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1. 17 d Br 4 E22 5 17 4 GR E21 20 o 18 SE P E21 5 SCT 18 S 12V B W 4 E21 2 EN 1 16 B E21 15 Ha 12V 19 4 GW E21 4 E E22 12 P G H Y B hoffe rr pr HH eee 28 2 24 oa oa aifeofrobsfi7fie 15 Lu felis hashem 1 Ignition switch 8 Shift solenoid A Shift solenoid No 1 15 Monitor connector No 2 2 Transmission range sensor Shift switch 9 Shift solenoid B Shift solenoid No 2 16 DLC 3 Input shaft speed sensor Turbine rev sensor 10 Shift solenoid C Shift solenoid No 3 17 To ECM 4 Output shaft speed sensor A T VSS 11 Shift solenoid D Shift solenoid No 4 18 To A C 5 Shield wire 12 TCC solenoid Lock up solenoid 19 To brake lamp switch 6 Vehicle speed sensor VSS 13 O D cut switch 20 To main relay 7 Transmission fluid temperature sensor 14 O D OFF lamp in combination meter 21 Terminal arrangement of TCM coupler A T fluid temp sensor Viewed from harness side 7B 8 AUTOMATIC TRANSMISSION 4 A T Throttle position sensor This sensor is installed to the throttle valve shaft Throttle valve opening signal is transmitted from TP sensor to ECM as voltage signal The signal is converted to duty signal in ECM and it is sent to TCM Output shaft speed sensor This sensor is a pulse generator type that detects re
2. if equipped A Connector K B Connector L C Connector M 1 To ignition switch BI G 1 To combination switch turn L G R 1 To transmission range switch G R A T vehicle if equipped 2 To fuel level gauge Y R 2 To combination switch R 2 To transmission range switch Or dimmer sw A T vehicle if equipped 3 To ECT sensor Y W 3 To VSS Y G 3 To transmission range switch R A T vehicle if equipped 4 To ground B Or 4 Blank 4 To transmission range switch Or B A T vehicle if equipped 5 Blank 5 To main fuse WD 5 To transmission range switch G A T vehicle if equipped 6 To ABS control module R BI 6 To door switch B Y 6 To transmission range switch G W if equipped A T vehicle if equipped 7 To ignition switch B W 7 To combination switch R Y 7 Blank dimmer sw 8 ToECM Br 8 To main fuse W 8 Blank 9 To ignition switch V R 9 To ground B 9 To TCM A T vehicle if equipped BI Y 10 To brake fluid level switch R B 10 To ECM if equipped R G 10 Blank 11 To parking brake switch R G 11 To ECM VIY 12 To alternator W R 12 To ground B 13 To oil pressure switch Y B or Y BI 13 To combination switch turn R G Y 14 To seat belt switch Lg if equipped 15 To SDM Bl if equipped 16 To 4WD control module BI BODY ELECTRICAL SYSTEM 8 19 REMOVAL 1 Disconnect negative cable at battery 2 Loosen ste
3. B A 4 So Ble D C C D A E F 1 G H I J A Dummy height of pinion form dummy 40 mm 1 575 in F Drive bevel pinion mounting distance 94 mm 3 701 5 Drive bevel gear in B Radius of bearing form dummy with dummy shaft 34 G Shim thickness for mounting distance adjustment E 6 Front bearing mm 1 339 in C Block dummy thickness 14 mm 0 5512 in 1 Pinion form dummy 7 Differential carrier D Block dummy thickness 6 mm 0 2362 in 2 Bearing form dummy with dummy shaft 8 Rear bearing A B C D Mounting distance adjusting dummy total size 94 mm 3 Block dummy 9 Spacer 3 701 in E Measured dimension 4 Dial gauge 10 Drive bevel pinion Special tool A 09922 76120 B 09922 76220 C 09922 76520 D 09922 76550 E 09922 76140 F 09922 76410 G 09922 76310 H 09922 76340 I 09922 76320 J 09922 76150 7E 14 FRONT DIFFERENTIAL 1 Assemble bearing form dummy with dummy shaft using spe cial tools Special tool A 09922 76120 B 09922 76220 2 Install dial gauge 1 to bearing form dummy with dummy shaft as shown in figure Dial gauge rod tip set distance c 2 3 mm 0 079 0 118 in NOTE This installation requires no spacer or oil seal 3 Apply differential oil to drive bevel pinion front and rear bear ings 4 Install pinion form dummy 1 the other special tools and
4. AUTOMATIC TRANSMISSION 4 A T 7B 111 11 Install thrust needle roller bearing 2 and rear sun gear 3 Turn rear sun gear right and left to match the brake discs and the spline of rear sun gear 12 Install thrust needle roller bearing and planetary set 1 Turn planetary set right and left to match the gears of the rear sun gear and the gears of the planetary set 13 Install new inner and outer O rings 4 to BO brake piston and apply grease to them A Grease 99000 25030 Install brake piston to BO brake drum 14 Install BO brake piston amp drum assembly to transmission case in such way that the edge A comes at the position as shown in figure Make sure that the O rings are not twisted or caught 15 Place BO brake piston return spring subassembly 2 on pis ton Make sure that each spring fits the holes on the piston 16 Push down return spring subassembly and install snap ring 1 CAUTION Check that the opening of snap ring does not face the cored hole 5 of the transmission case 3 BO brake piston 7B 112 AUTOMATIC TRANSMISSION 4 A T A 17 Install BO brake discs plates and flange in following order 1 Plate 2 Disc 3 Plate 4 Disc 5 Flange NOTE The flat surface of BO flange must face to BO disc 18 Inspect BO brake piston stroke and clearance by blowing compressed air into hole shown
5. AUTOMATIC TRANSMISSION 4 A T 7B 77 Unit Remounting WARNING When moving transmission assembly with torque con verter equipped in it be sure to keep it horizontal Tilting it with its front facing down may allow converter to fall off Whereby an injury may result For remounting reverse dismounting procedure Use specified torque as given below and left Tightening torque N m kg m lb ft Exhaust pipe to manifold bolts 50 5 0 36 5 Muffler to exhaust pipe bolts 50 5 0 36 5 Universal joint flange bolts 50 5 0 36 5 and nuts Drive plate bolts 19 1 9 14 0 Engine to transmission bolts 80 8 0 58 0 and nuts Rear mounting bracket to 25 2 5 18 0 transmission bolt Rear mounting to bracket bolt 25 2 5 18 0 Frame to rear mounting bolts 25 2 5 18 0 Clamp wiring harness and hoses securely Refer to Selector Rod in this section for adjusting proce dure of selector rod Follow fluid level check procedure in Maintenance Service in this section for refilling automatic transmission fluid its level adjusting and fluid specification Connect battery and confirm that engine and transmission function acceptably When remounting drive plate use specified bolts Torque converter housing Transmission rear mounting Transmission rear mounting bracket To transmission HERR To frame Unit Disassembly
6. IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 19 Table D DTC is Not Output From Immobilizer Control Module For Vehicle Equipped with Air Bag System 1 To ECM 2 Immobilizer control module 3 To 9 pin in DLC Step Action Yes No 1 Check voltage between G38 4 terminal and Go to Step 2 BI B wire open body ground with ignition switch turned ON or short to See Fig 1 ground Is it10 14V 2 1 Disconnect coupler at immobilizer control Poor G38 4 or G38 1 connec B wire open module tion 2 Is there continuity between coupler terminal Poor 9 pin connection in DLC G38 1 and body ground See Fig 2 Serial data line Y B open or short to ground If connections and line are OK substitute a known good Immobi lizer Control Module and recheck See NOTE NOTE After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM and Transponder code and ECM Immobilizer Control Module code in Immobi lizer Control Module by performing procedure described in Procedure After Immobilizer control Mod ule Replacement in this section 8G 20 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED A Fig 1 for step 1 B Fig 2 for step 2 A 1 B 1 Immobilizer control module 2 Immobilizer control module coupler IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 21 DTC11 32 Transponder Code No
7. INSPECTION 1 Disconnect transmission range sensor coupler 2 2 Check that continuity exists at terminals shown below by moving selector lever sne BJ A H C E D G 1 F P O ol oto R O O N O CP are D OTO 2 OTE L O O 1 Transmission range sensor INSTALLATION 1 Using flat tip screwdriver turn transmission range sensor 2 to align match marks transmission range sensor N range 1 Turn shift control shaft to N range to have the auto matic transmission to N range AUTOMATIC TRANSMISSION 4 A T 7B 63 2 Install transmission range sensor 1 to transmission case and then lever to shift control shaft after setting them in N position as shown in figure Tighten bolts and nut to specifi PRT cl Co cation Be a LX 5 Tightening torque 2 Transmission range sensor bolt a 18 N m 1 8 kg m 13 0 Ib ft Shift control shaft nut b 13 N m 1 3 kg m 9 5 Ib ft 1 Shift control shaft lever 3 Shift selector lever to N position and connect selector rod to shift control shaft lever 4 Move selector lever in cabin to each range and check the continuity of each terminal of transmission range sensor referring to Transmission Range Sensor Inspection in this section
8. Make sure that the sealant covers completely the end of flange 9 30 BODY SERVICE a ae a 6 Ar SECT N N A DETAIL W RS Max 3 mm 0 12 in 5 8mm 0 20 0 31 in a ay 2 or Max 2mm 0 08 in SECT FF FF SECT GG GG gt a SECT M M VIEW Q a A Apply sealant to painted area 1 Back door outer panel 6 Rear floor panel B Smooth out sealant with a brush in one direction 2 Back door inner panel 7 Roof panel C Wipe off excess sealant after application 3 Side body outer panel D Make sure that the sealant covers completely the end of flange 4 Rear wheel housing outer panel E Do not sealant to this area 5 Rear quarter inner panel BODY SERVICE 9 31 2 BEES nn a SECT HH HH VIEW O A Apply sealant to painted area 1 Side body outer panel B Smooth out sealant with a brush in one direction 2 Fuel inlet box C Do not sealant to this area 9 32 BODY SERVICE UNDER COATING ANTI CORROSION COMPOUND APPLICATION AREA E 1 ELLE N SSeS a er A Min 25 mm 0 98 in 200 mm 7 87 in Min 50 mm 1 97 in Min 80 mm 3 15 in SECT B B 100 mm 3 94 in SECT C C i GK E Leo Se ER a 7 U A T
9. Transmission fluid temp sensor 7 BoltC Oil strainer assembly 8 Ground wire Bolt A 9 Oil strainer bolt Bolt B N OJA wo 39 Connect couplers of wire to solenoid to solenoid valves Solenoid Valve Color No 1 Natural No 2 Green No 3 Natural No 4 Black Lock up Black 2 1 Shift solenoid No 1 coupler 2 2 Shift solenoid No 2 coupler 2 3 Shift solenoid No 3 coupler 2 4 Shift solenoid No 4 coupler 2 5 Lock up solenoid coupler 40 Install O ring to oil strainer assembly 41 Install oil strainer assembly with ground wire for shift sole noid valve No 1 to the top of valve body assembly Connect transmission fluid temperature sensor coupler Fix transmission fluid temperature sensor and oil strainer assembly with bolts Tightening torque Oil strainer bolts b 8 N m 0 8 kg m 6 Ib ft 7B 118 AUTOMATIC TRANSMISSION 4 A T 42 Install magnet 1 in oil pan NOTE If metal particles are attached to the magnet clean them before installing 43 Install gasket 2 to transmission case and install oil pan 3 Tightening torque A T oil pan bolts a 7 5 N m 0 75 kg m 5 5 Ib ft 44 Install oil cooler pipe 1 with new gaskets 2 Tightening torque Oil cooler pipe union bolts a 36 N m 3 6 kg m 26 0 Ib ft Transmission hook bolt b 19 N m 1 9 kg m 13 5 Ib ft
10. Special tool A 09932 76010 Connector Test Adapter Kit This must be used whenever a diagnostic procedure requests checking or probing a terminal Using the appropriate adapter in the special tool will ensure that no damage to the terminal will occur from the multimeter probe such as spreading or bending BASE OF COLUMN PASSENGER INFLATOR AIR BAG SYSTEM 10B 7 The adapter 1 will also give an idea of whether contact tension is sufficient helping to find an open or intermittent open due to poor terminal contact An SDM short bar release tool 2 is included in the connector test adapter kit Inserting it into the SDM connector 3 will release the shorting bar Special tool B 09932 75010 Air Bag Driver Passenger Load Tool This tool is used only when called for in this section It is used as a diagnostic aid and safety device to prevent inadvertent air bag inflator module deployment The load tool has three connectors attached to its case which are electrically functional and serve as resistive load substitutions No more than two connectors are used at any time One of connectors STEERING WHEEL is used to substitute the load of the followings e Driver air bag inflator module when it is connected at the top of the column to the contact coil assembly e Passenger air bag inflator module when it is connected to the air bag harness connector for passenger air bag
11. 1 Upper anchor 3 Retractor assembly m Tightening torque 2 Lower anchor 4 Buckle INSPECTION BEFORE REMOVAL Seat belts and attaching parts can affect the vital components and systems of a vehicle Therefore they should be inspected carefully and replaced with genuine parts only Anchor Bolt Anchor bolts should be torqued to specification Belt Latch It should be secure when latched Warning System if equipped Check driver s seat belt strap switch for continuity by ohmmeter Seat belt strap switch specification Without inserted buckle tongue to buckle catch Terminal A and B Continuity With inserted buckle tongue to buckle catch Terminal A and B No continuity Q 1 Buckle tongue 2 Buckle catch 10 6 RESTRAINT SYSTEM REMOVAL Refer to the component figure to remove front seat belts INSPECTION Seat belts and attaching parts can affect the vital components and systems of a vehicle Therefore they should be inspected carefully and replaced with genuine parts only Seat Belt Its webbing or strap should be free from damage Retractor Assembly It should lock webbing when pulled quickly The front seat belt retractor assembly should pass the above inspection and should lock webbing even when tilted approx 15 toward the fore and aft or right and left directions INSTALLATION Install in reve
12. Step Action Yes No 1 Check DTC of Engine Diagnosis referring to Inspect and repair Go to Step 2 Section 6 referring to DTC Is any DTC detected flow table of Engine Diagno sis in Section 6 2 1 Turn ignition switch OFF and disconnect TCM Go to Step 3 B Or wire shorted to ground and ECM couplers 2 Measure resistance between terminal E21 18 of disconnected harness side TCM cou pler and body ground Is it infinity 3 1 Turn ignition switch OFF and connect TCM _ Substitute a Substitute a know good ECM couplers 2 Turn ignition switch ON and check voltage between terminal E21 18 and body ground Is it 0 V known good TCM and recheck and recheck 7B 50 AUTOMATIC TRANSMISSION 4 A T DTC P0702 P1702 DTC No 52 Transmission Control System Electrical or Inter nal Malfunction of TCM 1 E21 2 BAW E21 15 B 1 TCM 2 Ignition switch DTC DETECTING CONDITION e Relay output voltage is too high although TCM orders the relay to turn OFF or relay output voltage is too low although TCM orders the relay to turn on e Calculation of current data stored in TCM is not correct comparing with pre stored checking data in TCM Step Action Yes No 1 1 Turn ignition switch ON Replace TCM Could be a temporary 2 Erase all DTCs referring to DTC Clear malfunction of the TCM ance in this section 3 Turn igniti
13. 1 Remove window regulator handle 2 if equipped For its removal pull off snap by using a cloth 1 as shown in the figure 2 Remove inside handle bezel 3 Remove door inner garnish 4 Remove inside lock knob and door grip fitting screw BODY SERVICE 9 3 5 Remove door trim With inside handle bezel tilted as shown in figure turn door trim 90 counterclockwise to remove it And disconnect power window switch lead wire at coupler if equipped 6 Remove door sealing cover 1 2 Adhesive 7 Remove door mirror 8 Remove door outside weatherstrip 1 Lower window all the way down Then use a tape wrapped putty knife or screwdriver to pry off weatherstrip CAUTION Use a tape wrapped putty knife or screwdriver to pry off weatherstrip Use of an unwrapped tool will cause dam age to painting 2 Door panel 3 Door glass 9 Remove door sash 3 mounting bolts 2 10 Remove glass attaching screws 1 11 Take out door glass 4 9 4 BODY SERVICE INSTALLATION Reverse removal procedure to install door glass noting following points Es e Tighten glass attaching screws 1 to specified torque D o Tighten rear screw first then front screw ane Tightening torque FO S j Front door glass attaching screws fl a a a 6 N m 0 6 kg m 4 3 Ib ft the lt e When wi
14. TERMI STANDARD NAL CIRCUIT VOLTAGE CONDITION 2 IG power source 10 14V_ IG switch ON 3 Transmission fluid temperature sensor 0 2 0 4 V IG switch ON fluid temperature 80 C 176 F 4 Brake switch 10 14V_ IG switch ON brake pedal depressed 0 2V_ A C OFF 5 A C compressor 10 14V ACON 8 D range idle up signal 10 14V_ Select lever at P or N range 0 1V Select lever other than P and N range 14 Vehicle speed sensor 15 Ground 0 1V IG switch ON 16 Transmission fluid temperature sensor BKS IG switch ON ground S 0 1V_ IG switch ON O D off switch ON Ee 10 14V_ IG switch ON O D off switch OFF IG switch ON normal operating temperature of 18 Engine coolant temperature signal 10 14V engine fluid 20 A T failure serial data 0 1V IG switch ON 10 14V_ IG switch ON O D off switch OFF Eh EEN D 1V IG switch ON O D off switch ON 22 Lock up solenoid 0 1V IG switch ON select lever at P range 23 Shift solenoid D No 4 0 1V IG switch ON select lever at P range 0 1V_ IG switch ON select lever at P range EEN 10 14V_ IG switch ON select lever at L range 0 1V_ IG switch ON select lever at R range SES 10 14V_ IG switch ON select lever at P range 26 Shift solenoid A No 1 0 1V IG switch ON select lever at P range 1 Transmission range sensor 10 14V_ IG switch ON select lever at P range P range O0 1V IG s
15. INSTALLATION Reverse removal procedure to install door assembly noting follow ing points NOTE When replacing door coat replacement door inside 1 with wax for proper anticorrosion treatment Refer to Undercoating Anti Corrosion Compound a Application Area in this section e Tighten door hinge bolts to specified torque Tightening torque Front door hinge bolts a 27 N m 2 7 kg m 19 5 Ib ft 9 14 BODY SERVICE e Adjust door latch striker position by referring to Front Door Lock Assembly in this section so that door is positioned cor rectly e Adjust front door cushion 2 so that door 1 contacts body when closed as shown in the figure Front door cushion position a 7 mm 0 3 in e After installation open and close the door to check loose ness Replace door open stopper pin when there is loose ness e When weatherstrip is hardened water leak may develop In such case replace it with new one BODY SERVICE 9 15 Back Door Assembly 1 Back door panel assy 3 Back door hinge 5 Back door trim 2 Back door window glass 4 Back door balancer unit REMOVAL 1 Remove back door trim and door sealing cover refer to steps 1 to 3 of REMOVAL under Back Door Lock Assem bly in this section 2 Remove wire harness connector inside the back door 3 Remove back door balancer 1 first at its door sid
16. BEN N Re 7 d Wal aN EE 4 L N a L eA SSS ar J 1 BK A VIEW P A DETAIL X DETAIL V A Apply sealant to painted area B Wipe off excess sealant after application C Smooth out sealant with a brush in one direction 9 28 BODY SERVICE Max 2mm 0 08 in SECT CC CC SECT AA AA o KS S I o N S 2 5 8mm AA Dr st E SY VIEW D cc a 7 oi m i G 0 o p o si l VELL Es VIEW VIEW E O UI Ke 4 Dash panel 5 Cowl top panel 1 Hood outer panel 2 Hood inner panel 3 Hood hinge reinforcement A Apply sealant to painted area B Make sure that the sealant covers completely the end of flange C Smooth out sealant with a brush in one direction BODY SERVICE 9 29 Li CC VIEW F MA ANON AAA ee g d ee eee TL eS i i Max 2mm 0 08 in Max 5 8 mm 0 20 0 31 in DETAIL Z SECT EE EE Max 2 mm 0 08 in Max 0 5 mm 0 02 in Apply sealant to painted area 1 Front door outer panel Wipe off excess sealant after application 2 Front door inner panel Smooth out sealant with a brush in one direction 3 Door weatherstrip rail a
17. cccccesseecesseeeeenseeeeesseeeeeneees 7E 24 Unit Repair Overhaul cccccseseseereeeeees 7E 5 7E 2 FRONT DIFFERENTIAL General Description The front 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 sliding tooth meshing with high pressure between bevel pinion and gear it is mandatory to lubricate them by hypoid gear oil The hypoid gears have an advantage of preventing gear noise at the same time they require accurate adjust ment of tooth contract and backlash Companion flange 5 Differential pinion Differential carrier 6 Differential side gear Drive bevel gear hypoid gear Alo Nj gt 7 Differential case Drive bevel pinion hypoid gear FRONT DIFFERENTIAL 7E 3 Diagnosis Condition Possible Cause Correction Gear noise Deteriorated or water mixed lubricant Repair and replenish Inadequate or insufficient lubricant Repair and replenish Maladjusted backlash between bevel pinion and gear Adjust and prescribed Improper tooth contact in the mesh between bevel pinion and gear Adjust or replace Loose bevel gear securing bolts Replace or retighten Damaged sid
18. Check system referring to Turn Sig nal and Hazard Warning Lights Sys tem in this section No flashing HAZARD and or METER fuse s blown After checking short circuit replace fuse Turn signal hazard relay faulty Combination switch or hazard switch faulty Wiring or grounding faulty Check system referring to Turn Sig nal and Hazard Warning Lights Sys tem in this section Clearance Tail and License Plate Lights Condition Possible Cause Correction All lights do not light up Bulb s blown Check bulb TAIL fuse blown After checking short circuit replace fuse Wiring or grounding faulty Repair circuit Some lights do not light up Bulb s blown Check bulb Wiring or grounding faulty Repair circuit Back up Light Condition Possible Cause Correction Back up lights do not light up Bulb s blown Check bulb BACK fuse blown After checking short circuit replace fuse Back up light switch faulty Check switch Wiring or grounding faulty Repair circuit Back up lights stay on Back up light switch faulty Check or replace switch Wiring or grounding faulty Repair circuit Brake Lights BODY ELECTRICAL SYSTEM 8 5 Condition Possible Cause Correction Brake lights do not light up Bulb s blown C
19. DESCRIPTION When the ignition switch is ON Immobilizer Control Module requests ECM and ECM requests Immobilizer Con trol Module to transmit ECM Immobilizer Control Module code If ECM Immobilizer Control Module code is not transmitted from ECM or Immobilizer Control Module Immobilizer Control Module sets DTC23 and ECM sets DTC83 INSPECTION Step Action Yes No 1 Check voltage between Immobilizer Con trol Module coupler terminal shown below and body ground with ignition switch turned ON See Fig 1 e Terminal for vehicle without air bag system G38 7 e Terminal for vehicle with air bag sys tem G38 2 Is it 4 5V Go to Step 2 Y B wire short 1 Disconnect ECM coupler with ignition switch turned OFF 2 Is there continuity between Immobi lizer Control Module coupler terminal shown below and serial data link ter minal E18 12 of ECM coupler For positions of Data link connector termi nal of ECM coupler refer to System and Location in this section e Terminal for vehicle without air bag system G38 7 e Terminal for vehicle with air bag sys tem G38 2 lt Vehicle without air bag system gt Poor G38 7 terminal connection or poor data link connector terminal con nection ECM lt Vehicle with air bag system gt Poor G38 2 terminal connection or poor data link connector terminal con nection ECM If connections are OK substitute a
20. WARNING e Do not place deployed air bag inflator module and activated seat belt pretensioner near any flammable objects e Do not apply water oil etc to deployed air bag infla tor module and activated seat belt pretensioner e Wait for about 30 minutes before touching any metal surface of air bag inflater module or seat belt preten sioner module Disregarding these precautions may cause fire or personal injury Failure to follow procedures may result in fire or personal injury 13 Separate two banana plugs 1 on deployment harness 14 Connect deployment harness to 12 volts vehicle battery 2 This will immediately deploy or activate air bag inflator module or seat belt pretensioner 15 Disconnect deployment harness from 12 volts vehicle bat tery 2 and short two deployment harness leads together by fully seating one banana plug into the other 10B 68 AIR BAG SYSTEM 16 After confirming that air bag inflator module deployed and or seat belt pretensioner activated proceed to Step 7 through Step 21 In the unlikely event that air bag inflator module did not deploy or seat belt pretensioner did not acti vate proceed to Step 22 through Step 25 17 Put on pair of shop gloves to protect your hands from possi ble irritation and heat when handling deployed air bag infla tor module or activated seat belt pretensioner 18 Disconnect adapter cable special tool from air
21. When overhauling 3 7 liters 7 82 6 51 US Imp pt 1 Dipstick 4 LOW HOT mark 2 Exhaust manifold cover 5 FULL COLD line 3 FULL HOT mark 6 LOW COLD line Oil cooler hoses The rubber hoses for the oil cooler should be checked at specified interval When replacing them be sure to note the following e Replace clamps at the same time e Insert hose as far as its limit mark e Clamp clamps securely 1 Oil cooler hose 2 Radiator AUTOMATIC TRANSMISSION 4 A T 7B 61 Selector Lever 3 1 Selector lever assembly 4 Illumination lamp assembly 2 Selector lever knob assembly 5 Selector lever guide 3 Screw 6 Shift lock solenoid if equipped INSPECTION Check selector lever for smooth and clear cut movement and position indicator for correct indication For operation of selector lever refer to the figure A Shift the selector lever with its button pushed in B Shift the selector lever without pushing its button 7B 62 AUTOMATIC TRANSMISSION 4 A T Transmission Range Sensor Shift Switch REMOVAL 1 Block wheels and turn selector lever to N range 2 Disconnect transmission range sensor coupler and remove selector rod from shift control shaft lever 3 Remove shift control shaft lever and then transmission range sensor CAUTION Do not overhaul transmission range sensor
22. ccceccccsseeeeeeeeeeeees 7B 58 7B 2 AUTOMATIC TRANSMISSION 4 A T Fluid level check 7B 58 Transmission Control Module TCM 7B 71 Elo change cissiictcececetieserettcrdecescantaae 7B 59 Learning Control Memory Initialization 7B 72 Oil Cooler NOSES eeceeeeeeeeeeeeeteeeeeeees 7B 60 Interlock Cable if equipped 1eeessnnn 7B 72 Selector L VEl cccccceccssseeeeeeeeeueeeeeeseeeeeees 7B 61 Unit Repair Overhbaul ENEE 7B 75 Transmission Range Sensor Unit Dismounting cccccceecseeecseteeeees 7B 76 Shift Switch EE ER 7B 62 Unit Remounting Let eeben Nt det CL et 7B 77 Selector R d dees deed SN 7B 64 Unit Disassembly EE ee 7B 77 Output Shaft Speed Gensor 7B 65 Disassembly of Subassembhy 7B 86 Input Shaft Speed Gemeen 7B 66 Cito ee eee ne ee nee 7B 86 Vehicle Speed Sensor iecere 7B 67 Front clutch C1 clutch SCENE A 7B 89 Throttle Position Gensor 7B 67 Rear clutch C2 clutch csccssseeseeseeeeeees 7B 94 Engine Coolant Temperature ECT Planetary SOU iat ee rt ee 7B 99 Sensor ee 7B 67 Valve body re ik aah E ee aN ae 7B 101 O D Off Switch Sie nin nan ee grier ieis 7B 68 Output shaft assembly adarme h AA a 7B 107 Shift Solenoid Valves and Transmission Unit Assembly ceeeeeeeeeeeteeeeeeeeeteeees 7B 108 Fluid Temperature Sensor n os 7B 68 Tightening Torque Specification 7B 120 Shift solenoid valves and lock up solenoid VAIVE ooceccccccccccccccec
23. 1 can be identified easily as it is covered with a yellow protection tube and it has yellow connectors Be very careful when handling it e When an open in air bag wire harness 1 damaged wire harness connector or terminal is found replace wire har ness connectors and terminals as an assembly e When installing it be careful so that the air bag wire harness 1 is not caught or does not interfere with other parts e Make sure all air bag system grounding point 2 is clean and ground is securely fastened for optimum metal to metal con tact Poor grounding can cause intermittent problems that are difficult to diagnose AIR BAG SYSTEM 10B 55 Repairs and Inspections Required after an Accident CAUTION es All air bag system components including the electrical harness component mounting points must be inspected after an accident If any components are damaged or bent they must be replaced even if air bag system activation did not occur e Never use air bag system parts from another vehicle es Do not attempt to service the parts below Service of these parts is by replacement only Driver Passenger air bag inflator module Driver Passenger seat belt pretensioner Contact coil and combination switch assembly Air bag wire harness in instrument panel harness floor harness and pretensioner harness e Proper operation of the air bag system requires that any repairs to the vehicle structure return it to its original prod
24. 11 and E22 5 of disconnected harness side coupler Is it about 0 Q 3 Measure resistance between terminal E22 5 Go to Step 4 Br wire shorted to of disconnected harness side coupler and body ground ground See figure Is it infinity 7B 46 AUTOMATIC TRANSMISSION 4 A T A Fig for Step 3 Step Action Yes No 4 1 Turn ignition switch OFF and connect ECM Intermittent trouble or Dr wire is shorted to couplers faulty ECM or TCM power circuit or faulty 2 Turn ignition switch ON and measure volt Check for intermittent ECM age between terminal E22 5 of discon referring to Intermittent If Dr wire is OK substi nected harness side TCM coupler and body and Poor Connection in tute a known good ECM ground Section OA and recheck Is it10 14 V If no trouble found substi tute a known good ECM or TCM and recheck A AUTOMATIC TRANSMISSION 4 A T 7B 47 DTC P0710 DTC No 36 38 Transmission Fluid Temperature Sensor Circuit Kaz 3 E21 3 BI E21 16 B BI E21 15 B 1 Transmission fluid temperature sensor 3 TCM 2 Coupler 4 Terminal arrangement of TCM coupler viewed from harness side DTC DETECTING CONDITION e Transmission fluid temperature signal input voltage is too low e Transmission fluid temperature signal input voltage does
25. Is it the original one Go to Step 2 Replace ignition key with original one and follow Diagnostic Flow Table again 1 Disconnect coil antenna coupler 1 with ignition switch turned OFF 2 Is there continuity between coil antenna coupler terminals A and B See Fig 2 Go to Step 3 Coil antenna open Measure resistance between terminals of coil antenna coupler 1 and body ground See Fig 3 Is it infinity Q Go to Step 4 Coil antenna shorted to ground IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 23 Step Action Yes No 4 1 With coil antenna coupler discon nected disconnect Immobilizer Con trol Module coupler 2 Measure resistance between coil antenna terminals of Immobilizer Control Module coupler 1 See Fig 4 Is it oe infinity Q Go to Step 5 P B wire shorted to Gr R wire 5 Measure resistance between terminal G38 4 of Immobilizer Control Module coupler 1 and body ground See Fig 5 Is it infinity Q Go to Step 6 P B wire shorted to ground 6 Measure resistance between terminal G38 3 of Immobilizer Control Module coupler 1 and body ground See Fig 6 Is it infinity Q Go to Step 7 Gr R wire shorted to ground 7 1 Connect coil antenna coupler 2 Is there continuity between Immobi lizer Control Module coupler 1 termi nals G38 4 and G38 3 See Fig 7
26. O D off switch OFF 7B 10 AUTOMATIC TRANSMISSION 4 A T Fail safe function 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 sensor solenoid or its circuit Area Detecting condition Fail safe function Input Turbine speed sensor cir cuit DTC P0715 Input shaft speed sensor signal voltage is too high or too low Output shaft speed sensor circuit DTC P0720 Output shaft speed sensor signal voltage is too high or too low When vehicle running and in shift change by automatic elec tronic control gear is fixed to gear which is going to be selected and lock up function is turned OFF When vehicle running and in no shift change gear is fixed to gear right before the trouble occurred and lock up function is turned OFF When vehicle is at stop after or during detecting trouble or in shift change by manual operation while running gear is fixed as the followings and lock up function is turned OFF P range P R range R N range gt N D range gt 3rd 2 range 2nd L range 1st Shift solenoid DTC P0753 DTC P0758 DTC P0763 DTC P0768 TCC circuit DTC P0743 e Solenoid output voltage is too high although TCM orders solenoid to turn off e Solenoid output volt
27. Oil cooler pipe bracket bolt 6 N m 0 6 kg m 4 5 Ib ft 45 Install A T fluid filler tube 4 and level gauge 3 Union bolt 46 Apply grease to thrust bearing 1 and install it to transmis sion case 47 Install output shaft assembly 2 to transmission case 48 Install extension case 1 Tightening torque Extension case bolt a 17 N m 1 7 kg m 12 5 Ib ft NOTE Use new bolts AUTOMATIC TRANSMISSION 4 A T 7B 119 49 Install output shaft speed sensor 1 and input shaft speed sensor 2 Apply grease to O ring of each sensor Tightening torque Output shaft speed sensor and input shaft speed sensor bolt a 8 N m 0 8 kg m 6 0 Ib ft 50 Install transmission range sensor 3 Install it temporarily so that the adjustment can be done after installing A T assembly back to the vehicle Tightening torque Transmission range sensor bolt b 18 N m 1 8 kg m 13 0 Ib ft 51 Install torque converter 1 to input shaft e Install torque converter using care not to damage oil seal of oil pump e After installing torque converter check that distance e is within specification Torque converter installing position Distance e More than 20 0 mm 0 787 in e Check torque converter for smooth rotation e Apply grease around cup at the center of torque converter Grease 99000 25010 CAUTION e Before installing converter make sure that its pump hub p
28. TO R CL A LH steering vehicle shown REMOVAL AND INSTALLATION Refer to Combination Switch Contact Coil and Combination Switch Assembly in Section 3C for details Hazard switch INSPECTION Check continuity between terminals at each switch position shown below Terminal Hazard SW B TR IG TRS TLL TLR IL ILE OFF OO O70 ON O O O O Stop Brake Lamp Stop brake lamp switch INSPECTION Check stop lamp brake switch for continuity as shown below If check result is not as specified replace switch Type 1 Connector color black Terminal Shaft 1 a b c d tt FREE O O PUSH es Terminal e b c d FREE Se OT PUSH BODY ELECTRICAL SYSTEM 8 17 Rear Fog Light If Equipped Rear fog light switch INSPECTION Use a circuit tester to check switch for continuity between termi nals shown below TERMINAL RR A B C D E F FOG SW QO Ge O FREE Peta FREE Z O PUSH O e O O FO Ca O FREE e O PUSH O O O PUSH O O FREE O pHo O O7 O RETURN O O O O PUSH O Ignition Switch INSPECTION 1 Disconnect negative cable at battery 2 Disconnect ignition switch lead wire coupler 3 Use a circuit tester to check the continuity at each switch position If any continu
29. nal E22 7 or E22 15 of 2 Measure resistance between terminal E22 7 of dis wire and ground TCM connected harness side coupler and body ground or Lg B wire If all the above are in then terminal E22 15 of disconnected harness side and ground good condition substitute coupler and body ground a known good TCM and Are they about 0 Q recheck See figure 7B 32 AUTOMATIC TRANSMISSION 4 A T A A Fig for Step 2 B Fig for Step 4 1 Input shaft speed sensor coupler 2 Input shaft speed sensor terminal AUTOMATIC TRANSMISSION 4 A T 7B 33 DTC P0730 DTC No 18 Incorrect Gear Ratio S EE E SC E226 3 3 2 REEE i BI E22 14 i ao E22 13 Lon E22 7 E xX Lg B E22 15 B E21 15 1 Input shaft speed sensor 4 Shield wire 2 Output shaft speed sensor 5 Terminal arrangement of TCM coupler viewed from harness side 3 TCM DTC DETECTING CONDITION Difference in detected revolution between input shaft soeed sensor and output shaft speed sensor is too wide Step Action Yes No 1 Check if DTC P0730 DTC No 18 dis Inspect according to DTC Go to Step 2 played with DTC P0715 DTC No 14 or P0715 DTC No 14 or DTC DTC P0720 DTC No 31 P0720 DTC No 31 flow table Is DTC P0730 DTC No 18 displayed with first DTC P0715 DTC No 14 or DTC P0720 DTC No 3
30. 1 Compress piston return springs and remove shaft snap ring Place special tool clutch spring compressor on spring seat and compress spring with a press 2 and then remove shaft snap ring using a screwdriver 3 CAUTION Do not push down return spring more than necessary Special tool A 09926 96020 4 Remove rear clutch balancer 1 and rear clutch return spring seat 2 5 Remove rear clutch piston 3 If piston does not pop out blow compressed air through input shaft oil hole to remove piston 6 Remove D ring and oil seals from input shaft subassembly 4 INSPECTION Clutch Discs Plates and Flange Check that sliding surfaces of discs plates and flanges are not worn or burnt If necessary replace NOTE e If disc lining is exfoliated or discolored replace all discs e Before assembling new discs soak them in A T fluid for at least two hours 7B 96 AUTOMATIC TRANSMISSION 4 A T Rear Clutch Return Spring Seat Measure height of overdrive clutch return spring Height of overdrive clutch return spring 28 14 mm 1 108 in NOTE e Do not apply excessive force when measuring spring height e Perform measurement at several points ASSEMBLY 1 Install new D ring 7 and oil seals 2 to input shaft subas sembly Apply grease to D ring and fit it to input shaft subassembly 1 A Grease 99000 25030 2
31. 12 N m 1 2 kg m D I 10 N m 1 0 kg m 1 Oil seal 7 Clutch drum thrust washer CH Apply grease 99000 25030 to oil seal lip SC 2 D ring SC 8 Clutch drum oil seal ring Apply grease 99000 25030 to all over surface Apply grease 99000 25030 to all over surface 3 Oil pump body an Apply automatic transmission fluid FLD 4 Oil pump drive gear m Tightening torque 5 Oil pump driven gear x lt Do not reuse 6 Stator shaft assembly AUTOMATIC TRANSMISSION 4 A T 7B 87 DISASSEMBLY 1 Remove D ring from pump body 2 Remove 2 oil seal rings and clutch drum thrust washer 3 Remove 11 bolts 4 Separate pump body from stator shaft assembly 5 Remove oil seal from pump body INSPECTION 1 Inspect pump body oil seal Check for wear damage or cracks Replace oil seal if necessary and apply grease to its lip por tion slightly when it is installed N Check body clearance of driven gear Push driven gear 2 to one side of body 3 Using a feeler gauge measure clearance between driven gear and body If clearance exceeds its standard value replace oil pump assembly Clearance between drive gear and body Standard 0 08 0 15 mm 0 0027 0 0059 in Limit 0 30 mm 0 018 in 1 Oil pump drive gear 3 Check tip clearance of both drive and driven gears Measure radial clearance between gear tooth and crescent If clearance exceeds its standard
32. 24 Tighten 11 case bolts Tightening torque Transfer case bolt a 18 N m 1 8 kg m 13 0 Ib ft 25 Install speed sensor 1 Tightening torque Speed sensor bolt a 10 N m 1 0 kg m 7 5 Ib ft 26 Install input flange tighten flange nut 1 and calk it Special tool A 09930 40113 Tightening torque Flange nut a 130 N m 13 0 kg m 94 0 Ib ft 27 Install steel ball and 4WD switch 1 Tightening torque AWD switch a 19 N m 1 9 kg m 14 0 lb ft 28 Install steel ball 3 locating spring 2 and locating spring bolt 1 Tightening torque Locating spring bolt a 25 N m 2 5 kg m 18 0 Ib ft 29 Install shift and select arm and fix it spring pin TRANSFER 7D 23 1 30 Set shift shaft 2 2 4 shift fork and Hi Lo shift fork 3 posi tion as shown in figure 2H shift position 31 Install transfer shift control lever through spring and cover and fit boot to front case after tightening bolts Tightening torque VIEWA Shift control lever bolts a 18 N m 1 8 kg m 13 0 Ib ft 1 Interlock block 7D 24 TRANSFER Tightening Torque Specification Tightening torque Fastening part Nem kom b fit Oil filler level and drain plug 23 2 3 17 0 Transfer mounting nut 30 3 0 22 0 Transfer mounting bracket bolt 23 2 3 17 0 Propeller shaft bolt 50 5 0 36 5 Flange nut 130 13 0 94 0 Lock up plate bolt 28 2 8 20 5 Interl
33. AEN EN 8G 21 DTC12 Fault in Immobilizer Control Module 8G 21 DTC13 No Transponder Code Transmitted or Coil Antenna Opened Shorted 8G 22 DTC21 ECM Immobilizer Control Module Code Not Matched Immobilizer Control Module Side cccceeeeeeeseceeeeeeeeeneeeees 8G 25 DTC81 ECM Immobilizer Control Module Code Not Matched P1623 ECM Side 8G 25 DTC84 ECM Immobilizer Control Module Code Not Registered P1620 000 8G 25 DTC82 P1622 Fault in ECH 8G 25 DTC22 Ignition Switch Circuit Open MOM fo state gege sgebbe e dee 8G 26 DTC23 No ECM Immobilizer Control Module Code Transmitted From ECM or DLC Circuit Opened Shorted 8G 28 DTC83 P1621 No ECM Immobilizer Control Module Code Transmitted From Immobilizer Control Module or DLC Circuit Opened Shorted sssnneeeeeeereeeeerer ereen 8G 28 Inspection of ECM Immobilizer Control Module and Its Circuit ceeeeeeeeees 8G 30 On Vehicle Service ecccceeeeeeeeneeeeees 8G 33 Precautions in Handling Immobilizer Control System eeceeeeeeeeeeeeeeteeeeeeeeeeees 8G 33 Immobilizer Control Module 8G 34 Coil Antenna Vehicle not equipped with air bag system eceeeeeceeeeeeeeteeeeeeeeneees 8G 34 How to Register Ignition Key 8G 36 Procedure After Immobilizer Control Module Replacementt cccccccsseeesseeseeeeees 8G 37 Procedure After ECM Rep
34. Buckle INSPECTION BEFORE REMOVAL Check the rear seat belt in the same way as when inspecting front seat belt without pretensioner referring to Inspection before Removal under Front Seat Belt without Pretensioner in this section REMOVAL Refer to the component figure to remove rear seat belts INSPECTION Check the rear seat belt in the same way as when inspecting front seat belt without pretensioner referring to Inspection under Front Seat Belt without Pretensioner in this secton INSTALLATION Install the rear seat belt observing the same precautions as when installing front seat belt without pretensioner referring to Front Seat Belt without Pretensioner in this section e Be sure to tighten seat belt anchor bolts to specified torque as shown in the figure Tightening Torque Specifications Tightening torque Fastening part Nem kam bt Upper and lower anchor bolt 35 3 5 25 5 Retractor assembly bolt 35 3 5 25 5 Buckle bolt 35 3 5 25 5 AIR BAG SYSTEM 10B 1 SECTION 10B AIR BAG SYSTEM WARNING e Service on or around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Please observe all WARNINGS and Service Precautions under On Vehicle Service in this section before performing service on or around the air bag system compo nents or wiring Failure to follow WARNINGS could result in unintended acti
35. CAUTION e Thoroughly clean transmission exterior before over hauling it e Keep working table tools and hands clean while over hauling e Use special care to handle aluminum parts so as not to damage them e Do not expose removed parts to dust Keep them always clean 7B 78 AUTOMATIC TRANSMISSION 4 A T 1 Remove torque converter 1 2 Remove following parts e Battery ground cable if still attached e Output shaft speed sensor 1 and input shaft speed sensor 2 e Shift control shaft lever 3 and transmission range sensor 4 e A T fluid level gauge 6 and filler tube 5 e Oil cooler pipes 7 3 Remove oil pan and oil pan gasket NOTE For removal of oil pan do not turn transmission over as this will contaminate valve body with foreign matters in the bottom of oil pan When removing oil pan tap around it lightly with a plastic hammer Do not force it off by using a screwdriver or the like ee O NN mO O NEA et NG N AUTOMATIC TRANSMISSION 4 A T 7B 79 4 Remove one of oil strainer bolts 9 and ground wire 8 of shift solenoid valve No 1 Disconnect couplers 2 from solenoid valves and transmis sion fluid temperature sensor Remove transmission fluid temperature sensor 3 and oil strainer assembly 4 5 Remove valve body assembly 1 CAUTION Be careful not to let manual valve fall off when removing valv
36. Connect voltmeter positive lead to terminal 1 and negative lead to terminal HE Push washer switch check that voltage changes as shown in the table 1 Combination switch lead wire coupler terminal viewed from terminal side Washer switch ON Sek Voltmeter 8 28 BODY ELECTRICAL SYSTEM Wiper motor INSPECTION Motor operation low speed 1 Connect battery 1 positive terminal to terminal A and its negative terminal to bracket 2 Check wiper motor rotates at specified speed below If check result is out of specification replace Specification 44 52 r min rpm Motor operation high speed 1 Connect battery positive terminal to terminal B and its negative terminal to bracket 2 Check wiper motor rotates at specified speed below If check result is out of specification replace Specification 64 78 r min rpm 2 Wiper motor 3 Red lead 4 Black lead Automatic stop operation 1 Connect battery 1 positive terminal to terminal A and its negative terminal to bracket and let the motor turn 2 Disconnect terminal A from battery positive terminal and let the motor stop 3 Connect terminal A and D with a jumper wire 5 and connect terminal C to battery positive terminal Observe the motor turns once again then stops at a original st
37. D 09932 78340 NOTE Upon completion of inspection and repair work perform the following items es Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected 10B 46 AIR BAG SYSTEM DTC B1051 Frontal Crash Detected System Activation Command Output ted CAUTION Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to flow table DTC WILL SET WHEN The SDM detects a frontal crash of sufficient force to warrant activation of the air bag system SDM outputs a deployment command TABLE TEST DESCRIPTION STEP 1 Check that DTC B1051 has been set although air bag has not been deployed STEP 2 Check that DTC has been set due to failure of SDM Step Action Yes No 1 1 Ignition switch OFF Replace components and Go to step 2 Has air bag inflator module deployed perform inspections as directed in Repairs and Inspections Required after an Accident in this section 2 1 Inspect front of vehicle and undercarriage Replace components and Substitute a known good for signs of impact perform inspections as SDM and recheck Are there signs of impact directed in Repairs and Inspections Required
38. LOCK position and remove key 3 Remove AIR BAG fuse 2 from fuse box 1 4 Disconnect Yellow connector 3 of contact coil and combi aN nation switch assembly a Release locking of lock slider b After unlocked disconnect connector 5 Pull out glove box while pushing its stopper from both right and left sides and disconnect Yellow connector 4 of pas senger air bag inflator module a Release locking of lock slider b After unlocked disconnect connector NOTE With AIR BAG fuse removed and ignition switch ON AIR BAG warning lamp will be ON This is normal operation and does not indicate a air bag system malfunction Enabling air bag system 1 Turn ignition switch to LOCK position and remove key 2 Connect Yellow connector 1 of contact coil and combina tion switch assembly by pushing connector till click is heard from it 10B 50 AIR BAG SYSTEM 3 Connect Yellow connector 1 of passenger air bag inflator module by pushing connector till click is heard from it 4 Install glove box 5 Install AIR BAG fuse to fuse box 6 Turn ignition switch to ON position and verify that AIR BAG warning lamp flashes 6 times and then turns OFF If it does not operate as described perform Air Bag Diag nostic System Check in this section Handling and storage SDM WARNING Never power up air bag system when SD
39. TCM and recheck 2 Turn ignition switch ON and check voltage between terminal E18 21 of disconnected harness side ECM coupler and body ground Is it 10 14 V 6 1 Check for proper connection of terminal Go to Step 7 B R wire open or poor E18 21 of ECM coupler connection of terminal 2 If OK turn ignition switch OFF and discon E22 8 of TCM coupler nect ECM couplers If wire and connection are 3 Turn ignition switch ON and check voltage OK substitute a known between terminal E18 21 of disconnected good TCM and recheck harness side ECM coupler and body ground Is it 10 14 V 7 1 Turn ignition switch OFF and disconnect Intermittent trouble or B R wire shorted to TCM couplers faulty ECM ground 2 Check resistance between terminal E22 8 Check for intermittent of disconnected harness side TCM coupler referring to Intermittent and body ground and Poor Connection in Is it infinity Section OA If no trouble found substi tute a known good ECM and recheck AUTOMATIC TRANSMISSION 4 A T 7B 43 DTC P0705 DTC No 34 Transmission Range Sensor Switch Circuit Malfunc tion 2 L E22 1 E22 2 E22 3 E22 9 E21 15 E22 10 E22 11 1 Transmission range sensor switch 3 Terminal arrangement of TCM coupler viewed from harness side 2 TCM DTC DETECTING CONDITION No transmission range sensor sig
