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Suzuki Wagon R Plus RB310 Service Manual

Summary of Wagon R Plus RB310

  • Page 1

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

  • Page 2: Foreword

    Foreword this supplementary service manual is a supplement to rb413 service manual. It has been pre- pared exclusively for the following applicable model. Applicable model: rb410/rb413 of and after the vehicle identification number below. If describes only different service information of the above ...

  • Page 4: Table Of Contents

    Table of contents general information engine and emission control system (g10 engine) 6e1 0a 6e1 general information 0a 0b 6e2 maintenance and lubrication 0b engine and emission control system (m13 engine) 6e2 6f1 heating and air conditioning 1a 6f2 heater and ventilation 1a ignition system (g10 eng...

  • Page 6: Section 0A

    General information 0a-1 0a section 0a general information contents how to use this manual.................................0a-2 precautions......................................................0a-3 precaution for vehicles equipped with a supplemental restraint (air bag) system.....0a-3 diagnosis.......

  • Page 7: How To Use This Manual

    0a-2 general information how to use this manual 1) there is a “table of contents” on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a “contents” on the first page of each section, where the main items in that section are li...

  • Page 8: Precautions

    General information 0a-3 precautions precaution for vehicles equipped with a sup- plemental restraint (air bag) system warning: • the configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be sure to follow proce...

  • Page 9

    0a-4 general information diagnosis • when troubleshooting air bag system, be sure to follow “diagnosis” in section 10b. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. • never use electrical test equipment other than that speci...

  • Page 10

    General information 0a-5 servicing and handling warning: many of service procedures require disconnection of “air bag” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, passenger and side air bag (inflator) modules • for handling and storage ...

  • Page 11

    0a-6 general information • even when the accident was light enough not to cause air bags to activate, be sure to inspect sys- tem parts and other related parts according to instructions under “repair and inspection required after an accident” in section 10b. • when servicing parts other than air bag...

  • Page 12

    General information 0a-7 • warning / caution labels are attached on each part of air bag system components. Be sure to fol- low the instructions. • after vehicle is completely repaired, perform “air bag diagnostic system check” in section 10b. General precautions the warning and caution below descri...

  • Page 13

    0a-8 general information • when removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. • when removing parts that are to be reused, ...

  • Page 14

    General information 0a-9 • 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, exhaust or brake systems, check all lines related to the system for leaks. • for vehicl...

  • Page 15

    0a-10 general information precaution for can communication system • the loose (1) in the wire harnesses twist of the can lines except around the connector (3) should be within 100 mm (3.9 in.) refer to the wiring diagram for the can line discrim- ination. Excessive loosed lines may be influenced by ...

  • Page 16

    General information 0a-11 precaution in servicing full-time 4wd vehicle this full-time 4wd vehicle can not be converted to 2wd manually. Observe the following caution in servicing. Otherwise, front wheels drive rear wheels or vise-versa and vehicle accidents, drivetrain damage and personal injury ma...

  • Page 17

    0a-12 general information precautions for electrical circuit service • when replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire. • when disconnecting and connecting coupler, make sure to turn...

  • Page 18

    General information 0a-13 • when installing the wiring harness, fix it with clamps so that no slack is left. • when installing vehicle parts, be careful so that the wir- ing harness is not interfered with or caught by any other part. • to avoid damage to the harness, protect its part which may conta...

  • Page 19

    0a-14 general information • when taking measurements at electrical connectors using a tester probe, be sure to insert the probe (2) from the wire harness side (backside) of the connector (1). • when connecting meter probe (2) from terminal side of coupler (1) because it can’t be connected from harne...

  • Page 20

    General information 0a-15 electrical circuit inspection procedure 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 for the open circuit are as...

  • Page 21

    0a-16 general information continuity check 1) measure resistance between connector terminals at both ends of the circuit being checked (between a-1 and c-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals a-1 and c-1. 2) di...

  • Page 22

    General information 0a-17 short circuit check (wire harness to ground) 1) disconnect negative (–) cable at battery. 2) disconnect connectors at both ends of the circuit to be checked. 3) measure resistance between terminal at one end of circuit (a-1 terminal in the figure) and body ground. If contin...

  • Page 23

    0a-18 general information • improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal. If contact tension is not enough, reform it to increase contact tension or replace. • poor termin...

  • Page 24: Identification Information

    General information 0a-19 identification information vehicle identification number the number is punched on front dash panel in engine room and it is also on the left side of instrument panel depending on the vehi- cle specification. Engine identification number the number is punched on cylinder blo...

  • Page 25

    0a-20 general information warning, caution and information labels the figure below 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 warning/caution label is found stained or...

  • Page 26: Vehicle Lifting Points

    General information 0a-21 vehicle lifting points when using frame contact hoist warning: • before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending on what part to be removed. • before lifting up the vehicl...

  • Page 27

    0a-22 general information when using floor jack when lifting front vehicle end with floor jack, be sure to put the wooden block (5) on the jack against front jacking bracket (1). When lifting rear vehicle end with floor jack, be sure to put the jack against the center portion of rear axle (2) (2wd v...

  • Page 28

    General information 0a-23 abbreviations and symbols may be used in this manual abbreviations a abs anti-lock brake system e efe heater early fuel evaporation heater (positive temperature coeffi- cient, ptc heater) atdc after top dead center api american petroleum institute atf automatic transmission...

  • Page 29

    0a-24 general information p psp switch power steering pressure switch (p/s pressure switch) pcm powertrain control module pcv positive crankcase ventilation r rh right hand s sae society of automotive engineers sdm sensing and diagnostic module (air bag controller, air bag control module) sfi sequen...

  • Page 30

    General information 0a-25 symbols wire color symbols 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. ...

  • Page 31: Fastener Information

    0a-26 general information fastener information metric fasteners information most of the fasteners used for this vehicle are jis-defined and iso-defined metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diame- ter, thread pitch and strength...

  • Page 32

    General information 0a-27 fastener strength identification most commonly used metric fastener strength property classes are 4t, 6.8, 7t, 8.8 and radial line with the class identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark strength identificatio...

  • Page 33

    0a-28 general information tightening torque chart: thread diameter (nominal diameter) (mm) 4 5 6 8 10 12 14 16 18 strength a equivalent of 4t strength fastener n·m 1.5 3.0 5.5 13 29 45 65 105 160 kg-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16 lb-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0 a equivalent...

  • Page 34: Section 0B

    Maintenance and lubrication 0b-1 0b section 0b maintenance and lubrication contents maintenance schedule ...................................0b-3 maintenance schedule under normal driving conditions .........................................0b-3 maintenance recommended under severe driving conditions....

  • Page 35

    0b-2 maintenance and lubrication transfer oil (4wd) and rear differential oil (4wd) inspection................................... 0b-19 transfer oil (4wd) and rear differential oil (4wd) replacement .............................. 0b-20 all latches, hinges and locks inspection...........................

  • Page 36: Maintenance Schedule

    Maintenance and lubrication 0b-3 maintenance schedule maintenance schedule under normal driving conditions note: • this interval should be judged by odometer reading or months, whichever comes first. • this table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km ...

  • Page 37

    0b-4 maintenance and lubrication interval km (x 1,000) 15 30 45 60 75 90 miles (x 1,000) 9 18 27 36 45 54 months 12 24 36 48 60 72 brake brake discs and pads (thickness, wear, damage) i i i i i i brake drums and shoes (wear, damage) – i – i – i brake hoses and pipes (leakage, damage, clamp) – i – i ...

  • Page 38

    Maintenance and lubrication 0b-5 maintenance recommended under severe driving conditions if the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as show...

  • Page 39: Maintenance Service

    0b-6 maintenance and lubrication maintenance service drive belt inspection (m13 engine) water pump and generator drive belt inspection 1) disconnect negative (–) cable at battery. 2) inspect belt for cracks, cuts, deformation, wear and cleanli- ness. If any defect exists, replace. Check belt for ten...

  • Page 40

    Maintenance and lubrication 0b-7 drive belt inspection (g10 engine) a/c compressor drive belt inspection (if equipped) 1) hoist vehicle and remove engine under cover of right side from vehicle body. 2) inspect belt for wear, deterioration and tension. Replace or adjust, if necessary. A/c compressor ...

  • Page 41

    0b-8 maintenance and lubrication camshaft timing belt replacement (g10 engine) replace belt with new one. Refer to section 6a for replacement procedure. Valve lash (clearance) inspection (m13 engine) 1) inspect intake and exhaust valve lash and adjust as neces- sary. Refer to “valve lash (clearance)...

  • Page 42

    Maintenance and lubrication 0b-9 engine oil and oil filter replacement before draining engine oil, check engine for oil leakage. If any evi- dence of leakage is found, make sure to correct defective part before proceeding to the following work. 1) drain engine oil by removing drain plug. 2) after dr...

  • Page 43

    0b-10 maintenance and lubrication 5) tighten the filter (1) 3/4 turn from the point of contact with the mounting surface using an oil filter wrench (2). Tightening torque oil filter (b): 14 n·m (1.4 kg-m, 10.5 lb-ft) (for reference) 6) replenish oil until oil level is brought to full level mark on d...

  • Page 44

    Maintenance and lubrication 0b-11 engine coolant replacement change engine coolant with new one referring to “cooling system flush and refill” in section 6b or 6b2. Exhaust system inspection when carrying out periodic maintenance, or the vehicle is raised for other service, check exhaust system as f...

  • Page 45

    0b-12 maintenance and lubrication distributor cap and rotor inspection (g10 engine) • check distributor cap and rubber caps for cracks. • clean dusty and stained parts using a dry, soft cloth. • check center electrode and terminals for wear. • check rotor for cracks and its electrode for wear. Repai...

  • Page 46

    Maintenance and lubrication 0b-13 fuel tank inspection check fuel tank damage, cracks, fuel leakage, corrosion and tank bolts looseness. If a problem is found, repair or replace. Pcv valve inspection check crankcase ventilation hose and pcv hose for leaks, cracks or clog, and pcv valve for stick or ...

  • Page 47

    0b-14 maintenance and lubrication brake drums and shoes (rear) inspection 1) remove wheel and brake drum. 2) check rear brake drums and brake linings for excessive wear and damage, while wheels and drums are removed. At the same time, check wheel cylinders for leaks. Replace these parts as necessary...

  • Page 48

    Maintenance and lubrication 0b-15 2) check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever. 3) check parking brake lever for proper operation and stroke, and adjust it if necessary. For checking and adjusting procedures, refer to “parking brake inspe...

  • Page 49

    0b-16 maintenance and lubrication wheel discs inspection inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Wheel bearing inspection 1) check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to “wheel disc,...

  • Page 50

    Maintenance and lubrication 0b-17 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 steering gear case for damage (leak, detachment, tear, etc.). If damage is found, replace defective boot with new one. I...

  • Page 51

    0b-18 maintenance and lubrication manual transmission oil inspection 1) inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) make sure that vehicle is placed level for oil level check. 3) remove oil filler/level plug (1) of transmission. 4) check oil level. Oil level ...

  • Page 52

    Maintenance and lubrication 0b-19 automatic transmission fluid replacement 1) inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) make sure that vehicle is placed level for fluid level check. 3) change fluid. For its procedure, refer to “fluid change” in section 7...

  • Page 53

    0b-20 maintenance and lubrication transfer oil (4wd) and rear differential oil (4wd) replacement change transfer oil and differential oil with new specified oil refer- ring to “transfer oil change” in section 7d or “rear differential oil change” in section 7f. All latches, hinges and locks inspectio...

  • Page 54: Final Inspection

    Maintenance and lubrication 0b-21 final inspection seats check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front seat back allows it to be locked at any angle. Seat belt inspect belt system including webbing, buckles, latch plates, retractors ...

  • Page 55

    0b-22 maintenance and lubrication foot brake check the followings: • that brake pedal has proper travel, • that brake works properly, • that it is free from noise, • that vehicle does not pull to one side when brake is applied. • and that brake do not drag. Parking brake check that lever has proper ...

  • Page 56

    Maintenance and lubrication 0b-23 recommended fluids and lubricants engine oil sg, sh, sj or sl grade (refer to “engine oil and oil filter replace- ment” in this section for engine oil viscosity.) engine coolant (ethylene glycol base coolant) “antifreeze / anticorrosion coolant” brake fluid dot 4 or...

  • Page 57

    0b-24 maintenance and lubrication.

  • Page 58: Section 1B

    Air conditioning (optional) 1b-1 1b section 1b air conditioning (optional) contents diagnosis........................................................ 1b-2 wiring circuit (m13 engine model)............... 1b-2 a/c system inspection of ecm and its circuits (m13 engine model)......................... 1...

  • Page 59: Diagnosis

    1b-2 air conditioning (optional) diagnosis wiring circuit (m13 engine model) 1. Main fuse box 7. A/c switch 13. A/c evaporator thermistor 2. Main relay 8. Dual pressure switch 14. Ect sensor 3. Radiator (and condenser) cooling fan motor relay 9. Blower fan motor relay 15. Compressor relay 4. Radiato...

  • Page 60

    Air conditioning (optional) 1b-3 a/c system inspection of ecm and its cir- cuits (m13 engine model) ecm and its circuits can be checked at ecm wiring couplers by measuring voltage. Inspection 1) remove ecm (1) from vehicle. 2) connect ecm (1) couplers to ecm. 3) check voltage at each terminal of cou...

  • Page 61

    1b-4 air conditioning (optional) terminal arrangement of ecm coupler (viewed from harness side) ecm voltage values table for relation of a/c control (m13 engine model) b. To “heater” fuse (25a) in circuit fuse box 2. Dual pressure switch 7. A/c evaporator thermistor 12. Radiator (and condenser) cool...

  • Page 62

    Air conditioning (optional) 1b-5 compressor drive belt (m13 engine model) inspection • check compressor drive belt (6) for wear and cracks, and replace as required. • check compressor drive belt (6) tension by measuring how much it deflects when pushed at intermediate point between compressor pulley...

  • Page 63: On-Vehicle Service

    1b-6 air conditioning (optional) 4) install new compressor drive belt. 5) adjust belt tension referring to above procedure. On-vehicle service dual pressure switch inspection 1) check dual pressure switch (1) for continuity at normal tempera- ture (approx. 25 º c (77 º f)) when a/c system has a prop...

  • Page 64

    Air conditioning (optional) 1b-7 4) check that there is continuity between terminals “a” and “b” when battery is connected to terminals “c” and “d”. If found defective, replace. Compressor (m13 engine model) removal 1) run engine at idle speed with air conditioning on for 10 min- utes. After that, s...

  • Page 65

    1b-8 air conditioning (optional).

  • Page 66: Section 3A

    Front wheel alignment 3a-1 3a section 3a front wheel alignment contents general description ........................................3a-2 front wheel alignment specifications ..........3a-2 warning: do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by t...

  • Page 67: General Description

    3a-2 front wheel alignment general description front wheel alignment specifications front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Generally, the only adjustment required for front alignment is toe setting. Camber and...

  • Page 68: Section 3B

    Manual rack and pinion 3b-1 3b section 3b manual rack and pinion contents on-vehicle service..........................................3b-2 tie rod end ..................................................3b-2 manual rack and pinion assembly (steering gear case) ....................................3b-3 ...

  • Page 69: On-Vehicle Service

    3b-2 manual rack and pinion on-vehicle service tie rod end installation 1) install tie rod end lock nut (1) and tie rod end (2) to tie rod (3). Align lock nut with mark (4) on tie rod thread. 2) connect tie rod end to knuckle. Tighten new tie rod end nut (1) to specified torque. Tightening torque ti...

  • Page 70

    Manual rack and pinion 3b-3 manual rack and pinion assembly (steering gear case) installation 1) apply grease to inside of pinion packing and install pinion packing onto pinion. Mount steering gear case (1) to body and tighten gear case mount bolts (2) and nuts (3) to speci- fied torque. Tightening ...

  • Page 71

    3b-4 manual rack and pinion 7) reinstall cover (1) removed previously to steering shaft joint. 8) put back floor mat as it was. 9) install both wheels and tighten wheel bolts to specified torque. Tightening torque wheel bolt: 95 n·m (9.5 kg-m, 69.0 lb-ft) 10) lower hoist. 11) check toe setting. Adju...

  • Page 72: Section 3B1

    Electrical power steering (eps) system (if equipped) 3b1-1 3b1 section 3b1 electrical power steering (eps) system (if equipped) contents general description ......................................3b1-2 wiring diagram ...........................................3b1-2 diagnosis.............................

  • Page 73: General Description

    3b1-2 electrical power steering (eps) system (if equipped) general description wiring diagram 1. Main fuse box 8. Speedometer 15. Motor assembly (with clutch incorporated) 2. “eps” fuse (30 a) 9. “eps” warning lamp 16. Torque sensor 3. Ignition switch 10. To vehicle speed sensor (vss) for g10 engine...

  • Page 74: Diagnosis

    Electrical power steering (eps) system (if equipped) 3b1-3 diagnosis “eps” warning lamp circuit check flow table for m13 engine model caution: be sure to perform “system check flow table” before starting diagnosis according to flow table. Step action yes no 1 1) make sure that battery voltage is abo...

  • Page 75

    3b1-4 electrical power steering (eps) system (if equipped) table-b “eps” warning lamp remains on step action yes no 1 was “system check flow table” performed? Go to step 2. Go to “system check flow table” in this section. 2 1) with ignition switch off, disconnect 8 pin (“a”) connector from p/s contr...

  • Page 76: Section 3D

    Front suspension 3d-1 3d section 3d front suspension contents general description ........................................3d-2 diagnosis.........................................................3d-3 wheel disc, bolt & bearing check................3d-3 on-vehicle service..................................

  • Page 77: General Description

    3d-2 front suspension general description the front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehi- cle body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also installed a little lower to the ...

  • Page 78: Diagnosis

    Front suspension 3d-3 diagnosis wheel disc, bolt & bearing check 1) inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. 2) check wheel bolts for tightness and retighten them to specifi- cation as necessary. Tightening torque wheel bolt (a): 9...

  • Page 79: On-Vehicle Service

    3d-4 front suspension on-vehicle service stabilizer bar and/or bushings components installation for installation, reverse removal procedure, observing the follow- ing instructions. • install stabilizer bar (1) so that paint mark (2) on it comes to the right side of vehicle. • align the outside edge ...

  • Page 80

    Front suspension 3d-5 • install mounting bracket (1) so that its oblong hole side (2) comes to the rear. • tighten stabilizer bar bracket bolts to specified torque. Tightening torque stabilizer bar bracket bolt: 45 n · m (4.5 kg-m, 32.5 lb-ft) • after tightening castle nut (1) to specified torque, i...

  • Page 81

    3d-6 front suspension • install wheel and tighten wheel bolts to specified torque. Tightening torque wheel bolt (a) 95 n · m (9.5 kg-m, 69.0 lb-ft) • confirm front end (wheel) alignment, referring to section 3a. Steering knuckle / bearing components 1. Wheel hub 5. Dust cover 9. Tie-rod end nut 13. ...

  • Page 82

    Front suspension 3d-7 removal 1) hoist vehicle and remove wheel. 2) uncaulk drive shaft nut (1). 3) depress foot brake pedal and hold it there. Remove drive shaft nut. 4) remove caliper carrier bolts. 5) remove caliper with carrier. 6) remove brake disk screws. 7) pull brake disc (1) off by using tw...

  • Page 83

    3d-8 front suspension 9) remove tie-rod end nut and disconnect tie-rod end (2) from knuckle (1) with puller. 10) remove wheel speed sensor (1) from knuckle (if equipped). 11) remove strut bracket bolts (1) from strut bracket and then control arm ball stud bolt (2). 12) remove knuckle (3). Disassembl...

  • Page 84

    Front suspension 3d-9 2) remove circlip (1). Special tool (a): 09900-06108 3) remove wheel bearing using special tool and hydraulic press. Special tool (a): 09913-75810 (for gasoline engine model) (a): 09913-85210 (for diesel engine model) 4) remove wheel bearing outside inner race (1) as shown by h...

  • Page 85

    3d-10 front suspension 2) install circlip (1). Special tool (a): 09900-06108 3) drive in dust cover (1) so that dimensions “a” and “b” become equal as shown. 4) caulk with a punch. Installation 1) using special tools and hydraulic press (1), drive wheel hub (2) into wheel bearing (3) as shown. Speci...

  • Page 86

    Front suspension 3d-11 • apply grease lightly to contact part (1) of wheel bearing and drive shaft. “a”: grease 99000-25050 2) install knuckle (2) to ball stud (3) on suspension control arm (4) and strut bracket (1). Installing direction of each bolt is as shown. Align knuckle bolt hole with ball st...

  • Page 87

    3d-12 front suspension 6) install brake disc. 7) tighten brake disc screws. Tightening torque brake disc screw (a): 9 nm (0.9 kg-m, 6.5 lb-ft) 8) install brake caliper/caliper carrier. 9) tighten caliper carrier bolts to specified torque. Tightening torque brake caliper carrier bolt (b): 95 n · m (9...

  • Page 88

    Front suspension 3d-13 7) remove bushing. Place suspension control arm onto flat surface side of spe- cial tool and push out bushing with special tool and oil hydraulic press as shown. Special tool (a): 09943-77910 installation 1) place suspension control arm onto flat surface side of spe- cial tool...

  • Page 89

    3d-14 front suspension 3) install ball stud (2) to knuckle (1). Align ball stud groove with knuckle bolt hole as shown. Then install ball stud bolt from the direction as shown. Tighten control arm ball stud bolt to specified torque. Tightening torque control arm ball stud bolt (a): 60 n · m (6.0 kg-...

  • Page 90: Required Service Material

    Front suspension 3d-15 required service material special tool material recommended suzuki product (part number) use lithium grease (should be applicable for –40 c° – 130 °c or –40 °f – 266 °f) suzuki super grease (e) (99000-25050) • wheel bearing 09943-17912 09942-15511 09900-06108 09913-75810 front...

  • Page 91

    3d-16 front suspension.

  • Page 92: Section 3E

    Rear suspension 3e-1 3e 3f 4 4b 5 5a 5b 5c 6-2 6a2 6b2 section 3e rear suspension contents general description ........................................3e-2 diagnosis.........................................................3e-4 wheel disc, bolt and bearing check ............3e-4 on-vehicle service......

  • Page 93: General Description

    3e-2 rear suspension general description 2wd model 1. Rear coil spring 4. Rear shock absorber 7. Rear axle 10. Circlip 2. Rear bump stopper 5. Lateral rod 8. Wheel bearing tightening torque 3. Rear spring upper seat 6. Trailing arm 9. Brake drum 6 7 5 2 1 3 4 90 n·m(9.0 kg-m) 63 n·m(6.3 kg-m) 63 n·m...

  • Page 94

    Rear suspension 3e-3 4wd model a: with abs 4. Rear shock absorber 9. Brake drum 14. Wheel bearing retainer ring or rear wheel sensor ring (if equipped with abs) b: without abs 5. Lateral rod 10. Rear axle shaft 15. Spacer 1. Rear coil spring 6. Trailing arm 11. Breather cap tightening torque 2. Rear...

  • Page 95: Diagnosis

    3e-4 rear suspension diagnosis wheel disc, bolt and bearing check • inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. • check wheel bolts for tightness and, as necessary, retighten to specification. Tightening torque wheel bolt (a): 95 n · ...

  • Page 96: On-Vehicle Service

    Rear suspension 3e-5 on-vehicle service 2wd model “a”: body outside 7. Lateral rod outer washer 14. Lspv bracket (only vehicle with lspv) 21. Trailing arm rear bolt: insert from vehicle inside. 1. Rear coil spring 8. Rear axle 15. Brake back plate: apply water tight sealant 99000-31090 to joint of p...

  • Page 97

    3e-6 rear suspension 4wd model “a”: body outside 11. Oil seal 22. Brake back plate bolt 1. Rear coil spring 12. Spacer: the tapered side of spacer inner diameter directed toward outside (brake drum side). 23. Bearing retainer ring (without abs) 2. Rear bump stopper: apply soap water, when installing...

  • Page 98

    Rear suspension 3e-7 lateral rod installation 1) install lateral rod (1) or (2) to rear axle (or axle housing) (3) and vehicle body (4) referring to figure for proper installing direction of bolt (5) and washer (6). Tighten nuts (7) temporarily at this step. 2) lower hoist. 3) tighten lateral rod nu...

  • Page 99

    3e-8 rear suspension coil spring installation 1) install coil springs (1) (right & left) on spring seat (2) of rear axle as shown in figure and then raise rear axle. 2) install shock absorber (1) lower side to rear axle (or axle housing). Tighten shock absorber lower bolt (2) temporarily by hand at ...

  • Page 100

    Rear suspension 3e-9 8) lower hoist and vehicle in non-loaded condition, tighten absorber lower bolt (1) and lateral rod body side nut (2) to specified torque. Tightening torque rear shock absorber lower bolt (a): 63 n·m (6.3 kg-m, 45.5 lb-ft) lateral rod nut (body side) (b): 100 n·m (10.0 kg-m, 72....

  • Page 101

    3e-10 rear suspension 2) install wheel speed sensor lead wire clamp, if equipped. 3) install parking brake cable clamp (1). 4) install shock absorber (1) to rear axle (2). 5) tighten shock absorber lower bolt (3) temporarily by hand. 6) remove floor jack from rear axle. 7) install wheel and tighten ...

  • Page 102

    Rear suspension 3e-11 rear axle (for 2wd model) installation install removed parts in reverse order of removal, noting the fol- lowing points. 1) place rear axle on floor jack. Then install lateral rod to rear axle and tighten nut temporarily by hand. 2) install trailing arm rear bolts (1) (right & ...

  • Page 103

    3e-12 rear suspension 7) install brake back plates (1) and tighten back plate bolts (2) to specified torque. Tightening torque brake back plate bolt (a): 23 n · m (2.3kg-m, 16.5 lb-ft) 8) connect wheel speed sensor and lead wire clamps (right & left) (if equipped). 9) connect brake pipes to wheel cy...

  • Page 104

    Rear suspension 3e-13 12) install brake drums (right & left). For details, refer to steps 3) to 8) of “brake drum installation” in section 5c. 13) fill reservoir with brake fluid and bleed brake system. (for bleeding operation, refer to section 5.) 14) install wheel and tighten wheel bolts to specif...

  • Page 105

    3e-14 rear suspension 2) remove circlip (1). Special tool (a): 09900-06108 3) remove wheel bearing by using special tool and hydraulic press. Special tool (a): 09913-76010 installation 1) install new wheel bearing (1) by using special tool and hydraulic press. Special tool (a): 09913-75810 2) instal...

  • Page 106

    Rear suspension 3e-15 rear axle shaft and wheel bearing (for 4wd model) removal 1) hoist vehicle and remove rear wheels. 2) remove brake drum screw and rear brake drum by using 8 mm bolts. For details referring to section 5c. 3) drain gear oil from rear axle housing by loosening drain plug (1). 4) r...

  • Page 107

    3e-16 rear suspension 10) in order to remove the retainer ring (1) from the axle shaft (2), grind (3) with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin. 11) break with a chisel the thin ground retainer ring, and it can be removed. 12) using special tools, remo...

  • Page 108

    Rear suspension 3e-17 installation install removed parts in reverse order of removal, noting the fol- lowing points. 1) install wheel bearing spacer (1) with the tapered side of its inner diameter directed toward outside, or brake drum side. 2) press in a new bearing (2) and retainer ring (3) in ord...

  • Page 109

    3e-18 rear suspension 6) install rear axle shaft to rear axle housing and tighten brake back plate bolts to specified torque. Tightening torque brake back plate bolt (a): 23 n·m (2.3 kg-m, 17.0 lb-ft) 7) connect brake pipe to wheel cylinder and tighten brake pipe flare nut to specified torque. Tight...

  • Page 110

    Rear suspension 3e-19 rear axle housing (for 4wd model) removal 1) hoist vehicle and remove rear wheels referring to “wheel removal and installation” in section 3f. 2) remove rear axle shafts (right & left) referring to steps 2) – 9) of “rear axle shaft and wheel bearing (for 4wd model)” in this sec...

  • Page 111

    3e-20 rear suspension 11) loosen trailing arm rear mounting nuts (3) (right & left) from axle housing, but don’t remove bolts. 12) remove shock absorber lower mounting bolts (1). 13) lower floor jack until tension of suspension coil spring becomes a little loose and remove trailing arm rear mounting...

  • Page 112

    Rear suspension 3e-21 installation install removed parts in reverse order of removal, noting the fol- lowing. 1) place rear axle housing on floor jack. Then install rear trail- ing arm bolts (1) (right & left) in proper direction as shown. Then tighten nuts (2) temporarily by hand. 2) install coil s...

  • Page 113

    3e-22 rear suspension 5) clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side. “a”: sealant 99000-31110 6) install differential carrier assembly to axle housing and tighten carrier bolts to specified torque. Tightening torque rear differential carrier ...

  • Page 114

    Rear suspension 3e-23 15) install rear axle shaft (right & left) to rear axle housing. 16) tighten brake back plate bolts to specified torque. Tightening torque brake back plate bolt (a): 23 n·m (2.3 kg-m, 17.0 lb-ft) 17) connect brake pipes (3) to wheel cylinders (1) (right & left) and tighten brak...

