4e-26 dtc c1041 / c1042 / c1045 / c1046 / c1051 / c1052 / c1055 / c1056: inlet / outlet solenoid s7rw0a4504017 dtc c1041 / c1045 / c1051 / c1055: right-front / left-front / right-rear / left- rear inlet solenoid dtc c1042 / c1046 / c1052 / c1056: right-front / left-front / right-rear / left- re...

  • Page 626

    4e-27 abs: dtc c1057: power supply voltage too high / too low s7rw0a4504018 wiring diagram dtc detecting condition and trouble area dtc troubleshooting wht grn 3 4 5 e08-23 blk 12v e08-9 grn/orn 2 1 [a] e08 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 i7rw01450009-03 [a]: abs...

  • Page 627

    Abs: 4e-28 dtc c1061: pump motor circuit s7rw0a4504019 wiring diagram dtc detecting condition and trouble area dtc troubleshooting wht/red 1 2 5 m 3 4 12v e08-25 e08-26 blk e08 [a] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 i7rw01450010-02 [a]: abs control module connector ...

  • Page 628

    4e-29 abs: dtc c1063: solenoid valve power supply driver circuit s7rw0a4504020 wiring diagram dtc detecting condition and trouble area dtc troubleshooting e08 [a] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 wht grn 3 4 7 e08-23 blk 12v e08-9 grn/orn 2 1 wht/blu 5 e08-24 6 i7...

  • Page 629

    Abs: 4e-30 dtc c1071: control module internal defect s7rw0a4504021 dtc detecting condition and trouble area dtc troubleshooting abs hydraulic unit / control module assembly power and ground circuit check s7rw0a4504022 wiring diagram circuit description when the ignition switch is turned on, power su...

  • Page 630

    4e-31 abs: troubleshooting repair instructions abs hydraulic unit operation check s7rw0a4506001 1) check that basic brake system other than abs is in good condition. 2) check that battery voltage is 11 v or more. 3) hoist vehicle. 4) set transmission to neutral (p range for a/t) and release parking ...

  • Page 631

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

  • Page 632

    4e-33 abs: abs hydraulic unit / control module assembly on-vehicle inspection s7rw0a4506003 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 633

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

  • Page 634

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

  • Page 635

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

  • Page 636

    4e-37 abs: front wheel speed sensor encoder on-vehicle inspection s7rw0a4506010 before inspecting front wheel speed sensor encoder, remove front drive shaft referring to “front drive shaft assembly removal and installation: front in section 3a”. • check sensor encoder (1) for crack, damage or deform...

  • Page 637

    Abs: 4e-38 g sensor removal and installation (4wd model) s7rw0a4506014 caution ! • do not drop and shock g sensor. It will affect its original performance. • regarding g sensor removal and installation, confirm specified torque and use hand tool to avoid damage. Removal 1) disconnect negative (–) ca...

  • Page 638

    4e-39 abs: specifications tightening torque specifications s7rw0a4507001 note the specified tightening torque is also described in the following. “abs hydraulic unit / control module assembly components” reference: for the tightening torque of fastener not specified in this section, refer to “fasten...

  • Page 639: Electronic Stability Program

    Electronic stability program: 4f-1 brakes electronic stability program precautions precautions in diagnosing troubles s7rw0a4600001 to ensure that the trouble diagnosis is done accurately and smoothly, observe the following and follow “electronic stability program check”. • diagnostic information st...

  • Page 640

    4f-2 electronic stability program: precautions in speedometer test or other tests s7rw0a4600005 when performing speedometer or other tests using speedometer tester or chassis dynamometer, esp ® function must be deactivated by esp ® off switch or using suzuki scan tool to complete the tests correctly...

  • Page 641

    Electronic stability program: 4f-3 electronic stability program construction s7rw0a4601005 components of electronic stability program s7rw0a4601006 esp ® control module / hydraulic unit the control module receives signals from each wheel speed sensor, esp ® off switch, brake master cylinder pressure...

  • Page 642

    4f-4 electronic stability program: steering angle sensor the steering angle sensor is assembled with the contact coil as a unit and mounted to the steering column. Detecting the angle as the steering wheel is turned, it sends that information to the esp ® control module. Yaw rate / g sensor the yaw ...

  • Page 643

    Electronic stability program: 4f-5 esp ® off switch this switch is momentary type. And this is attached to console box. Esp ® off light in combination meter lights up by pushing the switch more than 5 seconds. Then it informs that esp ® (except for abs) is controlled not to work to driver. The opera...

  • Page 644

    4f-6 electronic stability program: warning light, indicator light description s7rw0a4601003 there are five types of warning light and indicator light in instrument cluster, which are controlled by esp ® control module. They give warning / indication to driver by changing the modes light on / blinkin...

  • Page 645

    Electronic stability program: 4f-7 can communication system description s7rw0a4601004 refer to “can communication system description in section 1a” for can communication system description. Esp ® control module communicates control data with each control module as follows. Esp ® control module trans...

  • Page 646

    4f-8 electronic stability program: schematic and routing diagram electronic stability program schematic s7rw0a4602001 input output esp® control module wheel speed sensor (lf) wheel speed sensor (lr) wheel speed sensor (rf) battery voltage master cylinder pressure sensor ignition voltage pump motor d...

  • Page 647

    Electronic stability program: 4f-9 electronic stability program wiring circuit diagram s7rw0a4602002 27 g33-3 blk/orn 5v 9 g33-9 g33-10 g33-2 12v 37 red wht 28 grn/yel blk 12v e08-6 35 30 red red/blk 12v blk wht e08-22 e08-11 32 blk wht lt grn/blk lt grn 12v e08-10 e08-21 e08-23 e08-26 e08-1 e08-12 ...

  • Page 648

    4f-10 electronic stability program: connector “e08” (esp ® control module connector) component location electronic stability program component location s7rw0a4603001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. ...

  • Page 649

    Electronic stability program: 4f-11 7 6* 14* 15* 2 3 4 5 8 9 10* 12 11 13 1 16* i6rw0a460005-02 1. Esp ® warning light 7. Esp ® off switch 13. Yaw rate / g sensor 2. Ebd warning light (brake warning light) 8. Rear wheel speed sensor 14. Data link connector 3. Abs warning light 9. Rear wheel encoder ...

  • Page 650

    4f-12 electronic stability program: diagnostic information and procedures electronic stability program check s7rw0a4604001 refer to the following items for the details of each step. Step action yes no 1 ) malfunction analysis 1) perform “customer complaint analysis: ”. 2) perform “problem symptom co...

  • Page 651

    Electronic stability program: 4f-13 step 1: malfunction analysis customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting in...

  • Page 652

    4f-14 electronic stability program: step 2: driving test test the vehicle at 40 km/h for more than a minute including left and right turns and check if any trouble symptom (such as esp ® warning light and/or abs warning light) exists. If the malfunction dtc is confirmed at ignition switch on, procee...

  • Page 653

    Electronic stability program: 4f-15 dtc check s7rw0a4604005 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (1). Special tool (a): suzuki scan tool 3) turn ignition switch to on position. 4) read dtc according to instructions displayed on suzuki scan tool ...

  • Page 654

    4f-16 electronic stability program: ) c1024 steering angle sensor • steering angle sensor internal defect is detected. • steering angle sensor signal is out of specified range. • vehicle behavior and steering angle sensor signal is disagreed. — — { ) c1025 left-front wheel speed sensor circuit wheel...

  • Page 655

    Electronic stability program: 4f-17 ) c1036 left-rear wheel speed sensor or encoder • wheel speed is different from other wheel speed (vehicle speed) for more than specified time. • abnormal wheel speed sensor signal is detected for more than specified time. { *1 { ) c1037 steering angle sensor powe...

  • Page 656

    4f-18 electronic stability program: note • “{” in abs warning light, ebd warning light and esp ® warning light column of the above table means warning light is lit when dtc is detected. • *1: if three or more wheel speed sensor are defective, ebd warning light are lit. • *2: it is irregular whether ...

  • Page 657

    Electronic stability program: 4f-19 dtc clearance s7rw0a4604007 warning ! When performing a driving test, select a safe place where there is neither any traffic nor any traffic accident possibility and be very careful during testing to avoid occurrence of an accident. After repair or replace malfunc...

  • Page 658

    4f-20 electronic stability program: note • {: activated • x: deactivated • *1: if one wheel speed sensor is defective, ebd control function is activated. If two or more wheel speed sensor are defective, ebd control function is deactivated. • *2: if one or two wheel speed sensor is defective, ebd con...

  • Page 659

    Electronic stability program: 4f-21 scan tool data s7rw0a4604009 the parameter data below are values measured with the scan tool when the normally operating vehicle is under the following conditions. When taking measurements for comparison by using the scan tool, be sure to check that the vehicle is...

  • Page 660

    4f-22 electronic stability program: scan tool data definition battery volt (v) battery voltage is an analog input signal read by the esp ® control module. Certain esp® control module functions will be modified if the battery voltage falls below or rises above programmed thresholds. Rf wheel speed, l...

  • Page 661

    Electronic stability program: 4f-23 esp ® warning light does not come on at ignition switch on s7rw0a4604010 wiring diagram circuit description operation (on/off) of esp ® warning light is controlled by esp® control module through light driver module in combination meter. If esp ® system is in good ...

  • Page 662

    4f-24 electronic stability program: esp ® warning light comes on steady s7rw0a4604043 wiring diagram refer to “wiring diagram” under “esp ® warning light does not come on at ignition switch on”. Circuit description refer to “circuit description” under “esp ® warning light does not come on at ignitio...

  • Page 663

    Electronic stability program: 4f-25 abs warning light does not come on at ignition switch on s7rw0a4604044 wiring diagram circuit description operation (on/off) of abs warning light is controlled by esp ® control module through light driver module in combination meter. If abs is in good condition, e...

  • Page 664

    4f-26 electronic stability program: ebd warning light (brake warning light) comes on steady s7rw0a4604046 wiring diagram circuit description ebd warning light (brake warning light) is controlled by esp ® control module and bcm through light driver module in combination meter. If ebd system is in goo...

  • Page 665

    Electronic stability program: 4f-27 troubleshooting step action yes no 1 parking brake and brake fluid level check 1) make sure that: • parking brake is completely released. • brake fluid level is upper than the minimum level. Are the check results ok? Go to step 2. Release parking brake completely ...

  • Page 666

    4f-28 electronic stability program: serial data link circuit check s7rw0a4604047 wiring diagram wht grn 3 e08-2 e08-13 wht 5 e04-1 e04-2 g04-3 g04-1 4 6 9 8 10 blk red wht g04-4 g04-2 12v e08-25 e08-24 e08-9 e08-16 wht/red wht/blu grn/orn 6 2 1 7 12 e04-9 l313-3 g241-31 red/blk +bb b g g1 11 red e08...

  • Page 667

    Electronic stability program: 4f-29 troubleshooting step action yes no 1 scan tool communication check can scan tool communicate with bcm? Go to step 2. Go to step 3. 2 esp ® hydraulic unit / control module assembly power and ground circuit check 1) check that esp ® hydraulic unit / control module a...

  • Page 668

    4f-30 electronic stability program: dtc c1016: brake light switch s7rw0a4604016 wiring diagram dtc detecting condition and trouble area [b] 21 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 5453 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 3938 44 45 43 41 33 1...

  • Page 669

    Electronic stability program: 4f-31 dtc troubleshooting step action yes no 1 was “electronic stability program check” performed? Go to step 2. Go to “electronic stability program check”. 2 check brake light switch circuit 1) check brake light, brake light (brake pedal) switch and their circuit refer...

  • Page 670

    4f-32 electronic stability program: dtc c1017 / c1023: lateral g sensor / yaw rate sensor s7rw0a4604017 dtc detecting condition and trouble area dtc troubleshooting dtc c1020 / c1028: master cylinder pressure sensor power supply failure / circuit s7rw0a4604018 dtc detecting condition and trouble are...

  • Page 671

    Electronic stability program: 4f-33 dtc c1021 / c1022 / c1025 / c1026 / c1031 / c1032 / c1035 / c1036: wheel speed sensor circuit / sensor or encoder s7rw0a4604019 dtc c1021 / c1025 / c1031 / c1035: right-front / left-front / right-rear / left-rear wheel speed sensor circuit dtc c1022 / c1026 / c103...

  • Page 672

    4f-34 electronic stability program: dtc troubleshooting step action yes no 1 was “electronic stability program check” performed? Go to step 2. Go to “electronic stability program check”. 2 check tire condition 1) check that tire pressure is specifications. Are they in good condition? Go to step 3. R...

  • Page 673

    Electronic stability program: 4f-35 dtc c1024: steering angle sensor s7rw0a4604020 dtc detecting condition and trouble area dtc troubleshooting dtc c1027: esp ® off switch s7rw0a4604021 wiring diagram dtc detecting condition trouble area • steering angle sensor internal defect is detected. • steerin...

  • Page 674

    4f-36 electronic stability program: dtc detecting condition and trouble area dtc troubleshooting dtc c1033: wheel speed sensor deviation s7rw0a4604022 wiring diagram refer to “dtc c1021 / c1022 / c1025 / c1026 / c1031 / c1032 / c1035 / c1036: wheel speed sensor circuit / sensor or encoder”. Dtc dete...

  • Page 675

    Electronic stability program: 4f-37 dtc troubleshooting step action yes no 1 was “electronic stability program check” performed? Go to step 2. Go to “electronic stability program check”. 2 check dtc for esp ® 1) connect scan tool to dlc with ignition switch turned off. 2) turn ignition switch on and...

  • Page 676

    4f-38 electronic stability program: dtc c1034 / c1039: yaw rate / g sensor power supply failure / internal failure s7rw0a4604023 wiring diagram dtc detecting condition and trouble area dtc troubleshooting [b] l34 1 3 2 4 [a] e08 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 bl...

  • Page 677

    Electronic stability program: 4f-39 dtc c1037: steering angle sensor power supply failure s7rw0a4604024 wiring diagram dtc detecting condition and trouble area 4 check yaw rate / g sensor power supply circuit 1) turn ignition switch to off position. 2) disconnect yaw rate / g sensor connector. 3) ch...

  • Page 678

    4f-40 electronic stability program: dtc troubleshooting dtc c1038: steering angle sensor detect rolling counter s7rw0a4604025 dtc detecting condition and trouble area dtc troubleshooting step action yes no 1 was “electronic stability program check” performed? Go to step 2. Go to “electronic stabilit...

  • Page 679

    Electronic stability program: 4f-41 dtc c1040: esp ® continuous operation s7rw0a4604026 dtc detecting condition and trouble area dtc troubleshooting dtc c1041 / c1042 / c1043 / c1044 / c1045 / c1046 / c1051 / c1052 / c1053 / c1054 / c1055 / c1056: inlet / outlet / cut / suction solenoid s7rw0a460402...

  • Page 680

    4f-42 electronic stability program: dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area • solenoid valve circuit is opened, shorted to power, ground and/or each valve in esp ® hydraulic unit / control module assembly. • mismatching solenoid output and so...

  • Page 681

    Electronic stability program: 4f-43 dtc c1057: power supply voltage too high / too low s7rw0a4604048 wiring diagram dtc detecting condition and trouble area dtc troubleshooting wht grn 3 4 5 e08-23 blk 12v e08-9 grn/orn 2 1 e08 [a] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26...

  • Page 682

    4f-44 electronic stability program: dtc c1061: pump motor circuit s7rw0a4604029 wiring diagram dtc detecting condition and trouble area dtc troubleshooting wht/red 1 2 5 m 3 4 12v e08-25 e08-26 blk e08 [a] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 i6rw0h460013-01 [a]: esp ...

  • Page 683

    Electronic stability program: 4f-45 dtc c1063: solenoid valve power supply driver circuit s7rw0a4604030 wiring diagram dtc detecting condition and trouble area dtc troubleshooting e08 [a] 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 wht grn 3 4 7 e08-23 blk 12v e08-9 grn/orn ...

  • Page 684

    4f-46 electronic stability program: dtc c1071: control module internal defect s7rw0a4604049 dtc detecting condition and trouble area dtc troubleshooting dtc c1075: steering angle sensor calibration s7rw0a4604032 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition tro...

  • Page 685

    Electronic stability program: 4f-47 dtc c1091: can invalid data from ecm s7rw0a4604033 dtc detecting condition and trouble area dtc troubleshooting dtc c1096: yaw rate / g sensor message counter error s7rw0a4604034 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition ...

  • Page 686

    4f-48 electronic stability program: dtc u0073: control module communication bus off s7rw0a4604035 refer to “troubleshooting for communication error with scan tool using can in section 1a”. Dtc u0100: lost communication with ecm / pcm s7rw0a4604036 refer to “troubleshooting for communication error wi...

  • Page 687

    Electronic stability program: 4f-49 troubleshooting step action yes no 1 check fuse are main fuses and circuit fuses for esp ® in good condition? Go to step 2. Replace fuse and check for short circuit to ground. 2 check esp ® control module power supply circuit 1) turn ignition switch to off positio...

  • Page 688

    4f-50 electronic stability program: repair instructions esp ® hydraulic unit operation check s7rw0a4606001 1) check that basic brake system other than esp ® 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 b...

  • Page 689

    Electronic stability program: 4f-51 3) turn ignition switch to on position and confirm that only any of dtc(s) c1075 is detected. If any other dtc are detected, repair the detected dtc. 4) park and level the vehicle with parking brake, stop engine with ignition switch on, set steering in straight an...

  • Page 690

    4f-52 electronic stability program: 3) using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from esp ® 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 fl...

  • Page 691

    Electronic stability program: 4f-53 front wheel speed sensor on-vehicle inspection s7rw0a4606006 refer to “front and rear wheel speed sensor on- vehicle inspection in section 4e”. Front wheel speed sensor removal and installation s7rw0a4606007 refer to “front wheel speed sensor removal and installat...

  • Page 692

    4f-54 electronic stability program: 7) when bleeder plug loosen and depress brake pedal to make special tool gauge reading 10 mpa (100 kg/ cm 2 , 1422 psi), check “master cyl press” under “data list” of suzuki scan tool. If pressure displayed on suzuki scan tool is out of specification, replace esp ...

  • Page 693

    Electronic stability program: 4f-55 3) turn ignition switch to on position and select menu “data list” mode of suzuki scan tool. Refer to scan tool operator's manual for further derails. 4) check “yaw rate sensor” under “data list” of suzuki scan tool in the following vehicle conditions. • parking c...

  • Page 694

    4f-56 electronic stability program: yaw rate / g sensor inspection s7rw0a4606017 • check sensor for dents, cracks or deformation. • check sensor connector (sensor side and harness side) and sensor connector lock mechanism for damage or crack. • check connector terminals for bend, corrosion or rust. ...

  • Page 695

    Electronic stability program: 4f-57 steering angle sensor removal and installation s7rw0a4606019 removal 1) remove steering wheel and contact coil cable assembly. Refer to “steering wheel removal and installation” and “contact coil cable assembly removal and installation”. 2) remove steering angle s...

  • Page 696

    4f-58 electronic stability program: specifications tightening torque specifications s7rw0a4607001 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 s7rw0a4608001 fastening part tigh...

  • Page 697: Section 5

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

  • Page 698

    5-ii table of contents dtc p1702: internal control module memory check sum error ............................................5a-70 dtc p1723: range select switch malfunction......................................................5a-70 dtc p1878: torque converter clutch shudder ...........................

  • Page 699

    Table of contents 5-iii manual transmission/transaxle ............ 5b-1 general description .............................................5b-1 manual transaxle construction .......................... 5b-1 diagnostic information and procedures............5b-5 manual transaxle symptom diagnosis...........

  • Page 700: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions on transmission / transaxle s7rw0a5000001 air bag warning refer to “air bag warning in section 00”. Precautions in diagnosing trouble refer to “precautions in diagnosing trouble in section 5a”. Precautions for disassembly ...

  • Page 701

    Automatic transmission/transaxle: 5a-1 transmission / transaxle automatic transmission/transaxle precautions precautions in diagnosing trouble s7rw0a5100001 • do not disconnect couplers from tcm, battery cable from battery, tcm ground wire harness from engine or main fuse before checking the diagnos...

  • Page 702

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

  • Page 703

    Automatic transmission/transaxle: 5a-3 general description a/t description s7rw0a5101001 this automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (o/d) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped...

  • Page 704

    5a-4 automatic transmission/transaxle: slip controlled lock-up function (if equipped) even at a lower speed than when the tcc gets engaged completely, control over the tcc pressure control solenoid works to cause the tcc to slip (be engaged slightly), thereby improving the transmission efficiency. W...

  • Page 705

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

  • Page 706

    5a-6 automatic transmission/transaxle: specifications item specifications torque converter type stall torque ratio 3-element, 1-step, 2-phase type (with tcc (lock-up) mechanism) 1.9 – 2.1 oil pump type drive system internal involute gear type oil pump (non crescent type) engine driven gear change de...

  • Page 707

    Automatic transmission/transaxle: 5a-7 clutch / brake / planetary gear function of automatic transaxle s7rw0a5101002 functions 1 2 4 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 i4rs0a510001-01 1. Input shaft and intermediate shaft 8. One-way no.2 clutch 15. Front sun gear 2. Direct clutch 9. 2nd brake...

  • Page 708

    5a-8 automatic transmission/transaxle: table of component operation s7rw0a5101003 { : on ×: off u: on only when tcc is operating operation of shift solenoid valves, timing solenoid valve and tcc solenoid valve s7rw0a5101007 selector position gear position part shift solenoid valve-a (no.1) shift sol...

  • Page 709

    Automatic transmission/transaxle: 5a-9 { : on (turn power on) ×: off (turn power off) u: on only when tcc is operating automatic gear shift table s7rw0a5101008 automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the d, 3 and/or 2 position. M16a eng...

  • Page 710

    5a-10 automatic transmission/transaxle: 3. Slip lock-up point in d and/or 3 position (with slip control) m15a engine model 1.Shift point in d, 3 and/or 2 position 2. Lock-up point in d and/or 3 position 4th gear lock-up on over 85% 158 – 163 (98 – 101) • d range • except throttle opening shift from ...

  • Page 711

    Automatic transmission/transaxle: 5a-11 a/t diagnosis general description s7rw0a5101004 this vehicle is equipped with an electronic transaxle control system, which controls the automatic shift up and shift down timing, tcc operation, etc. Suitably to vehicle driving conditions. Tcm has an on-board d...

  • Page 712

    5a-12 automatic transmission/transaxle: can communication system description s7rw0a5101006 refer to “can communication system description in section 1a” for can communication system description. Tcm communicates control data with each control module as follows. Tcm transmission data tcm reception da...

  • Page 713

    Automatic transmission/transaxle: 5a-13 schematic and routing diagram transmission control module (tcm) wiring diagram s7rw0a5102001 12v ig1 11 9 10 p r n d 2 l 12 5v 12v 5v 12v 12v 12v blk blk blk ppl blk/wht blk/orn ig11 red/blk yel/blk yel/blu lt grn/blk +bb +bb wht/red 14 20 15 16 17 19 12v 18 1...

  • Page 714

    5a-14 automatic transmission/transaxle: 1. Tcm 15. Shift solenoid valve-a (no.1) 29. “st sig” fuse 2. Input shaft speed sensor 16. Shift solenoid valve-b (no.2) 30. “st” fuse 3. Output shaft speed sensor / vss 17. Timing solenoid valve 31. Mil 4. Ecm 18. Tcc solenoid valve 32. Transmission warning l...

  • Page 715

    Automatic transmission/transaxle: 5a-15 a/t system diagram s7rw0a5102002 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 solenoid valve and timing solenoid val...

  • Page 716

    5a-16 automatic transmission/transaxle: component location electronic shift control system components location s7rw0a5103001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 5* 17 15 1 2 8 9 10 11 12 13 16* 18 19 14...

  • Page 717

    Automatic transmission/transaxle: 5a-17 diagnostic information and procedures a/t system check s7rw0a5104001 refer to the following items for the details of each step. 6. Output shaft speed sensor (vss) 14. Transmission range sensor step action yes no 1 ) customer complaint analysis 1) perform custo...

  • Page 718

    5a-18 automatic transmission/transaxle: step 1. Customer complaint analysis record details of the problem such as failure, complaint and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for pro...

  • Page 719

    Automatic transmission/transaxle: 5a-19 step 2. Dtc / freeze frame data check, record and clearance first, referring to “dtc check”, check dtc and pending dtc. If dtc exists, print or write down dtc and freeze frame data and then clear malfunction dtc(s) by referring to “dtc clearance”. Malfunction ...

  • Page 720

    5a-20 automatic transmission/transaxle: malfunction indicator lamp (mil) check s7rw0a5104003 refer to the same item in “malfunction indicator lamp (mil) check in section 1a” for checking procedure. Transmission warning light check (non-euro-obd model) s7rw0a5104004 1) turn ignition switch on. 2) che...

  • Page 721

    Automatic transmission/transaxle: 5a-21 dtc no. Detecting item detecting condition (dtc will set when detecting) a b ) up0602 control module programming error data programming error. — — ) p0705 transmission range sensor circuit malfunction (prndl input) multiple signals are inputted simultaneously....

  • Page 722

    5a-22 automatic transmission/transaxle: dtc check s7rw0a5104006 note • there are two types of obd system depending on the vehicle specification. For identification, refer to “precaution on on-board diagnostic (obd) system in section 1a”. • for euro-obd model, the mil is turned on when the ecm and/or...

  • Page 723

    Automatic transmission/transaxle: 5a-23 dtc clearance s7rw0a5104007 after repair or replace malfunction part(s), clear all dtcs by performing the following procedure. 1) connect suzuki scan tool to data link connector in the same manner as when making this connection for “dtc check”. 2) turn ignitio...

  • Page 724

    5a-24 automatic transmission/transaxle: ) p0787 shift / timing solenoid control circuit low • power supply for all solenoid valves is cut. • gear position is fixed in 3rd gear. • line pressure control at gear shifting is inhibited. • look-up function is inhibited to operate. ) p0788 shift / timing s...

  • Page 725

    Automatic transmission/transaxle: 5a-25 scan tool data s7rw0a5104009 as the data values given in the following table are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good...

  • Page 726

    5a-26 automatic transmission/transaxle: ) shift solenoid- b command at vehicle stop on at 60 km/h (37.5 mile/h) constant speed, 20% or less throttle opening and 3rd gear (“3” range) off ) shift solenoid- b monitor at vehicle stop on at 60 km/h (37.5 mile/h) constant speed, 20% or less throttle openi...

  • Page 727

    Automatic transmission/transaxle: 5a-27 scan tool data definitions: gear position current gear position computed by throttle position coming from ecm and vehicle speed. Engine speed (rpm) engine speed computed by reference pulses from crankshaft position sensor. Input shaft revolution (rpm) input sh...

  • Page 728

    5a-28 automatic transmission/transaxle: mil request on: signal which tcm requires combination meter to turn on malfunction indicator lamp. Off: signal which tcm does not require combination meter to turn on malfunction indicator lamp. A/t basic check s7rw0a5104010 this check is important for trouble...

  • Page 729

    Automatic transmission/transaxle: 5a-29 troubleshooting condition possible cause correction / reference item unable to run in all range faulty valve body component replace valve body assembly. Faulty oil pump inspect. If ng, replace. Seized or broken planetary gear inspect. If ng, replace. Faulty on...

  • Page 730

    5a-30 automatic transmission/transaxle: o/d → 3 downshift fails to occur malfunction of shift solenoid valve-a inspect. If ng, replace. Malfunction of “3” position switch inspect. If ng, replace. Malfunction of output shaft speed sensor (vss) inspect. If ng, replace. Malfunction of input shaft speed...

  • Page 731

    Automatic transmission/transaxle: 5a-31 manual road test s7rw0a5104012 warning ! Carry out test in very little traffic area to prevent an accident. Test requires 2 persons, a driver and a tester. The purpose of this test is to judge whether causal factor of trouble which occurred in automatic transa...

  • Page 732

    5a-32 automatic transmission/transaxle: stall test s7rw0a5104014 this test is to check overall performance of automatic transaxle and engine by measuring stall speed at “d” and “r” ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is betw...

  • Page 733

    Automatic transmission/transaxle: 5a-33 time lag test s7rw0a5104015 this test is to check conditions of clutch, brake and fluid pressure. “time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) with chocks placed before and behind front and rear wheels r...

  • Page 734

    5a-34 automatic transmission/transaxle: line pressure test s7rw0a5104016 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 (...

  • Page 735

    Automatic transmission/transaxle: 5a-35 “p” range test s7rw0a5104017 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 gradua...

  • Page 736

    5a-36 automatic transmission/transaxle: 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 ci...

  • Page 737

    Automatic transmission/transaxle: 5a-37 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 circui...

  • Page 738

    5a-38 automatic transmission/transaxle: 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 fa...

  • Page 739

    Automatic transmission/transaxle: 5a-39 non operate tcc (lock- up) system tcc solenoid valve circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Shift solenoid valve-a and/or-b circuit faulty inspect circuit for open, short and intermittent. If ng, repair. Pressure contro...

  • Page 740

    5a-40 automatic transmission/transaxle: trouble diagnosis 2 on-vehicle repair condition possible cause correction / reference item unable to run in all range faulty valve body component replace valve body assembly. Excessive shift shock engine abnormal condition inspect and repair engine. Malfunctio...

  • Page 741

    Automatic transmission/transaxle: 5a-41 poor 3 → 4 shift malfunction of shift solenoid valve-b inspect. If ng, replace. Malfunction of timing solenoid valve inspect. If ng, replace. Malfunction of output shaft speed sensor (vss) inspect. If ng, replace. Malfunction of input shaft speed sensor inspec...

  • Page 742

    5a-42 automatic transmission/transaxle: trouble diagnosis 3 off-vehicle repair non operate tcc (lock- up) system malfunction of tcc solenoid valve inspect. If ng, replace. Malfunction of shift solenoid valve-a and/or -b inspect. If ng, replace. Malfunction of output shaft speed sensor (vss) inspect....

  • Page 743

    Automatic transmission/transaxle: 5a-43 transmission warning light circuit check – light remains “on” at ignition switch on (non-euro- obd model) s7rw0a5104019 troubleshooting transmission warning light circuit check – light does not come “on” at ignition switch on (non- euro-obd model) s7rw0a510402...

  • Page 744

    5a-44 automatic transmission/transaxle: dtc p0602: control module programming error s7rw0a5104021 system description internal control module is installed in ecm. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn o...

  • Page 745

    Automatic transmission/transaxle: 5a-45 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm memory by using scan tool. 3) start engine and shift select lever to “d” range. 4) keep engine running at idle speed ...

  • Page 746

    5a-46 automatic transmission/transaxle: table for step 4 dtc p0707: transmission range sensor circuit low s7rw0a5104023 wiring diagram dtc detecting condition and trouble area 7 1) check transmission range sensor referring to “transmission range sensor inspection and adjustment”. Are check results s...

  • Page 747

    Automatic transmission/transaxle: 5a-47 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out with 2 pe...

  • Page 748

    5a-48 automatic transmission/transaxle: table for step 4 dtc p0711: transmission fluid temperature sensor “a” control range / performance s7rw0a5104024 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if availabl...

  • Page 749

    Automatic transmission/transaxle: 5a-49 dtc troubleshooting dtc p0712: transmission fluid temperature sensor circuit low s7rw0a5104025 wiring diagram dtc detecting condition and trouble area step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 inspect tran...

  • Page 750

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

  • Page 751

    Automatic transmission/transaxle: 5a-51 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out with 2 pe...

  • Page 752

    5a-52 automatic transmission/transaxle: dtc p0717: input / turbine speed sensor circuit malfunction s7rw0a5104027 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a t...

  • Page 753

    Automatic transmission/transaxle: 5a-53 dtc p0722: output speed sensor (vss) circuit no signal s7rw0a5104028 wiring diagram dtc detecting condition and trouble area 3 inspect input shaft speed sensor 1) inspect input shaft speed sensor referring to “input shaft speed sensor inspection”. Is result sa...

  • Page 754

    5a-54 automatic transmission/transaxle: dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out with 2 pe...

  • Page 755

    Automatic transmission/transaxle: 5a-55 dtc p0741 / p0742: tcc circuit performance or stuck off / tcc circuit stuck on s7rw0a5104029 dtc detecting condition and trouble area dtc p0741 dtc p0742 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traff...

  • Page 756

    5a-56 automatic transmission/transaxle: dtc troubleshooting dtc p0751 / p0752 / p0756 / p0757: shift solenoid malfunction s7rw0a5104030 dtc p0751: shift solenoid-a (no.1) performance or stuck off dtc p0752: shift solenoid-a (no.1) stuck on dtc p0756: shift solenoid-b (no.2) performance or stuck off ...

  • Page 757

    Automatic transmission/transaxle: 5a-57 dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • road test should be carried out with 2 pe...

  • Page 758

    5a-58 automatic transmission/transaxle: dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine and shift select lever to “n” range. 4) repeat shifting select lever from “n” range to “d” range and vice versa for 3 tim...

  • Page 759

    Automatic transmission/transaxle: 5a-59 dtc p0788: shift / timing solenoid control circuit high s7rw0a5104032 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start en...

  • Page 760

    5a-60 automatic transmission/transaxle: dtc p0961: pressure control solenoid “a” control circuit range / performance s7rw0a5104033 wiring diagram 4 check timing solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on transaxle. 3) check for prope...

  • Page 761

    Automatic transmission/transaxle: 5a-61 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine. 4) keep engine running at idle speed for 30 seconds or more. 5) stop vehicle an...

  • Page 762

    5a-62 automatic transmission/transaxle: dtc p0962: pressure control solenoid control circuit low s7rw0a5104034 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start e...

  • Page 763

    Automatic transmission/transaxle: 5a-63 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check pressure control solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic ...

  • Page 764

    5a-64 automatic transmission/transaxle: dtc p0963: pressure control solenoid control circuit high s7rw0a5104035 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start ...

  • Page 765

    Automatic transmission/transaxle: 5a-65 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check pressure control solenoid circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper...

  • Page 766

    5a-66 automatic transmission/transaxle: dtc p0973 / p0976: shift solenoid-a (no.1) control circuit low / shift solenoid-b (no.2) control circuit low s7rw0a5104036 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a plac...

  • Page 767

    Automatic transmission/transaxle: 5a-67 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check shift solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transmissio...

  • Page 768

    5a-68 automatic transmission/transaxle: dtc p0974 / p0977: shift solenoid-a (no.1) / shift solenoid-b (no.2) control circuit high s7rw0a5104037 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 769

    Automatic transmission/transaxle: 5a-69 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check shift solenoid valve circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper conn...

  • Page 770

    5a-70 automatic transmission/transaxle: dtc p1702: internal control module memory check sum error s7rw0a5104038 dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtc in tcm memory. 3) after 10 seconds passed from turnin...

  • Page 771

    Automatic transmission/transaxle: 5a-71 dtc troubleshooting dtc p1878: torque converter clutch shudder s7rw0a5104040 dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no traffic or possibility of a traffic accid...

  • Page 772

    5a-72 automatic transmission/transaxle: dtc p2762: torque converter clutch (tcc) pressure control solenoid control circuit range / performance s7rw0a5104041 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if ava...

  • Page 773

    Automatic transmission/transaxle: 5a-73 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check tcc solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transaxle. 3)...

  • Page 774

    5a-74 automatic transmission/transaxle: dtc p2763: torque converter clutch (tcc) pressure control solenoid control circuit high s7rw0a5104042 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there is no t...

  • Page 775

    Automatic transmission/transaxle: 5a-75 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check tcc solenoid valve circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper connec...

  • Page 776

    5a-76 automatic transmission/transaxle: dtc p2764: torque converter clutch (tcc) circuit pressure control solenoid control circuit low s7rw0a5104043 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure warning ! • when performing a road test, select a place where there ...

  • Page 777

    Automatic transmission/transaxle: 5a-77 dtc troubleshooting step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check”. 2 check tcc solenoid valve resistance 1) turn ignition switch off. 2) disconnect valve body harness connector (1), (2) on automatic transaxle. 3)...

  • Page 778

    5a-78 automatic transmission/transaxle: dtc u0073: control module communication bus off s7rw0a5104044 refer to “troubleshooting for can-dtc in section 1a”. Dtc u0100: lost communication with ecm / pcm “a” s7rw0a5104045 refer to “troubleshooting for can-dtc in section 1a”. Inspection of tcm and its c...

  • Page 779

    Automatic transmission/transaxle: 5a-79 connector “c06” terminal wire color circuit standard voltage condition 1 blk ground 0 – 1 v ignition switch on 2 lt grn/ blk pressure control solenoid valve (–) 0.6 – 1.0 v ignition switch on 3 wht/blk tcc solenoid valve (–) 0.6 – 1.0 v ignition switch on 4 gr...