40. amp B2 return spring assembly more than necessary or it may get damaged Special tool A 09926 96010 AUTOMATIC TRANSMISSION 4 A T 7B 109 5 Install B1 brake discs plates and flange to B2 brake piston 2 in following order 1 Plate 2 Disc gt 3 Plate 4 Disc gt 5 Plate gt 6 Disc gt 7 Plate 8 Disc gt 9 Plate 10 Disc gt 11 Flange 6 Install snap ring 1 to B2 brake piston 2 with antirotation protrusion 3 aligned with gap between two fingers having mounded part 7 Measure B1 brake stroke and clearance in following manner B1 Brake Stroke Set the dial gauge 1 to 1st amp 2nd brake B1 brake piston through B1 brake spring seat 2 hole as shown Blow com pressed air into hole shown in figure Then measure the differ ence as the compressed air is blown in B1 brake piston stroke Standard 1 75 2 00 mm 0 0689 0 0787 in B1 Brake Clearance Blow compressed air into the hole shown in figure Measure the difference B1 brake disc clearance Standard 1 30 2 00 mm 0 0512 0 0787 in If the measured value s is are out of specification select the flange from table below and repeat this step until the measured values are within specification Available flange thickness 2 875 mm 0 113 in 3 050 mm 0 120 in 3 225 mm 0 127 in 3 400 mm 0 134 in 3 575 mm 0 141 in Tip of dial gauge B1 brake piston
41. inflator module e Each of driver and passenger seat belt pretensioners when it is connected to air bag harness connector for driver and pas senger seat belt pretensioners Another connector BASE OF COLUMN is used to substitute the load of the driver air bag inflator module and the contact coil assembly when it is connected at the base of the column to the air bag wire harness The third connector PASSENGER INFLATOR is not used By substituting the resistance of the load tool when called for a determination can be made as to whether an inflator circuit com ponent is causing system malfunction and which component is causing the malfunction The load tool should be used only when specifically called for in the diagnostic procedures 1 Connector for contact coil and driver air bag inflator module Located near the base of the steering column 2 Connector for driver passenger air bag inflator module and driver and passenger seat belt pretensioners 3 Not used 10B 8 AIR BAG SYSTEM Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring When a check for proper connection is requested in a diagnostic flow table perform careful check of suspect circuits for Poor mating of connector halves or terminals not fully seated in the connector body backed out Dirt or corrosion on the terminals The terminals must
42. is displayed If not repeat step 1 and 2 and check again 7B 28 AUTOMATIC TRANSMISSION 4 A T Diagnostic Trouble Code DTC Table CODE No 21 CODE No 21 CODE No 21 O D OFF lamp _ ee turn ON gt 2 1 2 1 2 i OFF gt WV eT EE o SS Sg e os os 10 03 3 0 3 0 Time sec DTC NO MIL Vehicle Vehicle Not O D OFF Light equipped equipped Using using Flashing Pattern of DTC DETECTING ITEMS SCH Wien scan tool scan Not using scan tool S Se Leg S tool lizer indi lizer indi cator cator lamp lamp 12 iil Normal f driving Not P0715 14 II Input Turbine speed sensor circuit cycle applicable P0730 18 II III Incorrect gear ratio SN f cycles applicable P0753 Shift solenoid A electrical Ee Sege P0758 Shift solenoid B electrical EE cycle applicable 24 TUUL 43 UUL E i P0763 Shift solenoid C electrical TIN RoE cycle applicable a5 UUL S P0768 Shift solenoid D electrical GE cycle applicable ae UUU AUTOMATIC TRANSMISSION 4 A T 7B 29 DTC NO MIL Vehicle Vehicle Not O D OFF Light gue ETE Using using Flashing Pattern of DTC DETECTING ITEMS P immobi immobi scan tool scan Not using scan tool SERA d SN lizer indi lizer indi tool cator cator lamp lamp Torque converter clutch lock up 1 driving Not P0743 cane clutch circ
43. l 1 LT GRN LT GRN yyy YEL RED Noa Loto L30 A Shorting bar 7 Connection detection pin 14 Ground for air bag system 1 To main fuse box 8 Data link connector DLC 15 SDM 2 Ignition switch 9 To circuit fuse box 16 Contact coil assembly 3 Circuit fuse box 10 Ground on body 17 Driver air bag inflator module 4 METER fuse 11 Ground on engine block 18 Passenger air bag inflator module 5 AIR BAG fuse 12 To ECM TCM and ABS control module if equipped 19 Driver seat belt pretensioner 6 AIR BAG warning lamp in combination meter 13 AIR BAG monitor coupler 20 Passenger seat belt pretensioner TERMINAL ARRANGEMENT OF SDM CONNECTOR Q60 VIEWED FROM HARNESS SIDE 4 3 L1 12 11 10 9 8 1 SDM connector Q60 10B 6 AIR BAG SYSTEM SDM connector Q60 terminal description To avoid deployment when troubleshooting the air bag system do not use electrical test equipment such as a battery powered or AC powered voltmeter ohmmeter etc or any type of electrical equip ment other than that specified in this manual Do not use a non powered probe type tester Instructions in this manual must be followed carefully otherwise personal injury may result TERMINAL CIRCUIT TERMINAL CIRCUIT Q60 1 7 Q60 11 Driver pretensioner Low Q60 2 AIR BA
44. terminal side 8 26 BODY ELECTRICAL SYSTEM Intermittent Wiper Relay Circuit 1 Disconnect negative cable at battery 2 Disconnect combination switch lead wire coupler 3 Turn the front wiper switch to INT position 4 Connect battery positive terminal to terminal B3 and bat tery negative terminal to terminal HE 5 Connect voltmeter positive lead to terminal 1 and negative lead to terminal HE Check that the voltmeter indicates the battery voltage 10 14 V 1 Combination switch lead wire coupler termi nal viewed from terminal side 6 Connect terminal As and terminal B3 by a jumper wire Then connect terminal B3 end to terminal HE Observe the voltmeter voltage drops to 0 V right after con necting the jumper wire from terminal B3 to HE Then the voltage rises to battery voltage 10 14 V within the time shown below 1 Combination switch lead wire coupler termi nal viewed from terminal side Voltage between B3 and HE 3 81 sec BODY ELECTRICAL SYSTEM 8 27 Washer Linked Operation Disconnect negative cable at battery Disconnect combination switch lead wire coupler Make sure that front wiper switch is at OFF position Connect battery positive terminal to terminal B3 and bat tery negative terminal to terminal HE
45. two times c Insert ignition key to ignition switch and then push LOCK button on transmitter more than five times 3 Confirm that hazard warning light or interior light flash once With this change of signal mode is completed Keyless entry system operation inspection NOTE If keyless entry system is in interior light signal mode change to hazard warning light signal mode referring to Change of Signal Mode in this section 1 Confirm that power door lock system is good condition refer ring to Power Door Lock System Operation Inspection in this section 2 Confirm that turn signal and hazard warning light system is good condition referring to Turn Signal and Hazard Warning Light System in this section 3 Check transmitter battery for dead If battery is dead replace battery referring to Replacement of Transmitter Battery under Transmitter in this section 4 Confirm that all doors are closed and unlocked 5 Check the following operation a When pushing LOCK button 1 on transmitter 2 check all doors lock and hazard warning lights flash once b When pushing UNLOCK button 3 on transmitter 2 check all doors unlock and hazard warning lights flash twice and interior light turn on about 15 seconds with the interior light switch in the middle position If check result is not satisfied go to Keyless Entry System Circuit Inspection in this section 8 40 BODY ELEC
46. 1 2 mm 0 039 0 079 in press fit drive bevel pinion 1 to companion flange 5 by using special tools and hydraulic press O NOTE Bearing axial clearance can be confirmed by shaking dif ferential carrier 4 in the direction shown in figure Special tool A 09925 58210 B 09951 46010 7F 20 REAR DIFFERENTIAL NOTE e Before taking measurement check for smooth rotation by hand Preload of drive bevel pinion bearings is adjusted by tightening flange nut to deform drive bevel pinion spacer Therefore be sure to use a new spacer for adjustment and tighten flange nut step by step and check for pre load by measuring starting torque as often as tighten ing to prevent over crushing of spacer If preload exceeds specification given below during adjustment replace spacer and repeat preload adjust ment procedure Attempt to decrease preload by loos ening flange nut will not do e For measuring preload of drive bevel pinion bearings turn drive bevel pinion at about 50 rpm is required e Make a record preload of drive bevel pinion bearings because the preload is used for checking composite preload of drive bevel pinion bearings and differential side bearings 19 Tighten flange nut gradually with special tools so that pre load of drive bevel pinion is in specification Tightening torque Flange nut 100 400 N m 10 40 kom 72 289 Ib ft Preload of drive beve
47. 1 An improper connection to the data link connector DLC will prevent communications from being established STEP 2 This test checks whether it is possible to communicate with other control module STEP 3 This test checks for an open in PNK GRN circuit in air bag harness DIAGNOSTIC FLOW TABLE Step Action Yes No 2 Ignition switch OFF 1 1 Make sure that SUZUKI scan tool is free from malfunc tion for air bag system is used 3 Check proper connection of SUZUKI scan tool to DLC Is connection in good condition Go to step 2 Properly connect SUZUKI scan tool to DLC 10B 22 AIR BAG SYSTEM Special tool A 09932 76010 NOTE Upon completion of inspection and repair work perform following items e Reconnect all air bag system components ensure all components are properly mounted e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected Step Action Yes No 2 1 Check if communication is possible by trying communi Go to step 3 Repair open in common cation with other control module ECM TCM if section of serial data circuit equipped or ABS control module if equipped PNK GRN wire circuit Is it possible to communicate with other control module used by all controllers or short to ground or power circuit which has occurred some where in serial data circ
48. 14 12 o 13 16 ne O 11 17 10 HN 15 AUTOMATIC TRANSMISSION 4 A T 7B 105 Upper Valve Body 1 Apply A T fluid to each valve plate washer spring plunger sleeve and key Insert valves plate washers springs sleeves and plunger referring to Valve Body in this section and hold them with keys as shown in the figure NOTE e Note the location of the key shown in picture e Each compression spring has an identification color paint es Note the direction of each valve 2 Install solenoid valve No 2 Tightening torque Solenoid valve bolt 8 N m 0 8 kg m 6 0 Ib ft 3 Install oil strainer and steel ball 1 Upper valve body 12 Lock up control valve 2 Primary regulator valve 13 Compression spring 3 Primary regulator valve sleeve 14 Plug 4 Primary regulator valve plunger 15 Fail valve No 2 5 Compression spring yellow painted 16 Fail valve No 2 sleeve 6 Plate washer 17 Fail valve No 1 7 Key 18 Fail valve No 1 sleeve 8 Secondary regulator valve 19 Signal valve 9 Compression spring blue painted 20 Compression spring blue painted 10 Plug 21 Oil strainer 11 Key 22 Steel ball Valve Body Assembly 1 Install gasket for upper valve body valve body plate 2 and gasket for lower valve body to upper valve body 4 NOTE Make sure that steel balls and oil strainers are installed at proper location Refer to Upper Valve B
49. 31 Low speed synchronizer hub assembly 46 Countershaft reverse gear 3 Front bearing 17 5th gear 32 Low speed synchronizer ring 47 Main shaft reverse gear 4 C ring 18 5th gear washer 33 Low speed synchronizer spring 48 Gear bush 5 Circlip 19 5th gear needle bearing 34 Synchronizer spring 49 Needle bearing SC 6 Oil seal 20 Main shaft bearing 35 High speed synchronizer hub assembly 50 Snap ring Apply grease 99000 25010 to Sep 21 C ring 36 High speed synchronizer ring 51 Circlip 7 Main shaft 22 Main shaft rear bearing 37 Synchronizer spring 52 Friction gear retainer 8 Main shaft washer ball 23 Circlip 38 Synchronizer spring 53 Friction spring 9 Main shaft bearing washer 24 Circlip 39 5th speed synchronizer hub assembly 54 Friction gear 10 Low gear 25 Countershaft 40 Synchronizer key x lt Do not reuse 11 Gear bush 26 Countershaft 5th gear 41 Synchronizer key St Apply transmission oil 12 Needle bearing 27 Front bearing 42 Reverse gear shaft 13 2nd gear 28 Circlip 43 Pin 14 Needle bearing 29 Center bearing 44 Reverse idle gear 7A 10 MANUAL TRANSMISSION Front gear shift control 1 Remove gear shift lever front case 1 2 Remove reverse gear shift limit bolt 11 3 Remove shift front arm pin 4 shift limit spring pin 2 and shift limit yoke pin 3 by using special tools Special tool A 09922 85811 B 09925 78210 4 Pull out gear
50. 5 Connect transmission range sensor coupler 6 Check that the engine can only be started in N and P range but can not in D 2 L or R range Also check that backup lights come ON at R range 7B 64 AUTOMATIC TRANSMISSION 4 A T Selector Rod 1 Selector lever assembly 4 Selector rod nut 2 Selector rod 5 Shift control shaft lever 3 Clip REMOVAL 1 Hoist vehicle 2 Remove clips on both ends of selector rod 3 Remove selector rod from transmission and selector lever assembly INSTALLATION Install selector rod by reversing removal procedure The important steps in installation are as follows e Apply grease to shift control shaft lever pin A Grease 99000 32020 e Tighten bolts and nut in the figure to specified torque Tightening torque Selector rod nut a 7 N m 0 7 kg m 5 0 Ib ft Selector lever assembly bolts b 18 N m 1 8 kg m 13 0 Ib ft e Adjusting procedure is as follows AUTOMATIC TRANSMISSION 4 A T 7B 65 ADJUSTMENT 1 Before tightening rod end nut shift selector lever to N range 2 Also shift control shaft lever to N range by aligning match marks 1 NOTE Make sure that nuts and rod joint have clearance under above conditions 2 Transmission range sensor 3 Turn nuts by hand till it contacts control shift lever joint Then tighten them with wrench 4 After selector r
51. 5 Lower valve body 17 Secondary regulator valve spring 29 Shift solenoid valve No 4 6 Plug 18 Secondary regulator valve 30 Shift solenoid valve No 3 7 Signal valve 19 Primary regulator valve sleeve 31 Shift solenoid valve No 1 8 Signal valve spring 20 Primary regulator valve plunger 32 Lock up solenoid valve 9 Fail valve No 1 sleeve 21 Primary regulator valve spring 4 Apply automatic transmission fluid 10 Fail valve No 1 22 Washer plate x Do not reuse 11 Fail valve No 2 sleeve 23 Primary regulator valve m Tightening torque 12 Fail valve No 2 24 Manual valve 7B 102 AUTOMATIC TRANSMISSION 4 A T B qc A o CO O CT Q O DISASSEMBLY Valve Body Assembly 1 Remove manual valve 2 Remove 18 bolts 1 from lower valve body NOTE e There are 4 different kinds of bolt fixing upper and lower valve body Do not mix them up and remember where they belong to e When separating lower and upper valve body be care ful not to let the steel ball to fall off Upper Valve Body 1 Remove shift solenoid No 2 2 Remove sleeves springs washers plunger and valves by removing keys 2 3 Remove oil strainer 1 Upper valve body AUTOMATIC TRANSMISSION 4 A T 7B 103 Valve spring dimensions Reference Color Spring of Paint Free length a Outside diameter b Primary regu
52. AIR BAG fuse STEP 3 Check if battery applied to SDM is within normal range STEP A Check if DTC B1032 still exists DIAGNOSTIC FLOW TABLE DTC B1032 POWER SOURCE VOLTAGE LOW Step Action Yes No 1 1 Measure voltage on battery Go to step 2 Check Charging System Is voltage 11 V or more and repair as necessary referring to Diagnosis in Section 6H 2 1 Ignition switch OFF Go to step 3 BLU RED wire short to 2 Remove and inspect AIR BAG fuse ground Is fuse good After repair replace AIR BAG fuse 10B 36 AIR BAG SYSTEM Step Action Yes No 3 1 With ignition switch OFF disconnect SDM Go to step 4 Possibly faulty points are connector Q60 as follows Check each of 2 Check proper connection to SDM at Q60 4 them and repair as neces terminal sary 3 If OK then ignition switch ON and then e Circuit from battery to check voltage from Q60 4 terminal on Q60 connector SDM connector to body ground e Charging System Is voltage 8 V or more Refer to Diagnosis in Section 6H A 1 With ignition switch OFF reconnect SDM Substitute a known good Check Charging System connector SDM and recheck and repair as necessary With ignition switch ON does DTC B1032 still referring to Diagnosis in exist Section 6H A A Fig for STEP 3 Special tool A 09932 76010 NOTE Upon completion of in
53. Air Bag harness 5 Body ground 6 Antenna wire 7 Heater control cable INSTALLATION 1 Install instrument panel by reversing removal procedure not ing the following items e Tighten instrument panel mounting bolts to specified torque Tightening torque Instrument panel mounting bolts a 23 N m 2 3 kg m 17 0 Ib ft e When installing each part be careful not to catch any cable or wiring harness When installing steering column assembly refer to Steering Column Assembly in Section 3C 2 Adjust control cables Refer to Step 1 of INSTALLATION under Heater Control Lever Assembly in Section 1A 3 Enable air bag system if equipped Refer to Enabling Air Bag System in Section 10B Front Seat Seats BODY SERVICE 9 23 2P ies 4 F 23 N m 2 3 kg m E 35 N m 3 5 kg m E 35 N m 3 5 kg m 1 Seat cushion 4 Reclining assembly LH side 7 Seat adjuster LH outside 2 Seat back 5 Seat adjuster RH outside 8 Seat adjuster LH inside 3 Reclining assembly RH side 6 Seat adjuster RH inside VW Tightening torque REMOVAL 1 Remove four mounting bolt to remove seat cushion 2 Remove four mounting bolts to remove seat back 3 Disassemble and repair seat as necessary INSTALLATION Reverse removal procedure to install front seat Torque to specifications as shown 9 24 BODY
54. As for drying time follow directions advised on the primer surfacer container e Use a wet or dry sand paper No 400 and water to polish the panel lightly f Wash the part again g Apply color coating to the part h Different paints demand different drying methods Hence follow directions advised on the pertinent paint container i When lacquer coating quick drying paint coating is applied dry coated surface and polish it with com pound In the case of the melamine or acrylic coating compound polishing can be omitted after drying j If the case of lacquer coating wax should not be applied to coated surface until the surface has dried com pletely for approx two months 2 Before replacing exterior parts or assemblies check paint conditions of all the covered or hidden interior sur faces If any rust scale is found at these places proceed as follows a Use a proper wire brush adhesive or liquid rust removing agent to remove rust As for the method of use follow directions advised for respective materials b If necessary wash parts with detergent rinse and dry them c Before installing exterior body parts apply anticorrosive compound to all cleaner surfaces of exterior body parts Also apply anticorrosive compound to inner surfaces of exterior body parts to be installed BODY SERVICE 9 27 SEALANT APPLICATION AREA M H a D Q d G V d Dh
55. Brake flange Air gun N o ao aA oo Transmission case 7B 110 AUTOMATIC TRANSMISSION 4 A T 8 Install B2 brake discs plates and flange in following order 1 Plate 2 Cushion plate 3 Plate 4 Disc gt 5 Plate thick 6 Disc 7 Plate thick 8 Disc gt 9 Flange NOTE Cushion plate 1 has installing direction as shown in fig ure 2 Front 3 Rear 9 Hold above parts with snap ring 10 Measure B2 brake stroke and clearance in following manner B2 Brake Stroke Set the dial gauge 1 to reverse brake B2 brake piston through B1 brake spring seat 2 hole as shown Blow compressed air into hole shown in figure Then measure the difference as the com pressed air is blown in B2 brake piston stroke Standard 2 22 2 47 mm 0 0874 0 0972 in B2 Brake Clearance Blow compressed air into the hole shown in figure Measure the difference B2 brake disc clearance Standard 0 60 1 70 mm 0 0236 0 0669 in If the measured value s is are out of specification select the flange from table below and repeat this step until the measured values are within specification Available flange thickness 2 36 mm 0 093 in 2 54 mm 0 100 in 2 72 mm 0 107 in 2 90 mm 0 114 in Tip of dial gauge B1 brake piston Brake flange Airgun N QO oO A Transmission case
56. Disconnect TCM couplers poor connection of sole 3 Measure the resistance between terminal noid wire harness cou E21 3 and E21 16 of disconnected har pler ness side coupler Is it about 0 or infinity 7 1 Turn ignition switch OFF and connect TCM Intermittent trouble or BI wire shorted to power couplers faulty TCM circuit or poor connection 2 Disconnect solenoid wire harness coupler Check for intermittent of terminal E21 3 3 Turn ignition switch ON then measure volt referring to Intermittent _ If wire and connection are age between BI wire terminal of discon and Poor Connection in OK substitute a known nected harness side coupler and engine Section OA good TCM ground See figure If no trouble found substi Is it 4 6 V tute a known good TCM and recheck A Fig for Step 7 A 1 BP wire terminal AUTOMATIC TRANSMISSION 4 A T 7B 49 DTC P1709 DTC No 51 Engine Coolant Temperature Signal Circuit ee apa Pak Tere fel E19 E18 x LTT Tt BEE EE HAAN TA III 1 ECM 4 Terminal arrangement of TCM coupler viewed from harness side 2 TCM 5 Terminal arrangement of ECM coupler viewed from harness side DTC DETECTING CONDITION e O D off signal from ECM require O D off although A T fluid temperature is normal operating temperature and engine rev is standard
57. G24 B Fig for STEP 3 and 6 2 BLU wire terminal C Fig for STEP 5 Special tool A 09932 76010 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected AIR BAG warning lamp flashes TABLE TEST DESCRIPTON STEP 1 Check AIR BAG monitor coupler STEP 2 Check diagnosis switch circuit for air bag system DIAGNOSTIC FLOW TABLE AIR BAG SYSTEM 10B 19 connector Q60 2 Measure resistance between Q60 15 ter minal of SDM connector and body ground Is resistance 1 MQ or more SDM and recheck Step Action Yes No 1 1 Check AIR BAG monitor coupler G63 Remove service wire Go to step 2 Is it connected diagnosis switch terminal and ground terminal in AIR BAG monitor coupler by service wire 2 1 With ignition switch OFF disconnect SDM Substitute a known good Repair short from PPL wire circuit to ground IA A Fig for STEP 2 Special tool A 09932 76010 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Repeat Air Bag Diagnost
58. Inspection and Repair Required after R Rees e ee 10 3 eae for vehicle witivain pag 10 4 On Vehicle Service SE EE Ee 10 4 Front Seat Belt without Pretensioner 10 5 Service Precautions ccccccccceeeeeeeeeeeeeeees 10 4 Front Seat Belt with Pretensioner Service and diagnosis eeeeeseutsteuegger 10 4 Rear Seat Belt Disabling air bag system for vehicle with Tightening Torque Specifications air Dag SYSTOM 000 eee eee eeeseteeeeeeeenees 10 4 10 2 RESTRAINT SYSTEM General Description There are three types of restraint system used for this vehicle Type 1 Type 2 Type 3 Front seat belt Seat belt with ELR Seat belt with ELR Seat belt with ELR Rear seat belt Seat belt with A ELR Seat belt with A ELR Seat belt with A ELR Driver and front passenger Driver and front passenger Supplemental air bags air bags restraint system Driver and front passenger pretensioners 1 Front seat belt 3 Driver side air bag inflator module if equipped 5 Front seat belt buckle 2 Rear seat belt 4 Passenger air bag inflator module if equipped 6 Rear seat belt buckle Seat Belt with ELR The seat belt with emergency locking retractor ELR is designed so that it locks immediately to prevent the webbing from being pulled out of the retractor any further when any of the following items is detected as exceed ing each set value e Speed at which the webb
59. Install piston 6 into input shaft subassembly Apply grease to the lip of the piston A Grease 99000 25030 Use care that the lip does not get twisted or caught 3 Install rear clutch return spring seat 5 and rear clutch bal ancer 4 3 Snap ring 4 Install shaft snap ring 1 Compress return springs and install shaft snap rings in groove by using a screwdriver 3 Place special tool clutch spring compressor on spring seat and compress springs with a press 2 CAUTION Do not compress return spring more than necessary Special tool A 09926 96020 AUTOMATIC TRANSMISSION 4 A T 7B 97 5 Install discs plates and flange 1 in following order 1 Plate 2 Disc 3 Plate 4 Disc 5 Plate gt 6 Disc 7 Plate 8 Disc 9 Plate 10 Disc gt 11 Plate 12 Disc gt 13 Flange NOTE Before assembly new discs should be soaked in auto matic transmission fluid for at least 2 hours 6 Install snap ring 1 NOTE Make sure that the ends of the snap ring do not come to the opening of the input shaft subassembly 7 Place special tool B on soft jawed vise 2 with wider open ing 1 facing up Special tool B 09926 26040 7B 98 AUTOMATIC TRANSMISSION 4 A T 8 Place rear clutch assembly 1 on special tool B 9 Set dial gauge 4 on the top of clutch flange 2 and mea sure clea
60. It 4 a ai 1st mounting installation hole f f Front suspension arm installation hole k Lateral rod front section installation hole b Lateral rod rear section installation g g Zig hole L P 4th mounting installation hole hole c c Engine mounting installation hole h h Rear suspension arm installation hole A Standard line dd Front shook absorber installation i P 8rd mounting installation hole B Standard line ee 2nd mounting installation LIT Rear shock absorber installation hole CT Standard line 9 18 BODY SERVICE Projection Dimension Measurement Length from line A Length from line B Length from line C Position mm in mm in mm in a 0 0 368 14 49 425 16 73 b 285 11 22 156 6 14 397 15 63 c 302 11 89 335 13 19 241 9 49 d 532 20 94 368 14 49 390 15 35 e 920 36 22 113 4 45 520 20 47 f 1025 40 35 0 0 356 14 02 g 1215 47 83 36 1 42 355 13 98 h 1900 74 80 16 0 63 481 18 94 i 2098 82 60 182 7 17 553 21 78 j 2719 107 05 370 14 57 226 8 90 k 2765 108 86 101 3 98 481 18 94 l 3065 120 67 325 12 80 523 20 59 Measurement Dimension Measurement Length Measurement Length Position mm in Position mm in a a 850 33 46 g e 927 36 50 a e 1343 52 87 g g 710 27 95 a e 96
61. Rear seat belt Buckle Rear seat Shoulder adjuster NJaj AJo N Diagnosis Diagnose air bag system including in seat belt pretensioner refer ring to Air Bag Diagnostic System Check in Section 10B Inspection and Repair Required after Acci dent After an accident whether the seat belt pretensioner has been activated or not be sure to perform checks inspections and repairs described on Repairs and Inspections Required after Accident in Section 10B 10 4 RESTRAINT SYSTEM On Vehicle Service Service Precautions Service and diagnosis WARNING If seat belt replacement is necessary replace buckle and seat belt together as a set This is for the reason of ensuring locking of tongue plate with buckle If these parts are replaced individually such a locking condition may become unreliable For this rea son SUZUKI will supply only the spare buckle and seat belt in a set part Before servicing or replacing seat belts refer to the following precautionary items e Seat belts should be normal relative to strap retractor and buckle portions Keep sharp edges and damaging objects away from belts Avoid bending or damaging any portion of belt buckle or latch plate Do not bleach or dye belt webbing Use only mild soap and lukewarm water to clean it When installing a seat belt anchor bolt start to tighten the bolt by hand to prevent cross threading and then to specified torque Do not at
62. SDM at terminals Q60 7 and Q60 8 3 If OK release shorting bar in SDM connector insert ing release tool 1 included in special tool A 4 Measure resistance between Q60 7 and Q60 8 terminals with special tools B and C connected to G61 connector Is resistance 4 5 Q or less known good SDM and recheck Step Action Yes No 1 1 With ignition switch OFF disconnect passenger air Go to step 2 Ignition switch OFF bag inflator module connector G61 behind the Replace passenger air glove box bag inflator module 2 Check proper connection to passenger air bag infla referring to Passenger tor module at terminals in G61 connector Air Bag Inflator Mod 3 If OK then connect special tools B and C to pas ule in this section senger air bag inflator module connector G61 With ignition switch ON does DTC B1015 still exist 2 1 With ignition switch OFF disconnect SDM connector Substitute a Repair high resistance or open in YEL RED or YEL wire circuit A Fig for STEP 1 and2 B Fig for STEP 2 Special tool A 09932 76010 B 09932 75010 C 09932 78340 NOTE Upon completion of inspection and repair work perform the following items es Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this sec
63. SERVICE Rear Seat 3 2 A F 35 N m 3 5 kg m F 35 N m 3 5 kg m fie A er 4 Ge We 3 14 N m 1 4 kg m 2 E 35 N m 3 5 kg m 4 8 14 N m 1 4 kg m e Ss E 35 N m 3 5 kg m g E 35 N m 3 5 kg m ae 1 U 35 N m 3 5 kg m A 2 4 1 Seat cushion 3 Seat auto lock release handle Wl Tightening torque 2 Seat back 4 Seat hinge male REMOVAL 1 Remove four mounting bolt to remove seat cushion 2 Remove four mounting bolts to remove seat back 3 Disassemble and repair seat as necessary INSTALLATION Reverse removal procedure to install rear seat Torque to specifications as shown BODY SERVICE 9 25 Paint and Coatings Anti Corrosion Treatment WARNING Standard shop practices particularly eye protection should be followed during the performance of the below itemized operations to avoid personal injury As rust proof treatment steel sheets are given corrosion resistance on the interior and or exterior These corrosion resistance steel sheet materials are called one of two side galvanized steel sheets It is for the sake of rust protection that these materials are selected and given a variety of treatments as described blow e Steel sheets are treated with cathodic electroprimer which is excellent in corrosion resistance e Rust proof wax coatings are applied to door and side sill insides where moisture is l
64. Short to ground B1025 25 PULA Short to power circuit B1032 32 EUR erte voltage 10B 14 AIR BAG SYSTEM AIR BAG warning lamp DTC flashing pattern Diagnosis NO MODE B1041 41 N n Resistance high B1042 42 UUU 1 Driver preten Resistance low B1043 43 II TLL SEL CHOU Short to ground B1044 44 II II UUU Short to power circuit B1045 45 UUW Resistance high Diagnose trou ble according to B1046 46 Passenger Resistance low diagnostic flow pretensioner table corre B1047 47 UUU UUUUUN circuit Short to ground sponding to B1048 48 MU III III g Short to power circuit each code No B1051 51 LULA j SDM Frontal crash detected B1071 71 UU I Internal fault SDM Specifications different B1013 13 LOLA between air bag system and SDM NOTE es When 2 or more codes are indicated the lowest numbered code will appear first e Current DTC and history DTC can be identified by lighting and flashing of AIR BAG warning lamp as follows However if a multiple number of DTC s are set an even one of them is a current DTC AIR BAG warning lamp remains on after ignition switch is turned ON Therefore it is not possible to identify any of them as to whether it is a current one or a history one But use of SUZUKI scan tool will make identification possible Current DTC is set Abno
65. Solenoid Valves and Transmission Fluid Temperature Sensor REMOVAL 1 Disconnect negative cable from battery 2 Drain A T fluid 3 Remove A T oil pan 4 Disconnect transmission fluid temperature sensor coupler 1 Drain plug AL a LL AY WJ eA N AUTOMATIC TRANSMISSION 4 A T 7B 69 5 Remove one of oil strainer bolts 9 and ground wire 8 for shift solenoid valve No 1 6 Disconnect shift solenoid and transmission fluid temperature sensor 3 couplers 2 7 Remove shift solenoid valves No 1 No 3 and No 4 and lock up solenoid valve 8 Remove valve body assembly 1 9 Remove shift solenoid valve No 2 Oil strainer assembly Bolt A Bolt B Bolt C N SoS Shift solenoid valves and lock up solenoid valve INSPECTION Resistance Check e Shift solenoid No 1 No 2 No 3 No 4 and lock up solenoid Check resistance between terminals or terminal and sole noid body Shift solenoid valves and lock up solenoid valve resis tance Standard 11 5 12 5 Q 1 Shift solenoid or lock up solenoid 7B 70 AUTOMATIC TRANSMISSION 4 A T Operation check Shift solenoid valves No 1 No 2 No 3 No 4 and lock up solenoid When solenoids is connected to the battery 2 as shown in fig ure check that the solenoid actuates with a click sound 1 Shift solenoid or l
66. The disc carrying three torsional coil springs is slidably mounted on the transmission input shaft with a serration fit The clutch cover is secured to the flywheel and carries the diaphragm spring in such a way that the peripheral edge of the spring pushes on the pressure plate against the flywheel with the disc in between when the clutch release bearing is held back This is the engaged condition of the clutch Depressing the clutch pedal causes the release bearing to advance and push on the tips of the tapering fingers of the diaphragm spring When this happens the diaphragm spring pulls the pressure plate away from the fly wheel thereby interrupting the flow of drive from flywheel through clutch disc to transmission input shaft 1 Crankshaft 7 Release bearing 2 Flywheel 8 Input shaft bearing 3 Clutch disc 9 Input shaft 4 Pressure plate 10 Release fork 5 Clutch cover 11 Release fork return spring 6 Diaphragm spring 12 Clutch release fork support CLUTCH 7C 3 Diagnosis Condition Possible Cause Correction Slipping clutch Loss of clearance at the tip of release fork Adjust as prescribed Clutch facings dirty with oil Replace Clutch facings excessively worn Replace Weakened diaphragm spring Replace Distorted pressure plate or flywheel surface Replace Improper clutch pedal free travel Adjust and as necessary replace clutch facings Draggi
67. WIPER WASHER fuse blown After checking short circuit replace fuse Wiper motor faulty Check wiper motor Rear wiper intermittent relay faulty Check relay Wiper switch faulty Check wiper switch Wiring or grounding faulty Repair circuit Washer malfunctions Washer hose or nozzle clogged Clean or repair clogged hose or noz zle WIPER WASHEP fuse blown After checking short circuit replace fuse Washer motor faulty Check washer motor Rear wiper intermittent relay faulty Check relay Wiper switch faulty Check wiper switch Wiring or grounding faulty Repair circuit Power Window Control System If Equipped Condition Possible Cause Correction All power windows do not operate POWER WINDOW fuse blown After checking short circuit replace fuse Ignition main switch faulty Check ignition main switch Power window switch faulty Check power window switch Wiring or grounding faulty Repair circuit Only one power win dow does not operate Wiring and or coupler faulty Check wiring and or coupler Power window switch main or sub faulty Check power window switch Window actuator faulty Check window actuator Grounding faulty Repair 8 8 BODY ELECTRICAL SYSTEM Power Door Lock System If Equipped Condition Possible Cause Correctio
68. Window Control System If Equipped Breaker INSPECTION e When the breaker 2 has worked insert a pin in the hole 1 indicated in the figure and push it until a click is heard If the system fails to operate properly replace the breaker Power window main switch INSPECTION Inspect switch continuity between terminals Driver Side Passeger Side Window Window Switch Switch Terminal Switch Position B E j DU DD B E PU PD up OTTO Oo O O O O OFF OFF o O GR O O OIO O DOWN Window Lock OtO Oro Switch ol TO UP O O Q O pown Oto SE j 1 Power window main switch 2 Power window lock switch 3 Driver side window switch 4 Passenger side window switch 8 34 BODY ELECTRICAL SYSTEM Power window sub switch INSPECTION Inspect switch continuity between terminal LH Switch Terminal p SD su D Position UP O O OFF O O DOWN LTH SU U BSD D Power Door Lock System If Equipped Power door lock system component location 1 Power door lock controller 3 LOCK position 2 Driver side door knob switch 4 UNLOCK position 5 Front door actuator 6 Back door actuator A B n2 iifio 9 8 elt BODY ELECTRICAL SYSTEM 8 35 Power door lock syste
69. Wire harness specification Stripped wire harness section 1 25 mm 0 0019 in or more Stripped wire harness diameter 1 25 mm 0 05 in or more NOTE Wind wire harness around at least 2 times c Drape blanket 5 over those tires 11 Connect adapter cable B or C to deployment harness A connector and lock connectors with lock lever A For driver air bag inflator module B For passenger air bag inflator module C For seat belt pretensioner AIR BAG SYSTEM 10B 67 12 Notify all people in immediate area that you intend to deploy activate air bag inflator module or seat belt pretensioner NOTE e When air bag inflator module deploys and seat belt pretensioner activates rapid gas expansion will create substantial report Wear suitable ear protection Notify all people in immediate area that you intend to deploy air bag inflator module or activate seat belt preten sioner and suitable ear protection should be worn e When driver air bag inflator module deploys driver air bag inflator module may jump about 30 cm 1 ft vertically This is normal reaction to force of rapid gas expansion inside of drive air bag inflator module e After air bag inflator module has been deployed sur face of air bag inflator may contain powdery residue This powder consists primarily of cornstarch used to lubricate bag inflator as it inflates and byproducts of chemical reaction
70. after an Accident in this section NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected AIR BAG SYSTEM 10B 47 DTC B1071 Internal SDM Fault DTC WILL SET WHEN An internal SDM fault is detected by SDM CAUTION Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to the following diagnostic procedures NOTE DTC B1071 can never be cleared once it has been set 1 Ignition switch OFF 2 Replace SDM referring to SDM in this section 3 Repeat Air Bag Diagnostic System Check in this section DTC B1013 System Specifications Different from SDM Specifications DTC WILL SET WHEN Specifications of the air bag system differ from those of SDM CAUTION Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to the following diagnostic procedures 1 Ignition switch OFF 2 Replace SDM referring to SDM in this section 3 Repeat Air Bag Diagnostic System Check in this section 10B 48 AIR BAG SYSTEM On vehicle Service Service Precautions Service and diagnosis WARNING CAUTION labels are attached on each part of air bag system compo
71. and gear set and if the seat is defective so is transfer case REAR DIFFERENTIAL 7F 25 Tightening Torque Specification Tightening torque Fastening part Nem kom bt Rear differential oil drain plug 27 2 7 19 5 Rear differential oil level filler plug 50 5 0 36 5 Differential carrier bolts 23 2 3 17 0 Propeller shaft bolts 50 5 0 36 5 Differential case bolts 41 4 1 30 0 Drive bevel gear bolts 85 8 5 61 5 Flange nut 100 400 10 40 72 289 Bearing cap bolts 85 8 5 61 5 Lock plate bolts 11 5 1 15 8 5 Required Service Material Material Recommended SUZUKI product Use Part Number Thread lock cement THREAD LOCK CEMENT 1322 e Drive bevel gear bolts 99000 32110 e Differential case bolts Lithium grease SUZUKI SUPER GREASE A Oil seal lip 99000 25010 Sealant SUZUKI BOND NO 1215 e Rear differential drain plug 99000 31110 e Mating surface of differential carrier e Mating surface of rear axle housing e Differential carrier bolts Special Tool 09900 20607 09900 20701 09900 23107 09913 50121 Dial gauge Magnetic stand Torque wrench Oil seal remover 7F 26 REAR DIFFERENTIAL 09913 60910 Bearing puller 09913 65135 Bearing puller 09913 75510 Bearing installer 09913 85230 Bearing removing jig 09915 24550 Adapter socket 09922 66020 Flange holder 09922 75222 Preload adjuster 09922 76120 Dummy
72. and internal cone of ring for abnormal wear Be sure that contact patterns on these surfaces indicate uniform full face contact and that surfaces are free from any wavy wear A badly worn member must be replaced Proper synchronizing action on gear shifting can be expected only when ring to gear clearance and condition of cone surfaces among other things are satisfactory Fork Shaft Locating Springs If gears slipping out of mesh has been complained check these springs for strength by measuring their free length and replace them if their free lengths are less than service limit Fork shaft spring free length a Standard 25 0 mm 0 984 in Service limit 23 0 mm 0 906 in Gear Shift Shafts Check the part of shaft as indicated in figure for uneven wear Replace shaft if uneven wear is noted Assembling Unit NOTE MANUAL TRANSMISSION 7A 19 e Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear e Use new circlips on shaft for reinstallation Don t reuse used circlips e Tighten each fastening bolt and nut according to Tightening Torque Specification in this section Main shaft and input shaft Install each parts by reversing respective removal procedures Be careful for installing direction of each washer gear synchronizer hub and sleeve Refer to figure
73. bolt 7A 30 MANUAL TRANSMISSION 3 When installing gear shift lever front case to extension case clean joint faces and then apply sealant to joint faces A Sealant 99000 31110 Tightening torque Gear shift lever front case bolts a 23 N m 2 3 kg m 17 0 lb ft Tightening Torque Specification Be sure to torque each bolt and nut according to specification given below whenever loosened If specified torque for particular bolt or nut is not included in the list refer to Section OA Tightening torque Fastening part Nem kom Gm Gear shift control boot cover bolts 23 2 3 17 0 Gear shift lever plate bolts 5 5 0 55 4 0 Extension rod joint bolt 35 3 5 25 5 Control shaft joint nuts 18 1 8 13 0 Select return spring bolts 23 2 3 17 0 Gear shift lever front case bolts 23 2 3 17 0 Transmission case bolts 23 2 3 17 0 Extension case bolts 23 2 3 17 0 Transmission oil filler and drain plugs 23 2 3 17 0 Input shaft bearing retainer bolts 23 2 3 17 0 Reverse gear shift limit bolt 23 2 3 17 0 Transmission to engine bolts and nuts 94 9 4 68 0 Transmission rear mounting bolts 25 2 5 18 0 Gear shift rear arm bolt 34 3 4 24 5 MANUAL TRANSMISSION 7A 31 Required Service Material Material Recommended SUZUKI product Part Number Use Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips Gear shift cont
74. carrier 1 4 Remove differential side bearing lock plates 4 and differen tial side bearing caps 6 by removing their bolts and then remove bearing adjusters 5 side bearing outer races and drive bevel gear 2 with differential case 3 Special tool A 09944 76010 IN REAR DIFFERENTIAL 7F 9 5 Turn differential assembly together with special tool A by 90 degrees and grip it with vise again Special tool A 09944 76010 6 Hold companion flange with special tool and then remove flange nut by using power wrench 3 and socket wrench 2 Special tool B 09922 66020 1 Bolt and nut CAUTION Do not make mating mark on the coupling surface of the flange to prevent propeller shaft from generating vibra tion 7 Make mating marks 1 on drive bevel pinion 2 and com panion flange 3 8 Remove companion flange from drive bevel pinion using special tool Special tool C 09913 65135 9 Remove drive bevel pinion with rear bearing and spacer from differential carrier If it is hard to remove screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on drive bevel pinion 10 Remove drive bevel pinion rear bearing 2 by using bearing puller 3 and hydraulic press 1 Drive bevel pinon 7F 10 REAR DIFFERENTIAL 11 Remove 10 bolts se
75. cir cuit ignition switch at ST position Wiring or grounding faulty Repair circuit Brake warning light Bulb in combination meter blown Check bulb does not light up when parking brake METER fuse blown After checking short circuit replace fuse pull up Combination meter wiring circuit faulty Check combination meter wiring cir cuit Parking brake switch faulty Check parking brake switch Wiring or grounding faulty Repair circuit Seat Belt Warning Light Condition Possible Cause Correction Seat belt warning light Bulb in combination meter blown Check bulb does not light up Seat belt switch faulty Check seat belt switch METER fuse blown After checking short circuit replace fuse Wiring or grounding faulty Repair circuit Rear Window Defogger If Equipped BODY ELECTRICAL SYSTEM 8 7 Condition Possible Cause Correction Defogger does not operate REAR DEEG fuse blown After checking short circuit replace fuse Defogger wire faulty Check heat wire Rear window defogger switch faulty Check switch Wiring or grounding faulty Repair circuit Front Wiper and Washer Rear wiper and washer If equipped Condition Possible Cause Correction Wiper malfunctions or does not return to its original position
76. drive bevel pinion spacer otherwise spacer and bearings may be dam aged Apply differential oil to drive bevel pinion rear bearing 2 Install drive bevel pinion 1 spacer 3 and companion flange 5 into differential carrier 4 18 Until bearing axial clearance come to 1 2 mm 0 039 0 079 in press fit drive bevel pinion 1 to companion flange 5 by using special tools and hydraulic press i t N O x Sr NOTE Bearing axial clearance can be confirmed by shaking dif ferential carrier 4 in the direction shown in figure Special tool A 09925 58210 B 09951 46010 7E 18 FRONT DIFFERENTIAL NOTE e Before taking measurement check for smooth rotation by hand Preload of drive bevel pinion bearings is adjusted by tightening flange nut to deform drive bevel pinion spacer Therefore be sure to use a new spacer for adjustment and tighten flange nut step by step and check for pre load by measuring starting torque as often as tighten ing to prevent over crushing of spacer If preload exceeds specification given below during adjustment replace spacer and repeat preload adjust ment procedure Attempt to decrease preload by loos ening flange nut will not do e For measuring preload of drive bevel pinion bearings turn drive bevel pinion at about 50 rpm is required e Make a record preload of drive bevel pinion bearings because the preload is used for checking com
77. drive bevel pinion bearings to differential carrier 2 Special tool A 09922 76140 B 09922 76410 C 09922 76310 D 09922 76340 E 09922 76320 F 09922 76150 FRONT DIFFERENTIAL 7E 15 NOTE Before taking measurement check for rotation by hand more than 15 revolutions 5 Tighten special tool 1 so that specified bearing preload is obtained Special tool A 09900 23107 B 09915 24550 C 09922 76150 Drive bevel pinion bearing preload at 50 rpm 0 9 1 7 N m 9 0 17 0 kg cm 7 8 14 7 Ib in NOTE e When setting dial gauge to bearing form dummy with dummy shaft tighten screw lightly Be careful not to overtighten it which will cause damage to dial gauge e With dial gauge set turn dummy back and forth by hand a couple of times and attain accurate zero adjust ment It is desirable that short pointer indicates beyond 2 mm when long one is at zero 6 Set dial gauge to bearing form dummy with dummy shaft and make zero adjustment on surface plate 7 Put block dummies 3 on pinion form dummy 2 Special tool A 09922 76520 B 09922 76550 NOTE e Repeat turning back and forth of dummy and measure distance as far as top surface of block dummy accu rately e When dial gauge measuring tip extends from zero position pointer turns counterclockwise Measured value may exceed 1 mm Therefore it is also necessary t