  • Page 115

    3e-24 rear suspension 26) tighten right and left trailing arm nuts (1) and shock absorber lower bolts (2) to specified torque. Tighten lateral rod nuts (3) to specified torque. Tightening torque trailing arm rear nut (a): 80 n·m (8.0 kg-m, 58.0 lb-ft) rear shock absorber lower bolt (b): 63 n·m (6.3 ...

  • Page 116: Required Service Material

    Rear suspension 3e-25 required service material material recommended suzuki product (part number) use lithium grease suzuki super grease (a) (99000-25010)···(for 4wd model) • axle shaft oil seal sealant suzuki bond no. 1215 (99000-31110)···(for 4wd model) • joint seam of differential carrier and axl...

  • Page 117: Special Tool

    3e-26 rear suspension special tool 09913-75810 09913-76010 09927-18411 09900-06108 bearing installer (for 2wd model) rear wheel bearing installer (for 2wd model) universal puller (for 4wd model) snap ring pliers (for 2wd model) 09942-15511 09943-17912 09921-57810 09913-50121 sliding hammer brake dru...

  • Page 118: Section 3F

    Wheels and tires 3f-1 3f section 3f wheels and tires contents general description ....................................... 3f-2 tires ............................................................. 3f-2 maintenance and minor adjustments........... 3f-2 wheel maintenance ...................................

  • Page 119: General Description

    3f-2 wheels and tires general description tires this vehicle is equipped with the following tire. Tire specification 165/60r14 75t ········ gasoline engine model 165/60r14 79t ····························· diesel engine model the tire is of tubeless type. The tire is designed to operate satisfactori...

  • Page 120: On-Vehicle Service

    Wheels and tires 3f-3 on-vehicle service service operations wheel bolts all models use metric lug wheel bolts. Metric lug bolt size (1): m12 x 1.5 wheel removal 1) loosen wheel bolts by approximately 180 ° (half a rotation). 2) hoist vehicle. 3) make sure that the vehicle will not fall off by trying...

  • Page 121

    3f-4 wheels and tires tightening order “a” – “b” – “c” – “d”: tightening torque wheel bolt (a): 95 n · m (9.5 kg-m, 69.0 lb-ft) tightening torque specifications fastening part tightening torque n•m kg-m lb-ft wheel bolt 95 9.5 69.0

  • Page 122: Section 4A

    Front drive shaft (g10/m13 engines) 4a-1 4a 4b 5 5a 5b 5c 6-2 6a2 6b2 section 4a front drive shaft (g10/m13 engines) contents general description ....................................... 4a-1 diagnosis........................................................ 4a-1 on-vehicle service.......................

  • Page 123: On-Vehicle Service

    4a-2 front drive shaft (g10/m13 engines) on-vehicle service front drive shaft assembly construction 1. Transaxle 7. Oil filler/level plug : apply sealant 99000-31260 to plug thread 13. Drive shaft washer 2. Drive shaft assembly 8. Oil drain plug : apply sealant 99000-31260 to plug thread 14. Center ...

  • Page 124

    Front drive shaft (g10/m13 engines) 4a-3 front drive shaft assembly removal and installation removal 1) undo caulking (1) and remove drive shaft nut (2). 2) loosen wheel bolts. 3) hoist vehicle. 4) remove wheel. 5) drain transaxle oil as follows. • for m/t model with g10 engine refer to “oil change”...

  • Page 125

    4a-4 front drive shaft (g10/m13 engines) 9) pull out drive shaft joint (2) as follows. • for left side of all model and right side of g10 engine model using tire lever (1), pull out drive shaft joint (2) so as to release snap ring fitting of joint spline at differential side. • for right side of 2wd...

  • Page 126

    Front drive shaft (g10/m13 engines) 4a-5 installation reverse removal procedure for installation noting the following. • install wheel side joint to steering knuckle first, and then dif- ferential side joint to transaxle. • tighten each bolt and nut to the specified torque referring to “front drive ...

  • Page 127

    4a-6 front drive shaft (g10/m13 engines) front drive shaft components [a]: tripod joint type 6. Wheel side joint (constant velocity ball joint) : apply black grease included in spare part to joint. 14. Circlip [b]: doj type 7. Boot (wheel side) 15. Center bearing support [c]: center shaft for 2wd mo...

  • Page 128

    Front drive shaft (g10/m13 engines) 4a-7 front drive shaft disassembly and assembly disassembly for doj type 1) remove differential side boot big band (1) as follows. • for boot big band without joint remove boot big band by tapping boot and band with plastic hammer. If it is hard to remove boot big...

  • Page 129

    4a-8 front drive shaft (g10/m13 engines) c) remove cage (1) with retaining ring (2) from housing (3) if necessary. 3) remove differential side boot small band, and then pull out differential side boot from shaft. 4) pull out damper through shaft. 5) remove wheel side boot big band (1) as follows. • ...

  • Page 130

    Front drive shaft (g10/m13 engines) 4a-9 1) remove differential side boot big band (1) as follows. • for boot big band without joint remove boot big band by tapping boot and band with plastic hammer. If it is hard to remove boot big band, cut it using a nipper or a iron saw with care not to damage t...

  • Page 131

    4a-10 front drive shaft (g10/m13 engines) 7) remove wheel side boot big band (1) as follows. • for boot big band without joint cut boot big band using a iron saw or a nipper with care not to damage wheel side joint housing. • for boot big band with joint draw hooks of boot big band together and remo...

  • Page 132

    Front drive shaft (g10/m13 engines) 4a-11 3) install new wheel side boot on shaft temporarily. 4) apply grease in the supplied parts to the inside of joint hous- ing. Grease color: black grease amount: approx. 70 g (2.5 oz) 5) fit wheel side boot onto grooves of housing and shaft. 6) place new wheel...

  • Page 133

    4a-12 front drive shaft (g10/m13 engines) 10) install damper (1) on left side drive shaft according to dimen- sion specified below. Damper installation position for m/t model with m13 engine “a”: 134 – 140 mm (5.28 – 5.51 in.) for a/t model with m13 engine “a”: 157 – 163 mm (6.18 – 6.42 in.) 11) ins...

  • Page 134

    Front drive shaft (g10/m13 engines) 4a-13 15) install boot on joint housing. • for right side when fixing boot (1) to joint housing (2) with differential side boot big band (3), adjust so that measurements become as indicated below. • for left side fit boot to grooves of shaft and housing and adjust...

  • Page 135

    4a-14 front drive shaft (g10/m13 engines) 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 (1) and differential side ...

  • Page 136

    Front drive shaft (g10/m13 engines) 4a-15 5) place new wheel side boot small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure. 6) install wheel side boot small band (1), putting its lower edge against projected end (4) of boot (3) so that clearance “a” is...

  • Page 137

    4a-16 front drive shaft (g10/m13 engines) 11) apply grease to inside of joint housing (1), then install hous- ing, joint it with boot and fit boot to joint housing. After fitting boot, insert screwdriver into boot on joint housing side and allow air to enter boot so that air pressure in boot becomes...

  • Page 138

    Front drive shaft (g10/m13 engines) 4a-17 center shaft and center bearing support dis- assembly and assembly (2wd model with m13 engine) disassembly 1) for m/t model, go to the next step. For a/t model, remove wheel side oil seal and circlip from center bearing support bracket (3). 2) using hydrauli...

  • Page 139

    4a-18 front drive shaft (g10/m13 engines) • when installing left oil seal (1) and right oil seal (2) to center bearing support bracket (3) by using special tools, use care so that the oil seals installed in proper direction and position as shown figure. Special tool (a): 09913-76010 (for a/t model) ...

  • Page 140: Requirped Service Material

    Front drive shaft (g10/m13 engines) 4a-19 requirped service material special tools material recommended suzuki product (part number) use lithium grease suzuki super grease a (99000-25010) • oil seal lip sealant suzuki bond no. 1217g (99000-31260) • oil drain and filler/level plugs for manual transmi...

  • Page 141

    4a-20 front drive shaft (g10/m13 engines).

  • Page 142: Section 4B

    Propeller shafts 4b-1 4b section 4b propeller shafts contents on-vehicle service..........................................4b-2 tightening torque specification...................4b-6 note: for the descriptions (items) not found in this section, refer to the same section of the service manual mentione...

  • Page 143: On-Vehicle Service

    4b-2 propeller shafts on-vehicle service on-vehicle inspection • check propeller shaft connecting bolts for looseness. If looseness is found, tighten to specified torque. • check propeller shaft joints for wear, rattle and damage. If any defect is found, replace. • check propeller shaft center suppo...

  • Page 144

    Propeller shafts 4b-3 removal 1) hoist vehicle. 2) before removing propeller shafts, give match marks (1) on propeller shaft no.2 (4) and companion flange (2) of rear dif- ferential as shown. Also give match marks (1) on propeller shaft no.2 yoke (5), dynamic damper (3), viscous coupling with center...

  • Page 145

    4b-4 propeller shafts 4) if disassembling propeller shaft assembly is necessary, loosen propeller shaft no.2 bolts (1) and viscous coupling nuts (2) to facilitate subsequent disassembling, but keeping each connection provisionally. 5) loosen center support bolts (1), then remove propeller shaft no.1...

  • Page 146

    Propeller shafts 4b-5 installation reverse removal procedure to install propeller shafts noting the following points. • when installing propeller shafts, dynamic damper and vis- cous coupling with center support, align the match marks (1). Otherwise, vibration may occur during driving. • apply threa...

  • Page 147

    4b-6 propeller shafts tightening torque specification fastening portion tightening torque n•m kg-m lb-ft propeller shaft bolt 23 2.3 17.0 propeller shaft no.2 bolt 23 2.3 17.0 center support bolt 55 5.5 40.0 viscous coupling nut 23 2.3 17.0

  • Page 148: Section 5

    Brakes 5-1 5 section 5 brakes contents general description .......................................... 5-2 check and adjustment ..................................... 5-3 bleeding brakes.............................................. 5-3 brake shoe check .......................................... 5-5 t...

  • Page 149: General Description

    5-2 brakes general description when the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis- tons (two in front and four in rear). The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two inde...

  • Page 150: Check And Adjustment

    Brakes 5-3 check and adjustment bleeding brakes bleeding operation is necessary to remove air whenever it entered hydraulic brake system. Hydraulic lines of brake system are based on the diagonal split system. When a brake pipe or hose was disconnected at the wheel, bleeding operation must be perfor...

  • Page 151

    5-4 brakes 3) depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one-third to one half turn. 4) when fluid pressure in the cylinder is almost depleted, retighten bleeder plug. 5) repeat this operation until there are no more air bubbles in hydraulic lin...

  • Page 152

    Brakes 5-5 brake shoe check inspection should be carried out on the following points after brake pedal travel “c” (pedal to silencer clearance) check as described on previous page of this section, even when it is more than specification. Amount of brake shoe wear can be checked as follows. 1) hoist ...

  • Page 153

    5-6 brakes.

  • Page 154: Section 5A

    Brakes pipe/hose/master cylinder 5a-1 5a section 5a brakes pipe/hose/master cylinder contents on-vehicle service..........................................5a-2 rear brake hose/pipe ..................................5a-2 warning: for vehicles equipped with supplemental restraint (air bag) system: • se...

  • Page 155: On-Vehicle Service

    5a-2 brakes pipe/hose/master cylinder on-vehicle service rear brake hose/pipe removal 1) raise and suitably support vehicle. Remove tire and wheel. 2) clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe. Installation 1) reverse removal procedure for bra...

  • Page 156

    Brakes pipe/hose/master cylinder 5a-3 [a]: with abs vehicle 1. Rear brake hose 4. Top side 7. Right side [b]: without abs vehi- cle (2wd) 2. Lspv assembly 5. Out side tightening torque a – g: clamp 3. E–ring (insert delection) 6. Front side [a] [b] view a a detail b view c b c d e f g 3 1 c 3 2 2 3 ...

  • Page 157

    5a-4 brakes pipe/hose/master cylinder [c]: without abs vehicle (4wd) 3. Rear brake hose 7. From master cylinder (secondary) 11. Front side a – g: clamp 4. To left rear wheel cylinder 8. Top side 12. E–ring (insert delection) 1. E–ring 5. To right rear wheel cylinder 9. Left side tightening torque 2....

  • Page 158: Section 5B

    Front brake 5b-1 5b section 5b front brake contents on-vehicle service..........................................5b-2 front disc brake pad ....................................5b-2 front disc brake caliper ...............................5b-3 front brake disc ..............................................

  • Page 159: On-Vehicle Service

    5b-2 front brake on-vehicle service front disc brake pad installation 1) install pads (1). Caution: lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber com- ponents may result. If any component is removed or line disconnected, bleed the brake system. Repla...

  • Page 160

    Front brake 5b-3 2) install caliper (1) and tighten caliper pin bolts (2) to specifica- tion. Tightening torque caliper pin bolt (a): 30 n·m (3.0 kg-m, 22.0 lb-ft) 3) tighten front wheel bolts to specification. Tightening torque wheel bolt (b): 95 n·m (9.5 kg-m, 69.0 lb-ft) 4) upon completion of ins...

  • Page 161

    5b-4 front brake 4) torque wheel bolts to specification. Tightening torque wheel bolt (c): 95 n · m (9.5 kg-m, 69.0 lb-ft) 5) after completing installation, fill reservoir with brake fluid and bleed brake system. Perform brake test and check each installed part for oil leakage. Front brake disc remo...

  • Page 162

    Front brake 5b-5 3) torque caliper carrier bolts (1) to specification. Tightening torque caliper carrier bolt (a): 95 n · m (9.5 kg-m, 69.0 lb-ft) 4) torque front wheel bolts to specifications. Tightening torque wheel bolt (b): 95 n · m (9.5 kg-m, 69.0 lb-ft) 5) upon completion of installation, perf...

  • Page 163

    5b-6 front brake.

  • Page 164: Section 5C

    Parking and rear brake 5c-1 5c section 5c parking and rear brake contents on-vehicle service..........................................5c-2 parking brake cable component location ...5c-4 brake drum (for 2wd model)........................5c-5 brake drum removal and installation (for 4wd model)...........

  • Page 165: On-Vehicle Service

    5c-2 parking and rear brake on-vehicle service caution: • replace all components included in repair kits to service this drum brake. Lubricate parts as speci- fied. • if any hydraulic component is removed or brake line disconnected, bleed the brake system. • the torque values specified are for dry, ...

  • Page 166

    Parking and rear brake 5c-3 1. Brake back plate: clean back plate and apply thin coat of bentonite base brake grease (anti-squeal agent) to six surfaces on which shoe rims rest. 9. Piston assembly 17. Parking brake cable 2. Brake shoe 10. Cover 18. Wheel speed sensor ··· if equipped with abs 3. Retr...

  • Page 167

    5c-4 parking and rear brake parking brake cable component location 1. Parking brake lever assembly 4. Parking cable bracket 7. Parking brake cable bolt 2. Equalizer 5. Parking brake cable: apply water tight sealant 99000-31090 to plate and cable contact. 8. Parking brake lever bolt 3. Adjusting nut ...

  • Page 168

    Parking and rear brake 5c-5 brake drum (for 2wd model) removal 1) hoist vehicle and remove wheel referring to “wheel” removal in section 3f. 2) remove spindle cap (1) as shown (by hammering lightly at 3 locations around it so as not to deform or cause damage to seating part of cap). 3) uncaulk spind...

  • Page 169

    5c-6 parking and rear brake e) pull brake drum (1) off by hand. If it is hard to remove, use special tools. Special tool (a): 09942-15511 (b): 09943-17912 6) remove sensor ring (1) from brake drum (2) using special tool (if equipped with abs). Special tool (a): 09913-75520 (b): 09913-65135 installat...

  • Page 170

    Parking and rear brake 5c-7 3) install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil. 4) install new spindle nut (1). 5) tighten spindle nut (1) to specified torque. Tightening torque spindle nut (a): 175 n·m (17.5 kg-m, 126.5 lb-ft) 6) calk spindl...

  • Page 171

    5c-8 parking and rear brake 2) remove brake drum screw (1) and release parking brake lever. 3) remove brake drum. If brake drum can not be removed easily, increase clearance between brake shoes and drum, referring to step a) – d) in “brake drum (for 2wd model)”. A) pull brake drum off by using 8 mm ...

  • Page 172

    Parking and rear brake 5c-9 6) install wheel and tighten wheel bolts to specified torque. Tightening torque wheel bolt (b): 95 n·m (9.5 kg-m, 69.0 lb-ft) 7) check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and perform brake test (fo...

  • Page 173

    5c-10 parking and rear brake installation 1) apply water tight sealant to mating surfaces of brake back plate and rear axle. “a”: sealant 366e, 99000-31090 2) install brake back plate and tighten back plate bolts to speci- fied torque. Tightening torque brake back plate bolt (a): 24 n·m (2.4 kg-m, 1...

  • Page 174: Required Service Material

    Parking and rear brake 5c-11 8) install wheel and tighten wheel bolts to specified torque. Tightening torque wheel bolt (a): 95 n·m (9.5 kg-m, 69.0 lb-ft) 9) upon completion of all jobs, depress brake pedal with about 300 n (30 kg, 66 lbs) load at least 10 – 15 times until adjuster actuator clicking...

  • Page 175: Special Tools

    5c-12 parking and rear brake special tools 09942-15511 09943-17912 09913-75520 sliding hammer brake drum remover (front wheel hub remover) bearing installer (for 2wd model) snap-on part no. B3404b or equivalent 09913-65135 09926-68310 09950-78230 bearing puller (for 2wd model) bearing installer (for...

  • Page 176: Section 6-2

    Engine general information and diagnosis (m13 engine) 6-2-1 6-2 section 6-2 engine general information and diagnosis (m13 engine) contents general information ....................................... 6-2-3 statement on cleanliness and care ............ 6-2-3 precaution ..................................

  • Page 177

    6-2-2 engine general information and diagnosis (m13 engine) dtc p0113 intake air temperature sensor circuit high .................................... 6-2-73 dtc p0117 engine coolant temperature circuit low............................ 6-2-76 dtc p0118 engine coolant temperature circuit high.............

  • Page 178: General Information

    Engine general information and diagnosis (m13 engine) 6-2-3 general information statement on cleanliness and care 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 179

    6-2-4 engine general information and diagnosis (m13 engine) precaution precaution on engine service the following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reli- able engine performance. • when raising or supporting engin...

  • Page 180

    Engine general information and diagnosis (m13 engine) 6-2-5 • fuel or fuel vapor hose connection varies with each type of pipe. When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to the figure hose connection. After connecting, make sure that it has...

  • Page 181

    6-2-6 engine general information and diagnosis (m13 engine) 3) disconnect fuel pump relay (1) from relay box (2). 4) remove fuel filter cap to release fuel vapor pressure in fuel tank and then reinstall it. 5) start engine and run it till it stops for lack of fuel. Repeat cranking engine 2-3 times f...

  • Page 182: Diagnosis

    Engine general information and diagnosis (m13 engine) 6-2-7 diagnosis engine diagnosis general description this vehicle is equipped with an engine and emission control system which are under control of ecm. The engine and emission control system in this vehicle are controlled by ecm. Ecm has an on-b...

  • Page 183

    6-2-8 engine general information and diagnosis (m13 engine) driving cycle a “driving cycle” consists of engine startup and engine shutoff. 2 driving cycle detection logic the malfunction detected in the first driving cycle is stored in ecm memory (in the form of pending dtc) but the malfunction indi...

  • Page 184

    Engine general information and diagnosis (m13 engine) 6-2-9 in the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the malfunction is detected. These data are not updated. Shown in the table below are examples of how freeze frame data are stored when t...

  • Page 185

    6-2-10 engine general information and diagnosis (m13 engine) precaution in diagnosing trouble for engine • don’t disconnect couplers from ecm, battery cable from bat- tery, ecm ground wire harness from engine or main fuse before confirming diagnostic information (dtc, freeze frame data, etc.) stored...

  • Page 186

    Engine general information and diagnosis (m13 engine) 6-2-11 engine and emission control system check 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 to “customer complaint analysis” in follo...

  • Page 187

    6-2-12 engine general information and diagnosis (m13 engine) 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 requir...

  • Page 188

    Engine general information and diagnosis (m13 engine) 6-2-13 customer problem inspection form (example) note: the above form is a standard sample. It should be modified according to conditions characteristic of each market..

  • Page 189

    6-2-14 engine general information and diagnosis (m13 engine) malfunction indicator lamp (mil) check 1) turn on ignition switch (but the engine at stop) and check that mil (1) lights. If mil does not light up (or mil dims), go to “malfunction indi- cator lamp does not come “on” at ignition switch on ...

  • Page 190

    Engine general information and diagnosis (m13 engine) 6-2-15 note: dtc and freeze frame data stored in ecm memory are also cleared in the following cases. Be careful not to clear them before keeping their record. • when power to ecm is cut off (by disconnecting bat- tery cable, removing fuse or disc...

  • Page 191

    6-2-16 engine general information and diagnosis (m13 engine) dtc table dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0010 camshaft position actuator circuit actual valve timing fails to become close to target advance level of each function although advance control fu...

  • Page 192

    Engine general information and diagnosis (m13 engine) 6-2-17 p0134 o2 sensor (ho2s) circuit no activity detected (sensor–1) output voltage of ho2s–1 fails to go above specifica- tion. (or ho2s–1 circuit open or short) 2 driving cycles p0136 o2 sensor (ho2s) circuit (sensor–2) maximum output voltage ...

  • Page 193

    6-2-18 engine general information and diagnosis (m13 engine) p1601 can communication error transmitting or receiving error detected to ecm for specified time continuously. 1 driving cycle p1603 tcm trouble code detected when ecm receives a trouble code from tcm, which indicates that some problem occ...

  • Page 194

    Engine general information and diagnosis (m13 engine) 6-2-19 fail-safe table when any of the following dtcs is detected, ecm enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ecm detects normal condition after that. Dtc no. Detected item fail-safe operati...

  • Page 195

    6-2-20 engine general information and diagnosis (m13 engine) visual inspection visually check the following parts and systems. Inspection item referring section • engine oil – level, leakage “engine oil and oil filter” in section 0b. • engine coolant – level, leakage “engine coolant” in section 0b. ...

  • Page 196

    Engine general information and diagnosis (m13 engine) 6-2-21 engine basic inspection this check is very important for troubleshooting when ecm has detected no dtc and no abnormality has been found in visual inspection. Follow the flow table carefully. Step action yes no 1 was “engine and emission co...

  • Page 197

    6-2-22 engine general information and diagnosis (m13 engine) 11 check ignition spark as follows: 1) disconnect injector couplers. 2) remove spark plugs and connect them to high-ten- sion cords or ignition coils. 3) ground spark plugs. 4) crank engine and check if each spark plug sparks. Is it in goo...

  • Page 198

    Engine general information and diagnosis (m13 engine) 6-2-23 engine symptom diagnosis perform troubleshooting referring to following table when ecm has detected no dtc and no abnormality has been found in visual inspection and engine basic inspection previously. Condition possible cause reference it...

  • Page 199

    6-2-24 engine general information and diagnosis (m13 engine) low oil pressure improper oil viscosity “engine oil and oil filter replacement” in section 0b. Malfunctioning oil pressure switch “oil pressure switch inspection” in sec- tion 8c. Clogged oil strainer “oil pan and oil pump strainer” in sec...

  • Page 200

    Engine general information and diagnosis (m13 engine) 6-2-25 overheating inoperative thermostat “thermostat inspection” in section 6b2. Poor water pump performance “water pump inspection” in section 6b2. Clogged or leaky radiator “radiator inspection” in section 6b2. Improper engine oil grade “engin...

  • Page 201

    6-2-26 engine general information and diagnosis (m13 engine) excessive engine oil consumption blown cylinder head gasket “valves and cylinder head inspection” in section 6a2. Leaky camshaft oil seals “camshaft, tappet and shim” in sec- tion 6a2. Sticky piston ring “pistons, piston rings, connecting ...

  • Page 202

    Engine general information and diagnosis (m13 engine) 6-2-27 surge (engine power vari- ation under steady throttle or cruise. Feels like vehicle speeds up and down with no change in accelera- tor pedal.) leaky or loosely connected high-tension cord “high-tension cords inspection” in sec- tion 6f2. F...

  • Page 203

    6-2-28 engine general information and diagnosis (m13 engine) engine has no power faulty spark plug “spark plugs inspection” in section 6f2. Faulty ignition coil with ignitor “ignition coil assembly (including igni- tor) inspection” in section 6f2. Leaks, loose connection or disconnection of high-ten...

  • Page 204

    Engine general information and diagnosis (m13 engine) 6-2-29 improper engine idling or engine fails to idle faulty spark plug “spark plugs inspection” in section 6f2. Leaky or disconnected high-tension cord “high-tension cords inspection” in sec- tion 6f2. Faulty ignition coil with ignitor “ignition...

  • Page 205

    6-2-30 engine general information and diagnosis (m13 engine) excessive hydrocar- bon (hc) emission or carbon monox- ide (co) faulty spark plug “spark plugs inspection” in section 6f2. Leaky or disconnected high-tension cord “high-tension cords inspection” in sec- tion 6f2. Faulty ignition coil with ...

  • Page 206

    Engine general information and diagnosis (m13 engine) 6-2-31 scan tool data as the data values given below 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 condi- ti...

  • Page 207

    6-2-32 engine general information and diagnosis (m13 engine) ✱ maf (mass air flow rate) at specified idle speed with no load after warm- ing up 1.0 – 4.0 g/s 0.14 – 0.52 lb/min at 2500 r/min with no load after warming up 4.0 – 12.0 g/s 0.53 – 1.58 lb/min ✱ calc load (calculated load value) at specif...

  • Page 208

    Engine general information and diagnosis (m13 engine) 6-2-33 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...

  • Page 209

    6-2-34 engine general information and diagnosis (m13 engine) long ft b1 (long term fuel trim, %) long term fuel trim value represents long term corrections to the air/fuel mixture computation. A value of 0 indi- cates no correction, a value greater than 0 means an enrichment correction, and a value ...

  • Page 210

    Engine general information and diagnosis (m13 engine) 6-2-35 ignition advance (ignition timing advance for no.1 cylinder, °) ignition timing of no.1 cylinder is commanded by ecm. The actual ignition timing should be checked by using the timing light. Battery voltage (v) this parameter indicates batt...

  • Page 211

    6-2-36 engine general information and diagnosis (m13 engine) inspection of ecm and its circuits ecm and its circuits can be checked at ecm wiring couplers by measuring voltage, pulse signal and resistance. Voltage check 1) remove ecm (1) from vehicle body referring to “engine control module (ecm) re...

  • Page 212

    Engine general information and diagnosis (m13 engine) 6-2-37 terminal number wire color circuit normal voltage condition e23-1 blk/yel ground for ecm below 0.3 v ignition switch turned on e23-2 blk/yel ground for ecm below 0.3 v ignition switch turned on e23-3 blu/red heater output of heated oxygen ...

  • Page 213

    6-2-38 engine general information and diagnosis (m13 engine) e23-16 blk/red egr valve (stepper motor coil 3) output 10 – 14 v ignition switch is turned on *0 – 2 v ↑↓ 8 – 14 v (reference wave- form no.5) ignition switch is turned to st (cranking) position. (output signal is active low duty pulse. Pu...

  • Page 214

    Engine general information and diagnosis (m13 engine) 6-2-39 e23-34 grn/blk egr valve (stepper motor coil 2) output 10 – 14 v ignition switch turned on *0 – 2 v ↑↓ 8 – 14 v (reference wave- form no.5) ignition switch is turned to st (cranking) position. (output signal is active low duty pulse. Pulse...

  • Page 215

    6-2-40 engine general information and diagnosis (m13 engine) e22-9 wht knock sensor signal *2 – 3 v (reference wave- form no.15 and no.16) ignition switch turned on engine running at idling with after warm- ing up e22-10 orn reference (classified cylinder) signal for cmp sensor *0 – 0.6 v ↑↓ 4 – 5 v...

  • Page 216

    Engine general information and diagnosis (m13 engine) 6-2-41 e22-21 – – – – e22-22 – – – – e22-23 – – – – e22-24 – – – – e22-25 – – – – e22-26 – – – – e22-27 – – – – e22-28 brn/wht ground for sensors below 0.3 v ignition switch turned on e22-29 – – – – e22-30 pnk ckp sensor signal 0 – 1 v ignition s...

  • Page 217

    6-2-42 engine general information and diagnosis (m13 engine) e21-9 grn/wht electric load signal for stop lamp 0 – 1 v ignition switch turned on, stop lamp not lighted up 10 – 14 v ignition switch turned on, stop lamp lighted up e21-10 – – – – e21-11 wht/blk serial communication line of data link con...

  • Page 218

    Engine general information and diagnosis (m13 engine) 6-2-43 e21-30 lt grn/ red a/c request signal (if equipped) 10 – 14 v (high input) ignition switch turned on, blower fan selector selected off position or a/c switch turned off or a/c evaporator temp. Less than 2.5°c, 36.5°f 0 – 1 v (low input) ig...