  • Page 780

    5a-80 automatic transmission/transaxle: connector “c07” terminal wire color circuit standard voltage condition 1 red transmission range sensor (“r” range) 8 – 14 v ignition switch on, select lever at “r” range 0 – 1 v ignition switch on, select lever at other than “r” range 2 — — — — 3 — — — — 4 — —...

  • Page 781

    Automatic transmission/transaxle: 5a-81 reference waveform no. 1 pressure control solenoid valve signal at engine idling. Reference waveform no. 2 tcc pressure control solenoid valve signal at engine idling. Reference waveform no. 3 can communication line (high & low) signal at engine idling. Refere...

  • Page 782

    5a-82 automatic transmission/transaxle: reference waveform no. 5 output shaft speed sensor (vss) signal at vehicle speed 60 km/h (37 mile/h). Tcm power and ground circuit check s7rw0a5104047 wiring diagram measurement terminal ch1: “c07-25” to “c06-1” oscilloscope setting ch1: 5 v/div time: 20 ms/di...

  • Page 783

    Automatic transmission/transaxle: 5a-83 troubleshooting brake interlock system inspection s7rw0a5104048 1) check that select lever cannot be moved to any other range from “p” range position when ignition switch key is at acc position, at lock position or it is removed from keyhole of ignition switch...

  • Page 784

    5a-84 automatic transmission/transaxle: • with shift lock solenoid release button (1) pushed and ignition key turned to acc position, select lever can be shifted from “p” range position to any other range. • with shift lock solenoid release button (1) pushed and ignition key turned to lock position,...

  • Page 785

    Automatic transmission/transaxle: 5a-85 7) pull out fluid level gauge (1) again and check fluid level indicated on it. The lowest fluid level should be between full hot (2) and low hot (3). If it is below low hot, add suzuki atf 3317 or mobil atf 3309 up to full hot. Automatic transaxle fluid suzuki...

  • Page 786

    5a-86 automatic transmission/transaxle: 5) lower vehicle and pour proper amount of suzuki atf 3317 or mobil atf 3309. 6) check fluid level referring to “a/t fluid level check”. Automatic transaxle fluid : suzuki atf 3317 or mobil atf 3309 automatic transaxle fluid capacity when draining from drain p...

  • Page 787

    Automatic transmission/transaxle: 5a-87 select lever inspection s7rw0a5106007 check select lever for smooth and clear-cut movement individually. If a malfunction is found, replace select lever assembly. “3” position switch inspection s7rw0a5106008 1) remove console box referring to “console box comp...

  • Page 788

    5a-88 automatic transmission/transaxle: select cable components s7rw0a5106011 select cable removal and installation s7rw0a5106012 removal 1) remove console box referring to “console box components in section 9h”. 2) disconnect select cable from select lever and then detach from bracket. 3) remove cl...

  • Page 789

    Automatic transmission/transaxle: 5a-89 2) remove adjuster (cable end) from select lever pin of select lever assembly. 3) remove adjuster (cable end) from select lever pin of select lever assembly. 4) release lock plate (1) which restrict moving of cable end holder (2). 5) push cable end holder (1) ...

  • Page 790

    5a-90 automatic transmission/transaxle: installation 1) lay interlock cable to its original cabling route. C 1 2 3 4 5 6 1 9 [c] [a] 7 1 2 3 4 5 6 7 8 2 [b] i5rw0c510073-01 [a]: lh steering vehicle 2. Clamp 6. Eps control module [b]: rh steering vehicle 3. Steering lock assembly / steering lock unit...

  • Page 791

    Automatic transmission/transaxle: 5a-91 2) turn ignition switch to acc position. 3) insert cable casing cap (1) into key cylinder cover (2) securely. 4) pull out lock button (1) of select lever side cable end (2). 5) shift select lever to “n” position. Note if select lever is in “p” position, shift ...

  • Page 792

    5a-92 automatic transmission/transaxle: 3) check that engine starts in “n” and “p” ranges but it doesn’t start in “d”, “2”, “l” or “r” range. Also, check that back-up lamp lights in “r” range. If faulty condition cannot be corrected by adjustment, disconnect transmission range sensor connector and c...

  • Page 793

    Automatic transmission/transaxle: 5a-93 input shaft speed sensor removal and installation s7rw0a5106018 removal 1) disconnect negative cable at battery. 2) disconnect input shaft speed sensor connector (2). 3) remove input shaft speed sensor (1) by removing its bolt. Installation 1) apply a/t fluid ...

  • Page 794

    5a-94 automatic transmission/transaxle: installation reverse removal procedure to install valve body harness and valve body assembly noting the following points. • for details of valve body assembly and their connectors installation, refer to “automatic transaxle unit assembly”. • for details of a/t...

  • Page 795

    Automatic transmission/transaxle: 5a-95 6) remove a/t oil pan (1) and oil pan gasket (2). 7) remove oil strainer assembly (3). 8) remove transmission fluid temperature sensor (1) from sensor clamp. 9) disconnect solenoid connectors (2). 10) remove shift solenoid valve-a (no.1) (1), shift solenoid va...

  • Page 796

    5a-96 automatic transmission/transaxle: 4) install oil strainer assembly (1). Tightening torque oil strainer bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) 5) install new oil pan gasket (1) and oil pan (2). 6) tighten oil pan bolts to specified torque diagonally and little by little. Tightening torque oil ...

  • Page 797

    Automatic transmission/transaxle: 5a-97 timing solenoid valve caution ! • do not insert air gun against strainer installed on inlet of solenoid valve too deeply, when blowing air into solenoid valve. If not, the strainer will be damaged. • be very careful as dust etc. Does not enter when solenoid va...

  • Page 798

    5a-98 automatic transmission/transaxle: 10) remove valve body assembly referring to “automatic transaxle unit disassembly”. 11) remove pressure control solenoid valve and tcc pressure control solenoid valve referring to “valve body assembly disassembly and reassembly”. Installation reverse removal p...

  • Page 799

    Automatic transmission/transaxle: 5a-99 not using regulated dc power supply 1) connect pressure control solenoid valve (1) to battery (2) setting 21 w bulb (4) on the way as shown in figure. 2) check for movement of valve (3) in the direction of arrow “a”. 3) disconnect pressure control solenoid val...

  • Page 800

    5a-100 automatic transmission/transaxle: differential side oil seal replacement s7rw0a5106028 1) lift up vehicle and drain automatic transaxle fluid. 2) remove drive shaft assembly and center shaft referring to “front drive shaft assembly removal and installation: front in section 3a”. 3) remove dif...

  • Page 801

    Automatic transmission/transaxle: 5a-101 automatic transaxle unit components s7rw0a5106030 i5rw0c510050-01 1. Drive plate 6. Transaxle and engine fastening bolt : 19 n ⋅m (1.9 kgf-m, 14.0 lb-ft) 2. Drive plate bolt 7. Transaxle and engine fastening nut : 69 n ⋅m (6.9 kgf-m, 50.0 lb-ft) 3. Drive plat...

  • Page 802

    5a-102 automatic transmission/transaxle: automatic transaxle unit dismounting and remounting s7rw0a5106031 dismounting 1) take down transaxle with engine. For its procedure, refer to “engine assembly removal and installation in section 1d”. 2) remove transaxle housing lower plate (1). 3) remove driv...

  • Page 803

    Automatic transmission/transaxle: 5a-103 remounting 1) make sure that torque converter is installed correctly to transaxle. Refer to “automatic transaxle unit assembly”. 2) attach transaxle to engine. Tighten engine oil pan bolts (1) to specified torque. Warning ! Be sure to keep transaxle with torq...

  • Page 804

    5a-104 automatic transmission/transaxle: automatic transaxle assembly components s7rw0a5106032 i5rw0c510057-01.

  • Page 805

    Automatic transmission/transaxle: 5a-105 1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly 2. Torque converter housing : apply sealant 99000-31230 to mating surface to transaxle case. 38. Cooler check valve 74. Rear sun gear thrust bearing race 3. Oil strainer...

  • Page 806

    5a-106 automatic transmission/transaxle: automatic transaxle unit disassembly s7rw0a5106033 caution ! • thoroughly clean transaxle exterior before overhauling it. • keep working table, tools and hands clean while overhauling. • use special care to handle aluminum parts so as not to damage them. • do...

  • Page 807

    Automatic transmission/transaxle: 5a-107 9) remove fluid cooler pipes (1) and pipe unions (2). 10) remove fluid level gauge (3) and fluid filler tube (4). 11) remove oil pan (1) and oil pan gasket (2). Note • for removal of oil pan, do not turn transaxle over as this will contaminate valve body with...

  • Page 808

    5a-108 automatic transmission/transaxle: 16) remove valve body harness (1). Caution ! When pulling valve body harness out of transaxle case, take care not to damage transmission fluid temperature sensor (2) at narrow exit of case. Careless sensor treatment might cause sensor malfunction. 17) remove ...

  • Page 809

    Automatic transmission/transaxle: 5a-109 20) remove transaxle case plug (1). 21) remove torque converter housing bolts. 22) remove torque converter housing (1) while tapping around it lightly with plastic hammer. 23) remove breather hose (1). 24) remove breather union (2). 25) measure input shaft th...

  • Page 810

    5a-110 automatic transmission/transaxle: 29) remove input shaft rear thrust bearing (1) and thrust bearing race (2). Note if input shaft rear thrust bearing is not found, it may have been taken out with direct clutch assembly. 30) remove direct clutch hub (1). 31) remove differential assembly (1) an...

  • Page 811

    Automatic transmission/transaxle: 5a-111 36) remove 2nd brake gasket (1). 37) measure o/d and 2nd coast brake piston stroke. If piston stroke exceeds specification, inspect and replace plates and discs. • measure dimension “a” from mating surface of transaxle case to o/d and 2nd coast brake rear pla...

  • Page 812

    5a-112 automatic transmission/transaxle: 40) remove o/d and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4). 41) remove forward clutch hub (1). 42) remove rear sun gear thrust bearing (1) from forward clutch hub (2). Note if rear sun gear thrust bearing is not ...

  • Page 813

    Automatic transmission/transaxle: 5a-113 48) remove o/d and 2nd coast brake retaining plate snap ring (1). 49) remove front planetary sun gear (1). 50) remove front sun gear thrust bearing race (2) from front planetary sun gear (1). 51) before disassembling 2nd brake piston assembly (4), check 2nd b...

  • Page 814

    5a-114 automatic transmission/transaxle: 53) remove 2nd brake piston assembly (1). 54) remove 2nd brake return spring subassembly (2). 55) remove 2nd brake separator plates (1), discs (2) and retaining plate (3). 56) remove brake drum gasket (1). 57) remove one-way clutch outer race retainer (1). 58...

  • Page 815

    Automatic transmission/transaxle: 5a-115 61) measure 1st and reverse brake piston stroke. If piston stroke exceeds specified value, disassemble, inspect and replace discs and plates. • using special tool, measure 1st and reserve brake piston stroke when compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 ,...

  • Page 816

    5a-116 automatic transmission/transaxle: 67) using special tools and hydraulic press, remove planetary ring gear subassembly (1). Caution ! Do not reuse planetary ring gear subassembly. Otherwise it may cause damage to planetary gear unit and/or reduction gears. Special tool (a): 09913–84510 (b): 09...

  • Page 817

    Automatic transmission/transaxle: 5a-117 71) remove parking lock pawl bracket (1). 72) with slotted screwdriver, cut and unfold manual valve lever spacer (1) and proceed to remove manual valve lever spacer. 73) using spring pin remover with 3 mm (0.12 in.) in diameter and hammer, drive out manual va...

  • Page 818

    5a-118 automatic transmission/transaxle: oil pump assembly components s7rw0a5106034 oil pump assembly disassembly and reassembly s7rw0a5106035 disassembly 1) remove o-ring from pump body. 2) remove 8 oil pump subassembly bolts (1) and stator shaft assembly (2). 3) remove oil seal (1) using special t...

  • Page 819

    Automatic transmission/transaxle: 5a-119 reassembly 1) install new oil pump body oil seal (1). Use special tool and hammer to install it, and then apply grease to its lip portion. Special tool (a): 09913–85210 “a”: grease 99000–25030 (suzuki super grease c) 2) install driven gear and drive gear to o...

  • Page 820

    5a-120 automatic transmission/transaxle: 3) check side clearance of both gears. Using a straightedge (1) and a feeler gauge (2), measure side clearance between gears and pump body. If clearance exceeds its standard value, replace oil pump assembly. Side clearance between gears and oil pump body stan...

  • Page 821

    Automatic transmission/transaxle: 5a-121 direct clutch assembly components s7rw0a5106037 direct clutch assembly preliminary check s7rw0a5106038 install direct clutch assembly (1) to oil pump assembly (2) blow in air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (3) of oil pump assem...

  • Page 822

    5a-122 automatic transmission/transaxle: direct clutch assembly disassembly and reassembly s7rw0a5106039 caution ! When clutch disc, retaining plate and/or separator plate of direct clutch have been replaced, all learned contents, which have been stored in tcm memory by executing learning control, s...

  • Page 823

    Automatic transmission/transaxle: 5a-123 reassembly reverse disassembly procedure for assembly, noting the following points. • use new seal ring and o-ring. Apply a/t fluid before installation. • do not damage direct clutch return spring subassembly (1) and piston by pressing in direct clutch return...

  • Page 824

    5a-124 automatic transmission/transaxle: direct clutch assembly inspection s7rw0a5106040 clutch discs, plates and retaining plate check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt. If necessary, replace. Note • if disc lining is exfoliated, discolo...

  • Page 825

    Automatic transmission/transaxle: 5a-125 forward and reverse clutch assembly components s7rw0a5106041 forward and reverse clutch assembly preliminary check s7rw0a5106042 1) install forward and reverse clutch assembly (1) to transaxle rear cover (2), blow in compressed air (400 – 800 kpa, 4 – 8 kg/cm...

  • Page 826

    5a-126 automatic transmission/transaxle: 2) blow compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (1) of transaxle rear cover with the special tool attached on the upper surface of forward clutch retaining plate, and measure forward clutch piston stroke. If piston stroke...

  • Page 827

    Automatic transmission/transaxle: 5a-127 6) install intermediate shaft subassembly (1) to transaxle rear cover (2). Apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole (3) of transaxle rear cover to remove forward clutch piston (4). 7) apply compressed air (400 – 800 kpa, ...

  • Page 828

    5a-128 automatic transmission/transaxle: • apply a/t fluid to forward clutch separator plates (1), discs (2) and retaining plate (3). • install forward clutch separator plates (1), discs (2) and retaining plate (3), then snap ring (4) to forward clutch drum. • install forward clutch plate snap ring ...

  • Page 829

    Automatic transmission/transaxle: 5a-129 • install reverse clutch plate snap ring so that its both ends would be positioned in correct locations as shown in figure. • measure reverse clutch piston stroke in the same manner as “forward and reverse clutch assembly preliminary check”. When piston strok...

  • Page 830

    5a-130 automatic transmission/transaxle: forward clutch piston lip and forward clutch balancer lip check each lip for wear, deformation, cut and/or hardening. If necessary, replace. Forward clutch drum lip check each lip for wear, deformation, cut and/or hardening. If necessary, replace. 2nd brake p...

  • Page 831

    Automatic transmission/transaxle: 5a-131 2) remove inner o-ring (1) and outer o-ring (2). Reassembly reverse disassembly procedure for assembly, noting the following points. • use new o-rings. Apply a/t fluid to the o-rings, before installation. • install 2nd brake piston (1) to which a/t fluid is a...

  • Page 832

    5a-132 automatic transmission/transaxle: transaxle rear cover (o/d and 2nd coast brake piston) assembly disassembly and reassembly s7rw0a5106048 disassembly 1) remove snap ring by using special tools and hydraulic press. Special tool (a): 09926–96030 (b): 09946–06710 caution ! Do not press o/d and 2...

  • Page 833

    Automatic transmission/transaxle: 5a-133 reassembly reverse disassembly procedure for assembly, noting the following points. • use new seal rings and o-rings. Apply a/t fluid to seal rings and o-rings before installation. • tighten rear cover plugs to specified torque. Tightening torque rear cover p...

  • Page 834

    5a-134 automatic transmission/transaxle: countershaft assembly components s7rw0a5106050 countershaft assembly disassembly and reassembly s7rw0a5106051 disassembly 1) remove countershaft lh bearing (1) and reduction driven gear (2) at once by using special tool and hydraulic press. Special tool (a): ...

  • Page 835

    Automatic transmission/transaxle: 5a-135 3) install countershaft lh bearing (1) with special tools and hydraulic press. Special tool (a): 09913–84510 (b): 09925–88210 valve body assembly components s7rw0a5106052 i2rh0b510214-01 i4rs0a510044-01 1. Pressure control solenoid valve 6. Temperature sensor...

  • Page 836

    5a-136 automatic transmission/transaxle: valve body assembly disassembly and reassembly s7rw0a5106053 caution ! When replacing pressure control solenoid valve and/or tcc pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing press...

  • Page 837

    Automatic transmission/transaxle: 5a-137 reassembly reverse disassembly procedure for assembly, noting the following points. • shift solenoid valve-a and -b are identical • after applying a/t fluid to new o-rings, fit them to solenoid valves, then install solenoid valves to valve body. • tighten sol...

  • Page 838

    5a-138 automatic transmission/transaxle: differential assembly disassembly and reassembly s7rw0a5106055 disassembly 1) remove final gear bolts (1), and then final gear (2). 2) remove differential side rh bearing by using special tools. Special tool (a): 09926–37610 (b): 09926–37610–001 (c): 09926–37...

  • Page 839

    Automatic transmission/transaxle: 5a-139 2) as shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. 3) tighten final gear bolts (1) to specified torque. Note to avoid rust, apply a/t fluid to final driven gear after installation. Tightening torque final...

  • Page 840

    5a-140 automatic transmission/transaxle: torque converter housing disassembly and reassembly s7rw0a5106057 disassembly 1) remove fluid reservoir rh plate (1) and lubrication tube clamp (2). 2) remove lubrication lh tube (1) and rh tube (2). Note do not bend lubrication tube with excessive force. 3) ...

  • Page 841

    Automatic transmission/transaxle: 5a-141 reassembly 1) after applying a/t fluid to new o-rings, fit them to housing plugs. Finally install plugs to torque converter housing. Tightening torque torque converter housing plug (a): 7.5 n·m (0.75 kgf-m, 5.5 lb-ft) 2) using special tools, assemble differen...

  • Page 842

    5a-142 automatic transmission/transaxle: transaxle case disassembly and reassembly s7rw0a5106058 disassembly 1) remove differential side oil seal (1). 2) remove countershaft lh bearing cup and shim with special tools. Special tool (a): 09944–96011 (b): 09942–15511 3) remove differential side lh bear...

  • Page 843

    Automatic transmission/transaxle: 5a-143 3) install new differential side oil seal to transaxle case by using special tools. Special tool (a): 09913–75810 differential side oil seal installing depth “a”: 3.8 – 4.8 mm (0.15 – 0.19 in.) 4) apply grease to oil seal lip. “a”: grease 99000–25030 (suzuki ...

  • Page 844

    5a-144 automatic transmission/transaxle: one-way clutch no.1 assembly 1) install one-way clutch no.1 assembly (2) to rear planetary sun gear subassembly (1). 2) securing rear planetary sun gear subassembly, ensure that one-way clutch no.1 assembly rotates only in one direction. If the one-way clutch...

  • Page 845

    Automatic transmission/transaxle: 5a-145 countershaft bearing preload 1) after applying a/t fluid to countershaft assembly (1) and differential assembly (2), fit them. 2) install torque converter housing to transaxle case, then tighten bolts to specified torque. Tightening torque torque converter ho...

  • Page 846

    5a-146 automatic transmission/transaxle: automatic transaxle unit assembly s7rw0a5106060 caution ! • automatic transaxle consists of highly precise parts. As even flaw in small part may cause oil leakage or decrease in function, check each part carefully before installation. • clean all parts with c...

  • Page 847

    Automatic transmission/transaxle: 5a-147 6) install parking lock pawl bracket (1) to transaxle case. Tightening torque parking lock pawl bracket bolt (a): 7.5 n·m (0.75 kgf-m, 5.5 lb-ft) 7) after applying a/t fluid to new o-rings, install them to 1st and reverse brake piston (3). 8) install 1st and ...

  • Page 848

    5a-148 automatic transmission/transaxle: 12) install 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations as shown in figure. 13) using special tools, measure 1st and reverse brake piston stroke when compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – ...

  • Page 849

    Automatic transmission/transaxle: 5a-149 16) install new planetary ring gear subassembly (1) to reduction drive gear (3) by using special tools and hydraulic press. Caution ! • do not reuse planetary ring gear subassembly. Otherwise it may cause damage to planetary gear unit and/or reduction gears. ...

  • Page 850

    5a-150 automatic transmission/transaxle: 20) check for correct installation of planetary gear assembly as follows. Measure the distance “a” by using micrometer caliper (1) and straightedge (2). If measured value is out of specification, remove planetary gear assembly and reinstall it properly. Dista...

  • Page 851

    Automatic transmission/transaxle: 5a-151 26) apply a/t fluid to 2nd brake piston assembly (1), and align the projection of 2nd brake piston assembly with the groove of transaxle case, then put together. 27) install 2nd brake piston snap ring (1) by using special tool and hydraulic press. Caution ! D...

  • Page 852

    5a-152 automatic transmission/transaxle: 31) install o/d and 2nd coast brake retaining plate snap ring (1). Caution ! Be sure to install o/d and 2nd coast brake retaining plate snap ring correctly in groove of transaxle case. 32) after applying grease to slide contact face of planetary carrier thrus...

  • Page 853

    Automatic transmission/transaxle: 5a-153 39) after applying a/t fluid to intermediate shaft thrust bearing rear race (3), thrust bearing (2) and front race (1), install them to forward and reverse clutch assembly (4). Bearing race dimension 40) apply a/t fluid to forward and reverse clutch assembly ...

  • Page 854

    5a-154 automatic transmission/transaxle: 43) measure o/d and 2nd coast brake piston stroke. • measure dimension “a” from end face of transaxle case to o/d and 2nd coast brake rear plate (1) using straightedge and micrometer caliper. • measure dimension “b” from o/d and 2nd coast brake piston (2) to ...

  • Page 855

    Automatic transmission/transaxle: 5a-155 48) install transaxle rear cover assembly on transaxle case. 49) install hook (2) to location shown in figure. 50) tighten rear cover bolts (1). Tightening torque rear cover bolt (a): 25 n·m (2.5 kgf-m, 18.0 lb-ft) 51) install fluid reservoir lh plate (1). Ti...

  • Page 856

    5a-156 automatic transmission/transaxle: 57) apply a/t fluid to direct clutch assembly (1). Install direct clutch assembly while rotating clockwise and counterclockwise frequently to fit clutch discs to mating hub. Note before installation, align teeth of direct clutch discs to facilitate installati...

  • Page 857

    Automatic transmission/transaxle: 5a-157 61) measure input shaft thrust play. Apply dial gauge onto input shaft end (1) and measure thrust play of input shaft. Special tool (a): 09900–20607 (b): 09900–20701 input shaft thrust play 0.3 – 0.9 mm (0.012 – 0.035 in.) when input shaft thrust play is out ...

  • Page 858

    5a-158 automatic transmission/transaxle: 68) install new o-rings to each accumulator piston and apply a/t fluid to them. Accumulator o-ring dimension note make sure that o-rings are not twisted or caught when installing. 69) install b1, c1, c2 accumulator pistons and springs. Accumulator piston iden...

  • Page 859

    Automatic transmission/transaxle: 5a-159 72) after applying a/t fluid to new o-ring, fit it to valve body harness connector (3), then install valve body harness to transaxle case. Caution ! When put valve body harness (1) into transaxle case, take care not to damage transmission fluid temperature se...

  • Page 860

    5a-160 automatic transmission/transaxle: 76) install oil strainer assembly (1). Tightening torque oil strainer bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) 77) install oil cleaner magnets (1) in oil pan (2). Note if metal particles are attached to the magnets, clean them before installing. 78) install ne...

  • Page 861

    Automatic transmission/transaxle: 5a-161 83) install select cable bracket (1). Tightening torque select cable bracket bolt (a): 23 n·m (2.3 kgf-m, 17.0 lb-ft) 84) apply a/t fluid to o-rings of each sensor and install input shaft speed sensor (1) and output shaft speed sensor (vss) (2). Tightening to...

  • Page 862

    5a-162 automatic transmission/transaxle: 94) install manual select lever (1). Tightening torque manual select lever nut (a): 13 n·m (1.3 kgf-m, 9.5 lb-ft) 95) install engine mounting lh bracket (1). Tighten engine mounting lh bracket bolts and nut to specified torque referring to “engine mountings c...

  • Page 863

    Automatic transmission/transaxle: 5a-163 specifications tightening torque specifications s7rw0a5107001 note the specified tightening torque is also described in the following. “select cable components” “automatic transaxle unit components” “automatic transaxle assembly components” “oil pump assembly...

  • Page 864

    5a-164 automatic transmission/transaxle: special tools and equipment recommended service material s7rw0a5108001 note required service material is also described in the following. “select cable components” “automatic transaxle assembly components” “oil pump assembly components” “direct clutch assembl...

  • Page 865

    Automatic transmission/transaxle: 5a-165 09913–84510 09913–85210 bearing installer bearing installer ) / ) / ) / ) ) 09923–78210 09924–74510 bearing installer bearing and oil seal handle ) ) / ) / ) / ) 09925–37811–001 09925–88210 oil pressure gauge bearing puller attachment ) ) / ) 09925–98210 0992...

  • Page 866

    5a-166 automatic transmission/transaxle: 09926–97620 09926–98310 spring compressor clutch spring compressor ) / ) ) / ) 09928–06050 09942–15511 differential preload adapter sliding hammer ) / ) ) / ) / ) / ) 09944–78210 09944–88220 bearing installer support oil seal installer ) / ) ) / ) / ) / ) 099...

  • Page 867

    Manual transmission/transaxle: 5b-1 transmission / transaxle manual transmission/transaxle general description manual transaxle construction s7rw0a5201001 the transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts-input shaft, countershaft...

  • Page 868

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

  • Page 869

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

  • Page 870

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

  • Page 871

    Manual transmission/transaxle: 5b-5 diagnostic information and procedures manual transaxle symptom diagnosis s7rw0a5204001 repair instructions manual transaxle oil level check s7rw0a5206001 1) lift up vehicle and check oil leakage. Repair leaky point, if any. 2) remove oil level / filler plug (1) an...

  • Page 872

    5b-6 manual transmission/transaxle: manual transaxle oil change s7rw0a5206002 1) before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) with vehicle lifted up, check leakage. If leakage exists, correct it. Note whenever vehicle is hoisted for any other service wo...

  • Page 873

    Manual transmission/transaxle: 5b-7 differential side oil seal replacement s7rw0a5206003 1) lift up vehicle and drain transaxle oil. 2) remove drive shaft assembly and center shaft referring to “front drive shaft assembly removal and installation: front in section 3a”. 3) remove oil seal (1) by usin...

  • Page 874

    5b-8 manual transmission/transaxle: gear shift control lever and cable components s7rw0a5206004 1 7 3 4 (a) 6 a 8 (b) 2 (c) 5 9 a i5rw0a520008-02 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut : 10 n ⋅m (1.0 kgf-m, 7.5 lb-ft) 2. Cable bracket bolt 7. Gear shift co...

  • Page 875

    Manual transmission/transaxle: 5b-9 gear shift control lever and cable removal and installation s7rw0a5206005 removal 1) remove console box. 2) disconnect cable ends (5) from pivot (6) of gear shift control lever assembly by removing clip. 3) disconnect gear shift and select control cables (1) from ...

  • Page 876

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

  • Page 877

    Manual transmission/transaxle: 5b-11 manual transaxle unit components s7rw0a5206009 3 7 (a) 4 6 5 8 2 [a] 1 10 (a) 7 (a) 9 (c) 11 (b) i5rw0a520010-02 [a]: forward 5. Ground cable bolt 10. Transaxle to engine nut 1. Engine 6. Ground cable 11. Stiffener bolt 2. Transaxle 7. Transaxle to engine bolt : ...

  • Page 878

    5b-12 manual transmission/transaxle: manual transaxle unit dismounting and remounting s7rw0a5206010 dismounting 1) drain coolant. 2) remove battery and tray with ecm. 3) remove air cleaner case and resonator. 4) remove clutch fluid pipe referring to “clutch fluid pipe removal and installation in sec...

  • Page 879

    Manual transmission/transaxle: 5b-13 gear shift and select shaft assembly components s7rw0a5206011 1 10 3 4 9 2 6 12 7 11 5 8 (a) (a) (a) (a) 1217g 1217g 1217g a 13 i6rw0c520001-01 1. Gear shift & select shaft 7. Gear shift guide case bolt no.1 : apply sealant 99000-31260 to bolt thread. 13. Oil sea...

  • Page 880

    5b-14 manual transmission/transaxle: gear shift and select shaft assembly removal and installation s7rw0a5206012 removal 1) remove battery and tray with ecm. 2) disconnect gear shift and gear select control cables from transaxle. 3) remove gear shift interlock bolt (1) and 5th to reverse interlock g...

  • Page 881

    Manual transmission/transaxle: 5b-15 gear shift and select shaft assembly disassembly and reassembly s7rw0a5206013 1) push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and specified spring pin removers as shown bellow. Special tool (a): 09922–85811 4...

  • Page 882

    5b-16 manual transmission/transaxle: manual transaxle assembly components s7rw0a5206014 i5rw0a520018-03 1. Transaxle right case 22. Shift fork bolt : apply thread lock 99000-32110 to all around thread part of bolt. 2. Transaxle left case : apply sealant 99000-31260 to mating surface of left case and...

  • Page 883

    Manual transmission/transaxle: 5b-17 fifth gear disassembly and reassembly s7rw0a5206015 disassembly 1) remove cover bolts and take off transaxle side cover. Caution ! Care should be taken not to distort side cover when it is removed from left case. 2) using special tool, remove circlip (1). Special...

  • Page 884

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

  • Page 885

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

  • Page 886

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

  • Page 887

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

  • Page 888

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

  • Page 889

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

  • Page 890

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

  • Page 891

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

  • Page 892

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

  • Page 893

    Manual transmission/transaxle: 5b-27 input shaft and countershaft components s7rw0a5206019 i3rh0a520017-01 1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer center cone 2. Oil seal : apply grease 99000-25010 to oil seal lip. 13. Circlip 24. 2nd gear synchronizer inner ring 3. Inp...

  • Page 894

    5b-28 manual transmission/transaxle: input shaft disassembly and reassembly s7rw0a5206020 disassembly 1) remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and hydraulic press. 2) drive out 5th gear spacer (2), left bearing (3) and 4th gear (4) all at once using pulle...

  • Page 895

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

  • Page 896

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

  • Page 897

    Manual transmission/transaxle: 5b-31 countershaft disassembly and reassembly s7rw0a5206021 disassembly 1) drive out left bearing cone (2) with 4th gear (3) by using puller (4) and hydraulic press. Caution ! • use puller and hydraulic press that will bear at least 5 ton (11,000 lb) safely. • to avoid...

  • Page 898

    5b-32 manual transmission/transaxle: 6) disassemble synchronizer sleeve & hub assembly. 7) take out 1st gear needle bearing from shaft. 8) in order to remove right bearing (1) from countershaft, grind with a grinder (2) one part “a” of right bearing (1) as illustrated till it becomes thin. Caution !...

  • Page 899

    Manual transmission/transaxle: 5b-33 5) fit low speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure. Note • no specific direction is assigned to each key but it is assigned as sleeve & hub assembly. • size of low speed synchronizer keys and s...

  • Page 900

    5b-34 manual transmission/transaxle: 9) install circlip (1) and confirm that circlip is installed in groove securely. Install needle bearing (2) and apply oil to needle bearing. With synchronizer outer ring (3), center cone (4) and inner ring (5) put together and installed to 2nd gear (6) as shown i...

  • Page 901

    Manual transmission/transaxle: 5b-35 gear shift shaft components s7rw0a5206022 5th and reverse gear shift shafts disassembly and reassembly s7rw0a5206023 disassembly disassemble component parts by using special tool and hammer. Special tool : 09922–85811 reassembly replace or correct parts as requir...

  • Page 902

    5b-36 manual transmission/transaxle: differential components s7rw0a5206025 differential disassembly and reassembly s7rw0a5206026 disassembly 1) using special tool, remove left bearing (1). Special tool (a): 09913–65135 (b): 09913–85230 2) using special tool, remove right bearing (1). Special tool (a...

  • Page 903

    Manual transmission/transaxle: 5b-37 3) support differential case (1) with soft jawed vise and remove final gear bolts then take out final gear. 4) drive out differential pinion shaft (3) pin by using special tool and hammer and then disassemble components parts. Special tool (a): 09922–85811 reasse...

  • Page 904

    5b-38 manual transmission/transaxle: 4) press-fit right bearing (1) by using special tools and hydraulic press. Special tool (a): 09925–15410 (b): 09924–07720 (c): 09913–85230 5) hold differential assembly with soft jawed vise (3), install final gear (2) and then tighten new final gear bolts (1). Ca...

  • Page 905

    Manual transmission/transaxle: 5b-39 special tools and equipment recommended service material s7rw0a5208001 note required service material is also described in the following. “gear shift control lever and cable components” “gear shift and select shaft assembly components” “manual transaxle assembly ...

  • Page 906

    5b-40 manual transmission/transaxle: 09913–76010 09913–80113 bearing installer bearing installer ) / ) ) / ) / ) 09913–84510 09913–85210 bearing installer bearing installer ) ) / ) 09913–85230 09922–85811 bearing remover tool spring pin remover (4.5 mm) ) / ) / ) ) / ) / ) 09923–78210 09924–07710 be...

  • Page 907

    Manual transmission/transaxle: 5b-41 09940–54910 09940–54950 front fork oil seal install driver bearing installer attachment ) ) 09941–64511 09942–15511 bearing and oil seal remover (30 mm min.) sliding hammer ) ) 09944–96011 09952–06010 bearing outer race remover dial gauge plate no.1 ) ).

  • Page 908: Clutch

    5c-1 clutch: transmission / transaxle clutch general description clutch (hydraulic type) construction s7rw0a5301001 the clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of...

  • Page 909

    Clutch: 5c-2 diagnostic information and procedures clutch system symptom diagnosis s7rw0a5304001 condition possible cause correction / reference item slipping improper clutch pedal free travel bleed air or replace master cylinder. Worn or oily clutch disc facing replace disc. Warped disc, pressure p...

  • Page 910

    5c-3 clutch: repair instructions clutch pedal inspection s7rw0a5306001 cylinder push rod play “a” 1) press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and measure how much pedal has moved (push rod play) as represented by “a” as shown. Push rod play “a”: m...

  • Page 911

    Clutch: 5c-4 clutch fluid pipe and hose components s7rw0a5306004 clutch fluid pipe removal and installation s7rw0a5306005 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 ...

  • Page 912

    5c-5 clutch: clutch master cylinder removal and installation s7rw0a5306007 removal 1) clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake master cylinder reservoir. 2) disconnect clutch fluid pipe (4) from clutch master cylinder (1) referring to “clutc...

  • Page 913

    Clutch: 5c-6 installation 1) install clutch operating cylinder assembly (2) to transaxle. Tighten new mounting bolts to specified torque. Tightening torque clutch operating cylinder assembly mounting bolt (a): 10 n·m (1.0 kgf-m, 7.5 lb-ft) 2) connect clutch fluid pipe (4) to clutch operating cylinde...

  • Page 914

    5c-7 clutch: clutch cover, clutch disc and flywheel removal and installation s7rw0a5306011 removal 1) dismount manual transaxle assembly referring to “manual transaxle unit dismounting and remounting in section 5b”. 2) hold flywheel with special tool and remove clutch cover bolts (1), clutch cover (...

  • Page 915

    Clutch: 5c-8 2) using special tool, install input shaft bearing to flywheel (1). Special tool (b): 09925–98210 3) aligning clutch disc to flywheel center using special tool, install clutch cover (1) and bolts (2). Then tighten bolts (2) to specification. Note • while tightening clutch cover bolts, c...

  • Page 916

    5c-9 clutch: clutch disc measure depth of rivet head depression, i.E. Distance between rivet head and facing surface. If depression is found to have reached service limit at any of rivet holes (2), replace clutch disc assembly (1). Rivet head depth standard: 1.65 – 2.25 mm (0.06 – 0.09 in.) limit: 0...

  • Page 917

    Clutch: 5c-10 special tools and equipment recommended service material s7rw0a5308001 special tool s7rw0a5308002 material suzuki recommended product or specification note grease suzuki silicone grease p/no.: 99000–25100 ) suzuki super grease i p/no.: 99000–25210 ) 09921–26020 09923–36320 bearing remo...

  • Page 918

    5c-11 clutch:.