78. e SIG R and GND S4 SS 3 e SIG L and GND 23225 4 1 6 1 8 Leveling actuator INSPECTION All headlight system couplers connected including leveling actua tor and switch and at Ignition switch ON listen to the leveling actuator sound on both actuators according to the movement of the leveling switch If no sound is heard with the movement of the leveling switch replace headlight assembly Turn Signal and Hazard Warning Lights Sys tem Turn signal and hazard warning lights system circuit inspection 1 Disconnect negative cable from battery 2 Disconnect turn signal and hazard warning relay 1 connec tor G34 BODY ELECTRICAL SYSTEM 8 15 3 Connect negative cable to battery 4 Confirm that right or left side turn signal light turn on when connect G34 4 terminal to G34 2 or G34 3 terminal with service wire If turn signal light does not turn on check bulb or repair applicable circuit 1 Turn signal and hazard warning relay connector G34 viewed from harness side 1 5 Check that voltage and continuity between the following ter minals and body ground are specifications under each condi tion If check result is not as specified repair applicable circuit If check result is OK replace turn signal and hazard warning relay and recheck Turn signal and hazard warning lights sys
79. follows 1 Confirm that the vehicle is the following conditions e All doors are closed e Ignition key is out of ignition switch e Driver side door is unlocked 2 Disconnect negative cable from battery 3 After 30 seconds perform the following procedure within 60 seconds a Connect negative cable to battery b Operate driver side door knob switch from lock to unlock c Push LOCK button on transmitter and confirm that are operated from lock to unlock d Push driver side door knob switch to lock position e Push LOCK button on transmitter twice and confirm that all doors are operated from unlock to lock With this code registration is completed NOTE e Two transmitter codes can be registered e When a new transmitter code is registered the oldest one will be cleared 8 42 BODY ELECTRICAL SYSTEM Driver side key cylinder switch Refer to Driver Side Key Cylinder Switch under Power Door Lock System If Equipped in this section Power door lock actuator Refer to Power Door Lock Actuator under Power Door Lock System If Equipped in this section Door switch INSPECTION Remove door switch from body and check switch for continuity if found defective replace switch OFF position Door closed No continuity ON position Door open Continuity BODY ELECTRICAL SYSTEM 8 43 Power Door Mirror Control System If Equipped Mirror switch INS
80. gear 1 is engaged with the lock up plate and fixed rotation of the sprocket output gear is transmitted through the ring gear 2 planetary pinion 4 and planetary carrier while being reduced and causes the output rear shaft to turn A 4H range B 4L range 7D 4 TRANSFER Gear Shift Control The gear is shifted to the 2H 4H or 4L shift position by using the shift lever provided inside of the vehicle The control mechanism consists of a shift lever shift shaft interlock block shift fork etc The shift lever is installed directly to the transfer case To shift the shift control lever between 2H and 4H posi tions move it in the shift shaft direction To shift it from the 4H position to the 4L position push it down at the 4H position and then move it in the shift shaft direction 1 Shift shaft 2 Shift lever 3 2 4 shift fork 4 Hi Lo shift fork 5 Interlock block Control Mechanism The shift lever fitted through the shift shaft and fixed to it with a pin Also the 2 4 shift fork to shift the gear in the 2H4H pattern and the Hi Lo shift fork in the AH AL pattern are fitted so that they can slide on the shift shaft The interlock block cannot move in the shaft direction of the shift shaft as its movement is restricted by the inter lock pin installed to the transfer case but it can turn within the range of the groove in the interlock block Inter lock block can be turned by push
81. gear is found out After gear is found out position of gear is held until ignition switch is turned OFF AUTOMATIC TRANSMISSION 4 A T 7B 11 Area Detecting condition Fail safe function Transmission range sensor cir cuit DTC P0705 No transmission range sensor signal is inputted or two or more transmission range sensor signals are inputted at the same time e When vehicle running shift range position is fixed to shift range position right before the trouble occurred until vehicle stop and lock up function is turned OFF e When vehicle is at stop after or during detecting the trouble gear is fixed as the followings and lock up function is turned OFF When 2 adjoining gear position signals are inputted P R range R R N range gt R N D range gt D D 2 range gt D 2 L range gt 2nd When 2 or more signals excepting above or no signal are inputted P range gt P R range gt R N range gt N D 2 L range gt 3rd Transmission fluid temperature sen sor circuit DTC P0710 e A T fluid temp sig nal input voltage is too low e A T fluid temp sig nal input voltage does not go down although standard value of engine rev signal is input ted e When detecting circuit open TCM control as fluid tempera ture is 100 C 212 F e Lock up function is turned OF
82. in front of screen 1 ahead of headlight surface Distance between screen and headlight a 10 m 32 8 ft b Adjust air pressure of all tires to a specified value respec tively c Bounce vehicle body up and down by hand to stabilize sus pension d Carry out with one driver aboard A Driver s weight 75 kg 165 Ib e Turn headlight leveling switch to 0 position 2 Check to see if hot spot high intensity zone of each low beam axis falls as illustrated Hot spot specification i HoT i H Approx 130 mm 5 15 in LH HEADLIGHT spor RL HEADLIGHT 3 If headlight aiming is not set properly align it to specification by adjusting aiming screw and aiming gear 1 Headlight assembly 2 Aiming for right left adjustment 3 Aiming for up down adjustment A The illustration shows LH steering vehicle And RH steering vehicle is symmetrical X X Horizontal center line of headlights bulb A A Vertical center line of left headlight bulb B B Vertical center line of right headlight bulb 8 14 BODY ELECTRICAL SYSTEM Headlights with Leveling System If Equipped Leveling switch INSPECTION Check for resistance between terminals at each switch position as shown below If check result is not as specified replace Position Terminals Resistance KQ IG and GND 3 7 5 6 0 4 0 4 5
83. installation of front axle shaft refer to Front Axle Shaft Oil Seal Kingpin Bearing Outer Race or Front Axle Housing in Section 3D Differential Gear Oil Refill differential housing with new specified differential oil Refer to Oil Change in this section DISASSEMBLY 1 Put match marks 7 on differential side bearing caps 6 and differential carrier 1 2 Remove differential side bearing lock plates 4 and differen tial side bearing caps by removing their bolts and then remove bearing adjusters 5 side bearing outer races and drive bevel gear 2 with differential case 3 7E 8 FRONT DIFFERENTIAL Fi 3 Hold companion flange with special tool and then remove flange nut by using power wrench 2 and socket wrench 1 Special tool A 09922 66020 CAUTION Do not make mating mark on the coupling surface of the flange to prevent propeller shaft from generating vibra tion 4 Make mating marks 1 on drive bevel pinion 2 and com panion flange 3 5 Remove companion flange from drive bevel pinion by using special tool if it is hard to remove Special tool B 09913 65135 6 Remove drive bevel pinion with rear bearing and spacer from differential carrier If it is hard to remove screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on drive bevel pinion 7 Remove
84. is in P position While on shifting from 1st gear to 2nd gear 0 100 SHIFT SOL 3 DUTY Ignition switch ON vehicle is at stop and selector 0 lever is in P position While on shifting from 2nd gear to 3rd gear 0 100 SHIFT SOL 4 DUTY Ignition switch ON vehicle is at stop and selector 0 lever is in P position While on shifting from 3rd gear to 4th gear 0 100 TCC SOL DUTY At 5 km h 3 mile h constant speed O D off switch 0 ON closed throttle and 1st gear At 60 km h 37 5 mile h constant speed T F 2H 100 range O D off switch OFF 5 to 16 throttle opening and 4th gear D range ENGINE SPEED At engine idle speed Engine idle speed is displayed VEHICLE SPEED At vehicle stop 0 km h 0 MPH O D OFF SWITCH Ignition switch O D off switch OFF OFF CON ON and normal O D off switch ON ON engine coolant temperature O D OFF SWITCH Ignition switch O D off switch OFF OFF MON ON O D off switch ON ON TRANS RANGE Ignition switch Selector lever is in P position P ON Selector lever is in R position R Selector lever is in N position N Selector lever is in D position D Selector lever is in 2 position 2 Selector lever is in L position L D RANGE SIGNAL Ignition switch Selector lever is in P position OFF ON Selector lever is in R position ON Selector lever is in N
85. its circuit Repair or replace faulty e O D OFF switch and or O D OFF indicator Refer to O D Off Switch in this light circuit faulty section and or inspect its circuit e Engine coolant temp sensor or its circuit Refer to ECT sensor in Section faulty 6E e TCM faulty Replace TCM 4th gt 3rd e Shift solenoid A No 1 4th gt 3rd 3rd gt Repair or replace ZS 3rd gt 2nd 2nd 2nd gt 1st B No 2 2nd 1st C e 2nd 1st No 3 8rd 2nd D No 4 4th gt 3rd or A its circuit faulty e e Throttle position sensor or its circuit faulty Inspect TP sensor 2 e TCM faulty Replace TCM Shift point too high or too low Throttle position sensor A T output shaft speed sensor or its circuit faulty Inspect TP sensor and or A T out put shaft speed sensor Vehicle does not move Shift solenoid A No 1 B No 2 C No 3 or its circuit faulty Repair or replace Excessive slip Shift solenoid A No 1 to D No 4 or its cir cuit faulty Repair or replace Excessive shock at N gt DorN gt R Shift solenoid B No 2 C No 3 or its cir cuit faulty ECM ISC Repair or replace Inspect ECM No lock up or No lock up OFF TCC lock up solenoid valve or its circuit faulty Repair or replace Throttle position sensor or its circuit faulty Refer to throttle position sensor in Section 6E Engine coolant temp sensor or its circuit faulty Refer
86. known good ECM or Immobilizer Con trol Module and recheck See NOTE Y B wire between Immobilizer Control Module and ECM open IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 29 NOTE e After replacing with a known good ECM register ECM Immobilizer Control Module code in ECM by performing procedure described in Procedure After ECM Replacement in this section e After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM and Transponder code and ECM Immobilizer Control Module code in Immobi lizer Control Module by performing procedure described in Procedure After Immobilizer Control Module Replacement in this section Fig 1 for step 1 1 2 Ale G38 2 1 1 Immobilizer Control Module Vehicle not equipped with air bag system 1 2 Immobilizer Control Module Vehicle equipped with air bag system Fig 2 for step 2 1 2 G38 2 1 1 Immobilizer Control Module coupler disconnected Vehicle not equipped with air bag system 1 2 Immobilizer Control Module coupler disconnected Vehicle equipped with air bag system A Connect to serial data link terminal E18 12 of ECM coupler disconnected 8G 30 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Inspection of ECM Immobilizer Control Mod ule and Its Circuit ECM Immobilizer Control Module and its circuit can be ch
87. measurement check for rotation by hand more than 15 revolutions 5 Tighten special tool 1 so that specified bearing preload is obtained Special tool A 09900 23107 B 09915 24550 C 09922 76150 Drive bevel pinion bearing preload at 50 rpm 0 9 1 7 N m 9 0 17 0 kg cm 7 8 14 7 Ib in NOTE e When setting dial gauge to bearing form dummy with dummy shaft tighten screw lightly Be careful not to overtighten it which will cause damage to dial gauge With dial gauge set turn dummy back and forth by hand a couple of times and attain accurate zero adjust ment It is desirable that short pointer indicates beyond 2 mm when long one is at zero O KSM Set dial gauge to bearing form dummy with dummy shaft and make zero adjustment on surface plate 7 Put block dummy 3 on pinion form dummy 2 Special tool A 09922 76550 NOTE e Repeat turning back and forth of dummy and measure distance as far as top surface of block dummy accu rately e When dial gauge measuring tip extends from zero position pointer turns counterclockwise Measured value may exceed 1 mm Therefore it is also necessary to know reading of short pointer 8 Place zero adjusted bearing form dummy with dummy shaft 1 and dial gauge set on block dummy 3 and take mea surement between zero position and extended dial gauge measuring tip 9 Obtain adjusting shim thickness by using measured value by dial gauge
88. o 50 100 140 km h a E et ee 0 50 mile h B Vehicle Speed amp g 140 km h Descr aa a en D a i 0 50 mile h Vehicle Speed AUTOMATIC TRANSMISSION 4 A T 7B 13 Diagnosis This vehicle is equipped with an electronic transmission control system which controls the automatic shift up and shift down timing etc suitably to vehicle driving conditions When diagnosing a trouble in the transmission including this system follow Automatic Transmission Diagnostic Flow Chart given below to obtain correct result smoothly Automatic Transmission Diagnostic Flow Table NOTE For the details of each step refer to the following Step Action Yes No 1 Customer Complaint Analysis Go to Step 2 Perform customer com 1 Perform customer complaint analysis refer plaint analysis ring to the following page Was customer complaint analysis performed according to instruction on the following page 2 Diagnostic Trouble Code DTC Check Record Print DTC or write it down Go to Step 4 and Clearance and clear it by referring to 1 Check for DTC referring to the following DTC Clearance in this page section Is there any DTC s Go to Step 3 2 Visual Inspection Repair or replace mal Go to Step 5 1 Perform visual inspection referring to the function part following page Go to Step 11 Is there any faulty condition 4 Visual Inspection Go to Step 8 1 Perform visual inspection referr
89. of puller against 5th gear so as not to cause damage to teeth 4 Remove countershaft rear bearing 1 and 5th gear 2 with puller 3 and hydraulic press 7A 12 MANUAL TRANSMISSION 5 Remove countershaft reverse gear 1 and center bearing 3 with puller 2 and hydraulic press 6 Remove countershaft from lower case 7 Remove circlip 3 of countershaft front bearing 2 and pull out bearing by using special tool Special tool B 09913 60910 iessen y p 1 Countershaft Input shaft and main shaft 1 Take out input shaft 1 by hand taking care not to let high speed synchronizer ring 3 fall off 2 Main shaft 5 3rd gear 4 Bearing 2 Remove circlip of input shaft 1 and pull out bearing 2 with puller 3 and hydraulic press as necessary NOTE Sealed bearing must not be washed Replace it with new one when required MANUAL TRANSMISSION 7A 13 3 Remove circlip retaining hub of high speed synchronizer sleeve and slide off sleeve hub third driven gear and needle bearing from main shaft 4 Remove circlip retaining rear bearing 1 on main shaft Remove main shaft bearing using special tool Special tool A 09913 65135 5 From main shaft take off 5th gear washer ball 5th gear 5th speed synchronizer ring and 5th gear needle bearing 1 6 Remove circlip ret
90. only in severe frontal collisions It is not designed to activate in rear impacts side impacts rollovers or minor frontal collisions since it would offer no protection in those types of accidents 10B 4 AIR BAG SYSTEM System Components and Wiring Location View and Connectors E 9 N m 0 9 kg m A F 5 5 Nem w ssn kg m E 35 N m 3 5 kg m A Connector G62 G70 1 Air bag harness in instrument panel harness 8 Passenger air bag inflator module B Connector G61 2 Air bag harness in floor harness 9 SDM C Connector Q60 3 Air bag harness in seat belt pretensioner harness 10 Seat belt pretensioner retractor assembly D Connector L30 4 Air bag monitor coupler 11 Ground for air bag system E Connector G63 5 DLC 12 AIR BAQ fuse in circuit fuse box F Connector Q07 Q09 6 Contact coil assembly G Connector Q08 Q10 7 Driver air bag inflator module System Wiring Diagram AIR BAG SYSTEM 10B 5 6 PNK GRN A lt 7 777 15 Q60 G62 G70 G41 16 17 GRN RED Ky S H H 1 1 GRN a a G61 YEL RED Gaz 18 YEL 5 J aye agar tone Q Qos PNK PNK YEL a roi 1 WHT WHT ya YEL RED syo 133 Q09 20 BRN BRN YEL ca ve Bel
91. out yoke pin on high speed gear shift fork 4 and pull out shift shaft 5 As in above case be careful not to let locating ball interlock ball and spring fly away Special tool A 09922 85811 1 Fork 3 Transmission case 2 Spring pin MANUAL TRANSMISSION 7A 15 3 Drive yoke pin out of low speed gear shift fork 1 and pull out fork shaft 2 and fork Special tool A 09922 85811 INSPECTION Gear Shift Lever Check lower end of gear shift lever where gear shift fork shaft contact for wear and any kind of damage Worn or damaged gear shift lever must be replaced with a new one Reverse amp Low Speed Select Guide Pins Check both select guide pins where gear shift front arm contacts for stepped wear Replace worn select guide pin 7A 16 MANUAL TRANSMISSION Move shaft and check low speed select guide pin for smooth movement without rattle If found defective replace it and apply grease to pin Gear Shift Fork Shaft Visually check each gear shift fork shaft High Low and Reverse where gear shift front arm contacts for wear Worn shaft must be replaced Gears Check each part for wear damage or discoloration Replace if found defective Synchronizer Hubs Sleeves and Keys Check each part for wear or damage Replace if found defective MA
92. proper retention of these parts CONTENTS Glass and WiNdOWS cccsesesseeeeeeeeeeeseeeeeees 9 2 SO ats eich AE T Front Door Glass 9 2 Lal E Front Door Window Regulator 9 5 e Windowshield 0 ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeees 9 6 Paint and Coatings Quarter WINdOW ccccccccceceeeeeeseseeeeeeeeeeees 9 11 Anti CorroSion Treaiment eean 9 25 Back Door Glass 9 12 Metal Replacement Parts Finishing SEENEN 9 26 Body Press gedeckt eEe 9 13 Security and Locke 9 34 Front Door Assembly eeeeesseerrrrrreee 9 13 Front Door Lock Assembhy 9 34 Back Door Assembly SEN EEN 9 15 Back Door Lock Assembly EECHELEN 9 36 Ge Body pensions ee eas a Exterior and Interior Trim ccecssssseeeeees 9 37 Body Dimensions ee eene 9 19 Instrumentation and Driver Information 922 Roof Rail f Equipped 887 Instrument Panel 9 22 Tightening Torque Specification 9 38 9 2 BODY SERVICE Glass and Windows Front Door Glass 1 Door glass 6 Door trim 11 Door sash 2 Out side weatherstrip 7 Door hinge 12 Door grip 3 Opening weatherstrip 8 Door open stopper 13 Door glass attaching screw Tighten rear screw first and then tighten front screw 4 Window regulator 9 Door sealing cover 14 Window regulator mounting screw Tighten proper procedure referring to Front Door Window Regulator 5 Glass run 10 Door open stopper pin w Tightening torque REMOVAL
93. release tool 1 included in special tool A 4 Measure resistance between Q60 9 and Q60 10 terminals with connected special tools B and C to G62 connector Is resistance 4 5 Q or less 3 1 With ignition switch OFF disconnect special tools B Ignition switch OFF Ignition switch OFF and C from G62 connector then reconnect contact Replace contact coil Replace driver air coil connector G62 located near the base of the assembly referring bag inflator module steering column as it was to Combination referring to Steering 2 Remove driver air bag inflator module from steering Switch Contact Coil Wheel and Driver Air wheel referring to Driver Air Bag Inflator Module in and Combination Bag Inflator Module Section 3C Switch Assembly in in Section 3C 3 Check proper connection to driver air bag inflator Section 3C module at terminals in G70 connector 4 If OK then connect special tools B and C to G70 connector With ignition switch ON does DTC B1021 still exist A TA Fig for STEP 1 and 2 B Fig for STEP 2 C Fig for STEP 3 Special tool A B C 09932 76010 09932 75010 09932 78340 10B 30 AIR BAG SYSTEM NOTE Upon completion of inspection and repair work perform the following items es Reconnect all air bag system components ensure all components are properly mount
94. replace 1st and 2nd gear 1st amp 2nd brake faulty Repair or replace 4th gear Overdrive brake faulty Repair or replace Any forward and reverse gear Parking lock pawl faulty Repair or replace Shock or engine stalls when starting off and Torque converter clutch faulty Inspect and replace as necessary stopping letz 2nd Rear clutch faulty Repair or replace 2nd gt 3rd Front clutch faulty Repair or replace 2 3rd 4th Overdrive brake faulty Repair or replace 2 2 m 2nd or 3rd gear Front or rear clutch or 1st amp 2nd brake faulty Repair or replace E L range 1st gear Front clutch or 1st amp 2nd brake faulty Repair or replace o 5 z No lock up Torque converter clutch faulty Inspect and replace as necessary Lock up control valve faulty Clean or replace Lock up solenoid faulty Clean or replace Secondary regulator valve faulty Clean or replace Signal valve faulty Clean or replace No lock up OFF TCC lock up solenoid faulty Clean or replace Lock up control valve faulty Clean or replace 7B 20 AUTOMATIC TRANSMISSION 4 A T Stall Test This test is to check overall performance of automatic transmis sion and engine by measuring stall speed at D and R ranges Be sure to perform this test only when transmission fluid is at nor mal operating temperature
95. reservoir in deployment fixture A with water or sand This is necessary to provide sufficient stabilization of fixture during deployment d Attach passenger air bag inflator module 1 in deploy ment fixture A securely using mounting attachment hold down bolts amp nuts and M8 bolts amp nuts 2 CAUTION Be sure to use M8 size and 7T strength bolt for fixing passenger air bag inflator module 1 to deployment fix ture A e For seat belt pretensioner a Cut webbing 1 at tongue plate stopper 3 of seat belt pre tensioner 2 side as shown NOTE Hold seat belt pretensioner 2 vertically in the same con dition as it is installed Otherwise webbing can t be pulled out b Remove tongue plate 4 and shoulder anchor 5 from webbing AIR BAG SYSTEM 10B 65 c Tie webbing 1 tightly at 10 cm 3 9 in from cutting edge as shown d Tie seat belt pretensioner 2 with wire harness 3 to wheel installed tire 4 as shown Wire harness specification Stripped wire harness section 1 25 mm 0 0019 in or more Stripped wire harness diameter 1 25 mm 0 05 in or more NOTE Wind wire harness 3 around at least 3 times e Clear space 5 on ground about 185 cm 6 ft in diameter where seat belt pretensioner 2 is to be activated Paved outdoor location where there is no activity is preferred If outdoor location is not available space on shop floor where the
96. self diagnosis function 3 and 4 VISUAL INSPECTION As a preliminary step perform visual check of the following items that support proper function of the automatic transmission INSPECTION ITEM REFERRING SECTION e Engine oil level leakage Section 0B e Engine coolant level leakage Section 0B e A T fluid level leakage color Section 0B e Battery fluid level corrosion of terminal e A T fluid hoses disconnection looseness deterioration e Connectors of electric wire harness disconnection friction Section 8 e Fuses burning Section 8 e Parts installation bolt looseness e Parts deformation e Other parts that can be checked visually Also add following items at engine start e Indicator warning lights in combination meter ON Section 8 indicating abnormality in system or OFF e Other parts that can be checked visually 5 TROUBLE SYMPTOM CONFIRMATION Check if what the customer claimed in CUSTOMER COMPLAINT ANALYSIS is actually found in the vehicle and if that symptom is found whether it is identified as a failure This step should be shared with the customer if possible When the symptom is not actually found possibility is e The symptom occurs under certain conditions Retry with the vehicle under different conditions e The trouble occurred only temporarily and normal operation has been restored Kee Perform Diagnostic Trouble Code Che
97. shaft T 09922 76140 Bevel pinion shaft 09922 76150 Bevel pinion nut EE 09922 76230 Bearing gear dummy 09922 76310 Rear collar 09922 76320 Rear collar 09922 76340 Rear collar 09922 76410 Front collar 2 09922 76550 Gauge block REAR DIFFERENTIAL 7F 27 D 09924 07730 Bearing installer 09924 74510 Installer attachment 09925 58210 Oil seal installer 09926 37610 003 Bearing remover attach ment el 09926 68310 Bearing installer 09930 40113 Rotor holder 09930 40120 Attachment 09940 53111 Bearing installer H 09944 66010 Oil seal installer 09944 66020 Bearing installer 09944 76010 Differential carrier holder 09951 16060 Bush remover O 09951 46010 Oil seal installer 7F 28 REAR DIFFERENTIAL BODY ELECTRICAL SYSTEM 8 1 SECTION 8 BODY ELECTRICAL SYSTEM WARNING For vehicles equipped with Supplement Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system secti
98. signal from transmission fluid temperature sensor installed on valve body SHIFT SOLENOID 1 DUTY Electricity duty ratio of duty pulse signal applied to shift solenoid valve A No 1 by TCM SHIFT SOLENOID 2 DUTY Electricity duty ratio of duty pulse signal applied to shift solenoid valve B No 2 by TCM SHIFT SOLENOID 3 DUTY Electricity duty ratio of duty pulse signal applied to shift solenoid valve C No 3 by TCM SHIFT SOLENOID 4 DUTY Electricity duty ratio of duty pulse signal applied to shift solenoid valve D No 4 by TCM TCC SOLENOID DUTY Electricity duty ratio of duty pulse signal applied to TCC solenoid valve by TCM ENGINE SPEED RPM Engine speed computed by reference pulse from crankshaft position sensor VEHICLE SPEED KPH MPH Vehicle speed computed by reference pulse signals coming from vehicle speed sensor on transfer case AUTOMATIC TRANSMISSION 4 A T 7B 55 O D OFF SWITCH CONTROL Condition which TCM controls automatic transmission if shift to O D is permitted or not ON Shift to O D is permitted OFF Shift to O D is not permitted O D OFF SWITCH MONITOR Input signal from O D off switch on selector knob ON O D off switch ON OFF O D off switch OFF TRANSMISSION RANGE Transmission range detected by signal fed from transmission range sensor D RANGE SIGNAL ON Signal which TCM require ECM to increase idle speed OFF Signal which TCM does not require ECM to increase idle speed THRO
99. specified time DTC B1024 The voltage measured at driver air bag initiator circuit is below a specified value for specified time DTC B1025 The voltage measured at driver air bag initiator circuit is above a specified value for specified time TABLE TEST DESCRIPTION DTC B1021 B1022 B1024 and B1025 STEP 1 Check whether malfunction is in contact coil and driver air bag inflator module or the others STEP 2 Check driver air bag inflator module initiator circuit STEP 3 Check whether malfunction is in contact coil or driver air bag inflator module DIAGNOSTIC FLOW TABLE DTC B1021 DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH AIR BAG SYSTEM 10B 29 Step Action Yes No 1 1 With ignition switch OFF disconnect contact coil con nector G62 located near the base of the steering column 2 Check proper connection to contact coil at terminals in connect coil connector G62 3 If OK then connect special tools B and C to contact coil connector G62 With ignition switch ON does DTC B1021 still exist Go to step 2 Go to step 3 2 1 With ignition switch OFF disconnect SDM connector Substitute a known Repair high resis Q60 good SDM and tance or open in 2 Check proper connection to SDM at terminals Q60 9 recheck GRN or GRN RED and Q60 10 wire circuit 3 If OK release shorting bar in SDM connector insert ing
100. this DTC is set INSPECTION Perform procedure described in Procedure After ECM Replacement in this section DTC82 P1622 Fault in ECM DESCRIPTION This DTC is set when an internal fault is detected in ECM INSPECTION Step Action Yes No 1 1 Ignition switch OFP Substitute a known good ECM and Repair or replace 2 Disconnect connectors from ECM recheck 3 Check for proper connection to ECM See NOTE at all terminals Are they in good condition NOTE After replacing with a known good ECM register ECM Immobilizer Control Module code in ECM by performing procedure described in Procedure After ECM Replacement in this section 8G 26 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED DTC22 Ignition Switch Circuit Open Short 1 Main fuse 2 Ignition switch 3 1 Immobilizer Control Module Vehicle not equipped with air bag system 3 2 Immobilizer Control Module Vehicle equipped with air bag system DESCRIPTION Immobilizer Control Module monitors ignition signal when the ignition switch is ON This DTC is set when no ignition signal input is detected by Immobilizer Control Module INSPECTION Step Action Yes No 1 Check voltage between Immobilizer Con lt Vehicle without air bag system gt B W wire open or trol Module coupler terminal shown below and body ground with ignition switch turned ON See Fig 1 e Terminal for vehicle
101. to ECT sensor in Section 6E Brake light switch circuit faulty Repair or replace ECM faulty Inspect ECM Vehicle does not move at any range Manual valve faulty Clean or replace Primary regulator valve faulty Clean or replace AUTOMATIC TRANSMISSION 4 A T 7B 19 Condition Possible Cause Correction ist 2nd Shift solenoid A No 1 and or B No 2 Clean or replace stuck g g Signal valve faulty Clean or replace 2nd 3rd Shift solenoid A No 1 C No 3 and or fail Clean or replace 3 valve No 1 stuck 3rd 4th Shift solenoid A No 1 D No 4 and or fail Clean or replace valve No 2 stuck P N gt R Rear clutch accumulator faulty Clean or replace IN gt D 1st amp 2nd brake accumulator faulty Clean or replace 1st 2nd at D Rear clutch accumulator faulty Clean or replace range or 2 range Si 2nd 3rd at D Front clutch accumulator faulty Clean or replace 2 range o 3rd 4th at D Overdrive brake accumulator faulty Clean or replace range All gear change Primary regulator valve faulty Clean or replace Excessive slip Primary regulator valve faulty Clean or replace low line pressure Vehicle does not move at 1st and 3rd gear Front clutch faulty Repair or replace Reverse gear Reverse brake faulty Repair or replace 2nd 3rd 4th and reverse gear Rear clutch faulty Repair or
102. to Ground DTC B1025 Driver Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM 6 Q60 G62 weve ly 5 GRN RED K5 o i iTo 1 GRN a l S 1 BLK BLU 1 From main fuse 4 SDM 7 Ground for air bag system 2 Ignition switch 5 Contact coil assembly A Shorting bar 3 AIR BAG fuse 6 Driver air bag inflator module CAUTION e Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to flow table e When measurement of resistance or voltage is required in this table use a specified digital multim eter described in Special Tool in this section along with a correct terminal adapter from special tool Connector test adapter kit es When a check for proper connection is required refer to Intermittent and Poor Connections in this section e If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC WILL SET WHEN DTC B1021 The combined resistance of the driver air bag inflator module contact coil assembly harness wiring and con nector terminal contact is above a specified value for specified time DTC B1022 The combined resistance of the driver air bag inflator module contact coil assembly harness wiring and con nector terminal contact is below a specified value for
103. tool 09932 76020 e E These connector are spare connector for adaptor cable 09932 78320 10B 76 AIR BAG SYSTEM Prepared by SUZUKI MOTOR CORPORATION 1st Ed January 2002 Printed in Japan Printing January 2002 XXXX
104. tool A 09925 98210 3 Install flywheel 1 to crankshaft and tighten bolts 2 applied with sealant at thread part to specification Special tool A 09924 17810 A Sealant 99000 31110 Tightening torque Flywheel bolts a 76 N m 7 6 kg m 55 0 lb ft 7C 12 CLUTCH 4 Using special tool install clutch disc and clutch cover 1 Tighten clutch cover bolts 2 to specification using special tool Special tool A 09923 36320 B 09924 17810 Tightening torque Clutch cover bolts a 23 N m 2 3 kg m 17 0 lb ft 5 Slightly apply grease to input shaft Then join transmission with engine Refer to Remounting of Section 7A A Grease 99000 25210 NOTE Turn crankshaft with wrench from front while inserting transmission input shaft to clutch disc until splines mesh CLUTCH 7C 13 Tightening Torque Specification Be sure to torque each nut or bolt if loosened to specification given below If specified tightening torque for par ticular bolt or nut is not included here refer to Section OA of this manual o Tightening torque Fastening part CS kom bt Flywheel bolts 76 7 6 55 0 Clutch cover bolts 23 2 3 17 0 Clutch release fork support 29 2 9 21 0 Required Service Material Material Recommended SUZUKI product Use Part Number Lithium grease SUZUKI SUPER GREASE A e Cable junctio
105. until adhesive is completely set e Each adhesive has its own setting time Be sure to refer to its maker s instruction check set ting time of adhesive to be used and observe precau tions to be taken before adhesive is set e Refrain from driving till adhesive is completely set so as to ensure proper and sufficient adhesion Quarter Window REMOVAL AND INSTALLATION Refer to Windshield section as removal and installation proce dures are basically the same However note the following NOTE e Observe following precautions when applying adhe sive 4 along glass edge Adhesive should be applied evenly especially in height Be careful not to damage primer 5 Press glass 2 against body quickly after adhesive is applied Adhesive amount specification and position for quarter window Height b 15 mm 0 59 in Width d 15 mm 0 59 in Width c 6 mm 0 23 in Distance e 17 mm 0 67 in for glass lower section and rear section Distance e 12 mm 0 47 in for glass upper section Distance e 14 mm 0 55 in for glass front section 1 Pin 3 Double face tape 9 12 BODY SERVICE Back Door Glass REMOVAL 1 2 3 Remover rear wiper arm Disconnect rear defogger coupler As rear window shield is fixed by means of back door window weatherstrip 1 remove glass 2 and weatherstrip together by removing end of weatherstrip l
106. value replace oil pump assembly Radial clearance between oil pump gear tooth and oil pump body Standard 0 13 0 20 mm 0 0051 0 0079 in Limit 0 30 mm 0 018 in 1 Pump body crescent portion 4 Check side clearance of both gears Using a straightedge and a feeler gauge measure side clearance between gear and pump body If clearance exceeds its standard value replace oil pump assembly Side clearance between gear and oil pump body Standard 0 02 0 04 mm 0 0008 0 0019 in 1 Straightedge Press it down while measuring 7B 88 AUTOMATIC TRANSMISSION 4 A T ASSEMBLY 1 Install pump body oil seal 1 Use special tool and hammer to install it and then apply grease to its lip portion Special tool A 09913 85210 A Grease 99000 25030 2 Install driven gear and drive gear to pump body 2 after applying A T fluid to gears 3 Install stator shaft assembly to pump body and tighten 11 pump cover bolts to specification Tightening torque Oil pump cover bolts a 10 N m 1 0 kg m 7 5 Ib ft 4 Install 2 new oil seal rings to stator shaft 5 Apply grease to 2 oil seal rings 6 Install D ring applied with grease and make sure that it is not twisted or extruded 7 Check drive gear for smooth rotation Front clutch C1 clutch AUTOMATIC TRANSMISSION 4 A T 7B 89 Front clutch No 1 drum 7 Clu
107. warning lamp come ON 2 Does AIR BAG warning lamp Proceed to AIR BAG Go to step 3 come ON steady Warning Lamp Comes On Steady in this section 3 Does AIR BAG warning lamp Proceed to AIR BAG Go to step 4 keep flashing indicating DTC Warning Lamp Flashes when ignition switch is ON in this section 4 Does AIR BAG warning lamp turn Go to step 5 Go to step 8 OFF after flashing 6 times 5 Do you have SUZUKI scan tool Go to step 6 Go to step 7 6 1 Check DTC referring to Using Air bag system is in good An intermittent trouble has occurred at SUZUKI Scan Tool under condition some place DTC Check in this section Check the connector harness etc Is NO CODES displayed on related to the sensed DTC SUZUKI scan tool Refer to Intermittent and Poor Con nections in this section Then clear DTC referring to DTC Clearance in this section and repeat this table 7 1 Check DTC referring to Not Air bag system is in good An intermittent trouble has occurred at Using SUZUKI Scan Tool condition some place under DTC Check in this sec Check the connector harness etc tion related to the sensed DTC Is flashing pattern No 12 indicated Refer to Intermittent and Poor Con on AIR BAG warning lamp nections in this section Then clear DTC referring to DTC Clearance in this section and repeat this table 8 Do you have SUZUKI scan tool Go to st
108. when measuring spring height e Perform measurement at several points Evidence of extreme heat or burning in the area of clutch may have caused springs to take a heat set and would require their replacement 7B 86 AUTOMATIC TRANSMISSION 4 A T Disassembly of Subassembly CAUTION Keep component parts in group for each subassembly and avoid mixing them up Clean all parts with cleaning solvent thoroughly and air dry them Use kerosene or automatic transmission fluid as cleaning solvent Do not use wiping cloths or rags to clean or dry parts All oil passages should be blown out and checked to make sure that they are not obstructed Keep face and eyes away from solvent spray while air blowing parts Check mating surface for irregularities and remove them if any and clean it again Soak new clutch discs and brake discs in transmission fluid for at least 2 hours before assembly Replace all gaskets and O rings with new ones Apply automatic transmission fluid to all O rings When installing seal ring be careful so that it is not expanded excessively extruded or caught Replace oil seals that are removed and apply grease to their lips Before installing be sure to apply automatic transmission fluid to sliding rolling and thrusting sur face of all component part Also after installation make sure to check each part for proper opera tion Always use torque wrench when tightening bolts Oil pump 3
109. with alcohol or the like to remove oil 9 8 BODY SERVICE 11 When reusing windshield remove the adhesive 1 from the windshield using care not to damage primer coated surface 2 INSTALLATION 1 N ed Using cleaning solvent clean windshield edge where wind shield glass is to be adhered Let it dry for more than 10 minutes Install new glass stoppers 1 2pcs to lower side of wind shield To determine installing position of glass 2 to body 3 posi tion glass against body so that clearance between upper end of glass and body is about 5 mm 0 197 in and clearances between each side end right amp left of glass and body are even Place glass so that lug of fastener is matched with cut in body and fit fastener Then mark mating marks 1 on glass and body as shown Upper clearance can be adjusted by moving stoppers posi tion Windshield clearance a Approx 5 mm 0 197 in 4 Molding 4 Clean contact surfaces of old adhesive 4 paint or bare metal thoroughly If surfaces of paint or bare metal come out apply primer 2 for body with caution not to apply primer to surface of adhe sive remaining on body NOTE e Be sure to refer to primer maker s instruction for proper handling and drying time e Do not touch body and old adhesive surfaces where glass is to be adhered 1 Do not apply primer 3 Ap
110. without air bag system G38 1 e Terminal for vehicle with air bag sys tem G38 3 Is it 10 14V Poor G38 1 terminal connection lt Vehicle with air bag system gt Poor G38 3 terminal connection If connection is OK substitute a known good Immobilizer Control Mod ule and recheck See NOTE short NOTE After replacing with a know good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM and Transponder code and ECM Immobilizer Control Module code in Immobi lizer Control Module by performing procedure described in Procedure After Immobilizer Control Mod ule Replacement in this section IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 27 Fig 1 for step 1 1 2 Ale G38 3 1 1 Immobilizer Control Module Vehicle not equipped with air bag system 1 2 Immobilizer Control Module Vehicle equipped with air bag system 8G 28 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED DTC23 No ECM Immobilizer Control Module Code Transmitted From ECM or DLC Circuit Opened Shorted DTC83 P1621 No ECM Immobilizer Control Module Code Transmitted From Immobilizer Control Module or DLC Circuit Opened Shorted 1 1 Immobilizer Control Module Vehicle not equipped with air bag system 1 2 Immobilizer Control Module Vehicle equipped with air bag system 2 ECM A To data link connector DLC
111. 0 A Fig for STEP 1 C Fig for STEP 3 E For DTC B1047 B Fig for STEP 2 and 3 D For DTC B1043 Special tool A 09932 76010 B 09932 75010 C 09932 78310 D 09932 78340 NOTE Upon completion of inspection and repair work perform the following items es Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected 10B 44 AIR BAG SYSTEM DTC B1044 DRIVER PRETENSIONER INITIATOR CIRCUIT TO POWER CIRCUIT DTC B1048 PASSENGER PRETENSIONER INITIATOR CIRCUIT TO POWER CIRCUIT Step Action Yes No P 1 With ignition switch OFF remove quarter lower trim of applicable side 2 Disconnect connector Q08 or Q10 con nector from seat belt pretensioner 3 Check proper connection to applicable seat belt pretensioner at terminals in Q08 or Q10 connector 4 If OK then connect special tools A B and C to Q08 or Q10 connector With ignition switch ON does DTC B1044 or B1048 still exist Go to step 2 Ignition switch OFF and replace seat belt pretensioner referring Front Seat Belt in Section 10 1 With ignition switch OFF disconnect special tools A B and C from Q
112. 0 C 09932 78340 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected DTC B1032 Power Source Voltage Low WIRING DIAGRAM AIR BAG SYSTEM 10B 35 1 From main fuse 3 AIR BAG fuse 5 Ground for air bag system 2 Ignition switch 4 SDM CAUTION e Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to flow table e When measurement of resistance or voltage is required in this table use a specified digital multim eter described in Special Tool in this section along with a correct terminal adapter from special tool Connector test adapter kit e When a check for proper connection is required refer to Intermittent and Poor Connections in this section e If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC WILL SET WHEN The power source voltage is below specified value for specified time TABLE TEST DESCRIPTION STEP 1 Check if voltage on battery is within normal range STEP 2 Check
113. 0 37 80 h h 962 37 87 b e 117 4 61 h i 1066 41 97 b e 649 25 55 h i 268 10 55 c c 515 20 28 i 1106 43 54 d d 780 30 71 i j 727 28 62 d e 1022 40 24 i k 676 26 61 d e 482 18 98 i e 978 38 50 e e 1040 40 94 j i 1014 39 92 e f 225 8 86 k 1233 48 54 e g 347 13 66 j 452 17 80 e i 1181 46 50 l i 1454 57 24 f e 889 35 00 1 7 1064 41 90 Body Dimensions BODY SERVICE 9 19 a Garnish installation clip hole dd Front fender installation hole KEES Headlight installation hole b b Front fender installation hole e Hood cushion installation hole h Front bumper installation clip hole c c Front fender installation hole f f Headlight installation resin nut hole ets 1st mounting installation hole Measurement Dimension Measurement Length Measurement Length Position mm in Position mm in a b 660 25 98 c 1222 48 11 a c 664 26 14 d b 1166 45 90 a d 833 32 80 d d 1393 54 84 a 890 35 04 f f 1266 49 84 a h 837 32 95 f h 661 26 02 a e 667 26 26 g 9g 654 25 75 b b 1266 49 84 g h 351 13 82 b d 681 26 81 i i 850 33 46 9 20 BODY SERVICE a Garnish installation clip hole d Parking brake rear installation hole g g Rear seat belt upper installation hole b b Front en
114. 0 Ib ft Gear shift rear arm bolt f 34 N m 3 4 kg m 24 5 Ib ft e When installing propeller shaft s refer to Propeller Shafts in Section 4B e When installing exhaust No 1 pipe refer to Component in Section 6K e After connecting clutch cable adjust clutch pedal free travel refer to Maintenance Service in Section 7C 1 Gear shift knob 10 Gear shift lever case 2 Gear shift lever 11 Gear shift rear shaft 3 Gear shift lever boot No 1 12 Extension rod 4 Gear shift lever boot No 2 13 Rear mounting bracket 5 Gear shift lever boot No 3 14 Gear shift case mounting bracket 6 Gear shift lever boot cover 15 Engine rear mounting 7 Gear shift lever plate 16 Oil seal 8 Gear shift lever plate bolt 17 Boot 9 Gear control select bolt 18 Gear shift rear arm bolt MANUAL TRANSMISSION 7A 7 Unit Repair Overhaul Dismounting Unit 1 Disconnect negative cable at battery 2 Remove shift lever and rear gear shift control assembly refer to Rear Gear Shift Control Removal in this section 3 Disconnect back up lamp switch lead wire at coupler respec tively 4 Remove starting motor from transmission case refer to Starting Motor of Section 6G 1 Back up lamp switch 5 Remove clutch housing cap 1 and disconnect clutch cable 4 from clutch release fork 3 2 Clutch cable nut 6 Remove clutch ca
115. 08 or Q10 connector 2 Disconnect connector Q07 or Q09 from air bag wire harness in floor harness 3 Check proper connection to air bag wire harness at terminals in Q07 or Q09 con nector 4 If OK then connect special tools B and D to Q07 or Q09 connector With ignition switch ON does DTC B1044 or B1048 still exist Go to step 3 Repair short YEL or YEL RED wire circuit to power circuit 1 With ignition switch OFF disconnect special tools A and D from seat belt pretensioner wire harness connector Q07 or Q09 2 Disconnect SDM connector Q60 from SDM 3 Measure voltage e DTC B1044 between Q60 11 terminal and body ground and between Q60 12 terminal and body ground e DTC B1048 between Q60 5 terminal and body ground and between Q60 6 terminal and body ground With ignition switch ON is voltage 1 V or less Substitute a known good SDM and recheck DTC B1044 Repair short WHT or PNK wire circuit to power circuit DTC B1048 Repair short from BRN or LT GRN wire circuit to power circuit AIR BAG SYSTEM 10B 45 A Q08 or Q10 A Fig for STEP 1 C Fig for STEP 3 E For DTC B1048 B Fig for STEP 2 and 3 D For DTC B1044 Special tool A 09932 76010 B 09932 75010 C 09932 78310
116. 1 See figure 2 1 Turn ignition switch OFF and discon Short in between shield portion Go to Step 3 nect TCM couplers or B Or wire and ground 2 Measure resistance between terminal E22 13 of the disconnected harness side coupler and body ground Is it about 0 Q See figure 7B 34 AUTOMATIC TRANSMISSION 4 A T Step Action Yes No Are they OK See figure 2 Check input shaft speed sensor and out put shaft speed sensor referring to each item in this section e Broken wire in shield portion or broken B Or wire or shorted to power source cir cuit e Malfunction of A T itself clutch slipping etc If all the above are in good con dition substitute a known good TCM and recheck Inspect and replace referring to each item in this section A IO A Fig for Step 1 B Fig for Step 2 C Fig for Step 3 1 Output shaft speed sensor 2 Input shaft speed sensor AUTOMATIC TRANSMISSION 4 A T 7B 35 DTC P0753 DTC No 21 22 Shift Solenoid A No 1 Electrical DTC P0758 DTC No 23 24 Shift Solenoid B No 2 Electrical DTC P0763 DTC No 43 44 Shift Solenoid C No 3 Electrical DTC P0768 DTC No 45 46 Shift Solenoid D No 4 Electrical DTC P0743 DTC No 25 26 TCC Lock Up Clutch Circuit Electrical Di E21 26 RIG SES 2 E21 25 Y G RA 3 E21 24 W SS
117. 1 with 3 grooves in synchronizer sleeve 2 on main shaft respectively 6 Tighten case bolts to specification Tightening torque Transmission case bolts 23 N m 2 3 kg m 17 0 Ib ft Extension case 1 Check knock pins 1 are fitted 2 Install extension case seal 2 so that end surface of oil seal becomes flush with that case Apply grease to extension case seal lip Grease 99000 25010 Special tool A 09913 85210 3 Clean surface of extension case to mate with transmission case and uniformly apply sealant A Sealant 99000 31110 4 Make sure that 3 shift shafts are in neutral position 5 Install extension case 1 to transmission case 6 Tighten case bolts to specification Tightening torque Extension case bolts a 23 N m 2 3 kg m 17 0 Ib ft 7A 28 MANUAL TRANSMISSION 7 Install select guide pins low select return spring and reverse select return springs outer and inner 8 Apply thread lock to thread of select return spring bolt And tighten select return spring bolt to extension case to specified torque Tightening torque Select return spring bolts a 23 N m 2 3 kg m 17 0 Ib ft A Cement 99000 32110 Input shaft bearing retainer 1 Install new oil seal 1 with special tool and hammer up to case surface apply grease to oil seal lip Special tool A 09951 16080 A Grease 99000 25010 2 Clean surface of retainer 2 t