  • Page 219

    6-2-44 engine general information and diagnosis (m13 engine) 1. Reference waveform no.1 heated oxygen sensor–2 heater signal at engine idling 2. Reference waveform no.2 heated oxygen sensor–1 signal at engine idling 3. Reference waveform no.3 heated oxygen sensor–1 heater signal at engine idling mea...

  • Page 220

    Engine general information and diagnosis (m13 engine) 6-2-45 4. Reference waveform no.4 iac valve signal 5. Reference waveform no.5 egr valve signal 6. Reference waveform no.6 ignition coil no.2 and no.3 signal at engine idling measurement terminal ch1: e23-8 to e23-1 oscilloscope setting ch1: 5 v/d...

  • Page 221

    6-2-46 engine general information and diagnosis (m13 engine) 7. Reference waveform no.7 ignition coil no.1 and no.4 signal at engine idling 8. Reference waveform no.8 oil control valve signal at engine idling 9. Reference waveform no.9 oil control valve signal at vehicle driving measurement terminal...

  • Page 222

    Engine general information and diagnosis (m13 engine) 6-2-47 10. Reference waveform no.10 fuel injector signal at engine racing 11. Reference waveform no.11 no.4 fuel injector signal at engine idling 12. Reference waveform no.12 no.3 fuel injector signal at engine idling measurement terminal ch1: e2...

  • Page 223

    6-2-48 engine general information and diagnosis (m13 engine) 13. Reference waveform no.13 no.2 fuel injector signal at engine idling 14. Reference waveform no.14 no.1 fuel injector signal at engine idling 15. Reference waveform no.15 knock sensor signal at engine speed 4000 r/min. 16. Reference wave...

  • Page 224

    Engine general information and diagnosis (m13 engine) 6-2-49 17. Reference waveform no.17 cmp sensor signal at engine idling 18. Reference waveform no.18 mass air flow sensor signal at engine racing 19. Reference waveform no.19 manifold absolute pressure sensor signal at ignition switch turned on me...

  • Page 225

    6-2-50 engine general information and diagnosis (m13 engine) 20. Reference waveform no.20 manifold absolute pressure sensor signal at engine racing 21. Reference waveform no.21 vss signal at 30 km/h (19 mil/h) 22. Reference waveform no.22 ignition pulse (engine revolution) signal at engine idling me...

  • Page 226

    Engine general information and diagnosis (m13 engine) 6-2-51 23. Reference waveform no.23 ignition pulse (engine revolution) signal at engine idling 24. Reference waveform no.24 engine coolant temperature signal at engine idling 25. Reference waveform no.25 evap canister purge valve signal measureme...

  • Page 227

    6-2-52 engine general information and diagnosis (m13 engine) resistance check 1) disconnect ecm couplers (1) from ecm with ignition switch off. 2) check resistance between each pair of terminals of discon- nected couplers as listed in the following table. Caution: never touch terminals of ecm itself...

  • Page 228

    Engine general information and diagnosis (m13 engine) 6-2-53 component location information sensors control devices others 1. Maf and iat sensor a: fuel injector a: ecm 2. Tp sensor b: evap canister purge valve b: combination meter 3. Stop lamp switch c: fuel pump relay c: evap canister 4. Ect senso...

  • Page 229

    6-2-54 engine general information and diagnosis (m13 engine) table a-1 malfunction indicator lamp circuit check – lamp does not come “on” with ignition switch on (but engine stops) wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn on (close t...

  • Page 230

    Engine general information and diagnosis (m13 engine) 6-2-55 3 mil power supply check 1) disconnect ignition switch connector. 2) remove “meter” fuse. 3) measure resistance between “blu/blk” wire terminal of ignition switch connector and “blu/blk” wire terminal of “meter” fuse connector. Is resistan...

  • Page 231

    6-2-56 engine general information and diagnosis (m13 engine) table a-2 malfunction indicator lamp circuit check-lamp remains “on” after engine starts wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn on (close the contact point). Then, ecm be...

  • Page 232

    Engine general information and diagnosis (m13 engine) 6-2-57 2 mil circuit check 1) turn ignition switch to off position. 2) remove combination meter referring to “combination meter removal and installation” in section8. 3) disconnect connectors from ecm. 4) measure resistance between “ppl/wht” wire...

  • Page 233

    6-2-58 engine general information and diagnosis (m13 engine) table a-3 ecm power and ground circuit check-mil doesn’t light with igni- tion switch on and engine doesn’t start though it is cranked up wiring diagram circuit description when the ignition switch tuned on, the main relay turns on (the co...

  • Page 234

    Engine general information and diagnosis (m13 engine) 6-2-59 3 main relay circuit check 1) turn ignition switch to off position. 2) check for fuse blow at fi fuse (20 a). (see fig. 1.) 3) if ok, measure voltage between “e23-15” wire terminal of ecm connector and body ground. Is voltage 10 – 14 v? Go...

  • Page 235

    6-2-60 engine general information and diagnosis (m13 engine) 9 main relay check 1) measure resistance between each two terminals of main relay. (see fig. 3). Between main relay terminals “a” and “b”: infinity “c” and “d”: 160 – 240 Ω at 20°c (68°f) 2) check that there is continuity between terminals...

  • Page 236

    Engine general information and diagnosis (m13 engine) 6-2-61 dtc p0010 camshaft position actuator circuit wiring diagram circuit description actual valve timing fails to become close to target advance level of each function although advance control func- tion or retarded advance control function is ...

  • Page 237

    6-2-62 engine general information and diagnosis (m13 engine) dtc confirmation procedure 1) clear dtc. Refer to “dtc clearance”. 2) start engine and keep it at idle for 10 seconds. 3) check dtc. Refer “dtc check”. Troubleshooting step action yes no 1 was “engine and emission control system check” per...

  • Page 238

    Engine general information and diagnosis (m13 engine) 6-2-63 8 check wire circuit. 1) disconnect connectors from ecm with ignition switch turned off. 2) measure resistance between “e22-3” terminal of ecm con- nector and “blk/yel” wire terminal of oil control valve con- nector. Is resistance 1 Ω or l...

  • Page 239

    6-2-64 engine general information and diagnosis (m13 engine) dtc p0011 camshaft position – timing over-advanced or system perfor- mance dtc p0012 camshaft position – timing over-retarded description actual value of advanced valve timing does not reach target value. Valve timing is advanced although ...

  • Page 240

    Engine general information and diagnosis (m13 engine) 6-2-65 4 vvt signal check 1) drive vehicle the following condition. • vehicle speed at 80 km/h (50 mile/h). • gear position at 5th or d range. 2) check that the vvt gap displayed on suzuki scan tool is 0 – 5°. Is it ok? Substitute a known-good ec...

  • Page 241

    6-2-66 engine general information and diagnosis (m13 engine) dtc p0102 mass air flow circuit low input wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3...

  • Page 242

    Engine general information and diagnosis (m13 engine) 6-2-67 troubleshooting step action yes no 1 was “engine and emission control system check” per- formed? Go to step 2. Go to “engine and emission control system check” in this section. 2 maf sensor check. 1) connect scan tool to dlc with ignition ...

  • Page 243

    6-2-68 engine general information and diagnosis (m13 engine) 9 check maf sensor output signal. 1) connect connectors to maf sensor and ecm with ignition switch turned off. 2) check voltage between “e22-14” and “e22-32” under the following condition. Voltage between “e22-14” and “e22-32” of ecm con- ...

  • Page 244

    Engine general information and diagnosis (m13 engine) 6-2-69 dtc p0103 mass air flow circuit high input wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. ...

  • Page 245

    6-2-70 engine general information and diagnosis (m13 engine) troubleshooting step action yes no 1 was “engine and emission control system check” per- formed? Go to step 2. Go to “engine and emission control system check” in this section. 2 maf sensor check. 1) connect scan tool to dlc with ignition ...

  • Page 246

    Engine general information and diagnosis (m13 engine) 6-2-71 dtc p0112 intake air temperature sensor circuit low wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using sc...

  • Page 247

    6-2-72 engine general information and diagnosis (m13 engine) troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 iat sensor and its circuit check. 1) connect scan tool with ...

  • Page 248

    Engine general information and diagnosis (m13 engine) 6-2-73 dtc p0113 intake air temperature sensor circuit high wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using s...

  • Page 249

    6-2-74 engine general information and diagnosis (m13 engine) 2 iat sensor and its circuit check. 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch. 3) check intake air temp. Displayed on scan tool. Is –40°c (–40°f) indicated? Go to step 3. Intermittent trouble. ...

  • Page 250

    Engine general information and diagnosis (m13 engine) 6-2-75 7 check ground circuit. 1) connect connectors to ecm. 2) check for proper connection of iat sensor connector at “brn/wht” wire terminal. 3) measure resistance between “brn/wht” wire terminal of iat sensor connector and body ground. Is resi...

  • Page 251

    6-2-76 engine general information and diagnosis (m13 engine) dtc p0117 engine coolant temperature circuit low wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan ...

  • Page 252

    Engine general information and diagnosis (m13 engine) 6-2-77 3 check ecm voltage. 1) disconnect connector from ect sensor with ignition switch turned off. 2) check for proper connection to ect sensor at “yel/grn” and “brn/wht” wire termi- nals. 3) if ok, then turn on ignition switch, check voltage b...

  • Page 253

    6-2-78 engine general information and diagnosis (m13 engine) dtc p0118 engine coolant temperature circuit high wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan...

  • Page 254

    Engine general information and diagnosis (m13 engine) 6-2-79 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 ect sensor and its circuit check. 1) connect scan tool with ...

  • Page 255

    6-2-80 engine general information and diagnosis (m13 engine) 7 check ect sensor ground circuit. 1) connect connectors to ecm. 2) check for proper connection of ect sensor connector at “brn/wht” wire terminal. 3) measure resistance between “brn/wht” wire terminal of ect sensor connector and vehicle b...

  • Page 256

    Engine general information and diagnosis (m13 engine) 6-2-81 dtc p0121 throttle position sensor circuit range/performance wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1. Tp sensor 3. To other sensors 2. To map sensor 4. Ecm e23 e22 e21 1 2 3 4 5 6 7 1 2 3 4 5 6 ...

  • Page 257

    6-2-82 engine general information and diagnosis (m13 engine) 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and warm up to normal operating temperature. 4) drive vehicle at 60 km/h (38 mile/h) at 5th gear or d range. 5...

  • Page 258

    Engine general information and diagnosis (m13 engine) 6-2-83 5 check wire circuit. 1) disconnect connectors from ecm with ignition switch turned off. 2) measure resistance between “wht/grn” wire ter- minal of ecm connector and body ground and between “gry” wire terminal of ecm connector and body gro...

  • Page 259

    6-2-84 engine general information and diagnosis (m13 engine) 11 check maf sensor and its circuit. 1) check maf sensor and its circuit, referring to “dtc p0102 mass air flow circuit low input” and “dtc p0103 mass air flow circuit high input” in this sec- tion. Is it in good condition? Go to step 12. ...

  • Page 260

    Engine general information and diagnosis (m13 engine) 6-2-85 dtc p0122 throttle position sensor circuit low wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan to...

  • Page 261

    6-2-86 engine general information and diagnosis (m13 engine) 2 check tp sensor and its circuit. 1) connect scan tool to dlc with ignition switch turned off and then turn on ignition switch. 2) check throttle valve opening percentage dis- played on scan tool. 3) check throttle valve opening percentag...

  • Page 262

    Engine general information and diagnosis (m13 engine) 6-2-87 6 check tp sensor. 1) check resistance between terminals of tp sensor. See fig. 2. Tp sensor resistance between 1 and 3: 4.0 – 6.0 k Ω between 1 and 2: 0.1 – 6.5 k Ω are measured values within specifications? Substitute a known-good ecm an...

  • Page 263

    6-2-88 engine general information and diagnosis (m13 engine) dtc p0123 throttle position circuit high input wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan to...

  • Page 264

    Engine general information and diagnosis (m13 engine) 6-2-89 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 check tp sensor and its circuit. 1) connect scan tool to dlc...

  • Page 265

    6-2-90 engine general information and diagnosis (m13 engine) 6 check wire circuit. 1) measure resistance between “e22-34” wire terminal of ecm connector and “gry” wire terminal of tp sensor connector with igni- tion switch turned off. Is resistance below 5 Ω ? Go to step 8. “gry” wire open circuit o...

  • Page 266

    Engine general information and diagnosis (m13 engine) 6-2-91 dtc p0131 o2 sensor (ho2s) circuit low voltage (sensor-1) dtc p0132 o2 sensor (ho2s) circuit high voltage (sensor-1) wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1. Relay box 4. Circuit fuse box 7. Hea...

  • Page 267

    6-2-92 engine general information and diagnosis (m13 engine) 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and warm up to normal operating temperature. 4) drive vehicle at 40 mph (60 km/h) or higher. (engine speed: 25...

  • Page 268

    Engine general information and diagnosis (m13 engine) 6-2-93 5 check ho2s–1 sensor ground. 1) with ignition switch turned on, check volt- age between “brn/wht” wire terminal of ho2s–1 sensor connector and engine ground. Is voltage about 0.1 v or less? Go to step 6. “brn/wht” wire high resistance cir...

  • Page 269

    6-2-94 engine general information and diagnosis (m13 engine) dtc p0133 o2 sensor (ho2s) circuit slow response (sensor-1) wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1. Relay box 4. Circuit fuse box 7. Heater 10. To other sensor 2. Shield wire 5. “ig coil” fuse ...

  • Page 270

    Engine general information and diagnosis (m13 engine) 6-2-95 1) perform step 1) to 6) of dtc p0131/p0132 confirmation procedure. 2) check if dtc and pending dtc exists by using scan tool. If not, check if oxygen sensor monitoring test has completed by using scan tool. If not in both of above checks ...

  • Page 271

    6-2-96 engine general information and diagnosis (m13 engine) dtc detecting condition and trouble area dtc confirmation procedure refer to “dtc p0133 o2 sensor (ho2s) circuit slow response (sensor–1)” in this section. Troubleshooting dtc detecting condition trouble area maximum ho2s voltage is lower ...

  • Page 272

    Engine general information and diagnosis (m13 engine) 6-2-97 5 check wire circuit. 1) disconnect connectors from ecm with igni- tion switch turned off. 2) remove ecm from vehicle body and con- nect connectors to ecm. 3) measure resistance between “red” wire terminal of ho2s–1 harness connector and “...

  • Page 273

    6-2-98 engine general information and diagnosis (m13 engine) dtc p0031 ho2s heater control circuit low (sensor-1) dtc p0032 ho2s heater control circuit high (sensor-1) wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan ...

  • Page 274

    Engine general information and diagnosis (m13 engine) 6-2-99 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 check ho2s–1 heater power circuit. 1) disconnect connector f...

  • Page 275

    6-2-100 engine general information and diagnosis (m13 engine) 8 check ho2s–1 heater power circuit. 1) disconnect connector from ecm with igni- tion switch turned off. 2) connect connector to ho2s–1 with ignition switch turned off. 3) measure resistance between “e23-4” wire and “e21-28” wire terminal...

  • Page 276

    Engine general information and diagnosis (m13 engine) 6-2-101 dtc p0136 o2 sensor (ho2s) circuit (sensor-2) wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1. Relay box 3. Ignition switch 5. “ig coil” fuse 7. Heater 9. Ecm 2. Shield wire 4. Circuit fuse box 6. Ho2s...

  • Page 277

    6-2-102 engine general information and diagnosis (m13 engine) 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and warm up to normal operating temperature. 4) increase vehicle speed to 60 – 80 km/h (37 – 50 mile/h) at 5t...

  • Page 278

    Engine general information and diagnosis (m13 engine) 6-2-103 6 check wire circuit. 1) disconnect connectors from ecm with igni- tion switch turned off. 2) remove ecm from vehicle body and con- nect connectors to ecm. 3) measure resistance between “blu” wire terminal of ho2s–2 sensor connector and “...

  • Page 279

    6-2-104 engine general information and diagnosis (m13 engine) dtc p0037 ho2s heater control circuit low (sensor-2) dtc p0038 ho2s heater control circuit high (sensor-2) wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan...

  • Page 280

    Engine general information and diagnosis (m13 engine) 6-2-105 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 check ho2s–2 heater power circuit. 1) disconnect connector ...

  • Page 281

    6-2-106 engine general information and diagnosis (m13 engine) dtc p0171 system too lean dtc p0172 system too rich 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) st...

  • Page 282

    Engine general information and diagnosis (m13 engine) 6-2-107 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 is there dtc(s) other than “p0171” and “p0172”? Go to appli...

  • Page 283

    6-2-108 engine general information and diagnosis (m13 engine) dtc p0300 random misfire detected dtc p0301 cylinder 1 misfire detected dtc p0302 cylinder 2 misfire detected dtc p0303 cylinder 3 misfire detected dtc p0304 cylinder 4 misfire detected system description ecm measure the angle of the cran...

  • Page 284

    Engine general information and diagnosis (m13 engine) 6-2-109 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) drive vehicle under freeze frame data condition as noted for 1 min. Or more. 4) stop vehicle and check dtc and pending dtc...

  • Page 285

    6-2-110 engine general information and diagnosis (m13 engine) dtc p0327 knock sensor circuit low dtc p0328 knock sensor circuit high wiring diagram dtc detecting condition and trouble area 9 engine mechanical systems check. Check engine mechanical parts or system which can cause engine rough idle or...

  • Page 286

    Engine general information and diagnosis (m13 engine) 6-2-111 dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc, pending dtc and freeze frame data by using scan tool. 3) start engine and run it for 10 sec. 4) check dtc by...

  • Page 287

    6-2-112 engine general information and diagnosis (m13 engine) dtc p0335 crankshaft position (ckp) sensor circuit wiring diagram dtc detecting condition and trouble area [a]: fig. For step 3 1. Ckp sensor 4. Main relay 2. Sensor plate on crankshaft 5. Ignition switch 3. Ecm 6. Starting motor e23 e22 ...

  • Page 288

    Engine general information and diagnosis (m13 engine) 6-2-113 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. Troubleshooting step action yes no 1 ...

  • Page 289

    6-2-114 engine general information and diagnosis (m13 engine) 7 check ckp sensor. 1) remove ckp sensor referring to “ckp sensor removal and installation” in section 6e2. 2) remove metal particles on end face of ckp sensor, if any. 3) connect ckp sensor connector. 4) turn ignition switch to on positi...

  • Page 290

    Engine general information and diagnosis (m13 engine) 6-2-115 [a]: fig. 1 for step 3 [b]: fig. 3 for step 8 [c]: fig. 2 for step 7.

  • Page 291

    6-2-116 engine general information and diagnosis (m13 engine) dtc p0340 camshaft position sensor circuit wiring diagram system description the cmp sensor located on the transmission side of cylinder head consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion). T...

  • Page 292

    Engine general information and diagnosis (m13 engine) 6-2-117 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 5 sec. 4) check dtc and pending dtc. Troubleshooting step action yes no 1 was ...

  • Page 293

    6-2-118 engine general information and diagnosis (m13 engine) 7 check cmp sensor. 1) remove cmp sensor referring to “cmp sensor removal and installation” in section 6e2. 2) remove metal particles on end face of cmp sen- sor, if any. 3) connect cmp sensor connector. 4) turn ignition switch to on posi...

  • Page 294

    Engine general information and diagnosis (m13 engine) 6-2-119 [a]: fig. 1 for step 3 [b]: fig. 3 for step 8 [c]: fig. 2 for step 7.

  • Page 295

    6-2-120 engine general information and diagnosis (m13 engine) dtc p0401 exhaust gas recirculation flow insufficient detected dtc p0402 exhaust gas recirculation flow excessive detected system/wiring diagram 1. Egr value 4. Sensed information 7. “ig coil” fuse 10. Main relay 2. Intake manifold 5. Fre...

  • Page 296

    Engine general information and diagnosis (m13 engine) 6-2-121 dtc detecting condition and trouble area (dtc p0401/p0402) dtc confirmation procedure (dtc p0401/p0402) 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan tool. 3) start engine and w...

  • Page 297

    6-2-122 engine general information and diagnosis (m13 engine) 4 map sensor check. 1) check map sensor for performance referring to “map sensor individual check” in “dtc p0108” diag. Flow table. Is check result satisfactory? Intermittent trouble or faulty ecm check for intermittent referring to “inte...

  • Page 298

    Engine general information and diagnosis (m13 engine) 6-2-123 dtc p0420 catalyst system efficiency below threshold system/wiring diagram circuit description ecm monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by ho2s–2 (2). When the catalyst is fun...

  • Page 299

    6-2-124 engine general information and diagnosis (m13 engine) dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch turned off. 2) turn on ignition switch and clear dtc using scan tool. 3) increase vehicle speed to 50 – 60 mph, 80 – 100 ...

  • Page 300

    Engine general information and diagnosis (m13 engine) 6-2-125 dtc p0443 evaporative emission system purge control valve circuit wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch off, connect scan tool to dlc. 2) turn on ignition switch and cle...

  • Page 301

    6-2-126 engine general information and diagnosis (m13 engine) 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 hot water. Step action yes no 1 was “engine and emission control...

  • Page 302

    Engine general information and diagnosis (m13 engine) 6-2-127 dtc p0480 fan 1 (radiator cooling fan) control circuit wiring diagram circuit description radiator fan relay is controlled by ecm if ect is specified value. When a/c condenser fan motor is running while head light is turned on and engine ...

  • Page 303

    6-2-128 engine general information and diagnosis (m13 engine) troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 check relay circuit 1) disconnect radiator fan relay from r...

  • Page 304

    Engine general information and diagnosis (m13 engine) 6-2-129 7 check relay circuit 1) turn ignition switch to off position. 2) disconnect connectors from ecm. 3) remove radiator fan relay from relay box. 4) check for proper connection to “e21-4” wire terminal of ecm connector and “blu” wire termina...

  • Page 305

    6-2-130 engine general information and diagnosis (m13 engine) dtc p0500 vehicle speed sensor (vss) malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using scan...

  • Page 306

    Engine general information and diagnosis (m13 engine) 6-2-131 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check”. 2 check vehicle speed signal. Is vehicle speed displayed on scan tool in step...

  • Page 307

    6-2-132 engine general information and diagnosis (m13 engine) 9 check vehicle speed sensor signal. 1) remove vss referring to “vehicle speed sensor (vss)” in section 7a2 or “output shaft speed sensor (vss)” in section 7b1. 2) remove metal particles on end face of vss, if any. 3) connect connectors t...

  • Page 308

    Engine general information and diagnosis (m13 engine) 6-2-133 [a]: fig. 1 for step 5 [b]: fig. 2 for step 9.

  • Page 309

    6-2-134 engine general information and diagnosis (m13 engine) dtc p0505 idle air control system system/wiring diagram dtc detecting condition and trouble area (dtc p0505) dtc confirmation procedure 1) with ignition switch turned off, connect scan tool. 2) turn on ignition switch and clear dtc using ...

  • Page 310

    Engine general information and diagnosis (m13 engine) 6-2-135 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check” in this section. 2 idle speed check 1) check idle speed/idle air control duty ...

  • Page 311

    6-2-136 engine general information and diagnosis (m13 engine) dtc p1500 starter signal circuit malfunction wiring diagram 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 at idle for...

  • Page 312

    Engine general information and diagnosis (m13 engine) 6-2-137 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check”. 2 signal circuit check 1) disconnect connectors from ecm with igni- tion swit...

  • Page 313

    6-2-138 engine general information and diagnosis (m13 engine) dtc p0107 manifold absolute pressure low input wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc using scan to...

  • Page 314

    Engine general information and diagnosis (m13 engine) 6-2-139 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check”. 2 check map sensor and its circuit. 1) connect scan tool to dlc with ignition...

  • Page 315

    6-2-140 engine general information and diagnosis (m13 engine) 8 check map sensor signal circuit. 1) turn on ignition switch. 2) measure voltage between “lt grn/red” wire terminal in map sensor harness con- nector and engine ground. Is voltage 4 – 5 v? Go to step 11. Go to step 9. 9 check map sensor ...

  • Page 316

    Engine general information and diagnosis (m13 engine) 6-2-141 dtc p0108 manifold absolute pressure high input 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 using...

  • Page 317

    6-2-142 engine general information and diagnosis (m13 engine) troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check”. 2 check map sensor and its circuit. 1) connect scan tool to dlc with ignition...

  • Page 318

    Engine general information and diagnosis (m13 engine) 6-2-143 dtc p0601 internal control module memory check sum error dtc p0602 control module programming error system description internal control module is installed in ecm. Dtc detecting condition and trouble area dtc confirmation procedure 1) con...

  • Page 319

    6-2-144 engine general information and diagnosis (m13 engine) dtc p1510 ecm back-up power supply malfunction wiring diagram circuit description battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ecm, etc. Are kept in ecm even when the ignition sw...

  • Page 320

    Engine general information and diagnosis (m13 engine) 6-2-145 troubleshooting step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check”. 2 battery voltage supply circuit check 1) disconnect connectors from ecm with...

  • Page 321

    6-2-146 engine general information and diagnosis (m13 engine) dtc p1601 can communication error wiring diagram dtc detecting condition and trouble area dtc confirmation procedure • connect scan tool to dlc with ignition switch turned off. • turn on ignition switch and clear dtc by using scan tool, t...

  • Page 322

    Engine general information and diagnosis (m13 engine) 6-2-147 3 circuit check 1) turn ignition switch to off position. 2) disconnect connectors from ecm and tcm. 3) check for proper connection to “e21-7” ter- minal of ecm connector and “e13-7” termi- nal of tcm connector. 4) if ok, measure resistanc...

  • Page 323

    6-2-148 engine general information and diagnosis (m13 engine) dtc p1603 tcm trouble code detected dtc detecting condition when ecm receives a trouble code from tcm, which indicates that some problem occurred in sensor circuits and its calculated values used for operations such as idle speed control,...

  • Page 324

    Engine general information and diagnosis (m13 engine) 6-2-149 dtc p2227 barometric pressure circuit range/performance dtc p2228 barometric pressure circuit low dtc p2229 barometric pressure circuit high system description barometric pressure sensor is installed in ecm (pcm). Dtc detecting condition ...

  • Page 325

    6-2-150 engine general information and diagnosis (m13 engine) dtc troubleshooting table b-1 fuel injector circuit check step action yes no 1 was “engine and emission control system check” performed? Go to step 2. Go to “engine and emis- sion control system check”. 2 is dtc p2227 set? Go to step 3. S...

  • Page 326

    Engine general information and diagnosis (m13 engine) 6-2-151 troubleshooting step action yes no 1 check each injector for operating sound at engine cranking using sound scope. Do all 4 injector make operating sound? Fuel injector circuit is in good condition. Go to step 2. 2 check fuel injector res...

  • Page 327

    6-2-152 engine general information and diagnosis (m13 engine) table b-2 fuel pump and its circuit check troubleshooting 1. Relay box 4. Fuel pump relay 7. Ignition switch 2. Main relay 5. Fuel pump 3. Ecm 6. “ig coil” fuse step action yes no 1 check fuel pump control system for operation. See fig.1....

  • Page 328

    Engine general information and diagnosis (m13 engine) 6-2-153 4 check fuel pump relay. 1) check fuel pump relay, referring to “main relay, fuel pump relay and radiator fan relay inspection” in section 6e2. Is relay in good condition? Go to step 5. Faulty relay. 5 check fuel pump relay drive signal. ...

  • Page 329

    6-2-154 engine general information and diagnosis (m13 engine) table b-3 fuel pressure check troubleshooting 1. Injector 3. Fuel filter and fuel pump b: hose 2. Delivery pipe a: gauge c: 3-way joint note: before using the following table, check to make sure that battery voltage is higher than 11 v. I...

  • Page 330

    Engine general information and diagnosis (m13 engine) 6-2-155 4 fuel line check 1) check fuel pipe, fuel hose and joint for damage or deform. Are they in good condition? Faulty fuel pressure reg- ulator. Repair or replace. 5 was fuel pressure higher than specification in step 1? Go to step 6. Go to ...

  • Page 331

    6-2-156 engine general information and diagnosis (m13 engine) table b-4 idle air control system check troubleshooting 1. Iac valve 3. Main relay 5. Ignition switch 2. Ecm 4. “ig coil” fuse 6. Relay box e23-15 e21-28 12v 5v e21-6 e21-5 blk/wht blk/red blk/red blk/red wht/blu 80a 60a 20a blk/yel blk/y...

  • Page 332

    Engine general information and diagnosis (m13 engine) 6-2-157 5 check a/c (input) signal circuit referring to step 1 of “table b-5 a/c signal circuit check”, if equipped. Is it in good condition? Go to step 6. Repair or replace a/c sig- nal circuit or a/c system. 6 check idle air control system. 1) ...

  • Page 333

    6-2-158 engine general information and diagnosis (m13 engine) table b-5 a/c signal circuits check (vehicle with a/c) 1. Blower fan motor 6. Compressor relay 11. Ecm 16. “ig coil” fuse 2. Blower fan switch 7. A/c compressor 12. Ignition switch 17. “a/c” fuse 3. A/c switch 8. Radiator fan motor relay ...