  • Page 919: 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 920

    6-ii table of contents repair instructions ............................................6c-35 steering gear case assembly components ....6c-35 tie-rod end boot on-vehicle inspection .........6c-36 tie-rod end removal and installation..............6c-36 tie-rod end initial position setting...............

  • Page 921: Precautions

    Precautions: 6-1 steering precautions precautions precautions on steering s7rw0a6000001 air bag warning refer to “air bag system service warning in section 00”. Precautions for steering diagnosis refer to “precautions for steering diagnosis in section 6a”. Service precautions of steering wheel and c...

  • Page 922: Steering General Diagnosis

    6a-1 steering general diagnosis: steering steering general diagnosis precautions precautions for steering diagnosis s7rw0a6100001 since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the ve...

  • Page 923

    Steering general diagnosis: 6a-2 steering system inspection s7rw0a6104002 check steering system referring to the following items. Erratic steering when braking worn wheel bearings replace wheel bearing. Broken or sagging coil springs replace coil spring. Wheel tires are inflated unequally inflate ti...

  • Page 924: Steering Wheel and Column

    6b-1 steering wheel and column: steering steering wheel and column precautions service precautions of steering wheel and column s7rw0a6200001 for service precautions, refer to “precautions on service and diagnosis of air bag system in section 8b”. Service and diagnosis for diagnosis and servicing, r...

  • Page 925

    Steering wheel and column: 6b-2 diagnostic information and procedures checking steering column for accident damage s7rw0a6204001 note vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed may have a damaged or misaligned steering column....

  • Page 926

    6b-3 steering wheel and column: repair instructions steering wheel and column components s7rw0a6206001 4 6 8 13 11 (b) 2 (a) 12 (b) 10 (c) 9 7 (c) 5 1 3 14 i7rw01620001-01 1. Steering wheel 10. Steering column assembly mounting nut no.2 : after tightening column mounting nut no.2, tighten column mou...

  • Page 927

    Steering wheel and column: 6b-4 steering wheel removal and installation s7rw0a6206002 caution ! Do not turn the contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively) with steering wheel removed, or coil will ...

  • Page 928

    6b-5 steering wheel and column: 4) connect horn connector and audio control switch connector, if necessary. 5) install driver air bag (inflator) module to steering wheel. Refer to “driver air bag (inflator) module removal and installation in section 8b”. 6) connect negative (–) cable to battery. 7) ...

  • Page 929

    Steering wheel and column: 6b-6 4) install steering column upper cover (1) and lower cover (2). Caution ! When installing covers, be careful so that each lead wire is not caught between covers. Otherwise, each lead wire is damaged. 5) install steering wheel to steering column. Refer to “steering whe...

  • Page 930

    6b-7 steering wheel and column: installation 1) install steering angle sensor (2) by fitting engagement parts (1) of contact coil cable assembly to claws of steering angle sensor as shown in figure. 2) install contact coil cable assembly and steering wheel. Refer to “contact coil cable assembly remo...

  • Page 931

    Steering wheel and column: 6b-8 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 that front wheels are in straight. 2) install steering column assembly to lower and upp...

  • Page 932

    6b-9 steering wheel and column: ignition switch cylinder assembly removal and installation (non- keyless start model) s7rw0a6206008 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system in section 8b”. 3) remove steering column upper an...

  • Page 933

    Steering wheel and column: 6b-10 5) tighten new bolts (1) until head of each bolt is broken off. 6) turn ignition key to “acc” or “on” position and check to be sure that steering shaft (2) rotates smoothly. Also check for lock operation. 7) install steering column. Refer to “steering column removal ...

  • Page 934

    6b-11 steering wheel and column: specifications tightening torque specifications s7rw0a6207001 note the specified tightening torque is also described in the following. “steering wheel and column components” reference: for the tightening torque of fastener not specified in this section, refer to “fas...

  • Page 935

    Power assisted steering system: 6c-1 steering power assisted steering system precautions p/s system note s7rw0a6300001 note all steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. The...

  • Page 936

    6c-2 power assisted steering system: general description p/s system description s7rw0a6301001 this electronic power steering (eps) system consists of a power steering (p/s) control module (3), a torque sensor (4), a p/s motor (5). In this system, the p/s control module determines the level and direc...

  • Page 937

    Power assisted steering system: 6c-3 eps diagnosis general description s7rw0a6301002 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 938

    6c-4 power assisted steering system: schematic and routing diagram eps system wiring circuit diagram s7rw0a6302001 [a] 1 2 3 4 5 3 2 1 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 1 2 [b] 1 2 [c] [d] 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 26 25 24 23 22 21 20 19 18 17 32 31 30 29 28 27 [f] [e] 1 2 b...

  • Page 939

    Power assisted steering system: 6c-5 terminal arrangement of p/s control module coupler (viewed from harness side) diagnostic information and procedures eps system check s7rw0a6304001 warning ! Carry out test drive in light traffic area to prevent an accident. Refer to the following items for the de...

  • Page 940

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

  • Page 941

    Power assisted steering system: 6c-7 step 1: customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analy...

  • Page 942

    6c-8 power assisted steering system: step 8: steering symptom diagnosis and p/s system symptom diagnosis perform basic steering system check according to “steering symptom diagnosis in section 6a” first. When the end of the flow has been reached, check the parts of the system suspected as a possible...

  • Page 943

    Power assisted steering system: 6c-9 dtc clearance s7rw0a6304004 1) turn ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located on underside of instrument panel at driver’s seat side. Special tool (a): suzuki scan tool 3) turn ignition switch to on posi...

  • Page 944

    6c-10 power assisted steering system: ) c1121 no vehicle speed signal (60 seconds or more) vehicle speed signal is 0 km/h even though engine speed is more than 4000 rpm for more than 60 seconds continuously (before elapse of 5 min from engine start) or vehicle speed signal is 0 km/h even though engi...

  • Page 945

    Power assisted steering system: 6c-11 visual inspection s7rw0a6304006 visually check the following parts and systems. ) c1141 p/s motor circuit voltage voltage between both motor drive circuit is more than 8.5 v or less than 0.2 v for 0.5 second continuously while motor is not driven. • p/s motor ci...

  • Page 946

    6c-12 power assisted steering system: scan tool data s7rw0a6304007 note when p/s motor is cold condition (that is, armature coil of p/s motor is not heated), normal value with asterisk (*) mark in the following table is displayed on scan tool scan tool data definitions power supply voltage this para...

  • Page 947

    Power assisted steering system: 6c-13 motor drive voltage (v) this parameter indicates the voltage between motor terminals. System power status (eps system power, on, off) this parameter indicates input status of eps system power supply. Ign switch status (on, off) this parameter indicates the condi...

  • Page 948

    6c-14 power assisted steering system: dlc and its communication check (no communication to p/s control module) s7rw0a6304009 wiring diagram troubleshooting [a] 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 1 2 [b] 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 26 25 24 23 22 21 20 19 18 17 32 31 30 29 ...

  • Page 949

    Power assisted steering system: 6c-15 3 communication check 1) check dlc terminal for deformation and wear. 2) if it is in good condition, connect suzuki scan tool to dlc with ignition switch tuned off. 3) check if communication is possible by making communication with other control modules (bcm, ab...

  • Page 950

    6c-16 power assisted steering system: “eps” warning light does not come on with ignition switch turned on before engine starts s7rw0a6304010 wiring diagram 8 scan tool operation check 1) check if communication is possible by making communication with other vehicles. Is it possible to communicate wit...

  • Page 951

    Power assisted steering system: 6c-17 circuit description operation (on/off) of “eps” warning light is controlled by p/s control module through combination meter. If the p/s system is in good condition, p/s control module turns “eps” warning light on at the ignition switch on, and then turns it off ...

  • Page 952

    6c-18 power assisted steering system: “eps” warning light remains on steady after engine starts s7rw0a6304011 wiring diagram refer to ““eps” warning light does not come on with ignition switch turned on before engine starts”. Circuit description operation (on/off) of “eps” warning light is controlle...

  • Page 953

    Power assisted steering system: 6c-19 dtc c1111 / c1113 / c1115: torque sensor circuit failure s7rw0a6304012 dtc c1111: steering torque sensor (main) circuit voltage dtc c1113: steering torque sensor (main and sub) circuit correlation dtc c1115: steering torque sensor (sub) circuit voltage wiring di...

  • Page 954

    6c-20 power assisted steering system: dtc troubleshooting step action yes no 1 was “eps system check” performed? Go to step 2. Go to “eps system check”. 2 dtc check is dtc c1153 or c1116 indicated, together? Go to applicable diag. Flow. Go to step 3. 3 torque sensor signal circuit check 1) with igni...

  • Page 955

    Power assisted steering system: 6c-21 dtc c1116: steering torque sensor power supply circuit s7rw0a6304013 wiring diagram dtc detecting condition and trouble area dtc troubleshooting [a] 1 2 3 4 5 3 2 1 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 1 2 [b] [c] lt grn/ blk wht grn blk e11-1 e11-10 e11...

  • Page 956

    6c-22 power assisted steering system: dtc c1121 / c1123 / c1124: vehicle speed signal circuit failure s7rw0a6304014 dtc c1121: no vehicle speed signal (60 seconds or more) dtc c1123: no vehicle speed signal (30 seconds or more) dtc c1124: vehicle speed performance (impossible deceleration) wiring di...

  • Page 957

    Power assisted steering system: 6c-23 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area dtc c1121: vehicle speed signal is 0 km/h even though engine speed is more than 4000 rpm for more than 60 seconds continuously (before elapse of 5 min from engine s...

  • Page 958

    6c-24 power assisted steering system: dtc c1122: engine speed signal s7rw0a6304015 wiring diagram 6 vehicle speed signal circuit check 1) with ignition switch turned off, disconnect connectors from bcm. 2) check bcm connector for proper connection. 3) if ok, turn on ignition switch, measure voltage ...

  • Page 959

    Power assisted steering system: 6c-25 dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area engine speed signal is less than 220 rpm for more than 0.8 seconds. Or engine speed signal is less than 220 rpm for more than 20 seconds continuously even though ve...

  • Page 960

    6c-26 power assisted steering system: dtc c1141 / c1142 / c1143 / c1145: motor circuit failure s7rw0a6304016 dtc c1141: p/s motor circuit voltage dtc c1142: p/s motor circuit range/performance dtc c1143: p/s motor circuit current too high dtc c1145: p/s motor circuit current too low wiring diagram d...

  • Page 961

    Power assisted steering system: 6c-27 dtc troubleshooting dtc c1153: p/s control module power supply circuit s7rw0a6304017 wiring diagram dtc detecting condition and trouble area step action yes no 1 was “eps system check” performed? Go to step 2. Go to “eps system check”. 2 dtc check is dtc c1153 a...

  • Page 962

    6c-28 power assisted steering system: dtc troubleshooting dtc c1155: p/s control module internal failure s7rw0a6304018 wiring diagram refer to “dtc c1153: p/s control module power supply circuit”. Dtc detecting condition and trouble area dtc troubleshooting step action yes no 1 was “eps system check...

  • Page 963

    Power assisted steering system: 6c-29 p/s control module power supply and ground circuit check s7rw0a6304019 wiring diagram refer to “dtc c1153: p/s control module power supply circuit”. Dtc troubleshooting step action yes no 1 circuit fuse check 1) disconnect p/s control module connector with ignit...

  • Page 964

    6c-30 power assisted steering system: inspection of p/s control module and its circuits s7rw0a6304020 the p/s control module and its circuits can be checked at the p/s control module wiring couplers by measuring voltage and resistance. Caution ! P/s control module cannot be checked by itself. It is ...

  • Page 965

    Power assisted steering system: 6c-31 terminal wire color circuit normal voltage condition e11-1 lt grn/blk ignition switch signal for p/s control module 10 – 14 v ignition switch on e11-2 — — — — e11-3 — — — — e11-4 ppl vehicle speed signal *0 – 1 v ↑↓ 8 – 14 v (“reference waveform no.7” under “ins...

  • Page 966

    6c-32 power assisted steering system: note *: the voltage of this circuit may not be checked by voltmeter. If so, use oscilloscope. Reference waveform no.1 motor output signal 1(1), motor output signal 2(2), with engine idling e11-20 red reference sensor power supply for torque sensor about 3.0 – 3....

  • Page 967

    Power assisted steering system: 6c-33 reference waveform no.2 motor output signal 1(1), motor output signal 2(2), with engine idling reference waveform no.3 motor output signal 1(1), motor output signal 2(2), with engine idling measurement terminal ch1: “e12-1” to vehicle body ground ch1: “e12-2” to...

  • Page 968

    6c-34 power assisted steering system: steering wheel play check s7rw0a6304021 • 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 969

    Power assisted steering system: 6c-35 repair instructions steering gear case assembly components s7rw0a6306001 note the figure shows left-hand steering vehicle. For right-hand steering vehicle the figure is symmetrical. 8 6 5 9 13 18 17 3 12 7 (b) (a) (c) 2 1 (e) (d) 3 (a) 2 5 6 8 7 9 (b) 16 21 19 2...

  • Page 970

    6c-36 power assisted steering system: tie-rod end boot on-vehicle inspection s7rw0a6306002 check boot for crack and damage. If any defect is found, replace it with a new one. Tie-rod end removal and installation s7rw0a6306003 removal 1) hoist vehicle and then remove wheel referring to “wheel (with t...

  • Page 971

    Power assisted steering system: 6c-37 2) connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to specified torque. Tightening torque tie-rod end nut (a): 45 n·m (4.5 kgf-m, 32.5 lb-ft) 3) for castle nut type, bend new cotter pin (2). Note after tightening tie-rod end nut to specified torque, ...

  • Page 972

    6c-38 power assisted steering system: steering gear case assembly removal and installation s7rw0a6306006 removal caution ! Be sure to set front wheels (tires) in straight direction and remove ignition key from key cylinder before performing the following steps, otherwise, contact coil of air bag sys...

  • Page 973

    Power assisted steering system: 6c-39 steering rack boot inspection s7rw0a6306007 hoist vehicle. Inspect each boot for tear. A torn boot allows entry of dust and water which can cause wear to steering rack and pinion to produce noise as well as rust to result in malfunction of steering system. Even ...

  • Page 974

    6c-40 power assisted steering system: 5) clamp boot with clip and wire. Wire should be new and should go around the boot twice. Pull its both ends together by screwdriver or such and make sure that the wire won’t be crossed. Then twist the ends 4 – 5 times, the twisted ends should be bent in the cir...

  • Page 975

    Power assisted steering system: 6c-41 installation 1) install plunger (1), new o-ring (6), washer (4), spring washers (5) and spring (2) as shown. Note do not wipe off grease previously applied to new plunger. 2) apply sealant to rack damper screw (3) and tighten them as follows. A) tighten damper s...

  • Page 976

    6c-42 power assisted steering system: torque sensor and its circuit inspection s7rw0a6306012 1) check that torque sensor circuit is in good condition referring to step 2 to 3 of “dtc c1111 / c1113 / c1115: torque sensor circuit failure”. If check result is not satisfactory, repair torque sensor circ...

  • Page 977

    Power assisted steering system: 6c-43 p/s motor and its circuit inspection s7rw0a6306013 1) check motor circuit referring to step 2 to 3 of “dtc c1141 / c1142 / c1143 / c1145: motor circuit failure”. If check result is not satisfactory, repair motor circuit. 2) disconnect motor connector from steeri...

  • Page 978

    6c-44 power assisted steering system: specifications tightening torque specifications s7rw0a6307001 note the specified tightening torque is also described in the following. “steering gear case assembly components” reference: for the tightening torque of fastener not specified in this section, refer ...

  • Page 979: 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 980

    7-ii table of contents compressor drive belt removal and installation.......................................................7b-31 compressor assembly removal and installation.......................................................7b-31 compressor assembly components.................7b-32 magnet clutc...

  • Page 981

    Table of contents 7-iii condenser cooling fan inspection...................7b-84 condenser assembly on-vehicle inspection.... 7b-84 condenser assembly removal and installation.......................................................7b-84 evaporator inspection ....................................... 7b...

  • Page 982: Precautions

    7-1 precautions: hvac precautions precautions precautions on hvac s7rw0a7000001 air bag warning refer to “air bag warning in section 00”. A/c system caution refer to “a/c system caution: manual type in section 7b” or “a/c system caution: automatic type in section 7b”. Precautions on servicing a/c sy...

  • Page 983: Heater and Ventilation

    Heater and ventilation: 7a-1 hvac heater and ventilation schematic and routing diagram heater and ventilation diagram s7rw0a7102002 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6rw0c710001-02 a: air flow 7. Def...

  • Page 984

    7a-2 heater and ventilation: heater and ventilation wiring circuit diagram s7rw0a7102001 non–a/c manual a/c refer to “a/c system wiring diagram: manual type in section 7b”. Auto a/c refer to “a/c system wiring diagram: automatic type in section 7b”. Component location electronic control system compo...

  • Page 985

    Heater and ventilation: 7a-3 diagnostic information and procedures heater and ventilation symptom diagnosis s7rw0a7104001 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 986

    7a-4 heater and ventilation: repair instructions hvac unit components s7rw0a7106001 for non-a/c and manual a/c, refer to “hvac unit components: manual type in section 7b”. For auto a/c, refer to “hvac unit components: automatic type in section 7b”. Hvac unit removal and installation (non-a/c) s7rw0a...

  • Page 987

    Heater and ventilation: 7a-5 • check for operation and current. A. Put blower motor (1) in a soft-jawed vise. B. Connect battery to blower motor as shown. C. Check if blower motor operates smoothly without noise. D. Check if ammeter indicates the specified current. If measured current is out of spec...

  • Page 988

    7a-6 heater and ventilation: blower motor relay inspection s7rw0a7106007 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system in section 8b”. 3) remove junction block assembly (2). 4) disconnect blower motor relay (1) from junction block assem...

  • Page 989

    Heater and ventilation: 7a-7 hvac control unit removal and installation s7rw0a7106009 removal 1) disconnect negative (–) cable at battery. 2) remove steering column hole cover from instrument panel. 3) remove audio unit from instrument panel referring to “audio unit removal and installation (if equi...

  • Page 990

    7a-8 heater and ventilation: b. Move temperature control lever (1) to “max hot” position “a” (lh steering vehicle) or “max cool” position “b” (rh steering vehicle), then fix temperature control inner cable (2) to pin of temperature control lever and fix outer cable (3) to cable lock clamp (4). Lh st...

  • Page 991

    Heater and ventilation: 7a-9 blower speed selector inspection s7rw0a7106010 check blower speed selector for each terminal to terminal continuity. If check result does not meet the following conditions, replace hvac control unit. Air intake selector inspection s7rw0a7106011 • check that there is cont...

  • Page 992

    7a-10 heater and ventilation: installation reverse removal procedure noting the following instruction. • be sure to insert the linkage rod (1) into the hole (2) of air intake control actuator. Air intake control actuator inspection s7rw0a7106013 check air intake control actuator as follows: 1) using...

  • Page 993

    Heater and ventilation: 7a-11 center ventilation louver removal and installation s7rw0a7106014 removal 1) disconnect negative (–) cable from battery. 2) remove audio unit from instrument panel referring to “audio unit removal and installation (if equipped) in section 9c”. 3) remove center ventilatio...

  • Page 994

    7a-12 heater and ventilation: rear duct removal and installation (if equipped) s7rw0a7106016 removal 1) disconnect negative (–) cable at battery. 2) remove front seats referring to “front seat removal and installation in section 9g”. 3) remove console box referring to “console box components in sect...

  • Page 995: Air Conditioning System

    Air conditioning system: manual type 7b-1 hvac air conditioning system manual type precautions a/c system caution s7rw0a7210001 caution ! The a/c system of this vehicle uses hfc-134a (r-134a) refrigerant, specified compressor oil and specified parts. Do not use cfc-12 (r-12) refrigerant, r-12 exclus...

  • Page 996

    7b-2 air conditioning system: manual type refrigerant recovery when discharging refrigerant out of a/c system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant hfc-134a (r-134a) into atmosphere would cause adverse effect to environments referrin...

  • Page 997

    Air conditioning system: manual type 7b-3 a/c operation description at ecm s7rw0a7211003 ecm controls the a/c compressor relay and condenser cooling fan relay according to signals from hvac control unit, a/c refrigerant pressure sensor, ect sensor and evaporator temperature sensor. The a/c switch on...

  • Page 998

    7b-4 air conditioning system: manual type schematic and routing diagram a/c system air flow diagram s7rw0a7212001 13 12 13 9 9 10 11 11 15 14 17 18 : a : b 4 7 3 5 6 2 16 8 19 1 20 i7rw01721002-03 a: air flow 5. Discharge hose 11. Foot air 17. Air intake door b: refrigerant flow 6. Suction hose 12. ...

  • Page 999

    Air conditioning system: manual type 7b-5 a/c system wiring diagram s7rw0a7212002 [c] 7 wht grn 5 yel blk 3 g154-3 g154-4 g154-7 g154-8 g154-10 g154-13 g154-5 g154-6 g155-5 g155-2 g155-3 g155-7 g155-6 g155-1 g154-9 g154-14 blk/wht yel blu/wht red brn grn/wht red/blk red grn grn/yel red/yel red/blu 2...

  • Page 1000

    7b-6 air conditioning system: manual type manual a/c electronic input output diagram s7rw0a7212003 component location a/c system major components location s7rw0a7213001 ecm bcm a/c switch air intake selector a/c refrigerant pressure sensor a/c evaporator temperature sensor compressor relay ect senso...

  • Page 1001

    Air conditioning system: manual type 7b-7 electronic control system components location s7rw0a7213002 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. [a] 8* 9* 10* 11 1 5 7* 6 7* 12 13 14 17 15 16 4 2 3 i6rw0c72100...

  • Page 1002

    7b-8 air conditioning system: manual type diagnostic information and procedures a/c system performance inspection s7rw0a7214001 1) confirm that vehicle and environmental conditions are as follows. • vehicle is put indoors. • ambient temperature is within 25 – 35 °c (77 – 95 °f). • relative humidity ...

  • Page 1003

    Air conditioning system: manual type 7b-9 10) check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective part referring to the following table. When diagnosing troubles of abnormal pressure on the low...

  • Page 1004

    7b-10 air conditioning system: manual type low pressure gauge 11) check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature near air inlet of hvac unit is 30 °c (86 °f) and the one at air outlet of center ventilation louver is 17 °c (62.6 °f), ...

  • Page 1005

    Air conditioning system: manual type 7b-11 thermometer at center ventilation louver trouble diagnosis for abnormal pressure s7rw0a7214002 note normal pressure values on high side and low side in following table are measured when the ambient temperature is 30 °c. As normal pressure values on high sid...

  • Page 1006

    7b-12 air conditioning system: manual type a/c system inspection at ecm s7rw0a7214003 when checking voltage at ecm terminals related to a/c system, refer to “inspection of ecm and its circuits in section 1a”. 0.05 – 0.15 (0.5 – 1.5) (4.2 – 21.3) 0.7 – 1.0 (7 – 10) (100 – 142) both low and high press...

  • Page 1007

    Air conditioning system: manual type 7b-13 a/c system symptom diagnosis s7rw0a7214004 condition possible cause correction / reference item no cool air comes out (a/ c compressor does not operate) no refrigerant perform recovery, evacuation and charge referring to “operation procedure for refrigerant...

  • Page 1008

    7b-14 air conditioning system: manual type cool air does not come out or insufficient cooling (a/c compressor normal operation) insufficient or excessive charge of refrigerant check the amount of refrigerant and system for leaks. Condenser clogged check condenser referring to “condenser assembly on-...

  • Page 1009

    Air conditioning system: manual type 7b-15 abnormal noise symptom diagnosis of a/c system s7rw0a7214005 abnormal noise from compressor abnormal noise from magnetic clutch cool air does not come out only at high speed excessive amount of refrigerant check the amount of refrigerant. A/c evaporator fro...

  • Page 1010

    7b-16 air conditioning system: manual type abnormal noise from tubing abnormal noise from condenser assembly abnormal noise from crankshaft pulley abnormal noise from tension pulley abnormal noise from a/c evaporator abnormal noise from blower motor condition possible cause correction / reference it...

  • Page 1011

    Air conditioning system: manual type 7b-17 repair instructions operation procedure for refrigerant charge s7rw0a7216001 warning ! • your eyes should not be exposed to refrigerant (liquid). Any liquid hfc-134a (r-134a) escaping by accident shows a temperature as low as approximately – 6 °c (21.2 °f) ...

  • Page 1012

    7b-18 air conditioning system: manual type recovery when discharging refrigerant out of a/c system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant hfc-134a (r-134a) into atmosphere would cause adverse effect to environments. Note • after recov...

  • Page 1013

    Air conditioning system: manual type 7b-19 evacuation caution ! Do not evacuate before recovering refrigerant in a/c system. Note once air conditioning system circuit is opened (exposed) to atmospheric air, system must be evacuated by using a vacuum pump. The a/c system should be attached with a man...

  • Page 1014

    7b-20 air conditioning system: manual type charge caution ! • because the sight glass is not used for this a/c system, do not perform an additional charge to the a/c system. To charge the proper amount of refrigerant, recover and evacuate the a/c system first. And then, charge the proper amount of r...

  • Page 1015

    Air conditioning system: manual type 7b-21 7) when refrigerant container (1) is emptied, use the following procedure to replace it with a new refrigerant container. A) close low pressure valve. B) replace empty container with a refrigerant container which has been charged with refrigerant. When usin...

  • Page 1016

    7b-22 air conditioning system: manual type check a/c system for refrigerant leaks whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result in malfunction of lines and connections, it is advisable to check for leaks. Common sense should be us...

  • Page 1017

    Air conditioning system: manual type 7b-23 condenser cooling fan inspection s7rw0a7216003 1) check condenser cooling fan motor for resistance between terminal “a” and “b” as shown. If there is no continuity, replace condenser cooling fan motor. 2) connect battery to condenser cooling fan motor termi...

  • Page 1018

    7b-24 air conditioning system: manual type 5) move condenser assembly from the vehicle in the arrow direction in the order of 1, 2 and 3 as shown, and it can be removed. Installation reverse the removal procedure to install condenser noting the following instructions. • replenish specified amount of...

  • Page 1019

    Air conditioning system: manual type 7b-25 hvac unit components s7rw0a7216007 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 1 10 1 9 8 25 25 3 20 3 19 19 19 24 24 21 4 23* 27 15 16* 14 25* 18* 2 25 26 17* 13 12 1...

  • Page 1020

    7b-26 air conditioning system: manual type hvac unit removal and installation s7rw0a7216008 removal 1) recover refrigerant from a/c system with recovery and recycling equipment referring to “recovery” in “operation procedure for refrigerant charge: manual type”. 2) drain engine coolant referring to ...

  • Page 1021

    Air conditioning system: manual type 7b-27 installation reverse removal procedure noting the following instructions. • replenish specified amount of compressor oil to compressor suction side referring to “replenishing compressor oil” in “operation procedure for refrigerant charge: manual type”. • in...

  • Page 1022

    7b-28 air conditioning system: manual type evaporator temperature sensor inspection s7rw0a7216011 check resistance between terminals of evaporator temperature sensor (1). If check results are as not specified, replace evaporator temperature sensor. Evaporator temperature sensor resistance 0 °c (32 °...

  • Page 1023

    Air conditioning system: manual type 7b-29 a/c refrigerant pressure sensor and its circuit inspection s7rw0a7216014 1) disconnect a/c refrigerant pressure sensor connector. 2) turn ignition switch to on position. 3) check if voltage between “red” wire terminal and “orn” wire terminal of a/c refriger...

  • Page 1024

    7b-30 air conditioning system: manual type a/c system relay inspection s7rw0a7216017 note do not use blue relay for the substitute of white relay because internal durability of a blue relay is different from the durability of a white relay. 1) disconnect negative (–) cable from battery. 2) remove co...

  • Page 1025

    Air conditioning system: manual type 7b-31 compressor drive belt removal and installation s7rw0a7216019 removal 1) loosen tension pulley nut (1). 2) loosen belt tension loosening tension pulley adjusting bolt (2). 3) remove compressor drive belt (3). Installation reverse removal procedure noting the...

  • Page 1026

    7b-32 air conditioning system: manual type compressor assembly components s7rw0a7216021 magnet clutch inspection s7rw0a7216022 • check armature plate and magnet clutch pulley for wear and oil soak respectively. • check magnet clutch pulley bearing for noise, wear and grease leakage. • measure magnet...

  • Page 1027

    Air conditioning system: manual type 7b-33 magnet clutch removal and installation s7rw0a7216023 removal 1) remove compressor from vehicle referring to “compressor assembly removal and installation: manual type”. 2) fix armature plate (1) with special tool and remove armature plate bolt (2). Special ...

  • Page 1028

    7b-34 air conditioning system: manual type installation 1) install magnet clutch coil (2) fitting protrusion (4) of magnet clutch coil onto hole (5) of compressor (3). 2) install circlip (1) directing chamfer side (6) downward. Special tool (b): 09900–06107 3) install thermal switch to compressor re...

  • Page 1029

    Air conditioning system: manual type 7b-35 thermal switch inspection s7rw0a7216024 measured thermal switch for resistance at 20 °c (68 °f) thermal switch resistance standard: 50 m Ω (dc 16 v, 5a at 20 °c (68 °f)) thermal switch removal and installation s7rw0a7216025 removal 1) remove compressor from...

  • Page 1030

    7b-36 air conditioning system: manual type installation reverse removal procedure noting the following instructions. • use new o-ring • apply compressor oil to o-ring. • tighten relief valve to the specified torque. Tightening torque relief valve (a): 8 n·m (0.8 kgf-m, 6.0 lb-ft) • evacuate and char...

  • Page 1031

    Air conditioning system: manual type 7b-37 special tools and equipment recommended service material s7rw0a7218001 note required service material is also described in the following. “hvac unit components: manual type” “compressor assembly components: manual type” special tool s7rw0a7218002 material s...

  • Page 1032: Automatic Type

    7b-38 air conditioning system: automatic type automatic type precautions a/c system caution s7rw0a7220001 refer to “a/c system caution: manual type”. Precautions in diagnosing trouble s7rw0a7220002 • do not disconnect couplers from hvac control module, battery cable from battery, hvac control module...

  • Page 1033

    Air conditioning system: automatic type 7b-39 hvac control description s7rw0a7221002 temperature control hvac control module calculates the target temperature control door position based on signals from the temperature selector, inside air temperature sensor, outside air temperature sensor and sunlo...

  • Page 1034

    7b-40 air conditioning system: automatic type on-board diagnostic system description s7rw0a7221004 note the diagnostic information as diagnostic trouble code (dtc) can be known by using suzuki scan tool. For further details, refer to “dtc check: automatic type”. Hvac control module detects malfuncti...

  • Page 1035

    Air conditioning system: automatic type 7b-41 a/c system wiring diagram s7rw0a7222002 19 13 15 16 10 11 12 5v 12v wht/blu red gry/blu brn/wht gry/red brn/yel pnk blk/orn red/blk red/blk red/blk 14 red wht wht/red blu yel wht wht/blu grn wht g20-18 g20-7 23 1 2 4 6 17 24 5v 5v 5v 5v 5v 12v 12v orn or...

  • Page 1036

    7b-42 air conditioning system: automatic type auto a/c electronic control input / output diagram s7rw0a7222003 component location a/c system major components location s7rw0a7223001 refer to “a/c system major components location: manual type”. [a]: hatchback model 9. Dlc 22. Compressor 35. Rear defog...

  • Page 1037

    Air conditioning system: automatic type 7b-43 electronic control system components location s7rw0a7223002 note the figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. [a] 2 3 5 1 4 7 8* 18 19 20 23 22 21 9* 10* 11* 12* 13* 15* ...

  • Page 1038

    7b-44 air conditioning system: automatic type diagnostic information and procedures air conditioning system check s7rw0a7224001 description for each step step 1. Customer complaint analysis talk to customer, and then record details of the problem. Step action yes no 1 customer complaint analysis 1) ...

  • Page 1039

    Air conditioning system: automatic type 7b-45 customer questionnaire (example) note the form is a standard sample. It should be modified according to conditions characteristic of each market. Step 2. Visual inspection as a preliminary step, be sure to perform visual check of the items that support p...

  • Page 1040

    7b-46 air conditioning system: automatic type a/c system symptom diagnosis s7rw0a7224002 condition possible cause correction / reference item no cool air comes out (a/ c system does not operate) no refrigerant perform recovery, evacuation and charge referring to “operation procedure for refrigerant ...

  • Page 1041

    Air conditioning system: automatic type 7b-47 cool air does not come out or insufficient cooling (a/c compressor normal operation) insufficient or excessive charge of refrigerant check the amount of refrigerant and system for leaks. Condenser clogged check condenser referring to “condenser assembly ...

  • Page 1042

    7b-48 air conditioning system: automatic type abnormal noise symptom diagnosis of a/c system s7rw0a7224003 refer to “abnormal noise symptom diagnosis of a/c system: manual type”. Dtc check s7rw0a7224004 using suzuki scan tool 1) turn ignition switch to off position. 2) connect suzuki scan tool to da...

  • Page 1043

    Air conditioning system: automatic type 7b-49 note • when 2 or more current dtcs are detected, only dtc having the highest priority is indicated. Therefore, after troubleshooting the malfunction, dtc check has to be performed again to see if any other dtc(s) is detected. • pressing “a/c” switch alte...

  • Page 1044

    7b-50 air conditioning system: automatic type not using suzuki scan tool 1) display history dtc by hvac control module referring to “not using suzuki scan tool” under “dtc check”. 2) press air intake selector (1) and “a/c” switch (2) at the same time for 5 seconds or more. 3) after completing above ...

  • Page 1045

    Air conditioning system: automatic type 7b-51 ) b1513 temperature control actuator (motor) and/or its circuit malfunction 6 3 motor of temperature control actuator is not operated more than specified time. Flashed ) b1514 air flow control actuator (motor) and/or its circuit malfunction 7 3 motor of ...

  • Page 1046

    7b-52 air conditioning system: automatic type dtc of a/c system detected by ecm note when no dtc is detected, “fre” [a] and “rec” [b] indicator lights on hvac control module flash at the same time in specific pattern. Fail-safe table s7rw0a7224007 when any of the following malfunctions (dtcs) is det...

  • Page 1047

    Air conditioning system: automatic type 7b-53 ) b1520 temperature selector malfunction hvac control module maintains last normal value. Hvac control module controls actuators assuming that setting of temperature selector is 25 °c (77 °f) position. ) b1521 blower speed selector malfunction hvac contr...

  • Page 1048

    7b-54 air conditioning system: automatic type scan tool data s7rw0a7224008 as the data values given in the following are standard values estimated on the basis of values obtained from the normally operation vehicles by using a scan tool, use them as reference values. Even when the vehicles are in go...

  • Page 1049

    Air conditioning system: automatic type 7b-55 scan tool data definitions temp cont switch: (temperature control selector position, max cool, °c / °f, max hot): this parameter indicates the selected position of temperature control selector. Cabin temperature: (in-car temperature, °c, °f): this parame...

  • Page 1050

    7b-56 air conditioning system: automatic type dtc b1502: inside air temperature sensor circuit malfunction s7rw0a7224010 wiring diagram dtc detecting condition and trouble area dtc troubleshooting note when dtc b1503, b1504, b1511 and b1512 are indicated together, it is possible that sensor ground c...

  • Page 1051

    Air conditioning system: automatic type 7b-57 dtc b1503: evaporator temperature sensor circuit malfunction s7rw0a7224011 wiring diagram dtc detecting condition and trouble area dtc troubleshooting note when dtc b1502, b1504, b1511 and b1512 are indicated together, it is possible that sensor ground c...

  • Page 1052

    7b-58 air conditioning system: automatic type dtc b1504: sunload sensor circuit malfunction s7rw0a7224012 wiring diagram step action yes no 1 was “air conditioning system check” performed? Go to step 2. Go to “air conditioning system check: automatic type”. 2 wire harness check 1) turn ignition swit...

  • Page 1053

    Air conditioning system: automatic type 7b-59 dtc detecting condition and trouble area note when dtc b1502, b1503, b1511 and b1512 are indicated together, it is possible that sensor ground circuit is open. Dtc troubleshooting dtc detecting condition trouble area • sunload sensor signal voltage is hi...

  • Page 1054

    7b-60 air conditioning system: automatic type dtc b1511: temperature control actuator (position sensor) and/or its circuit malfunction s7rw0a7224013 wiring diagram dtc detecting condition and trouble area dtc troubleshooting note • when dtc b1502, b1503, b1504 and b1512 are indicated together, it is...

  • Page 1055

    Air conditioning system: automatic type 7b-61 dtc b1512: air flow control actuator (position sensor) and/or its circuit malfunction s7rw0a7224014 wiring diagram dtc detecting condition and trouble area 3 position sensor of temperature control actuator power supply voltage check 1) connect connector ...