118. 3 Air gun 10 Attach special tool D to dial gauge 2 and set them on the lowest clutch plate Special tool D 09952 06010 Measure piston stroke by blowing compressed air 4 kg cm 56 9 psi as shown in figure If the piston stroke is out of specification use clutch flange of dif ferent thickness to match the piston stroke to specification Fol lowing 7 types of clutch flanges are available as spare parts Front clutch piston stroke 0 95 1 20 mm 0 037 0 047 in Available clutch flange thickness 2 750 mm 0 108 in 2 875 mm 0 113 in 3 000 mm 0 118 in 3 125 mm 0 123 in 3 250 mm 0 128 in 3 375 mm 0 133 in 3 500 mm 0 138 in 1 Front clutch assembly 3 Air gun 7B 94 AUTOMATIC TRANSMISSION 4 A T Rear clutch C2 clutch 1 Input shaft oil seal ring 8 Clutch plate CH Apply grease 99000 25030 to all over surface 2 Input shaft subassembly 9 Clutch disc AGH 3 D ring 10 Clutch flange Apply grease 99000 25030 to all over surface SC 4 Rear clutch piston 11 Snap ring Apply grease 99000 25030 to the lip of the piston 5 Rear clutch return spring seat e Apply automatic transmission fluid 6 Rear clutch balancer x lt Do not reuse 7 Shaft snap ring DISASSEMBLY 1 Remove snap ring 2 Remove flange 1 discs and plates AUTOMATIC TRANSMISSION 4 A T 7B 95 3 Remove shaft snap ring
119. 32 76010 09932 78310 Spare connector Connector test adapter Adapter cable See NOTE E set See NOTE D AIR BAG SYSTEM 10B 75 09932 78320 Adapter cable d Ah Ki Ki Kh Ge Z E CC e 09932 78332 Adapter cable 09932 78340 Adapter cable Mass storage cartridge for Tech 1A Digital multimeter See NOTE B and WARNING Tech 2 kit SUZUKI scan tool See NOTE C WARNING Be sure to use the specified digital multimeter Otherwise air bag inflator module deployment or per sonal injury may result NOTE e A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter e B Digital multimeter specification Maximum test current is 10 mA or less at minimum range of resistance measurement e C This kit includes the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector 11 Storage case 12 Power supply e D This set includes the following items 1 Connector test adapter kit 09932 75020 2 Connector test adapter amp shorting bar release
120. 4 21 23 BIY GEET 5 E21 22 P BI Kg E21 15 B Se 1 Shift solenoid A No 1 4 Shift solenoid D No 4 7 Terminal arrangement of TCM coupler viewed from harness side 2 Shift solenoid B No 2 5 TCC lock up solenoid 3 Shift solenoid C No 3 6 TCM DTC DETECTING CONDITION e Solenoid output voltage is too high although TCM orders solenoid to turn OFF e Solenoid output voltage is too low although TCM orders solenoid to turn ON Step Action Yes No 1 1 Turn ignition switch OFF and disconnect Go to Step 2 e Solenoid lead wire solenoid coupler open or shorted to 2 Measure the resistance between each sole ground noid terminal of the solenoid side coupler e Malfunction of solenoid and transmission ground Is it 11 15 Q See figure 2 is DTC No 22 24 44 46 or 26 Go to Step 4 Go to Step 3 2 Is DTC No 21 23 43 45 or 25 Go to Step 6 Go to Step 5 When DTC is P0753 P0758 P0763 P0768 or P0743 7B 36 AUTOMATIC TRANSMISSION 4 A T between terminal E21 26 E21 25 E21 24 E21 23 or E21 22 of the disconnected har ness side TCM coupler and body ground Is it about 0 V nal E21 26 E21 25 E21 24 E21 23 or E21 22 of TCM If all the above are in good condition substitute a known good TCM and recheck Step Action Yes No 4 1 Disconnect TCM couple
121. 73 e For seat belt pretensioner Remove seat belt referring to Front Seat Belt with Preten sioner in Section 10 25 Temporarily store undeployed air bag inflator module and or unactivated seat belt pretensioner referring to Service Precautions in this section 26 Contact your local distributor for further assistance Deployed Air Bag Inflator Module and Acti vated Seat Belt Pretensioner Disposal WARNING Failure to follow proper air bag inflator module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury The undeployed air bag inflator module and the inactivated seat belt pretensioner must not be disposed of through normal refuse channels The undeployed air bag inflator module and the inacti vated seat belt pretensioner contains substances that can cause severe illness or personal injury if the sealed container is damaged during disposal Deployed air bag inflator module and the activated seat belt pre tensioner can be disposed of through normal refuse channels just like any other parts For their disposal however the following points should be noted e The air bag inflator module and the seat belt pretensioner immediately after deployment activation is very hot Wait for 30 minutes to cool it off before handling it Never apply water oil etc to deployed air bag inflator module and the activate
122. 9925 18011 12 Install 3rd gear bearing 3rd gear 2 high speed synchro nizer ring hub 3 and sleeve 1 When installing hub direct the side with larger outer diameter boss to 3rd gear side Then fit circlip 4 into groove in main shaft 13 When installing bearing 1 bring it so that its groove for C ring is in the rear and press fit with special tool and hydraulic press Special tool A 09925 18011 2 Input shaft MANUAL TRANSMISSION 7A 23 14 After fitting circlip 1 air blow lubrication oil hole 2 15 Install synchronizer ring 3 needle bearing and input shaft 1 2 Main shaft 4 Bearing 5 3rd gear Countershaft and reverse idle gear 1 Press fit front bearing 1 and fit circlip Special tool A 09913 84510 2 Countershaft 2 With shaft inserted into case install center bearing 1 on it and then press fit shaft by using special tool and hammer Meanwhile case should be supported on wood blocks Special tool A 09925 18011 2 Countershaft 7A 24 MANUAL TRANSMISSION 3 Press fit reverse gear 1 and then 5th gear 2 NOTE When press fitting hold countershaft with its front end set on wood blocks Special tool A 09913 80113 3 Lower case 4 After press fitting countershaft rear bearing 1 make sure to fit circlip securely NOTE When pr
123. CK LOCK Terminal M1 M2 8 38 BODY ELECTRICAL SYSTEM Power Door Lock System with Keyless Entry System If Equipped Power door lock system with keyless entry system component location 7 Transmitter 4 UNLOCK position 5 Front door actuator 6 Back door actuator 1 Power door lock controller 2 Driver side door knob switch 3 LOCK position 8 Door switch System Description The keyless entry system has the following signal modes in order to feed back the signal when the controller received LOCK and UNLOCK signals from transmitter Received signal LOCK signal UNLOCK signal Signal mode Hazard warning light signal The hazard warning lights flash once The hazard warning lights flash twice and mode the interior light turns on about 15 seconds The interior light turns on about 15 seconds The interior light flashes twice Interior light signal mode NOTE e These signal modes are able to change referring to Change of Signal Mode in this section e The initial condition is the hazard warning light signal mode BODY ELECTRICAL SYSTEM 8 39 Change of signal mode 1 Confirm that all doors are closed and ignition key is out of ignition switch 2 Perform the following procedures within 15 seconds a Insert ignition key to ignition switch and pull out ignition key from ignition switch b Repeat step a
124. CM memory DTC No 12 is outputted repeatedly If no DTC is stored in TCM memory they are outputted start ing from smallest code number in increasing order After all DTCs are outputted all DTCs are outputted repeat edly Be sure to read Precautions for Electrical Circuit Service in Section OA before inspection and observe what is written there When replacing TCM with used one learning control mem ory in TCM should be initialized after the replacement refer ring to Learning Control Memory Initialization in this section 4 Data link connector DLC AUTOMATIC TRANSMISSION 4 A T 7B 25 Diagnostic Trouble Code s Check Check DTC with SUZUKI scan tool 1 Turn ignition switch OFF 2 After setting cartridge to connect SUZUKI scan tool to data link connector DLC 1 located on underside of instrument panel at driver s seat side Special tool A SUZUKI scan tool 3 Turn ignition switch ON 4 Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down Refer to SUZUKI scan tool operators manual for further details 5 After completing the check turn ignition switch OFF and dis connect SUZUKI scan tool from data link connector DLC Check DTC without SUZUKI scan tool 1 Turn ignition switch ON and make sure that O D OFF light is OFF in combination meter O D off switch OFF 2 Turn ignition swit
125. CUIT RESISTANCE HIGH DTC B1045 PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH cial tools A B and C from Q08 or Q10 connector 2 Disconnect connector Q07 or Q09 from air bag wire harness in floor harness 3 Check proper connection to air bag wire harness at terminals in Q07 or Q09 connector 4 If OK then connect special tools B and D to Q07 or Q09 connector With ignition switch ON does DTC B1041 or B1045 still exist Step Action Yes No 1 1 With ignition switch OFF remove quarter Go to step 2 Ignition switch OFF and lower trim of applicable side replace seat belt preten 2 Disconnect connector Q08 or Q10 con sioner referring Front Seat nector from seat belt pretensioner Belt in Section 10 3 Check proper connection to applicable seat belt pretensioner at terminals in Q08 or Q10 connector 4 If OK then connect special tools A B and C to Q08 or Q10 connector With ignition switch ON does DTC B1041 or B1045 still exist 2 1 With ignition switch OFF disconnect spe Go to step 3 Repair high resistance or open in YEL or YEL RED wire circuit AIR BAG SYSTEM 10B 39 Step Action Yes No 3 1 With ignition switch OFF disconnect SDM Substitute a known DTC B1041 connector Q60 good SDM and recheck Repai
126. F Engine speed input circuit DTC P0725 Inputted engine rev signal is too low or too high e Engine rev is processed as 4000 rpm e No compensation or judgement for gear shift control for which engine rev is considered is processed e Lock up function is turned OFF Engine coolant temp signal circuit DTC P1709 O D off signal from ECM require O D off although A T fluid temp is normal oper ating temp and engine rev is stan dard O D off signal from ECM is not used even though engine cool ant temperature is low Throttle position signal circuit DTC P1700 No or abnormal throt tle opening signal is inputted e Scheduling of automatic gear shift is performed as throttle valve opening is 0 e Control of automatic gear shift i e control of oil pressure is performed as throttle valve opening is 100 e Coast down shifting is performed when brake is applied and engine rev is less than 1 500 rpm e Lock up function is turned OFF 7B 12 AUTOMATIC TRANSMISSION 4 A T Automatic gear shift diagram Automatic shift schedule as a result of shift control is shown below Shift Throttle opening 1 2 253 3 4 453 3 gt 2 2 gt 1 Full throttle 36 85 127 118 74 30 22 53 73 46 19 Closed throttle 16 30 43 38 13 13 10 19 27 24 8 8 Gear Shift Diagram A and TCC lock up diagram B A fe E S Upshift en
127. G warning lamp Q60 12 High Q60 3 Q60 13 E Q60 4 Ignition switch power source Q60 14 Data link connector DLC Q60 5 Passenger pretensioner High Q60 15 Diagnosis switch Q60 6 Low Q60 16 Q60 7 Passenger air bag inflator High Q60 17 Ground Q60 8 module Low Q60 18 Q60 9 Driver air bag inflator Low Q60 19 Q60 10 module High Q60 20 Diagnosis WARNING Diagnostic Trouble Code DTC The Air Bag Diagnostic System Check must always be the starting point of any air bag system diagnosis The Air Bag Diagnostic System Check checks for proper AIR BAG warning lamp operation and checks for air bag diagnostic trouble codes using on board diagnosis function or SUZUKI scan tool Use of Special Tool WARNING To avoid deployment when troubleshooting the air bag system do not use electrical test equipment such as a battery powered or AC powered voltmeter ohmmeter etc or any type of electrical equip ment other than that specified in this manual Do not use a non powered probe type tester Instructions in this manual must be followed carefully otherwise personal injury may result You should be familiar with the tools listed in this section under the heading Special Tool You should be able to measure voltage and resistance You should be familiar with proper use of a scan tool such as Air Bag Driver Passenger Load Tool Adapter cable Connector Test Adapter Kit and the Digital Multimeter
128. Go to Step 8 P B or Gr R wire open Poor coil antenna to coupler 8 1 If connections are OK connect Immo bilizer Control Module coupler and substitute a known good coil antenna 2 Is DTC 13 also indicated with ignition switch turned ON Go to Step 9 Faulty coil antenna 9 Is DTC 18 still indicated even when another ignition key with built in tran sponder for that vehicle used Substitute a known good Immobilizer Con trol Module and recheck See NOTE Faulty transponder NOTE After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM and Transponder code and ECM Immobilizer Control Module code in Immobi lizer Control Module by performing procedure described in Procedure After Immobilizer Control Mod ule Replacement in this section A Fig 1 for step 1 B Fig 2 for step 2 C Fig 3 for step 3 A j Ignition key with built in transponder C 8G 24 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED D Fig 4 for step 4 E Fig 5 for step 5 F Fig 6 for step 6 Vehicle Equipped with Air Bag System Step Action Yes No 1 Check that knob shape and color for igni Substitute a known Replace ignition key with original tion key are as shown below good Immobilizer Con one and follow Diagnostic Flow e Knob color Dark gray tro
129. If water or rust is mixed in drained oil be sure to check boot of transmission Transmission oil API GL 4 For SAE classification refer to viscosity chart in the fig ure Transmission oil capacity 1 3 liters 2 75 2 29 US Imp pt 4 Torque drain plug 2 and level filler plug 1 as specified below after applying sealant to its thread CAUTION Transmission oil must not be poured through gear shift control lever part A Sealant 99000 31110 Tightening torque Transmission oil filler and drain plugs a 23 N m 2 3 kg m 17 0 Ib ft 7A 4 MANUAL TRANSMISSION Rear Gear Shift Control 1 Gear shift knob 5 Gear shift lever boot No 3 9 Gear control select bolt 13 Gear shift control seat spring 2 Gear shift lever 6 Gear shift lever boot cover 10 Gear shift lever case 3 Gear shift lever boot No 1 7 Gear shift lever plate 11 Gear shift rear shaft 4 Gear shift lever boot No 2 8 Gear shift control lower seat 12 Extension rod REMOVAL 1 Remove shift knob and remove center console box with shift lever boot No 3 2 Pull out shift lever boot No 2 3 and remove shift lever boot cover 1 and shift lever boot No 1 2 MANUAL TRANSMISSION 7A 5 3 Remove 3 bolts and then remove shift lever case plate shim spring and shift lever 4 Hoist vehicle and drain transmission oil 5 Remove exhaust No 1 pipe refer
130. LL and LOW on dipstick 1 Apply parking brake securely and place chocks against wheels N Remove fluid pressure check hole plug bolt 1 Attach oil pressure gauge to fluid pressure check hole in transmission case Wal lt Special tool A 09925 37810 CAUTION After attaching oil pressure gauge check that no fluid leakage exists 4 Depress foot brake fully run engine at idle and stall then check fluid pressure in D or R range CAUTION Do not continue running engine at stall speed longer than 5 seconds Automatic transmission line pressure D range R range At idle speed 8 2 9 6 kg cm 13 0 16 0 kg cm 116 6 136 5 psi 184 9 227 5 psi At stall speed 8 2 9 6 kg cm 13 0 16 0 kg cm 116 6 136 5 psi 184 9 227 5 psi Troubleshooting Test result Possible cause Line pressure higher e Malfunctioning regulator valve than standard level in each range Line pressure lower than standard level in each rang Malfunctioning regulator valve Defective oil pump Line pressure lower than standard level only in D range Fluid leakage from D range pres sure circuit Fluid leakage from 1st amp 2nd brake Fluid leakage from front clutch Line pressure lower than standard level only in R range Fluid leakage from R range pres sure circuit Fluid leakage from
131. M is not rigidly attached to the vehicle Otherwise personal injury may result CAUTION After detecting one time of such collision as to meet deployment conditions the SDM must not be used Refer to Air Bag Diagnostic System Check in this section when checking the SDM Never attempt disassembly of SDM When storing SDM select a place where neither high tem perature nor high humidity is anticipated and oil water and dust are kept off If SDM was dropped from a height of 90 cm 3 ft or more or if it is found to be damaged or deformed replace it with a new one If installation part of SDM was damaged repair that part completely before reinstallation All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointed toward the front of the vehicle to ensure proper operation of the air bag system AIR BAG SYSTEM 10B 51 LIVE UNDEPLOYED AIR BAG INFLATOR MODULES Special care is necessary when handling and storing a live unde ployed air bag inflator modules The rapid gas generation produced during deployment of the air bag could cause the air bag inflator module or an object in front of the air bag inflator module to be thrown through the air in the unlikely event of an accidental deployment WARNING Never attempt to measure the resistance of the air bag inflator modules driver and passenger It is very dan gerous as the electric current f
132. MANUAL TRANSMISSION 7A 1 SECTION 7A MANUAL TRANSMISSION CONTENTS General Description ccscccssseeeesseeeeesseees 7A 2 Assembling Um 7A 19 On Vehicle Service ssccececeeeeeeteeeees 7A 3 Main shaft and input eat 7A 19 Maintenance Service 7A 3 Countershaft and reverse idle gear 7A 23 Oleh ange anaiai eenia i 7A 3 Shift shafts and iorke 7A 25 Rear Gear Shift Control 7A 4 Transmission lower case and upper e e 7A 26 Man Repair vere Oe ne ge ee a at TA Extension Case 7A 27 Dismounting Unit Sage geen TA 7 Input shaft bearing retainer 7A 28 Remounting Unit EE 7A 8 Clutch release bearing sccssssessseeeeees 7A 28 Disassembling Unit dE 7A 9 Input shaft eecceeeeessseessteeeseeeaeeeees 7A 29 Geh gear Shift comte sesseeeseeeesseeees a Front gear shift Control 7A 29 Dresden Nee Torque Specifications 7A 20 Countershaft eieiei reenen 7A 11 Required Service Matertal 7A 31 Input shaft and main bat 7A 12 Special Tool eieegeeesgreege gie cacvesscesseasseasece 7A 32 Shift shafts and forks 0 cecceeeeeeeeeeee 7TA 14 7A 2 MANUAL TRANSMISSION General Description Not 2 el LC CHEN 15 11 6 27 Eas erty Cal lea L KA Gn ag d IC h E ant A 26 IN ama i a FER z an aa aina Gem CS ul IT de a ee AH CN Sg A oie T SECH et TT PP yt A e
133. MMOBILIZER CONTROL SYSTEM IF EQUIPPED High 0 5 0 5 0 5 0 5 gt TIME sec 0 5 lt Vehicle not equipped with immobilizer indicator lamp gt With the diagnosis switch terminal of monitor coupler for ECM not grounded the ignition switch turned ON but the engine at stop and regardless of the condition of the electronic fuel injection sys tem ECM indicates whether a trouble has occurred in the immo bilizer control system or not by causing the malfunction indicator lamp to flash or turn ON Malfunction indicator lamp is ON No trouble exists in the immobilizer control system Malfunction indicator lamp is flashing ECM or Immobilizer Control Module has detected some trouble in the immobilizer control system NOTE As soon as the ignition switch is turned ON ECM and Immobilizer Control Module diagnose if a trouble has occurred in the immobilizer control system While the diagnosis is being made the malfunction indicator lamp stays ON and if the diagnosis result is abnormal 2 it immediately changes to flashing but if the result if nor mal 1 it remains ON Diagnosis takes about 3 seconds at maximum Ignition switch ON High Low 1 0 5 0 5 0 5 0 5 gt TIME sec 0 5 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 7 lt Vehicle equipped with immobilizer indicator lamp gt With the ignition switch turned ON but the engine at stop
134. Make sure to install each ball on main shaft 1 High speed synchronizer hub 9 Ball 2 High speed synchronizer sleeve 10 Reverse gear 3 3rd gear 11 5th speed synchronizer hub 4 2nd gear 12 5th speed synchronizer sleeve 5 Low speed synchronizer hub 13 5th gear 6 Low speed synchronizer sleeve 14 5th gear washer 7 Low gear 15 Circlip 8 Washer 16 Main shaft 1 Fit sleeve 2 to low speed hub 1 place 3 synchronizer keys 4 in it and set synchronizer springs 3 Refer to figure for proper installing direction of hub sleeve and springs Synchronizer key has no specific direction for installation NOTE When installing each synchronizer spring insert its hooked end to hub hole and put it toward right A Thick 2nd gear side B Thin Low gear side C Punch mark Low gear side 2 Install needle bearing 2nd gear and 2nd synchronizer ring to main shaft 1 3 Press fit hub and sleeve assembly onto main shaft with press Special tool A 09927 08210 2 Low speed sleeve and hub assembly 7A 20 MANUAL TRANSMISSION 4 Install low gear bush needle bearing synchronizer ring low gear ball 3 and washer onto main shaft Fit ball into hole in shaft and install washer so that its slot 1 comes over ball To direct washer correctly bring its circumference cham fered side 2 to main shaft center bearin
135. NUAL TRANSMISSION 7A 17 Shift Forks and Sleeves Check contact surfaces for wear or damage Measure clearance between fork and sleeve Clearance a between fork and sleeve Service limit 1 0 mm 0 039 in 1 Thickness gauge 3 Sleeve 2 Shift fork Main Shaft Check each part of shaft for wear discoloration or damage Replace shaft if any part is found defective Bearings and Bushes Check each part for wear damage or discoloration With ball bearing check that it rotates smoothly and it does not make noise Replace if found defective Input Shaft Inspect cone 1 and toothed ring 2 for wear and damage Inspect gear teeth 3 and splines 4 for wear and damage If any part of input shaft inspected as above is found excessively worn or badly damaged replace shaft 7A 18 MANUAL TRANSMISSION K our i TORS DUV ITNI WEE Combination of Gear and Synchronizer Ring Check clearance a between synchronizer ring and gear key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring and gear Standard 1 0 1 4 mm 0 039 0 055 in Service limit 0 5 mm 0 019 in Key slot width b Standard 10 1 mm 0 397 in Service limit 10 4 mm 0 409 in Inspect external cone of gear
136. No 21 21 deck Mr ECM Immobilizer Con trol Module code 22 22 Ignition switch circuit 23 23 Serial data link circuit NOTE The DTC with asterisk in DTC column is for vehicle equipped with air bag system ECM IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 15 To learn how to read diagnostic trouble code DTC from flashing of malfunction indicator lamp refer to Diag nostic Trouble Code Table in Section 6 DTC indicated cane Malfunction Indicator lamp indicated by f DIAGNOSTIC AREA DIAGNOSIS on Suzuki MIL MIL flashing pattern scan tool This code appears when it is confirmed that none of other NO DTC 12 e iN Normal VONDE COFES ae for immobilizer con trol system or engine and emission control system P1623 81 II ECM Immobilizer Control Module code Diagnose trouble P1620 84 UUL II II II H according to Diag nostic Flow Table P1622 82 III III ECM corresponding to each code No P1621 83 Serial data link wire 8G 16 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Table A DTC is Not Output From Diagnostic Output Terminal For Vehicle Not Equipped with Air Bag System 2 1 Main fuse 4 Immobilizer diagnostic coupler 5 ToECM Vehicle not equipped with immobilizer indicator lamp 2 Main relay 4 1 Ground terminal A In cabin 3 Immobilizer Control Module 4 2 Diagnostic output term
137. On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM Diagnostic Trouble Code s Clearance 7B 27 Diagnostic Trouble Code DTC Table 7B 28 TCM Power and Ground Circuit Check 7B 30 DTC P0715 DTC No 14 Input Turbine Speed Sensor Circuit ceeeeeeeeeeees 7B 31 DTC P0730 DTC No 18 Incorrect Gear Ee EE EE 7B 33 DTC P0753 DTC No 21 22 Shift Solenoid A No 1 Electrical cc8 7B 35 CONTENTS General Description ccccccseseecceeseeseseeeees 7B 3 DTC P0758 DTC No 23 24 Shift Electronic Shift Control System 7B 6 Solenoid B No 2 Electrical ssseeeeeseeeeee 7B 35 Transmission Control Module TCM 7B 7 DTC P0763 DTC No 43 44 Shift Throttle position seet 7B 8 Solenoid C No 3 Electrical 7B 35 Output shaft speed eme 7B 8 DTC P0768 DTC No 45 46 Shift Input shaft speed sengt 7B 8 Solenoid D No 4 Electrical Transmissi
138. PECTION 1 Remove mirror switch from instrument panel 2 Check continuity at each switch position by using a circuit test If any continuity is not obtained replace mirror switch L d g a b c R e f UP O oto O DOWN O O O O LEFT O O ra ote d RIGHT O O O O p besad We GIS S Door mirror actuator INSPECTION 1 Remove front door inner garnish from front door 2 Disconnect door mirror coupler 3 Check that door mirror operates properly when battery volt age is applied to connector terminals Connect battery positive and negative terminal to the door mirror terminal shown below If it does not follow the table s operation replace door mirror assembly Terminal gt COM M1 M2 Operation Up Down L ER E CK d CH Left Right BID VOD WO NOTE When installing door mirror to door be careful not to pinch harness between door and door mirror 8 44 BODY ELECTRICAL SYSTEM o e cy Door Mirror Heater If Equipped Mirror heater switch INSPECTION Door mirror heater is operated by rear defogger switch Check rear defogger switch referring to Rear Defogger Switch in this section Mirror heater if equipped INSPECTION 1 Remove door inner garnish from front door 2 Disconnect door mirror coupler 1 and door mi
139. R W Br Y Passing ef Low Beam CC Main High Beam O O Terminal RF B2 M Switch Position Br Y WwW R Y OFF 5005 Gen mee y Fo Fo REMOVAL AND INSTALLATION Refer to Combination Switch Contact Coil and Combination Switch Assembly in Section 3C for details 8 12 BODY ELECTRICAL SYSTEM Headlight REMOVAL 1 Disconnect negative cable at battery 2 Remove front bumper 3 Remove headlight mounting bolts 1 4 Detach headlight assembly from vehicle 5 Disconnect couplers 2 from headlight assembly 6 Remove headlight assembly 3 INSTALLATION Reverse removal procedure for installation Bulb replacement WARNING e To avoid danger of being burned don t touch when the bulb is hot e Don t touch glass surface of bulb to avoid deteriorate as the case may be unclear when bulb light on at dirty condition 1 Disconnect negative cable at battery Disconnect harness from bulb N Remove socket cover and bulb 1 LA lt 2 Spring 4 Replace bulb and assemble all removed parts BODY ELECTRICAL SYSTEM 8 13 Headlight aiming adjustment with screen NOTE e Unless otherwise obligated by local regulations adjust headlight aiming according to following procedure e After replacing headlight be sure to adjust aiming 1 Before adjustment make sure the following a Place vehicle on a flat surface
140. RANSFER 15 Install bearing to input shaft by using bearing puller and hydraulic press NOTE Fit bearing puller at inner race of bearing 16 Assemble ring gear 2 and sprocket gear 1 and secure them with circlip 3 17 Fit needle roller bearing 1 to output shaft 18 Install input shaft 1 sprocket gear assembly 3 and drive chain 2 to front case as an assembly 19 Install speedometer sensor rotor 1 to output shaft TRANSFER 7D 21 20 Install bearing to rear case by using special tool and press and fix it with circlip Special tool A 09913 75810 B 09944 66020 21 By using special tool and hammer install oil seal 1 to rear case Apply grease to oil seal lip NOTE Refer to figure for oil seal installation position Special tool A 09913 75810 A Grease 99000 25010 Transfer rear case oil seal installing position a 69 35 0 5 mm 2 730 0 020 in 2 Bearing 3 Circlip 22 After cleaning mating surfaces of both cases coat mating surface of front case with sealant evenly and put it over rear case A Sealant 99000 31110 23 Align front case and rear case then install flange tighten flange nut 1 and calk it Special tool A 09930 40113 Tightening torque Flange nut a 130 N m 13 0 kg m 94 0 Ib ft 7D 22 TRANSFER
141. RN e DTC B1046 between Q60 5 and Q60 6 wire circuit to LT GRN terminals wire circuit or from BRN Is resistance 1 4 Q or more or LT GRN wire circuit to other wire circuit AIR BAG SYSTEM 10B 41 A Q08 or Q10 A Fig for STEP 1 C Fig for STEP 3 E For DTC B1046 B Fig for STEP 2 and 3 D For DTC B1042 Special tool A 09932 76010 B 09932 75010 C 09932 78310 D 09932 78340 NOTE Upon completion of inspection and repair work perform the following items es Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected 10B 42 AIR BAG SYSTEM DTC B1043 DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND DTC B1047 PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND Step Action Yes No P 1 With ignition switch OFF remove quarter lower trim of applicable side 2 Disconnect connector Q08 or Q10 con nector from seat belt pretensioner 3 Check proper connection to applicable seat belt pretensioner at terminals in Q08 or Q10 connector 4 If OK then connect special tools A B and C to Q08 or Q10 connector With igniti
142. Refer to Propeller Shafts in Section 4B for procedure 3 Remove extension case 2 oil seal 1 by using screwdriver or like 4 Install new extension case oil seal by using special tool NOTE For oil seal installation press fit oil seal so that transmis sion case end face is flush with oil seal end face Special tool A 09913 75520 5 Install propeller shafts referring to Propeller shafts in Sec tion 4B 6 Refill A T fluid referring to Maintenance Service in this sec tion Transmission Control Module TCM CAUTION TCM and ECM consist of highly precise parts so when handling it or them be careful not to expose to exces sive shock REMOVAL Remove ECM and separate TCM from ECM bracket Refer to Electronic Control System in Section 6E for ECM removal 7B 72 AUTOMATIC TRANSMISSION 4 A T INSTALLATION Reverse removal procedure noting the following e Connect ECM and TCM couplers securely e If the vehicle is equipped with air bag system be sure to enable air bag system after TCM and ECM are back in place Refer to Enabling Air Bag System in Section 10B Learning Control Memory Initialization Initialization of learning control memory in TCM should be made upon replacement of parts as explained below Automatic transmission assembly replacement with new or used one Any A T brake component parts replacement such as discs plates and fl
143. Step 6 End AUTOMATIC TRANSMISSION 4 A T 7B 15 1 CUSTOMER COMPLAINT ANALYSIS Record details of the problem failure complaint and how it occurred as described by the customer For this purpose use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis CUSTOMER QUESTIONNAIRE EXAMPLE User name Moe vN Date of issue Date of problem Mileage DESCRIPTION OF PROBLEM Engine does not start Engine stops Vehicle does not move Transmission does not shift forward rearward 1st 2nd 3rd 4th Rev gear No lock up TCC clutch operation Automatic shift does not occur Shift point too high or too low Transmission slipping in 1st 2nd 3rd 4th Rev gear Excessive gear change shock VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition fair cloudy rain snow always other hot warm cool cold C always always sometimes times day month only once urban suburb highway mountainous uphill downhill tarmacadam gravel other Vehicle Condition P R N D 2 L range z cold warming up phase warmed up at stop during driving constant speed accelerating decelerating right hand Weather Temperature Frequency Road Transmission range Transmission temp Vehicle range corner left hand corner oth
144. TRICAL SYSTEM Keyless entry system circuit inspection NOTE If keyless entry system is in interior light signal mode change to hazard warning light signal mode referring to Change of Signal Mode in this section Check that the voltage and continuity between the following termi nals and body ground are specifications under each conditions If check result is not as specified check applicable circuit If circuit is normal recheck keyless entry system circuit as follows 1 Substitute a known good door lock controller 2 Register key code referring to Code Registration Procedure under Transmitter in this section 3 Recheck keyless entry system circuit D oD lt oi 1 Door lock controller Keyless entry system circuit check Terminal Wire Circuit Specification Condition 10 14V Ignition key is in igniti itch G10 2 BLU GRN Key remainder circuit gn z 2y i m e ia ae a 0 1V Ignition key is not in ignition Driver side passenger side rear 0 1V driver side rear passenger side or back door is open 10 14V All doors are close Gi0 4 BLK RED UO Switch amp interior light Fulfill the following conditions circuit e All door is close Figure A s anh light switch is middle posi e 15 seconds after pushing UNLOCK button on transmitter Figure B Push LOCK button on transmi
145. TTLE POSITION Throttle opening ratio computed by duty pulse signal from ECM COOLANT TEMPERATURE Signal from ECM whether engine coolant temperature is more than 50 C 122 F or not A C SIGNAL ON Signal which inform that air conditioner compressor is turned ON OFF Signal which inform that air conditioner compressor is not turned ON BRAKE SWITCH Input signal from brake light switch on pedal bracket ON Brake pedal depressed OFF Brake pedal released 7B 56 AUTOMATIC TRANSMISSION 4 A T Inspection of TCM and Its Circuits TCM and its circuits can be checked at TCM wiring couplers by measuring voltage and resistance CAUTION TCM cannot be checked by itself it is strictly prohibited to connect voltmeter or ohmmeter to TCM with coupler disconnected from it VOLTAGE CHECK 1 Remove TCM 1 from vehicle referring to Transmission Control Module Removal in this section 2 Connect TCM couplers 2 to TCM 3 Check voltage at each terminal of couplers connected NOTE As each terminal voltage is affected by the battery volt age confirm that it is 11 V or more when ignition switch is ON 3 Body ground Terminal arrangement of TCM coupler Viewed from harness side AUTOMATIC TRANSMISSION 4 A T 7B 57
146. The front windshield is installed by using a special type of adhesive that is one component urethane adhesive used with primer For the Windshield replacement it is important to use an adhesive which provides sufficient adhesion strength and the follow the proper procedure 1 Windshield glass 3 Stopper e Do not reuse 2 Windshield molding 4 Spacer CAUTION e Described in this section is the glass replacement by using 3 types of primers and 1 type of adhe sive made by YOKOHAMA one component urethane adhesive to be used with primer in combina tion When using primer and adhesive made by other manufacturers be sure to refer to handling instructions supplied with them Negligence in following such procedure or misuse of the adhesive in any way hinders its inherent adhesive property Therefore before the work make sure to read carefully the instruction and description given by the maker of the adhesive to be used and be sure to follow the procedure and observe each precaution throughout the work e Should coated surface be scratched or otherwise damaged be sure to repair damaged part or cor rosion may start from there Use an adhesive of above mentioned type which has following property Glass adhesive shearing strength 40 kg cm 569 Ib in2 or more Adhesive materials and tools required for removal and installation One component urethane adhesive and primers used in combination For one shee
147. adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector 11 Storage case 12 Power supply Required Service Material Recommended SUZUKI product Material SS Part Number ES Automatic transmission fluid An equivalent of DEXRON IIE or e Automatic transmission DEXRONR III e Parts lubrication when installing Lithium grease SUZUKI SUPER GREASE C e Retaining parts in place when 99000 25030 assembling e Oil seal lips e Oil pump D ring SUZUKI SUPER GREASE A e Rod ends 99000 25010 e Converter center cup CLUTCH 7C 1 SECTION 7C CLUTCH CONTENTS General Description cccsssseeeeeeeseeeseeeeees 7C 2 Unit Repair Overhaul cs seeceeeeseeeeeeees 7C 7 RE Jl DC 7C 3 Clutch Cover Clutch Disc Flywheel and On Vehicle Service EVERE 7C 4 Release Bearing EEN 7C 7 Maintenance Service 7C 4 Tightening Torque Specification 70 13 Clutch pedal heat 7C 4 Required Service Material csssss 7C 13 Clutch pedal free travel teens 7C 4 Special TOO lassi raudonos nitaenda 7C 13 Clutch cable routmg 7C 5 Clutch Cable 7C 6 7C 2 CLUTCH General Description The clutch is a diaphragm spring clutch of a dry single disc type The diaphragm spring is of a taperingfinger type which is a solid ring in the outer diameter part with a series of tapering fingers pointing inward
148. after disassembly prepare replacing parts and proceed to reas sembly according to procedures as described below CAUTION e Drive bevel gear and pinion must be replaced as a set when either replacement becomes necessary e When replacing taper roller bearing replace as inner race and outer race assembly FRONT DIFFERENTIAL 7E 11 Drive Bevel Pinion Bearing Outer Race CAUTION Perform press fitting carefully so as not to tilt outer race Install drive bevel pinion bearing outer races using special tools as shown Special tool A 09913 75510 B 09913 75520 1 Differential carrier Differential Case Assembly 1 Assemble differential case assembly 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 A Right side B Left side Right side e Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surface of gear 2 e Using 2 screwdrivers 1 move gear 2 up and down and read movement of dial gauge pointer Left side e Using similar procedure to the above set dial gauge tip to gear shoulder e Move gear 2 up and down by hand and read dial gauge 3 If thrust play is out of specification select suitable side washer from among the following available size install it a
149. age is too low although TCM orders solenoid to turn on When select lever is P R N D or 2 range A T power relay is turned OFF and gear is fixed as follows P range gt P R range gt R N range gt N D 2 range gt 3rd When select lever is L range gear is fixed to pre pro grammed gear position of several patterns as follows Malfunction of No 1 solenoid 2nd or 3rd Malfunction of No 2 solenoid 1st or 3rd Malfunction of No 3 solenoid 3rd Malfunction of No 4 solenoid 3rd Malfunction of 2 or more solenoids gt 3rd Lock up function is turned OFF A T hardware itself DTC P0730 Difference in detected revolution between input shaft speed sensor and output shaft speed sensor is too wide p range P R range gt R N range gt N D 2 L range gt To be controlled as follows 1 When detecting trouble at first gear is selected well suited gear calculated with parameters of each sensor s rev num ber and gear position just when the trouble occurred Lock up function is turned OFF If A T can transmit driving force under the above condition gear is fixed the selected gear until ignition switch is turned OFF If A T can not transmit driving force under the above condi tion after once vehicle stop gear which can transmit drive force is searched one by one until
150. aining the 5th speed synchronizer hub 3 on main shaft 7 Remove 5th speed synchronizer hub reverse gear 2 and reverse gear needle bearing NOTE During this removal watch out for a ball which may fall off It must not be lost Also ball bearing should not be removed together with washer and bush 8 Remove bearing washer and reverse gear bush 2 on main shaft by using hydraulic press 1 NOTE In the state as shown there is a ball in washer which is located under bearing Be sure to prevent it from falling off and getting lost 9 Remove ball and main shaft center bearing by using hydraulic press 1 7A 14 MANUAL TRANSMISSION 10 Remove bearing washer ball low gear low synchronizer ring needle bearing and low gear bush 2 on main shaft 11 Remove low speed synchronizer sleeve and hub assembly 2nd gear and 2nd synchronizer ring all together by using hydraulic press 1 NOTE If bush can t be pulled out by hand pull off sleeve and hub together by using press 12 Remove sleeve from hub and then take off synchronizer keys and springs Shift shafts and forks 1 Pull out reverse gear shift shaft 1 As this shaft comes out locating ball and spring will jump out of hole do not let them fly away CAUTION When removing yoke pin be sure not to drive it out so far as to contact case Or it will cause damage to case 2 Using special tool drive
151. air bag inflator module attaching bolts 2 and passenger air bag inflator module 1 from vehicle 10B 60 AIR BAG SYSTEM INSPECTION WARNING Never measure resistance of passenger air bag inflator module or disassemble it Otherwise personal injury may result CAUTION If air bag Inflator module was dropped from a height or 90 cm 3 ft or more it should be replaced Check air bag inflator module appearance visually for the follow ing symptoms and if any one of them is applicable replace with a new one e Air bag has deployed e There is a crack in trim cover pad surface e Wire harness or connector is damaged e Air bag inflator module is damaged or a strong impact was applied to it INSTALLATION 1 Install passenger air bag inflator module 1 to instrument panel 2 2 Tighten passenger air bag inflator module attaching bolts to specified torque Tightening torque Passenger air bag inflator module mounting bolt a 23 N m 2 3 kg m 16 5 Ib ft 3 Connect negative cable to battery 4 Enable air bag system Refer to Enabling Air Bag System in this section Driver Air Bag Inflator Module Refer to Driver Air Bag Inflator Module in Section 3C for removal inspection and installation Contact Coil and Combination Switch Assem bly Refer to Contact Coil and Combination Switch Assembly in Sec tion 3C for remova
152. al G and it negative terminal to wiper bracket 1 2 Check wiper motor rotates at specified speed below If check result is out of specification replace Specification 35 45 r min rpm Automatic stop operation 1 Connect battery positive terminal to terminal G and bat tery terminal to wiper bracket 1 and let the motor turn 2 Disconnect terminal G from battery and let the motor stop 3 Connect terminal BI to battery positive terminal Observe the wiper motor turns once again then stops ata original stop position 4 Repeat Step 1 to 3 several times and inspect if the motor stops at the original stop condition every time If check result is not satisfied replace BODY ELECTRICAL SYSTEM 8 31 Rear wiper intermittent relay INSPECTION 1 Disconnect negative cable from battery 2 Remove rear wiper intermittent relay 1 from vehicle 2 Circuit fuse box 3 Check INT circuit as follows a Connect battery positive terminal to h terminal and battery negative terminal to e terminal b Check that voltage between b terminal and e terminal changes from 0 V to battery voltage when connecting bat tery positive terminal to g terminal If check result is not satisfied replace relay c Connect battery positive terminal to c terminal d Check that voltage
153. all 1 to pass shaft over it and keep inserting shaft until locating ball fits in center slot of 3 continuous slots in shaft Drive shift yoke pin into fork and shaft Special tool A 09922 85811 2 Shift shaft 7A 26 MANUAL TRANSMISSION 4 Install interlock ball and locating ball in upper case After installing interlock roller in high speed gear shift shaft and insert shaft into upper case as described in 2 and 3 Fork 2 should installed in such direction as shown Then drive shift yoke pin 1 until it becomes flush with outer sur face of fork 5 Install interlock ball and locating ball into upper case Then insert reverse gear shift shaft into upper case as described in 2 and 3 Transmission lower case and upper case 1 With countershaft assembly reverse idle gear and reverse gear shaft installed in lower case check that bearing stopper rings 1 are fitted in both sides of lower case as shown Also check for 2 knock pins 2 2 Make sure that mating surfaces of both lower and upper cases are clean 3 Install main shaft and input shaft assembly 1 in lower case 2 LN mE Ee Dh MANUAL TRANSMISSION 7A 27 4 Uniformly apply sealant to mating surface of lower case A Sealant 99000 31110 5 Install upper case to lower case by matching 3 shift forks
154. and NOTE If bearing cap does not fit tightly on carrier side bearing adjuster is not threaded properly Reinstall adjuster 5 Tighten bearing cap bolts to provisional torque Tightening torque Bearing cap bolts a 15 N m 1 5 kg m 11 0 Ib ft 6 Tighten both differential side bearing adjusters 1 so as to obtain specified gear backlash and at the same time obtain preload of differential side bearing Special tool A 09930 40120 B 09930 40113 C 09900 20701 D 09900 20607 Bevel gear backlash 0 10 0 20 mm 0 0039 0 0078 in NOTE e Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth e Measure at least 4 points on drive bevel gear periph ery e As a practical measure following would be recom mended to obtain specified backlash and differential side bearing preload at the same time To increase or decrease backlash for adjustment displace drive bevel gear toward or away from drive bevel pinion by running in one adjuster and running out the other adjuster by equal amount Tighten both adjusters further by one notch ata time 7E 20 FRONT DIFFERENTIAL 7 Measure composite preload of drive bevel pinion bearings and differential side bearings with torque wrench 1 or spring balance 2 8 Calculate preload of differential side bearings by using the following equation Preload of differ f P
155. and connectors for damage or tight ness Check contact coil case for damage If any faulty condition is found in above checks replace e SDM and SDM plate Check for external damage such as deformation scratch crack peeled paint etc Check that SDM cannot be installed properly due to a cause in itself There is a gap between SDM and SDM plate or it cannot be fixed securely Check that connector or lead wire of SDM has a scorching melting or damage Check that connector is connected securely or locked Check SDM connector and terminals for tightness Check SDM sets a diagnostic trouble code referring to DTC Check in this section and the diagnostic table leads to a malfunctioning SDM If any faulty condition is found in above checks replace e Instrument panel member and reinforcement Check for any distortion bending cracking or other dam age If any faulty condition is found in above checks replace e Passenger air bag inflator module Check for dents cracks damage or fitness Check trim cover for cracks or deformities Check harness and connector for damage or tightness If any faulty condition is found in above checks replace AIR BAG SYSTEM 10B 57 e Air bag wire harness and connections Check for damages deformities or poor connections refer ring to Intermittents and Poor Connections in this section Check wire harness c
156. and its level is between FULL and LOW marks CAUTION es Do not run engine at stall more than 5 seconds contin uously for fluid temperature may rise excessively high After performing stall test be sure to leave engine run ning at idle for longer than 30 seconds before another stall test AOUN x xw H Wu Apply parking brake and block wheels Install tachometer Start engine with select lever shifted to P Depress brake pedal fully Shift select lever to D and depress accelerator pedal fully while watching tachometer Read engine rpm quickly when it has become constant stall speed 6 Release accelerator pedal immediately after stall speed is checked 7 In the same way check stall speed in R range 8 Stall speed should be within following specification Engine stall speed Standard 2 550 2 850 rpm Troubleshooting Test result Possible cause Lower than e Lack of engine output standard level e Defective torque converter Higher than e Malfunctioning 1st amp 2nd brake standard level e Malfunctioning rear clutch in D range e Malfunctioning stator one way clutch Higher than e Low line pressure standard level e Malfunctioning front clutch in R range e Malfunctioning reverse brake e Malfunctioning stator one way clutch AUTOMATIC TRANSMISSION 4 A T 7B 21 Time Lag Test This test is to check conditions of clutch re