  • Page 334

    Engine general information and diagnosis (m13 engine) 6-2-159 troubleshooting step action yes no 1 check evaporator temp. Sensor 1) disconnect connectors from ecm with igni- tion switch turned off. 2) check for proper connection to “e21-15” and “e22-28” wire terminals of ecm con- nector. 3) if ok, m...

  • Page 335

    6-2-160 engine general information and diagnosis (m13 engine) 8 check a/c compressor relay circuit 1) check voltage between “e23-11” wire termi- nal of ecm connector and vehicle body ground under the following condition. While engine running and a/c switch off: 10 – 14 v while engine running, a/c an...

  • Page 336

    Engine general information and diagnosis (m13 engine) 6-2-161 table b-6 electric load signal circuit check troubleshooting table 1 for step 2 and 3 1. Blower fan motor 3. Position lamp 5. To “heater” fuse 2. Blower fan switch 4. Ecm 6. To “tail” fuse pnk/blu red/yel e21-13 e21-33 e23 e22 e21 1 2 3 4...

  • Page 337

    6-2-162 engine general information and diagnosis (m13 engine) table b-7 radiator fan control system check troubleshooting 1. Relay box 3. Radiator fan relay 5. Ect sensor 2. Main relay 4. Radiator fan motor 6. Ecm e23-15 12v 5v e21-6 e21-5 blk/red blk/red blk/red 80a blk/yel blk/yel blk/yel blu/blk ...

  • Page 338

    Engine general information and diagnosis (m13 engine) 6-2-163 5 check radiator fan relay 1) check radiator fan relay referring to “main relay, fuel pump relay and radiator fan relay inspection” in section 6e2. Is it in good condition? Go to step 6. Replace radiator fan relay. 6 radiator fan control ...

  • Page 339: Special Tool

    6-2-164 engine general information and diagnosis (m13 engine) special tool tech 2 kit (suzuki scan tool) (see note “c”.) note: “c”: this kit includes the following items. 1. Tech 2, 2. Pcmcia card, 3. Dlc cable, 4. Sae 16/19 adapter, 5. Cigarette cable, 6. Dlc loopback adapter, 7. Battery power cabl...

  • Page 340: Section 6A2

    Engine mechanical (m13 engine) 6a2-1 6a2 section 6a2 engine mechanical (m13 engine) contents general description ......................................6a2-3 engine construction description.................6a2-3 engine lubrication description ...................6a2-4 variable valve timing (vvt) syste...

  • Page 341

    6a2-2 engine mechanical (m13 engine) timing chain and chain tensioner components.............................................. 6a2-44 timing chain and chain tensioner removal and installation........................... 6a2-44 timing chain and timing chain tensioner inspection...........................

  • Page 342: General Description

    Engine mechanical (m13 engine) 6a2-3 general description engine construction description the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration and 16 valves (4 valves/one cylind...

  • Page 343

    6a2-4 engine mechanical (m13 engine) engine lubrication description the oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into 2 paths in cylinder block. In one path, oil ...

  • Page 344

    Engine mechanical (m13 engine) 6a2-5 variable valve timing (vvt) system description system description the vvt system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce ...

  • Page 345

    6a2-6 engine mechanical (m13 engine) 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 cont...

  • Page 346

    Engine mechanical (m13 engine) 6a2-7 timing retarding when the duty ratio of the signal output from the ecm is light, the spool valve of the oil control valve moves to the right (head for the coil). By this spool valve movement, the pressurized oil is led into the chambers for timing retarding and t...

  • Page 347: Diagnosis

    6a2-8 engine mechanical (m13 engine) diagnosis diagnosis table refer to “engine and emission control system check” in section 6-2. Compression check check compression pressure on all 4 cylinders as follows: 1) warm up engine to normal operating temperature. 2) stop engine after warming up. 3) discon...

  • Page 348

    Engine mechanical (m13 engine) 6a2-9 compression pressure 10) carry out steps 7) through 9) on each cylinder to obtain 4 readings. 11) after checking, install spark plugs and ignition coil assem- blies (1) with high-tension cord (2). 12) connect ignition coil couplers (3). 13) connect fuel injector ...

  • Page 349

    6a2-10 engine mechanical (m13 engine) 3) remove air cleaner case (1) and resonator (2). 4) remove pcv hose (1) from pcv valve (2). 5) connect special tool (vacuum gauge) to pcv hose (1). Special tool (a): 09915-67311 6) blind pcv valve (2) using tape (3) or the like. 7) install air cleaner case and ...

  • Page 350

    Engine mechanical (m13 engine) 6a2-11 oil pressure check • oil level in oil pan if oil level is low, add oil up to full level mark (hole) on oil level gauge. • oil quality if oil is discolored or deteriorated, change it. For particular oil to be used, refer to “engine oil and filter change” in secti...

  • Page 351

    6a2-12 engine mechanical (m13 engine) 6) after warming up, raise engine speed to 4,000 rpm and mea- sure oil pressure. Oil pressure specification more than 270 kpa (2.7 kg/cm 2 , 39.8 psi) at 4,000 rpm 7) stop engine and remove oil pressure gauge and attachment. 8) before reinstalling oil pressure s...

  • Page 352

    Engine mechanical (m13 engine) 6a2-13 valve lash (clearance) inspection 1) remove negative cable at battery. 2) remove cylinder head cover referring to “cylinder head cover removal and installation” in this section. 3) remove right side engine under cover, if necessary. 4) using 17 mm wrench, turn c...

  • Page 353

    6a2-14 engine mechanical (m13 engine) b) check housing no. And select special tool corresponding to housing no. Referring to the following table. Special tool selection table c) hold down the tappet so as not to contact the shim by installing special tool on camshaft housing with housing bolt (1) ti...

  • Page 354

    Engine mechanical (m13 engine) 6a2-15 5) using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by cal- culating the thickness of new shim with the following formula and table. Intake side: a = b + c – 0.200 mm (0.0078 in.) exhaust side: a = b + c – 0.3...

  • Page 355: On-Vehicle Service

    6a2-16 engine mechanical (m13 engine) 8) lift valve by turning crankshaft counterclockwise (in opposite direction against above step 4) and remove special tool. Special tool (a): 09916-67020 or 09916-67021 9) install camshaft housing (1) and tighten bolts to specified torque. Tightening torque camsh...

  • Page 356

    Engine mechanical (m13 engine) 6a2-17 air cleaner element inspection and cleaning • check air cleaner element for dirt. Replace excessively dirty element. • blow off dust by compressed air from air outlet side of ele- ment. Knock sensor removal and installation refer to “knock sensor removal and ins...

  • Page 357

    6a2-18 engine mechanical (m13 engine) 9) remove oil level gauge (1). 10) disconnect pcv hose (2) from pcv valve (3) and disconnect breather hose (4) from cylinder head cover. 11) remove cylinder head cover mounting bolts in such order as indicated in figure. 12) remove cylinder head cover (1) with c...

  • Page 358

    Engine mechanical (m13 engine) 6a2-19 • timing chain cover (1) and cylinder head (2) mating surface as shown. “a”: sealant 99000-31250 3) install cylinder head cover to cylinder head. 4) tighten bolts in such order as indicated in figure a little at a time till they are tightened to specified torque...

  • Page 359

    6a2-20 engine mechanical (m13 engine) throttle body and intake manifold components 1. Intake manifold 9. Gasket 17. Throttle body mounting bolt 25. To brake booster 2. Intake manifold o-ring 10. Map sensor 18. Air cleaner case 26. To water outlet cap 3. Throttle body 11. Pcv valve hose 19. Maf senso...

  • Page 360

    Engine mechanical (m13 engine) 6a2-21 throttle body removal and installation removal 1) relieve fuel pressure referring to “fuel pressure relief pro- cedure” in section 6-2. 2) disconnect negative cable at battery. 3) drain coolant by loosening drain plug (1). 4) disconnect maf sensor coupler (1). 5...

  • Page 361

    6a2-22 engine mechanical (m13 engine) intake manifold removal and installation removal 1) remove throttle body referring to “throttle body removal and installation” in this section. 2) disconnect map sensor coupler (1). 3) disconnect the following hoses: • brake booster hose (2) from cylinder head c...

  • Page 362

    Engine mechanical (m13 engine) 6a2-23 exhaust manifold components 1. Exhaust manifold gasket 6. Exhaust no.1 pipe 11. Exhaust manifold stiffener bolt 2. Exhaust manifold 7. Exhaust manifold stiffener 12. Exhaust pipe no.2 bolt 3. Exhaust oxygen sensor 8. Engine hook 13. Caution plate 4. Exhaust pipe...

  • Page 363

    6a2-24 engine mechanical (m13 engine) exhaust manifold removal and installation removal 1) disconnect negative cable at battery. 2) remove front bumper with front grille referring to “front bumper and rear bumper” in section 9. 3) remove radiator referring to “radiator removal and installa- tion” in...

  • Page 364

    Engine mechanical (m13 engine) 6a2-25 installation 1) install new gasket to cylinder head. Then install exhaust manifold. Tighten manifold bolts (1) and nuts (2) to specified torque. Tightening torque exhaust manifold bolt and nut (a): 50 n·m (5.0 kg-m, 36.5 lb-ft) 2) install new seal ring and conne...

  • Page 365

    6a2-26 engine mechanical (m13 engine) oil pan and oil pump strainer components oil pan and oil pump strainer removal and installation removal 1) remove oil level gauge. 2) drain engine oil by removing drain plug. 3) remove exhaust no.1 pipe (1), exhaust manifold stiffener (2) and clutch housing lowe...

  • Page 366

    Engine mechanical (m13 engine) 6a2-27 6) remove oil pan and then oil pump strainer (1) from cylinder block. Installation 1) clean oil pump strainer screen (1). 2) clean sealing surface on oil pan and cylinder block. Remove oil, old sealant and dust from sealing surface. 3) apply sealant continuously...

  • Page 367

    6a2-28 engine mechanical (m13 engine) 4) install new o-rings (2) in the position as shown in figure and install oil pump strainer (1). Tighten strainer bolt (3) first and then bracket bolt (4) to specified torque. Tightening torque oil pump strainer bolt (a): 11 n·m (1.1 kg-m, 8.0 lb-ft) oil pump st...

  • Page 368

    Engine mechanical (m13 engine) 6a2-29 engine mountings components 11 55 n·m (5.5 kg-m) 10 65 n·m (6.5 kg-m) 12 55 n·m (5.5 kg-m) 13 25 n·m (2.5 kg-m) 15 55 n·m (5.5 kg-m) 16 55 n·m (5.5 kg-m) 19 55 n·m (5.5 kg-m) 18 55 n·m (5.5 kg-m) 17 55 n·m (5.5 kg-m) 20 55 n·m (5.5 kg-m) 21 55 n·m (5.5 kg-m) 18 ...

  • Page 369: Unit Repair Overhaul

    6a2-30 engine mechanical (m13 engine) unit repair overhaul engine assembly removal and installation removal 1) relieve fuel pressure referring to “fuel pressure relief pro- cedure” in section 6-2. 2) disconnect negative and positive cables at battery. 3) remove engine hood after disconnecting windsh...

  • Page 370

    Engine mechanical (m13 engine) 6a2-31 14) disconnect the following electric lead wires: • tp sensor (1) • map sensor (2) • ect sensor (3) • egr valve (4) • cmp sensor (5) • iac valve (6) • ignition coil assembly (7) • injectors (8) • heated oxygen sensor (9) • oil control valve (10) • engine oil pre...

  • Page 371

    6a2-32 engine mechanical (m13 engine) 21) install lifting device. 22) remove engine rear mounting bolts (1), engine left mounting bracket nuts (2) and engine right mounting nuts (3). 23) before removing engine with transaxle from body, recheck to make sure all hoses, electric wires and cables are di...

  • Page 372

    Engine mechanical (m13 engine) 6a2-33 3) lift engine with transaxle into engine compartment, but do not remove lifting device. 4) install engine rear mounting bolts (1), engine left mounting bracket nuts (2) and engine right mounting nuts (3). Tighten these bolts and nuts to specified torque. Tighte...

  • Page 373

    6a2-34 engine mechanical (m13 engine) timing chain cover components [a]: sealant application amount 8. Oil pan mounting bolt and nut 18. Oil control valve “a”: 3 mm (0.12 in.) 9. Cylinder head cover : apply sealant 99000-31250 to the sealing point for timing chain cover mating surface and cylinder h...

  • Page 374

    Engine mechanical (m13 engine) 6a2-35 timing chain cover removal and installation removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation” in this section. 2) remove crankshaft pulley bolt (2). To lock crankshaft pulley (1), use special tool with it as s...

  • Page 375

    6a2-36 engine mechanical (m13 engine) 8) remove water outlet cap (1) from timing chain cover (2). 9) remove timing chain cover. 10) remove oil gallery pipe no.1 (1) and oil control valve (2) from timing chain cover (3). Installation 1) clean sealing surface on timing chain cover, cylinder block and ...

  • Page 376

    Engine mechanical (m13 engine) 6a2-37 5) apply sealant “a” to mating surface of cylinder and cylinder head and “b” to mating surface of timing chain cover as shown in figure. “a”: sealant 99000-31140 “b”: sealant 99000-31250 sealant amount for timing chain cover width “a”: 3 mm (0.12 in.) height “b”...

  • Page 377

    6a2-38 engine mechanical (m13 engine) 11) install water pump pulley. 12) install cylinder head cover referring to “cylinder head cover removal and installation” in this section. 13) install oil pan referring to “oil pan and oil pump strainer removal and installation” in this section. 14) install cra...

  • Page 378

    Engine mechanical (m13 engine) 6a2-39 oil control valve inspect strainer (1) and mating surface (2) of oil control valve. Clean oil control valve. Oil gallery pipe inspect oil gallery pipes no.1 (1), no.2 (2) and no.3 (3). Replace if crack, deformation or clog exists. Oil pump components 1 2 1 3 2.

  • Page 379

    6a2-40 engine mechanical (m13 engine) oil pump removal and installation removal remove timing chain cover referring to “timing chain cover removal and installation” in this section. Installation for installation referring to “timing chain cover removal and installation” in this section. Oil pump dis...

  • Page 380

    Engine mechanical (m13 engine) 6a2-41 3) remove relief valve (1), spring (2) and retainer (3) by remov- ing circlip (4). Assembly 1) wash, clean and then dry all disassembled parts. 2) apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case and...

  • Page 381

    6a2-42 engine mechanical (m13 engine) oil pump inspection oil seal • check oil seal lip for fault or other damage. Replace as nec- essary. Special tool (a): 09913-75810 drive in dimension “a”: 1.5 mm (0.06 in.) oil pump assembly • check outer (1) and inner rotors (2), rotor plate, and oil pump case ...

  • Page 382

    Engine mechanical (m13 engine) 6a2-43 radial clearance check radial clearance between outer rotor (1) and case (2), using thickness gauge (3). If clearance exceeds its limit, replace oil pump assembly. Limit on radial clearance between outer rotor and case for oil pump : 0.310 mm (0.0122 in.) side c...

  • Page 383

    6a2-44 engine mechanical (m13 engine) timing chain and chain tensioner components timing chain and chain tensioner removal and installation removal 1) remove timing chain cover referring to “timing chain cover removal and installation” in this section. 1. Crankshaft timing sprocket 4. Timing chain t...

  • Page 384

    Engine mechanical (m13 engine) 6a2-45 2) by turing crankshaft, align both intake and exhaust camshaft timing sprocket marks (1) with notches (2) of cylinder head respectively and align crank shaft sprocket key (3) with notch of cylinder block (4). 3) remove timing chain tensioner adjuster assembly (...

  • Page 385

    6a2-46 engine mechanical (m13 engine) 3) install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft timing sprocket as shown in figure. 4) fit crankshaft timing sprocket to timing chain by aligning gold plate (3) of timing chain and circle mark (4) on cran...

  • Page 386

    Engine mechanical (m13 engine) 6a2-47 7) check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with marking of timing chain (2) and match mark on crankshaft timing sprocket (3) are in with marking of timing chain (4). 8) screw in plunger (1) by turning body (2) in a...

  • Page 387

    6a2-48 engine mechanical (m13 engine) 10) apply engine oil to timing chain and then turn crankshaft clockwise by 2 revolutions and check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is in match with notch (4) on cylin...

  • Page 388

    Engine mechanical (m13 engine) 6a2-49 timing chain • check timing chain for wear or damage. Timing chain tensioner adjuster • check that tooth surface (1) are free from damage. Timing chain no.1 guide • check timing chain no.1 guide (1) for wear or damage..

  • Page 389

    6a2-50 engine mechanical (m13 engine) camshaft, tappet and shim components camshaft, tappet and shim removal and installation removal 1) remove timing chain cover referring to “timing chain cover removal and installation” in this section. 2) remove timing chain referring to “timing chain and chain t...

  • Page 390

    Engine mechanical (m13 engine) 6a2-51 3) with hexagonal section (1) of intake camshaft (2) held sta- tionary with spanner or the like, loosen mounting bolt of intake cam timing sprocket assembly (3) and remove it. 4) loosen camshaft housing bolts in such order as indicated in figure and remove them....

  • Page 391

    6a2-52 engine mechanical (m13 engine) installation 1) install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to cylinder head. 2) install camshaft bearing (1) to cylinder head. 3) install intake camshaft (1) and exhaust camshaft (2). Align knock pin (3) and ma...

  • Page 392

    Engine mechanical (m13 engine) 6a2-53 6) check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install hous- ings as indicated by these marks. 7) after applying engine oil to housing bolts, tighten them tem- por...

  • Page 393

    6a2-54 engine mechanical (m13 engine) cam wear using a micrometer, measure cam height “a”. If measured height underruns its limit, replace camshaft. Cam height “a” of camshaft camshaft runout set camshaft between two “v” blocks, and measure its runout by using a dial gauge. If measured runout exceed...

  • Page 394

    Engine mechanical (m13 engine) 6a2-55 7) remove housing, and using scale (2) on gaging plastic (1) envelop, measure gaging plastic width at its widest point. Camshaft journal clearance if measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camsha...

  • Page 395

    6a2-56 engine mechanical (m13 engine) measure cylinder head bore and tappet outside diameter to deter- mine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head. Cylinder head to tappet clearance standard: 0.025 – 0.066 mm (0.0010 – 0.0025 in.) limit: 0.15 m...

  • Page 396

    Engine mechanical (m13 engine) 6a2-57 valves and cylinder head removal and installation removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation” in this section. 2) remove oil pan referring to “oil pan and oil pump strainer removal and installation” in t...

  • Page 397

    6a2-58 engine mechanical (m13 engine) installation 1) clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface. 2) install knock pins (1) to cylinder block. 3) install new cylinder head gasket (2) to cylinder block. “top” mark provided on gasket c...

  • Page 398

    Engine mechanical (m13 engine) 6a2-59 cylinder head bolt diameter measurement points “a”: 83.5mm (2.81in.) “b”: 115mm (4.53in.) cylinder head bolt diameter difference (deformation) limit (“a” – “b”): 0.1mm (0.004in.) 6) install camshafts, tappet and shim referring to “camshaft, tappet and shim remov...

  • Page 399

    6a2-60 engine mechanical (m13 engine) valves and cylinder head disassembly and assembly disassembly 1) for ease in servicing cylinder head, remove intake manifold, injectors and exhaust manifold from cylinder head. 2) using special tools (valve lifter), compress valve spring and then remove valve co...

  • Page 400

    Engine mechanical (m13 engine) 6a2-61 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 ...

  • Page 401

    6a2-62 engine mechanical (m13 engine) 5) install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, chec...

  • Page 402

    Engine mechanical (m13 engine) 6a2-63 9) install intake manifold referring to “intake manifold removal and installation” in this section. 10) install fuel injectors referring to “fuel injector removal and installation” in section 6e2. 11) install exhaust manifold referring to “exhaust manifold remov...

  • Page 403

    6a2-64 engine mechanical (m13 engine) • inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not too much to grind off its chamber. When it is worn out too much that its chamber is gone, replace valve. Valve head thickness measure...

  • Page 404

    Engine mechanical (m13 engine) 6a2-65 valve seat repair a valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping. 1) exhaust valve seat: use valve...

  • Page 405

    6a2-66 engine mechanical (m13 engine) • check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using a straightedge and thickness gauge, check flatness of gasketed surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct ga...

  • Page 406

    Engine mechanical (m13 engine) 6a2-67 spring squareness use a square and surface plate to check each spring for square- ness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit given below must be replaced. Valve spring squarenes...

  • Page 407

    6a2-68 engine mechanical (m13 engine) pistons, piston rings, connecting rods and cylinders removal and installation removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation” in this section. 2) remove cylinder head referring to “valves and cylinder head r...

  • Page 408

    Engine mechanical (m13 engine) 6a2-69 4) install piston and connecting rod assembly into cylinder bore. Use special tool (piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft. Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor...

  • Page 409

    6a2-70 engine mechanical (m13 engine) b) force piston pin out. Assembly 1) decarbonize piston head and ring grooves using a suitable tool. 2) install piston pin to piston (1) and connecting rod (2): a) after applying engine oil to piston pin and piston pin holes in piston and connecting rod. B) fit ...

  • Page 410

    Engine mechanical (m13 engine) 6a2-71 pistons, piston rings, connecting rods and cylinders inspection cylinder visual inspection inspect cylinder walls for scratches, roughness or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched or ridged, rebore cylinder and ...

  • Page 411

    6a2-72 engine mechanical (m13 engine) piston clearance measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston...

  • Page 412

    Engine mechanical (m13 engine) 6a2-73 piston pin clearance check piston pin clearance in small end and piston. Replace con- necting rod and/or piston if its small end is badly worn or dam- aged or if measured clearance exceeds limit. Piston pin clearance in connecting rod small end standard: 0.003 –...

  • Page 413

    6a2-74 engine mechanical (m13 engine) 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 stan...

  • Page 414

    Engine mechanical (m13 engine) 6a2-75 crank pin and connecting rod bearings 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 dam- aged or out-of round or taper is out of limit, replace crankshaft or regrind...

  • Page 415

    6a2-76 engine mechanical (m13 engine) 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 and tighten cap nuts (3) gradually as follows. A) tighten all cap ...

  • Page 416

    Engine mechanical (m13 engine) 6a2-77 1) check stamped numbers on connecting rod and its cap as shown. Three kinds of numbers (“1”, “2” and “3”) represent the fol- lowing connecting rod big end inside diameters. For example, stamped number “1” indicates that correspond- ing connecting rod big end in...

  • Page 417

    6a2-78 engine mechanical (m13 engine) 3) there are five kinds of standard bearings differing in thick- ness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing. Standard size of c...

  • Page 418

    Engine mechanical (m13 engine) 6a2-79 main bearings, crankshaft and cylinder block components.

  • Page 419

    6a2-80 engine mechanical (m13 engine) main bearings, crankshaft and cylinder block removal and installation removal 1) remove engine assembly from vehicle referring to “engine assembly removal and installation” in this section. 2) remove clutch cover, clutch disc and flywheel (drive plate for a/t) b...

  • Page 420

    Engine mechanical (m13 engine) 6a2-81 5) loosen main bearing cap no.1 and no.2 bolts in such order as indicated in figure and remove them. 6) remove crankshaft from cylinder block. Installation 1) install sensor plate (1) to crankshaft (2) and tighten bolts to specified torque. Tightening torque sen...

  • Page 421

    6a2-82 engine mechanical (m13 engine) 3) install thrust bearings (1) to cylinder block between no.2 and no.3 cylinders. Face oil groove (2) sides to crank webs. 4) confirm that dowel pins (3) are installed to intake side of each journal. 5) install crankshaft to cylinder block. 6) install bearing ca...

  • Page 422

    Engine mechanical (m13 engine) 6a2-83 8) apply sealant to mating surface of rear oil seal housing (1). “a”: sealant 99000-31250 sealant amount for rear oil seal housing width “a”: 3 mm (0.12 in.) height “b”: 2 mm (0.08 in.) 9) install rear oil seal housing (1) and tighten bolts to specified torque b...

  • Page 423

    6a2-84 engine mechanical (m13 engine) main bearings, crankshaft and cylinder block inspection main bearing cap no.1 bolt measure each thread diameter main bearing cap no.1 bolts (1) at “a” on 60mm(2.36in.) from seat side of flange bolt and “b” on 90mm(3.54in.) from seat side of flange bolt by using ...

  • Page 424

    Engine mechanical (m13 engine) 6a2-85 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 kg-m, 22.0 lb-ft) according to numerical order in figure. B) in the same manner as in step 1), tighten ...

  • Page 425

    6a2-86 engine mechanical (m13 engine) • upper half of bearing (1) has an oil groove (2) as shown in figure. Install this half with oil groove to cylinder block. • lower half of bearing does not have an oil groove. Visual inspection check bearings for pitting, scratches, wear or damage. If any malcon...

  • Page 426

    Engine mechanical (m13 engine) 6a2-87 5) remove bearing caps and using scale (1) on gaging plastic (2) envelop, measure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce...

  • Page 427

    6a2-88 engine mechanical (m13 engine) 2) next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in figure. Three kinds of alphabets (“a”, “b” and “c”) or numbers (“1”, “2” and “3”) represent the following cap bore diameters. St...

  • Page 428

    Engine mechanical (m13 engine) 6a2-89 specification of new standard crankshaft main bearing size 5) using scale (1) on gaging plastic (2), check bearing clear- ance with newly selected standard bearing. If clearance still exceeds its limit, use next thicker bearing and recheck clearance. 6) when rep...

  • Page 429

    6a2-90 engine mechanical (m13 engine) 2) using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicu- lar to each other in order to check for out-of-round. 3) using journal diameter measured above and alphabets stamped on cylinder block, select an un...

  • Page 430

    Engine mechanical (m13 engine) 6a2-91 sensor plate check sensor plate for crack or damage. If malcondition is found, replace it. Cylinder block distortion of gasketed surface using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct it....

  • Page 431: Required Service Material

    6a2-92 engine mechanical (m13 engine) required service material tightening torque specification material recommended suzuki product (part number) use sealant suzuki bond no. 1207f (99000-31250) • to apply to mating surfaces of cylinder block and oil pan. • to apply to mating surfaces of cylinder blo...

  • Page 432

    Engine mechanical (m13 engine) 6a2-93 cylinder head bolt for m10 tighten 20 n·m (2.0 kg-m, 14.5 lb-ft), 40 n·m (4.0 kg-m, 29.0 lb-ft), 60° and 60° by the specified procedure. Bearing cap nut tighten 15 n·m (1.5 kg-m, 11.0 lb-ft), 45° and 45° by the specified procedure. Engine mounting bolt for m8 25...

  • Page 433: Special Tool

    6a2-94 engine mechanical (m13 engine) special tool 09911-97720 09911-97820 09913-75810 09915-64512 oil seal guide oil seal installer bearing installer compression gauge 09915-64530 09915-67010 09915-67311 09915-77310 hose attachment vacuum gauge oil pressure gauge 09915-78211 09916-14510 09916-14521...

  • Page 434

    Engine mechanical (m13 engine) 6a2-95 09916-58210 09916-67020 09916-67021 09916-77310 valve guide installer handle tappet holder see note below tappet holder piston ring compressor 09916-84511 09917-68221 09917-98221 09924-17810 forceps camshaft lock holder valve stem seal installer flywheel holder ...

  • Page 435

    6a2-96 engine mechanical (m13 engine).

  • Page 436: Section 6B2

    Engine cooling (m13 engine) 6b2-1 6b2 section 6b2 engine cooling (m13 engine) contents general description ......................................6b2-2 cooling system circulation .........................6b2-2 coolant........................................................6b2-3 diagnosis................

  • Page 437: General Description

    6b2-2 engine cooling (m13 engine) general description the cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is tube-and-fin type one. Cooling system circulation while the engine is warmed up (thermostat closed), cool...

  • Page 438

    Engine cooling (m13 engine) 6b2-3 coolant the coolant recovery system is standard. The coolant in the radiator expands with heat, and the coolant is over- flowed to the reservoir. When the system cools down, the coolant is drawn back into the radiator. The cooling system has been filled with a quali...

  • Page 439: Diagnosis

    6b2-4 engine cooling (m13 engine) diagnosis diagnosis table system circuit inspection refer to “table b-7 radiator fan control system check” in section 6-2 condition possible cause correction engine overheats (it is in case that radia- tor fan operates) loose or broken water pump belt adjust or repl...

  • Page 440: Maintenance

    Engine cooling (m13 engine) 6b2-5 maintenance coolant level check to check level, lift hood and look at “see-through” coolant reser- voir. It is not necessary to remove radiator cap to check coolant level. When engine is cool, check coolant level in reservoir (1). A normal coolant level should be be...

  • Page 441

    6b2-6 engine cooling (m13 engine) engine cooling system inspection and ser- vice 1) check cooling system for leakage or damage. 2) wash radiator cap and filler neck with clean water by remov- ing radiator cap when engine is cold. 3) check coolant for proper level and freeze protection. 4) using a pr...