  • Page 1056

    7b-62 air conditioning system: automatic type dtc troubleshooting note • when dtc b1502, b1503, b1504 and b1511 are indicated together, it is possible that sensor ground circuit is open. • when dtc b1511 is indicated together, it is possible that position sensor power supply circuit is open. Step ac...

  • Page 1057

    Air conditioning system: automatic type 7b-63 dtc b1513: temperature control actuator (motor) and/or its circuit malfunction s7rw0a7224015 wiring diagram dtc detecting condition and trouble area dtc troubleshooting 5 position sensor of temperature control actuator power supply voltage check 1) turn ...

  • Page 1058

    7b-64 air conditioning system: automatic type dtc b1514: air flow control actuator (motor) and/or its circuit malfunction s7rw0a7224016 wiring diagram dtc detecting condition and trouble area 4 wire harness check 1) turn ignition switch to off position. 2) disconnect connectors from temperature cont...

  • Page 1059

    Air conditioning system: automatic type 7b-65 dtc troubleshooting dtc b1520 / b1521 / b1522: temperature / blower speed / air flow selector malfunction s7rw0a7224017 dtc detecting condition and trouble area step action yes no 1 was “air conditioning system check” performed? Go to step 2. Go to “air ...

  • Page 1060

    7b-66 air conditioning system: automatic type dtc troubleshooting dtc b1541: back-up power supply circuit malfunction s7rw0a7224018 wiring diagram dtc detecting condition and trouble area note when checking dtc after connecting battery cable, be sure to turn ignition switch from off to on and from o...

  • Page 1061

    Air conditioning system: automatic type 7b-67 dtc b1546: a/c refrigerant pressure malfunction s7rw0a7224019 dtc detecting condition and trouble area dtc troubleshooting 3 battery voltage supply circuit check 1) disconnect connector from hvac control module with ignition switch turned off. 2) check f...

  • Page 1062

    7b-68 air conditioning system: automatic type dtc b1551: serial communication circuit malfunction s7rw0a7224020 wiring diagram dtc detecting condition and trouble area dtc troubleshooting 12v g20 g20-13 yel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30 1 2 3 [s] wh...

  • Page 1063

    Air conditioning system: automatic type 7b-69 dtc b1552: hvac control module check sum error s7rw0a7224021 dtc detecting condition and trouble area dtc troubleshooting dtc b1553: can communication circuit malfunction s7rw0a7224022 dtc detecting condition and trouble area 4 serial communication signa...

  • Page 1064

    7b-70 air conditioning system: automatic type dtc troubleshooting dtc b1557: vss signal failure s7rw0a7224023 dtc detecting condition and trouble area dtc troubleshooting dtc b1561: ect signal failure s7rw0a7224024 dtc detecting condition and trouble area dtc troubleshooting step action yes no 1 was...

  • Page 1065

    Air conditioning system: automatic type 7b-71 dtc b1562: outside air temperature signal failure s7rw0a7224025 dtc detecting condition and trouble area dtc troubleshooting dtc b1563: a/c refrigerant pressure signal failure s7rw0a7224026 dtc detecting condition and trouble area dtc troubleshooting dtc...

  • Page 1066

    7b-72 air conditioning system: automatic type dtc b1570: engine type signal failure s7rw0a7224027 dtc detecting condition and trouble area dtc troubleshooting dtc b1571: combination meter spec signal failure s7rw0a7224028 dtc detecting condition and trouble area dtc troubleshooting dtc detecting con...

  • Page 1067

    Air conditioning system: automatic type 7b-73 inspection of hvac control module and its circuit s7rw0a7224029 hvac control module and its circuits can be checked at hvac control module wiring couplers by measuring voltage. Caution ! Hvac control module can not be checked by itself. It is strictly pr...

  • Page 1068

    7b-74 air conditioning system: automatic type g20-8 blu/wht electric load signal for blower motor 10 – 14 v • ignition switch turned on, blower speed selector off or 1st position • ignition switch turned on, blower speed selector from 1st to 2nd position 0 – 2 v • ignition switch turned on, blower s...

  • Page 1069

    Air conditioning system: automatic type 7b-75 g20-25 pnk sunload sensor signal approx. 3.5 v ignition switch turned on, amount of insolation is 500 w/m 2 approx. 5 v ignition switch turned on, amount of insolation is 0 w/m 2 g20-26 blk/red rear defogger indicator 0 – 1 v ignition switch turned on, r...

  • Page 1070

    7b-76 air conditioning system: automatic type reference waveform no. 1 rear defogger switch or a/c switch signal (1) reference waveform no. 2 serial communication line of bcm (1) a/c system inspection at ecm s7rw0a7224030 when checking voltage at ecm terminals related to a/c system, refer to “inspec...

  • Page 1071

    Air conditioning system: automatic type 7b-77 hvac unit components s7rw0a7226002 1 10 1 29 9 8 3 29 21 3 20 20 20 19 23 22 5* 4 28* 15 16* 30 29* 30 17* 18* 2 13 12 11 5* 26 27 25 14 24 29 6 7 * i6rw0c722008-01 1. Blower upper case 9. Air intake control link 17. Expansion valve 25. Inside air temper...

  • Page 1072

    7b-78 air conditioning system: automatic type hvac unit removal and installation s7rw0a7226003 refer to “hvac unit removal and installation: manual type”. Temperature control actuator removal and installation s7rw0a7226004 removal 1) disconnect negative (–) cable at battery. 2) remove steering colum...

  • Page 1073

    Air conditioning system: automatic type 7b-79 7) set temperature selector of hvac control module to “max hot” position with ignition switch turned on, and make sure if the position of actuator lever is “max hot” position (a). 8) turn ignition switch to off position, and then disconnect connector fro...

  • Page 1074

    7b-80 air conditioning system: automatic type air flow control actuator removal and installation s7rw0a7226006 removal 1) disconnect negative cable at battery. 2) remove steering column hole cover from instrument panel. 3) remove driver side foot duct from hvac unit. 4) disconnect air flow control a...

  • Page 1075

    Air conditioning system: automatic type 7b-81 7) set air flow selector of hvac control module to “def” position with ignition switch turned on, and make sure if the position of actuator lever is “def” position (a). 8) turn ignition switch to off position, and then disconnect connector from air flow ...

  • Page 1076

    7b-82 air conditioning system: automatic type blower motor controller inspection s7rw0a7226012 1) check internal circuit of controller for resistance as follows. A) measure resistance between “1” terminal and “2” terminal of blower motor controller. Blower motor controller resistance “1” – “2”: appr...

  • Page 1077

    Air conditioning system: automatic type 7b-83 installation reverse removal procedure noting the following instructions. • install sunload sensor (1) to instrument panel fitting tab (2) of sunload sensor into the groove (3) of instrument panel as shown in figure. Sunload sensor inspection s7rw0a72260...

  • Page 1078

    7b-84 air conditioning system: automatic type condenser cooling fan relay inspection s7rw0a7226020 refer to “a/c system relay inspection: manual type”. Condenser cooling fan removal and installation s7rw0a7226021 refer to “condenser cooling fan removal and installation: manual type”. Condenser cooli...

  • Page 1079

    Air conditioning system: automatic type 7b-85 special tools and equipment recommended service material s7rw0a7228001 note required service material is also described in the following. “hvac unit components: automatic type” special tool s7rw0a7228002 suzuki scan tool — this kit includes following ite...

  • Page 1080

    7b-86 air conditioning system: automatic type.

  • Page 1081: 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 1082

    8-ii table of contents dtc b1062 / b1066: side-air bag circuit low resistance ......................................................8b-58 dtc b1063 / b1067: side-air bag circuit shorted to ground ..........................................8b-60 dtc b1064 / b1068: side-air bag circuit shorted to power...

  • Page 1083: Precautions

    Precautions: 8-1 restraint precautions precautions precautions on restraint s7rw0a8000001 air bag warning refer to “air bag system service warning in section 00”. Fastener caution refer to “fastener caution in section 00”. Precautions on service and diagnosis of seat belt refer to “precautions on se...

  • Page 1084: Seat Belts

    8a-1 seat belts: restraint seat belts precautions precautions on service and diagnosis of seat belt s7rw0a8100001 warning ! If replacing seat belt is necessary, replace buckle and seat belt together as a set. This is for the reason of ensuring locking of tongue plate with buckle. If these parts are ...

  • Page 1085

    Seat belts: 8a-2 general description seat belt construction s7rw0a8101001 hatchback model 1 1 6 6 6 5 5 5 6 6 2 2 3 4 6 5 5 6 2 2 5 7 [a] [b] i6rw0c810001-01.

  • Page 1086

    8a-3 seat belts: sedan model 2 2 5 5 5 6 6 7 1 6 6 4 1 2 2 5 5 5 6 6 6 3 [a] [b] i7rw0a810001-01 [a]: a-elr rear center seat belt model 2. Rear seat belt (with a-elr or elr) 5. Buckle for rear seat belt [b]: non-a-elr rear center seat belt model 3. Rear center seat belt (with a-elr or elr) 6. Retrac...

  • Page 1087

    Seat belts: 8a-4 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 1088

    8a-5 seat belts: repair instructions front seat belt components s7rw0a8106001 warning ! • never attempt to disassemble or repair the seat belt pretensioner (retractor). If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service and diagn...

  • Page 1089

    Seat belts: 8a-6 front seat belt removal and installation s7rw0a8106002 warning ! • never attempt to disassemble or repair the retractor (seat belt pretensioner). If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service and diagnosis o...

  • Page 1090

    8a-7 seat belts: front seat belt inspection s7rw0a8106003 warning ! • never attempt to disassemble or repair the seat belt pretensioner (retractor). If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service and diagnosis of seat belt”, ...

  • Page 1091

    Seat belts: 8a-8 rear seat belt components s7rw0a8106004 warning ! Be sure to read “precautions on service and diagnosis of seat belt” before starting to work and observe every precaution during work. Hatchback model i6rw0c810002-01.

  • Page 1092

    8a-9 seat belts: sedan model [a]: a-elr rear center seat belt model 11. Center retractor [b]: non-a-elr rear center seat belt model 12. Center retractor mounting bolt (hatchback model) : tighten lower bolt first, then tighten upper bolt. 1. Sash guide 13. Sash guide bolt (hatchback model) : tighten ...

  • Page 1093

    Seat belts: 8a-10 rear seat belt removal and installation s7rw0a8106005 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 (hatch...

  • Page 1094: Air Bag System

    8b-1 air bag system: restraint air bag system precautions precautions on service and diagnosis of air bag system s7rw0a8200001 warning ! • if the air bag system and another vehicle system both need repair, suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag ...

  • Page 1095

    Air bag system: 8b-2 • never attempt disassembly of sdm. • when storing sdm, select a place where neither high temperature nor high humidity is anticipated and oil, water and dust are kept off. • if sdm has been dropped, replace it with a new one. • if sdm installation part of floor was damaged, rep...

  • Page 1096

    8b-3 air bag system: warning ! • for handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °c (150 °f), without high humidity and away from electric noise. • when carrying a live air bag (inflator) module, make sure the bag opening is pointed...

  • Page 1097

    Air bag system: 8b-4 • never attempt to disassemble the seat belt pretensioners (retractor assembly). • if any abnormality is found, be sure to replace it with new one as an assembly. • when an abnormality is noted as existing in the live (inactivated) seat belt pretensioner, be sure to activate it ...

  • Page 1098

    8b-5 air bag system: precautions on disposal of air bag and seat belt pretensioner s7rw0a8200003 do not dispose of the live (undeployed) air bag (inflator) modules and the live (inactivated) seat belt pretensioners. When disposal is necessary, be sure to deploy / activate the air bag and seat belt p...

  • Page 1099

    Air bag system: 8b-6 the air bag system is designed to activate only in severe frontal “a” and sideward “b” collisions. It is not designed to activate in rear impacts, rollovers, or minor frontal and sideward collisions, since it would offer no protection in those types of accidents. Air bag system ...

  • Page 1100

    8b-7 air bag system: schematic and routing diagram air bag system wiring circuit diagram s7rw0a8202001 blk yel/grn yel/grn yel/blu yel/blu wht/red lt grn/blk wht/grn lt grn 22 23 15 29 29 21 19 20 grn/red grn/red grn grn [a] [b] “e40”, “e388”, “g04” “e388”, “l04” “l395”, “q102” “q134”, “s121” and “s...

  • Page 1101

    Air bag system: 8b-8 terminal arrangement of sdm (viewed from harness side) connector “l04” (sdm connector) [a]: shorting bar 9. “meter” fuse 23. Driver air bag (inflator) module [b]: connector 10. “a/b” fuse 24. Passenger air bag (inflator) module [c]: junction block with bcm model 11. Bcm 25. Driv...

  • Page 1102

    8b-9 air bag system: air bag system input / output diagram s7rw0a8202002 l04-22 passenger side curtain-air bag (–) (8-channel system) l04-48 — l04-23 — l04-49 — l04-24 — l04-50 forward impact-sensor (+) l04-25 — l04-51 forward impact-sensor (–) l04-26 — terminal circuit terminal circuit battery volt...

  • Page 1103

    Air bag system: 8b-10 component location air bag system components, wiring and connectors location s7rw0a8203001 17 14 7 b 19 a 17 20 16 18 18 5 4 3 1 a c 2 b 10 11 8 9 6 6 15 c 5 5 [d] [e] 13 12 i6rw0b820004-02.

  • Page 1104

    8b-11 air bag system: diagnostic information and procedures air bag diagnostic system check s7rw0a8204001 warning ! To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or ac powered voltmeter, ohmmeter, etc., or any type of elec...

  • Page 1105

    Air bag system: 8b-12 air bag diagnostic system check flow s7rw0a8204002 caution ! • be sure to perform “air bag diagnostic system check” before starting diagnosis according to each flow. • when measurement of resistance or voltage is required in the flow, use a tester along with a correct terminal ...

  • Page 1106

    8b-13 air bag system: dtc table s7rw0a8204003 note the dtcs (b1022 and b1023) shown with asterisk (*) below have been established only for the m15a engine model with 4a/t equipped with slip-control (i.E., hong kong model). These codes are meant to be recorded when external scrapping deployment contr...

  • Page 1107

    Air bag system: 8b-14 ) b1026 seat belt pretensioner activation record activation of seat belt pretensioner has been recorded in sdm. If this dtc has been recorded even though pretensioner has not been activated • sdm • driver and/or passenger seat belt pretensioner • those initiator circuit ) b1027...

  • Page 1108

    8b-15 air bag system: ) b1057 passenger seat belt pretensioner circuit shorted to ground passenger seat belt pretensioner circuit has been shorted to ground for more than 4 sec. • passenger seat belt pretensioner circuit • sdm ) b1058 passenger seat belt pretensioner circuit shorted to power supply ...

  • Page 1109

    Air bag system: 8b-16 ) b1085 driver side impact-sensor communication data inconsistent driver side impact-sensor has been communicated with inconsistent id code for more than 4 sec. • driver side impact-sensor • sdm ) b1091 passenger side impact-sensor no response communication with passenger side ...

  • Page 1110

    8b-17 air bag system: dtc check s7rw0a8204004 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 1111

    Air bag system: 8b-18 scan tool data definition buck up volt (v) this parameter indicates the capacity of the backup capacitor installed to maintain the ignition current (as much as possible) even when the power supply to sdm that ignites the inflator is shut off. Battery voltage (v) battery voltage...

  • Page 1112

    8b-19 air bag system: troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 sdm power supply and ground circuit check 1) check sdm power supply and ground circuit referring to “sdm power supply and gro...

  • Page 1113

    Air bag system: 8b-20 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • repeat “air bag diagnostic system check” to confirm that the trouble has been corrected. 5 “air bag” warn...

  • Page 1114

    8b-21 air bag system: “air bag” warning light does not come on s7rw0a8204008 wiring diagram refer to ““air bag” warning light comes on steady”. Troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all co...

  • Page 1115

    Air bag system: 8b-22 serial data link circuit check s7rw0a8204009 wiring diagram 1 2 3 3 18 12v red 7 14 9 10 “l313” “g273” yel/blk l04-2 l04-27 “l04” ppl/wht “g04” l04-32 12v 8 grn 15 +bb 5 6 wht wht 4 blu blu blk 16 11 12 “g241” 13 blk l04-28 red/blk wht/red yel/blk blk “g271” “g272” wht/red blk/...

  • Page 1116

    8b-23 air bag system: troubleshooting step action yes no 1 “air bag” warning light check 1) turn ignition switch to on position. Does “air bag” warning light come on steady? Go to ““air bag” warning light comes on steady”. Go to step 2. 2 scan tool condition check 1) make sure that suzuki scan tool ...

  • Page 1117

    Air bag system: 8b-24 dtc b1013: sdm internal failure s7rw0a8204010 dtc detecting condition and trouble area note dtc b1013 can never be cleared once it has been set. Dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system c...

  • Page 1118

    8b-25 air bag system: dtc b1014: “air bag” warning light circuit s7rw0a8204011 wiring diagram refer to““air bag” warning light comes on steady”. Dtc detecting condition and trouble area dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect a...

  • Page 1119

    Air bag system: 8b-26 dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system ...

  • Page 1120

    8b-27 air bag system: dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system ...

  • Page 1121

    Air bag system: 8b-28 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • repeat “air bag diagnostic system check” to confirm that the trouble has been corrected. • clear dtcs of ...

  • Page 1122

    8b-29 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 correct...

  • Page 1123

    Air bag system: 8b-30 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • repeat “air bag diagnostic system check” to confirm that the trouble has been corrected. • clear dtc b115...

  • Page 1124

    8b-31 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 drive air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector located under the steer...

  • Page 1125

    Air bag system: 8b-32 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1126

    8b-33 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector located under the stee...

  • Page 1127

    Air bag system: 8b-34 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1128

    8b-35 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector “g347” located under t...

  • Page 1129

    Air bag system: 8b-36 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1130

    8b-37 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver air bag circuit check 1) with ignition switch turned off, disconnect contact coil connector “g347” located under t...

  • Page 1131

    Air bag system: 8b-38 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1132

    8b-39 air bag system: dtc b1041: passenger air bag circuit high resistance s7rw0a8204022 wiring diagram dtc detecting condition and trouble area “l04” [a] blk l04-28 6 8 7 red grn “l313” l04-27 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37...

  • Page 1133

    Air bag system: 8b-40 dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 passenger air bag check 1) remove passenger air bag (inflator) module referring to “passenger air bag (inflator) module r...

  • Page 1134

    8b-41 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1135

    Air bag system: 8b-42 dtc b1042: passenger air bag circuit low resistance s7rw0a8204023 wiring diagram refer to “dtc b1041: passenger air bag circuit high resistance”. Dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area passenger air bag circuit is less ...

  • Page 1136

    8b-43 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1137

    Air bag system: 8b-44 dtc b1043: passenger air bag circuit shorted to ground s7rw0a8204024 wiring diagram refer to “dtc b1041: passenger air bag circuit high resistance”. Dtc detecting condition and trouble area dtc troubleshooting dtc detecting condition trouble area passenger air bag circuit has b...

  • Page 1138

    8b-45 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1139

    Air bag system: 8b-46 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1140

    8b-47 air bag system: dtc b1051 / b1055: seat belt pretensioner circuit high resistance s7rw0a8204026 dtc b1051: driver seat belt pretensioner circuit high resistance dtc b1055: passenger seat belt pretensioner circuit high resistance wiring diagram dtc detecting condition and trouble area dtc troub...

  • Page 1141

    Air bag system: 8b-48 2 seat belt pretensioner circuit check 1) with ignition switch turned off, remove center pillar lower trim of applicable side and disconnect seat belt pretensioner connector “l283” or “l285”. 2) check for proper connection to applicable seat belt pretensioner at terminals in “l...

  • Page 1142

    8b-49 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1143

    Air bag system: 8b-50 dtc b1052 / b1056: seat belt pretensioner circuit low resistance s7rw0a8204027 dtc b1052: driver seat belt pretensioner circuit low resistance dtc b1056: passenger seat belt pretensioner circuit low resistance wiring diagram refer to “dtc b1051 / b1055: seat belt pretensioner c...

  • Page 1144

    8b-51 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1145

    Air bag system: 8b-52 dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system ...

  • Page 1146

    8b-53 air bag system: dtc b1054 / b1058: seat belt pretensioner circuit shorted to power supply s7rw0a8204029 dtc b1054: driver seat belt pretensioner circuit shorted to power supply dtc b1058: passenger seat belt pretensioner circuit shorted to power supply wiring diagram refer to “dtc b1051 / b105...

  • Page 1147

    Air bag system: 8b-54 dtc b1061 / b1065: side-air bag circuit high resistance s7rw0a8204030 dtc b1061: driver side-air bag circuit high resistance dtc b1065: passenger side-air bag circuit high resistance wiring diagram dtc detecting condition and trouble area “l04” [a] blk l04-28 6 8 7 red grn “l31...

  • Page 1148

    8b-55 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 side-air bag circuit check 1) remove applicable driver / passenger side-air bag (inflator) module from seat back referrin...

  • Page 1149

    Air bag system: 8b-56 3 side-air bag circuit check 1) with ignition switch turned off, disconnect special tools from applicable side-air bag (inflator) connector “q104” or “q105”. 2) disconnect sdm connector “l04”. 3) check for proper connection to sdm connector at terminal “l04-11” and “l04-12” (fo...

  • Page 1150

    8b-57 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1151

    Air bag system: 8b-58 dtc b1062 / b1066: side-air bag circuit low resistance s7rw0a8204031 dtc b1062: driver side-air bag circuit low resistance dtc b1066: passenger side-air bag circuit low resistance wiring diagram refer to “dtc b1061 / b1065: side-air bag circuit high resistance”. Dtc detecting c...

  • Page 1152

    8b-59 air bag system: 3 side-air bag circuit check 1) with ignition switch turned off, disconnect special tools from applicable side-air bag (inflator) connector “q104” or “q105”. 2) disconnect sdm connector “l04”. 3) check for proper connection to sdm connector at terminal “l04-11” and “l04-12” (fo...

  • Page 1153

    Air bag system: 8b-60 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1154

    8b-61 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 side-air bag circuit check 1) remove applicable driver / passenger side-air bag (inflator) module from seat back referrin...

  • Page 1155

    Air bag system: 8b-62 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1156

    8b-63 air bag system: dtc b1064 / b1068: side-air bag circuit shorted to power supply s7rw0a8204033 dtc b1064: driver side-air bag circuit shorted to power supply dtc b1068: passenger side-air bag circuit shorted to power supply wiring diagram refer to “dtc b1061 / b1065: side-air bag circuit high r...

  • Page 1157

    Air bag system: 8b-64 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1158

    8b-65 air bag system: dtc b1071: driver forward impact-sensor communication data inconsistent s7rw0a8204034 dtc detecting condition and trouble area dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensu...

  • Page 1159

    Air bag system: 8b-66 dtc b1073: driver forward impact-sensor circuit shorted to ground s7rw0a8204036 wiring diagram dtc detecting condition and trouble area dtc troubleshooting 10 “l04” “l372” “e388” “e40” orn pnk/blk orn pnk/blk l04-50 l04-51 11 30v “l04” blk l04-28 6 8 7 red grn “l313” l04-27 9 1...

  • Page 1160

    8b-67 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1161

    Air bag system: 8b-68 dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system ...

  • Page 1162

    8b-69 air bag system: dtc b1081 / b1091: side impact-sensor no response s7rw0a8204038 dtc b1081: driver side impact-sensor no response dtc b1091: passenger side impact-sensor no response dtc detecting condition and trouble area dtc troubleshooting note upon completion of inspection and repair work, ...

  • Page 1163

    Air bag system: 8b-70 dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system ...

  • Page 1164

    8b-71 air bag system: dtc troubleshooting note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system ...

  • Page 1165

    Air bag system: 8b-72 dtc b1084 / b1094: side impact-sensor circuit open s7rw0a8204041 dtc b1084: driver side impact-sensor circuit open dtc b1094: passenger side impact-sensor circuit open wiring diagram refer to “dtc b1083 / b1093: side impact-sensor circuit shorted to ground”. Dtc detecting condi...

  • Page 1166

    8b-73 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1167

    Air bag system: 8b-74 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components and ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm th...

  • Page 1168

    8b-75 air bag system: dtc troubleshooting step action yes no 1 was “air bag diagnostic system check flow” performed? Go to step 2. Go to “air bag diagnostic system check flow”. 2 driver / passenger curtain-air bag circuit check 1) with ignition switch turned off, remove rear quarter upper trim (hatc...

  • Page 1169

    Air bag system: 8b-76 3 driver / passenger curtain-air bag circuit check 1) disconnect special tools from applicable side curtain-air bag connector. 2) with ignition switch turned off, disconnect sdm connector “l04”. 3) check for proper connection to sdm connector at terminal “l04-19” and “l04-20” (...

  • Page 1170

    8b-77 air bag system: note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1171

    Air bag system: 8b-78 dtc b1362 / b1366: curtain-air bag circuit low resistance s7rw0a8204044 dtc b1362: driver curtain-air bag circuit low resistance dtc b1366: passenger curtain-air bag circuit low resistance wiring diagram refer to “dtc b1361 / b1365: curtain-air bag circuit high resistance”. Dtc...

  • Page 1172

    8b-79 air bag system: 2 driver / passenger curtain-air bag circuit check 1) with ignition switch turned off, remove rear quarter upper trim (hatchback model [a]) or rear pillar inner trim (sedan model [b]) of applicable side and disconnect applicable side curtain-air bag (inflator) module connector....

  • Page 1173

    Air bag system: 8b-80 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1174

    8b-81 air bag system: dtc b1363 / b1367: curtain-air bag circuit shorted to ground s7rw0a8204045 dtc b1363: driver curtain-air bag circuit shorted to ground dtc b1367: passenger curtain-air bag circuit shorted to ground wiring diagram refer to “dtc b1361 / b1365: curtain-air bag circuit high resista...

  • Page 1175

    Air bag system: 8b-82 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1176

    8b-83 air bag system: dtc b1364 / b1368: curtain-air bag circuit shorted to power supply s7rw0a8204046 dtc b1364: driver curtain-air bag circuit shorted to power supply dtc b1368: passenger curtain-air bag circuit shorted to power supply wiring diagram refer to “dtc b1361 / b1365: curtain-air bag ci...

  • Page 1177

    Air bag system: 8b-84 note upon completion of inspection and repair work, perform the following items. • reconnect all air bag system components, ensure all components are properly mounted. • clear dtcs referring to “dtc clearance”, if any. • repeat “air bag diagnostic system check” to confirm that ...

  • Page 1178

    8b-85 air bag system: sdm power supply and ground circuit check s7rw0a8204047 wiring diagram troubleshooting “l04” 14 5 9 red red/blk grn yel/blk blk 8 7 11 12 15 l04-2 l04-28 l04-27 “g241” “g271” “l313” 13 12v 6 1 blk wht wht wht/red 2 3 4 3 10 blk “g273” “e324” 16 12v 5v 30v 17 i6rw0c820016-01 1. ...

  • Page 1179

    Air bag system: 8b-86 4 power supply circuit check 1) with ignition switch turned off, disconnect connector from sdm. 2) check for proper connection to sdm terminal at “l04- 27”. 3) with ignition switch turned on, measure voltage between “l04-27” terminal of sdm connector and body ground. Special to...

  • Page 1180

    8b-87 air bag system: contact coil cable and its circuit check s7rw0a8204048 troubleshooting step action yes no 1 driver air bag circuit check 1) remove driver air bag (inflator) module referring to “driver air bag (inflator) module removal and installation”. 2) with ignition switch turned off, disc...

  • Page 1181

    Air bag system: 8b-88 3 contact coil circuit (horn and audio control switch circuit) check (non cruise control model) 1) check for continuity between each terminal of horn switch terminals [a] and audio control switch terminals [b] (if equipped) as shown in figure. Is each measured resistance 3 Ω or...

  • Page 1182

    8b-89 air bag system: 4 contact coil circuit (horn, audio control and cruise control switch circuit) check (cruise control model) 1) check for continuity between each terminal of horn switch terminals, audio control switch terminals and cruise control switch terminals as shown in figure. Is each mea...

  • Page 1183

    Air bag system: 8b-90 inspection of intermittent and poor connections s7rw0a8204049 most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diagnostic flow, perform careful check of suspect circuits. If any abnormality is found, ...

  • Page 1184

    8b-91 air bag system: repair and inspection required after accident s7rw0a8204050 caution ! • all air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be replaced even if air bag...

  • Page 1185

    Air bag system: 8b-92 • contact coil assembly – check wire harness and connectors for damage or tightness. – check contact coil case for damage. – check contact coil circuit referring to “contact coil cable and its circuit check”. • instrument panel member and reinforcement – check for any distortio...

  • Page 1186

    8b-93 air bag system: • forward impact-sensor – check sensor (1) and apron-side-member (driver side) (2) for damage, bend or rust. – check connector (3) or lead wire (4) of forward- sensor for scorching, melting or damage. • side impact-sensor – check sensor (1) and under body (2) for dents, cracks,...

  • Page 1187

    Air bag system: 8b-94 repair instructions disabling air bag system s7rw0a8206001 note with “a/b” fuse removed and ignition switch on, “air bag” warning light will be on. This is normal operation and does not indicate air bag system malfunction. 1) turn steering wheel so that vehicle’s wheels (front ...

  • Page 1188

    8b-95 air bag system: enabling air bag system s7rw0a8206002 1) confirm that battery negative (–) cable is disconnected. 2) turn ignition switch to “lock” position and remove key. 3) connect yellow connector (1) of driver air bag (inflator) module by pushing connector till click is heard from it. 4) ...

  • Page 1189

    Air bag system: 8b-96 removal 1) disconnect negative (–) cable at battery. 2) disable air bag system referring to “disabling air bag system”. 3) remove console box referring to “console box components in section 9h”. 4) remove g sensor (abs model) or yaw rate / g sensor (esp ® model) referring to “g...

  • Page 1190

    8b-97 air bag system: 6) install g sensor or yaw rate / g sensor referring to “g sensor removal and installation (4wd model) in section 4e” or “yaw rate / g sensor removal and installation in section 4f”. 7) install console box upper cover. 8) enable air bag system referring to “enabling air bag sys...

  • Page 1191

    Air bag system: 8b-98 installation 1) connect horn connector (1) securely (if equipped). 2) connect driver air bag (inflator) module connector (2) to driver air bag (inflator) module (3) securely as shown in figure. A) connect connector. B) lock connector with lock button. 3) install driver air bag ...

  • Page 1192

    8b-99 air bag system: removal 1) disable air bag system. Refer to “disabling air bag system”. 2) remove center ventilation louver with garnish referring to “center ventilation louver removal and installation in section 7a”. 3) pull out glove box while pushing its stopper from both right and left sid...

  • Page 1193

    Air bag system: 8b-100 2) connect passenger air bag (inflator) module connector (1) securely as shown in figure. A) connect connector. B) lock connector with lock button (2). 3) install passenger air bag (inflator) module with its facing cover (3) to instrument panel at specified torque as shown. Ti...

  • Page 1194

    8b-101 air bag system: side-air bag (inflator) module removal and installation s7rw0a8206009 warning ! • never attempt to disassemble or repair the side-air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on servic...

  • Page 1195

    Air bag system: 8b-102 warning ! • when carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. Never carry air bag (inflator) module by wires or connector on the side of the module. In case of an accidental deployment, the bag will then deploy with minimal cha...

  • Page 1196

    8b-103 air bag system: side-air bag (inflator) inspection s7rw0a8206010 warning ! • never attempt to disassemble or repair the side-air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. • be sure to read “precautions on service and diagnosis of ai...

  • Page 1197

    Air bag system: 8b-104 4) remove side curtain-air bag (inflator) module fixing bolts (1) and clips (2). 5) remove side curtain-air bag (inflator) module. Warning ! • when carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. Never carry air bag (inflator) mod...

  • Page 1198

    8b-105 air bag system: 3) connect side curtain-air bag (inflator) module connector (1) securely as shown in figure. A) connect connector. B) lock connector with lock button (2). 4) install head lining referring to “head lining removal and installation in section 9h”. 5) enable air bag system. Refer ...

  • Page 1199

    Air bag system: 8b-106 forward impact-sensor removal and installation s7rw0a8206013 warning ! During service procedures, be very careful when handling a sensor. • never strike or jar a sensor. • a sensor and mounting bracket bolts must be carefully torqued to assure proper operation. Under loose con...

  • Page 1200

    8b-107 air bag system: forward impact-sensor inspection s7rw0a8206014 warning ! During service procedures, be very careful when handling a sensor. • never strike or jar a sensor. • a sensor and mounting bracket bolts must be carefully torqued to assure proper operation. Under loose connection, it co...

  • Page 1201

    Air bag system: 8b-108 side impact-sensor inspection s7rw0a8206016 warning ! During service procedures, be very careful when handling a sensor. • never strike or jar a sensor. • a sensor and mounting bracket bolts must be carefully torqued to assure proper operation. Under loose connection, it could...

  • Page 1202

    8b-109 air bag system: 4) cut off passenger air bag (inflator) module connector (1) and floor harness joint (yellow) connector (2) with passenger air bag (inflator) module of air bag harness included in instrument panel harness as shown, and then fasten it to instrument panel harness with vinyl tape...

  • Page 1203

    Air bag system: 8b-110 warning ! The following precautions must be observed for this work. Failure to observe any of them may result in personal injury. • procedure should be followed strictly as described here. • be sure to read “precautions on service and diagnosis of air bag system” beforehand. •...

  • Page 1204

    8b-111 air bag system: warning ! • for handing and storage of live air bag (inflator) module, select place where ambient temperature below 65 °c (150 °f), without high humidity and away from electric noise. • always carry live air bag (inflator) module with trim cover away from you. • when storing l...

  • Page 1205

    Air bag system: 8b-112 • for passenger air bag (inflator) module a. Clear space (3) on ground about 185 cm (6 ft) in diameter where passenger air bag (inflator) module (1) is set for deployment. Paved, outdoor location where there is no activity is preferred. If outdoor location is not available, us...

  • Page 1206

    8b-113 air bag system: • for side curtain-air bag (inflator) module a. Cut off bag (1) of side curtain-air bag (inflator) module. B. Tie side curtain-air bag inflator (1) to tire (3) with wire harness (2) as shown. Wire harness specifications stripped wire harness section 1.25 mm 2 (0.0019 in. 2 ) o...

  • Page 1207

    Air bag system: 8b-114 d. Tie seat belt pretensioner (2) with wire harness (3) to wheel-installed tire (4) as shown. Wire harness specifications stripped wire harness section 1.25 mm 2 (0.0019 in. 2 ) or more (stripped wire harness diameter 1.25 mm (0.05 in.) or more) note wind wire harness (3) arou...

  • Page 1208

    8b-115 air bag system: 11) connect adapter cable (b) to deployment harness (a) connector and lock connectors with lock lever. 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 deploy...

  • Page 1209

    Air bag system: 8b-116 13) separate two banana plugs (1) on deployment harness. 14) connect deployment harness to 12 volts vehicle battery (2). This will immediately deploy or activate air bag (inflator) module or seat belt pretensioner. 15) disconnect deployment harness from 12 volts vehicle batter...

  • Page 1210

    8b-117 air bag system: deployment / activation inside of vehicle when the vehicle will be destroyed, or salvaged for component parts, deploy the air bag modules and/or activate seat belt pretensioners installed on vehicle. Note if equipped with the seat belt pretensioners, activate both side of seat...

  • Page 1211

    Air bag system: 8b-118 5) check that there is no open, short or damage in special tools (deployment harness (a), adapter cable (b), (c) and (d)). If any faulty condition is found, do not use it and be sure to use new special tool. And connect adapter cable (b), (c) or (d) to deployment harness (a) a...

  • Page 1212

    8b-119 air bag system: 8) route deployment harness (1) out of vehicle. 9) check that inside of vehicle and area surrounding vehicle are clear of all people and loose or flammable objects. 10) stretch deployment harness (1) to its full length 10 m (33 ft). 11) place 12 volts vehicle battery (2) near ...

  • Page 1213

    Air bag system: 8b-120 21) disconnect adapter cable (special tool) from air bag (inflator) module or seat belt pretensioner as soon as possible. This will prevent adapter cable (special tool) from damage due to possible contact with hot air bag (inflator) module or hot seat belt pretensioner. 22) ch...

  • Page 1214

    8b-121 air bag system: specifications tightening torque specifications s7rw0a8207001 note the specified tightening torque is also described in the following. “side-air bag (inflator) module removal and installation” reference: for the tightening torque of fastener not specified in this section, refe...

  • Page 1215

    Air bag system: 8b-122 the adapter (1) will also give an idea of whether or not contact tension is sufficient, helping to find an open or intermittent open due to poor terminal contact. An sdm short bar release tool (2) is included in the connector test adapter kit. Inserting it into the sdm connect...