157. ange with new or used one s Any A T clutch component parts replacement such as discs plates and flange with new or used one s Replacement of TCM with used one Turn ignition switch to ON position Do not start engine NI Bring diagnosis switch terminal 2 of monitor coupler 1 in contact with ground terminal 3 using service wire 3 Repeat shifting selector lever from D to 2 position and vice versa for 3 times within 10 seconds to complete mem ory initialization 4 Confirm initialization by DTC set in system referring to DTC Check in this section DTC No 12 completion of initialization is confirmed DTC No 52 initialization is failed 5 If you failed initialization repeat steps 1 to 3 NOTE e O D OFF lamp continues to turn on while initializa tion e DTCs which might have been set in system other than No 12 and 52 are also erased by initialization Interlock Cable if equipped NOTE Don t bend interlock cable excessively when removing and installing it or system will not operate correctly REMOVAL 1 Disconnect negative cable at battery and disable air bag sys tem referring to Disabling Air Bag System in Section 10B 2 Remove steering upper and lower cover AUTOMATIC TRANSMISSION 4 A T 7B 73 3 Remove interlock cable 1 clamp screw 2 located at igni tion switch and disconnect interlock cable fr
158. ar the base of the steering col umn as it was Remove driver air bag inflator module from steering wheel referring to Driver Air Bag Inflator Module in Section 3C Check proper connection to driver air bag inflator module at terminals in G70 con nector 4 If OK then connect special tools B and C to G70 connector With ignition switch ON does DTC B1022 still exist 3 Ignition switch OFF Replace contact coil assembly referring to Combination Switch Contact Coil and Combi nation Switch Assembly in Section 3C Ignition switch OFF Replace driver air bag inflator module referring to Driver Air Bag Inflator Module in Section 3C AIR BAG SYSTEM 10B 31 B A Fig for STEP 1 and 2 B Fig for STEP 2 C Fig for STEP 3 Special tool A 09932 76010 B 09932 75010 C 09932 78340 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected 10B 32 AIR BAG SYSTEM DTC B1024 DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND Step Action Yes No 1 1 With ignition switch OFF disconnect conta
159. ase cam 2 moves smoothly by operating knob button 1 of selector lever 8 With selector lever set at P position turn ignition key to ACC position and then check for following conditions With knob button released ignition key can be turned from ACC position to LOCK position With knob button pressed ignition key cannot be turned from ACC position to LOCK position 9 Install steering upper and lower cover 10 Connect negative cable at battery and enable air bag sys tem referring to Enabling Air Bag System in Section 10B 1 Detent pin position when knob button is pressed at P position AUTOMATIC TRANSMISSION 4 A T 7B 75 Unit Repair Overhaul 1 Transmission case 6 Extension case 11 Planetary gear assembly 16 C2 Rear clutch assembly 2 Valve body assembly 7 B2 reverse brake piston assembly 12 BO O D brake piston assembly 17 C1 front clutch assembly 3 Oil strainer 8 B2 brake assembly 13 BO brake assembly 18 Torque converter housing 4 A T oil pan 9 B1 1st amp 2nd brake piston assembly 14 Front planetary sun gear 19 Oil pump assembly 5 Output shaft 10 B1 brake assembly 15 Intermediate shaft 20 Torque converter NOTE When transmission is replaced or when any A T clutch or brake component parts such as discs plates and flange are replaced with new or used one s learning control memory of TCM should
160. at belt pretensioner connectors 3 Confirm that each air bag inflator module and seat belt pre tensioner is securely mounted A Driver air bag inflator module B Passenger air bag inflator module C Seat belt pretensioner 10B 70 AIR BAG SYSTEM 5 Check that there is no open short or damage in special tools deployment harness A and adapter cable B If any faulty condition is found do not use it and be sure to use new deployment harness A and or adapter cable B And con nect adapter cable B to deployment harness A and lock connectors with lock slider 2 A Special tool A 09932 75031 B 09932 78332 6 Short two deployment harness leads 1 together by fully seating one banana plug into the other WARNING Deployment harness A shall remain shorted and not be A connected to 12 volts vehicle battery until you are ready to deploy air bag inflator module or activate seat belt pretensioner 7 Connect adapter cable B in series with deployment har ness A to air bag inflator module or seat belt pretensioner as follows For air bag inflator module Connect adapter cable B in series with deployment har ness A and push adapter cable B connector to air bag inflator module connector driver passenger or side of driver and passenger till click can be heard 1 For seat belt pretensioner Connect adapter cable B in series with deploy
161. at belt pretensioner on the work bench or other surface be sure not to lay it with its exhaust hole 1 provided side facing down It is also prohibited to put something on its face with an exhaust hole 1 or to put a seat belt pretensioner on top of another Otherwise personal injury may result 6 Set air bag inflator module or seat belt pretensioner as fol lows 10B 64 AIR BAG SYSTEM e For driver air bag inflator module a Clear space 3 on ground about 185 cm 6 ft in diameter where driver air bag inflator module 1 for deployment Paved outdoor location where there is no activity is pre ferred If outdoor location is not available space on shop floor where there is no activity and provide sufficient venti lation Ensure no loose or flammable objects are within deployment area b Place driver air bag inflator module 1 with its vinyl trim cover facing up 2 on ground in step a e For passenger air bag inflator module a Clear space 3 on ground about 185 cm 6 ft in diameter where passenger air bag inflator module 1 for deploy ment Paved outdoor location where there is no activity is preferred If outdoor location is not available space on shop floor where there is no activity and provide sufficient ventilation Ensure no loose or flammable objects are within deployment area b Place deployment fixture A on ground in step a Special tool A 09932 75041 c Fill plastic
162. bag inflator module or seat belt pretensioner as soon as possible This will prevent adapter cable special tool from damage due to possible contact with hot air bag inflator module or hot seat belt pretensioner 19 Check adapter cable connector as follows For air bag inflator module Air bag inflator module connector of adapter cable special tool are designed to be reused However they should be inspected for damage after deployment Replace it with new adapter cable special tool if necessary e For seat belt pretentioner Seat belt pretensioner connector of adapter cable special tool should be inspected for damage when seat belt preten sioner is activated Replace it with spare connector special tool if necessary NOTE Do not reuse faulty seat belt pretensioner connector of adapter cable special tool because it can be destroyed by shock when seat belt pretensioner is activated 20 Dispose of deployed air bag inflator module 1 or activated seat belt pretensioner 2 through normal refuse channels after it has cooled for at least 30 minutes and tightly seal air bag inflator module 1 or seat belt pretensioner 2 in strong vinyl bag Refer to Deployed Air Bag Inflator Mod ule and Activated Seat Belt Pretensioner Disposal in detail 21 Wash your hands with mild soap and water afterward NOTE Remaining steps are to be followed in the unlikely event that air bag inflator module did no
163. be clean and free of any foreign material which could impede proper terminal contact However cleaning the terminal with a sand paper or the like is prohibited Damaged connector body exposing the terminals to mois ture and dirt as well as not maintaining proper terminal ori entation with the component or mating connector Improperly formed or damaged terminals Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal included in the connector test adapter kit special tool If contact tension is not enough reform it to increase contact tension or replace Special tool A 09932 76010 Connector Test Adapter Kit Poor terminal to wire connection Check each wire harness in problem circuits for poor con nection by shaking it by hand lightly If any abnormal condi tion is found change the wire harness assembly or component parts with new ones Wire insulation which is rubbed through causing an intermit tent short as the bare area touches other wiring or parts of the vehicle Wire broken inside the insulation This condition could cause a continuity check to show a good circuit but if only 1 or 2 strands of a multi strand type wire are intact resistance could be far too high If any abnormality is found repair or replace as a wire harness assembly AIR BAG SYSTEM 10B 9 Air Bag Diagnostic System Check WARNING To avoid deployment
164. be initialized after those replacement referring to Learning Control Memory Initialization in this section 7B 76 AUTOMATIC TRANSMISSION 4 A T Unit Dismounting NOTE If automatic transmission is overhauled later on draining A T fluid at this point will facilitate work 1 Remove following parts Propeller shafts No 1 and No 2 refer to Propeller shafts in Section 4B Exhaust pipe refer to Component in Section 6K Negative cable from battery 2 Disconnect couplers 2 couplers from wire harness and 1 from shift switch 3 Remove selector rod 1 from shift control shaft lever 2 by removing pin 3 4 Remove oil cooler hoses from pipes NOTE To avoid leakage of transmission fluid plug open ends of oil cooler pipes and hoses right after they are discon nected 5 Remove torque converter housing lower plate 6 Remove drive plate bolts To lock drive plate engage a flat screwdriver 1 with drive plate gear 2 Wrench 7 Remove starting motor 8 With transmission held up on jack remove engine to trans mission bolts and nuts 9 Remove transmission rear mounting bracket 1 10 Move transmission to the rear a little and lower it including torque converter WARNING Be sure to keep transmission horizontal throughout the work Should it be tilted torque converter may fall off and cause personal injury and A T fluid may flow out
165. bench with a slit 1 or use the workbench vise 2 to hold it securely at its lower mounting bracket 3 It is also prohibited to place anything on top of the trim cover and stack air bag inflator modules This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of acci dental deployment Otherwise personal injury may result LIVE INACTIVATED SEAT BELT PRETENSIONER Special care is necessary when handling and storing a live inac tivated seat belt pretensioners Also when the seat belt pretensioners activate gas is generated and the seat belt is retracted into the retractor assembly quickly Note therefore that if they activate accidentally the seat belt pre tensioners and other object s around them may be thrown through the air WARNING Never attempt to measure the resistance of the seat belt pretensioners It is very dangerous as the electric current from the tester may activate pretensioner e Never attempt to disassemble the seat belt pretensioners retractor assembly e If any abnormality is found be sure to replace it with new one as an assembly When an abnormality is noted as existing in the live inacti vated seat belt pretensioner be sure to activate it before discarding it When grease cleaning agent oil water etc got on the seat belt pretensioners retractor assembly wipe it off imme
166. between b terminal If check result is not satisfied replace relay Voltage between b and e High ke Low gt 6 10 sec N Disconnect battery positive terminal from c terminals 1 Rear wiper intermittent relay 8 32 BODY ELECTRICAL SYSTEM 4 Check WIPER AND WASH circuit as follows a Connect battery positive terminal to h terminal and battery negative terminal to e terminal b Check that voltage between b terminal and e terminal changes as below figure when connecting battery positive terminal from q If check result is not satisfied replace relay Voltage between b and e High ke Low 6 10 sec Ee Disconnect battery positive terminal from c terminals c Check that voltage between b terminal and e terminal changes as below figure when disconnecting battery posi tive terminal from d If check result is not satisfied replace relay Voltage between b and e High Low 2 7 4 6 sec oe Disconnect battery positive terminal from d terminal 1 Rear wiper intermittent relay ill AJ T P ES m tw M Cc a a DA i eg a d PU PD BODY ELECTRICAL SYSTEM 8 33 Power
167. ble bracket 2 and clutch housing lower plate 1 from transmission case 7 Remove bolts and nuts fastening engine cylinder block and transmission case and separate transmission from engine 8 Take down transmission 9 Remove clutch cover disc and flywheel referring to Clutch Cover Clutch Disc Flywheel and Release Bearing in Sec tion 7C 7A 8 MANUAL TRANSMISSION Remounting Unit For remounting reverse dismounting procedure When installing flywheel clutch cover and disc refer to Clutch Cover Clutch Disc Flywheel and Release Bearing in Section 7C Use specified torques as given below Tightening torque Transmission to engine bolts and nut a 94 N m 9 4 kg m 68 0 Ib ft For tightening torques not mentioned above refer to Tight ening Torque Specification at the end of this section Connecting clutch cable refer to Maintenance Service in Section 7C in this manual for details When installing starting motor refer to Starting Motor in Section 6G When installing rear gear shift control assembly and shift lever refer to Rear Gear Shift Control in this section Pour transmission oil according to Maintenance Service in this section Disassembling Unit MANUAL TRANSMISSION 7A 9 1 Input shaft 15 3rd gear 30 Rear bearing 45 Washer 2 Input shaft bearing 16 3rd gear needle bearing
168. cate the cause of the trou ble namely in a sensor switch wire harness connector actuator TCM or other part and repair or replace faulty parts 10 CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur e g wire harness connector etc referring to Inter mittent and Poor Connection in Section OA and related circuit of DTC recorded in Step 2 11 FINAL CONFIRMATION TEST Confirm that the problem symptom has gone and the automatic transmission is free from any abnormal condi tions If what has been repaired is related to the malfunction DTC clear the DTC once and perform test driving and confirm that a normal code is indicated 7B 18 AUTOMATIC TRANSMISSION 4 A T Trouble Diagnosis Table NOTE For the inspection of throttle position sensor refer to TP SENSOR in Section 6E Condition Possible Cause Correction 1st 2nd e A T output shaft speed sensor or its circuit Inspect A T output shaft speed 2nd gt 3rd faulty sensor e Shift solenoid A No 1 1st 2nd 2nd gt Repair or replace 3rd B No 2 1st gt 2nd C No 3 2nd gt 3rd or its circuit faulty e TCM faulty Replace TCM z 3rd 4th e Transmission temp sensor or its circuit faulty Inspect Transmission fluid temp S sensor D e A T output shaft speed sensor or its circuit Inspect A T output shaft speed 5 faulty sensor e Shift solenoid A No 1 D No 4 or
169. ccccccccccccccccecece 7B 69 Special Tool errr rere SEENEN 7B 121 Transmission fluid temperature sensor 7B 70 Required Service Material cccssescsee 7B 122 Extension Case Oil Seal cece eee 7B 71 AUTOMATIC TRANSMISSION 4 A T 7B 3 General Description This automatic transmission is a full automatic type with 3 speed plus overdrive O D The torque converter is a 3 element 1 step and 2 phase type The gear shift device consists of 2 sets of plane tary gear units 2 sets of disc type clutches and 3 sets of disc type brakes The gear shift is done by selecting one of 6 positions P R N D 2 and L by means of the select lever installed on the floor On the shift knob there is an overdrive O D cut switch which allows shift up to the overdrive mode and shift down from the overdrive mode 1 Torque converter 7 Reverse brake 13 Valve body 2 Torque converter clutch Lock up clutch 8 1st and 2nd brake 14 Intermediate shaft 3 Input shaft speed sensor 9 Output shaft speed sensor 15 Front carrier Turbine rev sensor A T vehicle speed sensor 4 Front clutch C1 10 Output shaft 16 Rear carrier 5 Overdrive brake 11 Input shaft 17 Parking gear 6 Rear clutch C2 12 Oil pump 7B 4 AUTOMATIC TRANSMISSION 4 A T Item Specifications Torque Type 3 element 1 st
170. ce for damage Replace as required 7D 16 TRANSFER e Check gear tooth surface and shift mechanism in the same manner as with transmission Correct or replace as necessary Especially for following parts measure each clearance Clearance Between Sleeve and 2 4 Shift Fork a Service Limit 1 0 mm 0 039 in If clearance exceeds service limit replace sleeve and 2 4 shift fork Thrust Clearance Between Pinion gear and carrier b Standard 0 15 0 55 mm 0 0059 0 021 in If clearance is out of standard value replace planetary carrier subassembly Clearance Between Planetary Gear Unit and Hi Lo Shift Fork e Service Limit 1 0 mm 0 039 in If clearance exceeds service limit replace planetary sun gear shift fork spacer and Hi Lo shift fork Check each spring for distortion or breakage and change it with new one as necessary Especially for locating springs measure each free length and replace if it is below service limit Locating spring free length a Standard 23 7 mm 0 933 in Service limit 22 0 mm 0 866 in 1 Locating spring Check drive chain and sprockets for abnormal wear or dam age Replace as required Check oil seal for leakage and its lip for excessive hardness If either is found replace Also check corresponding surface of shaft where oil seal lip contacts Correct or replace as necessary Check clearance a between synchronizer ring a
171. ch 21 Ignition switch L SUZUKI scan tool 7 Transmission fluid temp sensor A T fluid temp sensor 22 Battery M Power supply 8 Transmission range sensor Shift switch 23 Brake light switch N Brake signal 9 Output shaft speed sensor A T VSS 24 A C compressor O A T failure signal 10 Input shaft speed sensor Turbine rev sensor A A C on signal P Idle up signal 11 TCC solenoid Lock up solenoid B A T output shaft speed signal Q Throttle signal 12 Shift solenoid A Shift solenoid No 1 C Turbine speed signal R Engine coolant temp signal 13 Shift solenoid B Shift solenoid No 2 D TCC lock up control signal S Engine speed rev signal 14 Shift solenoid C Shift solenoid No 3 E Shift control signal 15 Shift solenoid D Shift solenoid No 4 F A T fluid temp signal AUTOMATIC TRANSMISSION 4 A T 7B 7 Transmission Control Module TCM The TCM is an electronic circuit component that controls gear shift TCC lock up and idle up according to the signal from each sensor It is a microcomputer consisting of an IC transistor diode etc It is installed behind glove box 5V E21 14 4 E22 6 E21 8 GIY ki K E22 14 5V 12V 3 E21 3 BI E22 7 E22 15 E E21 16 B BI FEL E22 13 2S E22 8 E21 18 E22 1 E22 2 E22 3 IG11 E22 9 IG1 E22 10 Gu E22 11
172. ch OFF 3 Using service wire ground diagnosis switch terminal 2 of monitor connector No 2 1 3 Ground terminal 7B 26 AUTOMATIC TRANSMISSION 4 A T 4 Read DTC from flashing pattern of O D OFF lamp 5 After completing the DTC check turn ignition switch OFF and disconnect service wire from monitor connector No 2 1 2 Diagnosis switch terminal 3 Ground terminal oD opr DTC21 DTC21 DTC21 lamp 2 1 2 1 2 4 ON e E Seck serc MEN M ULTI 3 0 Time sec AUTOMATIC TRANSMISSION 4 A T 7B 27 Diagnostic Trouble Code s Clearance Clear DTC with SUZUKI scan tool 1 Turn ignition switch OFF 2 After setting cartridge to SUZUKI scan tool connect it to data link connector DLC 1 located on underside of instrument panel at driver s seat side Special tool A SUZUKI scan tool 3 Turn ignition switch ON 4 Erase DTC according to instructions displayed on SUZUKI scan tool Refer to SUZUKI scan tool operators manual for further details 5 After completing the check turn ignition switch OFF and dis connect SUZUKI scan tool from data link connector DTC Clear DTC without SUZUKI scan tool 1 Turn ignition switch ON 2 Using service wire ground diagnosis switch terminal of moni tor connector No 2 five times within 10 seconds 3 Perform DTC Check and confirm that only DTC 12 normal DTC
173. ck and if the diagnostic trouble code is indicated inspect according to the flow table for that DTC 6 and 7 RECHECKING AND RECORD OF DTC Refer to DTC Check in this section AUTOMATIC TRANSMISSION 4 A T 7B 17 8 AUTOMATIC TRANSMISSION BASIC CHECK AND TROUBLE DIAGNOSIS TABLE Perform basic automatic transmission check according to the list below first When the end of the list has been reached check the part of system suspected as a possible cause referring to Trouble Diagnosis Table and based on symptoms appearing on vehicle symptoms obtained through steps of customer complaint analysis trouble symptom confirmation and or A T basic check and repair or replace faulty parts if any AUTOMATIC TRANSMISSION BASIC CHECK LIST 1 Power Supply Voltage Check Check that the battery voltage is within 10 14 V at engine stop 2 A T Fluid Check Check A T fluid level and quality 3 STALL TEST Perform stall test Refer to Stall Test in this section for details 4 LINE PRESSURE TEST Perform line pressure test Refer to Line Pressure Test in this section 5 ROAD TEST Perform road test to understand correctly the trouble area 6 Electrical Harness and Coupler Check Check the connection of the harness coupler Check for the loose connection of the harness loose connec tion of the terminals 9 DIAGNOSTIC TROUBLE CODE FLOW TABLE Based on the DTC indicated in STEP 6 and STEP 7 and referring to DTC Check lo
174. ck e Resistance in table below represents that when parts temperature is 20 C 68 F NORMAL RESISTANCE CONDITION G38 4 G38 3 Coil antenna Continuity IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 33 On Vehicle Service Precautions in Handling Immobilizer Control System e Don t turn ON ignition switch with ignition key for immobilizer control system put together with another one or placed quite close to another one Or the system may detect abnormal condition and prevent engine from starting Do not turn ON ignition switch by using ignition key with any type of metal wound around its grip or in contact with it Or the system may detect abnormal condition and prevent engine from starting Do not leave ignition key where high temperature is antici pated High temperature will cause transponder in ignition key to be abnormal or damaged 8G 34 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED A B i e Do not turn ON ignition switch with a radio antenna placed near coil antenna or its harness to Immobilizer Control Mod ule Or the system may detect abnormal condition and pre vent engine from starting Immobilizer Control Module REMOVAL 1 2 3 Disconnect negative cable at battery Remove steering column hole cover Vehicle equipped with air bag system Remove steering column mounting bolts then re
175. ck if ECM Immobilizer Control Module codes registered in them respectively match iv Only when it is confirmed that ECM Immobilizer Control Module codes match the engine starts running If Transponder codes in Step ii or ECM Immobilizer Control Module codes in Step iii do not match ECM will stop operation of the injector and ignition of spark plug 8G 4 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED A E L ite E Geer rae peas ee gf P A KE B 1 Coil antenna 5 Malfunction indicator lamp 11 To 7 pin in data link connector 2 Immobilizer Control Module 6 Main relay 12 To ABS control module SDM and TCM 3 ECM 7 Ignition switch 13 Immobilizer indicator lamp if equipped 4 Immobilizer diagnostic coupler 8 Fuse 14 Monitor coupler Vehicle not equipped with immobilizer indicator lamp 4 1 Diagnostic output terminal 9 Main fuse A Vehicle equipped with air bag system 4 2 Ground terminal 10 To 9 pin in data link connector B Vehicle not equipped with air bag system IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 5 Immobilizer Control Module Immobilizer Control Module is installed to the steering lock assembly or the underside of the instrument panel at the drivers seat side As main functions Immobilizer Control Module checks matching not only between the Transponder Code transmitted from the i
176. clamp No 1 6 Dash panel 9 Radiator outlet hose 12 Clutch cable clamp No 2 7C 6 CLUTCH Clutch Cable REMOVAL 1 Remove clutch housing cap 3 2 Loosen clutch cable adjust nut 1 and disconnect clutch cable from release fork 2 3 Disconnect cable hook 2 at clutch pedal shaft arm 1 then take off cable INSPECTION Inspect clutch cable and replace it for any of following conditions e Excessive cable friction e Frayed cable e Bent or kinked cable e Worn end INSTALLATION 1 Before installing cable apply grease to cable end hook 2 and release fork 4 as shown figure A Grease 99000 25010 2 Screw in clutch cable adjust nut 3 and adjust free travel of pedal to specification by turning nut 3 Check clutch for proper function with engine running 1 Clutch pedal shaft arm 5 Cap CLUTCH 7C 7 Unit Repair Overhaul Clutch Cover Clutch Disc Flywheel and Release Bearing 2 9 kg m Le 2 8 23 Nm 2 3 kg m 1 Clutch cover 5 Clutch release fork support 9 Clutch housing cap 2 Bolt 6 Release bearing clip 10 Clutch cable bracket 3 Clutch disc 7 Release bearing m Tightening torque 4 Release fork 8 Release fork return spring 7C 8 CLUTCH REMOVAL 1 Removal of clutch presupposes that the transmission has been separated from engine acc
177. code ECM lt Vehicle not equipped with immobilizer indicator lamp gt Before identifying diagnostic trouble code indicated by malfunction indicator lamp or Suzuki scan tool don t disconnect couplers from ECM battery cable from battery ECM ground wire harness from engine Such disconnection will clear trouble codes for engine and emission control system and immobilizer control system stored in memory of ECM If abnormality or malfunction lies in two or more areas malfunction indicator lamp indicates applicable codes three times each And flashing of these codes is repeated as long as diagnosis terminal is grounded and ignition switch is held at ON position When ECM detects a trouble in both engine and emission control system and immobilizer control system malfunction indicator lamp indicates trouble codes of both systems alternately while the ignition switch is turned ON and the diagnosis terminal is grounded Take a note of diagnostic trouble code indicated first lt Vehicle equipped with immobilizer indicator lamp gt Before identifying diagnostic trouble code indicated through Suzuki scan tool don t disconnect couplers from ECM battery cable from battery ECM ground wire harness from engine Such disconnection will clear trouble codes for engine and emission control system and immobilizer control system stored in memory of ECM Take a note of diagnostic trouble code indicated first Immobilizer Control Module Take a note o
178. consists of highly precise parts As even a flaw in a small part may cause oil leakage or decrease in function check each part carefully before installation Clean all parts with compressed air Never use wiping cloths or rags Before assembling new clutch discs and brake discs soak them in automatic transmission fluid for at least 2 hours Be sure to use new gaskets and O rings Lubricate O rings with automatic transmission fluid Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly Use yellow petrolatum grease or Suzuki Super Grease C to retain parts in place Be sure to install thrust bearings and races in correct direction and position Make sure that snap ring ends are not aligned with one of cutouts and are installed in groove cor rectly Do not use adhesive cements on gaskets and similar parts Be sure to torque each bolt and nut to specification 1 Install new O rings 5 inside and outside to B2 brake pis ton 4 and apply grease to them A Grease 99000 25030 2 Install B2 brake piston with two fingers which have mounded part 7 between them aligned with transmission case hole 8 as shown in figure 3 Install B1 brake piston 3 and B1 and B2 return spring assembly 2 to transmission case 4 Install snap ring 1 by compressing return spring assembly through B2 brake piston seat with hydraulic press 6 and special tool NOTE Don t compress B1
179. cribed in Special Tool in this section along with a correct terminal adapter from special tool Connector test adapter kit e When a check for proper connection is required refer to Intermittent and Poor Connections in this section e If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly 10B 38 AIR BAG SYSTEM DTC WILL SET WHEN DTC B1041 and B1045 The resistance of driver or passenger seat belt pretensioner initiator circuit is above a specified value for speci fied time DTC B1042 and B1046 The resistance of driver or passenger seat belt pretensioner initiator circuit is below a specified value for speci fied time DTC B1043 and B1047 The voltage measured at driver or passenger seat belt pretensioner initiator circuit is below a specified value for specified time DTC B1044 and B1048 The voltage measured at driver or passenger seat belt pretensioner initiator circuit is above a specified value for specified time TABLE TEST DESCRIPTION DTC B1041 B1042 B1043 B1044 B1045 B1046 B1047 and B1048 STEP 1 Check whether malfunction is in seat belt pretensioner STEP 2 Check seat belt pretensioner initiator circuit in seat belt pretensioner harness STEP 3 Check seat belt pretensioner initiator circuit in air bag harness DIAGNOSTIC FLOW TABLE DTC B1041 DRIVER PRETENSIONER INITIATOR CIR
180. ct coil connector G62 located near the base of the steer ing column 2 Check proper connection to contact coil at terminals in G62 connector 3 If OK then connect special tools B and C to con tact coil connector G62 With ignition switch ON does DTC B1024 still exist Go to step 2 Go to step 3 1 With ignition switch OFF disconnect special tools B and C from G62 connector and SDM connec tor G62 from SDM respectively 2 Release shorting bar in SDM connector inserting release tool 1 included in special tool A 3 Measure resistance between Q60 9 terminal and body ground and between Q60 10 terminal and body ground Are they 1 MQ or more Substitute a known good SDM and recheck Repair short from GRN or GRN RED wire circuit to ground 1 With ignition switch OFF disconnect special tools B and C from G62 connector then reconnect contact coil connector G62 located near the base of the steering column as it was Remove driver air bag inflator module from steer ing wheel referring to Driver Air Bag Inflator Mod ule in Section 3C Check proper connection to driver air bag inflator module at terminals in G70 connector If OK then connect special tools B and C to G70 connector With ignition switch ON does DTC B1024 still exist 4 Ignition switch OFF Replace contact coil assembly refer
181. curing bevel gear to differential case and separate gear from case 12 There are 8 bolts fastening two differential case halves together Remove these bolts to sever right hand case half from left hand one and take off right hand one Special tool A 09930 40113 13 Remove differential pinion shafts side gears differential pin ions and thrust washers 14 Using special tools extract side bearing from each differen tial case half Special tool A 09913 60910 B 09913 85230 15 Remove oil seal 1 from differential carrier by using special tool Special tool A 09913 50121 REAR DIFFERENTIAL 7F 11 16 Drive out drive bevel pinion bearing outer races in differential carrier by hammering metal stick applied to them INSPECTION e Check companion flange for wear or damage e Check bearings for wear or discoloration e Check differential carrier for cracks e Check drive bevel pinion and bevel gear for wear or cracks e Check differential gears pinion gears and pinion shaft for wear or damage e Check side gear spline for wear or damage ADJUSTMENT AND REASSEMBLY Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc after disassembly prepare replacing parts and proceed to reas sembly according to procedures as described below CAUTION e Drive bevel gear and pinion must be replaced as a set when either r
182. d sensor side coupler and body ground Is it about 0 Q See figure Replace output shaft speed sensor Go to Step 4 1 Turn ignition switch OFF and connect out put shaft speed sensor coupler then discon nect TCM couplers 2 Measure resistance between terminal E22 6 of disconnected harness side coupler and body ground then terminal E22 14 of disconnected harness side coupler and body ground Is it about 0 Q See figure P or BI wire shorted to ground Go to Step 5 Measure resistance between terminal E22 6 and E22 13 of disconnected harness side coupler then terminal E22 14 and E22 13 of disconnected harness side coupler Is it about 0 Q See figure P wire or B wire shorted to shield portion Poor connection of termi nal E22 6 or E22 14 of the TCM If all the above are in good condition substitute a known good TCM and recheck A B C A Fig for Step 1 3 LS speed sensor coupler Output shaft speed sensor input shaft 4 Terminal 4 B Fig for Step 1 2 Output shaft speed sensor terminals C Fig for Step 3 3 Terminal 3 7B 40 AUTOMATIC TRANSMISSION 4 A T D D Fig for Step 2 5 E Fig for Step 4 AUTOMATIC TRANSMISSION 4 A T 7B 41 DTC P1700 DTC No 32 33 Throttle Position Signal In
183. d Torque wrench Bearing puller 09913 75510 09913 75520 09913 76010 09915 24550 Bearing installer Bearing installer Bearing installer Adapter socket T 09922 66020 09922 75222 09922 76120 09922 76140 Flange holder Preload adjuster Dummy shaft Bevel pinion shaft Y KEY 09922 76150 09922 76220 09922 76310 09922 76320 Bevel pinion nut Bearing gear dummy Rear collar Rear collar FRONT DIFFERENTIAL 7E 25 09922 76340 Rear collar 09922 76410 Front collar 09922 76520 Gauge block 09922 76550 Gauge block 09922 8581 1 Spring pin remover EZ 09924 07730 Bearing installer 09924 74510 Installer attachment 09925 58210 Oil seal installer UU H CH IC y U C A o CG O H 4 S 09926 37610 Bearing remover See NOTE 1 09926 37610 001 Bearing puller See NOTE 2 bt 09926 37610 002 Bearing puller attachment See NOTE 2 09926 37610 003 Bearing remover attach ment See NOTE 2 09930 40113 Rotor holder 09930 40120 Attachment 09944 66010 Oil seal installer 09944 66020 Bearing installer 7E 26 FRONT DIFFERENTIAL 09951 46010 Oil seal installer NOTE e 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 e 2 This tool is constituent of Bearing Remover
184. d of front windshield upper installa tion section ee Body outer panel clipping section h h Body outer panel 8 zig hole tion section CC Front end of front windshield lower installa f f Body outer panel clipping section Measurement Dimension Measurement Length Measurement Length Position mm in Position mm in a c 902 35 51 d g 1479 58 23 b b 1190 46 85 d g 1514 59 61 b c 620 24 41 d h 718 28 27 b c 1240 48 82 d h 795 31 30 c 969 38 15 e e 1102 43 39 d e 1179 46 42 f f 1127 44 37 d e 1221 48 07 g g 1103 43 43 d f 1063 41 85 h h 1254 49 37 d f 1111 43 74 BODY SERVICE 9 21 a Body outer panel clipping section Body outer panel clipping section Back door upper hinge in upper installation hole Body outer panel 8 zig hole Back door lower hinge in lower installation b Front door upper hinge in upper installation g hole hole c Front door lower hinge in lower installation h h Rear end of roof panel upper installation m Rear end of piller outer panel inside installa hole section tion section d Side sil scuff installation hole rear end i P Combination lamp upper installation hole Rear bumper installation hole e Body outer panel 8 zig hole Back door striker upper installation hole Measurement Dimensio
185. d seat belt pretensioner to cool it off and be careful so that water oil etc does not get on the deployed air bag inflator module and the activated seat belt pretensioner After the air bag inflator module has been deployed the surface of the air bag may contain a powdery residue This powder consists primarily of cornstarch used to lubricate the bag as it inflates and by products of the chemical reaction As with many service procedures you should wear gloves and safety glasses 10B 74 AIR BAG SYSTEM e When disposing of the deployed air bag inflator module and the activated seat belt pretensioner be sure to seal it in a vinyl bag e When air bag inflator module and seat belt pretensioner have been deployed activated inside the vehicle which is going to be scrapped leave them as installed to the vehicle e Be sure to wash your hands with mild soap and water after handling it Tightening Torque Specification Tightening torque Fast t SE Nem kg m GEI SDM mounting bolt 6 0 6 4 5 Passenger air bag inflator module bolt 23 2 3 16 5 Special Tool 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE A 09931 76030 09932 75010 09932 75031 16 14 pin DLC cable for Air bag driver passenger Air bag deployment har Tech 1A load tool ness 09932 75041 Passenger air bag infla tor module deployment fixture SECH cke 09932 75420 099
186. di ately with a dry cloth If seat belt pretensioner was dropped from a height of 90 cm 3 ft or more it should be replaced with a new one as an assembly AIR BAG SYSTEM 10B 53 WARNING e For handling and storage of a live seat belt preten sioner select a place where the ambient temperature below 65 C 150 F without high humidity and away from electric noise es Do not carry the seat belt pretensioner by webbing e When placing a live seat belt pretensioner on the work bench or other surface be sure not to lay it with its exhaust hole 1 provided side facing down It is also prohibited to put something on its face with an exhaust hole 1 or to put a seat belt pretensioner on top of another Otherwise personal injury may result DEPLOYED AIR BAG INFLATOR MODULE AND ACTI VATED SEAT BELT PRETENSIONER WARNING e The air bag inflator module and seat belt pretensioner immediately after deployment activation is very hot Wait for at least 30 minutes to cool it off before pro ceeding the work e Do not apply water oil etc to deployed air bag infla tor module and to activate seat belt pretensioner e After an air bag inflator module has been deployed the surface of the air bag may contain a powdery resi due This powder consists primarily of cornstarch used to lubricate the bag as it inflates and by prod ucts of the chemical reaction As with many service procedures gl
187. dicator lamp lights when ignition switch is turned OFF once and then turned ON e Vehicle not equipped with immobilizer indicator lamp malfunction indicator lamp MIL e Vehicle equipped with immobilizer indicator lamp immobilizer indicator lamp IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 39 Special Tools 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE A below Immobilizer cartridge of version 1 1 or more 09931 76030 16 14 pin DLC cable SS Mass storage cartridge of version 1 5 or more Tech 2 kit SUZUKI scan tool See NOTE B below NOTE e A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor e B This kit includes the following items and substitutes for the Tech 1 kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector 11 Storage case 12 Power supply 8G 40 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED BODY SERVICE 9 1 SECTION 9 BODY SERVICE WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI d
188. dis connected harness side TCM coupler Is it 10 14 V at 2 range and O V at the other range DG While ignition switch ON check voltage Intermittent trouble or Go to Step 7 between terminal E22 11 and E21 15 of dis faulty TCM connected harness side TCM coupler Check for intermittent Is it 10 14 V at L range and 0 V at the other trouble referring to Inter range mittent and Poor Connec tion in Section OB 7 Check transmission range sensor referring in Transmission range sen Replace transmission range sensor A Fig for Step 7 1 Transmission range sensor AUTOMATIC TRANSMISSION 4 A T 7B 45 DTC P0725 DTC No 35 Engine Speed Input Circuit E18 11 Br E22 5 1 ECM 3 Terminal arrangement of TCM coupler viewed from harness side 2 TCM 4 Terminal arrangement of ECM coupler viewed from harness side DTC DETECTING CONDITION Input engine rev signal voltage is too low or too high Step Action Yes No 1 Check DTC of Engine Diagnosis referring to Inspect and repair refer Go to Step 2 Section 6 ring to DTC flow table of Is there DTC related to engine speed sensor Engine Diagnosis in Section 6 2 1 Turn ignition switch OFF and disconnect Go to Step 3 Br wire open ECM or TCM couplers 2 Measure resistance between terminal E18
189. drive bevel pinion rear bearing 2 by using bearing puller 3 and hydraulic press 1 Drive bevel pinion FRONT DIFFERENTIAL 7E 9 8 Using special tools remove differential side bearings Special tool A 09926 37610 B 09926 37610 001 C 09926 37610 003 D 09926 37610 002 9 Hold differential case 1 with soft jawed vise 10 Remove drive bevel gear bolts 2 11 Remove drive bevel gear 3 from differential case 12 Push spring pin 1 out of pinion shaft with special tool and hammer Special tool A 09922 85811 13 Remove pinion shaft 2 differential gears 3 pinions 4 and washers from differential case 5 7E 10 FRONT DIFFERENTIAL 14 Remove oil seal 1 by using special tool Special tool A 09913 50121 15 Drive out bevel pinion bearing outer races 2 in differential carrier by hammering metal stick 1 applied to them INSPECTION e Check companion flange for wear or damage e Check bearings for wear or discoloration e Check differential carrier for cracks e Check drive bevel pinion and bevel gear for wear or cracks e Check differential gears pinion gears and pinion shaft for wear or damage Check side gear spline for wear or damage ADJUSTMENT AND REASSEMBLY Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc
190. dule in this section e For seat belt pretensioner Remove seat belt referring to Front Seat Belt with Preten sioner in Section 10 AIR BAG SYSTEM 10B 63 WARNING e For handing and storage of live air bag inflator mod ule select place where ambient temperature below 65 C 150 F without high humidity and away from electric noise e Always carry live air bag inflator module with trim cover away from you e When storing live air bag inflator module or when leaving live air bag inflator module unattended on bench or other surface always face trim cover up and away from surface As the live passenger air bag infla tor module must be placed with its bag trim cover facing up place it on the work bench with a slit 1 or use the work bench vise 2 to hold it securely at its lower mounting bracket 3 It is also prohibited to place anything on top of the trim cover and stack air bag inflator modules This is necessary so that free space is provided to allow air bag inflator module to expand in the unlikely event of accidental deployment Failure to follow procedures may result in personal injury WARNING e For handing and storage of a live seat belt preten sioner select a place where the ambient temperature below 65 C 150 F without high humidity and away from electric noise Do not carry the seat belt pretensioner by webbing es When placing a live se
191. dy assembly bolts 5 5 0 55 4 0 Valve body bolts 10 0 1 0 7 5 Oil cooler pipe union bolts 36 0 3 6 26 0 Oil cooler pipe bracket bolt 6 0 0 6 4 5 Extension case bolts 17 0 1 7 12 5 Oil pump cover bolts 10 0 1 0 7 5 AUTOMATIC TRANSMISSION 4 A T 7B 121 Special Tool 09900 06108 Snap ring plier Closing type 09900 20606 Dial gauge 09900 20701 Magnetic stand 09913 76010 Bearing installer 09913 80112 Bearing installer 09925 78210 Spring pin remover 6 mm 09925 37810 Oil pressure gauge 09926 26030 Clutch clearance checking base No 1 SS 09926 26040 Clutch clearance checking base No 2 09926 96010 Clutch spring compressor 09926 96020 Clutch spring compressor SS 09952 06010 Dial gauge plate No 1 7B 122 AUTOMATIC TRANSMISSION 4 A T 09931 76011 09931 76030 Tech 1A kit SUZUKI scan Mass storage cartridge for 16 14 pin DLC cable for Tech 2 kit SUZUKI scan tool See NOTE A Tech 1A Tech 1A tool See NOTE B NOTE e A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor e B This kit includes the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19
192. e Warning Light Oil pressure switch INSPECTION Use an ohmmeter to check switch continuity Oil pressure switch specification During Engine Running No continuity Q At Engine Stop Continuity 0 Q 1 To wiring harness 2 Cylinder block 3 Oil pressure switch REMOVAL AND INSTALLATION Refer to Oil Pressure Check in Section 6A1 8 22 BODY ELECTRICAL SYSTEM a Brake and Parking Brake Warning Light Brake fluid level switch INSPECTION Use an ohmmeter to check switch for continuity If found defective replace switch Brake fluid level switch specification OFF position float up No continuity ON position float down Continuity Parking brake switch INSPECTION Use an ohmmeter to check switch for continuity If found defective replace switch Parking brake switch specification OFF position parking brake released No continuity ON position parking brake lever pulled up Continuity Seat Belt Warning Light If Equipped Seat belt switch INSPECTION Refer to Front Seat Belt without Pretensioner in Section 10A for inspection Rear Window Defogger Defogger switch INSPECTION Use a circuit tester to check defogger switch for continuity If switch has no continuity between terminals replace T inal Defogger SW a IG E LOAD IL ILE OFF Cor Or ON ES ESCH BODY ELECTRICAL SYSTEM 8 23 Def
193. e and next at its body side as shown WARNING Handling of Back Door Balancer Damper e Handle balancer carefully Do not scar or scratch exposed surface of its piston rod and never allow any paint or oil to stick to its surface es Do not turn piston rod with balancer fully extended es Do not disassemble balancer 1 because its cylinder is filled with gas Discarding of Back Door Balancer e The gas itself in balancer is harmless but it may issue wl out of the hole together with chips generated by the drill 2 Therefore be sure to wear goggle when drill RS E gt ing H e Using a 2 to 3 mm 0 08 to 0 12 in drill 2 make a hole to remove gas inside as shown before discarding Sch kd 10 mm 0 4 in 4 Remove combination lamp 9 16 BODY SERVICE 5 Remove door hinge bolts and door 2 1 Back door hinge 3 Body INSTALLATION Reverse removal procedure to install back door noting following points e Secure wiring harness 1 e Secure door sealing cover 1 NOTE Use adhesive 2 to seal sealing cover to back door Adjust door latch striker position by referring Back Door Lock Assembly in this section so that door is positioned cor rectly Adjust door cushion so that door contacts body when closed Under Body Dimensions BODY SERVICE 9 17 Sy te I ec CD Ss
194. e as it inflates and by products of chemical reaction WARNING e Do not place deployed air bag inflator module and activated seat belt pretensioner near any flammable objects e Do not apply water oil etc to deployed air bag infla tor module and activated seat belt pretensioner e Wait for about 30 minutes before touching any metal surface of air bag inflater module or seat belt preten sioner module Disregarding these precautions may cause fire or personal injury Failure to follow procedures may result in fire or personal injury 10B 72 AIR BAG SYSTEM 14 15 16 17 18 19 20 21 22 23 Separate two banana plugs 1 on deployment harness 2 Connect deployment harness 2 to 12 volts vehicle battery 3 This will immediately deploy or activate air bag inflator module or seat belt pretensioner Disconnect deployment harness 2 from 12 volts vehicle battery 3 and short two deployment harness leads together by fully seating one banana plug into the other Repeat Step 3 through Step 16 to deploy activate air bag inflator modules and seat belt pretensioners which has not been deployed activated if any After confirming that air bag inflator module and seat belt pretensioner deployed and or activated proceed to Step 19 through Step 23 In the unlikely event that air bag inflator module did not deploy or seat belt pretensioner did not acti vate pr