  • Page 442

    Engine cooling (m13 engine) 6b2-7 2) with radiator cap removed, run engine until upper radiator hose is hot (this shows that thermostat is open and coolant is flowing through system). 3) stop engine and drain coolant from radiator drain plug (1). 4) close radiator drain plug (1). Add water until sys...

  • Page 443

    6b2-8 engine cooling (m13 engine) water pump/generator drive belt tension inspection and adjustment 1) inspect belt for cracks, cuts, deformation, wear and cleanli- ness. If it is necessary to replace belt, refer to “water pump/ generator drive belt removal and installation” in this sec- tion. 2) ch...

  • Page 444: On-Vehicle Service

    Engine cooling (m13 engine) 6b2-9 on-vehicle service cooling system components warning: • check to make sure that engine coolant temperature is cold before removing any part of cooling system. • also be sure to disconnect negative cord from battery terminal before removing any part. 1. Radiator 13. ...

  • Page 445

    6b2-10 engine cooling (m13 engine) cooling system draining 1) remove radiator cap. 2) drain coolant from radiator drain plug (1). 3) after draining coolant, be sure to tighten drain plug (1) securely. Cooling system refill refer to step 7) to 22) of “cooling system flush and refill” in this section....

  • Page 446

    Engine cooling (m13 engine) 6b2-11 thermostat removal and installation removal 1) drain coolant referring to “cooling system draining” in this section. 2) remove intake manifold referring to “intake manifold removal and installation” in section 6a2. 3) remove generator referring to “generator dismou...

  • Page 447

    6b2-12 engine cooling (m13 engine) • check thermostatic movement of wax pellet as follows: a) immerse thermostat (1) in water, and heat water gradually as shown. B) check that valve starts to open at specific temperature. Temperature at which valve begins to open : 80 – 84°c (176 – 183°f) temperatur...

  • Page 448

    Engine cooling (m13 engine) 6b2-13 radiator inspection check radiator for leakage or damage. Straighten bent fins, if any. Radiator cleaning clean frontal area of radiator cores. Radiator cooling fan relay inspection refer to “main relay, fuel pump relay and radiator fan relay” in section 6e2. Radia...

  • Page 449

    6b2-14 engine cooling (m13 engine) radiator cooling fan inspection for m/t vehicle 1) check continuity between terminals. If there is no continuity, replace radiator fan motor. 2) connect battery to radiator fan motor coupler as shown in figure, then check that the radiator fan motor operates smooth...

  • Page 450

    Engine cooling (m13 engine) 6b2-15 water pump/generator drive belt removal and installation removal 1) disconnect negative cable at battery. 2) if vehicle equipped with a/c, remove compressor drive belt (4) before removing water pump belt (1). Refer to “compressor drive belt removal and installation...

  • Page 451

    6b2-16 engine cooling (m13 engine) water pump removal and installation removal 1) disconnect negative cable at battery. 2) drain coolant referring to “cooling system draining” in this section. 3) remove water pump/generator drive belt referring to “water pump/generator drive belt removal and install...

  • Page 452: Required Service Material

    Engine cooling (m13 engine) 6b2-17 water pump inspection • rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, replace it. Engine coolant temperature sensor (ect sensor) removal and installation refer to “engine coolant temperature senso...

  • Page 453

    6b2-18 engine cooling (m13 engine) tightening torque specification fastening part tightening torque n•m kg-m lb-ft etc sensor 15 1.5 11.0 air ventilation bolt 4.5 0.45 3.5 thermostat cap bolt 11 1.1 8.0 thermostat case bolt 25 2.5 18.0 generator adjusting bolt 23 2.3 17.0 generator pivot bolt 50 5.0...

  • Page 454: Section 6E2

    Engine and emission control system (m13 engine) 6e2-1 6e2 section 6e2 engine and emission control system (m13 engine) contents general description ......................................6e2-3 engine and emission control system construction ................................................6e2-3 air int...

  • Page 455

    6e2-2 engine and emission control system (m13 engine) camshaft position sensor (cmp sensor) and its circuit inspection.............................................. 6e2-33 camshaft position sensor (cmp sensor) removal and installation ............................................. 6e2-34 crankshaft p...

  • Page 456: General Description

    Engine and emission control system (m13 engine) 6e2-3 general description engine and emission control system construction the engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air in...

  • Page 457

    6e2-4 engine and emission control system (m13 engine) engine and emission control system flow diagram.

  • Page 458

    Engine and emission control system (m13 engine) 6e2-5 engine and emission control system diagram 26 10 9 7 8 14 13 23 11 15 12 2 6 5 1 3 18 24 39 35 30 29 38 16 17 37 36 31 22 21 19 20 27 25 34 32 4 33 28.

  • Page 459

    6e2-6 engine and emission control system (m13 engine) air intake system description the main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air control valve (4) and intake manifold (5). The air (by the amount corresponding to the thrott...

  • Page 460

    Engine and emission control system (m13 engine) 6e2-7 fuel delivery system description the fuel system consists of fuel tank (1), fuel pump (2) (with built-in fuel filter (3) and fuel pressure regulator (4)), delivery pipe (5), injectors (6) and fuel feed line (7). The fuel (8) in the fuel tank (1) ...

  • Page 461

    6e2-8 engine and emission control system (m13 engine) electronic control system description the electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ecm which controls various devices according to the signals from the sensors and 3) v...

  • Page 462

    Engine and emission control system (m13 engine) 6e2-9 electronic control system component location information sensors control devices others 1. Maf and iat sensor a: fuel injector a: ecm 2. Tp sensor b: evap canister purge valve b: combination meter 3. Stop lamp switch c: fuel pump relay c: evap ca...

  • Page 463

    6e2-10 engine and emission control system (m13 engine) engine and emission control input/output table input output electric control device fuel level sensor for detecting fuel level barometric pressure sensor stop lamp switch start switch ignition switch lighting switch blower switch a/c switch a/c ...

  • Page 464

    Engine and emission control system (m13 engine) 6e2-11 ecm input/output circuit diagram 48 6 35 ig1 22 23 24 25 27 28 +b 29 43 55 ig1 ig11 +bb st ig2 ig2 42 47 52 + – +bb ig2 ig1 9 4 7 : 50 : 51 8 blu/wht blu/yel blu/red blu/orn red/blk grn grn pnk blk blk blu yel/blu blk/wht wht/blu blu/blk blk/red...

  • Page 465

    6e2-12 engine and emission control system (m13 engine) 1. Ckp sensor 20. Immobilizer control module 39. Stop lamp 2. Cmp sensor 21. Data link connector 40. Lighting switch 3. Vss 22. Injector no.1 41. Position lamp 4. Map sensor 23. Injector no.2 42. Ignition switch 5. Knock sensor 24. Injector no.3...

  • Page 466

    Engine and emission control system (m13 engine) 6e2-13 ecm terminal arrangement table con- nector termi- nal wire color circuit con- nector termi- nal wire color circuit e23 1 blk/yel ground for ecm e22 21 – – 2 blk/yel ground for ecm 22 – – 3 blu/red heater output of heated oxygen sensor–2 23 – – 4...

  • Page 467

    6e2-14 engine and emission control system (m13 engine) [a]: terminal arrangement of ecm coupler (viewed from harness side) e23 e22 e21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 ...

  • Page 468: On-Vehicle Service

    Engine and emission control system (m13 engine) 6e2-15 on-vehicle service accelerator cable adjustment with accelerator pedal depressed fully (1), check clearance between throttle lever (2) and lever stopper (3) of throttle body. If measured value is out of specification, adjust it to specification ...

  • Page 469

    6e2-16 engine and emission control system (m13 engine) 1) connect scan tool to dlc (1) with ignition switch off. Special tool (a): suzuki scan tool 2) warm up engine to normal operating temperature. 3) check engine idle speed and “iac duty” by using “data list” mode on scan tool to check “iac duty”....

  • Page 470

    Engine and emission control system (m13 engine) 6e2-17 air intake system throttle body components throttle body on-vehicle inspection • check that throttle valve lever (1) moves smoothly. Throttle body removal and installation removal 1) disconnect negative cable at battery. 2) drain coolant referri...

  • Page 471

    6e2-18 engine and emission control system (m13 engine) 5) disconnect connectors from tp sensor (1) and iac valve (2). 6) disconnect engine coolant hoses (3) and breather hose (4) from throttle body. 7) remove throttle body from intake manifold. 8) remove tp sensor and iac valve from throttle body. I...

  • Page 472

    Engine and emission control system (m13 engine) 6e2-19 throttle body cleaning clean throttle body bore (1) and idle air passage (2) by blowing compressed air. Idle air control (iac) valve operation check using suzuki scan tool 1) connect suzuki scan tool to dlc (1) with ignition switch off. Special ...

  • Page 473

    6e2-20 engine and emission control system (m13 engine) installation 1) install new gasket (2) to throttle body (1). 2) install iac valve (3) to throttle body (1). Tighten iac valve screws to specified torque. Tightening torque iac valve screw (a): 3.5 n·m (0.35 kg-m, 2.5 lb-ft) 3) install throttle b...

  • Page 474

    Engine and emission control system (m13 engine) 6e2-21 oil control valve removal and installation removal remove oil gallery pipe no.1 (1) and oil control valve (2) from tim- ing chain cover (3). Installation 1) install new o-ring (4) to oil control valve. 2) install oil control valve to timing chai...

  • Page 475

    6e2-22 engine and emission control system (m13 engine) fuel delivery system fuel pressure inspection 1) relieve fuel pressure in fuel feed line referring to “fuel pres- sure relief procedure” in section 6-2. 2) disconnect fuel feed hose from fuel delivery pipe. 3) connect special tools and hose betw...

  • Page 476

    Engine and emission control system (m13 engine) 6e2-23 8) after checking fuel pressure, remove fuel pressure gauge. 9) remove special tools from fuel delivery pipe and fuel feed hose. 10) connect fuel feed hose to fuel delivery pipe and clamp it securely. 11) with engine “off” and ignition switch “o...

  • Page 477

    6e2-24 engine and emission control system (m13 engine) fuel pump with pressure regulator removal and installation removal remove fuel tank from body according to procedure described in “fuel tank removal and installation” of section 6c and remove fuel pump from fuel tank. Installation 1) install fue...

  • Page 478

    Engine and emission control system (m13 engine) 6e2-25 fuel injector removal and installation removal 1) relieve fuel pressure according to procedure described in “fuel pressure relief procedure” of section 6-2. 2) disconnect battery negative cable at battery. 3) disconnect maf and iat sensor connec...

  • Page 479

    6e2-26 engine and emission control system (m13 engine) fuel injector inspection 1) install injector to special tool (injector checking tool). Special tool (a): 09912-58421 (b): 09912-57610 2) connect special tools (hose and attachment) to fuel feed pipe (1) of vehicle. 3) connect special tool (test ...

  • Page 480

    Engine and emission control system (m13 engine) 6e2-27 6) operate fuel pump and apply fuel pressure to injector as fol- lows: a) when using scan tool: i) connect scan tool to dlc (1) with ignition switch off. Special tool (a): suzuki scan tool ii) turn ignition switch on, clear dtc and select “misc ...

  • Page 481

    6e2-28 engine and emission control system (m13 engine) electronic control system engine control module (ecm) removal and installa- tion removal 1) disconnect battery negative cable at battery. 2) disable air bag system, refer to “disabling air bag system” in section 10b if equipped. 3) remove glove ...

  • Page 482

    Engine and emission control system (m13 engine) 6e2-29 manifold absolute pressure sensor (map sensor) inspection 1) disconnect connector from map sensor (1). 2) remove map sensor (1). 3) arrange 3 new 1.5 v batteries (2) in series (check that total voltage is 4.5 – 5.0 v) and connect its positive te...

  • Page 483

    6e2-30 engine and emission control system (m13 engine) throttle position sensor (tp sensor) on-vehicle inspection 1) disconnect negative cable at battery. 2) detach purge valve chamber, and remove air cleaner outlet hose. 3) disconnect tp sensor connector. 4) using ohmmeter, check resistance between...

  • Page 484

    Engine and emission control system (m13 engine) 6e2-31 engine coolant temperature sensor (ect sensor) removal and installation removal 1) disconnect battery negative cable at battery. 2) drain coolant referring to “cooling system draining” in sec- tion 6b2. 3) remove air intake pipe. 4) disconnect c...

  • Page 485

    6e2-32 engine and emission control system (m13 engine) engine coolant temperature sensor (ect sensor) inspection immerse temperature sensing part of ect sensor (1) in water (or ice) and measure resistance between terminals while heating water gradually. If measured resistance does not show such char...

  • Page 486

    Engine and emission control system (m13 engine) 6e2-33 heated oxygen sensor (ho2s-1 and ho2s-2) removal and installation removal 1) disconnect negative cable at battery. 2) for ho2s–1, disconnect connector of heated oxygen sensor and release its wire harness from clamps. 3) remove front bumper and e...

  • Page 487

    6e2-34 engine and emission control system (m13 engine) camshaft position sensor (cmp sensor) removal and installation removal 1) disconnect negative cable at battery. 2) disconnect connector from camshaft position sensor. 3) remove camshaft position sensor from cylinder head. Installation 1) check t...

  • Page 488

    Engine and emission control system (m13 engine) 6e2-35 crankshaft position sensor (ckp sensor) removal and installation removal 1) disconnect negative cable at battery. 2) remove generator drive belt, loosen pivot bolt (2) and move generator rearward. 3) disconnect connector from crankshaft position...

  • Page 489

    6e2-36 engine and emission control system (m13 engine) vehicle speed sensor (vss) and its circuit inspection 1) confirm that terminal voltage and ground circuit continuity at vss connector terminals are in good condition referring to step 3 to 5 of “dtc p0500 diag. Flow” in section 6-2. If not, repa...

  • Page 490

    Engine and emission control system (m13 engine) 6e2-37 main relay, fuel pump relay and radiator fan relay inspection 1) disconnect negative cable at battery. 2) remove main relay (1), fuel pump relay (2) and radiator fan relay (3) from relay box. 3) check that there is no continuity between terminal...

  • Page 491

    6e2-38 engine and emission control system (m13 engine) radiator fan control system inspection system inspection check system for operation referring to “diag. Flow table b-7” in section 6-2. If radiator fan fails to operate properly, check relay, radiator fan and electrical circuit. Mass air flow (m...

  • Page 492

    Engine and emission control system (m13 engine) 6e2-39 mass air flow (maf) and intake air temperature (iat) sensor removal and installation removal 1) disconnect negative cable at battery. 2) disconnect maf and iat sensor coupler (1). 3) remove maf and iat sensor (2) from air cleaner assembly. Insta...

  • Page 493

    6e2-40 engine and emission control system (m13 engine) mass air flow (maf) and intake air temperature (iat) sensor inspection • check sensor o-ring (1) for damage and deterioration. Replace as necessary. • blow hot air to temperature sensing part (2) of maf and iat sensor (3) using hot air drier (4)...

  • Page 494

    Engine and emission control system (m13 engine) 6e2-41 emission control system egr system inspection 1) connect suzuki scan tool to data link connector (dlc) with ignition switch turn off. 2) turn on ignition switch and erase dtc using “clear dtc” in “troublu codes” menu. 3) start engine and warm up...

  • Page 495

    6e2-42 engine and emission control system (m13 engine) 2) remove carbon from egr valve gas passage. 3) inspect valve (2), valve seat and rod for fault, cracks, bend or other damage. If found faulty, replace egr valve assembly. Evaporative emission control system inspection evap canister purge 1) dis...

  • Page 496

    Engine and emission control system (m13 engine) 6e2-43 ii) turn on ignition switch. Using service wire, ground “e23-13” terminal of ecm con- nector (valve on) “b” and unground it (valve off) “a”. 2) check purge valve for operation and vacuum passage for clog when valve is switched on and off by usin...

  • Page 497

    6e2-44 engine and emission control system (m13 engine) vacuum hose check hoses for connection, leakage, clog and deterioration. Replace as necessary. Evap canister purge valve 1) with ignition switch off, disconnect coupler from canister purge valve. 2) remove evap canister purge valve from air clea...

  • Page 498

    Engine and emission control system (m13 engine) 6e2-45 evap canister 1) check outside of evap canister visually. 2) disconnect vacuum hoses from evap canister. 3) check that there should be no restriction of flow through purge pipe (1) and air pipe (2) when air is blown (4) into tank pipe (3). If an...

  • Page 499

    6e2-46 engine and emission control system (m13 engine) 6) after checking vacuum, stop engine and remove pcv valve. Shake valve and listen for the rattle of check needle inside the valve. If valve does not the rattle, replace valve. 7) after checking, remove plug and install pcv valve. 8) install air...

  • Page 500: Special Tool

    Engine and emission control system (m13 engine) 6e2-47 special tool 09912-58442 09912-58432 09912-58490 09912-58421 pressure gauge pressure hose 3-way joint & hose checking tool set (see note “a”.) 09912-57610 09917-47911 09930-88530 checking tool plate vacuum pump gauge injector test lead tech 2 ki...

  • Page 501

    6e2-48 engine and emission control system (m13 engine) tightening torque specification fastening part tightening torque n•m kg-m lb-ft tp sensor mounting screw 2.5 0.25 1.8 iac valve screw 3.5 0.35 2.5 ect sensor 15 1.5 11.5 heated oxygen sensor 45 4.5 32.5 camshaft position sensor 10 1.0 7.5 knock ...

  • Page 502: Section 6F2

    Ignition system (m13 engine) 6f2-1 6f2 section 6f2 ignition system (m13 engine) contents general description ...................................... 6f2-2 ignition system construction ...................... 6f2-2 ignition system components locator diagram.......................................... 6f2...

  • Page 503: General Description

    6f2-2 ignition system (m13 engine) general description ignition system construction the ignition system is an electronic (distributorless) ignition system. Its consists of the parts as described below. • ecm it detects the engine and vehicle conditions through the signals from the sensors, determine...

  • Page 504

    Ignition system (m13 engine) 6f2-3 ignition system wiring circuit diagram 1. Ignition switch 7. No.1 spark plug 2. Main relay 8. No.2 spark plug 3. Ignition coil assembly for no.1 and no.4 spark plugs 9. No.3 spark plug 4. Ignition coil assembly for no.2 and no.3 spark plugs 10. No.4 spark plug 5. C...

  • Page 505: Diagnosis

    6f2-4 ignition system (m13 engine) diagnosis ignition system symptom diagnosis condition possible cause correction engine cranks, but will not start or hard to start (no spark) blown fuse for ignition coil replace. Loose connection or disconnection of lead wire or high-tension cord(s) connect secure...

  • Page 506

    Ignition system (m13 engine) 6f2-5 reference waveform oscilloscope waveforms of cmp sensor and no.1/no.4 ignition trigger signal are as shown in figure when connecting oscillo- scope between terminals e22-10 of ecm connectors connected to ecm and ground, and between terminal e23-32 and ground. Measu...

  • Page 507

    6f2-6 ignition system (m13 engine) 4 electrical connection check 1) check ignition coil assemblies and high-tension cords for electrical connection. Are they connected securely? Go to step 5. Connect securely. 5 high-tension cords check 1) check high-tension cord for resistance referring to “high-te...

  • Page 508: On-Vehicle Service

    Ignition system (m13 engine) 6f2-7 on-vehicle service ignition spark test 1) remove air cleaner assembly with air intake pipe. 2) disconnect all injector couplers from injectors. 3) remove spark plug and check it for condition and type refer- ring to “spark plugs removal and installation” in this se...

  • Page 509

    6f2-8 ignition system (m13 engine) installation 1) install no.1 cylinder (2) and no.3 cylinder (3) high-tension cords to spark plugs and ignition coil assemblies (1) while gripping each cap. 2) install cylinder head upper cover and air cleaner assembly with air intake pipe. High-tension cords inspec...

  • Page 510

    Ignition system (m13 engine) 6f2-9 installation 1) install spark plugs and torque them to specification. Tightening torque spark plug: 25 n·m (2.5 kg-m, 18.0 lb-ft) 2) install ignition coil assemblies referring to “ignition coil assembly (including ignitor) removal and installation” in this section....

  • Page 511

    6f2-10 ignition system (m13 engine) ignition coil assembly (including ignitor) removal and installation removal 1) disconnect negative cable at battery. 2) remove air cleaner assembly with air intake pipe and cylin- der head upper cover. 3) disconnect ignition coil coupler. 4) disconnect high-tensio...

  • Page 512

    Ignition system (m13 engine) 6f2-11 crankshaft position (ckp) sensor refer to “crankshaft position sensor (ckp sensor) removal and installation” and “crankshaft position sensor (ckp sensor) inspection” in section 6e2 for removal, inspection and installation. Ignition timing inspection 1) connect sca...

  • Page 513: Special Tool

    6f2-12 ignition system (m13 engine) 8) after checking initial ignition timing, release ignition timing fixation by using scan tool. 9) with engine idling (throttle opening at closed position and car stopped), check that ignition timing is about 3° – 13° btdc. (constant variation within a few degrees...

  • Page 514: Section 6G

    Cranking system (0.9 kw reduction type) 6g-1 6g section 6g cranking system (0.9 kw reduction type) contents specifications................................................. 6g-2 note: • starting motor vary depending on specifications, etc. Therefore, be sure to check model and specification of the ve...

  • Page 515: Specifications

    6g-2 cranking system (0.9 kw reduction type) specifications voltage 12 volts output 0.9 kw rating 30 seconds direction of rotation clockwise as viewed from pinion side brush length 12.3 mm (0.44 in.) number of pinion teeth 8 performance condition guarantee around at 20 °c (68 °f) no load characteris...

  • Page 516: Section 6H

    Charging system (g10/m13 engines) 6h-1 6h section 6h charging system (g10/m13 engines) contents generator .........................................................6h-2 diagnosis ......................................................6h-2 undercharged battery................................6h-2 unit r...

  • Page 517: Generator

    6h-2 charging system (g10/m13 engines) generator diagnosis undercharged battery this condition, as evidenced by slow cranking or indicator clear with red dot can be caused by one or more of the following condi- tions even though indicator lamp may be operating normal. The following procedure also ap...

  • Page 518: Specifications

    Charging system (g10/m13 engines) 6h-3 load check 1) run engine at 2,000 rpm and turn on head light and heater motor. 2) measure current and if it is less than 20 a repair or replace generator. Unit repair overhaul removal and installation for g10 engine refer to “unit repair overhaul” in the same s...

  • Page 519

    6h-4 charging system (g10/m13 engines).

  • Page 520: Section 6K2

    Exhaust system (m13 engine) 6k2-1 6k2 section 6k2 exhaust system (m13 engine) contents general description ......................................6k2-2 maintenance ..................................................6k2-2 on-vehicle service........................................6k2-3 exhaust system co...

  • Page 521: General Description

    6k2-2 exhaust system (m13 engine) general description the exhaust system consists of an exhaust manifold, three-way catalytic converter (twc) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust sys...

  • Page 522: On-Vehicle Service

    Exhaust system (m13 engine) 6k2-3 on-vehicle service exhaust system components 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. Gasket 8. Exhaust no.1 pipe 15. Exhau...

  • Page 523

    6k2-4 exhaust system (m13 engine) exhaust manifold removal and installation removal and installation refer to “exhaust manifold removal and installation” in section 6a2. Exhaust manifold inspection check gasket and seal for deterioration or damage. Replace them as necessary. Exhaust pipe removal and...

  • Page 524: Section 7A2

    Manual transaxle (m13 engine) 7a2-1 7a2 section 7a2 manual transaxle (m13 engine) contents general description ......................................7a2-2 manual transaxle construction and servicing .....................................................7a2-2 transaxle for 2wd model .....................

  • Page 525: General Description

    7a2-2 manual transaxle (m13 engine) general description manual transaxle construction and servicing the transaxle provides five forward speeds and one reverse speed by means of three synchronizers and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant me...

  • Page 526

    Manual transaxle (m13 engine) 7a2-3 transaxle for 2wd model 1. 5th speed sleeve & hub 8. Reverse idler gear 15. Countershaft 3rd gear 2. Input shaft 5th gear 9. Input shaft 16. Countershaft 2nd gear 3. Input shaft 4th gear 10. Right case 17. Low speed sleeve & hub 4. High speed sleeve & hub 11. Side...

  • Page 527

    7a2-4 manual transaxle (m13 engine) transaxle for 4wd model 1. 5th speed sleeve & hub 7. Reverse gear shaft 13. Countershaft 4th gear 19. Final gear 2. Input shaft 5th gear 8. Reverse idler gear 14. Countershaft 20. Differential case 3. Input shaft 4th gear 9. Input shaft 15. Countershaft 3rd gear 2...

  • Page 528: Diagnosis

    Manual transaxle (m13 engine) 7a2-5 diagnosis manual transaxle symptom diagnosis condition possible cause correction gears slipping out of mesh maladjusted gear shift/select control cables adjust. Worn shift fork shaft replace. Worn shift fork or synchronizer sleeve replace. Weak or damaged locating...

  • Page 529: On-Vehicle Service

    7a2-6 manual transaxle (m13 engine) on-vehicle service manual transaxle oil change 1) before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) with vehicle lifted up, check oil level and leakage. If leakage exists, correct it. 3) drain old oil and fill new specifie...

  • Page 530

    Manual transaxle (m13 engine) 7a2-7 4) remove oil seal (1) and install a new one until it becomes flush with case surface using special tool and hammer. Special tool (a): 09913-75510 (2wd and lh of 4wd) (a): 09951-46010 (rh of 4wd) 5) apply grease to oil seal lip and at the same time check drive sha...

  • Page 531

    7a2-8 manual transaxle (m13 engine) gear shift control lever and cable components 1. Gear shift control lever knob 5. Gear select control cable 9. Cable mounting bolt 2. Lever boot holder 6. Gear shift control lever assembly mounting nut 10. Cable bracket bolt 3. Gear shift lever boot 7. Gear shift ...

  • Page 532

    Manual transaxle (m13 engine) 7a2-9 gear shift control lever and cable removal and installation removal 1) remove console box. 2) disconnect gear shift and select control cables (1) from gear shift control lever assembly (2). A) disconnect cable end from pivot (7) while pushing cable end bush (4). B...

  • Page 533

    7a2-10 manual transaxle (m13 engine) gear shift control lever and cable adjust- ment • adjustment of shift cable: a) with shift control lever in “neutral” position, adjust shift cable adjusting nut (3) so that distance “a” between edge of instrument panel (1) and center of shift knob (2) measured as...

  • Page 534

    Manual transaxle (m13 engine) 7a2-11 vehicle speed sensor (vss) removal and installation removal 1) disconnect negative cable at battery. 2) disconnect vss coupler (1). 3) remove vss (2). Installation 1) apply oil to new o-ring (1) and then install vss to transaxle. 2) connect vss coupler (1). 3) co...

  • Page 535

    7a2-12 manual transaxle (m13 engine) back up lamp switch removal and installa- tion removal 1) disconnect negative cable at battery. 2) disconnect back up lamp switch coupler. 3) remove back up lamp switch (1). Installation 1) apply oil to new o-ring (1) and tighten back up lamp switch (2) to specif...

  • Page 536: Unit Repair Overhaul

    Manual transaxle (m13 engine) 7a2-13 unit repair overhaul transaxle unit components [a]: forward 8. Clutch cable 16. Engine rear mounting bolt 1. Engine 9. Backup lamp switch connector 17. Engine rear mounting 2. Transaxle 10. Vss connector 18. Engine rear mounting no.2 bracket bolts 3. Engine rear ...

  • Page 537

    7a2-14 manual transaxle (m13 engine) transaxle unit dismounting and remounting dismounting under hood 1) disconnect negative cable at battery. 2) undo wiring harness clamps, disconnect backup lamp switch coupler, vss coupler and ground cable. 3) disconnect clutch cable from clutch release lever and ...

  • Page 538

    Manual transaxle (m13 engine) 7a2-15 remounting reverse dismounting procedure for remounting noting the follow- ing. • install transfer referring to “transfer dismounting and remounting” in section 7d, if equipped. • refer to “transaxle unit components” for fastener specified torque. • push in drive...

  • Page 539

    7a2-16 manual transaxle (m13 engine) transaxle case components.

  • Page 540

    Manual transaxle (m13 engine) 7a2-17 gear shift and select shaft assembly components 1. Transaxle right case 11. Vss 2. Transaxle left case : apply sealant 99000-31260 to mating surface of left case and right case. 12. Oil gutter bolt : apply thread lock 99000-32110 to all around thread part of bolt...

  • Page 541

    7a2-18 manual transaxle (m13 engine) gear shift and select shaft assembly removal and installation removal 1) remove gear shift interlock bolt (1) and 5th to reverse inter- lock guide bolt (2) from transaxle case. 2) remove gear shift and select shaft assembly (3). Installation 1) apply grease to se...

  • Page 542

    Manual transaxle (m13 engine) 7a2-19 gear shift and select shaft disassembly and assembly 1) push spring pins out using specified spring pin removers as shown bellow. Special tool (a): 09922-85811 (4.5 mm) (b): 09925-78210 (6.0 mm) (c): 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pi...