  • Page 1216

    8b-123 air bag system: special tool s7rw0a8208002 09932–75010 09932–75031 air bag load tool air bag deployment harness ) / ) / ) / ) / ) / ) / ) / ) / ) / ) / ) ) / ) / ) 09932–75041 09932–76010 passenger air bag (inflator) module deployment fixture connector test adapter set ) / ) this set includes...

  • Page 1217: 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 1218

    9-ii table of contents b-6 power mirror circuit diagram (hatchback (except taiwan)) ...........................................9a-112 b-6 power mirror circuit diagram (hatchback (taiwan)) .......................................................9a-113 b-6 power mirror circuit diagram (sedan (except ta...

  • Page 1219

    Table of contents 9-iii self-diagnosis function for headlight auto leveling system................................................ 9b-7 headlight leveling warning light check ............ 9b-8 headlight symptom diagnosis (discharge headlight model)............................................... 9b-8...

  • Page 1220

    9-iv table of contents brake and parking brake warning light symptom diagnosis ..........................................9c-9 seat belt reminder light symptom diagnosis ....9c-9 a/t shift position indicator symptom diagnosis (a/t model) ......................................9c-9 charge warning light...

  • Page 1221

    Table of contents 9-v rear quarter window removal and installation (hatchback model)........................ 9e-11 rear end door window components (hatchback model)..........................................9e-12 rear end door glass removal and installation (hatchback model)........................ 9...

  • Page 1222

    9-vi table of contents specifications...................................................... 9g-6 tightening torque specifications....................... 9g-6 special tools and equipment ............................ 9g-6 recommended service material ........................ 9g-6 interior trim ..........

  • Page 1223: Precautions

    Precautions: 9-1 body, cab and accessories precautions precautions precautions on body, cab and accessories s7rw0a9000001 air bag warning refer to “air bag warning in section 00”. Fastener caution refer to “fastener caution in section 00”. Precautions for body service refer to “precautions for body ...

  • Page 1224: Wiring Systems

    9a-1 wiring systems: body, cab and accessories wiring systems precautions cautions in body electrical system servicing s7rw0a9100001 when servicing the electric systems, observe the cautions described in “precautions for electrical circuit service in section 00” to protect electrical parts and to pr...

  • Page 1225

    Wiring systems: 9a-2 symbols and marks s7rw0a9101003 battery ground normal fuse slow blow fuse circuit breaker coil, solenoid heater bulb cigarette lighter motor pump horn speaker buzzer chime condenser thermistor reed switch resistance variable resistance transistor npn pnp photo transistor diode z...

  • Page 1226

    9a-3 wiring systems: ignition switch keyless entry immobilizer system combination meter lighting switch headlight leveling hazard warning light front fog light rear fog light spark plug radiator fan fuel pump fuel injector xx control module windshield wiper windshield washer rear wiper rear washer r...

  • Page 1227

    Wiring systems: 9a-4 how to read connector layout diagram s7rw0a9101004 [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 1228

    9a-5 wiring systems: how to read connector codes and terminal nos. S7rw0a9101005 1) connector code/terminal no./terminal layout • the connector shape and terminal layout shown in this manual are those when viewed from “z” in the illustration. Refer to “list of connectors”. Note molded terminal numbe...

  • Page 1229

    Wiring systems: 9a-6 3) terminals in one connector (broken line) (b15)/terminals in different connectors (b14, b16) 4) joint connector (j/c) • several different wires with the same wire color are joined at a part of j/c. 5) weld splice (w/s) • several different wires with the same wire color are joi...

  • Page 1230: Cross-Reference

    9a-7 wiring systems: 6) junction block (j/b) 7) connector location, shape and terminal no. Refer to “connector layout diagram”. Refer to “system circuit diagram”. Refer to “list of connectors”. Immobi ig ig1 ig coil, etc e39 e41 e40 bcm g34 g33 g32 k01 l04 l05 l06 ig coil ig1 15a mtr 10a a/b 15a 2 6...

  • Page 1231: Cross-Reference

    Wiring systems: 9a-8 how to read ground point s7rw0a9101006 refer to “system circuit diagram”. Refer to “ground (earth) point”. Left side shown 10 11 12 "system circuit diagram" "ground point" cross-reference windoshield washer motor individual circuit fuse box 20 15a windoshield wiper motor e40 e09...

  • Page 1232

    9a-9 wiring systems: how to read power supply diagram s7rw0a9101007 refer to “power supply diagram”. Refer to “system circuit diagram”. How to read system circuit diagram s7rw0a9101008 the circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of th...

  • Page 1233

    Wiring systems: 9a-10 [d]: terminals-in-one-connector mark [e]: wire color [f]: shield wire [g]: ground point [h]: “from” or “to” (with id letter (s)) [i]: specification variation the white arrow between a and b means “or”. [j]: “from” (with id letter (s)) [k] “to” (with id letter (s)) [l]: connecto...

  • Page 1234

    9a-11 wiring systems: connector layout diagram connector layout diagram s7rw0a910a001 refer to “engine compartment”. Refer to “instrument panel”. Refer to “door, roof”. Refer to “floor”. Refer to “rear”. Esp ® is a registered trademark of daimler chrysler ag. Engine compartment s7rw0a910a002 a: batt...

  • Page 1235

    Wiring systems: 9a-12 c: engine harness no. Color connective position remarks c01 gry ecm c06 n tcm a/t c07 n tcm a/t c31 gry ckp sensor c32 blk cmp sensor c34 gry vss a/t c36 blk map sensor c37 gry knock sensor c39 blk ect sensor c40 blk a/f sensor c42 grn heated oxygen sensor c44 blu input shaft s...

  • Page 1236

    9a-13 wiring systems: a: battery cable / c: engine harness (m16a engine rhd) c: engine harness c124 c32 c42 c102 c91 c192 c194 w/s c43 c162 c141 c196 c195 c93 c94 c101 c39 c92 c31 c36 w/s c48 c37 c123 c47 c32 c282 c283 c343 (to e371) c01 c34 c07 c06 c122 c165 c139 c44 c166 4 3 2 1 5 c a without ocv ...

  • Page 1237

    Wiring systems: 9a-14 a: battery cable / c: engine harness (m16a engine lhd) c124 blu ocv if eqpd c139 gry shift solenoid a/t c141 blk a/c compressor c162 — oil pressure switch c165 blk back-up light switch m/t c166 gry transaxle range sensor a/t c192 — generator c194 blk generator c195 blk starting...

  • Page 1238

    9a-15 wiring systems: c: engine harness no. Color connective position remarks c01 gry ecm c06 n tcm a/t c07 n tcm a/t c31 gry ckp sensor c32 blk or gry cmp sensor c34 gry vss a/t c36 blk map sensor c37 gry knock sensor c39 blk ect sensor c42 blk heated oxygen sensor #1 c43 grn heated oxygen sensor #...

  • Page 1239

    Wiring systems: 9a-16 a: battery cable / c: engine harness (j20a engine rhd) c: engine harness c42 c101 c91 c64 c92 c194 c163 c141 c102 c196 c192 c195 w/s c93 c104 c103 c94 c31 c32 c40 c162 c39 c123 c48 c37 c47 c282 c283 c46 c343 (to e371) c01 c45 c07 c06 c139 c44 c165 c166 3 2 1 4 a c i7rw0a910960-...

  • Page 1240

    9a-17 wiring systems: a: battery cable / c: engine harness (j20a engine lhd) c123 blu evap canister purge valve c139 gry shift solenoid a/t c141 blk a/c compressor c162 n oil pressure switch c163 n p/s pressure switch if eqpd c165 blk back-up light switch m/t c166 blk transaxle range sensor a/t c192...

  • Page 1241

    Wiring systems: 9a-18 c: engine harness no. Color connective position remarks c01 gry ecm c06 n tcm a/t c07 n tcm a/t c31 gry ckp sensor c32 n cmp sensor c37 gry knock sensor c39 blk ect sensor c40 grn a/f sensor c42 gry heated oxygen sensor c44 blk input shaft speed sensor a/t c45 blk output shaft ...

  • Page 1242

    9a-19 wiring systems: e: main harness (rhd) e: main harness e68 e40 e33 e165 e36 e161 e151 e159 e70 e281 e163 e62 e63 e65 e37 e164 e64 e183 e08 e311 e312 e222 e224 e225 e223 e221 e371 (to c343) e166 e227 e229 e234 e230 e01 e35 e241 e69 e162 e152 e160 e231 e226 8 9 7 6 e i6rw0c910906-07 no. Color con...

  • Page 1243

    Wiring systems: 9a-20 e: main harness (lhd) e183 gry brake fluid level switch e221 blk main relay e222 blk radiator fan relay #1 e223 blk radiator fan relay #2 e224 blk radiator fan relay #3 e225 blk starting motor relay e226 blk throttle actuator control relay e227 blk fuel pump relay e229 blk a/c ...

  • Page 1244

    9a-21 wiring systems: e: main harness no. Color connective position remarks e01 gry ecm e08 blk abs control module e33 n wheel speed sensor (fr) e35 blu wheel speed sensor (fl) e36 blk a/c refrigerant pressure sensor e37 blk outside air temperature sensor e40 yel forward sensor e62 blu windshield wa...

  • Page 1245

    Wiring systems: 9a-22 instrument panel s7rw0a910a003 e: main harness, power steering wire (rhd) e: main harness e: power steering wire e12 e13 e11 e387 (to l371) e04 e388 (to l372) e31 e61 e377 e378 e325 e323 e324 e381 (to g333) e382 (to g334) e191 e181 e192 10 power steering wire e i6rw0c910908-04 ...

  • Page 1246

    9a-23 wiring systems: e: main harness, power steering wire (lhd) e: main harness e: power steering wire e12 e13 e11 e387 (to l371) e04 e388 (to l372) e31 e61 e377 e378 e325 e323 e324 e381 (to g333) e382 (to g334) e191 e181 10 power steering wire e i6rw0c910909-02 no. Color connective position remark...

  • Page 1247

    Wiring systems: 9a-24 g: instrument panel harness, instrument panel antenna wire / s: contact coil (rhd) g: instrument panel harness g146 g141 g309 g34 g26 g253 g266 g255 g144 g241 g17 g310 g153 g248 g311 g61 g259 13 11 14 g16 g341 (to l374) g354 (to k154) g342 (to l375) g348 (to k153) g254 g152 g04...

  • Page 1248

    9a-25 wiring systems: g: instrument panel antenna wire s: contact coil g253 grn multi information display g254 n keyless receiver if eqpd g255 blk diode #1 auto a/c g259 orn passenger inflator g271 n j/b g272 n j/b g273 n j/b g306 n j/c g307 n j/c if eqpd g308 n j/c g309 gry j/c g310 n j/c auto a/c ...

  • Page 1249

    Wiring systems: 9a-26 g: instrument panel harness, instrument panel antenna wire / s: contact coil (lhd) g: instrument panel harness g146 g141 g309 g34 g253 g266 g255 g144 g241 g17 g33 g311 g153 g63 g248 g310 g61 g259 g243 g267 g355 (to l409) 13 11 14 g16 g341 (to l374) g354 (to k154) g342 (to l375)...

  • Page 1250

    9a-27 wiring systems: g: instrument panel antenna wire s: contact coil g248 blu audio (navigation) g251 n acc socket g253 grn multi information display g254 n keyless receiver if eqpd g255 blk diode #1 auto a/c g259 orn passenger inflator #1 g265 n security option taiwan g271 n j/b g272 n j/b g273 n...

  • Page 1251

    Wiring systems: 9a-28 door, roof s7rw0a910a004 j: front and rear door wire and rear door wire / k: roof wire, roof audio antenna wire (rhd) j: door harness (driver side) j: door harness (passenger side) j21 j153 j31 j83 j35 k51 j28 j154 k121 j32 k152 (to l383) j27 j85 j151 j25 k52 j22 j148 j86 j152 ...

  • Page 1252

    9a-29 wiring systems: j: rear door wire k: roof wire k: roof audio antenna wire no. Color connective position remarks j25 blk rear power window motor (r) j26 blk rear power window motor (l) j35 n rear door lock motor (r) j36 n rear door lock motor (l) j83 n rear power window sub switch (r) j84 n rea...

  • Page 1253

    Wiring systems: 9a-30 j: front and rear door wire and rear door wire / k: roof wire, roof audio antenna wire (lhd) j22 j154 j32 j83 j35 k51 j27 j153 k121 j31 k152 (to l383) j28 j86 j151 j25 k52 j21 j148 j85 j152 j216 (to l380) j141 j147 j82 j87 k153 (to g348) k154 (to g354) j145 j142 j81 j146 j218 (...

  • Page 1254

    9a-31 wiring systems: j: door harness (driver side) j: door harness (passenger side) j: rear door wire k: roof wire k: roof audio antenna wire no. Color connective position remarks j21 blk front power window motor (driver side) j27 n mirror motor (driver side) j31 n front door lock motor (driver sid...

  • Page 1255

    Wiring systems: 9a-32 floor s7rw0a910a005 l: floor harness, coupling harness, floor antenna wire / q: side curtain air-bag wire, side air-bag (r) harness, side air-bag (l) harness / r: fuel pump wire (rhd, hatchback) l: floor harness 21 20 24 19 17 18 15 16 l383 (to k152) l390 (to o231) l391 (to o23...

  • Page 1256

    9a-33 wiring systems: l: coupling harness l: floor antenna wire q: side curtain air-bag wire l167 blk parking brake switch l169 brn esp ® off switch if eqpd l170 n seat belt switch l174 n 2wd/4wd switch if eqpd l283 blk pretensioner (driver side) l285 blk pretensioner (passenger side) l292 gry back ...

  • Page 1257

    Wiring systems: 9a-34 q: side air-bag (r) harness q: side air-bag (l) harness r: fuel pump wire l: floor harness, coupling harness, floor antenna wire / q: side air-bag (r) harness, side air-bag (l) harness / r: fuel pump wire (rhd, sedan) l: floor harness no. Color connective position remarks q104 ...

  • Page 1258

    9a-35 wiring systems: m: trunk room harness l36 n passenger side-sensor 8ch l101 n a/t shift lever assy (shift lock solenoid, 3 position switch) l133 n rear combination light (r) l134 n rear combination light (l) l139 n high mounted stop light l141 n trunk room light l161 n front door switch (driver...

  • Page 1259

    Wiring systems: 9a-36 q: side air-bag (r) harness q: side air-bag (l) harness r: fuel pump wire l: floor harness, floor antenna wire / q: side curtain air-bag wire, side air-bag (r) harness, side air-bag (l) harness / r: fuel pump wire (lhd, hatchback) no. Color connective position remarks q104 blk ...

  • Page 1260

    9a-37 wiring systems: l: floor harness no. Color connective position remarks l01 blu bcm except taiwan l04 pnk a/b sdm 4ch l04 brn a/b sdm 8ch l31 gry wheel speed sensor (rr) l32 gry wheel speed sensor (rl) l35 n driver side-sensor 8ch l36 n passenger side-sensor 8ch l101 n a/t shift lever assy (shi...

  • Page 1261

    Wiring systems: 9a-38 l: floor antenna wire q: side curtain air-bag wire q: side air-bag (r) harness q: side air-bag (l) harness r: fuel pump wire no. Color connective position remarks l307 blk tv antenna #1 if eqpd l308 blk tv antenna #2 if eqpd l409 gry instrument panel antenna wire (to g355) if e...

  • Page 1262

    9a-39 wiring systems: l: floor harness, coupling harness, floor antenna wire / m: trunk room harness / q: side air-bag (r) harness, side air-bag (l) harness / r: fuel pump wire (lhd, sedan) l: floor harness 17 18 16 15 21 25 20 19 l32 m54 m53 m82 m81 l292 l173 l133 l134 l301 l141 22 24 l293 l139 l16...

  • Page 1263

    Wiring systems: 9a-40 l170 n seat belt switch l171 yel seat heater switch (driver side) l172 grn seat heater switch (passenger side) l173 n trunk room light switch l233 blk rear defogger relay l283 blk pretensioner (driver side) l285 blk pretensioner (passenger side) l290 blk side curtain air-bag (r...

  • Page 1264

    9a-41 wiring systems: m: trunk room harness q: side air-bag (r) harness q: side air-bag (l) harness r: fuel pump wire no. Color connective position remarks m53 n license plate light #1 m54 n license plate light #2 m81 n trunk room lock solenoid m82 n trunk room request switch m152 blk floor harness ...

  • Page 1265

    Wiring systems: 9a-42 rear s7rw0a910a006 o: rear end door harness, high mounted stop light wire, rear end door antenna wire o: rear end door harness o: high mounted stop light wire o: rear end door antenna wire 23 o231 (to l390) o232 (to l391) o181 o240 (to l410) o94 o122 o121 o95 o21 o92 o187 o186 ...

  • Page 1266

    9a-43 wiring systems: ground point ground (earth) point s7rw0a910c001 refer to “connector layout diagram”. 23 21 22 left side shown (hatch back) (lh) 19 20 (rh) 21 22 right side shown (sedan) (lh) 19 20 (rh) 3 4 5 2 8 9 17 10 11 fwd fwd (rh) 12 13 (lh) 15 16 fwd fwd 18 fwd 6 7 1 fwd 14 24 25 i7rw0a9...

  • Page 1267

    Wiring systems: 9a-44 power supply diagram power supply diagram s7rw0a910d001 g273 j/b j/b 3 wht/blu grn/wht red/wht wht/red 4 g147 3 1 2 8 blk 2 1 blk/gry 15a 15a 15a 2 3 1 4 6 7 8 1 e311 2 wht 11 12 14 15 16 blk/yel gry 3 yel/blu 2 1 blu/yel 4 blu red wht wht wht/red 11 wht/grn 14 wht/blu 15 16 46...

  • Page 1268

    9a-45 wiring systems: 5 4 3 2 yel blu blu grn g273 1 e323 7 g273 5 2 j/b 42 19 30a 15a 25 30a 35 10a 23 15a 24 15a 20 15a 21 10a 22 10a 26 10a 27 15a 28 10a relay blower fan relay bcm 1 wht e324 2 29 10a 30 15a 39 15a 36 10a 38 30a 31 20a 37 15a flasher relay relay tail light relay relay h bcm excep...

  • Page 1269

    Wiring systems: 9a-46 fuses and the protected parts s7rw0a910d002 the chart below describes what parts each fuse protects. Fuses in main fuse box s7rw0a910d003 43 45 44 i7rw0a910908-01 no. Fuse protected circuit 80 a all electric circuit battery generator 50 a j/b 50 a j/b.

  • Page 1270

    9a-47 wiring systems: individual circuit fuse box no. 1 s7rw0a910d004 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 use the desingnated fuses and relays only. Relay #1 "a-5" e222 relay #2 "a-5" e223 relay #3 "a-5" e224 "a-5" e227 relay relay "d-3" e234 compressor relay "e-1" e229 condenser fan relay ...

  • Page 1271

    Wiring systems: 9a-48 individual circuit fuse box no. 2 (in j/b (except taiwan)) s7rw0a910d005 19 25 20 26 34 21 27 35 22 28 36 23 29 37 24 30 38 31 39 32 40 33 41 42 use the desingnated fuses and relays only. I7rw01910912-02 no. Fuse description on the cover protected circuit 15 a rr wip rear wiper...

  • Page 1272

    9a-49 wiring systems: 30 a wip comb switch windshield washer motor windshield wiper motor rear wiper relay drl controller 10 a ig1 sig power steering control module a/t relay brake light switch 15 a a/b a/b sdm 10 a abs abs control module g sensor 10 a tail comb switch drl controller 15 a stop brake...

  • Page 1273

    Wiring systems: 9a-50 individual circuit fuse box no. 2 (in j/b (taiwan)) s7rw0a910d006 19 25 20 26 34 21 27 35 22 28 36 23 29 37 24 30 38 31 39 32 40 33 41 42 use the desingnated fuses and relays only. I7rw01910912-02 no. Fuse description on the cover protected circuit 15 a rr wip rear wiper motor ...

  • Page 1274

    9a-51 wiring systems: 10 a abs abs control module g sensor blank blank blank 15 a stop brake light switch 20 a d/l bcm blank blank blank 10 a st sig starting motor relay blank blank blank 10 a ig2 sig blower motor relay 10 a tail tail light relay 15 a dome audio bcm comb meter dlc ecm interior light...

  • Page 1275

    Wiring systems: 9a-52 individual circuit fuse box no.3 (sedan) s7rw0a910d012 47 46 19 47 46 25 20 26 34 21 27 35 22 28 36 23 29 37 24 30 38 31 39 32 40 33 41 42 use the desingnated fuses and relays only. 47 46 47 46 19 46 47 25 20 26 34 21 27 35 22 28 36 23 29 37 24 30 38 31 39 32 40 33 41 42 use th...

  • Page 1276

    9a-53 wiring systems: junction block (j/b) connector / fuse layout s7rw0a910d007 bcm side 2 1 6 5 3 4 4 3 2 12 1 11 14 13 15 5 9 8 7 17 6 16 19 18 20 10 6 5 4 3 2 8 1 7 10 9 12 11 3 4 6 5 2 1 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 g272 g271 g273 bcm (j/b side connector) 3 4 1 2 5 15 14 1...

  • Page 1277

    Wiring systems: 9a-54 relay side junction block inner circuit (overview (except taiwan)) s7rw0a910d008 abbreviations 5 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 blower fan relay relay 2 3 4 1 2 1 1 2 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 1 2 3 4 5 6 7 8 9 ...

  • Page 1278

    9a-55 wiring systems: 1 ig2 sw 2 6 lamp fl 1 a/b cont a/b signal k-line k-line a/b signal bcm ig1 d/sl-in d/l-in d/ul-1 sequlity in hazard tail bcm d/l (bcm) rr def rly bcm (+b) dome lp cont acc r/wip gnd signal gnd (bcm) 4 a/b ind 3 2 9 8 25 11 24 23 20 6 14 12 18 1 2 15 10 7 22 17 3 1 ig 3 lp-l 2 ...

  • Page 1279

    Wiring systems: 9a-56 junction block inner circuit (detail (except taiwan)) s7rw0a910d009 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3...

  • Page 1280

    9a-57 wiring systems: bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1281

    Wiring systems: 9a-58 e323 e325 e324 bcm g272 g271 g273 l312 l313 l314 l315 j/b 7 18 8 5 4 14 6 3 (continued) def ind rr def 6 htr mir (r) 7 htr mir (l) rr def rly rr-def rly epi stop sw dome (+b) dome (+b) dome lp (+b) 15 10 tail (+b) rr def dome horn-haz 30a 15a 15a 2 38 tail 10a 29 8 4wd cont rr ...

  • Page 1282

    9a-59 wiring systems: (continued) bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 ...

  • Page 1283

    Wiring systems: 9a-60 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1284

    9a-61 wiring systems: junction block inner circuit (overview (taiwan)) s7rw0a910d010 abbreviations abbreviation full term abbreviation full term as assistant (front passenger) lp lamp ctr center o/h over head dr driver r/b relay box f-l front l r-l rear l f-r front r r-r rear r fr front rr rear inp ...

  • Page 1285

    Wiring systems: 9a-62 1 ig2 sw 2 6 lamp fl 1 a/b cont 4 a/b ind 3 2 9 8 25 11 24 23 20 6 14 12 18 1 2 15 10 7 22 17 3 1 ig 3 lp-l 2 lp-r 4 +b 5 sw-l 7 gnd 6 sw-r 8 haz dome lp (+b) 5 4 3 gnd sp are-1 6 htr 4 st 1 ig2 5 acc 3 ig sw (+b) 2 ig1 18 10 7 g271 4 15 g272 7 g272 19 g272 1 g272 12 g271 9 g27...

  • Page 1286

    9a-63 wiring systems: junction block inner circuit (detail (taiwan)) s7rw0a910d011 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 ...

  • Page 1287

    Wiring systems: 9a-64 bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1288

    9a-65 wiring systems: e323 e325 e324 bcm g272 g271 g273 l312 l313 l314 l315 j/b 7 14 8 5 4 14 6 3 (continued) def ind rr def 6 htr mir (r) 7 htr mir (l) rr def rly rr-def rly epi stop sw dome (+b) dome (+b) dome lp (+b) rr def dome horn-haz 30a 15a 15a 2 38 2 stop 15a 30 37 39 (continued) individual...

  • Page 1289

    Wiring systems: 9a-66 (continued) bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 ...

  • Page 1290

    9a-67 wiring systems: bcm (j/b side connector) 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 g271 g273 g272 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 3 4 5 6 1 2 l312 2 3 4 1 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 ...

  • Page 1291

    Wiring systems: 9a-68 system circuit diagram system circuit diagram s7rw0a910e001 refer to “a-1 cranking system circuit diagram”. Refer to “a-2 charging system circuit diagram”. Refer to “a-3 ignition system circuit diagram (m15a engine, m16a engine)”. Refer to “a-3 ignition system circuit diagram (...

  • Page 1292

    9a-69 wiring systems: refer to “d-10 rear fog light circuit diagram (hatchback)”. Refer to “d-10 rear fog light circuit diagram (sedan)”. Refer to “e-1 heater system circuit diagram”. Refer to “e-2 auto a/c system circuit diagram”. Refer to “f-1 air-bag system circuit diagram (4ch)”. Refer to “f-1 a...

  • Page 1293

    Wiring systems: 9a-70 a-1 cranking system circuit diagram s7rw0a910e002 starting motor relay w "a-5" ecm e225 c195 1 c196 1 starting motor m blk 1 blk/gry c282 1 battery e371 c343 3 red individual circuit fuse box (no.1) 8 30a 33 10a wht wht j/b e325 10 4 2 3 1 red/wht st st sig yel/grn yel/grn yg "...

  • Page 1294

    9a-71 wiring systems: a-2 charging system circuit diagram s7rw0a910e003 20 e371 c343 20 g334 e382 blk/wht blk/wht blk/wht 80a main fuse box c192 j/b 1 c283 ig coil 43 15a 20 generator w/s ic regulator 1 e325 5 c194 2 4 wht/blu wb bcm "a-8" 1 blu/yel by 3 brn/wht bw ecm "a-5" 9 wht/blu blk taiwan m15...

  • Page 1295

    Wiring systems: 9a-72 a-3 ignition system circuit diagram (m15a engine, m16a engine) s7rw0a910e004 15a 20 e371 c343 2 c101 1 3 ig coil #1 w/s c102 blk blk/wht grn/yel blk/wht j/b ecm gy gw 20 ig coil blk blk ig coil #2 e325 5 3 grn/wht 1 3 2 c01 5 6 blk/wht i7rw0a910969-02.

  • Page 1296

    9a-73 wiring systems: a-3 ignition system circuit diagram (j20a engine) s7rw0a910e005 15a 20 e371 c343 2 c101 3 1 ig coil #1 w/s w/s w/s c102 blk blk/wht blk/wht blk/wht grn/yel blk/wht j/b ecm gy gw 20 ig coil blk blk blk blk blk ig coil #2 e325 5 3 grn/wht 4 3 1 2 c01 20 21 blk/wht gb grn/blk 19 g...

  • Page 1297

    Wiring systems: 9a-74 a-4 cooling system circuit diagram (m15a engine, m16a engine) s7rw0a910e006 e65 4 5 9 "a-5" lg br bw relay motor e222 3 1 2 1 blu/red lt grn brn/wht gry blk/red blk/yel blk/yel 30a rdtr 10 e221 1 2 15a fi 1 3 4 main relay blk ecm individual circuit fuse box (no.1) m i6rw0c91091...

  • Page 1298

    9a-75 wiring systems: a-4 cooling system circuit diagram (j20a engine) s7rw0a910e007 e65 4 5 9 lt grn "a-5" lg br bb bw g brn/wht bw blk/yel blk/yel relay #1 motor e222 3 1 2 4 3 1 blu/red blu/red blu/blk blk blu/red blu/red gry gry blu/wht grn grn 30a rdtr 10 e221 1 2 15a fi 1 3 4 main relay blk bl...

  • Page 1299

    Wiring systems: 9a-76 a-5 engine and a/c control system circuit diagram (m15a engine) s7rw0a910e008 yel/red e387 l371 10 12 l389 r151 4 2 pnk yel/red p pnk yel/red 3 1 4 3 3 3 1 e371 c343 blk/orn blk/orn blk/orn blk/orn 19 8 blk 4 2 r101 and fuel gauge main relay 1 blk/red blu/yel grn/wht blk/wht bl...

  • Page 1300

    9a-77 wiring systems: 2 c39 lt grn 1 c47 c01 c01 grn/orn grn/red brn/yel wht/red c122 3 blk/red blk/red blk/red blk/red 55 red/blk gry/red gry/blu egr valve w/s w/s w/s w/s 4 6 3 1 2 5 3 4 5 6 map sensor c36 3 1 2 c124 ecm c91 2 1 c92 2 1 c93 2 1 c94 2 1 #2 #1 #3 #4 blu/red blu/wht blu/yel blu/orn b...

  • Page 1301

    Wiring systems: 9a-78 ckp sensor 3 c31 51 pnk blk/orn blk/red 1 2 gw j/b 2 15a stop 30 15a dome 37 e01 20 grn/wht grn/wht grn e323 4 e181 brake light switch w/s w/s 1 2 ecm 2 cmp sensor c01 c01 blk blk blk 3 4 6 3 15 29 30 31 1 c32 52 c01 e01 22 30 28 13 red/yel blk/orn blk blk blk blk blk/red blk/r...

  • Page 1302

    9a-79 wiring systems: tcm wht red 7 17 c06 49 44 c01 14 e01 36 41 35 12 27 c01 21 20 50 ecm wht abs cont.M app sensor electric throttle body throttle position sensor sub open close open close open close open close main sub main throttle actuator red blu grn brn wht yel red blk wht grn red yel blu e0...

  • Page 1303

    Wiring systems: 9a-80 a-5 engine and a/c control system circuit diagram (m16a engine) s7rw0a910e009 yel/red e387 l371 10 12 l389 r151 4 2 pnk yel/red p pnk yel/red 3 1 4 3 1 e371 c343 blk/orn blk/orn blk/orn blk/orn 19 8 blk 4 2 r101 and fuel gauge main relay 1 blk/red blu/yel grn/wht blk/wht blk/wh...

  • Page 1304

    9a-81 wiring systems: 2 c39 lt grn 1 c47 c01 c01 c124 ecm c91 2 1 c92 2 1 c93 2 1 c94 2 1 #2 #1 #3 #4 blu/red blu/wht blu/yel blu/orn blk/red blu/blk grn/orn grn/red brn/yel wht/red evap canister purge valve c123 c122 ect sensor gry/blu gry/blu "a-4" lg 30a rdtr 10 relay motor "a-1" generator blu/re...

  • Page 1305

    Wiring systems: 9a-82 gw j/b 2 15a stop 30 15a dome 37 e01 20 grn/wht grn/wht grn e323 4 e181 brake light switch 1 2 ecm 2 cmp sensor w/s c01 blk 3 6 15 31 30 1or3 c32 20 c01 e01 48 30 28 13 red/yel blk/orn blk/orn blk/orn blk blk blk c01 e01 58 blk/red 3or2 2or1 j/b e325 1 2 yg yel/grn yel/blk wht/...

  • Page 1306

    9a-83 wiring systems: esp ® is a registered trademark of daimler chrysler ag. Abs cont.M or esp cont.M r tcm wht red 7 17 c06 12 4 c01 e01 14 54 57 19 55 26 c01 6 5 13 ecm wht app sensor electric throttle body throttle position sensor sub open close open close open close open close main sub main thr...

  • Page 1307

    Wiring systems: 9a-84 a-5 engine and a/c control system circuit diagram (j20a engine) s7rw0a910e010 yel/red e387 l371 10 12 l389 r151 4 2 pnk yel/red p pnk yel/red 3 1 4 3 3 3 1 e371 c343 blk/orn blk/orn blk/orn blk/orn 19 8 blk 4 2 r101 and fuel gauge main relay 1 blk/red blu/yel grn/wht blk/wht bl...

  • Page 1308

    9a-85 wiring systems: 2 c39 lt grn 1 c47 c01 c01 pressure switch c64 ecm c91 2 1 c92 2 1 c93 2 1 c94 2 1 #2 #1 #3 #4 blu/red blu/wht blu/yel blu/orn blk/red blk/red blu/wht blu/blk evap canister purge valve c123 ect sensor gry/blu gry/blu gry "a-4" lg g 30a rdtr 10 relay #1 motor "a-1" generator blu...

  • Page 1309

    Wiring systems: 9a-86 g333 e381 s171 g346 16 15 14 gw gy j/b 2 15a stop 30 15a dome 37 e01 20 grn/wht grn/wht grn 12 10a ig1 sig 26 lt grn/blk 8 grn/yel 6 22 red/wht lt grn 21 blk/yel red/wht red/blk lt grn blk/yel rb e325 e323 e325 e323 4 15a ig coil 20 5 e181 3 4 brake light switch w/s main resume...

  • Page 1310

    9a-87 wiring systems: abs cont.M or esp cont.M r tcm wht red 7 17 c06 49 44 c01 14 e01 36 41 35 12 27 c01 21 20 50 ecm wht app sensor electric throttle body throttle position sensor sub open close open close open close open close main sub main throttle actuctor red blu grn brn wht yel red blk wht gr...

  • Page 1311

    Wiring systems: 9a-88 a-6 a/t control system circuit diagram s7rw0a910e011 grn/red shift lock relay e241 grn/red c07 20 8 7 19 18 e371 c343 grn/yel back-up light 14 red "d-8" brake light switch "d-7" r gw transaxle range sensor tcm l101 4 3 position switch a/t shift lock solenoid a/t shift lever ass...

  • Page 1312

    9a-89 wiring systems: tcm lock up solenoid a/t fluid temperature sensor shift solenoid no.2 shift solenoid no.1 11 12 c139 1 2 9 blk/yel brn orn 15 4 2 5 wht/blu pressure control solenoid lt grn/blk gry shift solenoid lt grn ecm wht red wht/red ppl wht/red blk/wht blk/red blk/red blk/red blk/wht blk...

  • Page 1313

    Wiring systems: 9a-90 a-7 immobilizer system circuit diagram s7rw0a910e012 j/b side connector (bcm) except taiwan taiwan except m16a engine m/t m16a engine m/t a b c d e c b b c d e ecm icm dlc if eqpd g211 4 j/c g309 5 7 11 4 ig coil g272 6 j/b 29 15a 20 blk/wht 13 28 yel/blk yb w yr e382 g334 19 g...

  • Page 1314

    9a-91 wiring systems: a-8 body control system circuit diagram (except taiwan) s7rw0a910e013 4 g04 e04 g04 2 wht red 3 g211 1 6 14 wht red pnk lt grn g04 dlc 4 11 14 blk blk blk b b j/c g309 13 l312 5 2 14 12 receiver 5 e04 9 blu blu blu blu blu blu wht "f-2" "f-3" "f-3" p/s cont.M hvac cont.M abs co...

  • Page 1315

    Wiring systems: 9a-92 15 7 "d-5" 16 b b g04 10 blu/yel blu/yel j/c g308 g146 1 4 7 4 main switch (key switch) rhd flasher relay dome g271 5 15a 37 acc mtr 15a 23 22 8 1 12 horn -haz 15a 39 11 10a 22 wht/red wht/red yel/red yel/blk 1 e37 2 outside air temperature sensor "b-5" switch 6 14 16 17 12 5 r...

  • Page 1316

    9a-93 wiring systems: 18 17 grn/wht grn/yel "e-1" "e-2" hvac control unit g04 l01 "b-5" "b-5" "b-5" "b-5" 11 9 l346 10 b e e rear grn grn red/blu grn red/blu b l347 red/blu grn red/blu grn red/blu b 1 10 b e grn/red red/blu blu/yel grn rear end 4 wht/red rear end door lock switch 3 d d f "d-5" blk/y...

  • Page 1317

    Wiring systems: 9a-94 3 a a g271 6 l312 13 j/c g309 blk/orn blk/orn 4 l314 16 blk/orn c c j/c g308 c c j/c l346 yel "a-2" generator rhd "d-5" spot light "d-5" interior light e04 4 wht/blu wb wht/red wht/red wht/red wr wr 11 yel y gry 8 g04 g "g-2" multi information display bcm "e-2" j/b a 3 14 2 5 w...

  • Page 1318

    9a-95 wiring systems: a-8 body control system circuit diagram (taiwan) s7rw0a910e014 1 g05 3 wht red 2 g211 4 6 14 wht red pnk lt grn g05 dlc 4 11 14 12 blk blk blk b b j/c g309 18 blk/wht g04 1 wht/red 13 19 20 receiver 35 blu 15 blu blu blu blu blu blu wht wht "f-2" "f-3" "f-3" p/s cont.M abs cont...

  • Page 1319

    Wiring systems: 9a-96 38 39 "d-5" "d-1" blk/blu 3 a a b b g04 2 blu/yel blu/yel j/c g307 1 g265 j/c g308 g146 1 4 main switch (key switch) dome g271 5 15a 37 acc g272 5 15a 23 wht/red wht/blk wht/red yel/red yel/red yel/blk yel/blk 1 e37 2 outside air temperature sensor "b-5" switch 8 40 37 36 27 26...