195. e body assembly NOTE There are three kinds of bolts fixing valve body assembly 1 5 BoltA 6 BoltB 7 BoltC 6 Remove solenoid harness assembly 7 Remove accumulator pistons and springs To remove C1 1 C2 2 and B1 3 accumulator pistons and springs position a rag on pistons to catch each piston To remove pistons force low pressure compressed air 1 kg cm 15 psi 100 kPa max into hole 4 as shown in figure and pop each piston into the rag To remove BO accumulator piston and spring remove snap ring and accumulator spacer then remove spring and piston NOTE Do not push accumulator pistons with fingers or any thing before removing them Pushing them may cause compressed fluid in accumulator to spew out of hole and get to your face and clothes 8 Remove torque converter housing 1 a Remove housing bolts b Remove housing while tapping around it lightly with a plas tic hammer NOTE Never reuse housing bolts 7B 80 AUTOMATIC TRANSMISSION 4 A T 9 Remove extension case 1 and disconnect output shaft assembly Remove thrust bearing from transmission case 10 Remove parking pawl shaft 1 spring 2 and then parking pawl 3 11 Remove detent spring 1 and parking rod 2 12 Remove manual shift shaft as follows if necessary a Remove sleeve cover 1 by using caulking tool 2 b Using a punch drive out ma
196. e for DTC No Substitute a known good ECM and recheck See NOTE NOTE After replacing with a known good ECM register ECM Immobilizer Control Module code in ECM by performing procedure described in Procedure after ECM Replacement in this section Fig 1 for step 1 p 20 AO 10 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 11 Diagnostic Trouble Code DTC Check Immobilizer Control Module Vehicle not equipped with air bag system 1 Using analog type voltmeter connect positive probe to diag nostic output terminal 4 and negative probe to ground ter minal 5 of immobilizer diagnostic coupler 3 with ignition switch turned ON 2 Read deflection of voltmeter indicator which represents DTC as shown in example below and write it down For details of DTC refer to Immobilizer Control Module side in Diagnostic Trouble Code Table If voltmeter indicator does not deflect go to Diagnostic Flow Table A NOTE If abnormality or malfunction lies in two or more areas voltmeter indicator lamp indicates applicable codes three times each 1 Immobilizer control module 2 DLC Data link connector EXAMPLE e COIL ANTENNA FAILURE CODE NO 13 CODE No 13 CODE No 13 CODE No 13 ie 5E 2 5 3 High an a geen A a aC 1g Voltmeter Indicator Low S E S a T A Al kl cb 15 20 eZ 20 3 0 TIME sec 0 5 e Normal No code High Vol
197. e gear s or side pinion s Replace Bearing noise Constant noise Deteriorated or water mixed lubricant Repair or replenish Constant noise Inadequate or insufficient lubri cant Repair or replenish Noise while coasting Damaged bearing s of Replace bevel pinion Noise while turning Damaged differential side Replace bearing s or axle bearing s Oil leakage Clogged breather plug Clean Worn or damaged oil seal Replace Excessive oil Adjust oil level Loose differential carrier bolts Replace or retighten 7E 4 FRONT DIFFERENTIAL On Vehicle Service Viscosity chart SAE c 30 20 10 D 10 20 30 40 Temperature e We WE E E Le GE et i 4 14 32 50 68 86 104 Oil Change 1 Before oil change or inspection be sure to stop engine and set vehicle horizontally 2 Check oil level and existence of leakage For checking oil level roughly lower point of level hole can be assumed to be standard point of level If leakage is found correct its cause 3 Remove level filler plug 2 and drain plug 1 then drain dif ferential oil 4 Apply sealant to drain plug thread A Sealant 99000 31110 5 Tighten drain plug to specified torque Tightening torque Front differential oil drain plug b 27 N m 2 7 kg m 19 5 Ib ft 6 Pour proper amount of new differential oil as specified below roughly up to level hole 7 Install new
198. ealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM e When servicing vehicle body if shock may be applied to air bag system component parts remove those parts beforehand Refer to Section 10B 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 of with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute a design Torque values must be used as specified during reassembly to assure
199. ears hubs sleeves synchronizer ring shift shaft etc For 4WD model the planetary gear unit installed at the center of the output rear shaft selects the Lo range or the Hi range and the sleeve on the output front shaft side selects the 2WD or 4WD IA B 5 Sa sier N 1 Input shaft 9 Output rear shaft 17 Shift fork spacer for 4WD model 2 Drive chain 10 Hi Lo shift fork for 4WD model 18 Ring gear for 4WD model 3 Output front shaft for 4WD model 11 Pinion gear for 4WD model 19 Planetary carrier for 4WD model 4 Sleeve for 4WD model 12 Sprocket gear for 4WD model 20 Front case 5 2 4 shift fork for 4WD model 13 Speedometer sensor rotor 21 Rear case 6 Synchronizer key for 4WD model 14 Key retainer for 4WD model A 4WD model 7 Synchronizer ring for 4WD model 15 Key spring for 4WD model B 2WD model 8 Lock up plate for 4WD model 16 Sun gear for 4WD model A TRANSFER 7D 3 Planetary Gear Unit The planetary gear unit consists of a planetary carrier 1 3 pin ion gears 2 and a sun gear 3 As the Hi Lo shift fork moves this planetary gear unit the gear is selected in the 4HN lt 4L pat tern Planetary Gear Operation 4H range As the sprocket output gear 5 and the output rear shaft 6 are engaged through the planetary carrier 3 serration they turn as one unit L range As the sun
200. echeck function matic transmission Is it OK 7B 38 AUTOMATIC TRANSMISSION 4 A T DTC P0720 DTC No 31 Output Shaft Speed Sensor Circuit E22 6 E22 14 E22 13 E21 15 1 Output shaft speed sensor A T VSS 4 TCM 2 Coupler 5 Terminal arrangement of TCM coupler viewed from harness side 3 Shield wire DTC DETECTING CONDITION Output shaft speed sensor signal voltage is too high or too low then disconnect TCM couplers 2 Measure resistance between terminal E22 6 and E22 14 of disconnected harness side coupler Is it 160 200 Q See figure Step Action Yes No 1 1 Turn ignition switch OFF and disconnect Go to Step 2 Replace output shaft output shaft speed sensor input shaft speed sensor speed sensor coupler 1 See figure 2 Measure resistance between terminals of disconnected sensor side coupler Is it 160 200 Q See figure 2 1 Connect output shaft speed sensor coupler Go to Step 3 P or BI wire open or shorted each other AUTOMATIC TRANSMISSION 4 A T 7B 39 Step Action Yes No 1 Turn ignition switch OFF and disconnect output shaft speed sensor input shaft speed sensor coupler See figure 2 Measure resistance between terminal 3 of disconnected sensor side coupler and body ground then terminal 4 of disconnecte
201. ecked at ECM wiring couplers and Immobilizer Control Module wiring coupler by measuring voltage Described here is only inspection of Immobilizer Control Module For inspection of ECM refer to Inspection of ECM and Its Circuits in Section 6 CAUTION Immobilizer Control Module cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to Immobilizer Control Module with coupler disconnected from it Voltage Check 1 Remove Immobilizer Control Module referring to Immobi lizer Control Module for removal in this section 2 Connect Immobilizer Control Module coupler to Immobilizer Control Module 3 Check voltage at each terminal of coupler connected NOTE As each terminal voltage is affected by the battery volt age confirm that it is 11V or more when ignition switch is ON 1 Immobilizer Control Module 2 1 Immobilizer Control Module coupler Vehicle not equipped with air bag system 2 2 Immobilizer Control Module coupler Vehicle equipped with air bag system 3 Body ground lt Vehicle not equipped with air bag system gt IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 31 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Gi 10 14V Ignition switch ON Gg WS 0 0 8V ignition switch OFF G38 2 Power source 10 14V Ignition switch ON G38 3 Coil antenna 2 OV Ignition switch ON G38 4 Coil antenna 1 OV Ignition s
202. ection passenger air bag inflator module connector G61 With ignition switch ON does DTC B1019 still exist 2 1 With ignition switch OFF disconnect special tools Go to step 3 Repair short from YEL B and C from G61 connector and SDM con RED wire circuit to power nector Q60 from SDM respectively circuit 2 Release shorting bar in SDM connector inserting release tool 1 included in special tool A 3 Measure voltage from Q60 7 terminal to body ground With ignition switch ON is voltage 1 V or less 3 1 Measure voltage from Q60 8 terminal to body Substitute a known Repair short from YEL wire circuit to power cir cuit A B IW Fig for STEP 1 2 and 3 B Fig for STEP 2 and 3 Special tool A B C 09932 76010 09932 75010 09932 78340 NOTE Upon completion of inspection and repair work perform the following items es Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected 10B 28 AIR BAG SYSTEM DTC B1021 Driver Air Bag Initiator Circuit Resistance High DTC B1022 Driver Air Bag Initiator Circuit Resistance Low DTC B1024 Driver Air Bag Initiator Circuit Short
203. ed e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected DTC B1022 DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW Step Action Yes No 1 1 With ignition switch OFF disconnect contact coil connector G62 located near the base of the steering column 2 Check proper connection to contact coil at terminals in G62 connector 3 If OK then connect special tools B and C to contact coil connector G62 With ignition switch ON does DTC B1022 still exist Go to step 2 Go to step 3 1 With ignition switch OFF disconnect SDM connector Q60 2 Check proper connection to SDM at termi nals Q60 9 and Q60 10 3 If OK release shorting bar in SDM connec tor inserting release tool 1 included in spe cial tool A 4 Measure resistance between Q60 9 and Q60 10 terminals with connected special tools B and C to G62 connector Is resistance 1 7 Q or more Substitute a known good SDM and recheck Repair short from GRN wire circuit to GRN RED wire circuit or from GRN or GRN RED wire cir cuit to other wire circuit 1 With ignition switch OFF disconnect special tools B and C from G62 connector then reconnect contact coil connector G62 located ne
204. eeeeeeeeeeeeeteeeeeetetteteeeees 8 43 MirrOr SWItChinwate Ace aan 8 43 Door mirror achiator eee 8 43 Door Mirror Heater If Equipped 8 44 Mirror heater switch neeesser 8 44 Mirror heater if equipped ee 8 44 Front Seat Heater If Equipped 8 45 Seat heater switch driver and passenger side 8 45 Seat heater wire 8 45 BODY ELECTRICAL SYSTEM 8 3 Diagnosis Headlight Condition Possible Cause Correction Headlights do not light Bulb blown Check bulb up Headlight switch faulty Check headlight switch Headlight R and L fuses blown After checking short circuit replace fuse Wiring or grounding faulty Repair circuit Only one headlight does not light up Bulb blown Check bulb Headlight R or L fuse blown After checking short circuit replace fuse Headlight switch faulty Check headlight switch Wiring or grounding faulty Repair circuit Only one beam CH Bulb burnt out Replace bulb or Lo does not light Lighting or dimmer switch faulty Check switch Headlights with Leveling System If Equipped Condition Possible Cause Correction Both headlights do not move WIPER WASHER fuse blown After checking short circuit replace fuse Leveling switch faulty Check switch or replace it as neces sary Supply voltage too low Recharge or replace battery O
205. em and Location 8G 3 Diagnostic Trouble Code Table Immobilizer Control Module 8G 5 Immobilizer control module 006 EE 8G 5 Table A DTC is Not Output From On Board Diagnostic System Diagnostic Output Terminal Self Diagnosis Function 0ccccccceeeeeeees 8G 5 For Vehicle Not Equipped with Air Bag DiagnosiS eteeeeebegee eege 8G 8 System enigen Eugen 8G 16 Precautions in Diagnosing Troubles 8G 8 Tabie B Immobilizer Indicator kamp Check Precautions in identifying diagnostic E EE BEE trouble code 8G 8 a P Diagnostic Flow Table 8G 9 Immobilizer Indicator Lamp Does Not Diagnostic Trouble Code DTC Check Light at Ignition Switch ON EE 8G 17 Immobilizer Control Module 8G 11 Table C Immobilizer Indicator Lamp Check Vehicle not equipped with air bag oo for Vehicle Equipped with Immobilizer system 8G 11 Indicator Lamp onele Cubed with air ba CIORAN OS Immobilizer Indicator Lamp Remains on system ER g 8G 12 After Engine Giartel ee 8G 18 Diagnostic Trouble Code DTC Check Tavis EDIE is Not Output From ECM 8G 12 Immobilizer Control Module For Vehicle Equipped with Air Bag Not using SUZUKI scan tool System 8G 19 Except for vehicle equipped with immobilizer indicator Lamp 8G 12 8G 2 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED DTC11 32 Transponder Code Not Mathes csceicics scsi seseseaenecac tithagedivesvestenets 8G 21 DTC31 Transponder Code Not Hegtstered
206. embly and the spline of intermediate shaft 23 Install thrust bearing race 1 and thrust needle roller bearing 2 A Grease 99000 25030 7B 114 AUTOMATIC TRANSMISSION 4 A T 24 Install front disc clutch assembly 1 by turning it right and left to match the clutch disc of front disc clutch assembly and the spline of follow shaft 2 Transmission case 25 Install gasket to transmission case and install oil pump assembly 1 to transmission case Tightening torque Oil pump assembly bolts a 12 N m 1 2 kg m 8 5 Ib ft 26 Measure input shaft end play Set dial gauge 1 as shown in figure and measure the play of the input shaft Input shaft end play Standard 0 3 0 9 mm 0 012 0 036 in If the obtained value is out of standard value select thrust bearing race installed in step 22 of different thickness shown in table below and adjust the play Available thrust bearing race thickness 1 3 mm 0 051 in 1 7 mm 0 067 in 2 1 mm 0 083 in 2 Input shaft end 3 Oil pump 27 Apply grease to oil pump D ring Install new gasket to transmission case and install torque converter housing 1 Tightening torque Torque converter housing bolt a 19 N m 1 9 kg m 14 0 Ib ft Grease 99000 25030 NOTE Use new bolts AUTOMATIC TRANSMISSION 4 A T 7B 115 28 Apply grease to lip of
207. emm 23 Differential case bolt z Apply thread lock cement 99000 32110 to thread 6 Drive bevel pinion front bearing 15 Thrust washer 24 Differential carrier bolt Apply sealant 99000 31110 to thread SC 7 OU seal 16 Differential side bearing x lt Do not reuse Apply grease 99500 25010 to oil seal lip 8 Flange nut 17 Differential side bearing adjuster m Tightening torque le After tightening nut so as rotational torque of drive bevel pinion to be in specified torque caulk nut securely vz 9 Differential carrier assembly 18 Lock plate Apply differential oil Apply sealant 99000 31110 to mating face with axle housing 110 7F 6 REAR DIFFERENTIAL Differential Unit DISMOUNTING 1 Lift up vehicle and remove wheels 2 Drain differential oil from rear axle housing referring to Oil Change in this section 1 Drain plug 2 Level Filler plug 3 Remove rear brake drums and pull out right and left rear axle shaft referring to Rear Axle Shaft and Wheel Bearing in Section 3E 4 Before removing propeller shaft give match marks 1 on companion flange 2 and propeller shaft 3 as shown 5 Remove differential carrier bolts 1 and differential assem bly REAR DIFFERENTIAL 7F 7 REMOUNTING Reverse removal procedure for installation noting the following Rear Differential e Clean mating surface of rear axle housing 1 and differe
208. ent Activation Component Inspections 10B 55 SDM initete casein ei an ae 10B 58 Passenger Air Bag Inflator Module 10B 59 Driver Air Bag Inflator Module 10B 60 Contact Coil and Combination Switch Assembly e cee iaaea 10B 60 Seat Belt Preiensioner eee 10B 60 Air Bag Inflator Module and Seat Belt Pretensioner DispoSal csssssseceeeeees 10B 61 Deployment Activation Outside of Meel 10B 62 Deployment Activation Inside Vehicle 10B 69 Deployed Air Bag Inflator Module and Activated Seat Belt Pretensioner DiSpoSal visa t aca oe 10B 73 Tightening Torque Specification 10B 74 Special Foot etinsnheeeeete ege eeg 10B 74 AIR BAG SYSTEM 10B 3 General Description With the air bag system which includes air bags for both the driver s and passenger s sides as well as the seat belt pretension ers the sag of the seat belt is taken up for seat belt with preten sioner the driver air bag inflator module is deployed from the center of the steering column and the passenger air bag inflator module from the top of the instrument panel in front of the front passenger seat in occurrence of a front collision with an impact larger than a certain set value to supplement protection offered by the driver and front passenger seat belts 1 Driver side air bag 2 Passenger side air bag 3 Seat belt pretensioner The air bag system is designed to activate
209. ep 2 phase type converter Stall torque ratio More than 1 7 e Type Internal gear type oil pump Spee Drive system Engine driven Type Forward 4 step reverse 1 step planetary gear type P range Gear in neutral output shaft fixed engine start R range Reverse N range Gear in neutral engine start D range O D ON Forward 1st co 2nd 3rd 4th O D Shift position automatic gear change D range O D OFF Forward 1st lt lt 2nd 3rd lt 4th automatic gear change 2 range Forward 1st 2nd lt 3rd automatic gear change Gear L range Forward 1st lt 2nd reduction and fixed at 1st gear change ist 2 962 device 2nd 1 515 Number of teeth Front sun gear 21 3rd 1 000 Rear sun gear 34 ea 4th Front pinion gear 19 aoe overdrive gear SE Rear pinion gear 16 Reverse Front internal gear 59 reverse gear 2 809 Rear internal gear 66 ET EE Wet type multi disc clutch 2 sets Wet type multi disc brake 3 sets Final gear reduction ratio Differential 208 Lubrication Lubrication system Force feed system by oil pump Cooling Cooling system Radiator assisted cooling water cooled Fluid used Equivalent of DEXRON IIE or DEXRON III FUNCTIONS NOTE AUTOMATIC TRANSMISSION 4 A T 7B 5 For operation of each part refer to Table of Component Operation in this section PART NAME FUNCTION Front clutch Meshes input shaft and front sun gear Rear clutch Meshes
210. ep 9 Go to step 10 9 1 Check DTC referring to Using Substitute a known good Check and repair according to corre SUZUKI Scan Tool under SDM and recheck sponding DTC flow table DTC Check in this section Is NO CODES displayed on SUZUKI scan tool 10 1 Check DTC referring to Not Substitute a known good Check and repair according to corre Using SUZUKI Scan Tool SDM and recheck sponding DTC flow table under DTC Check in this sec tion Is flashing pattern No 12 indicated on AIR BAG warning lamp AIR BAG SYSTEM 10B 11 DTC Check Using SUZUKI Scan Tool 1 Turn ignition switch to OFF position 2 After setting SUZUKI scan tool connect it to data link con nector DLC located on underside of instrument panel at driver s seat side Special tool A SUZUKI scan tool 3 Turn ignition switch to ON position 4 Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down referring to SUZUKI scan tool operator s manual for further details If communication between scan tool and SDM is not possi ble proceed to SDM Serial Data Circuit Trouble Diagnosis Table in this section 5 After completing the check turn ignition switch to OFF posi tion and disconnect SUZUKI scan tool from data link connec tor DLC 1 Data link connector DLC Not Using SUZUKI Scan Tool 1 Check that AIR BAG wa
211. eplacement becomes necessary e When replacing taper roller bearing replace as inner race and outer race assembly 7F 12 REAR DIFFERENTIAL Drive Bevel Pinion Bearing Outer Race CAUTION Perform press fitting carefully so as not to tilt outer race Install bevel pinion bearing outer races using special tools and hydraulic press Special tool A 09924 74510 B 09926 68310 C 09913 75510 1 Differential carrier Differential Case Assembly 1 Install differential side gears pinions thrust washers and pinion shafts in differential case REAR DIFFERENTIAL 7F 13 2 To check thrust play of differential side gear fasten together two case halves by tightening securing bolts to prescribed torque By comparing thrust play reading taken as shown in figure against thrust play indicated below increase or decrease total thickness of thrust washers which are located in two places that is on the inner side of each case half Special tool A 09930 40113 Tightening torque Differential case bolts a 41 N m 4 1 kg m 30 0 Ib ft Differential side gear thrust play Standard 0 12 0 37 mm 0 005 0 014 in Available differential gear thrust washer thickness 0 6 0 7 and 0 8 mm 0 024 0 028 and 0 032 in 3 Remove differential case bolts again 4 Apply thread lock cement to differential case bolts A Cemen
212. er speed km h Engine Speed r min throttle opening idle about full Brake Apply Not apply O D OFF switch ON OFF MALFUNCTION INDICATOR LAMP O D OFF LIGHT FUNCTION always ON sometimes ON not on Diagnostic trouble code indicated not indicated Diagnostic trouble code recorded NOTE The above form is a standard sample It should be modified according to conditions characteristic of each market 7B 16 AUTOMATIC TRANSMISSION 4 A T 2 DIAGNOSTIC TROUBLE CODE DTC CHECK RECORD AND CLEAR DTCs are indicated by the malfunction indicator lamp Refer to Diagnostic Trouble Code s Check in this sec tion When a DTC is indicated by this lamp it means existence of a malfunction in the system represented by that code but whether it still exists current or it occurred in the past and has gone history is unknown To know it clear this DTC once Refer to How to Clear Diagnostic Trouble Code s in this section perform Test Drive and or Problem Symptom Confirmation in this section and then check DTC again as described in Diag nostic Trouble Code s Check in this section Attempt to diagnose the trouble based on the DTC recorded in this step or failure to clear the DTC in this step may mislead the diagnosis or make diagnosing difficult Even after checking the DTC with the SUZUKI scan tool diagnosis should be performed according to this flow chart to check TCM for proper
213. er 93 C 200 F for example during a paint baking pro cess remove the air bag system components beforehand to avoid component damage or unintended sys tem activation When handling the air bag inflator modules driver and passenger seat belt pretensioners driver and passenger or SDM be careful not to drop it or apply an impact to it If an excessive impact was applied e g dropped from a height of 90 cm 3 ft or more never attempt disassembly or repair but replace it with a new one When using electric welding be sure to disconnect air bag inflator module connectors driver and passen ger and seat belt pretensioner connectors driver and passenger respectively When applying paint around the air bag system related parts use care so that the harness or connector will not be exposed to the paint mist Never expose air bag system component parts directly to hot air drying or baking the vehicle after painting or flames WARNING When performing service on or around air bag system components or air bag wiring disable the air bag system temporarily referring to Disabling Air Bag System in this section Failure to follow procedures could result in possible air bag system activation personal injury or unneeded air bag system repairs AIR BAG SYSTEM 10B 49 Disabling air bag system 1 Turn steering wheel so that vehicle s wheels front tires and pointing straight ahead 2 Turn ignition switch to
214. ered for the vehicle with without air bag sys tem is as shown below The ignition key with wrong knob color cannot be registered e Knob color of ignition key for vehicle with air bag sys tem Dark gray e Knob color of ignition key for vehicle without air bag system Black 1 Prepare SUZUKI scan tool and cartridge for immobilizer con trol system 2 With ignition switch OFF connect SUZUKI scan tool to data link connector DLC 1 located on underside of instrument panel at driver s seat side A SUZUKI scan tool NOTE For operation procedure of SUZUKI scan tool refer to SUZUKI scan tool operator s manual 3 Prepare ignition key with a built in transponder 1 And then V turn ignition switch ON by using it 2 Key knob 4 Number of Transponder codes for ignition key with a built in transponder that can be registered in Immobilizer Control Module is limited to 4 If needed clear all Transponder codes for ignition key with a built in transponder that have been registered in Immobilizer Control Module by executing the CLR TRANS COD CLEAR TP CODE command in the SELECT MODE menu by using SUZUKI scan tool IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 37 NOTE When CLR TRANS COD CLEAR TP CODE command is executed with the malfunction indicator lamp if not equipped with immobilizer indicator lamp ON or the immobilizer indicator lamp ON it rema
215. ering column mounting bolts and nuts referring to Steering Column Assembly in Section 3C 3 Remove meter cluster panel 2 Make sure to disconnect all couplers of switches and wires of cigarette lighter on meter cluster panel 2 4 Disconnect couplers from combination meter 1 5 Remove combination meter 1 INSTALLATION Reverse removal procedure for installation Fuel Meter Fuel Gauge Unit Fuel level meter INSPECTION 1 Disconnect Y R lead wire going to gauge unit 2 Use a bulb 12 V 3 4 W 3 in position to ground lead wire as illustrated 1 Battery 2 Fuel meter 3 Turn ignition switch ON Make sure that bulb is lighted with meter pointer fluctuating several seconds thereafter If meter is faulty replace 8 20 BODY ELECTRICAL SYSTEM Fuel sender gauge INSPECTION 1 Remove fuel pump assembly 1 referring to Fuel Pump Assembly in Section 6C 2 Use an ohmmeter to confirm that resistance of sender gauge unit changes with change of float position If the measured value is out of specification replace Fuel sender gauge specification Float Position Resistance Q Full Upper a 91 4 mm 4 03 in 2 4 Middle 1 2 d 154 8 mm 6 20 in 29 5 35 5 Full Lower c 263 5 mm 8 60 in 119 121 2 Fuel level gauge terminal 3 Fuel level gauge terminal 4 Float Engine Coola
216. erlock block pin screw a 25 N m 2 5 kg m 18 0 Ib ft 3 Interlock block 6 By using special tools and hydraulic press install bearing to output shaft Special tool A 09913 75520 B 09940 53111 7 Install output front shaft to front case 8 Install flange tighten flange nut and caulk nut Special tool A 09930 40113 Tightening torque Flange nut a 130 N m 13 0 kg m 94 Ib ft 9 Install shift shaft 1 to front case with spring 2 washers 4 and snap rings 8 installed as shown in figure TRANSFER 7D 19 10 Assemble output rear shaft 2 sleeve 1 keys 3 and key springs 4 as shown in figure Sleeve has specific installing direction NOTE Install key springs deviating their openings so that they are not in line with each other 11 Install output rear shaft 3 and 2 4 shift fork 1 as an assembly 2 Sleeve 12 Install lock up plate 1 and oil gutter 2 and tighten 3 bolts Tightening torque Lock up plate bolts a 28 N m 2 8 kg m 20 5 Ib ft NOTE Chamfer of lock up plate must face to rear side 13 Assemble planetary gear assembly 1 shift fork spacer 3 needle roller bearing 2 planetary sun gear 4 and thrust washer 5 and secure then with circlip 6 14 Install planetary gear unit 3 and Hi Lo shift fork 2 to output rear shaft as an assembly Fit snap ring 1 to shift shaft 7D 20 T
217. ess fitting hold countershaft with its front end set on wood blocks Special tool A 09913 80113 a Ke DE Ee Le Le e EE Bu 5 Install reverse idle gear 3 and washer onto reverse gear shaft and pin 1 into it Install above as assembled into lower case with pin and washer tongue 2 aligned as shown 6 Fit circlip 1 around bearing and check that circlip just con tacts with case surface 2 Front bearing MANUAL TRANSMISSION 7A 25 Shift shafts and forks 1 High speed gear shift fork 1 2 3 2 Reverse gear shift fork 3 Low speed gear shift fork Note that 3 shift shafts individually have a locating ball and locat 1 ing spring and that 2 interlock balls and an interlock roller are 9 used between shafts as shown 2 Install low high and reverse shafts in that order 1 Install 3 locating springs into 3 holes in upper case Fit locat ing ball on top of locating spring in hole EIN 1 Locating ball 7 Reverse gear shift shaft 2 Interlock ball 8 High speed gear shift shaft 3 Locating ball 9 Low speed gear shift shaft 4 Interlock roller 10 Locating spring 5 Interlock ball 11 Locating ball 6 Locating ball 12 Upper case 2 Insert low speed gear shift shaft 2 into upper case and low speed shift fork 1 in the direction as shown 3 Push down low speed gear shift shaft locating b
218. eteeeeeeteee 8 22 Rear Window Defogger 8 22 Defogger switch AA 8 22 Defogger wire 8 23 Wiper and Washer eeeeeeseeeereerreenen 8 24 Front wiper washer switch 8 25 Wiper MOto ss ieii iaaa 8 28 Washer pDump 8 29 Rear Wiper and Washer AA 8 30 Wiper and washer switchen 8 30 Rear Wiper motor ee 8 30 Rear wiper intermittent relay 0 8 31 Power Window Control System If Equipped eee eeeeeeeeeeeeeteeeeeeeeteeeeeeeetees 8 33 Breakelisitcaanad idan n dal dee ee 8 33 Power window main switch seee 8 33 Power Door Lock System If Equipped 8 34 Power door lock system component lOCAON tetera nati dannii Maat 8 34 Power door lock system operation lee TEE 8 35 Power door lock system circuit INSPOCUON Yasar A iene 8 35 Driver side key cylinder switch 8 36 Power door lock actuator eea 8 37 Power Door Lock System with Keyless Entry System If Equipped esseeeeeeee neee 8 38 Power door lock system with keyless entry system component location 8 38 System Description 8 38 Change of signal mode sece 8 39 Keyless entry system operation SPECION na ai geck Aaa tee a 8 39 Keyless entry system circuit inspection 8 40 Tronsmo eg Geegeegcie a dddedeee e 8 41 Driver side key cylinder switch 0 8 42 Power door lock actuator eee 8 42 Door SWItCN cece ceeee eee e eee tteeeeeeenaeaaaee 8 42 Power Door Mirror Control System If Equipped cece eee e
219. f diagnostic trouble code indicated first INTERMITTENT TROUBLES e There are cases where output of diagnostic output terminal malfunction indicator lamp and or Suzuki scan tool indicate a diagnostic trouble code representing a trouble which occurred only temporarily and has gone In such case it may occur that good parts are replaced unnecessarily To prevent such accident be sure to follow instructions given below when checking by using Diagnostic Flow Table When trouble can be identified it is not an intermittent one Check coil antenna ignition key wires and each connection and if they are all in good condition substi tute a known good ECM and recheck When trouble can not be identified but output of diagnostic output terminal malfunction indicator lamp and or Suzuki scan tool indicate a trouble code Diagnose trouble by using that code No and if ignition key coil antenna wires and each connection are all in good condition turn OFF ignition switch and then ON Then check what malfunction indicator lamp output of diagnostic output terminal and or Suzuki scan tool indi cate Only when they indicate trouble code again substitute a known good ECM or Immobilizer Control Module and check again If they indicate not trouble code but normal code it means that an intermittent trouble did occur and has gone In this case check wires and connections carefully again Diagnostic Flow Table Vehicle Not Equipped With Immobili
220. for STEP 2 Special tool A 09932 76010 B 09932 75010 C 09932 78340 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected 10B 26 AIR BAG SYSTEM DTC B1018 PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND body ground Is resistance 1 MQ or more known good SDM and recheck Step Action Yes No 1 1 With ignition switch OFF disconnect passenger air Go to step 2 Ignition switch OFF bag inflator module connector G61 behind the Replace passenger air glove box bag inflator module 2 Check proper connection to passenger air bag infla referring to Passenger tor module at terminals in G61 connector Air Bag Inflator Mod 3 If OK then connect special tools B and C to pas ule in this section senger air bag inflator module connector G61 With ignition switch ON does DTC B1018 still exist 2 1 With ignition switch OFF disconnect special tools B Go to step 3 Repair short from YEL and C from G61 connector and SDM connector RED wire circuit to Q60 from SDM respectively ground 2 Release shorting bar in SDM connecto
221. front clutch Fluid leakage from reverse brake AUTOMATIC TRANSMISSION 4 A T 7B 23 Engine Brake Test WARNING Before test make sure that there is no vehicle behind so as to prevent rear end collision 1 While driving vehicle in 3rd gear of D range shift select lever down to 2 range and check if engine brake operates 2 In the same way as in Step 1 check engine brake for oper ation when select lever is shifted down to L range 3 Engine brake should operate in above test Troubleshooting Test result Possible cause Fails to operate when e Defective shift switch shifted down to 2 range Fails to operate when e st amp 2nd brake defective shifted down to L range Defective A T P Range Test 1 Stop vehicle on a slope shift select lever to P range and at the same time apply parking brake 2 After stopping engine depress brake pedal and release parking brake 3 Then release brake pedal gradually and check that vehicle remains stationary 4 Depress brake pedal and shift select lever to N range 5 Then release brake pedal gradually and check that vehicle moves WARNING Before test check that no one is around vehicle or down on a slope and keep watchful for safety during test Troubleshooting Test result Possible cause Vehicle moves at P Defective parking lock pawl or range or remains station sprin
222. g 5 Press fit center bearing with bearing installer special tool using care for its installing direction Special tool A 09925 18011 1 Ring groove 6 Install ball 3 and washer 4 As figure shows install washer so that its circumference chamfered side faces center bearing 1 and its slot 2 comes over ball A Input shaft side B Rear bearing side 7 Press fit reverse gear bush preventing ball installed in step 6 from coming off Special tool A 09925 18011 MANUAL TRANSMISSION 7A 21 3 8 Install reverse gear bearing reverse gear and 5th speed synchronizer hub 4 and sleeve 3 For proper direction make sure to install hub so that the side whose inside boss 1 is smaller in diameter and longer is directed to main shaft rear bearing and sleeve so that the side whose inside is stepped is also directed to main shaft rear bearing 2 Stepped sleeve 4 4 A Rear bearing side 9 Fit 5th speed synchronizer hub circlip 1 into groove in main shaft 2 5th speed synchronizer hub and sleeve assembly 10 Install 5th gear bearing 5th gear synchronizer ring 4 and 5th gear 3 Then install ball 1 and washer 2 making oil groove of washer face 5th gear 7A 22 MANUAL TRANSMISSION 11 Press fit main shaft rear bearing 2 and fit circlip 1 into groove in main shaft 3 Special tool A 0
223. g ary at N range 7B 24 AUTOMATIC TRANSMISSION 4 A T Electronic Control System Diagnosis TCM has on board diagnostic system a system self diagnosis function Investigate where the trouble is by referring to Diagnostic Flow Table and Diagnostic Trouble Code Table on later pages Precautions in diagnosing troubles PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE For vehicle equipped with immobilizer indicator lamp 2 which comes on when turning on ignition switch leaving engine OFF malfunction indicator lamp MIL 1 comes on when TCM detests malfunction of automatic transmission system But MIL does not come on in case of DTC P1887 For vehicle equipped without immobilizer indicator lamp 2 malfunction indicator lamp MIL 1 does not come on although TCM detests malfunction of automatic transmission system Using SUZUKI scan tool Tech 1 6 diagnostic trouble code DTC stored in TCM memory can be checked and cleared as well Before its use be sure to read Operator s instruction Man ual supplied with it carefully to have good understanding of its functions and usage Not using scan tool the DTC stored in TCM memory also can be checked and cleared DTC stored in the TCM memory is outputted by flashing of O D OFF lamp 8 with diagnosis switch terminal of monitor connector No 2 5 grounded If no DTC is stored in T
224. g points e Door latch striker Adjust door latch striker so that its center aligns with the cen ter of groove in door latch base To adjust door latch and striker with each other insert proper number of shims 1 below the bottom of striker as shown e Door rubber cushion Move rubber cushion 1 installed at the left side of back door to align it with its guide BODY SERVICE 9 37 Exterior and Interior Trim Splash Guard ON Q e 1 1 Fender splash guard 3 Rear splash guard 2 Front door splash guard 4 Side sill splash guard REMOVAL AND INSTALLATION Remove and install as shown in figure Roof Rail If Equipped 1 Roof rail assembly 3 Rear cap 5 Nut 2 Front cap 4 Base seal REMOVAL 1 Remove roof rail front and rear caps as shown in figure 2 Remove nuts 3 Remove roof rail assembly INSTALLATION Reverse removal procedure for installation Confirm that each roof rail fixing nut is tightened securely 9 38 BODY SERVICE Tightening Torque Specification Fastening part Tightening torque Nem kg m lb ft Front door glass attaching screw 6 0 6 4 3 Front door hinge bolt 27 2 7 19 5 Door latch striker screw 10 1 0 7 2 Door latch screw 6 0 6 4 3 RESTRAINT SYSTEM 10 1 SECTION 10 RESTRAINT SYSTEM WARNING For vehicles equipped with Supplemental Restra
225. gasket to level filler plug and tighten level filler plug to specified torque Tightening torque Front differential oil level filler plug a 50 N m 5 0 kg m 36 5 Ib ft NOTE e Itis highly recommended to use SAE 80W 90 viscosity e Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage Differential oil Hypoid gear oil API GL 5 For oil viscosity refer to the chart Differential oil capacity 1 35 liters 2 9 2 3 US Imp pt Unit Repair Overhaul 15 EI E 8 U 100 400 Nm 10 0 40 0 kg m FRONT DIFFERENTIAL 7E 5 20 S T 85 Nm 8 5 kg m r F 12 Nm 1 2 kg m Apply differential oil Companion flange 9 Differential carrier 17 Differential side bearing adjuster Apply sealant 99000 31110 to mating face with axle housing Drive bevel Hypoid gear set 10 Differential pinion 18 Lock plate Drive bevel pinion spacer 11 Differential gear 19 Pinion washer Shim 12 Pinion shaft em 20 Drive bevel gear bolt z Apply thread lock cement 99000 32110 to thread Drive bevel pinion rear bearing 13 Differential case vz 21 Differential carrier bolt Apply sealant 99000 31110 to thread Drive bevel pinion front bearing 14 Differential side bearing cap x Do not reuse SC Oil seal 15 Thrust washer m Tightening torque Apply grease 99500 25010 to oil seal lip Flange nut 16 Differential side bearing After tigh
226. gnition key and that registered in Immobilizer Control Module Up to 4 different Transponder codes can be registered but also between the ECM Immobilizer Control Module code transmitted from ECM and that registered in Immobilizer Control Module In addition it has an on board diagnostic system self diagnosis function which is described in On Board Diagnostic System Self Diagnosis Function in this section 1 Immobilizer Control Module Vehicle not equipped with air bag system 2 Immobilizer Control Module Vehicle equipped with air bag system 3 Coil antenna Vehicle not equipped with air bag system ECM As main functions ECM not only checks matching of ECM Immobilizer Control Module code but also has an on board diag nostic system self diagnosis function as described in On Board Diagnostic System Self Diagnosis Function in this section For installation position of ECM refer to Engine Control Module in Section 6E On Board Diagnostic System Self Diagnosis Function Immobilizer Control Module and ECM diagnose troubles which may occur in the area including the following parts when the igni tion switch is ON ECM e ECM Immobilizer Control Module code e Serial data link circuit e ECM Immobilizer Control Module e Transponder code e Coil antenna e ECM Immobilizer Control Module code e Serial data link circuit e Immobilizer Control Module e Ignition signal 8G 6 I
227. heck bulb STOP fuse blown After checking short circuit replace fuse Brake light switch faulty Check switch Wiring or grounding faulty Repair circuit Brake lights stay on Brake light switch faulty Check adjust or replace switch Wiring or grounding faulty Repair circuit Tachometer and ECM Condition Possible Cause Correction Tachometer shows no operation METER fuse blown After checking short circuit replace fuse Wiring or grounding faulty Repair circuit Tachometer faulty Replace tachometer ECM or other controller faulty Check ECM and other controller Speedometer and VSS Condition Possible Cause Correction Speedometer shows no operation METER fuse blown After checking short circuit replace fuse VSS faulty Check VSS Wiring or grounding faulty Repair Speedometer faulty Replace speedometer Fuel Meter and Fuel Gauge Unit Condition Possible Cause Correction Fuel meter shows no operation METER fuse blown After checking short circuit replace fuse Fuel gauge unit Check fuel gauge unit Fuel meter Check fuel meter Wiring or grounding Repair circuit Engine Coolant Temp ECT Meter and ECT Sensor Condition Possible Cause Correction Engine coolant temp meter show
228. i EE eg SE OEE Ki SS SSS NEN ANAAASE e e LAWNS Sy ER ae aa ZUR 2 ET Hu E IK DA WOU 23 Ge Ai A Apply rustproof wax to shaded area Over 50 um BODY SERVICE 9 33 Ze AN A Apply undercoating to shaded area Over 400 um 5 Rear floor 10 Front fender 1 Rear wheel housing 6 Frame 11 Front wheel housing 2 Side body outer 7 Main floor 12 Dash panel 3 Rear splash guard holder 8 Side sill inner 13 Tunnel front 4 Rear quarter inner 9 Front fender apron 14 Center floor 9 34 BODY SERVICE Security and Locks Front Door Lock Assembly U 6 N m 0 6 kg m 1 Door latch 3 Inside handle bezel Wl Tightening torque 2 Outside handle 4 Latch striker REMOVAL 1 Raise window all the way up 2 Remove door trim and door sealing cover refer to steps 1 to 6 of REMOVAL under Front Door Glass in this section 3 Remove door sash 4 Remove door opening control rods 2 5 Disconnect control rod 3 6 Disconnect door lock motor lead wire 7 Remove lock assembly 1 Out side door handle BODY SERVICE 9 35 INSTALLATION To install front door lock reverse removal procedure noting fol lowing e Door latch striker 2 Move door latch striker up or down so its center aligns
229. iable to stay e Vinyl coating is applied to body underside and wheel housing inside e Sealer is applied to door hem engine compartment steel sheet to steel sheet joint and the like portions to prevent water penetration and resulting in rust occurrence In panel replacement or collision damage repair leaving the relevant area untreated as it is in any operation which does disturb the above mentioned rust proof treatment will cause corrosion to that area Therefore it is the essential function of any repair operation to correctly recoat the related surfaces of the relevant area All the metal panels are coated with metal conditioners and primer coating during vehicle production Following the repair and or replacement parts installation every accessible bare metal surface should be cleaned and coated with rust proof primer Perform this operation prior to the application of sealer and rust proof wax coating Sealer is applied to the specific joints of a vehicle during production The sealer is intended to prevent dust from entering the vehicle and serves also as an anticorrosion barrier The sealer is applied to the door and hood hem areas and between panels Correct and reseal the originally sealed joints if damaged Reseal the attaching joints of a new replacement panel and reseal the hem area of a replacement door or hood Use a quality sealer to seal the flanged joints overlap joints and seams The sealer must have flexible character i
230. ic System Check in this section to confirm that the trouble has been cor rected 10B 20 AIR BAG SYSTEM AIR BAG warning lamp can not indicate flashing TABLE TEST DESCRIPTON STEP 1 Check AIR BAG monitor coupler STEP 2 Check diagnosis switch circuit for air bag system DIAGNOSTIC FLOW TABLE Step Action Yes No 1 1 Inspect connection between diagnostic Go to step 2 switch terminal on AIR BAG monitor cou pler G63 and body ground by service wire Is it securely connected between them by ser Properly connection diag nostic switch terminal on AIR BAG monitor cou pler and body ground by 2 Check for proper connection at PPL wire If OK then PPL wire cir Q60 15 terminal of SDM connector and cuit high resistance or G63 2 terminal of AIR BAG monitor cou open pler terminals 3 If OK then measure resistance between Q60 15 terminal and G63 2 terminal Is resistance 1 Q or more vice wire service wire 2 1 Disconnect SDM connector Q60 from Check PPL wire termi Substitute a known good SDM nals SDM and recheck A 2 Q60 15 A A Fig for STEP 2 1 AIR BAG monitor coupler 2 PPL wire terminal Special tool A 09932 76010 NOTE Upon completion of inspection and repair work perform the following items es Reconnect all air bag sy
231. ic Trouble Code DT 10B 6 DTC B1018 Passenger Air Bag Initiator Use of Special Tool 10B 6 CAR Circuit Short to Groungd eee 10B 23 Intermittents and Poor Connections 10B 8 a d f DTC B1019 Passenger Air Bag Initiator Air Bag Diagnostic System Check 10B 9 eae lt TEE i Circuit Short to Power Coup 10B 23 Air Bag Diagnostic System Check Flow a SZ DTC B1021 Driver Air Bag Initiator ables attenuate eit 10B 10 een Circuit Resistance Hoh 10B 28 DTC Check in iiaa 10B 11 i a DTC B1022 Driver Air Bag Initiator DTC Clearance cccceeccceceeeeeeeeeteeeeeeees 10B 12 ee 8 Circuit Resistance LOW n 10B 28 DTC Table esccctccccncitaceseeceuinnctacheberectaeeteans 10B 13 Se 7 S EECH DTC B1024 Driver Air Bag Initiator AIR BAG Warning Lamp Circuit Trouble emie Circuit Short to Ground 10B 28 Diagnosis Table o e 10B 15 S Ge P fi DTC B1025 Driver Air Bag Initiator AIR BAG warning lamp comes on pee Eer Circuit Short to Power Coup 10B 28 SlCAA se iecche degtietieedieeseihib haces 10B 16 DTC B1032 Power Source Voltage AIR BAG warning lamp does not cOme O 10B 17 COW eeen e a isi iii Nodes 10B 35 c Gan E DTC B1041 Driver Pretensioner Initiator AIR BAG warning lamp flashes 10B 19 ae e R Circuit Resistance Hoh 10B 37 AIR BAG warning lamp can not i S SG d on R DTC B1042 Driver Pretensioner Initiator indicate Tashi
232. if there are cracks dents or other defects in the case or plate replace it with a new one Check SDM 2 and SDM plate 3 for dents cracks or defor mation Check SDM connector 1 for damage cracks or lock mech anism Check SDM terminal for bent corrosion or rust If any faulty condition is found in above checks replace F Forward AIR BAG SYSTEM 10B 59 INSTALLATION For installation reverse removal procedure noting the following points e Ensure that arrow 3 on the SDM 2 is pointing toward the front of the vehicle e Tighten SDM bolts to specified torque Tightening torque SDM mounting bolt a 6 N m 0 6 kg m 4 5 Ib ft e Connect SDM connector 1 to SDM 2 securely e Enable air bag system referring to Enabling Air Bag Sys tem in this section F Forward Passenger Air Bag Inflator Module WARNING es Never attempt to disassemble or repair the passenger air bag inflator module If any abnormality is found be sure to replace it with new one as an assembly e Be sure to read Service Precautions in this section before starting to work and observe every pre caution during work Neglecting them may result in personal injury or undeployment of the air bag when necessary REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system referring to Disabling Air Bag Sys tem in this section 3 Remove passenger
233. ighten drain plug 1 after applying sealant to its thread and fill new specified oil as shown below by speci fied amount roughly up to level hole A Sealant 99000 31110 Tightening torque Oil drain plug a 23 N m 2 3 kg m 17 0 Ib ft NOTE e Itis highly recommended to use SAE 75W 90 gear oil e Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage Gear oil API GL 4 For SAE classification refer to viscosity chart in the fig ure Oil capacity for 4WD model 0 9 liters 1 9 1 6 US Imp pt Oil capacity for 2WD model 1 34 liters 2 8 2 4 US Imp pt 4 Torque level filler plug 2 as specified below after applying sealant to its thread A Sealant 99000 31110 Tightening torque Oil level filler plug b 23 N m 2 3 kg m 17 0 Ib ft 4WD Switch Inspection 1 Hoist vehicle 2 Disconnect 4WD switch coupler 1 TRANSFER 7D 7 3 Check continuity between two terminals of 4WD switch Transfer position 2H Not continuity 4H 4L Continuity 4 Connect 4WD switch coupler 7D 8 TRANSFER Unit Repair Overhaul DISMOUNTING In Engine Room 1 Disconnect negative cable 1 at battery In Cabin 1 Remove transfer shift knob 1 by removing screw 2 On Lift 1 Drain transfer oil referring to Oil Change in this section 2 Remove exhaust p