  • Page 543

    7a2-20 manual transaxle (m13 engine) 2) using special tool, remove circlip (1) and then remove hub plate (2). Special tool (a): 09900-06107 3) drive out spring pin using special tool and hammer. Special tool (a): 09922-85811 4) remove gear shift fork (2), sleeve & hub assembly (3), syn- chronizer ri...

  • Page 544

    Manual transaxle (m13 engine) 7a2-21 assembly 1) install seat countershaft left bearing outer race (1) to bearing cone, tap cup using special tool and plastic hammer (2). Special tool (a): 09913-84510 2) with putting a shim (2) on bearing outer race (3), place straight edge (1) over it and compress ...

  • Page 545

    7a2-22 manual transaxle (m13 engine) 4) place left case plate (2) inserting its end in groove of shift guide shaft (4) and tighten new adhesive pre-coated screw (1) and bolts (7) temporarily with less than specified toque. 5) tighten new screw and new bolts to specified torque finally in the order o...

  • Page 546

    Manual transaxle (m13 engine) 7a2-23 8) install needle bearing of separated steel cage type to input shaft, apply oil then install 5th gear (1) and special tool to stop shaft rotation. Special tool (b): 09927-76010 9) install new countershaft nut (2) and tighten it to specification. Tightening torqu...

  • Page 547

    7a2-24 manual transaxle (m13 engine) 15) clean mating surface of both left case (2) and side cover (1), apply sealant to side cover (1) as shown in figure by such amount that its section is 1.5mm (0.059 in.) in diameter, mate it with left case and then tighten bolts. “b”: sealant 99000-31260 tighten...

  • Page 548

    Manual transaxle (m13 engine) 7a2-25 6) remove reverse shaft bolt (1) with washer. 7) remove case bolts (2) from outside and another bolts from clutch housing side. 8) tapping left case (3) flanges with plastic hammer, remove left case. 9) pull out reverse gear shaft (1) with washer (2), then take o...

  • Page 549

    7a2-26 manual transaxle (m13 engine) 3) 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). 4) install 5th & reverse gear shift shaft (1) with 5th & reverse gear shift guide shaft (...

  • Page 550

    Manual transaxle (m13 engine) 7a2-27 7) clean mating surfaces of both right and left cases, apply sealant to right case (2) as shown in figure by such amount that its section is 1.5mm (0.059 in.) in diameter then mate it with left case (1). “b”: sealant 99000-31260 8) tighten case bolts (3) from lef...

  • Page 551

    7a2-28 manual transaxle (m13 engine) 14) clean mating surface of guide case. 15) install fifth gear referring to “fifth gear disassembly and assembly” in this section. 16) install gear shift and select shaft assembly referring to “gear shift and select shaft assembly removal and installation” in thi...

  • Page 552

    Manual transaxle (m13 engine) 7a2-29 assembly 1) if input shaft oil seal (1) has been removed, install it with its spring side facing upward. Use special tool and hammer for installation and apply grease to oil seal lip. “b”: grease 99000-25010 special tool (a): 09951-76010 2) if counter shaft right...

  • Page 553

    7a2-30 manual transaxle (m13 engine) input & counter shaft components.

  • Page 554

    Manual transaxle (m13 engine) 7a2-31 input shaft disassembly and assembly disassembly 1) remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and press. 2) drive out 5th gear spacer (2), left bearing (3) and 4th gear (4) all at once from input shaft (1) using puller (5)...

  • Page 555

    7a2-32 manual transaxle (m13 engine) 4) using special tool, remove circlip (1). Special tool (a): 09900-06107 5) drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) from input shaft (1) using puller (4) and press. 6) take out 3rd gear needle bearing from shaft. 7) ...

  • Page 556

    Manual transaxle (m13 engine) 7a2-33 4) fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure. Synchronizer key installation position : a = b 5) drive in right bearing (1) to input shaft (2) using special tool and hammer. Special tool ...

  • Page 557

    7a2-34 manual transaxle (m13 engine) 8) install circlip (1) and confirm that circlip is installed in groove securely. Install needle bearing (2) of steel cage type, apply oil to bearing and then install synchronizer ring (3) and 4th gear (4). 9) press-fit left bearing (2) using special tool and hamm...

  • Page 558

    Manual transaxle (m13 engine) 7a2-35 4) using special tool, remove circlip (1). Special tool (a): 09900-06107 5) apply puller (3) to 1st gear (2) and drive out low speed syn- chronizer sleeve & hub assembly (1) with 1st gear (1) using press. 6) disassemble synchronizer sleeve & hub assembly. 7) take...

  • Page 559

    7a2-36 manual transaxle (m13 engine) 3) put the synchronizer outer ring (1), inner ring (3) and the cone (2) together and then measure the step difference between the outer ring and the inner ring. And also check each chamfered tooth of gear and synchronizer ring and replace with new one, if necessa...

  • Page 560

    Manual transaxle (m13 engine) 7a2-37 8) drive in low speed sleeve & hub assembly (1) using special tools and hammer, facing “b” side of sleeve to 1st gear. Special tool (a): 09923-78210 (b): 09925-18011 (c): 09940-53111 9) install circlip (1) and confirm that circlip is installed in groove securely....

  • Page 561

    7a2-38 manual transaxle (m13 engine) 11) press-fit 4th gear (2) using the same procedure as step 10). 12) install left bearing cone (1) using special tools and hammer. Special tool (a): 09923-78210 (e): 09925-98221 gear shift shaft components note: for protection of right bearing cone (3), always su...

  • Page 562

    Manual transaxle (m13 engine) 7a2-39 high speed and low speed gear shift shafts inspection 1) using feeler gauge, check clearance between fork (1) and sleeve (2) and replace those parts if it exceeds limit below. Clearance between fork and sleeve service limit “a”: 1.0 mm (0.039 in.) 2) insert each ...

  • Page 563

    7a2-40 manual transaxle (m13 engine) differential components 1. Differential pinion washer 9. Final gear 2. Differential side pinion gear 10. Final gear bolt : apply thread lock 99000-32110 to all around thread part of bolt 3. Differential side gear 11. Differential pinion shaft 4. Side gear washer ...

  • Page 564

    Manual transaxle (m13 engine) 7a2-41 differential disassembly and assembly disassembly 1) using special tools, remove right bearing (1) and sensor rotor (2). Special tool (a): 09913-60910 (b): 09925-88210 2) remove left bearing in the same manner at step 1). 3) support differential case with soft ja...

  • Page 565

    7a2-42 manual transaxle (m13 engine) 5) hold differential assembly with soft jawed vise (3), install final gear (2) as shown in figure and then tighten bolts (1) with thread lock cement applied to specified torque. “a”: thread lock cement 99000-32110 tightening torque final gear bolt (a): 90 n·m (9....

  • Page 566

    Manual transaxle (m13 engine) 7a2-43 • for right side a) using similar procedure to the above, set dial gauge tip to gear (1) shoulder. B) move gear up and down by hand and read dial gauge. Special tool (a): 09900-20606 (b): 09900-20701 2) if thrust play is out of specification, select suitable thru...

  • Page 567

    7a2-44 manual transaxle (m13 engine) tightening torque specification fastening part tightening torque n•m kg-m lb-ft transaxle oil level/filler and drain plugs 21 2.1 15.5 oil gutter bolt 10 1.0 7.5 final gear bolt 90 9.0 65.0 reverse gear shift lever bolt 23 2.3 17.0 transaxle case bolt 19 1.9 14.0...

  • Page 568: Required Service Material

    Manual transaxle (m13 engine) 7a2-45 required service material special tool material recommended suzuki product (part number) use lithium grease suzuki super grease a (99000-25010) • oil seal lip • select lever boss • select lever shaft bush sealant suzuki bond no.1217g (99000-31260) • oil drain plu...

  • Page 569

    7a2-46 manual transaxle (m13 engine) 09923-74510 09923-78210 09924-74510 09925-18011 bearing remover bearing installer installer attachment bearing installer 09925-68210 09925-78210 09925-88210 09925-98221 bearing outer race installer spring pin remover 6 mm (0.24 in.) bearing puller attachment bear...

  • Page 570: Section 7B1

    Automatic transaxle (m13 engine) 7b1-1 7b1 section 7b1 automatic transaxle (m13 engine) contents general description ......................................7b1-3 specifications ..............................................7b1-5 clutch/brake/planetary gear ......................7b1-6 functions..........

  • Page 571

    7b1-2 automatic transaxle (m13 engine) dtc p0713 transmission fluid temperature sensor circuit high ............. 7b1-58 dtc p0717 input/turbine speed sensor circuit malfunction ........................ 7b1-60 dtc p0722 output speed sensor (vss) circuit no signal............................. 7b1-62 ...

  • Page 572: General Description

    Automatic transaxle (m13 engine) 7b1-3 general description this automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (o/d) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically control...

  • Page 573

    7b1-4 automatic transaxle (m13 engine) 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. Countershaft 5. Oil pump 1...

  • Page 574

    Automatic transaxle (m13 engine) 7b1-5 specifications item specifications torque converter type stall torque ratio 3-element, 1-step, 2-phase type (with tcc (lock-up) mechanism) 1.9 – 2.1 oil pump type drive system internal involute gear type oil pump (non crescent type) engine driven gear change de...

  • Page 575

    7b1-6 automatic transaxle (m13 engine) clutch/brake/planetary gear functions 1. Input shaft and intermediate shaft 8. Reduction driven gear b1: o/d and 2nd coast brake 2. Reduction drive gear 9. Front sun gear b2: 2nd brake 3. Planet carrier 10. Ring gear b3: 1st and reverse brake 4. Short planet pi...

  • Page 576

    Automatic transaxle (m13 engine) 7b1-7 table of component operation.

  • Page 577

    7b1-8 automatic transaxle (m13 engine) electronic shift control system 14 13 12 9 10 11 8 21 1 2 5 6 7 15 16 17 18 19 20 22 23 4 3.

  • Page 578

    Automatic transaxle (m13 engine) 7b1-9 1. Engine 9. Pressure control solenoid valve 17. Transmission range sensor coupler 2. Transaxle 10. Shift solenoid valve-b (no.2) 18. Solenoid valve coupler 3. “o/d off” lamp 11. Shift solenoid valve-a (no.1) 19. Output shaft speed sensor (vss) 4. Mil 12. Timin...

  • Page 579

    7b1-10 automatic transaxle (m13 engine) transmission control module (tcm) 1. Tcm 8. Data link connector (dlc) 15. A/t 2. Input shaft speed sensor 9. Transmission fluid temperature sensor 16. “o/d off” lamp 3. Output shaft speed sensor (vss) 10. Shift solenoid valve-a (no.1) 17. A/t relay 4. Ecm 11. ...

  • Page 580

    Automatic transaxle (m13 engine) 7b1-11 operation of shift solenoid valves, timing solenoid valve and tcc solenoid valve valve status turn power on turn power off shift solenoid valve-a (no.1) close open shift solenoid valve-b (no.2) close open timing solenoid open close tcc (lock-up) solenoid close...

  • Page 581

    7b1-12 automatic transaxle (m13 engine) automatic gear shift diagram automatic shift schedule as a result of shift control is shown below. In case that selector lever is shifted to “l” range at a higher than 44 km/h (27 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower...

  • Page 582: Diagnosis

    Automatic transaxle (m13 engine) 7b1-13 diagnosis general description 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 diagnosis system wh...

  • Page 583

    7b1-14 automatic transaxle (m13 engine) on-board diagnostic system for automatic transaxle control system, tcm has following func- tions. • when ignition switch is turned on with o/d off switch turned off and no malfunction in a/t control system is detected, “o/d off” lamp (1) lights for about 2 sec...

  • Page 584

    Automatic transaxle (m13 engine) 7b1-15 precaution in diagnosing trouble • don’t disconnect couplers from tcm, battery cable from battery, tcm ground wire harness from engine or main fuse before checking the diagnosis information stored in tcm memory. Such disconnection will clear memorized informat...

  • Page 585

    7b1-16 automatic transaxle (m13 engine) automatic transaxle diagnostic flow table 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 according to instruction? Go...

  • Page 586

    Automatic transaxle (m13 engine) 7b1-17 1. Customer complaint analysis (see customer problem inspection form) 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 t...

  • Page 587

    7b1-18 automatic transaxle (m13 engine) 11. Final confirmation test confirm that the problem symptom has gone and the vehicle is free from any abnormal conditions. If what has been repaired is related to the malfunction dtc, clear the dtc once and check to ensure that no malfunction dtc is indicated...

  • Page 588

    Automatic transaxle (m13 engine) 7b1-19 customer problem inspection form (example) note: the above form is a standard sample. It should be modified according to conditions characteristic of each market..

  • Page 589

    7b1-20 automatic transaxle (m13 engine) “o/d off” lamp check 1) turn ignition switch on. 2) check that “o/d off” lamp (1) lights for about 2 sec. And then goes off. If anything faulty is found, advance to “diagnostic flow table a-3” or “diagnostic flow table a-4”. Malfunction indicator lamp (mil) ch...

  • Page 590

    Automatic transaxle (m13 engine) 7b1-21 2) connect scan tool to data link connector (dlc) (1). Special tool (a): suzuki scan tool 3) turn ignition switch on. 4) read dtc, pending dtc and freeze frame data according to instructions displayed on scan tool and print it down. Refer to scan tool operator...

  • Page 591

    7b1-22 automatic transaxle (m13 engine) diagnostic trouble code (dtc) table dtc no. Detecting item detecting condition (dtc will set when detecting) driving cycle when mil lighted p0705 transmission range sensor cir- cuit malfunction (prndl input) multiple signals are inputted simultaneously. 1drivi...

  • Page 592

    Automatic transaxle (m13 engine) 7b1-23 p0977 shift solenoid “b” control circuit high voltage of shift solenoid terminal is high although tcm is commanding shift solenoid to turn off. 1driving cycle p1701 can communication problem - tcm no signal inputted from ecm to tcm for specified time continuou...

  • Page 593

    7b1-24 automatic transaxle (m13 engine) fail safe table this function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The table below shows the fail safe function for each fail condition of solenoid, solenoid or its circuit....

  • Page 594

    Automatic transaxle (m13 engine) 7b1-25 p1701 can communication problem - tcm • throttle opening used for line pressure control is assumed to be 100%. • throttle opening used for gear shifting control is assumed to be 0%. • after 15 minutes pass from detecting malfunction, engine coolant temperature...

  • Page 595

    7b1-26 automatic transaxle (m13 engine) visual inspection visually check the following parts and systems. Inspection item referring section • a/t fluid ----- level, leakage, color section 0b • a/t fluid hoses ----- disconnection, looseness, deterioration section 7b1 • throttle cable ----- play (unde...

  • Page 596

    Automatic transaxle (m13 engine) 7b1-27 automatic transaxle basic check this check is important for troubleshooting when tcm has detected no dtc and no abnormality has been noted in visual inspection. Follow the flow table carefully. Step action yes no 1 was “automatic transaxle diagnostic flow tabl...

  • Page 597

    7b1-28 automatic transaxle (m13 engine) trouble diagnosis table trouble diagnosis table-1 electrical repair condition possible cause correction excessive shift shock shift solenoid valve-a and/or-b circuit faulty inspect circuit for open, short and intermit- tent. If ng, repair. Pressure control sol...

  • Page 598

    Automatic transaxle (m13 engine) 7b1-29 poor 3 → o/d shift shift solenoid valve-b circuit faulty inspect circuit for open, short and intermit- tent. If ng, repair. Pressure control solenoid valve circuit faulty timing solenoid valve circuit faulty output shaft speed sensor (vss) circuit faulty input...

  • Page 599

    7b1-30 automatic transaxle (m13 engine) incorrect gear shift point output shaft speed sensor (vss) circuit faulty inspect circuit for open, short and intermit- tent. If ng, repair. Pressure control solenoid valve circuit faulty can communication circuit faulty pressure control solenoid valve circuit...

  • Page 600

    Automatic transaxle (m13 engine) 7b1-31 trouble diagnosis table-2 on-vehicle repair condition possible cause correction unable to run in all range faulty valve body component replace valve body assembly excessive shift shock engine abnormal condition inspect and repair engine malfunction of shift so...

  • Page 601

    7b1-32 automatic transaxle (m13 engine) poor o/d → 3 shift malfunction of shift solenoid valve-b inspect. If ng, replace. Malfunction of timing solenoid valve malfunction of output shaft speed sensor (vss) malfunction of input shaft speed sensor malfunction of o/d off switch malfunction of throttle ...

  • Page 602

    Automatic transaxle (m13 engine) 7b1-33 trouble diagnosis table-3 off-vehicle repair condition possible cause correction unable to run in all range faulty oil pump inspect. If ng, replace. Seized or broken planetary gear faulty one-way no.2 clutch damaged drive plate faulty forward clutch faulty rev...

  • Page 603

    7b1-34 automatic transaxle (m13 engine) road test this test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a level road. 1) warm up engine. 2) with engine running at idle, shift selector lever to “d” range. 3) accelerate vehicle speed b...

  • Page 604

    Automatic transaxle (m13 engine) 7b1-35 3 → o/d upshift fails to occur malfunction of shift solenoid valve-b inspect. If ng, replace. Malfunction of o/d off switch malfunction of engine coolant temperature sen- sor malfunction of output shaft speed sensor (vss) malfunction of input shaft speed senso...

  • Page 605

    7b1-36 automatic transaxle (m13 engine) tcc (lock-up) function does not operate malfunction of tcc solenoid valve inspect. If ng, replace. Malfunction of shift solenoid valve-a and/or-b malfunction of brake light switch malfunction of engine coolant temperature sen- sor malfunction of output shaft s...

  • Page 606

    Automatic transaxle (m13 engine) 7b1-37 manual road test this test checks the gears being used in “l”, “2” or “d” range when driven with unoperated gear shift control system. Test drive vehicle on a level road. 1) with select lever in “p”, start engine and warm it up. 2) after warming up engine, tur...

  • Page 607

    7b1-38 automatic transaxle (m13 engine) engine brake test 1) while driving vehicle in 3rd gear of “d” range, shift select lever down to “2” range and check if engine brake operates. 2) in the same way as in step 1), check engine brake for operation when select lever is shifted down to “l” range. 3) ...

  • Page 608

    Automatic transaxle (m13 engine) 7b1-39 stall test 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 between full and l...

  • Page 609

    7b1-40 automatic transaxle (m13 engine) time lag test this test is to check conditions of clutch, brake and fluid pressure. “time lag” means time elapsed since selector lever is shifted with engine idling till shock is felt. 1) with chocks placed before and behind front and rear wheels respectively,...

  • Page 610

    Automatic transaxle (m13 engine) 7b1-41 line pressure test purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following conditions. • automatic fluid is at normal operating temperature (70 – 80°c /158 – 1...

  • Page 611

    7b1-42 automatic transaxle (m13 engine) troubleshooting “p” range test 1) stop vehicle on a slope of 5 degrees or more, shift select lever to “p” range and at the same time apply park- ing brake. 2) after stopping engine, depress brake pedal and release parking brake. 3) then, release brake pedal gr...

  • Page 612

    Automatic transaxle (m13 engine) 7b1-43 diagnostic flow table a-1: no gear shift to o/d system description tcm does not shift to o/d gear under any of the following conditions. • o/d off switch is turned on (“o/d off” lamp lights). • engine coolant temperature is less than 50°c (122°f). • a/t fluid ...

  • Page 613

    7b1-44 automatic transaxle (m13 engine) diagnostic flow table a-2: no lock-up occurs system description tcm turns tcc solenoid off under any of the following conditions. • brake light switch is turned on. (brake pedal is depressed) • engine coolant temperature is less than 60°c (140°f). • throttle o...

  • Page 614

    Automatic transaxle (m13 engine) 7b1-45 diagnostic flow table a-3: “o/d off” lamp circuit check (“o/d off” lamp lights steadily) wiring diagram circuit description “o/d off” lamp operation of on/off is controlled by transmission control module (tcm) and combination meter. When ignition switch is tur...

  • Page 615

    7b1-46 automatic transaxle (m13 engine) fig. For step 2 and step 4 4 check o/d off switch for operation. 1) disconnect o/d off switch coupler. 2) check continuity between terminals under each condition below. (see fig.) o/d off switch under being released: no conti- nuity o/d off switch under being ...

  • Page 616

    Automatic transaxle (m13 engine) 7b1-47 diagnostic flow table a-4: “o/d off” lamp circuit check (“o/d off” lamp does not light anytime) wiring diagram circuit description “o/d off” lamp operation of on/off is controlled by transmission control module (tcm) and combination meter. When ignition switch...

  • Page 617

    7b1-48 automatic transaxle (m13 engine) diagnostic flow table a-5: tcm power and ground circuit check wiring diagram troubleshooting 1. Tcm 3. Ignition switch 2. A/t relay [a]: terminal arrangement of tcm connector (viewed from harness side) blk blk blk e13-1 e13-23 e13-6 wht/red grn blk/wht +bb e13...

  • Page 618

    Automatic transaxle (m13 engine) 7b1-49 4 check tcm ground circuit. 1) turn ignition switch off. 2) with tcm connectors disconnected, check for proper connection to tcm at “e13-1”/ “e13-23” terminal. 3) if ok, check resistance between “e13-1”/ “e13-23” terminal of disconnected tcm connector and body...

  • Page 619

    7b1-50 automatic transaxle (m13 engine) dtc p0705 transmission range sensor circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm memory by using scan tool. 3) start engine and...

  • Page 620

    Automatic transaxle (m13 engine) 7b1-51 troubleshooting step action yes no 1 was “automatic transaxle diagnostic flow table” performed? Go to step 2. Go to “automatic tran- saxle diagnostic flow table” in this section. 2 do you have suzuki scan tool? Go to step 3. Go to step 4. 3 check transmission ...

  • Page 621

    7b1-52 automatic transaxle (m13 engine) table for step 4 terminal e12-20 e12-1 e12-8 e12-7 e12-19 e12-18 select lever position p 8 – 14 v 0 v 0 v 0 v 0 v 0 v r 0 v 8 – 14 v 0 v 0 v 0 v 0 v n 0 v 0 v 8 – 14 v 0 v 0 v 0 v d 0 v 0 v 0 v 8 – 14 v 0 v 0 v 2 0 v 0 v 0 v 0 v 8 – 14 v 0 v l 0 v 0 v 0 v 0 v ...

  • Page 622

    Automatic transaxle (m13 engine) 7b1-53 dtc p0707 transmission range sensor circuit low wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtcs in tcm memory by using scan tool. 3) start engine and shift s...

  • Page 623

    7b1-54 automatic transaxle (m13 engine) troubleshooting step action yes no 1 was “automatic transaxle diagnostic flow table” performed? Go to step 2. Go to “automatic tran- saxle diagnostic flow table” in this section. 2 do you have suzuki scan tool? Go to step 3. Go to step 4. 3 check transmission ...

  • Page 624

    Automatic transaxle (m13 engine) 7b1-55 table for step 4 terminal e12-20 e12-1 e12-8 e12-7 e12-19 e12-18 select lever position p 8 – 14 v 0 v 0 v 0 v 0 v 0 v r 0 v 8 – 14 v 0 v 0 v 0 v 0 v n 0 v 0 v 8 – 14 v 0 v 0 v 0 v d 0 v 0 v 0 v 8 – 14 v 0 v 0 v 2 0 v 0 v 0 v 0 v 8 – 14 v 0 v l 0 v 0 v 0 v 0 v ...

  • Page 625

    7b1-56 automatic transaxle (m13 engine) dtc p0712 transmission fluid temperature sensor circuit low 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 and start engine. 3) ke...

  • Page 626

    Automatic transaxle (m13 engine) 7b1-57 troubleshooting step action yes no 1 was “automatic transaxle diagnostic flow table” performed? Go to step 2. Go to “automatic tran- saxle diagnostic flow table” in this section. 2 check transmission fluid temperature circuit for ground short. Check continuity...

  • Page 627

    7b1-58 automatic transaxle (m13 engine) dtc p0713 transmission fluid temperature sensor circuit high 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 and start engine. 3) s...

  • Page 628

    Automatic transaxle (m13 engine) 7b1-59 troubleshooting step action yes no 1 was “automatic transaxle diagnostic flow table” performed? Go to step 2. Go to “automatic tran- saxle diagnostic flow table” in this section. 2 check transmission fluid temperature circuit for open. 1) turn ignition switch ...

  • Page 629

    7b1-60 automatic transaxle (m13 engine) dtc p0717 input/turbine speed sensor circuit malfunction 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 and start engine. 3) shift...

  • Page 630

    Automatic transaxle (m13 engine) 7b1-61 troubleshooting fig. For step 4 step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check” in this section. 2 check input shaft speed sensor circuit. 1) disconnect tcm connectors with ignition switch off. 2) check for proper ...

  • Page 631

    7b1-62 automatic transaxle (m13 engine) dtc p0722 output speed sensor (vss) circuit no signal 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 and start engine. 3) shift se...

  • Page 632

    Automatic transaxle (m13 engine) 7b1-63 troubleshooting step action yes no 1 was “automatic transaxle diagnostic flow table” in this section performed? Go to step 2. Go to “automatic tran- saxle diagnostic flow table” in this section. 2 check output shaft speed sensor (vss) power circuit. 1) turn ig...

  • Page 633

    7b1-64 automatic transaxle (m13 engine) 7 check output shaft speed sensor (vss) gears visually. Check output shaft speed sensor gears for the followings. • no damage in drive gear on differential case • no damage in driven gear in output shaft speed sensor is result satisfactory? Intermittent troubl...

  • Page 634

    Automatic transaxle (m13 engine) 7b1-65 dtc p0741/p0742 tcc circuit performance or stuck off/tcc circuit stuck on dtc detecting condition and trouble area [dtc p0741] [dtc p0742] dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory...

  • Page 635

    7b1-66 automatic transaxle (m13 engine) dtc p0751/p0752/p0756/p0757 shift solenoid-a (no.1) performance or stuck off/shift solenoid-a (no.1) stuck on/shift solenoid-b (no.2) performance or stuck off/shift solenoid-b (no.2) stuck on dtc detecting condition and trouble area [dtc p0751] [dtc p0752] [dt...

  • Page 636

    Automatic transaxle (m13 engine) 7b1-67 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine and warm it up to normal operating temperature. 4) shift select lever to “n” and “d” range for each 10 seconds. 5) start vehicle and increase vehicl...

  • Page 637

    7b1-68 automatic transaxle (m13 engine) dtc p0785 timing solenoid wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine and shift selector lever to “n” range. ...

  • Page 638

    Automatic transaxle (m13 engine) 7b1-69 troubleshooting fig. For step 4 step action yes no 1 was “a/t system check” performed? Go to step 2. Go to “a/t system check” in this section. 2 check timing solenoid valve circuit for ig short or open. 1) turn ignition switch on and measure volt- age between ...

  • Page 639

    7b1-70 automatic transaxle (m13 engine) dtc p0962 pressure control solenoid control circuit low wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine. 4) keep ...

  • Page 640

    Automatic transaxle (m13 engine) 7b1-71 fig. For step 2. 2 check pressure control solenoid valve resistance 1) turn ignition switch off 2) disconnect valve body harness connector on automatic transmission. 3) check for proper connection to solenoid at “brn/yel” and “lt grn/red” circuit. 4) check res...

  • Page 641

    7b1-72 automatic transaxle (m13 engine) dtc p0963 pressure control solenoid control circuit high wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine. 4) keep...

  • Page 642

    Automatic transaxle (m13 engine) 7b1-73 fig. For step 3. 3 check pressure control solenoid valve resistance 1) turn ignition switch off 2) disconnect valve body harness connector on automatic transmission. 3) check for proper connection to solenoid at “brn/yel” and “lt grn/red” circuit. 4) check res...

  • Page 643

    7b1-74 automatic transaxle (m13 engine) dtc p0974/p0977 shift solenoid-a (no.1) control circuit high/shift solenoid- b (no.2) control circuit high wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2)...

  • Page 644

    Automatic transaxle (m13 engine) 7b1-75 fig. For step 3. 2 check shift solenoid valve circuit for ig short 1) connect valve body harness connector. 2) disconnect tcm connectors. 3) check for proper connection to tcm at termi- nal “e13-16” (for shift solenoid valve-a (no.1)) or “e13-15” (for shift so...

  • Page 645

    7b1-76 automatic transaxle (m13 engine) dtc p1701 can communication error wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off, if available. 2) clear dtc in tcm memory. 3) start engine and warm it up to normal operat...

  • Page 646

    Automatic transaxle (m13 engine) 7b1-77 2 check can communication circuit for open. 1) turn ignition switch to off position. 2) disconnect connectors from ecm and tcm. 3) check for proper connection to “e21-7” termi- nal of ecm connector and “e13-7” terminal of tcm connector. If ok, measure resistan...

  • Page 647

    7b1-78 automatic transaxle (m13 engine) dtc p1702 internal control module memory check sum error dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) clear dtc in tcm memory. 3) after 10 seconds passed from turning ignition swit...

  • Page 648

    Automatic transaxle (m13 engine) 7b1-79 dtc p2769 torque converter clutch (tcc) circuit low 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 dtcs in tcm memory. 3) start engine. 4) keep eng...