  • Page 1320

    9a-97 wiring systems: 6 20 grn/wht grn/yel "e-1" "e-2" hvac control unit g05 g04 g05 g06 "b-5" "b-5" "b-5" "b-5" 7 2 l346 3 b e e rear grn grn red/blu grn red/blu b l347 red/blu grn red/blu grn red/blu b 9 8 b e grn/red red/blu blu/yel blu/yel grn rear end 30 wht/red rear end door lock switch hatchb...

  • Page 1321

    Wiring systems: 9a-98 19 g04 1 b b g06 11 j/c g309 a a j/c g306 blk 14 blk "f-1" yel blk a/b sdm switch "d-6" hvac control unit "e-1" "e-2" a/t shift lever "d-4" switch "d-3" audio "g-1" y g04 34 g05 wht w 14 blk/yel blk/yel by c c j/c g306 14 blk/yel c c j/c g308 yel blk by "a-2" generator 10 wht/b...

  • Page 1322

    9a-99 wiring systems: a-10 4wd control system (except taiwan) s7rw0a910e015 4wd cont.M g26 12 3 2 11 2wd/4wd switch dlc g211 6 14 l174 1 5 6 4 2 10 7 5 4 16 21 l376 g343 19 e382 g334 19 e371 c343 8 17 r w "c-3" r ry w bcm "a-8" "d-4" 11 16 11 4 blk g272 g271 g271 8 8 5 j/b 21 10a back 15a 4wd 32 15a...

  • Page 1323

    Wiring systems: 9a-100 b-1 windshield wiper and washer circuit diagram s7rw0a910e016 j/b lo hi e64 blk e323 3 9 g141 11 switch motor motor 18 blu/wht blu/wht blu/red blu/red blu/yel blu/yel 4 wip 30a 25 2 e62 1 g271 1 yel/grn m yel/grn blu/orn 13 7 blk off on wf ew p t mist off int lo hi +b +2 +1 +s...

  • Page 1324

    9a-101 wiring systems: b-2 rear wiper and washer circuit diagram (except taiwan) s7rw0a910e017 j/b o21 4 2 3 blk blk blk blk blk l312 l314 4 g272 9 b g141 9 g272 8 1 g04 l390 o231 2 o231 l391 20 m wash off int on on+wash wr ew +1r p t blk blk 2 e63 1 yel yel yel m yel/blk orn orn yel 30a wip j/c g30...

  • Page 1325

    Wiring systems: 9a-102 b-2 rear wiper and washer circuit diagram (taiwan) s7rw0a910e018 j/b o21 4 2 3 blk blk blk blk blk l312 l314 4 g272 9 b g141 9 g272 4 8 1 3 g04 l390 o231 2 o231 l391 5 20 m wash off int on on+wash wr ew +1r p t blk blk 2 e63 1 yel yel red yel m yel/blk orn orn yel 30a wip j/c ...

  • Page 1326

    9a-103 wiring systems: b-3 rear defogger circuit diagram (hatchback (except taiwan)) s7rw0a910e019 l390 o231 3 o231 l390 2 blk/red o181 1 o182 1 23 21 4 3 2 1 30a rr def 38 relay grn/yel g04 17 g271 7 blk/red blk/red l314 8 rear def hvac control unit blk/orn 13 blk/orn g309 j/c a a blk blk blk g154 ...

  • Page 1327

    Wiring systems: 9a-104 b-3 rear defogger circuit diagram (hatchback (taiwan)) s7rw0a910e020 l390 o231 3 o231 l390 2 blk/red o181 1 o182 1 23 21 4 3 2 1 30a rr def 38 relay grn/yel brn g04 20 g271 7 g272 14 blk/red blk/red l314 8 rear def hvac control unit blk/orn 13 blk/orn g309 j/c a g05 14 a blk b...

  • Page 1328

    9a-105 wiring systems: b-3 rear defogger circuit diagram (sedan) s7rw0a910e057 l376 g343 blk/red blk l299 1 l300 1 19 4 3 2 1 relay grn/yel wht/red wht/red red/blk wht/red g04 blk/red blk/red blk/red l317 l233 2 5 18 l315 rear def hvac control unit blk/orn 13 blk/orn g309 j/c j/b a a blk 25 blk g154...

  • Page 1329

    Wiring systems: 9a-106 b-4 power window circuit diagram s7rw0a910e021 2 1 j82 l380 j216 j215 l379 12 12 13 6 14 6 16 2 3 5 10 11 17 16 1 4 30a p/w 42 sub switch main switch j22 1 2 grn red red 15 l314 j/b blk blk blk 14 13 wht/blu wht/blu wht/blu wht/blu wht/blu wht/blu 1 2 3 4 5 6 red/wht wht/blu g...

  • Page 1330

    9a-107 wiring systems: j84 l382 j218 j83 2 3 5 2 2 6 1 3 5 l381 j217 2 6 1 5 j26 j25 red/blk blu/yel wht/blu grn/yel wht/blu wht/grn 11 4 3 j215 l379 1 4 1 2 m grn red 1 4 1 2 grn red 1 2 3 4 5 6 unlock up off down up off down lock ig e rlu rld rear (l) sub switch rear motor (l) m unlock up off down...

  • Page 1331

    Wiring systems: 9a-108 b-5 power door lock circuit diagram (except taiwan) s7rw0a910e022 17 16 23 34 switch j31 l379 j215 blk main switch 13 14 9 5 12 22 33 j81 blk blk brn lt grn/blk gry/red gry/wht 17 blk 20 up off down lock unlock e receiver g254 g04 l01 lt grn pnk 14 13 12 3 1 4 up off down lock...

  • Page 1332

    9a-109 wiring systems: 11 4 l346 7 4 2 l381 j217 8 b e e 7 l382 j218 8 7 l390 o231 o121 rear motor (r) j/c grn grn b j35 red/blu grn red/blu grn yel red/blu 3 m b 1 j32 l347 l01 m 1 3 rear motor (l) j36 m b e 25 26 m 24 l380 j216 2 o231 l390 grn 3 yel yel red/blu grn 3 yel yel red/blu grn red/blu ye...

  • Page 1333

    Wiring systems: 9a-110 b-5 power door lock circuit diagram (taiwan) s7rw0a910e023 36 37 23 34 switch j31 l379 j215 brn blk lt grn/blk main switch 13 14 9 26 27 22 33 g352 l402 8 9 4 5 1 j81 gry/red blk blk gry/wht brn lt grn/blk gry/red gry/wht 17 blk 20 up off down lock unlock e receiver g254 g05 g...

  • Page 1334

    9a-111 wiring systems: 7 4 l346 7 4 2 l381 j217 8 b e e 7 l382 j218 8 7 l390 o231 3 10 2 12 11 o121 rear motor (r) j/c grn grn grn red/blu blk/red b j35 5 g06 red/blu grn red/blu grn grn red/blu 3 m b 9 2 3 j32 l347 g05 4 g271 m 1 3 1 3 rear motor (l) j36 m b e 25 26 m l380 j216 2 o231 l390 grn red/...

  • Page 1335

    Wiring systems: 9a-112 b-6 power mirror circuit diagram (hatchback (except taiwan)) s7rw0a910e024 13 13 5 9 r l 3 20 7 7 j87 l315 l379 j215 6 j27 j28 13 j215 l379 j215 l379 blk blk 17 17 20 17 switch motor if eqpd m m down up 5 r l 6 motor m m m down set rtr up mirror heater mirror heater m set rtr ...

  • Page 1336

    9a-113 wiring systems: b-6 power mirror circuit diagram (hatchback (taiwan)) s7rw0a910e025 13 10 4 12 5 13 5 9 r l 3 20 7 7 j87 l315 l379 j215 6 j27 j28 13 j215 l379 j215 l379 blk blk 17 17 20 17 switch motor m m down up 5 r l 6 motor m m m down set rtr up mirror heater mirror heater m set rtr 4 3 2...

  • Page 1337

    Wiring systems: 9a-114 b-6 power mirror circuit diagram (sedan (except taiwan)) s7rw0a910e068 13 13 5 9 r l 3 20 7 7 j87 l315 2 l317 l379 j215 6 j27 j28 13 j215 l379 j215 l379 blk blk 17 17 20 17 switch motor if eqpd m m down up 5 r l 6 motor m m m down set rtr up mirror heater mirror heater m set r...

  • Page 1338

    9a-115 wiring systems: b-6 power mirror circuit diagram (sedan (taiwan)) s7rw0a910e069 13 10 4 12 5 13 5 9 r l 3 20 7 7 j87 l315 2 l317 l233 l379 j215 6 j27 j28 13 j215 l379 j215 l379 blk blk 17 17 20 17 switch motor m m down up 5 r l 6 motor m m m down set rtr up mirror heater mirror heater m set r...

  • Page 1339

    Wiring systems: 9a-116 b-7 horn circuit diagram s7rw0a910e026 3 3 j/b 15a horn-haz 39 grn blu 1 1 steering switch (horn switch) contact coil h 4 3 1 2 20 relay h e281 s61 e325 g272 b g346 s171 1 j/b side connector (bcm) except taiwan a b bcm a b i7rw0a910981-02.

  • Page 1340

    9a-117 wiring systems: b-8 seat heater circuit diagram s7rw0a910e027 lt grn lt grn lt grn red/yel red/yel red/yel red/yel blu blk l171 5 6 l281 3 4 4 1 2 l172 5 l282 3 4 blk gry blk 4 1 2 blk blk blk blk blk switch free lock free lock switch l314 15 15a s/h 34 j/b 6 j/c l346 c a l347 ry b g "d-4" 7 ...

  • Page 1341

    Wiring systems: 9a-118 b-9 keyless start system circuit diagram s7rw0a910e028 g271 kls ecm bcm wht/red wht/red wht/red wht/red blu/yel wht red wht red orn blu/yel "a-8" w wr r g16 14 34 20 18 19 blk/orn blk/orn 9 5 j/b 15a dome 37 g272 8 10a back 21 11 15a acc2 24 b b b b j/c j/c g308 b g307 b a a j...

  • Page 1342

    9a-119 wiring systems: c-1 combination meter circuit diagram (meter) s7rw0a910e029 dome j/b 15a 37 mtr 10a 22 wht/red wht/red (can) g241 32 31 5 stepper motor and led output driver voltage regulator micro controller interface circuit ill (dial) ill (display) ill (pointer) g271 6 red/blk 16 b b blk b...

  • Page 1343

    Wiring systems: 9a-120 c-2 combination meter circuit diagram (indicator) s7rw0a910e030 dome 15a 37 mtr 10a 22 wht/red wht/red 32 31 5 stepper motor and led output driver voltage regulator micro controller keyless start g271 6 red/blk "d-1" beam 22 red (dimmer / passing) j/b 16 b b blk blk j/c g308 1...

  • Page 1344

    9a-121 wiring systems: c-3 combination meter circuit diagram (warning light) s7rw0a910e031 j/b mtr 10a 22 31 stepper motor and led output driver voltage regulator micro controller g271 6 red/blk 5 16 yb yel/blk "f-1" can high low wht wht red r w 10 g241 9 7 l01 g05 red/blu brn/yel l167 1 parking bra...

  • Page 1345

    Wiring systems: 9a-122 esp ® is a registered trademark of daimler chrysler ag. Gear abs belt door charge check engine airbag oil drl d/f lock 4wd auto set cruise immobi brake fuel dome 15a 37 32 5 wht/red wht/red j/b g271 g241 1 2 j/c g308 b b if eqpd esp active esp system esp off r r r i7rw0a910940...

  • Page 1346

    9a-123 wiring systems: d-1 headlight system circuit diagram (except taiwan) s7rw0a910e032 1 headlight (r) headlight (l) wht/blu red dimmer / passing switch light switch 2 2 3 3 15 1 22 g241 e151 g272 e152 g271 5 32 wht/red wht/red wht/red 15a 37 dome wht/red blk 13 g144 15a 16 15a 15 h/l r h/l l 13 ...

  • Page 1347

    Wiring systems: 9a-124 yel/grn red/wht red/grn 3 red/yel 5 20 e382 g334 30a wip 25 drl controller g214 10 wht/red 8 red/wht 6 g271 1 4 9 gry gry blk/orn blk/orn 2 blk blk 1 "c-3" 1 4 2 3 g ry j/b bcm "d-4" 11 14 13 a a j/c j/b with drl controller g309 i7rw0a910a04-01.

  • Page 1348

    9a-125 wiring systems: d-1 headlight system circuit diagram (taiwan) s7rw0a910e033 2 headlight (l) headlight (r) headlight hi relay (l) wht/red wht/red wht/blu red/wht red/wht dimmer / passing switch light switch 1 1 3 3 2 e152 e151 red/yel wht/blu 8 2 13 g144 15a 15 15a 16 h/l l h/l r brn brn/wht w...

  • Page 1349

    Wiring systems: 9a-126 d-2 position, tail and licence plate light system circuit diagram (hatchback (except taiwan)) s7rw0a910e034 3 5 l134 1 2 o95 1 2 o94 (r) (l) (l) (r) blk 7 15 g272 g144 10a tail 29 1 2 e161 1 2 e162 blk blk blk blk blk j/b l314 3 e325 16 blk blk licence plate light #2 licence p...

  • Page 1350

    9a-127 wiring systems: d-2 position, tail and licence plate light system circuit diagram (sedan (except taiwan)) s7rw0a910e064 1 5 l134 1 2 m54 1 2 m53 (r) (l) (l) (r) blk 7 15 g272 g144 10a tail 29 1 2 e161 1 2 e162 blk blk blk blk j/b l314 3 e325 16 blk blk licence plate light #2 licence plate lig...

  • Page 1351

    Wiring systems: 9a-128 d-2 position, tail and licence plate light system circuit diagram (hatchback (taiwan)) s7rw0a910e035 3 5 l134 1 2 o95 1 2 o94 (r) (l) (r) (l) blk 18 7 12 g272 10 11 blk g144 13 g05 g04 12 10a tail 36 1 2 e161 1 2 e162 blk blk blk blk blk j/b l314 3 e325 16 blk blk licence plat...

  • Page 1352

    9a-129 wiring systems: d-2 position, tail and licence plate light system circuit diagram (sedan (taiwan)) s7rw0a910e058 1 5 l134 1 2 m54 1 2 m53 (r) (l) (r) (l) blk 18 7 12 g272 10 11 blk g144 13 g05 g04 12 10a tail 36 1 2 e161 1 2 e162 blk blk blk blk blk j/b l314 3 e325 16 blk blk licence plate li...

  • Page 1353

    Wiring systems: 9a-130 d-3 front fog light system circuit diagram (except taiwan) s7rw0a910e036 fr fog (r) (l) 2 e164 1 2 e163 1 20a 14 relay switch 3 e234 2 1 4 wht/grn gry/red lt grn blk blk blk lt grn lt grn 1 d d g334 e382 free ig load e il ile terminal position push 6 7 4 8 g306 g151 red/yel re...

  • Page 1354

    9a-131 wiring systems: d-3 front fog light system circuit diagram (taiwan) s7rw0a910e037 fr fog (r) (l) 2 e164 1 2 e163 1 20a 14 relay switch 3 e234 2 1 4 wht/grn red/yel red/yel lt grn blk blk blk lt grn lt grn 14 d d g333 e381 13 e381 g333 free ig load e il ile terminal position push 7 6 4 8 g306 ...

  • Page 1355

    Wiring systems: 9a-132 d-4 illumination light system circuit diagram (except taiwan) s7rw0a910e038 blk blk blk red/blu red/blu 11 j/c j/c b b 14 g309 a a c c g306 blk/yel red/yel by yel yel y y multi information display "g-2" audio "g-1" "c-3" ill cancel switch g150 7 5 8 4 push free wht/red 10a tai...

  • Page 1356

    9a-133 wiring systems: d-4 illumination light system circuit diagram (taiwan) s7rw0a910e039 blu/wht red/yel 10a tail 36 j/b 12 g272 10 g144 13 13 17 21 red/yel red/yel red/yel red/yel red/yel l314 3 blk blk blk blk "d-3" a/t ry switch j/c g306 red/yel ry red/yel switch ry red/yel hvac control unit "...

  • Page 1357

    Wiring systems: 9a-134 d-5 interior light system circuit diagram (hatchback (except taiwan)) s7rw0a910e040 15a 37 dome j/b off door on on off k51 l312 2 6 3 1 interior light spot light off on off on l161 1 1 blk blk blk off on off on l164 l162 1 l163 1 rear door switch front door switch blk blk blk ...

  • Page 1358

    9a-135 wiring systems: d-5 interior light system circuit diagram (hatchback (taiwan)) s7rw0a910e041 15a 37 dome j/b off door on on off k51 l312 2 6 3 1 interior light spot light off on off on l161 1 1 blk/blu blk blk blk off on off on l164 l162 1 l163 1 rear door switch front door switch blk/red blk...

  • Page 1359

    Wiring systems: 9a-136 d-5 interior light system circuit diagram (sedan (except taiwan)) s7rw0a910e065 15a 37 dome j/b off door on on off k51 l312 2 6 3 1 interior light spot light off on off on l161 1 1 off on off on l164 l162 1 l163 1 rear door switch front door switch blk blk blk blk wht wht blk ...

  • Page 1360

    9a-137 wiring systems: d-5 interior light system circuit diagram (sedan (taiwan)) s7rw0a910e059 15a 37 dome j/b off door on on off k51 l312 2 6 3 1 interior light spot light off on off on l161 1 1 blk/blu off on off on l173 1 off on l164 l162 1 l163 1 rear door switch front door switch trunk room li...

  • Page 1361

    Wiring systems: 9a-138 d-6 turn signal and hazard warning light system circuit diagram (hatchback (except taiwan)) s7rw0a910e042 4 d d g153 g306 2 switch blk/orn rear turn signal light 6 l134 blk 11 8 12 22 haz lp-l lp-r flasher relay red/yel wht red/yel turn signal switch g144 10a mtr 22 red/blu bl...

  • Page 1362

    9a-139 wiring systems: 9 grn/red grn/red grn/red 9 turn (l) turn (r) e165 12 g271 6 blu/yel blu/yel blu/yel grn/red blu/yel "c-2" gr by front turn signal light (r) side turn signal light (r) e159 2 e166 front turn signal light (l) side turn signal light (l) blk e323 5 blk blk blk blk 1 2 1 2 1 2 1 e...

  • Page 1363

    Wiring systems: 9a-140 d-6 turn signal and hazard warning light system circuit diagram (sedan (except taiwan)) s7rw0a910e066 4 d d g153 g306 2 switch blk/orn rear turn signal light 4 l134 blk 11 8 12 22 haz lp-l lp-r flasher relay red/yel wht red/yel turn signal switch g144 10a mtr 22 red/blu blu/re...

  • Page 1364

    9a-141 wiring systems: 9 grn/red grn/red grn/red 9 turn (l) turn (r) e165 12 g271 6 blu/yel blu/yel blu/yel grn/red blu/yel "c-2" gr by front turn signal light (r) side turn signal light (r) e159 2 e166 front turn signal light (l) side turn signal light (l) blk e323 5 blk blk blk blk 1 2 1 2 1 2 1 e...

  • Page 1365

    Wiring systems: 9a-142 d-6 turn signal and hazard warning light system circuit diagram (hatchback (taiwan)) s7rw0a910e043 4 d d g153 g306 2 switch blk/orn rear turn signal light 6 l134 blk 11 8 1 3 2 4 haz lp-l lp-r flasher relay red/yel wht red/yel blu/wht wht wht turn signal switch 6 g144 7 5 10a ...

  • Page 1366

    9a-143 wiring systems: 9 grn/red grn/red grn/red 9 turn (l) turn (r) e165 12 g271 6 blu/yel blu/yel blu/yel grn/red blu/yel "c-2" gr by front turn signal light (r) side turn signal light (r) e159 2 e166 front turn signal light (l) side turn signal light (l) blk e323 5 blk blk blk blk 1 2 1 2 1 2 1 e...

  • Page 1367

    Wiring systems: 9a-144 d-6 turn signal and hazard warning light system circuit diagram (sedan (taiwan)) s7rw0a910e060 4 d d g153 g306 2 switch blk/orn rear turn signal light 4 l134 blk 11 8 1 3 2 4 haz lp-l lp-r flasher relay red/yel wht red/yel blu/wht wht wht turn signal switch 6 g144 7 5 10a mtr ...

  • Page 1368

    9a-145 wiring systems: 9 grn/red grn/red grn/red 9 turn (l) turn (r) e165 12 g271 6 blu/yel blu/yel blu/yel grn/red blu/yel "c-2" gr by front turn signal light (r) side turn signal light (r) e159 2 e166 front turn signal light (l) side turn signal light (l) blk e323 5 blk blk blk blk 1 2 1 2 1 2 1 e...

  • Page 1369

    Wiring systems: 9a-146 d-7 brake light system circuit diagram (hatchback) s7rw0a910e044 brake light switch shift lock relay (r) brake light grn lt grn/blk blk (l) e181 l134 grn/wht grn/wht grn/wht grn/wht 5 l315 e325 j/b "f-2" "f-3" abs cont.M grn/wht 2 2 1 "a-5" ecm 21 gw gw grn/yel "a-5" ecm gy gw...

  • Page 1370

    9a-147 wiring systems: d-7 brake light system circuit diagram (sedan) s7rw0a910e061 brake light switch shift lock relay (r) brake light grn lt grn/blk blk (l) e181 l134 grn/wht grn/wht grn/wht grn/wht 5 l315 e325 j/b "f-2" "f-3" abs cont.M grn/wht 2 2 1 "a-5" ecm 21 gw gw grn/yel "a-5" ecm gy gw 4 2...

  • Page 1371

    Wiring systems: 9a-148 d-8 back-up light system circuit diagram (hatchback) s7rw0a910e045 blk blk blk 20 21 blk blk 23 back-up light switch back-up light back-up light without rear fog light (r) red red red/blk red/blk on off j/b 10a 21 back e371 c343 c165 2 1 l134 1 l133 1 red red red l315 3 e325 1...

  • Page 1372

    9a-149 wiring systems: d-8 back-up light system circuit diagram (sedan) s7rw0a910e062 blk blk 19 21 back-up light switch back-up light back-up light (r) red red red/blk red/blk on off j/b 10a 21 back e371 c343 c165 2 1 l134 3 l133 3 red red red l315 3 e325 11 j/b e325 14 5 5 (l) r 14 13 a/t m/t p r ...

  • Page 1373

    Wiring systems: 9a-150 d-9 headlight beam leveling system circuit diagram (manual leveling) s7rw0a910e046 10a grn grn red/blk grn blk blk switch 21 back red/blk red/blk e69 g272 3 e68 3 2or1 8 e325 14 2or1 1or2 g152 e381 g333 4 3 5 1 g333 e381 2 1or2 blk blk actuator (l) actuator (r) control circuit...

  • Page 1374

    9a-151 wiring systems: d-10 rear fog light circuit diagram (hatchback) s7rw0a910e047 20 21 23 blk blk blk l390 o231 2 15a rr fog blk yel/grn yel/grn yel/blk off on 5 4 "c-1" yg yg g144 3 g272 10 4 j/b g343 l376 4 36 l133 l134 b a a b switch (comb switch) rhd lhd a b i6rw0d910922-03.

  • Page 1375

    Wiring systems: 9a-152 d-10 rear fog light circuit diagram (sedan) s7rw0a910e067 19 21 15a rr fog blk yel/grn yel/grn yel/blk off on 5 6 "c-1" yg yg g144 3 g272 10 4 j/b g343 l376 4 36 l133 l134 b a a b switch (comb switch) rhd lhd a b i7rw0a910991-01.

  • Page 1376

    9a-153 wiring systems: e-1 heater system circuit diagram s7rw0a910e048 brn grn/wht 10a back 21 m blk/red j/b j/b blk/orn g309 j/c g62 air intake control actuator 6 1 4 grn red 9 g154 7 8 g306 j/c 4 g272 bcm "a-8" gw bcm "b-3" gy grn/yel 8 red/yel red/yel red/blk red/blk red/blk 10 13 14 5 6 rear def...

  • Page 1377

    Wiring systems: 9a-154 red m blu/wht yel blk/wht blk/wht blu/wht blu/wht blk/wht g155 5 brn j/b blk/yel 2 1 g61 11 g65 blower motor controller 4 2 1 3 blower motor g273 6 1 3 2 7 6 fan blower speed selector 4 2 5 1 3 30a blw 6 10a 35 ig2 sig blower motor relay e323 7 g272 9 g309 j/c 11 14 b b blk bl...

  • Page 1378

    9a-155 wiring systems: e-2 auto a/c system circuit diagram s7rw0a910e049 except taiwan taiwan except m16a engine m/t m16a engine m/t a b c d g20 5 23 6 blk blk blk blk blk/orn red/yel 26 blk/red red/yel g271 ill auto a/c panel 13 yel "a-8" y "b-3" br 3 7 blu wht/red wht/red blu wht/red blk/orn blk/y...

  • Page 1379

    Wiring systems: 9a-156 g32 1 3 24 9 29 g20 10 25 g64 m 16 2 15 28 12 1 27 3 1 m 2 g65 blk/wht gry/blu gry/red wht brn/wht wht/blk orn pnk wht yel wht wht/blu brn/yel orn orn orn blk/yel blk blk/yel blk/yel blu blk/wht gry 30 4 blu/red blk/wht blk blower motor controller diode #1 blower motor evapora...

  • Page 1380

    9a-157 wiring systems: f-1 air-bag system circuit diagram (4ch) s7rw0a910e050 2 orn y a/b sdm l04 j/b 15a a/b 27 red l313 bcm 15 blk 1 15a dome 37 wht/red g271 5 e388 l372 1 g349 l399 2 pnk/blk e40 forward sensor 1 2 contact coil g347 s172 l377 g344 2 l399 g349 1 1 l283 1 2 s121 yel/red grn 1 2 2 1 ...

  • Page 1381

    Wiring systems: 9a-158 f-1 air-bag system circuit diagram (8ch) s7rw0a910e051 y a/b sdm l04 j/b 15a a/b 27 red wht/red l313 bcm 15 blk 1 15a dome 37 g271 5 2 28 32 27 37 "a-8" yel yel g349 l399 j/c g308 b b l399 g349 1 5 4 11 14 e382 g334 19 c343 e371 8 blk/orn wht/red blk/orn blk/orn 7 blu ppl/wht ...

  • Page 1382

    9a-159 wiring systems: q103 q102 1 2 21 22 20 19 blk/yel brn/yel yel/grn yel/blu blk/yel brn/yel yel/grn yel/blu 1 2 l395 q132 1 2 2 45 44 46 47 side-sensor side-sensor lt grn wht/grn wht/red lt grn/blk 1 2 orn yb e388 l372 1 pnk/blk e40 forward sensor hatchback sedan check terminal 1 2 2 50 51 orn ...

  • Page 1383

    Wiring systems: 9a-160 f-2 anti-lock brake system circuit diagram s7rw0a910e052 23 26 24 25 7 2 13 e08 blk 30a abs sol 40a abs mot 11 wht/red wht/blu grn/wht 8 blk r red w wht red wht red wht "a-8" "a-5" j/b 10a abs 28 e325 9 grn/orn 9 l315 l33 8 3 2 grn/yel grn/orn 6 gw "d-7" brake light switch ind...

  • Page 1384

    9a-161 wiring systems: a yel abs cont.M l32 lt grn/blk lt grn lt grn/blk lt grn l371 e387 2 8 wheel speed sensor (rl) brn yel brn 7 1 l31 wheel speed sensor (rr) wht/blk e33 wheel speed sensor (fr) wht red e35 wheel speed sensor (fl) red/blk 18 17 11 22 19 20 21 10 e08 1 2 1 2 1 2 1 2 16 dlc e382 g3...

  • Page 1385

    Wiring systems: 9a-162 f-3 electronic stability program system circuit diagram s7rw0a910e063 23 26 24 25 2 13 e08 blk 30a abs sol 40a abs mot 11 wht/red wht/blu grn/orn red wht red wht blk red red wht red wht red wht wht/red wht/red wht 10a ig1 sig 26 g272 16 l315 8 8 11 blk/orn grn/orn 7 "d-7" brak...

  • Page 1386

    9a-163 wiring systems: yel l32 lt grn/blk lt grn lt grn/blk lt grn l371 e387 2 8 wheel speed sensor (rl) brn yel brn 7 1 l31 wheel speed sensor (rr) wht/blk e33 wheel speed sensor (fr) wht red e35 wheel speed sensor (fl) red/blk 18 17 11 22 19 20 21 10 e08 1 2 1 2 1 2 1 2 16 dlc e382 g334 5 blu blu ...

  • Page 1387

    Wiring systems: 9a-164 f-4 power steering system circuit diagram s7rw0a910e053 p/s cont.M 60a p/s 12 e325 12 j/b 10a ig1 sig 26 red 20 e377 e378 torque sensor blk e13 10 grn lt grn/blk wht 10 grn 8 yel 18 blk 9 19 1 2 1 e11 ppl ppl 4 lt grn/blk 1 e377 e378 4 ppl g333 e381 e31 e13 e11 e11 individual ...

  • Page 1388

    9a-165 wiring systems: b p/s cont.M 3 e377 e378 e61 m red blk e12 ecm "a-5" brn 1 2 11 12 brn 6 e11 red/blu 5 rb 14 red/blu g211 dlc 4 blk blk b b j/c motor g309 blu blu e382 g334 19 e382 g334 12 e371 c343 8 blk/orn 5 j/b 15a dome 37 g271 5 wht/red blk/orn 7 16 b b j/c g308 blk/orn 11 14 wht/red blk...

  • Page 1389

    Wiring systems: 9a-166 g-1 audio system circuit diagram s7rw0a910e054 g271 5 5 4 11 2 1 2 1 5 15 6 16 "d-4" ry wht/red wht/red g248 1 g307 j/b 15a dome 37 j/c blu/wht blu/wht red/yel 15a acc2 24 rear (r) j/c rear (l) gry/red gry lt grn/blk lt grn gry/red gry lt grn/blk lt grn gry/red gry lt grn/blk ...

  • Page 1390

    9a-167 wiring systems: k121 1 2 10 2 10 2 2 1 1 2 2 1 1 2 11 g248 g248 blk tweeter (l) front (l) j142 j148 tweeter (r) front (r) j141 j147 blk yel blk audio g306 j/c ill cancel switch a a c c g306 j/c c c steering switch (audio control switch) 19 g267 10 1 20 blk grn wht/grn blk blu pnk blu pnk blu ...

  • Page 1391

    Wiring systems: 9a-168 g-2 multi information display / accessory socket system circuit diagram s7rw0a910e055 11 15a acc 2 24 j/c g307 g y multi information display j/b bcm 13 blk/orn 2 blk/orn 15a dome 37 15a acc 23 5 wht/red gry yel blu/wht g253 1 4 3 wht/red yel red/yel 7 g309 j/c j/b 5 g272 g271 ...

  • Page 1392

    9a-169 wiring systems: g-4 navigation system circuit diagram s7rw0a910e056 g271 5 5 4 11 2 1 2 1 5 15 6 16 "d-4" ry wht/red wht/red g248 g248 1 g307 j/b 15a dome 37 j/c blu/wht blu/wht red/yel 15a acc2 24 rear (r) j/c rear (l) gry/red gry lt grn/blk lt grn gry/red gry lt grn/blk lt grn gry/red gry l...

  • Page 1393

    Wiring systems: 9a-170 k121 l307 1 2 10 2 10 2 2 1 1 2 2 1 1 2 11 g248 g248 blk tweeter (l) front (l) j142 j148 tweeter (r) front (r) j141 j147 blk blk navigation g306 j/c a a c c g306 j/c c c steering switch (audio control switch) 19 g267 10 2 20 blk grn wht/grn blk blu pnk blu pnk blu pnk blu blk ...

  • Page 1394

    9a-171 wiring systems: list of connector list of connectors s7rw0a910f001 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 “m connector (sedan)”. Refer to “o connector (hatchback)”. Refer to “q co...

  • Page 1395

    Wiring systems: 9a-172 e connector s7rw0a910f003 c91 c92 c93 c94 c101 c101 m15a engine, m16a engine j20a engine c102 c102 c103 c104 c122 c123 m15a engine, m16a engine j20a engine j20a engine j20a engine if eqpd m15a engine, m16a engine c123 c124 c139 c139 c141 c162 j20a engine if eqpd m15a engine a/...

  • Page 1396

    9a-173 wiring systems: e13 e31 e33 e35 e36 e37 e40 e61 e62 e63 e64 e65 m16a engine e65 e68 e69 e70 e151 e152 j20a engine if eqpd if eqpd e159 e160 e161 e162 e163 e164 e165 e166 e181 e183 e191 e192 e221 e222 e223 e224 e225 j20a engine j20a engine j20a engine e226 e227 e229 e230 e231 e232 a/t if eqpd ...

  • Page 1397

    Wiring systems: 9a-174 g connector s7rw0a910f004 e371 (to c343) e377 (to e378) e378 (to e377) e381 (to g333) e382 (to g334) e387 (to l371) e388 (to l372) g04 g04 except taiwan taiwan g05 g06 taiwan taiwan g14 g16 if eqpd if eqpd g17 g20 auto a/c g26 g32 g33 if eqpd if eqpd g34 g35 g61 g62 g63 g64 au...

  • Page 1398

    9a-175 wiring systems: g65 g65 g141 g144 auto a/c manual a/c g146 g147 g150 g151 g152 g153 if eqpd if eqpd g154 g155 g211 g214 manual a/c manual a/c if eqpd g241 g243 g248 if eqpd g251 g253 g254 g255 g259 if eqpd auto a/c g265 g266 g267 g267 g271 taiwan if eqpd with navigation without navigation g27...

  • Page 1399

    Wiring systems: 9a-176 j connector s7rw0a910f005 g310 g311 g333 (to e381) auto a/c g334 (to e382) g335 (to e383) g341 (to l374) if eqpd g342 (to l375) g343 (to l376) g344 (to l377) g345 (to l378) g346 (to s171) if eqpd with auto cruise g346 (to s171) g347 (to s172) g347 (to s172) g348 (to k153) g349...

  • Page 1400

    9a-177 wiring systems: k connector s7rw0a910f006 l connector s7rw0a910f007 j146 j147 j148 j151 j152 j153 if eqpd if eqpd if eqpd if eqpd if eqpd j154 j215 (l379) j216 (l380) j217 (to l381) j218 (to l382) if eqpd k51 k52 k121 k121 k152 (to l383) k152 (to l383) hatchback sedan hatchback sedan k153 (to...

  • Page 1401

    Wiring systems: 9a-178 l31 l32 l33 l34 l35 l36 if eqpd if eqpd 8ch 8ch l37 l40 l101 l102 l132 if eqpd if eqpd if eqpd hatchback l133 l133 l134 l134 l139 l141 hatchback sedan hatchback sedan sedan sedan l161 l162 l163 l164 l167 l169 if eqpd l170 l171 l172 l173 l174 l233 if eqpd if eqpd sedan if eqpd ...

  • Page 1402

    9a-179 wiring systems: l346 l347 l348 l371 (to e387) l372 (to e388) l374 (to g341) l375 (to g342) l376 (to g343) l377 (to g344) l378 (to g345) l379 (j215) if eqpd l380 (j216) l381 (to j217) l382 (to j218) l383 (to k152) l383 (to k152) l384 (to q133) hatchback sedan 8ch a a b b c c d d e e f f ( ) mc...

  • Page 1403

    Wiring systems: 9a-180 m connector (sedan) s7rw0a910f012 o connector (hatchback) s7rw0a910f008 l385 (to q134) l389 (to r151) l390 (to o231) l391 (to o232) l393 (to o233) l394 (to m152) 8ch hatchback hatchback if eqpd hatchback sedan l395 (to q132) l397 (to l408) l399 (to g349) l402 (to g352) l408 (t...

  • Page 1404

    9a-181 wiring systems: q connector (8ch) s7rw0a910f009 r connector s7rw0a910f010 s connector s7rw0a910f011 q102 q103 q104 q105 q132 (to l395) q133 (to l384) hatchback hatchback q134 (to l385) r101 r151 (l389) s61 s61 s121 s121 s171 (to g346) with auto cruise without auto cruise with auto cruise with...

  • Page 1405: Lighting Systems

    Lighting systems: 9b-1 body, cab and accessories lighting systems precautions precautions for discharge headlight service (if equipped) s7rw0a9200001 warning ! • do not touch igniter or ballast when lighting switch is at “head” position to avoid possible electric shock. • do not measure voltage or r...

  • Page 1406

    9b-2 lighting systems: igniter igniter generates high voltage needed to turn on the discharge headlight. It is charged with high voltage raised by the ballast and it applies voltage pulse as high as about 20,000 v to the tungsten electrode in the discharge headlight bulb. After the discharge headlig...