234. ignal light oewitch eee Oil Pressure Light 8 6 Hazard SWItCh eee Brake and Parking Brake Warning Light SEA 8 6 Stop Brake Lamp SEENEN EE Seat Belt Warning Light ccccscceeceseeeees 8 6 Stop brake lamp switch un Rear Window Defogger If Equipped 8 7 Rear Fog Light If Eouipped e Front Wiper and WaSher ssieeen 8 7 Rear fog light ewitch 2uesgserere ereuugeun Rear wiper and washer If equipped Ke Eech 8 7 Ignition E ue BEE Power Window Control System Combination Meier UE eieiei 8 7 Fuel Meter Fuel Gauge Unn en Power Door Lock System If Equipped 8 8 Fuel level meter AAA Power Door Lock System with Keyless Entry Fuel Sender gauge ccsscccsceeeeeeeeeeeees System If Eouippedt 8 8 Engine Coolant Temperature Meter and Power Door Mirror Control System ed bene N 8 9 Sensor Un 8 20 Door Mirror Heater If Eouipped 8 9 Engine coolant temperature meter 8 20 Front Seat Heater If Equipped ccccee 8 9 Engine coolant temperature sensor 8 21 Cigarette Lgbter 8 9 Oil Pressure Warning Cotten 8 21 Interior Lights 232 ac scccactetactccnticaiececceccaardesecteeiag 8 10 Oil pressure awitch EE 8 21 On Vehicle Service EEN An 8 11 Brake and Parking Brake Warning Light 8 22 Brake fluid level aewitch 8 22 8 2 BODY ELECTRICAL SYSTEM Parking brake switch AA 8 22 Seat Belt Warning Light If Equipped 8 22 Seat belt switch eeeeeeeeee
235. in 10 min to ensure suffi cient adhesion Be sure to refer to adhesive maker s instruction for proper handling and drying time Adhesive amount specifications and position for wind shield Width d Approx 8 mm 0 31 in Width e Approx 9 mm 0 35 in Height f Approx 15 mm 0 59 in Height g Approx 17 mm 0 67 in Distance h Approx 10 5 mm 0 41 in 1 Molding 2 Adhesive 3 Glass 11 12 Holding rubber sucker grips 1 place glass onto body by aligning mating marks marked in step 3 and press it Check for water leakage by pouring water over windshield through hose If leakage is found dry windshield and fill leaky point with adhesive If water still leaks even after that remove glass and start installation procedure all over again NOTE Do not use high pressure water Do not blow compressed air directly at adhesive applied part when drying Do not use infrared lamp or like for drying ANNANIN ENAR LRT KA KEES ES EE BODY SERVICE 9 11 CAUTION Upon completion of installation note the following e Sudden closing of door before adhesive is completely set may cause glass to become loose or to come off Therefore if door is opened or closed before adhesive is completely set make sure to open all door glasses and use proper care e If molding is not securely in place hold it down with a tape
236. in dif ferential oil 4 Apply sealant to drain plug thread A Sealant 99000 31110 5 Tighten drain plug to specified torque Tightening torque Rear differential oil drain plug b 27 N m 2 7 kg m 19 5 Ib ft 6 Pour proper amount of new differential oil as specified below roughly up to level hole 7 Install new gasket to level filler plug and tighten level filler plug to specified torque Tightening torque Rear differential oil level filler plug a 50 N m 5 0 kg m 36 5 Ib ft NOTE e Itis highly recommended to use SAE 80W 90 viscosity e Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage Differential oil Hypoid gear oil API GL 5 For oil viscosity refer to the chart Differential oil capacity 1 5 liters 3 2 2 6 US Imp pt 8 12 N m 1 2 kg m 21 E L T Ca a a i g 22 Q 85 N m 8 5 kg m E REAR DIFFERENTIAL 7F 5 Unit Repair Overhaul ei 12 N m 1 2 kg m 18 e Rd T 100 400 N m 10 0 40 0 kg m 1 Companion flange 10 Differential pinion 19 Pinion shaft No 2 2 Drive bevel Hypoid gear set 11 Differential gear 20 Pinion joint 3 Drive bevel pinion spacer 12 Pinion shaft No 1 21 Pinion washer 4 Shim 13 Differential left case em 22 Drive bevel gear bolt z Apply thread lock cement 99000 32110 to thread 5 Drive bevel pinion rear bearing 14 Differential right case
237. in figure Make sure that the obtained piston stroke and clearance sat isfy the standard value BO brake clearance Set dial gauge 1 to the top of BO brake flange and blow com pressed air into the hole shown in figure BO brake disc clearance Standard 0 50 1 05 mm 0 0197 0 0413 in BO piston stroke Set dial gauge to the step of BO brake piston as shown in figure Blow compressed air into the hole shown in figure and measure the value for piston stroke BO brake piston stroke Standard 0 70 1 05 mm 0 0275 0 0413 in If the measured value s is are out of specification select the flange from table below and repeat this step until the measured values are within specification Available flange thickness 2 35 mm 0 093 in 2 60 mm 0 102 in 2 85 mm 0 112 in 3 10 mm 0 122 in Tip of dial gauge on BO brake flange Airgun AJ oj N Blow compressed air into this hole Tip of dial gauge on BO brake piston A Clearance B Piston stroke a AUTOMATIC TRANSMISSION 4 A T 7B 113 19 Install front sun gear 2 to planetary set 1 Needle roller bearing 20 Install thrust needle roller bearing 1 to intermediate shaft 2 21 Install intermediate shaft 1 to transmission case 22 Install rear disc clutch assembly 1 by turning it right and left to match the clutch disc of rear disc clutch ass
238. in the following equation Necessary shim thickness Dial gauge measured value D 7F 18 REAR DIFFERENTIAL A A 10 Select adjusting shim s 2 closest to measured value from among following available sizes 11 Put shim s in place and press fit drive bevel pinion rear bearing 1 to drive bevel pinion 3 by using special tools and hydraulic press Special tool A 09924 07730 B 09926 37610 003 Available shim thickness 0 30 1 00 1 03 1 06 1 09 1 12 1 15 1 18 1 21 1 24 1 27 and 1 30 mm 0 012 0 039 0 041 0 042 0 043 0 044 0 045 0 046 0 048 0 049 0 050 and 0 051 in 12 Apply differential oil to drive bevel pinion front bearing 1 13 Install drive bevel pinion front bearing in differential carrier 14 Apply grease to oil seal lip Grease 99000 25010 15 Install oil seal in differential carrier by using special tool Special tool A 09944 66010 B 09924 74510 REAR DIFFERENTIAL 7F 19 CAUTION e Use new drive bevel pinion spacer otherwise bearings 4 5 may be damaged e Take care not to give press force to drive bevel pinion spacer otherwise spacer and bearings may be dam aged ee Apply differential oil to drive bevel pinion rear bearing 2 17 Install drive bevel pinion 1 spacer 3 and companion flange 5 into differential carrier 4 18 Until bearing axial clearance come to
239. in this section and confirm that nor mal DTC NO CODES is displayed and not malfunction DTC NOTE If DTC B1051 or DTC B1071 is stored in SDM it is not possible to clear DTC 1 Data link connector DLC AIR BAG SYSTEM 10B 13 Not Using SUZUKI Scan Tool 1 Turn ignition switch to ON position and wait about 6 seconds or more 2 Using service wire repeat shorting and opening between diagnosis switch terminal on AIR BAG monitor coupler and body ground 5 times at about 1 second intervals 3 Perform DTC Check in this section and confirm that nor mal DTC DTC 12 is displayed and not malfunction DTC NOTE If DTC B1051 or DTC B1071 is stored in SDM it is not possible to clear DTC 1 AIR BAG monitor coupler a Open 2 Body ground b Short 3 Diagnosis switch terminal c About 10 seconds 4 Service wire d 1 sec a 0 DTC Table AIR BAG warning lamp DTC flashing pattern Diagnosis NO MODE 12 SLA Normal B1015 15 l MAAN Resistance high B1016 16 POULT Passenger air Resistance low B1018 18 LAU pag circuit Short to ground B101 1 Sh naw Diagnose trou 019 9 n LLL ort to power circuit ble according to Bio21 21 AMN Resistance high diagnostic flow table corre B1022 22 II TU Driver air bag Resistance low sponding to ircuit each code No B1024 24 IL PULL SE
240. inal Step Action Yes No 1 Check voltage between G38 2 terminal and Go to Step 2 BI B wire open body ground with ignition switch turned ON Is it 10 14V 2 1 Connect voltmeter between G38 10 termi Go to Step 3 Poor G38 2 G38 10 or G38 nal and body ground 8 connection 2 Does voltmeter indicator deflect B wire of G38 8 terminal open P G wire between G38 10 terminal and diagnostic out put terminal of immobilizer diagnostic coupler short If wire and connections are OK substitute a known good Immobilizer Control Module and recheck See NOTE 3 1 Connect voltmeter between diagnostic out B wire of ground ter P G wire between G38 10 put terminal of immobilizer diagnostic cou minal for immobilizer terminal and diagnostic out pler and body ground diagnostic coupler put terminal of immobilizer 2 Is it possible to read DTC by checking open diagnostic coupler open deflection of voltmeter indicator NOTE After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM and Transponder code and ECM Immobilizer Control Module code in Immobi lizer Control Module by performing procedure described in Procedure After Immobilizer Control Mod ule Re placement in this section IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 17 Table B Immobilizer Indicator Lamp Check For Vehicle Equipped wi
241. ing is pulled out of the retractor e Acceleration or deceleration of the vehicle speed e Inclination Seat Belt with A ELR The Automatic and Emergency Locking Retractor A ELR works as an Emergency Locking Retractor ELR till its webbing is pulled all the way out and then on as an Automatic Locking Retractor ALR till it is retracted fully ALR Automatically locks when the webbing is pulled out from the retractor and allowed to retract even a little Then the webbing can not be pulled out any further unless it is wound all the way back into the retractor which releases the lock and allows the webbing to be pulled out RESTRAINT SYSTEM 10 3 Seat Belt Pretensioner If Equipped Some seat belts of the driver and front passenger seats are pro vided with a pretensioner as an optional function unit The preten sioner is incorporated in retractor assembly 6 and controlled by SDM as one of air bag system components It will be activated to takes up the sag of the seat belt at the same time as the air bag deployment when an impact at the front of vehicle exceeds the specified value When servicing seat belt with pretensioner be sure to observe all WARNINGS and CAUTIONS in this section and Service Precau tions in Section 10B CAUTION Do not reuse the seat belt retractor assembly if preten sioner has been activated Replace it with a new one as an assembly Front seat Front seat belt
242. ing shift control lever downward at 4H shift position it restricts 2 4 shift fork movement and enable Hi Lo shift fork to side forward causes 4L shift position TRANSFER 7D 5 Diagnosis Condition Possible Cause Correction Gear slipping out of mesh Worn shift fork shaft Replace Worn shift fork or sleeve Replace Weak or damaged locating spring Replace Worn bearings on input shaft or output shaft Replace Worn chamfered tooth on sleeve or gear Replace sleeve and gear Worn synchronizer ring Replace Gears refusing to disengage Distorted shift shaft or shift fork Replace Weakened or broken synchronizer spring Replace Hard shifting Inadequate or insufficient lubricant Replenish Worn chamfered tooth on sleeve or gear Replace sleeve and gear Distorted shift shaft Replace Noise Inadequate or insufficient lubricant Replenish Damaged or worn bearing s Replace Damaged or worn gear s Replace Damaged or worn chamfered tooth on sleeve Replace or gear 7D 6 TRANSFER On Vehicle Service Viscosity chart SAE C 30 20 10 0 10 20 30 40 E ee Ve ON E Ve F 22 4 14 32 50 68 86 104 Temperature 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 or repair it 3 Drain old oil t
243. ing to the following page Is there any faulty condition 5 Trouble Symptom Confirmation Go to Step 6 Go to Step 7 1 Confirm trouble symptom referring to the following page Is trouble symptom identified 6 Rechecking and Record of DTC Go to Step 9 Go to Step 8 1 Recheck for DTC referring to DTC Check in this section Is there any DTC s 7 _ Rechecking and Record of DTC Go to Step 9 Go to Step 10 1 Recheck for DTC referring to DTC Check in this section Is there any DTC s 7B 14 AUTOMATIC TRANSMISSION 4 A T Step Action Yes No 8 Automatic Transmission Basic Check and Trou ble Diagnosis Table 1 Check and repair according to A T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE in this section Are check and repair complete Troubleshooting for DTC 1 Check and repair according to applicable DTC Diagnostic Flow Table Are check and repair complete Go to Step 11 Check and repair mal function part s Go to Step 11 10 Check for Intermittent Problems 1 Check for intermittent problems referring to the following page Is there any faulty condition Repair or replace mal function part s Go to Step 11 Go to Step 11 11 Final Confirmation Test 1 Clear DTC if any 2 Perform final confirmation test referring to the following page Is there any problem symptom DTC or abnor mal condition Go to
244. input shaft and front internal gear and front carrier Overdrive brake Fixes front sun gear 1st amp 2nd brake Fixes rear sun gear Reverse brake Fixes front carrier and rear internal gear TABLE OF COMPONENT OPERATION Part i Steier E Fronteiutch Rear clutch Overdrive ist amp 2nd Reverse position position brake brake brake O X X Ka X O X X x O O x x x X ist QO X x O x D 2nd x O x O X 3rd O O x x x Ath O D x O O x x S 1st O X x O Ka 2nd x O x O X L 1st O x x O x Operating X Not operating TABLE OF SHIFT SOLENOID VALVE OPERATION Shift Solenoid Valve Range amp Gear A No 1 B No 2 C No 3 D No 4 P x O x x 1st gear of O D D 2 L Xx O O x 2st gear of O D D 2 L O x O x 3st gear of O D D 2 L x x x x 4st gear of O D O x x O R x x x X Operating X Not operating 7B 6 AUTOMATIC TRANSMISSION 4 A T Electronic Shift Control System 1 Engine 16 Vehicle speed sensor VSS G Range signal 2 Transmission 17 Blank H Vehicle speed signal 3 TCM 18 Blank L O D OFF signal 4 ECM 19 Monitor connector No 2 J O D OFF lamp signal 5 Combination meter O D OFF lamp 20 SUZUKI scan tool K Diagnosis switch signal 6 O D off swit
245. ins ON even after execution of that command is over It will start flashing when the ignition switch is turned OFF once and then turned ON after some seconds 5 Using SUZUKI scan tool register Transponder code in Immobilizer Control Module by executing ENT TRANS COD ENT TP CODE command in SELECT MODE menu 6 Make sure that following indicator lamp lights when ignition switch is turned OFF once and then turned ON e Vehicle not equipped with immobilizer indicator lamp malfunction indicator lamp MIL e Vehicle equipped with immobilizer indicator lamp immobilizer indicator lamp 7 H any other Transponder code for ignition key with a built in transponder needs to be registered repeat above steps 3 5 and 6 NOTE es Up to 4 Transponder codes for ignition key with a built in transponder can be registered e It is not possible to register the same Transponder code for ignition key with a built in transponder as the one already registered in Immobilizer Control Module Procedure After Immobilizer Control Module Replacement When Immobilizer Control Module was replaced including when replaced because rechecking by using a known good Immobilizer Control Module was necessary during trouble diagnosis register Transponder code and ECM Immobilizer Control Module code in Immobilizer Control Module and ECM Immobilizer Control Mod ule code in ECM by performing following procedure CAUTION When registering the ign
246. int Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either or these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE To determine if the vehicle is equipped with seat belt pretensioner refer to Owner s Manual CONTENTS General Description secccssseeeeesseeeeeseeees 10 2 Enabling air bag system for vehicle with Seat Belt Pretensioner If Equipped 10 3 air bag System 10 4 DlagnoselesseeegessseseeeerzergegugeueEegeeEgeegeg erg eg 10 3 Handling and storage for vehicle with i air DAG SYSTOM eee iiuen 10 4
247. ipe 1 3 Give match marks on each joint flange and propeller shaft 4 Remove securing bolts from each flange connection sever 3 propeller shafts from transfer gear box and suspend propel ler shafts with a wire hook or like TRANSFER 7D 9 5 Disconnect 4WD switch wire at coupler 1 and unclamp har ness Disconnect speed sensor coupler 2 Speed sensor 3 Clamp 6 With transfer supported on jack remove 3 mounting nuts 1 and 4 bolts 2 7 Remove transfer with mountings from body 8 Remove mounting from transfer 3 Mounting right bracket 4 Mounting left bracket 5 Mounting REMOUNTING For remounting reverse dismounting procedure noting following e Use specified torques as given below Tightening torque Transfer mounting nut a 30 N m 3 0 kg m 22 0 Ib ft Transfer mounting bracket bolt b 23 N m 2 3 kg m 17 0 Ib ft Set each clamp for wiring securely Connect couplers to speed sensor and 4WD switch securely Pour gear oil to transfer as specified When installing propeller shafts align the each match marks For tightening torque of flange bolts refer to Propeller shafts in Section 4B Install exhaust pipe to Component in Section 6K Install shift knob Connect battery 7D 10 TRANSFER DISASSEMBLY 1 Remove boot and then plate bush 4 and spring 3 1 Disconnect gear shift control le
248. ir bag modules and or acti vate seat belt pretensioners installed on vehicle WARNING The following precautions must be observed for this work Failure to observe any of them may result in personal injury Procedure should be followed strictly as described here Be sure to read Service Precautions in this section beforehand To avoid accidental deployment activation this work should be performed by no more than one per son Since smoke is produced when air bag inflator module is deployed and pretensioner is activated select well ventilated area Air bag inflator module and seat belt pretensioner will immediately deploy activate when 12 volts vehicle battery is connected to it Wear safety glasses throughout this entire deployment activation and disposal procedure Wear suitable ear protection when deploying air bag inflator module activating seat belt preten sioner Also advise those who are in area close to deploymenvtactivation site to wear suitable ear protection Do not deploy activate two or more air bag system components air bag inflator modules and seat belt pretensioners at the same time Never connect deployment harness to any 12 volts vehicle battery before connecting deployment harness to air bag inflator module and seat belt pretensioner Deployment harness shall remain shorted and not be connected to 12 volts vehicle battery till you are ready to deploy air bag inflator module or activate seat be
249. iscs e Before assembling new discs soak them in A T fluid for at least two hours Front Clutch Return Spring Seat Measure height of front clutch return spring Height of front clutch return spring 14 85 mm 0 585 in NOTE e Do not apply excessive force when measuring spring height es Perform measurement at several points Front Clutch Piston Lip and Front Clutch Balancer Lip Check each lip for wear deformation cut and or hardening If necessary replace AUTOMATIC TRANSMISSION 4 A T 7B 91 ASSEMBLY 1 Install new D ring 5 to front clutch No 1 drum Apply grease to D ring and fit it to drum A Grease 99000 25030 2 Install piston 4 into front clutch No 1 drum 6 Use care that the piston lip does not get twisted or caught Apply grease to the lip of the piston A Grease 99000 25030 3 Install front clutch return spring 3 seat and front clutch bal ancer 2 1 Snap ring 4 Install shaft snap ring 1 A Compress return springs and install shaft snap ring in groove by using a screwdriver 3 Place special tool clutch spring compressor on spring seat and compress springs with a press 2 Go i CAUTION E Bei SY Do not compress return spring more than necessary Special tool A 09926 96010 5 Install discs plates and flange 1 in following order 1 Plate 2 Disc 3 Plate 4 Disc 5 Plate g
250. isted or caught when installing C2 accumulator piston large O ring C2 accumulator spring with pink paint B1 accumulator piston with 1 groove B1 accumulator spring with light blue paint Snap ring Accumulator spacer BO accumulator spring with white paint 9 BO accumulator piston Nlo a a e r s 10 C1 accumulator piston with 2 grooves 11 C1 accumulator spring 12 C2 accumulator spring with orange paint 13 C2 accumulator piston small 37 Install wire to solenoid assembly 1 Fix it with sleeve lock plate 2 and a bolt NOTE e Apply grease to O ring of wire to solenoid assembly e Match the arrow mark on wire to solenoid assembly with the sleeve lock plate Tightening torque Wire to solenoid assembly bolt a 8 0 N m 0 8 kg m 6 0 Ib ft Grease 99000 25030 AUTOMATIC TRANSMISSION 4 A T 7B 117 sd 38 Install valve body 1 to transmission case a First match the pin of the manual valve lever to the slot of the Sais OR 0 manual valve ES SS E SO HR WY EE ERO Set J NOTE PERY O SUI i cal K Cl S C Sg Connect shift solenoid No 2 coupler green before tight my Poe e ening bolts SS Tightening torque i R EH Valve body bolts a 10 N m 1 0 kg m 7 5 Ib ft Bolt Length a Pieces A 25 mm 0 98 in 2 S B 25 mm 0 98 in 7 gomm C 20 mm 0 79 in 3
251. ition key including a transponder into the immobilizer control module by using Suzuki scan tool confirm that the knob color of the ignition key to be registered for the vehicle with without air bag system is as shown below The ignition key with wrong knob color cannot be registered e Knob color of ignition key for vehicle with air bag system Dark gray e Knob color of ignition key for vehicle without air bag system Black 1 Perform steps 1 and 2 described in How To Register Ignition Key in this section 2 Prepare ignition key with a built in transponder And then turn ignition switch ON by using it 3 Using SUZUKI scan tool clear all transponder codes registered in Immobilizer Control Module by executing CLR TRANS COD CLEAR TP CODE command in SELECT MODE menu 8G 38 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED NOTE When CLR TRANS COD CLEAR TP CODE command is executed with the malfunction indicator lamp if not equipped with immobilizer indicator lamp ON or the immobilizer indicator lamp ON it remains ON even after execution of that command is over It will start flashing when the ignition switch is turned OFF once and then turned ON after some seconds 4 Using SUZUKI scan tool register Transponder code in Immobilizer Control Module by executing ENT TRANS COD ENT TP CODE command in SELECT MODE menu 5 Using SUZUKI scan tool register ECM Immobilizer Control Module code in both Immobilize
252. ittle by little while pushing the entire glass from inside toward outside as shown in fig ure NOTE Do not apply an excessive force to glass locally 3 Back door panel A Viewed A 1 1 2 oa A lt x INSTALLATION Install weatherstrip 1 to glass 2 Pass string 4 through outer groove of weatherstrip groove where back door panel 3 fits in so that weatherstrip can be installed to back door Apply soap water to outer edge of back door panel and install glass and weatherstrip together to back door by pull ing the string little by little Connect rear defogger coupler Install rear wiper arm Check for water leakage by running water from hose over window If leakage is found complete the installation of leaky point If water still leaks even after that remove glass and start installation procedure all over again NOTE Do not use high pressure water BODY SERVICE 9 13 Body Structure Front Door Assembly REMOVAL 1 Remove front fender 2 Disconnect door harness lead wires at each coupler 3 Remove stopper pin 1 2 Door open stopper 4 Support door panel using a jack with a piece of wood placed between jack and panel as shown 1 Rags 2 Wooden piece 5 Remove door assembly 3 by loosening hinge mounting bolts 1 Upper hinge mounting bolts 2 Lower hinge mounting bolt
253. ity is not obtained replace ignition switch Terminal 5 4acc ia1 ice st ut v2 Kt k Key Position obrweal B pm op BY B BG G OUT LOCK ACC IN ON 91919 O AU OG O O O START ccessory afa s l REMOVAL AND INSTALLATION Refer to Steering Lock Assembly Ignition Switch in Section 3C for details 8 18 BODY ELECTRICAL SYSTEM Combination Meter 18 10 12 14 15 16 17 1 Tachometer 7 Immobilizer warning light if equipped 13 High beam light 2 Speedometer 8 CHECK ENGINE light 14 Oil pressure warning light 3 Fuel lever meter 9 Turn signal pilot light RH 15 Charge warning light 4 Water temperature meter 10 AIR BAG warning light if equipped 16 Brake warning light 5 Turn signal pilot light LH 11 O D OFF light A T vehicle only 17 ABS warning light if equipped 6 4WD indicator if equipped 12 Fasten seat belt light if equipped 18 Shift position indicator A T vehicle if equipped COMBINATION METER INTERNAL CIRCUITS AND COUPLERS NOTE Terminal arrangement of coupler viewed from harness side L8 K7 L3 a L13 or ABS if equipped L5 L7 M6 E M1 M2 M3 M4 K1 Se 5046665 K9 K10 K11 K13 K15 K12 K6 L10 L11 M9 K1 L9 L12 L6 C CELLE EEE
254. l inspection and installation Seat Belt Pretensioner Refer to Front Seat Belt in Section 10 for removal inspection and installation AIR BAG SYSTEM 10B 61 Air Bag Inflator Module and Seat Belt Pretensioner Disposal WARNING Failure to follow proper air bag inflator module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury Do not dispose of live undeployed air bag inflator modules and seat belt pretensioners Because undeployed air bag inflator module inactivated seat belt pretensioner must not be disposed of through normal refuse channels Undeployed air bag inflator module and inactivated seat belt pretensioner contain substances that can cause severe illness or personal injury if sealed container is damaged during disposal Air bag inflator module seat belt pretensioner can be deployed activated inside or outside of vehicle Deploy ment Activation method used depends upon final disposition of vehicle Review the following instructions in order to determine which will work best in a given situation Deployment Activation Outside of Vehicle When you intend to return the vehicle to service deploy the air bag inflator module s or activate seat belt pre tensioner s outside of the vehicle Deployment Activation Inside of Vehicle When the vehicle will be destroyed or salvaged for component parts deploy the a
255. l Module and Table again e Knob shape the same as shown in recheck Fig 1 See NOTE Is it the original one NOTE After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM and Transponder code and ECM Immobilizer Control Module code in Immobi lizer Control Module by performing procedure described in Procedure After Immobilizer Control Mod ule Replacement in this section Fig 1 for step 1 o Ignition key with built in transponder IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 25 DTC21 ECM Immobilizer Control Module Code Not Matched Immobilizer Control Module Side DTC81 ECM Immobilizer Control Module Code Not Matched P1623 ECM Side DTC84 ECM Immobilizer Control Module Code Not Registered P1620 DESCRIPTION e DTC21 Immobilizer Control Module checks if ECM Immobilizer Control Module code transmitted from ECM and that registered in Immobilizer Control Module match when ignition switch is ON If they do not this DTC is set DTC81 P1623 ECM checks if ECM Immobilizer Control Module code transmitted from Immobilizer Control Module and that registered in ECM match when ignition switch is ON If they do not this DTC is set DTC84 P1620 ECM checks if code transmitted from Immobilizer Control Module and that registered in ECM match when ignition switch is ON If there is no ECM Immobilizer Control Module code registered in ECM
256. l pinion bearings Starting torque of drive bevel pinion when measuring by torque wrench 0 9 1 7 N m 9 0 17 0 kg cm 7 8 14 7 Ib in Preload of drive bevel pinion bearings Starting torque of drive bevel pinion when measuring by spring balance 18 34 N 1 8 3 4 kg 4 0 7 5 Ib Special tool A 09900 23107 B 09915 24550 C 09922 75222 D 09922 66020 1 Power wrench 4 10 magnification 2 Socket wrench 3 Spring balance REAR DIFFERENTIAL 7F 21 Differential Assembly 1 Place differential side bearing outer races on their respective bearings Used left and right outer races are not interchangeable 2 Install differential case assembly in differential carrier 3 Install differential side bearing adjusters on their respective carrier making sure adjuster are threaded properly NOTE Screw in each adjuster till it contacts bearing outer race so that outer race is prevented from including 4 Align match marks 1 on differential side bearing cap and carrier Screw in two side bearing cap bolts two or three turns and press down bearing cap by hand NOTE If bearing cap does not fit tightly on carrier side bearing adjuster is not threaded properly Reinstall adjuster 5 Tighten bearing cap bolts to provisional torque Tightening torque Bearing cap bolts a 15 N m 1 5 kg m 11 0 Ib ft 6 Tighten both differential side bearing adj
257. lacement 8G 38 Special TOONS sssrinin aieeaii cecetteeeeeeseces 8G 39 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 3 General Description System and Location B ii iv i Immobilizer iii Control ECM Module SRS AIRBAG 4 Data link connector DLC 6 Immobilizer indicator lamp if equipped 5 Immobilizer diagnostic coupler The immobilizer control system designed to prevent vehicle burglar consists of following components Vehicle not equipped with air bag system A e Engine control module ECM e Immobilizer control module 3 e Ignition key with built in transponder Knob color Black 2 e Coil antenna 1 Vehicle equipped with air bag system B e Engine control module ECM e Immobilizer control module with coil antenna 7 e Ignition key with built in transponder Knob color Dark gray 8 Operation of this system is as follows i Each ignition key has its own code Transponder code stored in memory When the ignition switch is turned ON Immobilizer Control Module tries to read the Transponder code through the coil antenna installed to the steering lock assembly ii Immobilizer Control Module compares the Transponder code read in 1 and that registered in Immobilizer Control Module and checks if they match iii When it is confirmed that two Transponder codes match each other as described above Immobilizer Con trol Module and ECM che
258. lamps for tightness If any faulty condition is found correct or replace e Seat belt pretensioner Check for dents cracks damage or fitness Check harness and connector for damage or tightness If any faulty condition is found in above checks replace e Seat belts and mounting points Refer to Front Seat Belt in Section 10 e AIR BAG warning lamp After vehicle is completely repaired perform Air Bag Diag nostic System Check in this section 10B 58 AIR BAG SYSTEM SDM WARNING During service procedures be very careful when han dling a Sensing and Diagnostic Module SDM Be sure to read Service Precautions in this section before starting to work and observe every precaution during work Neglecting them may result in personal injury or inactivation of the air bag system when neces sary REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system referring to Disabling Air Bag Sys tem in this section 3 Remove center console box 1 by removing screws 4 Disconnect SDM connector 2 from SDM 3 5 Remove SDM 3 with SDM plate 4 as an assembly from vehicle CAUTION Do not separate SDM 3 and SDM plate 4 INSPECTION CAUTION Do not connect a tester whatever type it may be Never repair or disassemble SDM 3 If SDM has been dropped from a height of 90 cm 3 ft or more or
259. lator valve Yellow 66 9 mm 2 633 in 16 0 mm 0 630 in Signal Blue valve 20 5 mm 0 807 in 6 2 mm 0 244 in Lock up control valve 29 5 mm 1 161 in 8 8 mm 0 346 in Second ary regu Blue lator valve 38 7 mm 1 524 in 8 8 mm 0 346 in Lower Valve Body 1 Remove oil strainer 2 bypass valve 3 and spring 4 1 Lower valve body 2 Remove solenoid valves Lower valve body Solenoid valve No 1 Lock up control valve Solenoid valve No 3 oaj A w N Solenoid valve No 4 Cooler bypass valve spring dimensions reference Free length a 22 8 mm 8 98 in Outside diameter b 8 0 mm 0 31 in 7B 104 AUTOMATIC TRANSMISSION 4 A T ASSEMBLY Lower Valve Body 1 Install solenoid valves Tightening torque Solenoid valve bolt a 8 N m 0 8 kg m 6 0 Ib ft NOTE Solenoid valve No 1 and No 2 are the same solenoid valve Lower valve body Solenoid valve No 1 Lock up solenoid valve Solenoid valve No 3 Solenoid valve No 4 HERR 2 Insert oil strainers 2 and bypass valve 3 to lower valve body 1 NOTE Clean oil strainer before installing 4 Spring 3 456 O Q 11 10 2198 S O O
260. ler b Recheck power door lock system circuit 1 Power door lock controller coupler G10 viewed from harness side 8 36 BODY ELECTRICAL SYSTEM Power door lock system circuit check Terminal Wire Circuit Specification Condition G10 7 WHT GRN Main power supply 10 14V rae Driver side door knob switch is lock i Continuity Sg Driver side door knob switch position G10 8 BLU RED GE ET lock signal circuit ne Driver side door knob switch is No continuity SG unlock position ve Driver side door knob switch is S d Continuity Ss Driver side door knob switch unlock position G10 9 BRN YEL SEA f unlock signal circuit Eer Driver side door knob switch is lock No continuity Si position G10 12 BLK Ground 0 1V Driver side key cylinder switch INSPECTION Inspect continuity at terminals according to the key action Ke Terminal LOCK UNLOCK BODY ELECTRICAL SYSTEM 8 37 Power door lock actuator INSPECTION 1 Disconnect power door lock actuator coupler 2 Connect 12 V battery positive and negative terminals to the door lock actuator terminals shown below If it does not follow the table s operation replace the faulty door lock actuator Front Door Operation UNLOCK LOCK Terminal R L R L M1 CH M2 CH CH Back Door Operation UNLO
261. lt pretensioner 10B 62 AIR BAG SYSTEM Deployment Activation Outside of Vehicle When you intend to return the vehicle to service deploy the air bag inflator module s or activate seat belt pretensioner s out side of the vehicle 1 Turn ignition switch to LOCK position and remove key 2 Wear safety glasses during this deployment activation pro cedure 3 Check that there is no open short or damage in special tools deployment harness A adapter cable B and adapter cable C If any faulty is found do not use it and be sure to use new special tool Special tool A 09932 75031 B 09932 78332 C 09932 78320 NOTE If faulty seat belt pretensioner connector of adapter cable C is found replace it to spare connector special tool 4 Short two deployment harness leads 1 together by fully seating one banana plug into the other WARNING Deployment harness A shall remain shorted and not be connected to 12 volts vehicle battery till you are ready to deploy air bag module or activate seat belt pretensioner 5 Remove applicable air bag inflator module or seat belt pre tensioner as follows e For driver air bag inflator module Remove driver air bag inflator module referring to Driver Air Bag Inflator Module in Section 3C e For passenger air bag inflator module Remove passenger air bag inflator module referring to Passenger Air Bag inflator Mo
262. lty Power door lock controller faulty Wiring or grounding faulty Check system referring to Power Door Lock System in this section Turn signal lights are not flashed when doors are locked unlocked by transmit ter Keyless entry system is in interior light signal mode Change signal mode referring to Change of Signal Mode in this sec tion if necessary Turn signal and hazard warning system faulty Check system referring to Turn Sig nal and Hazard Warning Light Sys tem in this section Power door lock controller faulty Wiring or grounding faulty Check system referring Power Door Lock System With Keyless Entry System in this section Interior light does not turn ON when interior light switch is at DOOR position and doors are unlocked by transmitter Power door lock controller faulty Wiring or grounding faulty Check system referring to Power Door Lock System With Keyless Entry System in this section Power Door Mirror Control System BODY ELECTRICAL SYSTEM 8 9 Condition Possible Cause Correction All power mirrors do not operate CIGAR fuse blown After checking short circuit replace fuse does not operate Power door mirror switch faulty Check switch Wiring or grounding faulty Repair as necessary One power mirror Power door mirror switch faulty Check switch Actuator power door mirr
263. lvanization or other anticorrosive materials to be burnt the interior and under body panel surfaces must be cleaned Removal of residues of the burning should be carried out carefully when the relevant place has box type con struction or has shape which limits the access to the interior surfaces In general the following method can be used satisfactorily for the removal of those residues Scrape the accessible places If a standard putty knife or scraper does not fit to the relevant place consider to use a more flexible scraper to a place narrowly enclosed by sheet metals A jet of compressed air can remove most residues and is effective to limited areas However this type of operation absolutely requires eye protection Metal Replacement Parts Finishing 1 The metal service replacement parts or assemblies are coated with electro deposition primer For the proper adhesion of a paint the following finish process refinish steps becomes necessary a Use wax or grease removing solvent to clean the part b Use a wet or dry sand paper No 400 to polish the panel lightly DO not polish it forcibly to produce any scratch Clean the part again c If factory applied primer coating is cut through to the bare metal apply metal conditioner to the bare metal exposed to open air As for method of use of the metal conditioner follow directions on the container d Apply primer surfacer to the part completely dry before starting sand paper polishing
264. m operation inspection 1 Check the following operation a When the driver side key cylinder is turned LOCK check all doors lock b When the driver side door key cylinder is turned UNLOCK check all doors unlock If check result is not satisfied go to Power Door Lock System Cir cuit Inspection in this section Power door lock system circuit inspection 1 Disconnect negative cable from battery 2 Disconnect door lock controller coupler 1 3 Confirm that all doors are unlocked Connect battery positive and negative terminals to door lock controller coupler terminals and check power door lock operation as follows If it does not operate as specified repair applicable circuit or check actuator If it operates as specified go to next step Power door lock operation for vehicle TERMINAL G10 10 G10 11 1 UNLOCK Lock 2 Lock gt UNLOCK Step OPERATION A Step 1 Lock operation check B Step 2 Unlock operation check 1 Power door lock controller coupler G10 viewed from harness side 4 Connect negative cable to battery 5 Check that the voltage and continuity between the following terminals and body ground are specifications under each conditions If check result is not as specified repair circuit If check result is OK recheck power door lock system as fol lows a Substitute a known good door lock control
265. mbly by removing circlip 3 Special tool A 09920 76010 1 Sprocket gear 2 Ring gear 15 Remove snap ring 1 and pull out Hi Lo shift fork 2 and planetary gear assembly 3 as an assembly 16 Disassemble planetary gear unit by removing circlip 6 Planetary gear assembly Needle roller bearing Shift fork spacer Planetary sun gear aj AJ ow pm Thrust washer 17 Remove lock up plate 1 and oil gutter 2 by removing 3 bolts 18 Remove output rear shaft shift shaft reduction clutch sleeve 1 and 2 4 shift fork 2 as an assembly Disassemble shift shaft by removing snap ring as necessary 19 Remove synchronizer ring 7D 14 TRANSFER 20 Remove output front shaft 1 21 Remove screw 1 and drive out pin with special tool Special tool A 09922 85811 22 Remove interlock block 1 and return spring 2 23 By using bearing puller 2 and hydraulic press 1 remove bearing from output front shaft TRANSFER 7D 15 24 By using special tool remove oil seals 1 from front case Special tool A 09913 50121 25 Remove circlip and then remove bearing from front case Special tool A 09913 75830 1 Hydraulic press INSPECTION e Check each bearing for smooth rotation If found abnormal replace e Check needle bearing and bearing contacting surfa
266. ment har ness A to seat belt pretensioner and lock connector with lock part A Driver air bag inflator module B Passenger air bag inflator module C Seat belt pretensioner AIR BAG SYSTEM 10B 71 8 Route deployment harness 1 out of vehicle 9 Verify that inside of vehicle and area surrounding vehicle are clear of all people and loose or flammable objects 10 Stretch deployment harness 1 to its full length 10 m 33 ft 11 Place 12 volts vehicle battery 2 near shorted end of deploy ment harness 1 12 Completely cover windshield area and front door window openings with drop cloth a blanket or any similar item 3 This reduces possibility of injury due to possible fragmenta tion of vehicle s glass or interior 13 Notify all people in immediate area that you intend to deploy air bag inflator module or activate seat belt pretensioner NOTE e When air bag inflator module deploys or seat belt pre tensioner activates rapid gas expansion will create substantial report Wear suitable ear protection Notify all people in immediate area that you intend to deploy air bag inflator module or to activate seat belt preten sioner and suitable ear protection should be worn e After air bag inflator module has been deployed sur face of air bag may contain powdery residue This powder consists primarily of cornstarch used to lubri cate air bag inflator modul
267. minal 2 Read DTC from flashing pattern of malfunction indicator lamp as shown in example below and write it down For details of DTC refer to ECM side in Diagnostic Trouble Code Table If lamp remains ON go to Malfunction Indicator Lamp Check in Section 6 NOTE If abnormality or malfunction lies in two or more areas malfunction indicator lamp indicates applicable codes three times each And flashing of these codes is repeated as long as diag nosis terminal is grounded and ignition switch is held at ON position IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 13 EXAMPLE When serial data link wire is defective Code No 83 Malfunction indicator lamp Code No 83 ON g 3 OFF gt Code No 83 Code No 83 a ee 8 3 8 3 3 0 Time sec 3 After completing the check turn ignition switch OFF and dis connect service wire from monitor coupler Using SUZUKI scan tool 1 2 3 4 Wu Turn ignition switch OFF After setting cartridge to Suzuki scan tool connect it to data link connector DLC 1 located on underside of instrument panel at driver s seat side Special tool A Suzuki scan tool Turn ignition switch ON Read DTC stored in ECM according to instructions displayed on Suzuki scan tool and print it or write it down Refer to Suzuki scan tool operator s manual for further details If communication between Suzuki scan tool and ECM is
268. move steer ing column upper and lower cover Disconnect coupler at Immobilizer Control Module Remove immobilizer control module 1 2 Steering support member 3 Steering shaft A For vehicle not equipped with air bag system B For vehicle equipped with air bag system INSTALLATION Reverse removal procedure for installation NOTE After replacing Immobilizer Control Module be sure to register Transponder code and ECM Immobilizer Con trol Module code in Immobilizer Control Module and ECM Immobilizer Control Module code in ECM by performing procedure described in Procedure After Immobilizer Control Module Replacement in this section Coil Antenna Vehicle not equipped with air bag system REMOVAL 1 2 3 Disconnect negative cable at battery Remove steering column hole cover Remove steering column upper and lower cover 1 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 35 4 Remove coil antenna 1 INSTALLATION For installation reverse removal procedure 8G 36 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED How to Register Ignition Key Register the ignition key with a built in transponder in Immobilizer Control Module by using the following procedure CAUTION When registering the ignition key including a transpon der into the immobilizer control module by using Suzuki scan tool confirm that the knob color of the ignition key to be regist
269. n Measurement Length Measurement Length Position mm in Position mm in a d 1094 43 07 h i 1186 46 69 a f 683 26 89 h m 896 35 28 a g 861 33 90 h m 1224 48 19 b g 1099 43 27 h n 1024 40 31 c f 1428 56 22 i 1297 51 06 c g 1162 45 75 j k 1136 44 72 d e 1074 42 28 j i 1160 45 67 h h 867 34 13 m m 804 31 65 h i 540 21 26 n n 1033 40 67 9 22 BODY SERVICE Instrumentation and Driver Information Instrument Panel WARNING See WARNING at the beginning of this section REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to Disabling Air Bag System in Section 10B 3 Remove glove box 2 and column hole cover 4 Disconnect wires and cables from heater unit and air inlet box assembly 5 Remove steering column assembly 1 Refer to Steering Column Assembly in Section 3C 6 Disconnect speedometer connector and remove speedome ter assembly 7 Remove engine hood opener 3 8 Disconnect couplers 4 which need to be disconnected for removal for instrument panel 9 Remove instrument panel mounting screws 8 10 Remove instrument panel mounting bolt 9 11 Remove instrument panel CAUTION For vehicle with Air Bag instrument panel could not be removed with SDM coupler connected Use are not to damage
270. n All are not locked unlocked by only driver side key cylin der switch D L fuse blown After checking short circuit replace fuse Driver side key cylinder switch faulty Power door lock controller faulty Wiring or ground faulty Check system referring to Power Door Lock System in this section Only one door is not locked unlocked Power door lock actuator faulty Wiring or grounding faulty Check system referring to Power Door Lock System in this section Power Door Lock System with Keyless Entry System If Equipped Condition Possible Cause Correction All are not locked unlocked by only driver side key cylin der switch D L fuse blown After checking short circuit replace fuse Driver side key cylinder switch faulty Power door lock controller faulty Wiring or ground faulty Check system referring to Power Door Lock System in this section Only one door is not locked unlocked Power door lock actuator faulty Wiring or grounding faulty Check system referring to Power Door Lock System in this section All doors are not locked unlocked by only keyless entry transmitter Transmitter battery dead Replace battery Transmitter faulty Replace transmitter Code registration error Perform code registration Door switch faulty Key remainder switch in ignition switch fau
271. n with pedal shaft arm 99000 25010 e Release fork e Inside of release bearing SUZUKI SUPER GREASE e Input shaft spline and front end 99000 25210 Sealant SUZUKI BOND No 1215 e Flywheel bolts 99000 31110 Special Tool 09921 26020 09923 36320 09924 17810 09925 98210 Bearing remover for input Clutch center guide Flywheel holder Input shaft bearing shaft bearing installer 7C 14 CLUTCH TRANSFER 7D 1 SECTION 7D TRANSFER NOTE When servicing 2WD vehicles use the same procedure described in this section but refer to the parts diagram of 2WD vehicles on page 7D 2 to check their differences from 4WD vehicles CONTENTS General Description ccccsesseeeseeeeeeeeeeeees 7D 2 Oil CHANGE eege eege derdegede ce deed a 7D 6 Planetary Gear Un 7D 3 AWD SWIICH ccececceeeceeteee eee eeeeeeeeeeeeeeeneeeees 7D 6 Planetary Gear Operation ssseesseeeeeeeeeeee 7D 3 Unit Repair Overhaul ccs ceeeeeeeeeseeeeeeees 7D 8 Gear Shift Control ccccccsssecsseeceeeeeeeeeeeees 7D 4 Tightening Torque Specification whe Cat 7D 24 Diagnosis cuneceunnccesceccuscesnuccenscccuseussecesecueuseennucens 7D 5 Required Service Material NNN NNN AN 7D 24 On Vehicle ServiCe cccsccseececeseeeeeeeeneeeeees 7D 6 Special Tool 7D 2 TRANSFER General Description The transfer consists of an input shaft drive chain output front shaft for 4WD model output rear shaft and their accompanying g