  • Page 649

    7b1-80 automatic transaxle (m13 engine) dtc troubleshooting fig. For step 3. Step action yes no 1 was “automatic transaxle diagnostic flow table” performed? Go to step 2. Go to “automatic tran- saxle diagnostic flow table” in this section. 2 check tcc solenoid valve resistance 1) turn ignition switc...

  • Page 650

    Automatic transaxle (m13 engine) 7b1-81 dtc p2770 torque converter clutch (tcc) circuit high 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 dtcs in tcm memory. 3) start engine. 4) keep en...

  • Page 651

    7b1-82 automatic transaxle (m13 engine) dtc troubleshooting fig. For step 3. Step action yes no 1 was “automatic transaxle diagnostic flow table” performed? Go to step 2. Go to “automatic tran- saxle diagnostic flow table” in this section. 2 check tcc solenoid valve circuit for ig short 1) connect v...

  • Page 652

    Automatic transaxle (m13 engine) 7b1-83 scan tool data as the data values given below 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 condi- tion, there may be case...

  • Page 653

    7b1-84 automatic transaxle (m13 engine) timing sole- noid monitor ignition switch on and selector lever is in “n” range off for about 0.5 sec. While on gear shifting between 3rd and 4th or gear shifting n to d on tcc solenoid command at 5 km/h (3 mile/h) constant speed, o/d off switch on, closed thr...

  • Page 654

    Automatic transaxle (m13 engine) 7b1-85 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 655

    7b1-86 automatic transaxle (m13 engine) o/d off switch inputted signal from o/d off switch on selector knob. On: o/d off switch on off: o/d off switch off transaxle range transaxle range detected by signal fed from transmission range sensor. D range signal on: signal which tcm require ecm to increas...

  • Page 656

    Automatic transaxle (m13 engine) 7b1-87 inspection of tcm and its circuits tcm and its circuits can be checked at tcm wiring connectors by measuring voltage and resistance. Inspection 1) remove tcm (1) from vehicle referring to “transmission control module” in this section. 2) connect tcm connectors...

  • Page 657

    7b1-88 automatic transaxle (m13 engine) e12 6 wht input shaft speed sensor (+) 2 – 3 v ignition switch turned on, engine stops. (reference waveform no.1) while engine running. (output signal is waveform. Wave- form frequency varies depending on output shaft speed. (16 pulses are generated par 1 inpu...

  • Page 658

    Automatic transaxle (m13 engine) 7b1-89 con- nector terminal number wire color circuit normal voltage condition e13 1 blk ground 0 – 1 v ignition switch on 2 lt grn/red pressure control solenoid valve (–) 0.6 – 1.0 v ignition switch on 3 – – – – 4 brn/yel pressure control solenoid valve (+) 0 – 0.6 ...

  • Page 659

    7b1-90 automatic transaxle (m13 engine) 1. Reference waveform no.1 input shaft speed sensor signal at engine idling. 2. Reference waveform no.2 output shaft speed sensor (vss) signal at vehicle speed 60 km/h (37 mile/h). 3. Reference waveform no.3 pressure control solenoid valve signal at engine idl...

  • Page 660: On-Vehicle Service

    Automatic transaxle (m13 engine) 7b1-91 on-vehicle service maintenance service fluid level check at normal operating (hot) tempera- ture (hot check) inspection 1) stop vehicle and place it level. 2) apply parking brake and place chocks against wheels. 3) with selector at p position, start engine. 4)...

  • Page 661

    7b1-92 automatic transaxle (m13 engine) fluid level check at room (cold) temperature (cold check) inspection fluid level can be checked temporarily at room (cold) temperature which correspond to 20 – 30°c (68 – 86°f). This level check is considered to be preparation before performing level check und...

  • Page 662

    Automatic transaxle (m13 engine) 7b1-93 5) check fluid level referring to “fluid level check at room (cold) temperature (cold check)” and “fluid level check at normal operating (hot) temperature (hot check)” in this section. Automatic transaxle fluid an equivalent of dexron ® -iii automatic transaxl...

  • Page 663

    7b1-94 automatic transaxle (m13 engine) selector lever inspection check selector lever for smooth and clear-cut movement and position indicator for correct indication. For operation of select lever, refer to the figure. 1. Selector lever assembly 4. Indicator assembly 2. Knob assembly 5. Illuminatio...

  • Page 664

    Automatic transaxle (m13 engine) 7b1-95 select cable removal 1) remove parking brake lever cover. 2) remove console box. 3) disconnect select cable from selector lever and then detach from bracket. 4) remove clip and disconnect select cable from manual select lever. 5) remove select cable retainer f...

  • Page 665

    7b1-96 automatic transaxle (m13 engine) adjustment 1) shift manual shift lever to “n” range (transmission range sen- sor “n” range). 2) remove adjuster (cable end) from selector lever pin of selec- tor lever assembly. 3) release lock plate (1) which restrict moving of cable end holder (2). 4) push c...

  • Page 666

    Automatic transaxle (m13 engine) 7b1-97 transmission range sensor (shift switch) adjustment and inspection 1) shift manual select lever (4) to “n” range. 2) check that needle direction shaped on lock washer (2) and “n” reference line (1) on transmission range sensor are aligned. If not, loosen senso...

  • Page 667

    7b1-98 automatic transaxle (m13 engine) output shaft speed sensor (vss) inspection 1) connect positive cable of 12 volt battery to “a” terminal of sensor and ground cable to “c” terminal. Then using voltme- ter, check voltage between “b” terminal and “c” terminal with output shaft speed sensor (vss)...

  • Page 668

    Automatic transaxle (m13 engine) 7b1-99 input shaft speed sensor inspection 1) disconnect negative cable at battery. 2) disconnect input shaft speed sensor connector (2). 3) check resistance between input shaft speed sensor termi- nals. Input shaft speed sensor resistance standard: 560 – 680 Ω at 20...

  • Page 669

    7b1-100 automatic transaxle (m13 engine) engine coolant temperature sensor inspection check engine coolant temperature sensor referring to “engine coolant temperature sensor” in section 6e1. O/d off switch inspection 1) remove console box. 2) disconnect o/d off switch connector (1). 3) check continu...

  • Page 670

    Automatic transaxle (m13 engine) 7b1-101 solenoid valves (shift solenoid valves, tcc solenoid valve and timing solenoid valve) removal 1) disconnect negative cable at battery. 2) lift up vehicle. 3) remove drain plug and drain a/t fluid. 4) install drain plug. Tightening torque a/t fluid drain plug:...

  • Page 671

    7b1-102 automatic transaxle (m13 engine) 9) remove tcc solenoid valve (1), shift solenoid valve-a (no.1) (2), shift solenoid valve-b (no.2) (3) and timing sole- noid valve (4) by removing bolts. Inspection resistance check shift solenoid valves, timing solenoid valve and tcc solenoid valve resistanc...

  • Page 672

    Automatic transaxle (m13 engine) 7b1-103 operation check shift solenoid valve-a (no.1), -b (no.2) and tcc solenoid valve • check that solenoid valve (1) actuate with click sound when battery voltage is conducted. • when solenoid valve (1) is connected to battery (2), confirm that solenoid valve is c...

  • Page 673

    7b1-104 automatic transaxle (m13 engine) timing solenoid valve • check that solenoid valve (1) actuate with click sound when battery voltage is conducted. • when timing solenoid valve (1) is connected to battery (2), confirm that timing solenoid valve is open condition by blow- ing air (50 – 200 kpa...

  • Page 674

    Automatic transaxle (m13 engine) 7b1-105 installation 1) install shift solenoid valve-a (no.1) (1), shift solenoid valve-b (no.2) (2), tcc solenoid valve (3) and timing solenoid valve (4). Tightening torque solenoid valve bolt (a): 11 n·m (1.1 kg-m, 8.0 lb-ft) 2) connect solenoid connectors identify...

  • Page 675

    7b1-106 automatic transaxle (m13 engine) pressure control solenoid valve removal 1) disconnect negative cable at battery. 2) lift up vehicle. 3) remove drain plug and drain a/t fluid. 4) install drain plug. Tightening torque a/t fluid drain plug: 17 n·m (1.7 kg-m, 12.5 lb-ft) 5) remove a/t oil pan (...

  • Page 676

    Automatic transaxle (m13 engine) 7b1-107 inspection resistance check measure resistance between pressure control solenoid valve (1) terminals. Pressure control solenoid valve resistance standard: 5.0 – 5.6 Ω (at 20°c (68°f)) operation check check pressure control solenoid valve operation in the eith...

  • Page 677

    7b1-108 automatic transaxle (m13 engine) [not using regulated dc power supply] 1) connect pressure control solenoid valve (1) to battery (2) setting the 8 – 10 w bulb (4) on the way as shown in the fig- ure. 2) check for movement of valve (3) in the direction of arrow “a”. 3) disconnect pressure con...

  • Page 678

    Automatic transaxle (m13 engine) 7b1-109 transmission control module (tcm) removal 1) disconnect negative cable at battery. 2) if the vehicle is equipped with air bag system, disable air bag system. Refer to “disabling air bag system” in section 10b. 3) disconnect connectors (1) from tcm (2). 4) rem...

  • Page 679

    7b1-110 automatic transaxle (m13 engine) a/t relay inspection 1) disconnect negative cable at battery. 2) remove glove box. 3) remove a/t relay (1) from instrument panel wire harness. 4) check that there is no continuity between terminal “c” and “d”. If continuity is indicated, replace a/t relay. 5)...

  • Page 680

    Automatic transaxle (m13 engine) 7b1-111 transmission fluid temperature sensor inspection 1) disconnect negative cable at battery. 2) lift up vehicle. 3) with engine is cool, remove drain plug and drain a/t fluid. 4) install drain plug. (refer to “fluid change” in this section.) 5) remove a/t oil pa...

  • Page 681

    7b1-112 automatic transaxle (m13 engine) installation reverse removal procedure to install solenoid wire harness and valve body assembly noting the following points. • for details of valve body assembly and their connectors installation, refer to “unit assembly” in this section. • for details of a/t...

  • Page 682

    Automatic transaxle (m13 engine) 7b1-113 differential side oil seal replacement 1) lift up vehicle and drain automatic transaxle fluid. 2) remove drive shaft joints from differential gear of transaxle. Refer to “drive shaft assembly” in section 4a for procedure to disconnect drive shaft joints. For ...

  • Page 683

    7b1-114 automatic transaxle (m13 engine) 5) install new differential side oil seals (1) by using special tool. Special tool (c): 09944-88220 (d): 09924-74510 differential side oil seal installing depth right side “a”: 2.6 – 3.6 mm (0.10 – 0.14 in) left side “b”: 3.8 – 4.8 mm (0.15 – 0.19 in) 6) inst...

  • Page 684

    Automatic transaxle (m13 engine) 7b1-115 automatic transaxle assembly components 1. Drive plate 5. Lower stiffener 2. Drive plate bolt : apply sealant 99000-31230 to thread. 6. Transaxle and engine fastening bolt 3. Drive plate to torque converter bolt 7. Transaxle and engine fastening nut 4. Torque...

  • Page 685

    7b1-116 automatic transaxle (m13 engine) dismounting 1) take down transaxle with engine. For its procedure, refer to “engine assembly” in section 6a2. 2) remove lower stiffener (1). 3) remove drive plate to torque converter bolts. To lock drive plate (1), engage flat head rod or the like (2) with dr...

  • Page 686

    Automatic transaxle (m13 engine) 7b1-117 remounting 1) make sure that torque converter is installed correctly to tran- saxle. Refer to “unit assembly” in this section. 2) attach transaxle to engine. Tightening torque transaxle and engine fastening bolt and nut (a): 85 n·m (8.5 kg-m, 61.5 lb-ft) 3) t...

  • Page 687: Unit Repair

    7b1-118 automatic transaxle (m13 engine) unit repair when repairing automatic transaxle, it is necessary to conduct the on-vehicle test to investigate where the cause of the trouble lies first. Then whether overhaul should be done or not is determined. If the transaxle is disassembled without such p...

  • Page 688

    Automatic transaxle (m13 engine) 7b1-119 part inspection and correction table part inspect for correction casted part, machined part small flaw, burr remove with oil stone. Deep or grooved flaw replace part. Clogged fluid passage clean with air or wire. Flaw on installing surface, residual gasket re...

  • Page 689

    7b1-120 automatic transaxle (m13 engine) unit disassembly components caution: • thoroughly clean transaxle exterior before overhauling it. • keep working table, tools and hands clean while over- hauling. • use special care to handle aluminum parts so as not to damage them. • do not expose removed pa...

  • Page 690

    Automatic transaxle (m13 engine) 7b1-121.

  • Page 691

    7b1-122 automatic transaxle (m13 engine) 1. Torque converter 33. Oil pan 65. 2nd brake retaining plate 2. Torque converter housing : apply sealant 99000-31230 to mating surface to transaxle case. 34. A/t fluid drain plug 66. 2nd brake disc 3. Oil strainer assembly : replace oil strainer when overhau...

  • Page 692

    Automatic transaxle (m13 engine) 7b1-123 disassembly 1) remove torque converter (1). 2) remove engine mounting lh bracket (1). 3) remove manual select lever (1). 4) uncaulk lock washer (1), then remove lock nut (2) and lock washer (1). Caution: remove torque converter as much straight as possible. L...

  • Page 693

    7b1-124 automatic transaxle (m13 engine) 5) remove transmission range sensor (1). 6) remove input shaft speed sensor (1) and output shaft speed sensor (vss) (2). 7) remove harness bracket (3) and select cable clamp (4). 8) remove fluid cooler pipes (1) and pipe union (2). 9) remove fluid level gauge...

  • Page 694

    Automatic transaxle (m13 engine) 7b1-125 11) remove oil strainer assembly (1). 12) disconnect connectors from solenoid valves, and transmis- sion fluid temperature sensor (1). 13) remove valve body assembly bolts. 14) remove manual valve rod (1) from manual valve lever (2), then remove valve body as...

  • Page 695

    7b1-126 automatic transaxle (m13 engine) 15) remove valve body harness (1). 16) remove governor apply no.1 gasket (1). 17) remove cooler check valve (1) and spring (2). Caution: when pulling valve body harness (1) out of transaxle case, take care not to damage transmission fluid temper- ature sensor...

  • Page 696

    Automatic transaxle (m13 engine) 7b1-127 18) remove accumulator pistons and springs. To remove c2 (1), c1 (2) and b1 (3) accumulator pistons and springs, position rag on pistons to catch each piston. To remove pistons, force low-pressure compressed air (1 kg/ cm 2 , 15 psi, 100 kpa, max) into hole (...

  • Page 697

    7b1-128 automatic transaxle (m13 engine) 22) remove breather hose (1). 23) remove breather union (2). 24) measure input shaft thrust play. Apply dial gauge onto input shaft end (1) and measure thrust play of input shaft. When input shaft thrust play is out of specification, select input shaft front ...

  • Page 698

    Automatic transaxle (m13 engine) 7b1-129 27) remove input shaft front thrust bearing (1). 28) remove input shaft rear thrust bearing (1) and thrust bearing race (2). 29) remove direct clutch hub (1). 30) remove differential assembly (1) and counter shaft assem- bly (2). 31) remove governor apply no....

  • Page 699

    7b1-130 automatic transaxle (m13 engine) 32) remove fluid reservoir lh plate (1). 33) turn over transaxle and remove rear cover assembly (1). 34) remove reverse clutch drum thrust bearing (1). 35) remove 2nd brake gasket (1). Note: if reverse clutch drum thrust bearing is not found, it may have been...

  • Page 700

    Automatic transaxle (m13 engine) 7b1-131 36) measure o/d and 2nd coast brake piston stroke. • measure dimension “a” from mating surface 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 (...

  • Page 701

    7b1-132 automatic transaxle (m13 engine) 39) remove o/d and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4). 40) remove forward clutch hub (1). 41) remove rear sun gear thrust bearing (1) from forward clutch hub (2). 42) remove rear sun gear thrust bearing race...

  • Page 702

    Automatic transaxle (m13 engine) 7b1-133 44) remove planetary gear thrust bearing (1). 45) remove one-way clutch no.1 assembly (2) from rear plane- tary sun gear subassembly (3). 46) remove planetary carrier thrust washer (1). 47) remove o/d and 2nd coast brake retaining plate snap ring (1). 48) rem...

  • Page 703

    7b1-134 automatic transaxle (m13 engine) 50) before disassembling 2nd brake piston assembly (4), check 2nd brake piston stroke by measuring clearance between 2nd brake separator plate (1) and piston (2) with feeler gauge (3). If clearance (piston stroke) is out of specification, replace brake discs ...

  • Page 704

    Automatic transaxle (m13 engine) 7b1-135 54) remove 2nd brake separator plates (1) discs (2) and retain- ing plate (3). 55) remove brake drum gasket (1). 56) remove one-way clutch outer race retainer (1). 57) check one-way clutch no.2 as follows. • ensure planetary carrier (1) rotates only in counte...

  • Page 705

    7b1-136 automatic transaxle (m13 engine) 59) remove planetary gear assembly (1). 60) measure 1st and reverse brake piston stroke • using special tool, measure 1st and reserve brake piston stroke when compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) is blown through oil hole. Special tool...

  • Page 706

    Automatic transaxle (m13 engine) 7b1-137 64) turn over transaxle and uncaulk reduction drive gear nut (1). 65) secure reduction drive gear (1) with parking lock pawl, then remove reduction drive gear nut. 66) using special tools and hydraulic press, remove planetary ring gear subassembly (1). Specia...

  • Page 707

    7b1-138 automatic transaxle (m13 engine) 68) screwing 3 bolts (1), remove reduction drive gear (2). 69) blowing compressed air from oil hole of oil pump, remove 1st and reverse brake piston (1). 70) remove parking lock pawl bracket (1). 71) with slotted screw driver, cut and unfold manual valve leve...

  • Page 708

    Automatic transaxle (m13 engine) 7b1-139 72) using spring pin remover with 3 mm (0.12 in.) in diameter and hammer, drive out manual valve lever pin (1). 73) remove manual shift shaft (2). 74) remove parking lock pawl rod (2) from manual valve lever (1). 75) remove manual detent spring (1). 76) remov...

  • Page 709

    7b1-140 automatic transaxle (m13 engine) inspection brake discs dry and inspect them for pitting, burn flaking, significant wear, glazing, cracking, charring and chips or metal particles imbedded in lining. If discs show any of the above conditions, replacement is required. Brake separator plates an...

  • Page 710

    Automatic transaxle (m13 engine) 7b1-141 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 711

    7b1-142 automatic transaxle (m13 engine) oil pump assembly disassembly 1) remove o-ring from pump body. 2) remove 8 oil pump subassembly bolts (1) and stator shaft assembly (2). 1. Oil seal : apply grease 99000-25030 to oil seal lip. 7. Oil pump subassembly bolts 2. O-ring apply automatic transaxle ...

  • Page 712

    Automatic transaxle (m13 engine) 7b1-143 3) remove oil seal (1) using special tool. Special tool (a): 09913-50121 inspection 1) check body clearance of driven gear. Push driven gear to one side of body using feeler gauge, measure clearance between driven gear and body. If clearance exceeds its stand...

  • Page 713

    7b1-144 automatic transaxle (m13 engine) 4) using special tool, measure stator shaft bush bore. If measured stator shaft bush bore is out of specifications, replace oil pump assembly with new one. Special tool (a): 09900-20605 stator shaft bush bore standard: 18.424 – 18.450 mm (0.7254 – 0.7264 in.)...

  • Page 714

    Automatic transaxle (m13 engine) 7b1-145 3) install stator shaft assembly to oil pump body and tighten 8 pump subassembly bolts (1) to specification. Tightening torque oil pump subassembly bolt (a): 10 n·m (1.0 kg-m, 7.5 lb-ft) 4) after applying a/t fluid to new o-ring, install it to oil pump body. ...

  • Page 715

    7b1-146 automatic transaxle (m13 engine) direct clutch assembly 1. Input shaft front thrust bearing 8. Shaft snap ring 2. Input shaft seal ring 9. Direct clutch separator plate 3. Input shaft subassembly 10. Direct clutch disc 4. Inner o-ring 11. Direct clutch retaining plate 5. Direct clutch piston...

  • Page 716

    Automatic transaxle (m13 engine) 7b1-147 preliminary check 1) install direct clutch assembly (1) to oil pump assembly (2), blow in air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (3) of oil pump assembly with special tool attached on upper surface of direct clutch piston, and mea-...

  • Page 717

    7b1-148 automatic transaxle (m13 engine) 5) remove outer o-ring (1). 6) remove inner o-ring (2). 7) remove input shaft seal rings (1). Inspection clutch discs, plates and retaining plate check that sliding surfaces of discs, separator plates and retain- ing plate are not worn hard or burnt. If neces...

  • Page 718

    Automatic transaxle (m13 engine) 7b1-149 direct clutch return spring subassembly measure free length of direct clutch return spring. Free length of direct clutch return spring “a”: 36.04 mm (1.419 in.) direct clutch piston shake direct clutch piston lightly and check that check ball (1) is not stuck...

  • Page 719

    7b1-150 automatic transaxle (m13 engine) • install plate snap ring so that its both ends would be posi- tioned in correct locations as shown in figure. • after assembly, measure direct clutch piston stroke. Special tool (a): 09900-20607 (b): 09900-20701 direct clutch piston stroke: 0.4 – 0.7 mm (0.0...

  • Page 720

    Automatic transaxle (m13 engine) 7b1-151 forward and reverse clutch assembly 1. Forward clutch balancer 11. Reverse clutch separator plate 2. Forward clutch return spring subassembly 12. Reverse clutch disc 3. Forward clutch piston 13. Reverse clutch cushion plate 4. Forward clutch piston o-ring 14....

  • Page 721

    7b1-152 automatic transaxle (m13 engine) preliminary check 1) install forward and reverse clutch assembly (1) to transaxle rear cover (2), blow in compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) through oil hole (4) of transaxle rear cover with the special tool attached on the upper sur...

  • Page 722

    Automatic transaxle (m13 engine) 7b1-153 3) remove balancer snap ring by using special tool and hydraulic press. Special tool (a): 09926-97610 4) remove forward clutch balancer (1). 5) remove forward clutch return spring subassembly (1). 6) install intermediate shaft subassembly (1) to transaxle rea...

  • Page 723

    7b1-154 automatic transaxle (m13 engine) 8) remove forward clutch piston o-ring (1) from intermediate shaft subassembly (2). 9) remove forward clutch drum o-ring (1) from forward clutch drum (2). 10) remove intermediate shaft seal ring (1) from intermediate shaft subassembly (2). Inspection clutch d...

  • Page 724

    Automatic transaxle (m13 engine) 7b1-155 forward clutch return spring subassembly measure free length of forward clutch return spring. Free length of forward clutch return spring: 24.04 mm (0.946 in.) forward clutch piston lip and forward clutch balancer lip check each lip for wear, deformation, cut...

  • Page 725

    7b1-156 automatic transaxle (m13 engine) • do not damage forward clutch return spring subassembly and balancer by pressing in forward clutch return spring sub- assembly passing through its original installing position over 1.5 mm (0.059 in.). Special tool (a): 09926-97610 • apply a/t fluid to forwar...

  • Page 726

    Automatic transaxle (m13 engine) 7b1-157 • measure forward clutch piston stroke in the same manner as “preliminary check”. Special tool (a): 09900-20607 (b): 09900-20701 (c): 09952-06020 forward clutch piston stroke: 1.30 – 1.50 mm (0.051 – 0.059 in.) when piston stroke is out of specification, sele...

  • Page 727

    7b1-158 automatic transaxle (m13 engine) • 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 “preliminary check”. Special tool (a): 09900-20607 (b): 09900-20701 revers...

  • Page 728

    Automatic transaxle (m13 engine) 7b1-159 2nd brake piston assembly disassembly 1) apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole (1) of 2nd brake cylinder (3) to remove 2nd brake piston (2). 2) remove inner o-ring (1) and outer o-ring (2). 1. 2nd brake cylinder 4. Out...

  • Page 729

    7b1-160 automatic transaxle (m13 engine) assembly reverse disassembly procedure for assembly, noting the following points. • use new o-rings. Apply a/t fluid to the o-rings, before installation. • install 2nd brake piston (1) to which a/t fluid is applied to 2nd brake cylinder (2). Do not damage o-r...

  • Page 730

    Automatic transaxle (m13 engine) 7b1-161 transaxle rear cover assembly (o/d and 2nd coast brake piston) disassembly 1) remove snap ring by using special tools and hydraulic press. Special tool (a): 09926-96030 (b): 09946-06710 2) remove o/d and 2nd coast brake return spring assembly. 1. Snap ring 7....

  • Page 731

    7b1-162 automatic transaxle (m13 engine) 3) apply compressed air (400 – 800 kpa, 4 – 8 kg/cm 2 , 57 – 113 psi) to oil hole (2) of transaxle rear cover (1) to remove o/d and 2nd coast brake piston. 4) remove o/d and 2nd coast brake piston front o-ring (1) and rear o-ring (2). 5) remove rear cover sea...

  • Page 732

    Automatic transaxle (m13 engine) 7b1-163 inspection o/d and 2nd coast blake return spring subassembly measure free length of o/d and 2nd coast blake return spring. Free length of o/d and 2nd coast blake return spring “a”: 18.99 mm (0.748 in.) transaxle rear cover bush 7) measure transaxle rear cover...

  • Page 733

    7b1-164 automatic transaxle (m13 engine) • do not damage o/d and 2nd coast brake return spring sub- assembly and piston by pressing in o/d and 2nd coast brake return spring subassembly passing through its original installing position over 1.0 mm (0.039 in.). Special tool (a): 09926-96030 (b): 09946-...

  • Page 734

    Automatic transaxle (m13 engine) 7b1-165 disassembly 1) remove final gear bolts (1), and then final gear (2). 2) remove differential side rh bearing by using special tools. Special tool (a): 09926-37610 (b): 09926-37610-001 (c): 09926-37610-003 (d): 09926-47610-002 3) remove output shaft speed senso...

  • Page 735

    7b1-166 automatic transaxle (m13 engine) inspection 1) hold differential case subassembly with soft jawed vice and set special tools as shown. Special tool (a): 09900-20607 (b): 09900-20701 2) measure differential gear thrust play. Differential gear thrust play: 0.05 – 0.20 mm (0.002 – 0.008 in.) 3)...

  • Page 736

    Automatic transaxle (m13 engine) 7b1-167 3) tighten final gear bolts (1) to specified torque. Tightening torque final gear bolt (a): 78 n·m (7.8 kg-m, 56.5 lb-ft) 4) after applying a/t fluid to output shaft speed sensor (vss) drive gear (1), install output shaft speed sensor drive gear. 5) install n...

  • Page 737

    7b1-168 automatic transaxle (m13 engine) countershaft assembly disassembly 1) remove countershaft lh bearing (1) and reduction driven gear (2) at once by using special tool and hydraulic press. Special tool (a): 09925-98221 2) remove countershaft rh bearing (1) by using special tools. Special tool (...

  • Page 738

    Automatic transaxle (m13 engine) 7b1-169 assembly 1) install new countershaft rh bearing (1) by using special tool and hydraulic press. Special tool (a): 09913-84510 2) install reduction driven gear (1) with special tools and hydraulic press. Special tool (a): 09913-84510 (b): 09925-88210 3) install...

  • Page 739

    7b1-170 automatic transaxle (m13 engine) valve body assembly disassembly 1) pull out manual valve (1). 1. Pressure control solenoid valve 8. Manual valve 2. Shift solenoid valve-a (no.1) 9. Solenoid lock plate 3. Shift solenoid valve-b (no.2) 10. O-ring 4. Tcc (lock-up) solenoid valve apply automati...

  • Page 740

    Automatic transaxle (m13 engine) 7b1-171 2) remove pressure control solenoid valve (1). 3) remove tcc (lock-up) solenoid valve (1). 4) remove shift solenoid valve-a (1). 5) remove shift solenoid valve-b (1). 6) remove timing solenoid valve (1). 2. Solenoid lock plate.

  • Page 741

    7b1-172 automatic transaxle (m13 engine) 7) remove temperature sensor clamp (1). Assembly reverse disassembly procedure for assembly, noting 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 v...

  • Page 742

    Automatic transaxle (m13 engine) 7b1-173 2) remove lubrication lh tube (1) and rh tube (2). 3) remove differential side oil seal (1). 4) remove countershaft rh bearing cup by using special tools. Special tool (a): 09944-96011 (b): 09942-15511 5) remove differential side rh bearing cup by using speci...

  • Page 743

    7b1-174 automatic transaxle (m13 engine) assembly 1) after applying a/t fluid to new o-rings, fit them to housing plugs. Finally install plugs to torque converter housing. Tightening torque torque converter housing plug (a): 7.5 n·m (0.75 kg-m, 5.5 lb-ft) 2) using special tools, assemble differentia...