  • Page 1407

    Lighting systems: 9b-3 with more passenger(s) or luggage in the vehicle, the vehicle position differs from that in such vehicle state with one person and no load in the vehicle and angle of the headlight optical axis varies accordingly. This system automatically adjusts the varied angle to maintain ...

  • Page 1408

    9b-4 lighting systems: headlight leveling actuator headlight leveling actuator is (1) located in the headlight housing (2). It moves the reflector (3) in the headlight housing according to the drive signal from the headlight leveling control module so as to adjust the optical axis of the headlight t...

  • Page 1409

    Lighting systems: 9b-5 schematic and routing diagram headlight auto leveling system wiring circuit diagram s7rw0a9202001 component location lighting system components location s7rw0a9203001 note below figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are instal...

  • Page 1410

    9b-6 lighting systems: 11 10 10 11 9 [d] 25* 30 21 27* 26* 29 31* 20* 1 3 4 2 4 [a] [b] 8 1 3 2 7 5 6 12 13 22 28* 15 16 [a] 17 18 19 15 16 17 18 [c] 14 23* 24* i7rw0a920001-03.

  • Page 1411

    Lighting systems: 9b-7 interior light system location s7rw0a9203002 diagnostic information and procedures self-diagnosis function for headlight auto leveling system s7rw0a9204001 the headlight leveling control module has self-diagnosis function to monitor the system components and circuits while the...

  • Page 1412

    9b-8 lighting systems: headlight leveling warning light check s7rw0a9204002 1) turn ignition switch to on position. 2) check that headlight leveling warning light (1) lights for about 2 seconds and then goes off. If the headlight leveling warning light lights up again 10 seconds after it turned off,...

  • Page 1413

    Lighting systems: 9b-9 headlight symptom diagnosis (other than discharge headlight model) s7rw0a9204004 auto-on headlight system symptom diagnosis (if equipped) s7rw0a9204005 condition possible cause correction / reference item only one low beam does not light up circuit fuse blown replace fuse and ...

  • Page 1414

    9b-10 lighting systems: drl system symptom diagnosis (if equipped) s7rw0a9204006 headlight auto leveling system symptom diagnosis (if equipped) s7rw0a9204007 headlight manual leveling system symptom diagnosis (if equipped) s7rw0a9204008 condition possible cause correction / reference item headlight ...

  • Page 1415

    Lighting systems: 9b-11 turn signal and hazard warning light symptom diagnosis s7rw0a9204009 clearance, tail and license plate light symptom diagnosis s7rw0a9204010 condition possible cause correction / reference item flash rate high or one side only flashes bulb blown on “flash rate high”-side repl...

  • Page 1416

    9b-12 lighting systems: back-up light symptom diagnosis s7rw0a9204011 brake light symptom diagnosis s7rw0a9204012 front fog light symptom diagnosis (if equipped) s7rw0a9204013 rear fog light symptom diagnosis (if equipped) s7rw0a9204014 condition possible cause correction / reference item back-up li...

  • Page 1417

    Lighting systems: 9b-13 illumination cancel system symptom diagnosis (if equipped) s7rw0a9204015 interior light symptom diagnosis s7rw0a9204016 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer t...

  • Page 1418

    9b-14 lighting systems: inspection of drl controller and its circuits (if equipped) s7rw0a9204018 1) confirm that lighting switch is in good condition referring to “headlight switch (in lighting switch) inspection”. 2) confirm that oil pressure switch is in good condition referring to “oil pressure ...

  • Page 1419

    Lighting systems: 9b-15 auto-on headlight operation inspection (if equipped) s7rw0a9204019 1) turn ignition switch to on position and then turn lighting switch to “auto” position. 2) check headlights for operation as follows. If headlights do not turn on or off, go to “inspection of auto-on headligh...

  • Page 1420

    9b-16 lighting systems: inspection of headlight leveling control module and its circuit (headlight auto leveling system) s7rw0a9204021 headlight auto leveling control module and its circuits can be checked at headlight auto leveling control module wiring couplers by measuring voltage and pulse signa...

  • Page 1421

    Lighting systems: 9b-17 terminal circuit specification condition 1 power source 10 – 14 v ignition switch is at on position. 2 — — — 3 lighting switch less than 1.5 v lighting switch is at “head” position. 10 – 14 v lighting switch is at off position. 4 — — — 5 diagnosis switch terminal about 5 v ig...

  • Page 1422

    9b-18 lighting systems: reference waveform no.1 vehicle speed signal (1). Vehicle speed signal is pulse. Pulse frequency varies depending on vehicle speed. Repair instructions headlight housing removal and installation s7rw0a9206001 warning ! • to avoid danger of being burned, don’t touch when the b...

  • Page 1423

    Lighting systems: 9b-19 headlight bulb replacement (discharge headlight model) s7rw0a9206002 warning ! • to avoid danger of being burned, don’t touch when the bulb is hot. • don’t touch glass surface of bulb, to avoid deteriorate as the case may be unclear when bulb light on at dirty condition. • be...

  • Page 1424

    9b-20 lighting systems: igniter removal and installation (discharge headlight model) s7rw0a9206004 warning ! Be sure to read “precautions for discharge headlight service (if equipped)” carefully before working. Neglecting them may result in personal injury. Removal 1) remove ballast referring to “ba...

  • Page 1425

    Lighting systems: 9b-21 1 “h” “b” “a” 2 10 [g] [f] [e] 7 8 9 6 7 5 10 11 8 9 7 6 5 a a 4 3 b b a a 4 b b “h” “h” “h” “h” [c] [d] a a 4 b b [a] [b] “h” “h” x x x x x x a a 4 b b [a] [b] “h” “h” [i] [h] [i] [h] 3 3 3 3 3 3 3 x x [a] [b] [a] [b] 6 5 8 9 i6rw0c920018-02 2. Headlight bulb 10. Headlight h...

  • Page 1426

    9b-22 lighting systems: headlight switch (in lighting switch) removal and installation s7rw0a9206006 removal 1) disconnect negative (–) cable at battery. 2) remove steering column hole cover (3). 3) remove steering column covers (1). Turn steering wheel to access steering column cover screws (2). 4)...

  • Page 1427

    Lighting systems: 9b-23 with auto-on headlight switch hazard warning switch removal and installation s7rw0a9206008 removal 1) disconnect negative (–) cable at battery. 2) remove center ventilation louver (1) referring to “center ventilation louver removal and installation in section 7a”. 3) disconne...

  • Page 1428

    9b-24 lighting systems: turn signal light switch (in lighting switch) removal and installation s7rw0a9206011 for removal and installation, refer to “headlight switch (in lighting switch) removal and installation”. Turn signal light switch (in lighting switch) inspection s7rw0a9206012 check for conti...

  • Page 1429

    Lighting systems: 9b-25 turn signal and hazard warning relay inspection s7rw0a9206014 1) connect turn signal and hazard warning relay (1), battery (2) and six test bulbs ((12 v, 21 w) (3) and 12 v, 5 w (4)) as shown. 2) check turn l circuit connect terminal “5” and battery negative (–) terminal by a...

  • Page 1430

    9b-26 lighting systems: license light removal and installation (sedan) s7rw0a9206029 removal 1) remove trunk lid trim (1) from trunk lid panel. 2) remove trunk lid license garnish referring to “trunk lid lock assembly components (sedan model) in section 9f” 3) disconnect coupler from license light s...

  • Page 1431

    Lighting systems: 9b-27 front fog light switch inspection (if equipped) s7rw0a9206017 note front fog lights light up only when headlight switch is in headlight position (low or high beams) or small position. Front fog lights turn off automatically when headlight switch is turned to off position. If ...

  • Page 1432

    9b-28 lighting systems: 3) if it is not set properly, align front fog light to specification by rotating aiming gear. Rear fog light switch inspection (if equipped) s7rw0a9206019 note • rear fog light switch can be turned to on position only when headlight switch is turned to headlight position (low...

  • Page 1433

    Lighting systems: 9b-29 headlight manual levering switch inspection (if equipped) s7rw0a9206020 check for resistance between terminals at each switch position. If check result is not as specified, replace switch. Headlight leveling actuator inspection (if equipped) s7rw0a9206021 headlight auto level...

  • Page 1434

    9b-30 lighting systems: height sensor removal and installation (if equipped) s7rw0a9206022 removal caution ! • do not remove bracket (4) and link (3) from height sensor (2). Removal will spoil its original function. If faulty condition is found, replace it with new one in a set. • if height sensor w...

  • Page 1435

    Lighting systems: 9b-31 height sensor and its circuit inspection (if equipped) s7rw0a9206023 1) remove front or rear height sensor from vehicle referring to “height sensor removal and installation (if equipped)”. 2) connect connector to height sensor. 3) vary position of height sensor link (1) and m...

  • Page 1436

    9b-32 lighting systems: without initialization of the headlight auto leveling system, it is not possible to obtain its proper function. Also, if the headlight auto leveling system is not initialized after replacing the headlight leveling control module, the headlight leveling warning light in the co...

  • Page 1437

    Lighting systems: 9b-33 illumination cancel switch inspection (if equipped) s7rw0a9206027 check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Tail light relay, headlight relay, front fog light relay inspection (if equipped) s7rw0a92060...

  • Page 1438

    9b-34 lighting systems: specifications tightening torque specifications s7rw0a9207001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. Fastening part tightening torque note n ⋅m kgf-m lb-ft height sensor bolt 5.5 0.6 4.0 ...

  • Page 1439

    Instrumentation / driver info. / horn: 9c-1 body, cab and accessories instrumentation / driver info. / horn precautions precautions in diagnosing troubles for combination meter s7rw0a9300001 combination meter uses signals (information) from each control module by can communication to control speedom...

  • Page 1440

    9c-2 instrumentation / driver info. / horn: combination meter reception data note *: esp ® model ecm bcm keyless start control module (if equipped) combination meter 4wd control module (if equipped) tcm (a/t model) engine speed signal immobilizer indicator light control signal vehicle speed signal e...

  • Page 1441

    Instrumentation / driver info. / horn: 9c-3 auto volume control system description (if equipped) s7rw0a9301002 function of auto volume control system is to vary sound volume according to changes of vehicle speed. How much sound volume varies depends on selected level. Reference correlation chart of ...

  • Page 1442

    9c-4 instrumentation / driver info. / horn: schematic and routing diagram combination meter circuit diagram s7rw0a9302001 7 6 5 4 g241-9 9 g241-5 1 2 11 g241-13 23 g241-31 g241-26 3 g241-16 g241-22 12 g241-25 13 g241-1 3 8 17 15 14 20 g241-32 g241-6 9 16 18 19 g241-21 21 g241-7 g241-10 10 24 24 10 g...

  • Page 1443

    Instrumentation / driver info. / horn: 9c-5 terminal arrangement of coupler viewed from terminal side note molded numbers (1) have no relation to the terminal numbers. Terminal circuit terminal circuit g241-1 to turn signal light switch (turn r) g241-17 — g241-2 — g241-18 — g241-3 — g241-19 to headl...

  • Page 1444

    9c-6 instrumentation / driver info. / horn: component location audio system component location s7rw0a9303001 11 10 3 2 3 2 1 4 8 8 9 9 6 5 7 (a) i7rw0a930003-02 1. Radio or navigation assembly 4. Antenna feeder 7. Gps antenna (if equipped) 10. Glass antenna (sedan) 2. Front speaker 5. Antenna (hatch...

  • Page 1445

    Instrumentation / driver info. / horn: 9c-7 diagnostic information and procedures speedometer and vss symptom diagnosis s7rw0a9304001 tachometer symptom diagnosis s7rw0a9304002 engine coolant temperature (ect) meter symptom diagnosis s7rw0a9304003 fuel meter symptom diagnosis s7rw0a9304004 condition...

  • Page 1446

    9c-8 instrumentation / driver info. / horn: low fuel warning light symptom diagnosis s7rw0a9304005 note • confirm that fuel meter is in good condition before referring to the following possible causes. • when fuel level sensor circuit is open or short, fuel level meter indicates empty even if fuel t...

  • Page 1447

    Instrumentation / driver info. / horn: 9c-9 brake and parking brake warning light symptom diagnosis s7rw0a9304007 seat belt reminder light symptom diagnosis s7rw0a9304008 a/t shift position indicator symptom diagnosis (a/t model) s7rw0a9304009 condition possible cause correction / reference item bra...

  • Page 1448

    9c-10 instrumentation / driver info. / horn: charge warning light symptom diagnosis s7rw0a9304010 main beam (high beam) indicator symptom diagnosis s7rw0a9304011 warning buzzer circuit symptom diagnosis s7rw0a9304012 note • use of suzuki scan tool makes it easy to check whether a faulty condition is...

  • Page 1449

    Instrumentation / driver info. / horn: 9c-11 cigarette lighter symptom diagnosis (if equipped) s7rw0a9304013 horn symptom diagnosis s7rw0a9304014 information display symptom diagnosis (if equipped) s7rw0a9304015 note this thermometer indicates the ambient temperature in the under side of front bumpe...

  • Page 1450

    9c-12 instrumentation / driver info. / horn: clock system diagnosis (if equipped) s7rw0a9304016 display of thermometer does not change at 50 ° c (122 ° f) outside air temperature is 50 °c (122 °f) or more — outside air temperature sensor faulty check outside air temperature sensor referring to “outs...

  • Page 1451

    Instrumentation / driver info. / horn: 9c-13 audio system symptom diagnosis (if equipped) s7rw0a9304017 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 1452

    9c-14 instrumentation / driver info. / horn: auto volume control system remote audio control switch symptom diagnosis (if equipped) s7rw0a9304018 navigation symptom diagnosis (if equipped) s7rw0a9304019 cd player is operative, but all speakers does not sound wiring or grounding faulty repair circuit...

  • Page 1453

    Instrumentation / driver info. / horn: 9c-15 repair instructions ignition switch removal and installation s7rw0a9306001 removal 1) disconnect negative cable at battery. 2) confirm that ignition key is removed. 3) remove dash side trim (4) and steering column hole cover (1). 4) turn steering wheel to...

  • Page 1454

    9c-16 instrumentation / driver info. / horn: 3) remove center ventilation louver referring to step 1) and 2) of “information display (clock) removal and installation”. 4) remove combination meter cluster panel (1) pulling it in arrow direction shown in figure. 5) remove screws (1) fastening combinat...

  • Page 1455

    Instrumentation / driver info. / horn: 9c-17 engine coolant temperature (ect) sensor inspection s7rw0a9306008 check engine coolant temperature sensor for resistance, refer to “engine coolant temperature (ect) sensor inspection in section 1c”. Brake fluid level switch inspection s7rw0a9306009 check f...

  • Page 1456

    9c-18 instrumentation / driver info. / horn: trunk lid switch inspection (sedan) s7rw0a9306028 check for continuity between trunk lid connector terminal (1) and body ground. If check result is not as specified, replace switch. Trunk lid switch specification trunk lid switch (2) is pushed: no continu...

  • Page 1457

    Instrumentation / driver info. / horn: 9c-19 6) remove glove box (1). 7) remove hood latch release lever (2). 8) remove console box referring to “console box components in section 9h”. 9) remove instrument panel center lower bracket bolts (1). 10) remove front pillar trims (1). 11) disconnect instru...

  • Page 1458

    9c-20 instrumentation / driver info. / horn: information display (clock) removal and installation s7rw0a9306016 removal 1) remove audio unit referring to “audio unit removal and installation (if equipped)”. 2) remove center ventilation louver (1) from instrument panel and then disconnect hazard swit...

  • Page 1459

    Instrumentation / driver info. / horn: 9c-21 rear speaker removal and installation (if equipped) s7rw0a9306019 removal 1) remove rear door trim referring to step 1) to 3) of “rear door glass removal and installation in section 9e”. 2) remove 3 rear speaker mounting screws (1). 3) remove rear speaker...

  • Page 1460

    9c-22 instrumentation / driver info. / horn: horn relay inspection s7rw0a9306023 1) disconnect negative (–) cable at battery. 2) remove junction block. 3) remove horn relay (1) from junction block (2). 4) check that there is no continuity between terminals “c” and “d”. If there is continuity, replac...

  • Page 1461

    Instrumentation / driver info. / horn: 9c-23 remote audio control switch inspection (if equipped) s7rw0a9306026 1) remove driver air bag (inflator) module referring to “driver air bag (inflator) module removal and installation in section 8b”. 2) disconnect remote audio control switch connector from ...

  • Page 1462: Wipers / Washers

    9d-1 wipers / washers: body, cab and accessories wipers / washers diagnostic information and procedures front wiper and washer symptom diagnosis s7rw0a9404001 rear wiper and washer symptom diagnosis s7rw0a9404002 condition possible cause correction / reference item wiper malfunctions circuit fuse bl...

  • Page 1463

    Wipers / washers: 9d-2 repair instructions wipers and washers components s7rw0a9406001 11 5 6 (b) (a) 1 1 (b) 2 13 14 14 [a] 14 12 15 (c) (b) (a) 3 2 4 7 10 10 10 11 11 8 16 9 16 i7rw01940001-03 1. Windshield wiper blade 8. Washer pump for rear washer 15. Windshield wiper bolt :tighten bolts in spec...

  • Page 1464

    9d-3 wipers / washers: washer tank and washer pump removal and installation s7rw0a9406002 removal 1) disconnect negative (–) cable at battery. 2) remove front bumper referring to “front bumper and rear bumper components in section 9k”. 3) disconnect washer pump lead wire couplers and hoses. 4) remov...

  • Page 1465

    Wipers / washers: 9d-4 installation 1) install windshield wiper assembly (1), and tighten bolts to specified torque in order of “i”, “ii” and “iii” indicated in figure. Tightening torque windshield wiper bolt (a): 8 n·m (0.8 kgf-m, 6.0 lb-ft) 2) connect coupler to windshield wiper motor. 3) install ...

  • Page 1466

    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 63 – 77 r/min (rpm) • fo...

  • Page 1467

    Wipers / washers: 9d-6 rear wiper removal and installation s7rw0a9406006 removal 1) disconnect negative (–) cable at battery. 2) remove arm cover (1), rear wiper arm nut (2), rear wiper arm with blade assembly (3), rear wiper pivot cap (4), rear wiper nut (5) and rear wiper seal (6). 3) remove rear ...

  • Page 1468

    9d-7 wipers / washers: rear wiper motor inspection s7rw0a9406007 note make sure that battery voltage is 12 v or more. 1) make a mark (1) on rear wiper motor (2) stop position as shown. 2) check rear wiper motor for operation as follows. • for motor operation a. Connect battery positive terminal to t...

  • Page 1469

    Wipers / washers: 9d-8 windshield wiper and washer switch removal and installation s7rw0a9406008 removal 1) disconnect negative (–) cable at battery. 2) remove steering column hole cover (1). 3) remove steering column covers (2). Turn steering wheel to access steering column cover rear end screws (3...

  • Page 1470

    9d-9 wipers / washers: 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 1471

    Wipers / washers: 9d-10 rear wiper and washer switch removal and installation s7rw0a9406010 for removal and installation, refer to “windshield wiper and washer switch removal and installation”. Rear wiper and washer switch inspection s7rw0a9406011 check for continuity between terminals at each switc...

  • Page 1472

    9d-11 wipers / washers: specifications tightening torque specifications s7rw0a9407001 note the specified tightening torque is also described in the following. “wipers and washers components” reference: for the tightening torque of fastener not specified in this section, refer to “fasteners informati...

  • Page 1473: Glass / Windows / Mirrors

    Glass / windows / mirrors: 9e-1 body, cab and accessories glass / windows / mirrors precautions precautions for power window service (pinching prevention function model) s7rw0a9500001 warning ! When checking the pinching prevention function, never attempt intentionally to have your hand, arm or any ...

  • Page 1474

    9e-2 glass / windows / mirrors: schematic and routing diagram power window circuit diagram (pinching prevention function model) s7rw0a9502001 6 5 [c] [d] ds b ig e sg sv sb sa dru drd sg sv sb sa dru drd asu, rru or rlu asd, rrd or rld [c] [c] d u [c] [d] su sb b [c] [d] [e] [e] e sg sv sb sa dru dr...

  • Page 1475

    Glass / windows / mirrors: 9e-3 diagnostic information and procedures rear end door window / back window defogger symptom diagnosis s7rw0a9504001 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer...

  • Page 1476

    9e-4 glass / windows / mirrors: inspection of pinching prevention function (pinching prevention function model) s7rw0a9504004 1) open driver side door glass fully. 2) hold a hummer so that its handle (wooden) (1) is placed as shown. Warning ! Never attempt to have your hand, arm or any other part of...

  • Page 1477

    Glass / windows / mirrors: 9e-5 door mirror heater symptom diagnosis (if equipped) s7rw0a9504005 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of suzu...

  • Page 1478

    9e-6 glass / windows / mirrors: windshield removal and installation s7rw0a9506002 preparation the windshield is installed by using a special type of adhesive (that is, one component urethane adhesive used with primer). For the windshield replacement, it is important to use an adhesive which provides...

  • Page 1479

    Glass / windows / mirrors: 9e-7 9) cut adhesive all around windshield (1) with piano string (2). When using tool, windshield knife (3), to cut adhesive, be careful not to cause damage to windshield. Use wire to cut adhesive along lower part of windshield. Note use piano string (2) as close to glass ...

  • Page 1480

    9e-8 glass / windows / mirrors: 4) clean contact surfaces of old adhesive (4), paint or bare metal thoroughly. If surfaces of paint or bare metal come out, apply primer (2) for body with caution not to apply primer (2) to surface of adhesive remaining on body. Note • be sure to refer to primer maker...

  • Page 1481

    Glass / windows / mirrors: 9e-9 adhesive amount specifications and position for windshield width “a”: approx. 7 mm (0.27 in.) height “b”: approx. 15 mm (0.59 in.) position “c”: approx. 10 mm (0.39 in.) for right, left and upper sections position “d”: approx. 50 mm (1.97 in.) for bottom section 11) h...

  • Page 1482

    9e-10 glass / windows / mirrors: front pillar window components s7rw0a9506003 front pillar window removal and installation s7rw0a9506004 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. However, note the following. • observe t...

  • Page 1483

    Glass / windows / mirrors: 9e-11 rear quarter window components (hatchback model) s7rw0a9506005 rear quarter window removal and installation (hatchback model) s7rw0a9506006 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. Howe...

  • Page 1484

    9e-12 glass / windows / mirrors: rear end door window components (hatchback model) s7rw0a9506007 rear end door glass removal and installation (hatchback model) s7rw0a9506008 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. How...

  • Page 1485

    Glass / windows / mirrors: 9e-13 back window components (sedan model) s7rw0a9506029 back window removal and installation (sedan model) s7rw0a9506030 refer to “windshield removal and installation” as preparation, removal and installation procedures are basically the same. However, note the following....

  • Page 1486

    9e-14 glass / windows / mirrors: front door window components s7rw0a9506009 2 8 11 4 1 7 3 6 9 10 12 5 i7rw01950002-01 1. Door glass 7. Front door sash 2. Window regulator assembly : apply lithium grease 99000-25011 to sliding part. 8. Door glass mounting screw : tighten rear screw first, and then t...

  • Page 1487

    Glass / windows / mirrors: 9e-15 front door glass removal and installation s7rw0a9506010 note (for pinching prevention function model) after disconnecting the power window main switch, make sure to execute to the initial setting, (to have the door glass closed position learned) refer to “power windo...

  • Page 1488

    9e-16 glass / windows / mirrors: • secure door sealing cover (1) with adhesive (2). • install front door trim. Front door trim attaching order (1) → (2) → (3) → (4) → (5) → (6) → (7) → (8) front door window regulator removal and installation s7rw0a9506011 note (for pinching prevention function model...

  • Page 1489

    Glass / windows / mirrors: 9e-17 rear door window components s7rw0a9506013 2 8 12 4 6 3 13 10 11 9 7 5 1 1 3 4 5 6 7 9 10 12 14 15 [a] [b] b a c 2 8 i8rw01950001-02 1. Door glass 10. Rear door inner weather-strip 2. Window regulator assembly : apply lithium grease 99000-25011 to sliding part. 11. Re...

  • Page 1490

    9e-18 glass / windows / mirrors: rear door glass removal and installation s7rw0a9506014 removal 1) remove rear door inner garnish (1) (hatchback model). 2) remove door trim mounting screws (2). 3) remove door trim (1) as shown. 4) remove door outer garnish (1) (hatchback model). 5) remove door outer...

  • Page 1491

    Glass / windows / mirrors: 9e-19 11) remove door glass as shown. Installation reverse removal procedure noting the following instructions. • tighten door sash mounting bolts and screw (“1” – “3”) according to numerical order as shown in figure. • if there is deformity for glass run, replace it with ...

  • Page 1492

    9e-20 glass / windows / mirrors: installation reverse removal procedure noting the following. • apply grease to sliding and rotating portions of window regulator. : grease 99000–25011 (suzuki super grease a) • tighten rear door window regulator attaching screws. Rear door window regulator screw tigh...

  • Page 1493

    Glass / windows / mirrors: 9e-21 4) check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay. 5) check that there is continuity between terminals “c” and “d” when a 12 v battery is connected to terminals “a” and “b”. If malfunction is found, replace it wi...

  • Page 1494

    9e-22 glass / windows / mirrors: 4) touch voltmeter negative (–) lead to defogger wire ground terminal end (1). 5) touch voltmeter positive (+) lead with a foil strip to defogger wire power source terminal end (2), then move it along wire to defogger wire ground terminal end (1). For hatchback model...

  • Page 1495

    Glass / windows / mirrors: 9e-23 with pinching prevention function model note after replacing or disconnecting the power window main switch, make sure to execute to the initial setting, (to have the door glass closed position learned) refer to “power window main switch initialization (pinching preve...

  • Page 1496

    9e-24 glass / windows / mirrors: switch for other window than driver side 1) remove driver side door trim referring to step 1) to 4) of “front door glass removal and installation”. 2) remove power window main switch from door trim. 3) check for continuity between terminals as shown below. If check r...

  • Page 1497

    Glass / windows / mirrors: 9e-25 pulse sensor and its circuit inspection (pinching prevention function model) s7rw0a9506031 note after replacing or disconnecting the driver side power window regulator (motor), power window main switch, battery and/or fuse, make sure to execute the initial setting, (...

  • Page 1498

    9e-26 glass / windows / mirrors: power window main switch initialization (pinching prevention function model) s7rw0a9506032 caution ! • after replacing or disconnecting the driver side door window regulator (motor), power window main switch, battery or fuse, be sure to execute initial setting (to ha...

  • Page 1499

    Glass / windows / mirrors: 9e-27 door mirror removal and installation s7rw0a9506024 when removing or installing door mirror, refer to the figure in “door mirror components”. Power door mirror switch inspection s7rw0a9506025 1) remove driver side door trim referring to step 1) to 4) of “front door gl...

  • Page 1500

    9e-28 glass / windows / mirrors: door mirror heater switch inspection (if equipped) s7rw0a9506034 door mirror heater is operated by rear end door window / back window defogger switch. Check rear end door window / back window defogger switch referring to “rear end door window / back window defogger s...

  • Page 1501: Security and Locks

    Security and locks: 9f-1 body, cab and accessories security and locks general description key coding construction s7rw0a9601001 key usage and identification key is used for ignition and door lock cylinders. Key is cut on both edges to make them reversible. Key identification is obtained from five ch...

  • Page 1502

    9f-2 security and locks: component location power door lock and keyless entry system component location s7rw0a9603001 3 7 4 5 6 1 2 8 9 i6rw0c960002-01 1. Keyless entry receiver 4. Front door actuator 7. Door switch 2. Transmitter 5. Rear door actuator 8. Bcm (junction block with bcm type) 3. Power ...

  • Page 1503

    Security and locks: 9f-3 diagnostic information and procedures power door lock system symptom diagnosis s7rw0a9604001 note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output ...

  • Page 1504

    9f-4 security and locks: keyless entry system symptom diagnosis s7rw0a9604003 note • confirm that power door lock system is in good condition before referring to the following possible causes. • check each part in the order from the top of the following list. Condition possible cause correction / re...

  • Page 1505

    Security and locks: 9f-5 keyless entry system operation inspection s7rw0a9604004 note when performing the this inspection, make sure to have any of the door once opened/ closed after the ignition key has been removed from the ignition key cylinder. 1) confirm that power door lock system operates nor...

  • Page 1506

    9f-6 security and locks: repair instructions front door lock assembly components s7rw0a9606001 front door lock assembly removal and installation s7rw0a9606002 removal 1) remove door trim and door sealing cover referring to step 1) to 6) of “front door glass removal and installation in section 9e”. 2...

  • Page 1507

    Security and locks: 9f-7 5) disconnect door opening control rod (1) from outside handle. 6) disconnect door lock motor lead wire at coupler. 7) remove door latch screws (2) and remove door lock assembly (3). Installation reverse removal procedure to install front door lock assembly noting the follow...

  • Page 1508

    9f-8 security and locks: front door lock assembly inspection s7rw0a9606003 • check that door open and closes smoothly and properly. • check that door stops in the secondary latched position properly (preventing door from opening freely) and that door closed completely in the fully latched position. ...

  • Page 1509

    Security and locks: 9f-9 power door lock actuator inspection s7rw0a9606006 1) remove door trim from door panel. For front door, refer to step 1) to 3) of “front door glass removal and installation in section 9e”. For rear door, refer to step 1) to 3) of “rear door glass removal and installation in s...

  • Page 1510

    9f-10 security and locks: rear door lock assembly components s7rw0a9606007 rear door lock assembly removal and installation s7rw0a9606008 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 1511

    Security and locks: 9f-11 rear end door lock assembly components (hatchback model) s7rw0a9606010 1 3 (a) (b) 4 5 2 6 7 8 i ii iv iii (c) 8 (c) 8 (c) i7rw01960007-04 1. Rear end door latch assembly (rear end door switch is built in this assembly) 7. Rear end door license garnish 2. Rear end door open...

  • Page 1512

    9f-12 security and locks: rear end door lock assembly removal and installation (hatchback model) s7rw0a9606011 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 latch assembly (2). Installation revers...

  • Page 1513

    Security and locks: 9f-13 rear end door opener switch inspection (hatchback model) s7rw0a9606013 1) remove rear end door trim. 2) disconnect rear end door switch coupler. 3) check that there is continuity between terminals “a” and “b” when rear end door opener switch (1) is pushed. 4) check that the...

  • Page 1514

    9f-14 security and locks: trunk lid lock assembly removal and installation (sedan model) s7rw0a9606021 removal 1) remove trunk lid trim (1) from trunk lid panel (if equipped). 2) disconnect trunk lid latch control rod (1) from trunk lid. 3) (keyless start model) disconnect trunk lid latch actuator c...

  • Page 1515

    Security and locks: 9f-15 trunk lid lock assembly inspection (sedan model) s7rw0a9606022 • check that trunk lid opens and closes smoothly and properly. • adjust trunk lid latch striker position referring to “front door lock assembly removal and installation”, if necessary. Replacement of transmitter...

  • Page 1516

    9f-16 security and locks: keyless entry answer back function change- over procedure s7rw0a9606023 output of keyless entry answer back function can be switched over by performing the following procedure. 1) confirm that all doors are closed, all doors are unlocked, ignition key is out of ignition key...

  • Page 1517

    Security and locks: 9f-17 keyless entry receiver and its circuit inspection s7rw0a9606018 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 1518

    9f-18 security and locks: specifications tightening torque specifications s7rw0a9607001 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 (hatchback model)” “trun...

  • Page 1519: Seats

    Seats: 9g-1 body, cab and accessories seats diagnostic information and procedures front seat heater symptom diagnosis (if equipped) s7rw0a9704001 condition possible cause correction / reference item both seat back and cushion do not become hot although seat heater switch is on position wiring or gro...

  • Page 1520

    9g-2 seats: repair instructions front seat components s7rw0a9706001 3 2 8 7 a c 4 d b 1 5 5 4 6 6 4 a b c d (b) (b) (b) (b) (a) (a) (a) (a) a a a (b) (c) b a a a b a b i6rw0c970001-01 1. Seat cushion 7. Side air bag module (if equipped) 2. Seat back : apply lithium grease 99000-25011 to sliding part...

  • Page 1521

    Seats: 9g-3 front seat removal and installation s7rw0a9706002 warning ! Refer to “air bag warning in section 00”before starting service work. 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 equip...

  • Page 1522

    9g-4 seats: rear seat components s7rw0a9706003 3 5 4 4 4 7 4 1 2 6 b c a 7 12 [a] (a) (b) (b) (b) (b) (c) (d) (d) a a i7rw0a970001-02.

  • Page 1523

    Seats: 9g-5 1 3 2 11 3 [b] 9 11 8 8 6 10 12 3 i (b) (e) (f) (e) f (e) d (e) e (e) g (e) h (e) (e) i (e) j (e) (f) (b) i7rw0a970002-01 [a]: hatchback model 11. Rear seat side hinge [b]: sedan model 12. Rear seat back lock 1. Seat cushion : 35 n ⋅m (3.5 kgf-m, 25.5 lb-ft) 2. Seat back : 23 n ⋅m (2.3 k...

  • Page 1524

    9g-6 seats: rear seat removal and installation s7rw0a9706004 hatchback model removal 1) fold rear seat back forward. 2) remove seat mounting bolts and nuts to remove seat assembly. 3) disassemble and repair seat as necessary. Installation reverse removal procedure to install rear seat. • torque to s...

  • Page 1525: Interior Trim

    Interior trim: 9h-1 body, cab and accessories interior trim repair instructions floor carpet removal and installation s7rw0a9806001 removal 1) remove front seat and rear seat referring to “front seat removal and installation in section 9g” and “rear seat removal and installation in section 9g”. 2) r...

  • Page 1526

    9h-2 interior trim: head lining removal and installation s7rw0a9806002 warning ! Refer to “air bag warning in section 00” before starting service work. Removal 1) remove sun visor (1). 2) remove dome lights of front (1) and center (2). 3) for hatchback model, remove front pillar upper trims (1), cen...

  • Page 1527

    Interior trim: 9h-3 4) for sedan model, remove front pillar upper trims (1), center pillar inner lower trims (3), rear side sill scuffs (2), center pillar upper trims (4), side backs (6) and rear pillar inner trims (5). 5) remove assistant grip (1). 6) remove head lining clips (2) at rear end and re...

  • Page 1528

    9h-4 interior trim: console box components s7rw0a9806003 specifications tightening torque specifications s7rw0a9807001 reference: for the tightening torque of fastener not specified in this section, refer to “fasteners information in section 0a”. B a b a a b a a a a a a a a a a a a a a 2 3 1 4 i5rw0...

  • Page 1529: Hood / Fenders / Doors

    Hood / fenders / doors: 9j-1 body, cab and accessories hood / fenders / doors repair instructions hood removal and installation s7rw0a9a06001 removal caution ! Place cloth to prevent body from any damage. 1) remove hood silencer (4). 2) disconnect window washer hose (1) from hood. 3) remove 4 mounti...

  • Page 1530

    9j-2 hood / fenders / doors: front fender components s7rw0a9a06003 front fender removal and installation s7rw0a9a06004 removal 1) remove side sill splash guard and front fender splash guard (if equipped) referring to “splash guard removal and installation (if equipped) in section 9m”. 2) remove fron...

  • Page 1531

    Hood / fenders / doors: 9j-3 front door assembly components s7rw0a9a06005 front door assembly removal and installation s7rw0a9a06006 removal 1) remove front fender referring to “front fender removal and installation”. 2) disconnect door harness lead wires at each coupler. 3) remove door open stopper...

  • Page 1532

    9j-4 hood / fenders / doors: 5) remove door assembly (1) by loosening hinge mounting bolts (2). Installation reverse removal procedure to install door assembly noting the following instructions. • when replacing door, coat replacement door inside with wax for proper anti-corrosion treatment. Refer t...

  • Page 1533

    Hood / fenders / doors: 9j-5 rear door assembly components s7rw0a9a06007 rear door assembly removal and installation s7rw0a9a06008 refer to “front door assembly removal and installation” as removal and installation procedures are basically the same. However, note the following. • tighten rear door h...

  • Page 1534

    9j-6 hood / fenders / doors: rear end door assembly components (hatchback model) s7rw0a9a06009 b a a b a a a a a a a a a 5 6 1 4 2 (a) [a] 3 7 8 9 10 (a) 10 i7rw0a9a0003-01 [a]: rear end door spoiler installation position 6. Rear end door opening wether-strip 1. Rear end door panel assembly 7. Rear ...

  • Page 1535

    Hood / fenders / doors: 9j-7 rear end door assembly removal and installation (hatchback model) s7rw0a9a06010 warning ! Be careful enough when you open and shut with door balancer has not adhered to rear end door. Otherwise, rear end door doses in weight and is injured. Removal 1) remove rear end doo...

  • Page 1536

    9j-8 hood / fenders / doors: • adjust door latch striker position by referring to “rear end door lock assembly removal and installation (hatchback model) in section 9f”. • adjust door cushion so that door contacts body when closed. • apply sealant to contact face “a” of door hinge (1) and apply grea...

  • Page 1537

    Hood / fenders / doors: 9j-9 trunk lid removal and installation (sedan model) s7rw0a9a06012 removal warning ! When removing torsion bar, be careful for its repulsion. 1) remove trunk lid trim (if equipped). 2) remove trunk lid opener wire and trunk room harness from trunk lid panel (1). 3) remove tr...

  • Page 1538

    9j-10 hood / fenders / doors: installation reverse removal procedure noting the following. • install torsion bars as following: a. Open trunk lid and hold it. B. Distinguish left side torsion bar (marking color: yellow) from right side torsion bar (marking color: blue) by marking color (1). C. Apply...

  • Page 1539

    Hood / fenders / doors: 9j-11 specifications tightening torque specifications s7rw0a9a07001 note the specified tightening torque is also described in the following. “front door assembly components” “rear door assembly components” “rear end door assembly components (hatchback model)” reference: for t...

  • Page 1540: Body Structure

    9k-1 body structure: body, cab and accessories body structure repair instructions front bumper and rear bumper components s7rw0a9b06001 1 2 3 4 5 a a a a 6 7 8 9 [a] i8rw019b0001-01.

  • Page 1541

    Body structure: 9k-2 radiator grille removal and installation s7rw0a9b06003 6 7 8 10 6 a a 6 [b] 9 i8rw019b0002-02 [a]: hatchback model 3. Front bumper upper member 7. Rear bumper [b]: sedan model 4. Front bumper lower member 8. Reflector 1. Front bumper 5. Front bumper holder 9. Rear bumper absorbe...

  • Page 1542

    9k-3 body structure: front bumper extension removal and installation (if equipped) s7rw0a9b06004 [a]: hatchback model 1. Radiator upper grille 3. Retainer [b]: sedan model 2. Radiator lower grille 4. Front bumper i8rw019b0004-01 i8rw019b0005-02.

  • Page 1543

    Body structure: 9k-4 rear bumper extension removal and installation (if equipped) s7rw0a9b06005 [a]: hatchback model 1. Front bumper center extension 3. Front bumper [b]: sedan model 2. Front bumper side extension i8rw019b0006-01 a a a 1 3 [b] i8rw019b0007-02 [a]: hatchback model 1. Rear bumper cent...

  • Page 1544

    9k-5 body structure: cowl top and front lower crossmember components s7rw0a9b06002 i7rw0a9b0001-02 1. Cowl top garnish 3. Hood rear seal 5. Damper : 55 n ⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Cowl top panel 4. Front lower crossmember 6. Damper bracket : 25 n ⋅m (2.5 kgf-m, 18.5 lb-ft).

  • Page 1545

    Body structure: 9k-6 specifications body dimensions s7rw0a9b07001 engine room 2 4 6 8 10 12 14 16 18 20 24 21 3 5 7 13 15 19 623 mm (24.543 in.) 662 mm (26.063 in.) 916 mm (36.063 in.) 1421 mm (54.945 in .) 966 mm (38.031 in. ) 651 mm (25.630 in.) 564 mm (22.205 in.) 586 mm (23.071 in.) 1249 mm (49....

  • Page 1546

    9k-7 body structure: rear end door (hatchback model) 31 30 32 33 41 35 40 37 36 39 34 784 mm(30.866 in.) 753 mm (29.646 in.) 1117 mm (43.976 in.) 686 mm (27.008 in.) 906 mm (36.669 in.) 898 mm (35.354 in.) 909 mm (35.787 in.) 342 mm (13.465 in.) 987 mm (38.858 in.) 970 mm (38.189 in.) 1104 mm (43.46...

  • Page 1547

    Body structure: 9k-8 trunk room (sedan model) 48 50 54 47 49 53 55 57 59 58 56 54 50 51 48 1086 mm (42.756 in.) 1162 mm (45.748 in.) 920 mm (36.220 in.) 894 mm (35.197 in.) 761 mm (29.961 in.) 1037 mm (40.827 in.) 740 mm (29.134 in.) 761 mm (29.961 in.) 556 mm (21.890 in.) 959 mm (37.756 in.) i7rw0a...

  • Page 1548

    9k-9 body structure: side body (hatchback model) 95 73 75 71 79 77 87 67 69 73 75 87 83 81 85 85 89 89 91 93 77 91 71 95 67 69 79 83 93 81 1221 mm (48.071 in.) 1276 mm (50.236 in.) 913 mm (35.945 in.) 784 mm (30.866 in.) 978 mm (38.504 in.) 1315 mm (51.772 in.) 1445 mm (56.890 in.) 1139 mm (44.843 i...

  • Page 1549

    Body structure: 9k-10 95 102 101 102 95 104 103 103 1511 mm (59.488 in.) 1328 mm (52.283 in.) 1280 mm (50.394 in.) 1428 mm (56.22 0 in.) 801 mm (31.535 in.) 1052 mm (41.417 in.) i7rw0a9b0007-02 point position 95 parking brake wire bracket front hole φ11 101 front end of windshield upper installation...

  • Page 1550

    9k-11 body structure: side body (sedan model) 140 112 114 126 130 138 124 128 122 132 134 136 116 120 118 112 114 126 138 124 140 122 132 134 136 116 120 118 1221 mm (48.071 in.) 913 mm (35.945 in.) 784 mm (30.866 in.) 978 mm (38.504 in.) 1139 mm (44.843 in.) 1303 mm (51.299 in.) 1362 mm (53.622 in....

  • Page 1551

    Body structure: 9k-12 140 147 148 146 147 150 152 151 140 149 148 1052 mm (41.41 7 in.) 1511 mm (59.488 in.) 1328 mm (52.283 in. ) 1280 mm (50.394 in.) 1210 mm (47.638 in.) 1210 mm (47.638 in.) 1308 mm (51.496 in.) 1428 mm (56.220 in.) 801 mm (31.535 in.) i7rw0a9b0009-02 point position 140 parking b...

  • Page 1552

    9k-13 body structure: under body (hatchback model) 160 162 164 166 168 170 160 162 164 166 168 170 172 174 176 178 172 174 176 178 177 175 173 177 175 173 169 159 167 165 163 161 169 159 167 165 163 161 171 171 529 mm (20.827 in.) 1167 mm (45.945 in .) 1066 mm (41.969 in.) 931 mm (36.654 in.) 1386 m...

  • Page 1553

    Body structure: 9k-14 under body (sedan model) “a” 178 176 174 172 170 168 166 164 162 160 489 mm (19.252 in.) 316 mm (12.441 in.) 360 mm (14.173 in.) 565 mm (22.244 in.) 325 mm (12.795 in.) 644 mm (25.354 in.) 1145 mm (45.079 in.) 280 mm (11.024 in.) 155mm (6.102 in.) -31 mm (-1.220 in.) -78 mm (-3...

  • Page 1554

    9k-15 body structure: point position 184 jig hole r φ20 185 ↑ l ↑ 186 front suspension frame installation hole r 187 ↑ l 188 ↑ r 189 ↑ l 190 jig hole r φ10 191 ↑ l ↑ 192 ↑ r ↑ 193 ↑ l ↑ 194 ↑ r φ15 195 ↑ l ↑ 196 ↑ r φ25 197 ↑ l ↑ 198 rear axle housing installatiom inside hole r 199 ↑ l 200 drain hol...

  • Page 1555

    Body structure: 9k-16 front suspension frame 785 mm (30.905 in.) 805 mm (31.693 in.) 805 mm (31.693 in.) 690 mm (27.165 in.) 900 mm (35.433 in.) 218 216 214 213 215 217 212 220 219 211 i7rw0a9b0014-01 point position 211 root of stud r 212 ↑ l 213 front suspension frame installation hole r 214 ↑ l 21...

  • Page 1556

    9k-17 body structure: engine front mounting member point position 212 root of stud l 214 front suspension frame installation hole l 216 front suspension control arm installation hole l 218 front suspension frame installation hole l 220 front suspension control arm installation hole l 951 mm (37.441 ...

  • Page 1557

    Body structure: 9k-18 panel clearance s7rw0a9b07002 o aa p bb b w a v c d f g j h e i u l k m n x o r t s p q [a] [b] a b c d e f g h i y k l z cc dd ee i6rw0b9b0009-01.

  • Page 1558

    9k-19 body structure: panel to panel distance tightening torque specifications s7rw0a9b07003 note the specified tightening torque is also described in the following. “cowl top and front lower crossmember components” reference: for the tightening torque of fastener not specified in this section, refe...

  • Page 1559: Paint / Coatings

    Paint / coatings: 9l-1 body, cab and accessories paint / coatings general description anti-corrosion treatment construction s7rw0a9c01001 warning ! Standard shop practices, particularly eye protection, should be followed during the performance of the following operations to avoid personal injury. As...

  • Page 1560

    9l-2 paint / coatings: 5) polypropylene must raise no readily distinguishable smoke while burning. Component location sealant application areas s7rw0a9c03001 i8rw019c0001-01.

  • Page 1561

    Paint / coatings: 9l-3 i7rw0a9c0001-01 [a]: hatchback model “a”: apply sealant. “e”: never fill up drain holes with sealant. [b]: sedan model “b”: wipe off excess sealant after application. “f”: fill gap / hole with sealant. [c]: rhd “c”: smooth out sealant with a brush. “g”: r end [d]: lhd “d”: do ...

  • Page 1562

    9l-4 paint / coatings: i8rw019c0003-01.

  • Page 1563

    Paint / coatings: 9l-5 i8rw019c0004-01 [a]: hatchback model “b”: fill gap / hole with sealant. “e”: wipe off excess sealant after application. [b]: sedan model “c”: smooth out sealant with a brush. “f”: smooth out sealant with a brush. Do not fill hole with sealant. “a”: apply sealant. “d”: do not a...

  • Page 1564

    9l-6 paint / coatings: i6rw0b9c0005-01 [a]: hatchback model “a”: apply sealant. “c”: never fill up drain holes (“a” to “f”) with sealant. [b]: sedan model “b”: wipe off excess sealant after application. “d”: apply sealant covering flange end..

  • Page 1565

    Paint / coatings: 9l-7 i8rw019c0005-01.

  • Page 1566

    9l-8 paint / coatings: i8rw019c0006-01 [a]: hatchback model “b”: wipe off excess sealant application. “e”: apply sealant covering flange end. [b]: sedan model “c”: smooth out sealant with a brush. “f”: apply sealant covering flange end. Do not fill hole with sealant. “a”: apply sealant. “d”: fill ga...

  • Page 1567

    Paint / coatings: 9l-9 i8rw019c0007-01 “a”: apply sealant covering flange end..

  • Page 1568

    9l-10 paint / coatings: under coating application areas s7rw0a9c03002 i8rw019c0008-01 [a]: lh side “c”: do not apply undercoating. [b]: rh side “d”: apply under coating (pvc, 400 µm or more) after panting black color. [c]: both side “e”: apply under coating (pvc, 600 µm or more). “a”: apply undercoa...

  • Page 1569

    Paint / coatings: 9l-11 “b”: apply anti-chip coat (300 µm or more) (except vehicle with splash guard). I8rw019c0009-01 [a]: hatchback model “a”: apply undercoating (pvc, 400 µm or more). “d”: do not apply undercoating (apply all stud-bolts). [b]: sedan model “b”: apply undercoating (pvc, 600 µm or m...

  • Page 1570

    9l-12 paint / coatings: anti-corrosion compound application area s7rw0a9c03003 i6rw0b9c0011-01 [a]: hatchback model “b”: apply rust proof wax (high viscosity wax 50 µm or more) (with side turn signal light). [b]: sedan model “c”: never fill up drain holes with rust proof wax. “a”: apply rust proof w...

  • Page 1571

    Paint / coatings: 9l-13 i6rw0b9c0012-01 [a]: hatchback model “a”: apply rust proof wax (hot wax 50 µm or more). [b]: sedan model “b”: never fill up drain holes with rust proof wax..

  • Page 1572: Exterior Trim

    9m-1 exterior trim: body, cab and accessories exterior trim repair instructions roof molding removal and installation s7rw0a9d06001 2 3 1 2 3 4 4 [a] a b [b] 5 6 (a) (a) i5rw0c9d0002-04 [a]: roof molding installation position roof molding with touching a to b. 3. Roof rail nut (if equipped) [b]: roo...

  • Page 1573

    Exterior trim: 9m-2 splash guard removal and installation (if equipped) s7rw0a9d06002 specifications tightening torque specifications s7rw0a9d07001 note the specified tightening torque is also described in the following. “roof molding removal and installation” reference: for the tightening torque of...

  • Page 1574

    9m-3 exterior trim:.

  • Page 1575: 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 1576

    10-ii table of contents immobilizer indicator light remains on after engine start ..................................................10c-10 dtc p1614: transponder response error.....10c-10 dtc p1615: steering lock unit communication error ....................................10c-11 dtc p1616: unregist...

  • Page 1577: Precautions

    Precautions: 10-1 control systems precautions precautions precautions for control systems s7rw0aa000001 air bag warning refer to “air bag warning in section 00”. Precaution of troubleshooting for can refer to “precaution on can troubleshooting in section 1a”..

  • Page 1578

    10b-1 body electrical control system: control systems body electrical control system precautions precautions in diagnosing trouble s7rw0aa200001 • diagnostic information stored in bcm memory can be cleared as well as checked by using suzuki scan tool. Before using scan tool, read its operator’s (ins...

  • Page 1579

    Body electrical control system: 10b-2 can communication system description s7rw0aa201002 refer to “can communication system description in section 1a” for can communication system description. Bcm communication control data with each control module as follows. Bcm transmission data bcm reception dat...

  • Page 1580

    10b-3 body electrical control system: theft deterrent light description s7rw0aa201003 the information display or clock (1) of this vehicle includes a theft deterrent light (2) for the theft preventive purpose. The bcm makes the theft deterrent light flash at certain intervals after the ignition swit...

  • Page 1581

    Body electrical control system: 10b-4 the alarm stops under either of the following conditions. • ignition switch is turned on • a certain time has elapsed since the alarm started for selection of the mode of the security alarm system, refer to “security alarm mode selection procedure (if equipped)”...

  • Page 1582

    10b-5 body electrical control system: blk/blu blk/yel blk/red 12v 12v +bb blu/yel wht/blu +bb red/yel g272-7 yel/red yel/blk 5v ig1 ig2 ig2 l312-4 orn l314-9 yel blu l313-3 blu ppl/wht +b +b grn/red grn grn red/blu l315-9 l315-10 l01-10 l01-1 on door off +b +b ig1 wht l312-5 12v lt grn blk 5v 5v 5v ...

  • Page 1583

    Body electrical control system: 10b-6 [a]: without security alarm system 20. Hvac control module (if equipped) 43. To abs / esp ® control module and p/s control module [b]: with security alarm system 21. Keyless entry receiver (if equipped) 44. To sdm [c]: hatchback 22. Driver side door switch 45. T...

  • Page 1584

    10b-7 body electrical control system: connector layout diagram of bcm and junction block s7rw0aa202002 bcm and junction block connectors (viewed from harness side) i6rw0ca20004-01 [a]: junction block (viewed from bcm side) 2. Junction block 5. Rear wiper relay [b]: junction block (viewed from relay ...

  • Page 1585

    Body electrical control system: 10b-8 component location bcm and related system component location s7rw0aa203001 13 12 17 18 21 19 14 24 25 25 26 27 22 23 22 24 7 20 11 5 15 16 15 16 [a] [b] 2 3 8 4 1 6 28 9 10 29 [d] [c] 30 i7rw0aa20004-02 [a]: auto a/c 9. Rear end door opener switch (if equipped) ...

  • Page 1586

    10b-9 body electrical control system: diagnostic information and procedures bcm self-diagnosis function s7rw0aa204001 • 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 1587

    Body electrical control system: 10b-10 body electrical control system check s7rw0aa204002 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 fa...

  • Page 1588

    10b-11 body electrical control system: customer questionnaire (example) problem symptom confirmation check if what the customer claimed in “customer questionnaire” is accurately found in the vehicle. If that symptom is found, check whether the symptom is identified as a failure. (this step should be...

  • Page 1589

    Body electrical control system: 10b-12 scan tool data s7rw0aa204003 scan tool data condition normal condition / reference value vehicle speed ) at stop with ignition switch turned on 0 km/h outside air temp ) reference value is relative to outside air temperature –40 °c – 70 °c (–40 °f – 158 °f) bat...

  • Page 1590

    10b-13 body electrical control system: scan tool data definitions vehicle speed (km/h, mph): this parameter indicates the vehicle speed computed by ecm. Outside air temp ( °c, °f): it is detected by outside air temperature sensor. Battery voltage (v): this parameter indicates battery positive voltag...

  • Page 1591

    Body electrical control system: 10b-14 note *1: junction block without bcm type *2: with security alarm system dtc table s7rw0aa204004 dtc (displayed on suzuki scan tool) dtc (indicated by theft deterrent light) dtc (displayed on odometer in combination meter) detected item detecting condition no dt...

  • Page 1592

    10b-15 body electrical control system: dtc check s7rw0aa204005 using suzuki scan tool 1) prepare suzuki scan tool. 2) with ignition switch turned off, connect it to data link connector (dlc) located on underside of instrument panel of driver’s side. Special tool (a): suzuki scan tool 3) turn ignitio...

  • Page 1593

    Body electrical control system: 10b-16 3) check dtc displayed on odometer of combination meter or read flashing pattern of theft deterrent light which represents dtc as shown in the following example and write it down. When more than 2 dtcs are stored in memory, flashing for each dtc starts with the...

  • Page 1594

    10b-17 body electrical control system: bcm power circuit and ground circuit check s7rw0aa204007 wiring diagram troubleshooting +b ig1 +bb grn g273-2 blk blk/orn g272-9 g271-3 blk/orn l314-4 blu g273-5 wht e324-2 2 3 1 e324 l314 1 2 4 5 3 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 1 2 4 5 3 6 1 2 4 5 3 6...

  • Page 1595

    Body electrical control system: 10b-18 dtc b1133 (no. 1133): battery voltage too high s7rw0aa204008 wiring diagram refer to “bcm power circuit and ground circuit check”. Dtc detecting condition and possible cause flow test description step 1: check charging system dtc troubleshooting 4 ground circui...

  • Page 1596

    10b-19 body electrical control system: dtc b1141 / b1142 (no. 1141 / no. 1142): outside air temperature (ambient temp.) sensor circuit malfunction s7rw0aa204009 wiring diagram dtc detecting condition and possible cause flow test description step 1: check whether malfunction is in outside air tempera...

  • Page 1597

    Body electrical control system: 10b-20 dtc b1150 (no. 1150): air bag communication circuit malfunction s7rw0aa204010 wiring diagram dtc detecting condition and possible cause flow test description step 1: check air bag communication circuit. Step 2: check air bag communication circuit. Dtc troublesh...

  • Page 1598

    10b-21 body electrical control system: dtc b1157 (no. 1157): air bag deployment signal input s7rw0aa204011 wiring diagram refer to “dtc b1150 (no. 1150): air bag communication circuit malfunction”. Dtc detecting condition and possible cause flow test description step 1: check dtc for sdm. Dtc troubl...

  • Page 1599

    Body electrical control system: 10b-22 inspection of bcm and its circuits s7rw0aa204018 bcm and its circuits can be checked at bcm wiring couplers by measuring voltage and resistance. Caution ! Bcm cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to bcm with co...

  • Page 1600

    10b-23 body electrical control system: bcm connector “e04” l01-8 — — — l01-9 — — — l01-10 driver side door lock actuator control (unlock) (if equipped) 10 – 14 v unlock signal is output for driver side door lock actuator 0 v unlock signal is not output for driver side door lock actuator l01-11 rear ...

  • Page 1601

    Body electrical control system: 10b-24 bcm connector “g04” e04-11 oil pressure switch *3 – 14 v refer to “reference waveform no. 4: ” 0 v ignition switch is at on position and engine is at stop e04-12 — — — e04-13 — — — e04-14 — — — terminal circuit normal voltage condition g04-1 can communication l...

  • Page 1602

    10b-25 body electrical control system: junction block connector “e324” junction block connector “e325” junction block connector “g271” junction block connector “g272” junction block connector “g273” junction block connector “l312” g04-22 rear wiper low switch *0 – 1 v ↑↓ 10 – 14 v refer to “referenc...

  • Page 1603

    Body electrical control system: 10b-26 junction block connector “l313” junction block connector “l314” junction block connector “l315” terminal circuit normal voltage condition l313-2 air bag communication line *0 – 1 v ↑↓ 4 – 6 v refer to “reference waveform no. 10: ” l313-3 serial communication li...

  • Page 1604

    10b-27 body electrical control system: reference waveform no. 1 parking brake or brake fluid level switch signal (1) reference waveform no. 2 driver seat belt switch signal (1) reference waveform no. 3 can communication signal reference waveform no. 4 oil pressure switch signal (1) measurement termi...

  • Page 1605

    Body electrical control system: 10b-28 reference waveform no. 5 information display and hvac control module serial communication signal (1) reference waveform no. 6 keyless entry receiver signal (1) reference waveform no. 7 vehicle speed pulse output signal (1) reference waveform no. 8 a/c or rear e...

  • Page 1606

    10b-29 body electrical control system: reference waveform no. 9 rear wiper switch signal (1) reference waveform no. 10 sdm communication signal (1) repair instructions bcm (included in junction block) removal and installation s7rw0aa206001 caution ! Do not attempt removal of bcm from junction block ...

  • Page 1607

    Body electrical control system: 10b-30 5) disconnect connectors from bcm and junction block. 6) detach wiring harness clamp from junction block. Installation reverse removal procedure for installation, noting following points. • connect connectors securely. • enable air bag system referring to “enab...

  • Page 1608: Immobilizer Control System

    10c-1 immobilizer control system: control systems immobilizer control system precautions precautions in diagnosing troubles s7rw0aa300001 • before confirming the diagnostic trouble code (dtc), do not disconnect connector from ecm, battery cable from battery, ground wire harness, or main fuse. Such d...

  • Page 1609

    Immobilizer control system: 10c-2 • do not leave ignition key in a place where temperature is high. High temperature may cause damage to the transponder built in the ignition key. • do not turn ignition switch to on position by bringing radio antenna close to coil antenna. Or, the immobilizer contro...

  • Page 1610

    10c-3 immobilizer control system: schematic and routing diagram immobilizer control system wiring circuit diagram s7rw0aa302001 note for more details about power supply circuit, ground wire circuit, and each circuit for ecm, bcm, abs control module, keyless start control module and combination meter...

  • Page 1611

    Immobilizer control system: 10c-4 blk/wht blk/orn 12v g17-1 g17-2 12v 5v 12v 12v yel/red yel/blk g17-4 g17-3 5v brn brn/yel blk/yel 1 2 2 2 2 3 4 2 5 10 14 15 1 2 3 4 g17 [a] 5 6 g16-20 g16-29 g16-30 g146-3 g146-7 g146-8 wht/red 5v 5v 9 g16-18 g16-19 e01-13 e01-28 blu red wht e08-12 e08-1 e01-18 e01...

  • Page 1612

    10c-5 immobilizer control system: component location immobilizer control system components location s7rw0aa303001 diagnostic information and procedures immobilizer control system check s7rw0aa304001 3 4 5 6 7 1 2 2 1 3 i6rw0ba30001-01 1. Ecm 5. Ignition key (non keyless entry model) 2. Immobilizer i...

  • Page 1613

    Immobilizer control system: 10c-6 dtc check s7rw0aa304002 note to know how to use suzuki scan tool in detail, refer to its operator’s manual. 1) turn the ignition switch to off position. 2) connect suzuki scan tool to data link connector (dlc) (1) located under instrument panel at driver’s seat side...

  • Page 1614

    10c-7 immobilizer control system: dtc table s7rw0aa304004 ecm note ecm detects dtc. Icm does not. Note if any dtc other than the above dtcs is detected, refer to “dtc table in section 1a”. Dtc no. Detecting item detecting condition immobilizer indicator light ) p1614 transponder response error trans...

  • Page 1615

    Immobilizer control system: 10c-8 scan tool data s7rw0aa304005 suzuki scan tool displays the following data using “registration information” mode. Scan tool data definitions component id (****) this parameter indicates the vehicle id number of four digits used for the suzuki scan tool. Keyfree syste...

  • Page 1616

    10c-9 immobilizer control system: immobilizer indicator light does not come on with ignition switch on and engine stop s7rw0aa304006 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description when the ignition switch is turned on, ecm transmits the indication on...

  • Page 1617

    Immobilizer control system: 10c-10 immobilizer indicator light remains on after engine start s7rw0aa304007 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description refer to “immobilizer indicator light does not come on with ignition switch on and engine stop”....

  • Page 1618

    10c-11 immobilizer control system: dtc p1615: steering lock unit communication error s7rw0aa304009 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description when the transponder code in the ignition key is registered in ecm, the id code is registered in both ec...

  • Page 1619

    Immobilizer control system: 10c-12 dtc p1616: unregistered keyless start control module s7rw0aa304010 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Circuit description p1616 is detected when ecm detects different id codes registered in ecm and keyless start control mod...

  • Page 1620

    10c-13 immobilizer control system: dtc p1618: keyless start control module can communication error s7rw0aa304011 refer to “troubleshooting for can-dtc in section 1a”. Dtc p1621: immobilizer communication line error s7rw0aa304012 wiring diagram refer to “immobilizer control system wiring circuit diag...

  • Page 1621

    Immobilizer control system: 10c-14 dtc p1622: eeprom reading / writing error s7rw0aa304013 detecting condition and trouble area troubleshooting 1) clear dtc(s) referring to “dtc clearance”. 2) turn the ignition switch to off position. 3) check if dtc p1622 is still detected referring to “dtc check”....

  • Page 1622

    10c-15 immobilizer control system: dtc p1625: immobilizer antenna error s7rw0aa304015 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Detecting condition and trouble area troubleshooting dtc p1636: immobilizer information registration failure s7rw0aa304016 wiring diagram...

  • Page 1623

    Immobilizer control system: 10c-16 dtc p1638: immobilizer information mismatched s7rw0aa304017 wiring diagram refer to “immobilizer control system wiring circuit diagram”. Detecting condition and trouble area troubleshooting 4 can communication circuit check 1) disconnect connectors from ecm, bcm an...

  • Page 1624

    10c-17 immobilizer control system: inspection of icm and its circuit s7rw0aa304018 icm and its circuit can be checked at icm wiring connector by measuring voltage. Caution ! Icm cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to icm with connector disconnected...

  • Page 1625

    Immobilizer control system: 10c-18 reference waveform note when ecm cannot read the transponder code at the first try, ecm tries to read the transponder code repeatedly up to 8 times. The second waveform is the example showing that ecm read the transponder code successfully at the second try. Termin...

  • Page 1626

    10c-19 immobilizer control system: repair instructions icm removal and installation s7rw0aa306001 removal 1) disconnect negative (–) cable at battery. 2) remove dash side trim (4) and steering column hole cover (3). 3) remove steering column covers (1). Turn steering wheel to access steering column ...

  • Page 1627

    Immobilizer control system: 10c-20 special tools and equipment special tool s7rw0aa308001 suzuki scan tool (suzuki- sdt) — this kit includes following items. 1. Suzuki-sdt 2. Dlc3 cable 3. Usb cable 4. Ac/dc power supply 5. Voltage meter probe 6. Storage case ) / ) 1 2 3 4 5 6.

  • Page 1628: Keyless Start System

    10e-1 keyless start system: control systems keyless start system precautions precautions in diagnosing troubles s7rw0aa500002 • the keyless start system executes data transmission/reception by means of the radio wave. Therefore, proper operation may not be obtained if use of the door lock function a...

  • Page 1629

    Keyless start system: 10e-2 general description keyless start system description s7rw0aa501001 keyless start system consisting of the parts shown below has four functions as described below. • keyless engine start function: with the remote controller which has been registered in the keyless start co...

  • Page 1630

    10e-3 keyless start system: parts and functions s7rw0aa501002 parts function keyless start control module • activates each antenna • verifies id code of remote controller • requests steering lock unit to release steering lock • requests bcm to lock or unlock doors • requests bcm to open trunk lid (s...

  • Page 1631

    Keyless start system: 10e-4 keyless engine start function s7rw0aa501003 when the ignition knob switch (2) installed to the steering lock unit (1) is pushed, the keyless start control module (3) activates the center antenna (4) to send out the request signal in the vehicle compartment. When the remot...

  • Page 1632

    10e-5 keyless start system: door lock function of keyless start system s7rw0aa501004 when the request switch (1) incorporated in the outside handle of the driver side door, front passenger side door or rear end door (hatchback) is pushed, the keyless start control module (2) activates the center ant...

  • Page 1633

    Keyless start system: 10e-6 trunk lid opener function of keyless start system (sedan) s7rw0aa501008 when the trunk lid request switch (1) is pushed, the keyless start control module (2) activates the trunk room antenna (3) to send out the radio wave in the trunk room to check if the remote controlle...

  • Page 1634

    10e-7 keyless start system: operation area of remote controller s7rw0aa501005 shown below are the operation areas of the remote controller for the keyless engine start function, door lock function and trunk lid opener function (sedan) of the keyless start system. However, even when the remote contro...

  • Page 1635

    Keyless start system: 10e-8 • the ignition knob switch cannot be turned using the keyless engine start function fails to turn: – the remote controller which has been registered in the keyless start control module and another un-registered one are both carried at the same time – the remote controller...

  • Page 1636

    10e-9 keyless start system: keyless start control module reception data schematic and routing diagram keyless start system electric wiring circuit diagram s7rw0aa502001 vehicle speed signal ecm-keyless start control module code door switch status trunk lid switch status door lock status charing syst...

  • Page 1637

    Keyless start system: 10e-10 diagnostic information and procedures self-diagnosis function s7rw0aa504002 the keyless start control module has self-diagnosis function to monitor the system components and circuits while the keyless start system is at work. When the keyless start control module detects...

  • Page 1638

    10e-11 keyless start system: customer questionnaire (example) s7rw0aa504005 key indicator light check s7rw0aa504006 push the ignition knob switch (2) of the steering lock unit (1) and check that the key indicator light (3) in the combination meter lights up in red or blue. If it does not light, go t...

  • Page 1639

    Keyless start system: 10e-12 dtc check s7rw0aa504007 1) check to make sure that all doors are closed. 2) open driver side door window glass and door. 3) check to make sure that ignition key is not inserted in ignition key cylinder. If it is, remove it. 4) perform “key indicator light check”. 5) clos...

  • Page 1640

    10e-13 keyless start system: dtc table s7rw0aa504008 dtc clearance s7rw0aa504009 1) perform steps 1) through 5) of dtc check procedure and have dtc indicated. 2) open driver side door. 3) close driver side door and within 10 seconds after that, perform steps a) to c) described below. A) push unlock ...

  • Page 1641

    Keyless start system: 10e-14 keyless start system symptom diagnosis s7rw0aa504010 door lock function of keyless start system note before performing trouble diagnosis procedure for door lock function of keyless start system, check that power door lock system operates properly referring to “power door...

  • Page 1642

    10e-15 keyless start system: trunk lid opener function of keyless start system (sedan) note • use of suzuki scan tool makes it easy to check whether a faulty condition is on the input side or output side of bcm. For checking procedure, refer to “diagnosis using output test function of suzuki scan to...

  • Page 1643

    Keyless start system: 10e-16 keyless start system operation inspection s7rw0aa504011 keyless engine start operation 1) sit in driver seat with remote controller carried with you. 2) check that all doors are closed and ignition key is not inserted in ignition key cylinder. 3) while pushing ignition k...

  • Page 1644

    10e-17 keyless start system: voltage check 1) disconnect negative cable (–) at battery. 2) remove keyless start control module from vehicle body referring to “keyless start control module removal and installation”. 3) connect connector to keyless start control module. 4) check voltage at each termin...

  • Page 1645

    Keyless start system: 10e-18 g16-18 can communication line (low) *1.6 – 2.5 v refer to “reference waveform no. 4: ” g16-19 can communication line (high) *2.5 – 3.6 v g16-20 power supply for steering lock unit 4 – 6 v full time g16-21 — — — g16-22 — — — g16-23 passenger side door antenna (–) *0 – 5 v...

  • Page 1646

    10e-19 keyless start system: reference waveform no. 1 driver, passenger and rear end door / trunk lid antenna request signals (request signal (1) transmitted by each door antenna when each door request switch is pushed) reference waveform no. 2 center antenna signal (request signal (1) transmitted b...

  • Page 1647

    Keyless start system: 10e-20 reference waveform no. 4 can communication signals (can signal communicated to each control module when ignition switch is turned on) reference waveform no. 5 steering lock unit signal (signal (1) communicated between keyless start control module and steering lock unit w...

  • Page 1648

    10e-21 keyless start system: in case the position of passenger side door lock is changed from the lock to the unlock when the position of driver and passenger side door is at the lock in case the position of driver side door lock is changed from the lock to the unlock when the position of driver and...

  • Page 1649

    Keyless start system: 10e-22 no dtc detection after performing dtc check s7rw0aa504014 wiring diagram description the keyless start control module detects dtc by using signals from the key reminder and driver side door request switches. The keyless start control module makes the key indicator light ...

  • Page 1650

    10e-23 keyless start system: key indicator light circuit check (key indicator light doesn’t light when ignition knob switch is pushed) s7rw0aa504015 wiring diagram 4 keyless start control module power and ground circuit check 1) check keyless start control module power and ground circuit for conditi...

  • Page 1651

    Keyless start system: 10e-24 description when the ignition knob switch is pushed, the key indicator light lights up in blue if you carry the remote controller registered in the keyless start control module and it lights in red if you carry the remote controller which has not been registered in the k...

  • Page 1652

    10e-25 keyless start system: keyless start control module power and ground circuit check s7rw0aa504016 wiring diagram troubleshooting blk/orn g16-9 g16-15 g16-10 g16-11 blu/wht wht/red red/blk 5v 12v 1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 [a] 4 2 3 3 1 g16 5 8 6 7 3 i7r...

  • Page 1653

    Keyless start system: 10e-26 dtc no. 11: communication error with steering lock unit s7rw0aa504017 wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance”. 2) turn ignition knob switch pushing ignition knob switch. 3) check dtc ref...

  • Page 1654

    10e-27 keyless start system: dtc no. 13 / no. 14: release signal error from steering lock unit / steering lock unit malfunction s7rw0aa504018 dtc detecting condition and trouble area dtc confirmation procedure 1) clear dtc referring to “dtc clearance”. 2) turn ignition knob switch pushing ignition k...

  • Page 1655

    Keyless start system: 10e-28 dtc no. 31: lost communication with bcm s7rw0aa504020 refer to “troubleshooting for can-dtc in section 1a”. Dtc no. 33: control module communication bus off s7rw0aa504021 refer to “troubleshooting for can-dtc in section 1a”. Dtc no. 51 / no. 52 / no. 53: driver side / pa...

  • Page 1656

    10e-29 keyless start system: repair instructions antennas and request switches removal and installation s7rw0aa506001 remove and install antennas and request switches referring to the following figures. 2 request switch check 1) check related door request switch for function referring to “front door...

  • Page 1657

    Keyless start system: 10e-30 front door (driver and passenger side), rear end door / trunk lid request switch inspection s7rw0aa506002 1) remove front door trim, rear end door trim or trunk lid trim. 2) disconnect request switch connector. 3) check for continuity between terminals “1” and “2” at eac...

  • Page 1658

    10e-31 keyless start system: front door lock switch inspection s7rw0aa506005 1) remove door trim from door panel referring to step 1) to 3) of “front door glass removal and installation in section 9e”. 2) check for continuity between terminals “1” and “2” at each switch position as shown below. If c...

  • Page 1659

    Keyless start system: 10e-32 3) remove battery (4) from lower case (5). Caution ! Use care not to allow grease or dirt to be attached on the printed circuit board and the battery. 4) replace the battery (lithium disc-type cr 2032 or equivalent battery) so its (+) terminal faces on remote controller ...

  • Page 1660

    10e-33 keyless start system: if remote controller or keyless start control module is replaced or additional remote controller is necessary, register id code(s) of remote controller. 1) sit in driver seat and close all doors. 2) check that door lock of driver seat is unlocked. 3) insert ignition key ...

  • Page 1661

    Prepared by 1st ed. Jul., 2007.

  • Page 1662: Service Manual

    36.5 mm 9 9 5 0 0 -5 2 l 1 0 -0 1 e s e r v ic e m a n u a l vol. 1 of 2 99500-52l10-01e service manual volume 1 of 2 rw415/rw416.

  • Page 1663: Service Manual

    30.0 mm 9 9 5 0 0 -5 2 l 1 0 -0 1 e s e r v ic e m a n u a l vol. 2 of 2 99500-52l10-01e service manual volume 2 of 2 rw415/rw416.