  • Page 744

    Automatic transaxle (m13 engine) 7b1-175 5) install lubrication lh tube (1) and rh tube (2). 6) install fluid reservoir rh plate (1) and lubrication tube clamp (2). Tightening torque lubrication tube clamp bolt (a): 5.5 n·m (0.55 kg-m, 4.0 lb-ft) fluid reservoir rh plate bolt (b): 5.5 n·m (0.55 kg-m...

  • Page 745

    7b1-176 automatic transaxle (m13 engine) 3) remove differential side lh bearing cup and shim with spe- cial tools. Special tool (a): 09944-96011 (b): 09942-15511 assembly 1) using special tools, assemble shim and differential side lh bearing cup. Special tool (a): 09924-74510 (b): 09944-88220 2) usi...

  • Page 746

    Automatic transaxle (m13 engine) 7b1-177 adjustment before unit assembly differential side bearing preload 1) after applying a/t fluid to differential assembly, fit it to tran- saxle case. 2) install torque converter housing to transaxle case, then tighten bolts (1) to specified torque. Tightening t...

  • Page 747

    7b1-178 automatic transaxle (m13 engine) available shim thickness 5) remove differential assembly. Counter shaft bearing preload 1) after applying a/t fluid to countershaft assembly (1) and dif- ferential assembly (2), fit them. 2) install torque converter housing to transaxle case, then tighten bol...

  • Page 748

    Automatic transaxle (m13 engine) 7b1-179 3) measure bearing preload (b) by using special tool. Special tool (a): 09928-06050 counter shaft bearing preload = (b) – differential side bearing preload (a) counter shaft bearing preload (starting torque) in the case of new bearing 0.33 – 0.76 n·m (3.3 – 7...

  • Page 749

    7b1-180 automatic transaxle (m13 engine) unit assembly 1) install new manual shift shaft oil seal to transaxle case. Use special tool and hammer to install it, and then apply grease to its lip. Special tool (a): 09925-98210 “a”: grease 99000-25030 manual shift shaft oil seal installing depth “a”: 0....

  • Page 750

    Automatic transaxle (m13 engine) 7b1-181 4) after applying a/t fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3) and manual valve lever to transaxle case. 5) after installing manual valve lever pin (2) by using spring pin remover with 3 mm (0.12 in.) in diameter...

  • Page 751

    7b1-182 automatic transaxle (m13 engine) 9) install 1st and reverse brake return spring subassembly (1) to transaxle case (2). 10) apply a/t fluid to 1st and reverse brake discs (2) separator plates (3) and retaining plate (1), then install them to tran- saxle case. 11) compress 1st and reverse brak...

  • Page 752

    Automatic transaxle (m13 engine) 7b1-183 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 753

    7b1-184 automatic transaxle (m13 engine) 15) install parking lock pawl (1) and spring (2). Apply a/t fluid to parking lock pawl shaft, then insert it into transaxle case. 16) install new planetary ring gear subassembly (1) to reduction drive gear (3) by using special tools and hydraulic press. Speci...

  • Page 754

    Automatic transaxle (m13 engine) 7b1-185 18) caulk reduction drive gear nut (1). 19) apply a/t fluid to planetary gear assembly (1), then fit it to planetary ring gear assembly. 20) check for correct installation of planetary gear assembly as follows. Measure the distance “a” by using micrometer cal...

  • Page 755

    7b1-186 automatic transaxle (m13 engine) 21) apply a/t fluid to one-way clutch no.2 assembly (1), then install it to planetary gear assembly. After that, ensure that planetary carrier rotates only in counterclockwise direction “a”, not in clockwise direction “b”. 22) install one-way clutch outer rac...

  • Page 756

    Automatic transaxle (m13 engine) 7b1-187 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. Special too...

  • Page 757

    7b1-188 automatic transaxle (m13 engine) 30) apply a/t fluid to front planetary sun gear (1) and install it to planetary gear assembly (2). 31) install o/d and 2nd coast brake retaining plate snap ring (1). 32) after applying grease to slide contact face of planetary car- rier thrust washer (1), ins...

  • Page 758

    Automatic transaxle (m13 engine) 7b1-189 36) after applying a/t fluid to rear sun gear thrust bearing race (1), install it to rear planetary sun gear (2). 37) after applying a/t fluid to rear sun gear thrust bearing (1), install it to forward clutch hub (2). 38) after applying a/t fluid to forward c...

  • Page 759

    7b1-190 automatic transaxle (m13 engine) 41) check for correct installation of forward and reverse clutch assembly as follows. Measure distance “a” by using micrometer caliper (1) and straightedge (2). If out of specification, remove forward and reverse clutch assembly, forward clutch hub, rear plan...

  • Page 760

    Automatic transaxle (m13 engine) 7b1-191 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 761

    7b1-192 automatic transaxle (m13 engine) 46) remove sealant attached to mating surface of transaxle rear cover (1) completely. 47) apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “...

  • Page 762

    Automatic transaxle (m13 engine) 7b1-193 54) after applying a/t fluid to direct clutch hub (1), install it to planetary gear assembly. 55) after applying a/t fluid to input shaft rear thrust bearing (1) and thrust bearing race (2), install them into direct clutch hub (3). 56) after applying a/t flui...

  • Page 763

    7b1-194 automatic transaxle (m13 engine) 58) check for correct installation of direct clutch assembly as fol- lows. Measure distance “a” by using micrometer caliper (1) and straightedge (2). If out of specification, remove direct clutch assembly, direct clutch hub and reinstall them properly. Distan...

  • Page 764

    Automatic transaxle (m13 engine) 7b1-195 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.) 62) after applying a/t fluid to new...

  • Page 765

    7b1-196 automatic transaxle (m13 engine) 67) after applying a/t fluid to new o-ring, fit it to transaxle case plug (1). Then install the transaxle case plug to transaxle case (2). Tightening torque transaxle case plug (a): 7.5 n·m (0.75 kg-m, 5.5 lb-ft) 68) install new o-rings to each accumulator pi...

  • Page 766

    Automatic transaxle (m13 engine) 7b1-197 70) after applying a/t fluid to cooler check valve (1) and spring (2), install them to transaxle case (3). 71) after applying a/t fluid to new governor apply no.1 gasket (1), install it to transaxle case. 72) after applying a/t fluid to new o-ring, fit it to ...

  • Page 767

    7b1-198 automatic transaxle (m13 engine) 74) tighten valve body bolts to specified torque. Tightening torque valve body bolt 11 n·m (1.1 kg-m, 8.0 lb-ft) valve body bolt length 75) connect solenoid connectors to solenoid valves identifying their installing positions by wire colors, and install trans...

  • Page 768

    Automatic transaxle (m13 engine) 7b1-199 77) install oil cleaner magnets (1) in oil pan (2). 78) install new oil pan gasket (1) between transaxle case and oil pan (2). Tightening torque oil pan bolt (a): 7.0 n·m (0.7 kg-m, 5.0 lb-ft) 79) after applying a/t fluid to new o-ring, fit it to fluid inlet ...

  • Page 769

    7b1-200 automatic transaxle (m13 engine) 82) 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 torque input shaft speed sensor bolt (a): 5.5 n·m (0.55 kg-m, 4.0 lb-ft) output shaft speed sensor (vss) bolt (b): 13 n·...

  • Page 770

    Automatic transaxle (m13 engine) 7b1-201 91) bend dents of lock washer (1) in order to prevent displace- ment of lock washer. 92) install manual select lever (1). Tightening torque manual select lever nut (a): 13 n·m (1.3 kg-m, 9.5 lb-ft) 93) install engine mounting lh bracket (1). Tightening torque...

  • Page 771

    7b1-202 automatic transaxle (m13 engine) • install torque converter aligning grooves (1) of torque con- verter and projection (2) of oil pump drive gear. • install torque converter, using care not to damage oil seal of oil pump. • after installing torque converter, check that distance “a” is within ...

  • Page 772

    Automatic transaxle (m13 engine) 7b1-203 tightening torque specification fastening part tightening torque n•m kg-m lb-ft a/t fluid drain plug 17 1.7 12.5 output shaft speed sensor bolt 13 1.3 9.5 input shaft speed sensor bolt 5.5 0.55 4.0 transaxle case plug 7.5 0.75 5.5 solenoid valve bolt 11 1.1 8...

  • Page 773: Special Tool

    7b1-204 automatic transaxle (m13 engine) special tool 09900-20605 09900-20607 09900-20701 09913-50121 dial caliper gauge dial gauge magnetic stand oil seal remover 09913-61510 09913-70123 09913-84510 09913-85210 bearing puller bearing installer bearing installer bearing installer 09923-78210 09924-7...

  • Page 774

    Automatic transaxle (m13 engine) 7b1-205 09926-37610-002 09926-37610-003 09926-58010 09926-96030 bearing puller attachment see note 2. Bearing remover attach- ment see note 2. Bearing remover attach- ment clutch spring compressor 09926-96050 09926-97610 09926-97620 09926-98310 brake piston compresso...

  • Page 775: Required Service Material

    7b1-206 automatic transaxle (m13 engine) required service material note: • “1”: this tool consists of bearing puller with 09926-37610-001, bearing puller attachment with 09926-37610-002 and bearing remover attachment with 09926-37610-003. • “2”: this tool is constituent of bearing remover with 09926...

  • Page 776: Section 7C

    Clutch (g10/m13 engines) 7c-1 7c section 7c clutch (g10/m13 engines) contents on-vehicle service......................................... 7c-2 clutch cable................................................. 7c-2 clutch pedal and clutch pedal bracket ....... 7c-5 clutch cover, clutch disc and flywheel ...

  • Page 777: On-Vehicle Service

    7c-2 clutch (g10/m13 engines) on-vehicle service clutch cable [a]: for rh vehicle 5. Clutch release lever nut 11. Adjust bolt [b]: for lh vehicle 6. Clutch release lever bolt 12. Clutch cable outer bolt 1. Clutch cable 7. Clutch pedal 13. Clamp bolt 2. Clutch release lever 8. Clutch cable hook : app...

  • Page 778

    Clutch (g10/m13 engines) 7c-3 removal 1) disconnect negative cable at battery. 2) remove clutch cable joint nut (1). 3) remove joint pin (2) from clutch release lever (3). 4) remove clutch cable outer bolts (1) from dash panel (2) in engine room. 5) disconnect cable hook from clutch pedal, then take...

  • Page 779

    7c-4 clutch (g10/m13 engines) installation 1) apply grease to cable end hook (1) and also joint pin (2) before installing cable. “a”: grease 99000-25010 2) hook cable end with pedal using screwdriver or long nose pliers from cabin inside, then join inner cable joint pin in release lever. 3) fasten c...

  • Page 780

    Clutch (g10/m13 engines) 7c-5 clutch pedal and clutch pedal bracket 1. Clutch pedal bracket 9. Adjust bolt 2. Pedal bracket bolt 10. Packing (in cabin) 3. Pedal bracket nut 11. Pedal return cushion 4. Pedal shaft 12. Clutch pedal 5. Pedal bush 13. Pedal pad 6. Pedal spring : apply grease 99000-25010...

  • Page 781

    7c-6 clutch (g10/m13 engines) clutch cover, clutch disc and flywheel removal 1) dismount transaxle assembly referring to “transaxle unit dismounting and remounting” in section 7a. 2) hold flywheel with special tool and loosen clutch cover bolts (1). Remove clutch cover (2) and clutch disc. Special t...

  • Page 782

    Clutch (g10/m13 engines) 7c-7 3) pull out input shaft bearing (1) using the special tools, if bearing removal is necessary. Special tool (a): 09921-26020 (b): 09930-30104 (c): 09917-58010 4) loosen flywheel bolt while holding flywheel with special tool and removal flywheel from crank shaft. Inspecti...

  • Page 783

    7c-8 clutch (g10/m13 engines) clutch cover 1) check diaphragm spring (1) for abnormal wear or damage. 2) inspect pressure plate (2) for wear or heat spots. 3) if abnormality is found, replace clutch cover. Do not disas- semble it into diaphragm spring and pressure plate. Flywheel check surface conta...

  • Page 784

    Clutch (g10/m13 engines) 7c-9 3) aligning clutch disc to flywheel center using special tool, install clutch cover (1) and bolts (2). Then tighten bolts to specification. Special tool (a): 09924-17810 (c): 09923-36320 (m13 engine) (c): 09923-36330 (g10 engine) tightening torque clutch cover bolt (b):...

  • Page 785

    7c-10 clutch (g10/m13 engines) 6) install tap (m16 x 1.5) (1) to clutch release shaft no.1 bush. 7) pull out no.1 bush using tap (1) and special tools. Special tool (b): 09923-46020 (c): 09930-30104 inspection clutch release bearing check clutch release bearing for smooth rotation. If abnormality is...

  • Page 786

    Clutch (g10/m13 engines) 7c-11 installation 1) drive in a new no.1 bush using special tools, and then apply grease to bush inside. Special tool (a): 09930-30104 (b): 09923-46030 “a”: grease 99000-25010 2) install release shaft with return spring. 3) apply grease to no.2 bush (1) inside and press-fit...

  • Page 787: Required Service Material

    7c-12 clutch (g10/m13 engines) 9) set release lever (1) to release shaft (2) aligning their punch marks (3), then tighten nut. Tightening torque clutch release lever nut (a): 23 n·m (2.3 kg-m, 16.5 lb-ft) tightening torque specification required service material fastening part tightening torque n•m ...

  • Page 788: Special Tool

    Clutch (g10/m13 engines) 7c-13 special tool 09917-58010 09921-26020 09922-46010 09923-36320 bearing remover bearing remover bush remover clutch center guide 09923-36330 09923-46020 09923-46030 09924-17810 clutch center guide joint pipe joint pipe flywheel holder 09925-98210 09925-98221 09930-30104 i...

  • Page 789

    7c-14 clutch (g10/m13 engines).

  • Page 790: Section 7D

    Transfer 7d-1 7d section 7d transfer contents unit repair overhaul ......................................7d-2 tightening torque specification ...................7d-6 required service material ..............................7d-7 note: • for the descriptions (items) not found in this section, refer to ...

  • Page 791: Unit Repair Overhaul

    7d-2 transfer unit repair overhaul 7 50 n·m (5.0 kg-m) 4 55 n·m (5.5 kg-m) 3 55 n·m (5.5 kg-m) 11 55 n·m (5.5 kg-m) 5 55 n·m (5.5 kg-m) 10 50 n·m (5.0 kg-m) 8 23 n·m (2.3 kg-m) 6 2 1 9 12 1. Transfer assy 6. Transfer to engine stiffener 11. Transfer rear mounting bracket bolts 2. Transfer rear mount...

  • Page 792

    Transfer 7d-3 1. Transfer left case 11. Bevel gear shim 21. Driven gear bearing 2. Transfer right case 12. Bevel gear (hypoid gear) 22. Reduction drive gear bearing 3. Transfer output retainer 13. Bevel pinion shaft (hypoid gear) 23. Flange nut : after tightening nut so as rotation torque of bevel p...

  • Page 793

    7d-4 transfer dismounting 1) disconnect negative cable at battery. 2) hoist vehicle and remove wheels. 3) drain transaxle oil referring to “manual transaxle oil change” in section 7a2. 4) drain transfer oil referring to “oil change” in section 7d of the service manual mentioned in the “foreword” of ...

  • Page 794

    Transfer 7d-5 12) remove transfer rear mounting bracket (2) with transfer rear mounting (1) from transfer assembly. Mounting reverse dismounting procedure for installation noting the follow- ing. 1) tighten transfer mounting bolts (3) to specified torque. Tightening torque transfer mounting bolt (a)...

  • Page 795

    7d-6 transfer 4) tighten transfer to engine stiffener bolts to specified torque. Tightening torque transfer to engine stiffener no.1 bolt (a): 50 n·m (5.0 kg-m, 36.5 lb-ft) transfer to engine stiffener no.2 bolt (b): 23 n·m (2.3 kg-m, 17.0 lb-ft) 5) tighten transfer to transaxle stiffener bolts (1) ...

  • Page 796: Required Service Material

    Transfer 7d-7 required service material material recommended suzuki products (part number) use lithium grease suzuki super grease a (99000-25010) • oil seal lips • o-ring sealant suzuki bond no. 1217g (99000-31260) • oil drain plug • oil level plug • mating surface of transfer case.

  • Page 797

    7d-8 transfer.

  • Page 798: Section 7F

    Rear differential 7f-1 7f section 7f rear differential contents general description ........................................ 7f-2 differential unit.............................................. 7f-3 unit repair overhaul ...................................... 7f-5 drive bevel pinion bearing outer rac...

  • Page 799: General Description

    7f-2 rear differential general description the rear differential assembly for 4wd model 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. Further, because of sl...

  • Page 800

    Rear differential 7f-3 3) remove brake drum and disconnect parking brake cable from brake back plate referring to “parking brake lever cable removal and installation” in section 5c. 4) remove axle shafts referring to “rear axle shaft and wheel bearing remove and installation (for 4wd model)” in sec-...

  • Page 801

    7f-4 rear differential remounting reverse removal procedure for installation, noting the following. • clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side. “a”: sealant 99000-31260 • apply sealant to carrier bolts (2) and tighten carrier bolts to speci...

  • Page 802: Unit Repair Overhaul

    Rear differential 7f-5 unit repair overhaul 1. Drive bevel pinion nut : after tightening nut so as rotational torque of drive bevel pinion to be in specified torque, caulk nut securely. 10. Drive bevel pinion rear taper roller bearing 19. Differential pinion 2. Companion flange 11. Bevel pinion shim...

  • Page 803

    7f-6 rear differential disassembly 1) put match marks (4) on differential side bearing caps (3) and differential carrier (1). 2) take off differential side bearing caps by removing their bolts and remove differential gear assembly (2) with shims. 3) with aluminum plates placed on vise first, grip di...

  • Page 804

    Rear differential 7f-7 9) hold companion flange (1) with special tool and then remove drive bevel pinion nut. Special tool (a): 09930-40113 10) remove companion flange from drive bevel pinion. Use special tool if it is hard to remove. Special tool (b): 09913-65135 11) remove drive bevel pinion with ...

  • Page 805

    7f-8 rear differential 15) drive out drive bevel pinion bearing outer races (1) by using metallic stick (2). Inspection • check companion flange for wear of damage. • check bearings for wear or discoloration. • check differential carrier for cracks. • check drive bevel pinion and bevel gear for wear...

  • Page 806

    Rear differential 7f-9 drive bevel pinion bearing outer race for press-fitting bevel pinion bearing outer races, use special tools as shown. Special tool (a): 09925-98210 (b): 09941-34513-004 (c): 09924-74510 (d): 09951-16090 differential case assembly 1) assemble differential case assembly noting i...

  • Page 807

    7f-10 rear differential 2) measure thrust play of differential gear (2) as follows. Special tool (a): 09900-20607 (b): 09900-20701 differential gear thrust play 0 – 0.37 mm (0 – 0.014 in.) right side • hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surfa...

  • Page 808

    Rear differential 7f-11 7) press-fit differential side bearings (3) to differential case (1) by using special tools. Special tool (a): 09951-76010 (b): 09951-16060 differential carrier and drive bevel pinion special tool (a): 09922-76120 (b): 09922-76230 (c): 09922-76140 (d): 09922-76410 (e): 09922-...

  • Page 809

    7f-12 rear differential 1) assemble bearing form dummy with dummy shaft using spe- cial tools. Special tool (a): 09922-76120 (b): 09922-76230 2) install dial gauge (1) to bearing form dummy with dummy shaft as shown in figure. Special tool set distance (reference) “c”: 2 – 3 mm (0.079 – 0.118 in.) 3...

  • Page 810

    Rear differential 7f-13 6) tighten bevel pinion nut (special tool) (1) so that specified bearing preload is obtained. Drive bevel pinion bearing preload (at 50 rpm) 0.5 – 1.3 n·m (5.0 – 13.0 kg-cm, 0.35 – 0.90 lb-ft) 7) set dial gauge to bearing form dummy with dummy shaft and make 0 (zero) adjustme...

  • Page 811

    7f-14 rear differential 11) select adjusting shim(s) (1) closest to calculated value from among following available sizes and put it in place and then press-fit rear bearing. Special tool (a): 09940-51710 available shim thickness “a”: 0.30, 1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21, 1.24, 1.27,...

  • Page 812

    Rear differential 7f-15 15) install companion flange (3) to drive bevel pinion and tighten drive bevel pinion nut gradually with special tool, set preload of bearing to specification. Tightening torque drive bevel pinion nut (reference) 70 – 250 n·m (7.0 – 25.0 kg-m, 51.0 – 181.0 lb-ft) drive bevel ...

  • Page 813

    7f-16 rear differential 2) divide selected shim(s) between both sides (right and left) and install them to differential carrier. Then install differential side bearing caps. Tightening torque differential side bearing cap bolt (a): 23 n·m (2.3 kg-m, 17.0 lb-ft) 3) measure backlash by using dial gaug...

  • Page 814

    Rear differential 7f-17 5) after completing of gear tooth contact check, caulk drive bevel pinion nut (2) with caulking tool (1) and hammer. 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 pinio...

  • Page 815: Required Service Material

    7f-18 rear differential tightening torque specification required service material these contact patterns, located on toe or heel on both drive and coast sides, mean that 1) both pinion and gear are defective, 2) carrier is not true and square, or 3) gear is not properly seated on differential case. ...

  • Page 816: Special Tool

    Rear differential 7f-19 special tool 09900-20607 09900-20701 09913-50121 09913-60910 dial gauge magnetic stand oil seal remover bearing puller 09913-65135 09913-75810 09922-76120 09922-76140 bearing puller bearing installer dummy shaft bevel pinion shaft 09922-76150 09922-76230 09922-76320 09922-763...

  • Page 817

    7f-20 rear differential 09925-88210 09925-98210 09930-40113 09940-51710 bearing puller attachment bearing installer flange holder bearing installer 09941-34513-004 09951-16060 09951-16090 09951-76010 bearing installer lower arm bush remover oil seal installer bearing installer.

  • Page 818: Section 8B

    Lighting system 8b-1 8b section 8b lighting system contents diagnosis.........................................................8b-2 rear fog light ..............................................8b-2 on-vehicle service..........................................8b-3 rear fog light ..........................

  • Page 819: Diagnosis

    8b-2 lighting system diagnosis rear fog light condition possible cause correction rear fog light does not come on when head- lights and front fog lights (if equipped) come on • main fuse and/or fuses blown replace main fuse and/or fuses to check for short • rear fog light switch faulty check switch ...

  • Page 820: On-Vehicle Service

    Lighting system 8b-3 on-vehicle service rear fog light rear fog light circuit inspection 1) check headlights and front fog lights (if equipped) come on. If headlight and/or fog light does not come on, check for light controller circuit as follows. 2) disconnect negative cable at battery. 3) disconne...

  • Page 821

    8b-4 lighting system.

  • Page 822: Section 8C

    Instrumentation/driver information 8c-1 8c section 8c instrumentation/driver information contents general description ........................................8c-2 combination meter ........................................8c-2 diagnosis.........................................................8c-3 low...

  • Page 823: General Description

    8c-2 instrumentation/driver information general description combination meter [a]: terminal arrangement of coupler viewed from harness side 3. Tachometer (if equipped) 7. Abs/ebd circuit (if equipped) [b]: the upper side of combination meter 4. Fuel meter 8. Buzzer 1. Voltage regulator 5. Temp. Mete...

  • Page 824: Diagnosis

    Instrumentation/driver information 8c-3 diagnosis low engine oil level warning light symptom diagnosis for z13dt engine condition possible cause correction low engine oil level warning light does not light up when low engine oil level fuse blown replace fuse to circuit for short. Wiring or grounding...

  • Page 825: On-Vehicle Service

    8c-4 instrumentation/driver information on-vehicle service low fuel warning system operation this light comes on for 4 seconds after ignition switch is turned to on position, and goes out. However, in insufficient fuel level, this light indicates low fuel level by the following operation. Low fuel w...

  • Page 826

    Instrumentation/driver information 8c-5 7) after 4 seconds, check for low fuel warning lamp operation under the following each float position (1) of fuel pump (2). If faulty condition is found, replace combination meter. Low fuel warning light operation for g10/m13 engine low fuel warning light oper...

  • Page 827

    8c-6 instrumentation/driver information.

  • Page 828: Section 8G

    Immobilizer control system (g10/m13 engines) 8g-1 8g section 8g immobilizer control system (g10/m13 engines) contents general description ....................................... 8g-2 on-board diagnostic system for m13 engine model ....................................... 8g-3 diagnosis..................

  • Page 829: General Description

    8g-2 immobilizer control system (g10/m13 engines) general description components the immobilizer control system designed to prevent vehicle burglar and it consists of following components. • engine control module (ecm) • immobilizer control module (with coil antenna) • ignition key (with built-in tr...

  • Page 830

    Immobilizer control system (g10/m13 engines) 8g-3 on-board diagnostic system for m13 engine model ecm and immobilizer control module diagnose troubles which may occur in the area including the following parts when the igni- tion switch is turned to on position. Immobilizer control module • immobiliz...

  • Page 831: Diagnosis

    8g-4 immobilizer control system (g10/m13 engines) diagnosis diagnostic flow table for m13 engine model step action yes no 1 turn ignition switch to start engine. Does engine run? Go to step 5. Go to step 2. 2 w-line circuit check measure terminal voltage of immobilizer control module connector g17-7...

  • Page 832

    Immobilizer control system (g10/m13 engines) 8g-5 diagnostic trouble code (dtc) check for m13 engine model immobilizer control module 1) prepare suzuki scan tool. 2) with ignition switch off position ( ● ), connect suzuki scan tool to data link connector (dlc) located under instrument panel at drive...

  • Page 833

    8g-6 immobilizer control system (g10/m13 engines) inspection of immobilizer control module and its circuits for m13 engine model voltage inspection immobilizer control module can be checked at wiring connectors by measuring voltage. Caution: immobilizer control module can not be checked by itself. I...

  • Page 834

    Immobilizer control system (g10/m13 engines) 8g-7 dtc b3040 w-line communication fail for m13 engine model wiring circuit refer to “wiring circuit for m13 engine model” on page 8g-2. Dtc detecting condition and trouble area troubleshooting dtc detecting condition trouble area no response from ecm wh...

  • Page 835

    8g-8 immobilizer control system (g10/m13 engines) dtc b3042 w-line ckt malf (short to ground) for m13 engine model wiring circuit refer to “wiring circuit for m13 engine model” on page 8g-2. Dtc detecting condition and trouble area troubleshooting dtc detecting condition trouble area w-line circuit ...

  • Page 836

    Immobilizer control system (g10/m13 engines) 8g-9 dtc b3043 w-line ckt malf (short to battery) for m13 engine model wiring circuit refer to “wiring circuit for m13 engine model” on page 8g-2. Dtc detecting condition and trouble area troubleshooting dtc detecting condition trouble area w-line circuit...

  • Page 837

    8g-10 immobilizer control system (g10/m13 engines) dtc b3059 no request from ecm for m13 engine model wiring circuit refer to “wiring circuit for m13 engine model” on page 8g-2. Dtc detecting condition and trouble area troubleshooting dtc detecting condition trouble area no request from ecm via mil ...

  • Page 838: Special Tools

    Immobilizer control system (g10/m13 engines) 8g-11 special tools 09931-76011 tech-1a kit (suzuki scan tool) (see note “a”.) tech-2 kit (suzuki scan tool) (see note “b”.) note: • “a”: this kit includes the following items. 1. Storage case, 2. Operator's manual, 3. Tech-1a, 4. Dlc cable, 5. Test lead/...

  • Page 839

    8g-12 immobilizer control system (g10/m13 engines).

  • Page 840: Section 9

    Body service 9-1 9 section 9 body service contents body structure .................................................. 9-2 front fender ................................................... 9-2 front bumper and rear bumper..................... 9-3 exterior and interior trim.................................

  • Page 841: Body Structure

    9-2 body service body structure front fender removal 1) remove front bumper. 2) disconnect connector of side turn signal lamp. 3) remove front fender lining (1). 4) remove front fender (2). Installation reverse removal procedure for installation. Adjust panel clearance referring to “panel clearance”...

  • Page 842

    Body service 9-3 front bumper and rear bumper note: fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if rep...

  • Page 843: Exterior and Interior Trim

    9-4 body service exterior and interior trim back door emblem back door emblem dimension position dimension position dimension mm in mm in a 568 22.36 g 40 1.57 b 76 2.99 h 2 0.08 c 69 2.72 i 9 0.35 d 574 22.6 j 9 0.35 e 74.5 2.93 k 9 0.35 f 74 2.91.

  • Page 844: Panel Clearance

    Body service 9-5 panel clearance panel to panel clearance position dimension position dimension mm in. Mm in. A 4.1 – 6.1 0.161 – 0.24 k 6 – 8 0.236 – 0.315 b 5 – 7 0.197 – 0.276 l 4.8 – 7.8 0.189 – 0.307 c 5 – 7 0.197 – 0.276 m 2.5 – 4.5 0.098 – 0.177 d 5 – 7 0.197 – 0.276 n 4.2 – 6.2 0.165 – 0.244...

  • Page 845

    9-6 body service.

  • Page 846

    Prepared by 1st ed. August, 2003 printed in japan 844.