272. nal is input or two or more transmission range sensor signals are input at the same time Step Action Yes No 1 1 Turn ignition switch OFF disconnect TCM coupler 2 Turn ignition switch ON check voltage between terminal E22 1 and E21 15 of disconnected harness side TCM coupler Is it 10 14 V at P range and O V at the other range Go to Step 2 Go to Step 7 While ignition switch ON check voltage between terminal E22 2 and E21 15 of dis connected harness side TCM coupler Is it 10 14 V at R range and 0 V at the other range Go to Step 3 Go to Step 7 While ignition switch ON check voltage between terminal E22 3 and E21 15 of dis connected harness side TCM coupler Is it 10 14 V at N range and 0 V at the other range Go to Step 4 Go to Step 7 7B 44 AUTOMATIC TRANSMISSION 4 A T this section Is it OK See figure sor wire shorted If wire harnesses are OK substitute a known good TCM and recheck Step Action Yes No 4 While ignition switch ON check voltage Go to Step 5 Go to Step 7 between terminal E22 9 and E21 15 of dis connected harness side TCM coupler Is it 10 14 V at D range and 0 V at the other range 5 While ignition switch ON check voltage Go to Step 6 Go to Step 7 between terminal E22 10 and E21 15 of
273. nals for dents cracks or dam ages Is it in good condition 3 1 Check proper connection to SDM at termi Substitute a known good Go to step 4 nal Q60 2 SDM and recheck 2 If OK check voltage from Q60 2 terminal of SDM connector to body ground with igni tion switch ON Is it 8 V or more 4 1 Turn ignition switch OFF Go to step 5 Replace bulb AIR BAG 2 Remove and inspect AIR BAG warning warning lamp bulb or lamp bulb and combination meter referring combination meter to Combination Meter in section 8 Are there in good condition 5 1 Check proper connection to combination Go to step 6 Repair high resistance or meter at BLU terminal for AIR BAG open in BLU wire circuit warning lamp and to SDM at terminal Q60 between combination 2 meter and SDM 2 If OK check resistance between BLU wire terminal of combination meter connector G24 16 pin connector and Q60 2 termi nal of SDM connector Is resistance 1 Q or less 6 1 Measure voltage from Q60 2 terminal of Repair short from BLU Substitute a known good SDM connector to body ground with ignition wire circuit between com SDM and recheck switch ON bination meter and SDM Is itO V or more to power circuit 10B 18 AIR BAG SYSTEM A B C Q60 2 A Fig for STEP 2 1 16 pin connector for combination meter connector
274. nd check again that specified gear thrust play is obtained Available side washer thickness 0 9 1 0 1 1 and 1 2 mm 0 035 0 039 0 043 and 0 047 in 7E 12 FRONT DIFFERENTIAL 4 Drive spring pin 1 in pinion shaft till depth come to value shown below Special tool A 09922 85811 Spring pin installing depth a 8 5 9 5 mm 0 335 0 374 in 5 Put drive bevel gear 1 on differential case 2 6 Hold differential case 2 with soft jawed vise CAUTION Use specified bolts Use of any other bolts than specified may cause loosening of bolts and damage to drive bevel gear 7 Apply thread lock cement to drive bevel gear bolt 3 A Cement 99000 32110 8 Tighten drive bevel gear bolt to specified torque Tightening torque Drive bevel gear bolts a 85 N m 8 5 kg m 61 5 Ib ft 9 Install right differential side bearing 1 to differential case by using special tool and hydraulic press Special tool A 09913 76010 FRONT DIFFERENTIAL 7E 13 10 Install left differential side bearing 1 to differential case by using special tools and hydraulic press Special tool A 09913 76010 B 09926 37610 003 Differential Carrier and Drive Bevel Pinion To engage drive bevel pinion and gear correctly it is prerequired to install drive bevel pinion to differential car rier properly by using adjusting shim
275. nd output front shaft key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and synchro nizer ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring and output front shaft Standard 0 85 1 55 mm 0 035 0 061 in Service limit 0 75 mm 0 030in TRANSFER 7D 17 Slot width b Standard 12 3 mm 0 484 in Service limit 12 6 mm 0 496 in ASSEMBLY 1 Install bearing to front case by using special tool and press Special tool A 09913 75810 B 09944 66020 2 Fix output front shaft with circlip by using special tool Special tool A 09900 06108 3 By using special tool and hummer install oil seal to front case Apply grease to each oil seal lip Special tool A 09913 75810 NOTE Refer to figure below for each oil seal installation posi tion A Grease 99000 25010 Transfer front case oil seal installing position a 53 2 54 2 mm 2 1 2 13 in c 179 3 180 3 mm 7 06 7 10 in 1 Output front bearing 2 Circlip 3 Input bearing 4 Oil seal 7D 18 TRANSFER 4 Install interlock block and spring as shown in figure 5 Drive in pin 1 a little with special tool and tighten screw 2 Special tool 09922 85811 Tightening torque Int
276. ndow becomes hard to raise and lower adjust S screws to correct tilted glass as shown in figure e Adjust equalizer of window regulator so that measurement A and B are equal 1 Screws e Secure door sealing cover 1 with adhesive 2 e Install door window regulator handle so that it has a 45 angle when glass is fully closed as shown in the figure A H BODY SERVICE 9 5 Front Door Window Regulator REMOVAL 1 Remove door glass referring to steps 1 to 11 of REMOVAL under Front Door Glass in this section 2 Disconnect power window motor lead wire at coupler and loosen clamp 3 Loosen regulator mounting screws 1 and take out regulator through hole 2 as shown in the figure INSPECTION 1 Check regulator sliding and rotating parts for greasing 2 Check rollers for wear and damage 3 Check wire for damage INSTALLATION Reverse removal procedure to install window regulator noting fol lowing point e Tighten screws according to the order a b c d 1 2 shown in the figure When installing glass check that the top part of the glass contacts the glass run evenly and that the glass moves up and down smoothly If the glass is tilted with respect to the glass run make a fine adjustment with the screws Refer to Front Door Glass in this section 9 6 BODY SERVICE Windowshield
277. ne of headlights either Right or Left does not move Socket wiring or grounding faulty Repair as necessary Actuator faulty Replace actuator Vehicle body around headlight deformed Repair body Headlight assembly itself deformed Replace headlight assembly Rear Fog Light If Equipped Condition Possible Cause Correction Rear fog light does not come on FOG or REAR FOG fuse blown After checking short circuit replace fuse Rear fog light switch faulty Check fog light switch Lighting switch faulty Check switch Wiring or grounding faulty Repair as necessary Bulb blown Replace 8 4 BODY ELECTRICAL SYSTEM Turn Signal and Hazard Warning Lights Condition Possible Cause Correction Flash rate high or one Bulb blown on flash rate high side Replace bulb side only flashes Incorrect bulb Replace bulb Turn signal hazard warning relay faulty Wiring or grounding faulty Check system referring to Turn Sig nal and Hazard Warning Lights Sys tem in this section Flash rate low Supply voltage low Check charging system Turn signal hazard relay faulty Check system referring to Turn Sig nal and Hazard Warning Lights Sys tem in this section One side only flashes Turn signal switch faulty Turn signal and hazard warning relay faulty Wiring or grounding faulty
278. nents SDM air bag inflator modules and seat belt pretensioners Be sure to follow the instructions WARNING If the air bag system and another vehicle system both need repair Suzuki recommends that the air bag system be repaired first to help avoid unintended air bag system activation Do not modify the steering wheel dashboard or any other on or around air bag system compo nents Modifications can adversely affect air bag system performance and lead to injury Failure to follow procedures could result in possible air bag system activation personal injury or unneeded air bag system repairs Many of service procedures require disconnection of AIR BAG fuse and air bag inflator module s driver and passenger from initiator circuit to avoid an accidental deployment Do not apply power to the air bag system unless all components are connected or a diagnostic chart requests it as this will set a diagnostic trouble code DTC The Air Bag Diagnostic System Check must be the starting point of any air bag diagnostics The Air Bag Diagnostic System Check will verify proper AIR BAG warning lamp operation and will lead you to the cor rect table to diagnose any air bag malfunctions Bypassing these procedures may result in extended diag nostic time incorrect diagnosis and incorrect parts replacements Never use air bag component parts from another vehicle If the vehicle will be exposed to temperatures ov
279. nents or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE Whether the immobilizer indicator lamp is used in the particular vehicle or not depends on vehicle specifications If there is an heated oxygen sensor sensor 2 on exhaust pipe the vehicle is equipped with immobilizer indicator lamp and if there isn t it is not equipped with immobilizer indicator lamp For details of heated oxygen sensor sensor 2 refer to Section 6E in this manual CONTENTS General Description cs cccessseeeeeseees 8G 3 Using SUZUKI scan tool Syst
280. new oil seal 1 and drive in oil seal till it contacts with transmission case 29 After installing new sleeve cover 2 and washers 5 to man ual shift lever 3 install manual shift shaft 4 and manual shift lever to transmission case 30 Align hole in manual shift shaft with that in manual shift lever and drive in new manual shift lever pin through sleeve cover 31 Turn sleeve cover by 90 and caulk securely with pin punch 1 Then check that manual shift shaft turns smoothly 32 Install detent spring 1 and parking rod 2 as shown in fig ure Tightening torque Detent spring assembly bolt a 15 N m 1 5 kg m 11 0 Ib ft 33 Install parking pawl 3 spring 2 and parking pawl shaft 1 as shown in figure 7B 116 AUTOMATIC TRANSMISSION 4 A T DN IC K O o 92 Can aj gt 10 S 1 S 11 2 A Q or ae eo O7 ab E Gis ES 34 Install O rings to each accumulator piston and apply grease or ATF to them A Grease 99000 25030 35 Install BO accumulator piston compression spring gray paint and accumulator spacer Hold them with snap ring NOTE e Make sure that the snap ring is fitted to the groove of B1 B0 accumulator cylinder e Make sure that the O ring is not twisted or caught when installing 36 Install B1 accumulator spring with light blue paint and accu mulator piston NOTE Make sure that the O ring is not tw
281. ng 10B 20 Circuit Resistance Low 10B 37 10B 2 AIR BAG SYSTEM DTC B1043 Driver Pretensioner Initiator Circuit Short to Ground eeseeeaea0001a1aeaeene 10B 37 DTC B1044 Driver Pretensioner Initiator Circuit Short to Power Circuit 10B 37 DTC B1045 Passenger Pretensioner Initiator Circuit Resistance High 10B 37 DTC B1046 Passenger Pretensioner Initiator Circuit Resistance Low 10B 37 DTC B1047 Passenger Pretensioner Initiator Circuit Short to Ground 10B 37 DTC B1048 Passenger Pretensioner Initiator Circuit Short to Power Circuit 10B 37 DTC B1051 Frontal Crash Detected System Activation Command t ie EE 10B 46 DTC B1071 Internal SDM Fault 10B 47 DTC B1013 System Specifications Different from SDM Specifications 10B 47 On vehicle ServiCe cccsseseessseeeeeeneeeees 10B 48 Service Precautions cceeeeeeeeeeeeeeees 10B 48 Service and diagnosis eeee 10B 48 Disabling air bag system ee 10B 49 Enabling air bag evstem ee 10B 49 Handling and etorage eee 10B 50 RI EE 10B 54 Air bag wire harness and connector in instrument panel harness floor harness and pretensioner harness 10B 54 Repairs and Inspections Required after GE EIERE E T eege deiert 10B 55 Accident with Deployment Activation Component Hepnlacement AA 10B 55 Accident with or without Deploym
282. ng clutch Improper clutch pedal free travel Adjust free travel Weakened diaphragm spring or worn spring tip Replace Damaged or worn splines of transmission input shaft Replace Front input shaft bearing worn or broken Replace Excessively wobbly clutch disc Replace Clutch facings broken or dirty with oil Replace Clutch vibration Glazed clutch facings Repair or replace Clutch facings dirty with oil Replace Wobbly clutch disc or poor facing contact Replace Weakened torsion springs in clutch disc Replace Clutch disc rivets loose Replace the disc Distorted pressure plate or flywheel surface Replace Weakened engine mounting or loosened mounting bolt or nut Retighten or replace Noisy clutch Worn or broken release bearing Replace Front input shaft bearing worn down Replace Excessive rattle of clutch disc hub Replace the disc Cracked clutch disc Replace Pressure plate and diaphragm spring rattling Replace Grabbing clutch Clutch facings soaked with oil Replace Excessively worn clutch facings Replace Rivet heads showing out of the facing Replace Weakened torsion springs Replace 7C 4 CLUTCH On Vehicle Service Maintenance Service Clutch pedal height Check that clutch pedal height is within a range as illustrated If clutch pedal height is out of specification adjust it by turning pedal sto
283. not possible check if Suzuki scan tool is communicable by con necting it to ECM in another vehicle If communication is possible in this case Suzuki scan tool is in good condition Then check data link connector and serial data line circuit in the vehicle with which communication was not possible NOTE e When reading DTC stored in ECM using Suzuki scan tool select ECM from the applications menu and SUZUKI mode from the communication mode menu displayed on Suzuki scan tool If ECM detects a trouble in both engine and emission control system and immobilizer control system Suzuki scan tool indicates trouble codes of both systems using Suzuki mode of ECM application After completing the check turn ignition switch OFF and dis connect Suzuki scan tool from data link connector DLC 8G 14 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Diagnostic Trouble Code Table Immobilizer control module DTC DTC indicated indicatedby VOLTMETER on Suzuki voltmeter INDICATION DIR NOSE Ones Dna scan tool indicator This code appears NO DTC Normal No code when none of the other codes are identified 11 11 31 31 Transponder code 32 32 12 12 TION Immobilizer Control Diagnose trouble Module according to Diagnos Coil antenna or ignition tic Plow Table corre 13 13 key with built in tran SPoNding to each code sponder
284. not go down although standard value of engine rev signal is input Step Action Yes No 1 1 Turn ignition switch OFF and disconnect Faulty transmission tem Go to Step 2 sensor wire harness coupler perature sensor 2 Measure resistance between BI wire and Replace transmission B BI wire terminal of sensor harness side temperature sensor coupler Is it infinity or 0 Q 2 Is DTC No 36 Go to Step 4 Go to Step 3 3 Is DTC No 38 Go to Step 5 Go to Step 6 When DTC is P0710 4 1 Turn ignition switch OFF and connect sen BI and B BI wire Substitute a known good sor wire harness coupler shorted each other TCM and recheck 2 Disconnect TCM couplers 3 Measure the resistance between terminal E21 3 and E21 16 of disconnected har ness side coupler Is it about 0 Q 5 1 Turn ignition switch OFF and connect sen BI or B B wire open or Go to Step 7 sor wire harness coupler 2 Disconnect TCM couplers 3 Measure the resistance between terminal E21 3 and E21 16 of disconnected har ness side coupler Is it infinity poor connection of sole noid wire harness cou pler 7B 48 AUTOMATIC TRANSMISSION 4 A T Step Action Yes No 6 1 Turn ignition switch OFF and connect sen BI or B B wire open Go to Step 7 sor wire harness coupler shorted each other or 2
285. nt Temperature Meter and Sen sor Unit Engine coolant temperature meter INSPECTION 1 Disconnect Y W lead wire going to sender gauge installed to thermostat case 2 Use a bulb 12 V 3 4 W 3 in position to ground wire as illustrated 1 Battery 2 Engine coolant temperature meter 3 Turn main switch ON Confirm that bulb is lighted with meter pointer fluctuating several seconds thereafter If not replace BODY ELECTRICAL SYSTEM 8 21 Engine coolant temperature sensor REMOVAL 1 2 3 4 Disconnect negative cable at battery Drain cooling system Disconnect coupler from ECT sensor 1 Remove ECT sensor from intake manifold xw wm lt x INSTALLATION Reverse removal procedure for installation noting the following points e Clean mating surface of sensor and intake manifold e Check O ring for damage and replace if necessary e Tighten ECT sensor to specified torque Tightening torque ECT sensor a 15 N m 1 5 kg m 11 0 Ib ft INSPECTION 1 Warm up ECT sensor 1 observing resistance between sen sor terminal 2 and sensor unit 1 Resistance should be decreased with increase of its temperature 2 Check resistance between sensor terminal 2 and sensor unit 1 as shown If check result is not as specified replace sensor ECT sensor specification Temperature 50 C 122 F Resistance 136 216 Q Oil Pressur
286. ntial amp carrier and apply sealant to housing side A Sealant 99000 31110 ZZ e Apply sealant to carrier bolts and tighten carrier bolts to specified torque A Sealant 99000 31110 Tightening torque Differential carrier bolts a 23 N m 2 3 kg m 17 0 Ib ft e Install propeller shaft to companion flange aligning match marks 2 and tighten propeller shaft bolts to specified torque Tightening torque Propeller shaft bolts b 50 N m 5 0 kg m 36 5 Ib ft Rear Axle Shaft For installation of rear axle shafts refer to Rear Axle Shaft and Wheel Bearing in Section 3E Rear Brake Drum For installation of rear brake drums refer to Rear Axle Shaft and Wheel Bearing in Section 3E Differential Gear Oil Refill differential housing with new specified differential oil Refer to Oil Change in this section Brake Circuit Air Purging Make sure to purge air out of brake circuit Refer to Bleeding Brakes in Section 5 Then ensure that joint seam of pipe is free from oil leak 7F 8 REAR DIFFERENTIAL VIEW A KK OZ G DISASSEMBLY 1 Set special tool on vise 1 securely Special tool A 09944 76010 2 Using 2 bolts and nuts set differential assembly onto special tool Special tool A 09944 76010 1 Differential carrier 3 Put match marks 7 on differential side bearing caps and differential
287. nual shift lever pin pull out manual shift shaft 2 and remove manual shift lever 1 Then remove sleeve cover from manual shift lever Remove oil seal from both sides of transmission case and replace as necessary AUTOMATIC TRANSMISSION 4 A T 7B 81 13 Remove oil pump 1 14 Remove front disc clutch assembly 1 2 Transmission case 15 Remove rear disc clutch assembly 1 16 Remove thrust bearing race 1 and thrust needle roller bear ing 2 7B 82 AUTOMATIC TRANSMISSION 4 A T weu E Ko trom i Nw han Sat i em 17 Remove intermediate shaft assembly 1 and front sun gear 2 3 Thrust bearing 18 Remove BO brake snap ring brake flanges brake discs and brake plates 19 Remove snap ring 1 then remove BO brake piston return spring subassembly 2 and BO brake piston 3 amp drum assembly 20 Remove planetary carrier assembly 1 thrust needle bear ing 2 and rear sun gear 3 AUTOMATIC TRANSMISSION 4 A T 7B 83 21 Remove B2 brake snap ring 1 brake flange brake discs brake plates and cushion plate 2 Rear sun gear 22 Remove B1 brake snap ring 1 brake flange brake discs and brake plates 2 B2 brake piston 7B 84 AUTOMATIC TRANSMISSION 4 A T 23 Use hydraulic press 6 and special tool to com
288. o know reading of short pointer 8 Place zero adjusted bearing form dummy with dummy shaft 1 and dial gauge set on block dummies 3 and take mea surement between zero position and extended dial gauge measuring tip Obtain adjusting shim thickness by using measured value by dial gauge in the following equation Ko Necessary shim thickness Dial gauge measured value E 7E 16 FRONT DIFFERENTIAL i A AN I 10 Select adjusting shim s 2 closest to measured value from among following available sizes 11 Put shim s in place and press fit drive bevel pinion rear bearing 1 to drive bevel pinion 3 by using special tools and hydraulic press Special tool A 09924 07730 B 09926 37610 003 Available shim thickness 0 30 1 00 1 03 1 06 1 09 1 12 1 15 1 18 1 21 1 24 1 27 and 1 30 mm 0 012 0 039 0 041 0 042 0 043 0 044 0 045 0 046 0 048 0 049 0 050 and 0 051 in 12 Apply differential oil to drive bevel pinion front bearing 1 13 Install drive bevel pinion front bearing in differential carrier 14 Apply grease to oil seal lip Grease 99000 25010 15 Install oil seal in differential carrier by using special tool Special tool A 09944 66010 B 09924 74510 FRONT DIFFERENTIAL 7E 17 CAUTION e Use new drive bevel pinion spacer otherwise bearings 2 may be damaged e Take care not to give press force to
289. o mate with transmission case and uniformly apply sealant Sealant 99000 31110 3 Tighten retainer bolts to specification Tightening torque Input shaft bearing retainer bolts a 23 N m 2 3 kg m 17 0 lb ft 4 Check transmission input shaft for easy rotation by hand 5 Check each select and shift shaft for operation 1 Input shaft bearing retainer Clutch release bearing Before installing bearing apply grease to inner surface of clutch release bearing For detail refer to Clutch Cover Clutch Disc Flywheel and Release Bearing in Section 7C MANUAL TRANSMISSION 7A 29 Input shaft Before remounting transmission assembly to engine and vehicle apply grease to input shaft A Grease 99000 25210 Front gear shift control 1 Clean all parts thoroughly inspect them and replace with new ones as required 2 Assemble component parts by reversing removal procedure Special tool A 09922 85811 B 09925 78210 e Apply grease to lip portion of oil seal Refer to the figure for installing direction A Grease 99000 25010 e Install boot in such direction that breather faces downward e Apply thread lock cement to reverse gear shift limit bolt and tighten it to specified torque B Cement 99000 32110 Tightening torque Reverse gear shift limit bolt a 23 N m 2 3 kg m 17 0 Ib ft 1 Oil seal 2 Boot 3 Reverse gear shift limit
290. oceed to Step 24 through Step 26 Carefully remove drop cloth from vehicle and clean off any fragments or discard it entirely Put on pair of shop gloves to protect your hands from possi ble irritation and heat when handling deployed air bag infla tor module and activated seat belt pretensioner Disconnect adapter cable special tool from air bag inflator module or seat belt pretensioner as soon as possible This will prevent adapter cable special tool from damage due to possible contact with hot air bag inflator module or hot seat belt pretensioner Check adapter cable connector as follows Adapter cable connector special tool are designed to be reused However they should be inspected for damage after deployment and replaced if necessary Scrap the vehicle in the same manner as the vehicle without air bag system NOTE Remaining steps are to be followed in the unlikely event that air bag inflator module did not deploy or seat belt pretensioner did not activate 24 Remove undeployed air bag inflator module s and or inac tivated seat belt pretensioner s from vehicle as follows For driver air bag inflator module Remove driver air bag inflator module referring to Driver Air Bag Inflator Module in Section 3C For passenger air bag inflator module Remove passenger air bag inflator module referring to Passenger Air Bag Inflator Module in this section AIR BAG SYSTEM 10B
291. ock bolt 23 2 3 17 0 Transfer case bolt 18 1 8 13 0 4WD switch 19 1 9 14 0 Locating spring bolt 25 2 5 18 0 Shift control lever bolt 18 1 8 13 0 Speed sensor bolt 10 1 0 7 5 Interlock block pin screw 25 2 5 18 0 Required Service Material Material Recommended SUZUKI products Use Part Number Lithium grease SUZUKI SUPER GREASE A Oil seal lip 99000 25010 Sealant SUZUKI BOND NO 1215 e Oil filter and level plug 99000 31110 e Oil drain plug e Mating surface of front case Special Tool TRANSFER 7D 25 09900 06108 Snap ring plier Closing type 09912 34510 Separator 09913 50121 Oil seal remover 09913 65135 Bearing puller 09913 75520 Bearing installer 09913 75810 Bearing installer 09913 75830 Bearing installer 09920 76010 Snap ring plier Opening type 09922 85811 Pin remover 09930 40113 Flange holder 09940 53111 Differential side bearing installer 09944 66020 Bearing installer 7D 26 TRANSFER FRONT DIFFERENTIAL 7E 1 SECTION 7E FRONT DIFFERENTIAL CONTENTS General Description ccccsseseecceeeeesseeeees 7E 2 Differential Unit cceeceeeeeeeeeeeeeteeeeeees 7E 6 BET Ile CC 7E 3 Tightening Torque Specifications 7E 23 On Vehicle ServiCe ccccesesseecceeeseeeesereees 7E 4 Required Service Materials cs 0s00 7E 23 Oil Change enk 7E 4 Special TOOIS
292. ock up solenoid E21 22 P BI 1 A A Fig for Step 1 5 2 Transmission fluid temp sensor terminal 5 Shift solenoid C No 3 terminal B Fig for Step 4 3 Shift solenoid A No 1 terminal 6 Shift solenoid D No 4 terminal 1 TCC lock up solenoid terminal 4 Shift solenoid B No 2 terminal AUTOMATIC TRANSMISSION 4 A T 7B 37 DTC P0741 DTC No 29 TCC Lock Up Circuit Performance or Stuck OFF DTC DETECTING CONDITION e Difference between turbine rev and engine rev is too close even though TCM ordered TCC solenoid to turn OFF e Difference between turbine rev and engine rev is too wide even though TCM ordered TCC solenoid to turn ON Step Action Yes No 1 Was Automatic Transmission Diagnostic Flow Go to Step 2 Go to Automatic Trans Chart performed mission Diagnostic Flow Chart 2 Check TCC lock up solenoid referring to Shift Go to Step 3 Replace TCC lock up Solenoid Valve and TCC Lock Up Solenoid solenoid Valve Inspection in this section Is it in good condition 3 Check valve body for fluid passage clog or Go to Step 4 Faulty valve body lock up control valve secondary regulator valve or signal valve stuck referring to Transmission Unit Repair Overhaul in this section Are they in good condition 4 Substitute a known good torque converter and _ Torque converter mal Overhaul and repair auto r
293. ock up solenoid Transmission fluid temperature sensor INSPECTION Warm up transmission fluid temperature sensor Thus make sure its resistance decrease with the increase of temperature Transmission fluid temperature sensor resistance Temperature Resistance 20 C 68 F 2 50 40 C 104 F 1 20 60 C 140 F 0 60 80 C 176 F 0 30 1 Transmission fluid temperature sensor coupler INSTALLATION Reverse removal procedure for installation noting following points e Tighten solenoid valve bolts and valve body assembly bolts to specification referring to Unit Assembly in this section Tightening torque Solenoid valve bolts 8 N m 0 8 kg m 6 0 Ib ft Tightening torque Valve body bolts 10 N m 1 0 kg m 7 5 Ib ft e Make sure that slot of manual valve is fitted to pin of manual valve lever AUTOMATIC TRANSMISSION 4 A T 7B 71 e Clean mating surface of A T oil pan 3 and A T case and install new gasket 2 to A T oil pan Tighten bolts to specification Tightening torque A T oil pan bolts a 7 5 N m 0 75 kg m 5 5 Ib ft 1 Magnet e Refill A T fluid referring to Maintenance Service in this sec tion and verify that there is no A T fluid leakage Extension Case Oil Seal REPLACEMENT 1 Lift up vehicle and drain transmission oil 2 Remove propeller shaft No 1 and No 2
294. od was installed check for the following e Push vehicle with selector lever shifted to P range Vehicle should not move e Vehicle can not be driven in N range e Vehicle can be driven in D 2 and L ranges e Vehicle can be backed in R range Output Shaft Speed Sensor INSPECTION 1 Disconnect negative cable at battery 2 Disconnect output shaft speed sensor input shaft speed sensor coupler 1 3 Check resistance between output shaft speed sensor termi nals 2 Output shaft speed sensor resistance Standard 160 200 at 20 C 68 F 7B 66 AUTOMATIC TRANSMISSION 4 A T REMOVAL 1 Disconnect negative cable at battery 2 Disconnect output shaft speed sensor input shaft speed sensor coupler 3 Remove output shaft speed sensor input shaft speed sen sor 2 by removing its bolt 1 Output shaft speed sensor INSTALLATION 1 Apply A T fluid to output shaft speed sensor O ring 2 Install output shaft speed sensor to A T case and tighten bolt to specified torque Tightening torque Output shaft speed sensor bolt 8 N m 0 8 kg m 6 0 Ib ft 3 Connect output shaft speed sensor input shaft speed sen sor coupler 4 Connect negative cable to battery Input Shaft Speed Sensor INSPECTION 1 Disconnect negative cable at battery 2 Disconnect output shaft speed sensor input shaft speed sensor coupler 1 3 Check resistance between inp
295. ody Assembly for steel ball location 1 Gasket for lower valve body 3 Gasket for upper valve body 7B 106 AUTOMATIC TRANSMISSION 4 A T 3 a 2 Assemble upper valve body with gaskets and plate to lower s 3 e valve body Make sure that bypass valve is installed to lower 9 a valve body before assembly o SS ER Tightening torque 3 a o r Valve body assembly bolts a 5 5 N m 0 55 kg m 4 0 Ib s 2 a Ow SCH NOTE GU There are four kinds of bolts fixing upper and lower valve body Refer to the table below for the bolt specifications Bolt Length a Pieces A 41 0 mm 1 61 in 2 B 38 0 mm 1 50 in 4 C 23 0 mm 0 91 in 11 D 29 5 mm 1 16 in 1 1 Bolt A 3 Bolt C 2 Bolt B 4 Bolt D 3 Install manual valve to valve body assembly AUTOMATIC TRANSMISSION 4 A T 7B 107 Output shaft assembly DISASSEMBLY 1 Remove circlip 4 and pull out output shaft 1 from parking gear assembly 2 3 Bearing 2 Pull out bearing from parking gear by using puller and hydraulic press Special tool A 09913 80112 ASSEMBLY Reverse disassembly procedure noting following point e Press fit bearing by using press and special tool Special tool B 09913 76010 7B 108 AUTOMATIC TRANSMISSION 4 A T Unit Assembly CAUTION Automatic transmission
296. ogger wire INSPECTION NOTE e When cleaning rear window glass use a dry cloth to wipe it along heat wire 1 direction e When cleaning glass do not use detergent or abras sive containing glass cleaner be held down on wire by finger pressure 1 Check defogger wire damage as follows a Turn main switch ON b Turn defogger switch ON c Use a voltmeter 1 to check voltage at the center of each heat wire as shown If measured voltage is 10 V wire must be damaged between its center and positive end If voltage is zero wire must be damaged between its center and ground 3 e When measuring wire voltage use a tester with nega tive probe 3 wrapped with a tin foil 2 which should 2 i C Voltage Criteria Approx 5 V Good No break in wire Approx 10 V or0 V Broken wire A Good B Broken wire C Atcenter 2 Locate damage in defogger wire as follows a Touch voltmeter positive lead to heat wire positive termi nal end b Touch voltmeter negative lead with a foil strip to heat wire positive terminal end then move it along wire to the negative terminal end c The place where voltmeter fluctuates from zero to several volts is where there is damage NOTE If heat wire is free from damage voltmeter should indi cate 12 V at heat wire positive terminal end and its indica tion should decrease gradually toward zero at the other terminal gr
297. om key cylinder cam 3 with ignition switch turned at ACC position And then turn ignition switch to LOCK position 4 Remove parking brake cover and console box 5 Remove cable bracket nut 1 and detach cable end 3 from key release cam 2 while pressing claws of release cam boss 4 At this time be careful not to cause damage to its claws 6 Remove interlock cable INSTALLATION 1 Install interlock cable 1 as shown in figure 2 Tape 2 Connect cable 1 end to steering lock and tighten cable clamp screw 2 securely Tightening torque Interlock cable screw a 2 2 N m 0 22 kg m 1 6 Ib ft 3 Key cylinder cam 7B 74 AUTOMATIC TRANSMISSION 4 A T 1 3 Shift selector lever 1 to P position and with lock plate manually moved toward front side of vehicle push knob but ton of selector lever 4 Under above condition fix key release cam 2 inserting spe cial tool into holes on cam and selector bracket 3 Special tool A 09925 78210 6 mm 5 Connect cable end to key release cam 6 With cable bracket pushed in arrow direction by spring force tighten cable bracket nut 4 Tightening torque Interlock cable bracket nut a 13 N m 1 3 kg m 9 5 Ib ft 5 Leaf spring 7 Remove special tool Then with lock plate of shift lock sole noid 3 manually moved toward front side of vehicle check that key rele
298. on 1 REQUIRED GEAR Ignition switch Selector lever is in P position PorN ON and vehicle Selector lever is in R position R at stop Selector lever is in N position PorN Selector lever is in D position 1 Selector lever is in 2 position 1 Selector lever is in L position 1 INPUT SHAFT REV Ignition switch ON and engine stop 0 RPM At 60 km h 37 5 mile h constant speed T F 2H 2650 RPM range O D off switch ON 20 or less throttle displayed in increments of 50 opening and 3rd gear D range rpm OUTPUT SHAFT REV At vehicle stop 0 RPM At 60 km h 37 5 mile h constant speed T F 2H 2650 RPM range O D off switch ON 20 or less throttle displayed in increments of 50 opening and 3rd gear D range rpm BATTERY VOLT Ignition switch ON and engine stop Battery voltage is displayed 8 16 V AUTOMATIC TRANSMISSION 4 A T 7B 53 NORMAL CONDITION SCAN TOOL DATA VEHICLE CONDITION REFERENCE VALUES ATF TEMP After driving at 60 km h 37 5 mile h for 15 min 70 80 C 158 176 F utes or more and A T fluid temperature around sensor reaches 70 80 C 158 176 F SHIFT SOL 1 DUTY Ignition switch ON vehicle is at stop and selector 0 lever is in P position While on shifting from 1st gear to 2nd gear 0 100 SHIFT SOL 2 DUTY Ignition switch ON vehicle is at stop and selector 100 lever
299. on 7D 2 Check VSS rotor referring to Section 7D Is it in good condition faulty TCM Section OA and recheck Intermittent trouble or Check for intermittent referring to Intermittent and Poor Connection in If no trouble found substi tute a known good TCM Replace VSS rotor 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 cases where the checked value does not fall within each specified data range Therefore judgement as normal as abnormal should not be made by checking with those data alone Also condition in the below table that can be cases where the automatic transmission or actuator is not operat ing in the condition as indicated by the scan tool NOTE The following scan tool data related to automatic transmission can be checked only by communicat ing with TCM SCAN TOOL DATA VEHICLE CONDITION NORMAL CONDITION REFERENCE VALUES GEAR POSITION Ignition switch Selector lever is in P position PorN ON and vehicle Selector lever is in R position R at stop Selector lever is in N position PorN Selector lever is in D position 1 Selector lever is in 2 position 1 Selector lever is in L positi
300. on before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM pereto e an T eege dE 8 11 CONTENTS DIAQNOSIS wecccccacccuseccaciicadecesendesenccedeanedicuecedaeentacas 8 3 Headlight switch AA 8 11 SAM EE 8 3 Headlight ENEE 8 12 Headlights with Leveling System Bulb replacement A 8 12 If Equipped de 8 3 Headlight aiming adjustment with Rear Fog Light If Equipped EE E Ea 8 3 SChECM g ere es gd NNN ENNEN teen EES E ESA deih 8 13 Turn Signal and Hazard Warning Lights 8 4 Headlights with Leveling System Clearance Tail and License Plate Lights event 8 4 If Equipped SERCO CCD Eege 8 14 Back up ight saeco ois ee ae 8 4 Leveling ewitch ENEE 8 14 Brake bessere det coke ealin 8 5 Leveling achuetor EEN 8 14 Tachometer and ECH 8 5 Turn Signal and Hazard Warning Lights Speedometer and V 8 5 System E Fuel Meter and Fuel Gauge Un 8 5 Turn signal and hazard warning lights Engine Coolant Temp ECT Meter and ECT system circuit inspection ceee EE 8 5 Turn s
301. on range sensor DTC P0743 DTC No 25 26 TCC Shift SWITCH cian vr Eed 7B 8 Lock Up Clutch Circuit Electrical 7B 35 O D Off Sweet 7B 9 DTC P0741 DTC No 29 TCC Lock Up Fail safe function sser 7B 10 Circuit Performance or Stuck OFF 7B 37 Automatic gear shift dagram 7B 12 DTC P0720 DTC No 31 Output Shaft Deet 7B 13 Speed Sensor Clou 7B 38 SE DTC P1700 DTC No 32 33 Throttle eS Transmission Diagnostic riow 7B 13 Position Signal Input Malfunction 7B 41 Trouble Diagnosis Table 12 7B 18 PIE Ee eee eee Sidi Testes Mewes Narn 7B 20 Range Sensor Switch Circuit Time Lag Test 7B 21 Malfunction seese BET 7B 43 Line Pressure Test 7B 22 BIG E No 35 Engine Speed Engine Brake Test 7B 23 Input Clou 7B 45 Engine Brake Test DTC P0710 DTC No 36 38 Transmission P Range Test 7B 23 Fluid Temperature Sensor Circuit 7B 47 Electronic Control System Diagnosis 7B 24 p TE A on f DTC P1709 DTC No 51 Engine Coolant Precautions in diagnosing troubles 7B 24 Temperature Sianeli Circuit 7B 49 Diagnostic Trouble Code s Check 7B 25 P EE DTC P0702 P1702 DTC No 52 Transmission Control System Electrical or Internal Malfunction of TOM 7B 50 DTC P1887 DTC No 57 Vehicle Speed Sensor VSS Signal Creun eee 7B 51 Scan Tool Data 7B 52 Inspection of TCM and Its Circuits 7B 56 On Vehicle Service See EEEEEE ENNEN 7B 58 Maintenance Service
302. on switch OFF 4 Turn ignition switch ON once again and check for any DTC Is it DTC P1702 DTC No 52 or DTC P0702 DTC No 52 AUTOMATIC TRANSMISSION 4 A T 7B 51 DTC P1887 DTC No 57 Vehicle Speed Sensor VSS Signal Circuit al b Y G B Or BIB 2 E21 14 e 4 a b c Cc 1 VSS 3 Power supply from main relay 5 Terminal arrangement of TCM coupler Viewed from harness side 2 TCM 4 VSS terminal DTC DETECTING CONDITION Difference in detected vehicle speed between output shaft speed sensor and VSS is too wide Step Action Yes No 1 Confirm if DTC P0720 DTC No 31 is detected Inspect and repair refer Go to Step 2 together ring to DTC flow table of Is DTC P0720 DTC No 31 detected Output Shaft Speed Sen sor in this section 2 1 Turn ignition switch OFF and disconnect Go to Step 3 BI B or B Or wire open VSS coupler or shorted 2 Turn ignition switch ON and measure volt age between BI B wire terminal and B Or wire terminal of disconnected harness side coupler Is it 10 14V 2 Measure voltage between Y G wire terminal of Go to Step 4 Y G or Y wire open or disconnected harness side coupler and engine ground Is it 3 V or more shorted to ground 7B 52 AUTOMATIC TRANSMISSION 4 A T Step Action Yes No 4 1 Remove VSS referring to Secti
303. on switch ON does DTC B1043 or B1047 still exist Go to step 2 Ignition switch OFF and replace seat belt pretensioner referring Front Seat Belt in Section 10 1 With ignition switch OFF disconnect special tools A B and C from Q08 or Q10 connector 2 Disconnect connector Q07 or Q09 from air bag wire harness in floor harness 3 Check proper connection to air bag wire harness at terminals in Q07 or Q09 con nector 4 If OK then connect special tools B and D to Q07 or Q09 connector With ignition switch ON does DTC B1043 or B1047 still exist Go to step 3 Repair short YEL or YEL RED wire circuit to ground 1 With ignition switch OFF disconnect special tools A and D from seat belt pretensioner wire harness connector Q07 or Q09 2 Disconnect SDM connector Q60 from SDM 3 Measure resistance e DTC B1043 between Q60 11 terminal and body ground and between Q60 12 terminal and body ground e DTC B1047 between Q60 5 terminal and body ground and between Q60 6 terminal and body ground Is resistance 1 MQ or more Substitute a known good SDM and recheck DTC B1043 Repair short WHT or PNK wire circuit to ground DTC B1047 Repair short from BRN or LT GRN wire circuit to ground AIR BAG SYSTEM 10B 43 A Q08 or Q1
304. ont nector from seat belt pretensioner Seat Belt in Section 10 3 Check proper connection to applicable seat belt pretensioner at terminals in Q08 or Q10 connector 4 If OK then connect special tools A B and C to Q08 or Q10 connector With ignition switch ON does DTC B1042 or B1046 still exist 2 1 With ignition switch OFF disconnect special Go to step 3 Repair short from YEL tools A B and C from Q08 or Q10 wire circuit to YEL RED connector wire circuit or from YEL 2 Disconnect connector Q07 or Q09 from or YEL RED wire circuit air bag wire harness in floor harness to other wire circuit 3 Check proper connection to air bag wire harness at terminals in Q07 or Q09 con nector 4 If OK then connect special tools B and D to Q07 or Q09 connector With ignition switch ON does DTC B1042 or B1046 still exist 3 1 With ignition switch OFF disconnect SDM Substitute a known good DTC B1042 connector Q60 SDM and recheck Repair short from PNK 2 Check proper connection between Q60 11 wire circuit to WHT wire and Q60 12 or Q60 6 and Q60 5 circuit or from PNK or 3 If OK measure resistance with connected WHT wire circuit to other special tools B and D wire circuit e DTC B1042 between Q60 11 and Q60 DTC B1046 12 terminals Repair short from B
305. op posi tion 4 Repeat Step 1 to 3 several times and check that the motor stops at the original stop position every time If check result is not satisfied replace 2 Wiper motor 3 Red lead 4 Black lead BODY ELECTRICAL SYSTEM 8 29 Washer pump REMOVAL 1 Disconnect battery cable 2 Remove washer tank fitting screws 4 5 Remove washer tank 3 3 Disconnect pump lead wire coupler s and hose s Remove pump from tank 1 Front washer pump 2 Rear washer pump INSPECTION Connect battery and terminals to pump and termi nals respectively to check pumping rate Check for both front and rear washer pump Pumping Rate Front washer pump more than 1 0 I min 2 1 US pt min 1 76 Imp pt min Rear washer pump more than 1 0 I min 2 1 US pt min 1 76 Imp pt min INSPECTION Reverse removal procedure for installation 8 30 BODY ELECTRICAL SYSTEM Rear Wiper and Washer Wiper and washer switch INSPECTION Check for continuity between terminals at each switch position Terminal Position OFF WIPER INT A WIPER and WASHER ON B 1 Combination switch lead wire cou pler viewed from terminal side Rear wiper motor INSPECTION Motor operation 1 Use a 12 V battery positive terminal to termin
306. op vehicle and place it level 2 Apply parking brake and place chocks against wheels 3 With selector at P position start engine 4 Warm up engine till fluid temperature reaches normal oper ating temperature 70 80 C 158 176 F As a guide to check fluid temperature warm up engine to normal operat ing temperature 5 Keep engine idling and shift selector slowly to L and back to P position 6 With engine idling pull out dipstick wipe it off with a clean cloth and put it back into place A Shift the selector lever with its button pushed in B Shift the selector lever without pushing its button 7 Pull out dipstick 1 again and check fluid level indicated on it Fluid level should be between FULL HOT and LOW HOT If it is below LOW HOT add an equivalent of DEXRON IIE or DEXRON III up to FULL HOT Automatic transaxle fluid An equivalent of DEXRON III or DEXRON IIE NOTE es DO NOT RACE ENGINE while checking fluid level even after the engine start e DO NOT OVERFILL Overfilling can cause foaming and loss of fluid through breather Then slippage and transmission failure can result e Bringing the level from LOW HOT to FULL HOT requires 0 13 liters 0 27 0 23 US Imp pt e If vehicle was driven under high load such as pulling a trailer fluid level should be checked about half an hour after it is stopped Exhaust manifold cover FULL HOT mark LOW HOT ma
307. or motor faulty Check actuator Wiring or grounding faulty Repair as necessary Door Mirror Heater If Equipped Condition Possible Cause Correction All door mirrors mist when rear defogger switch is ON Cigar fuse blown After checking short circuit replace fuse Rear defogger switch faulty Check switch Door mirror heater relay faulty Check relay Wiring or grounding faulty Repair circuit One door mirror mists when rear defogger switch is ON Mirror heater faulty Check actuator Wiring or grounding faulty Repair circuit Front Seat Heater If Equipped Condition Possible Cause Correction Both seat back and cushion do not become hot although seat heater switch is ON Heater and or Seat Heater fuse s blown After checking short circuit replace fuse Seat heater switch faulty Check switch Wiring or grounding faulty Repair circuit Only seat back does not become hot although seat heater switch is ON Seat heater circuit in seat back faulty Check seat heater Wiring or grounding faulty Repair circuit Only seat cushion does not become hot although seat heater switch is ON Seat heater circuit in seat back and or seat cushion faulty Check seat heater Wiring or grounding faulty Repair circuit Cigarette Lighter Condition Po
308. ording to the method out lined in Dismounting of Transmission of Section 7A 2 Hold flywheel stationary with special tool and remove bolts securing clutch cover to flywheel and take off clutch cover and disc Special tool A 09924 17810 3 Hold flywheel stationary with special tool and remove bolts securing flywheel to crank shaft and take off flywheel Special tool A 09924 17810 4 Use special tool for pulling out of input shaft bearing 1 Special tool A 09921 26020 5 Detach clutch release fork 1 from clutch release fork return spring 2 CLUTCH 7C 9 6 Remove release bearing 1 and clutch release fork 2 INSPECTION Clutch Disc Facing Surface Condition A burnt or glazed facing can be reconditioned by grinding it with No 120 200 sandpaper If surface is in bad condition beyond repair replace whole clutch disc assembly 1 Sandpaper Clutch Facing Wear Check wear of facing by measuring depth of each rivet head depression i e distance between rivet head and facing surface If depressing is found to have reached service limit at any of the holes replace clutch disc assembly Rivet head depth of clutch disc Standard 1 2 mm 0 05 in Service limit 0 5 mm 0 02 in Backlash in Disc Serration Fit Check backlash by turning disc back and forth as mounted on transmission input shaft Replace disc assembly if backlash i
309. ortion is free from nicks burrs or damage which may cause oil seal to leak e Be very careful not to drop converter on oil pump gear Damage in gear should it occur may cause a critical trouble 2 Torque converter housing 7B 120 AUTOMATIC TRANSMISSION 4 A T Tightening Torque Specification 3 Tightening torque Fastening part Nem kom Gm A T fluid drain plug 22 0 2 2 16 0 Transmission range sensor bolts 18 0 1 8 13 0 Output shaft speed sensor bolt 8 0 0 8 6 0 Input shaft speed sensor bolt 8 0 0 8 6 0 Selector rod nut 7 0 0 7 5 0 A T oil pan bolts 7 5 0 75 5 5 Oil strainer bolts 8 0 0 8 6 0 Selector lever assembly bolt 18 0 1 8 13 0 Shift control shaft nut 13 0 1 3 9 5 Solenoid valve bolts 8 0 0 8 6 0 Interlock cable screw 2 2 0 22 1 6 Interlock cable bracket nut 13 0 1 3 9 5 Drive plate bolts 19 0 1 9 14 0 Rear mounting to bracket blot 25 0 2 5 18 0 Rear mounting bracket to transmission bolts 25 0 2 5 18 0 Frame to rear mounting bolts 25 0 2 5 18 0 Engine to transmission bolts and nuts 80 0 8 0 58 0 Universal joint flange bolts and nuts 50 0 5 0 36 5 Exhaust pipe to manifold bolts 50 0 5 0 36 5 Muffler to exhaust pipe bolts 50 0 5 0 36 5 Detent spring assembly bolt 15 0 1 5 11 0 Oil pump assembly bolts 12 0 1 2 8 5 Torque converter housing bolts 19 0 1 9 14 0 Wire to solenoid assembly bolt 8 0 0 8 6 0 Valve bo
310. ose any air bag system malfunctions Bypassing these procedures may result in extended diagnostic time incorrect diagnosis and incorrect parts replacement Wal lt Repeat the Air Bag Diagnostic System Check Flow Table after any repair or diagnostic procedures have been performed Performing the Air Bag Diagnostic System Check Flow Table after all repair or diagnostic procedures will ensure that the repair has been made correctly and that no other malfunctions exist FLOW TABLE TEST DESCRIPTION STEP 1 Check that AIR BAG warning lamp lights STEP 2 Check that AIR BAG warning lamp lights STEP 3 Check diagnosis switch circuit STEP 4 Check that AIR BAG warning lamp flashes 6 times after ignition switch is turned ON STEP 6 Check that history codes are in SDM memory using SUZUKI scan tool STEP 7 Check that history codes are in SDM memory using monitor coupler STEP 9 Check that current code is in SDM memory using SUZUKI scan tool STEP 10 Check that current code is in SDM memory using monitor coupler 10B 10 AIR BAG SYSTEM Air Bag Diagnostic System Check Flow Table Step Action Yes No 1 1 Make sure that battery voltage Go to step 2 Proceed to AIR BAG Warning Lamp is about 11V or higher Does Not Come On in this section 2 Note AIR BAG warning lamp as ignition switch is turned to ON position Does AIR BAG
311. ound A Several volts B Ovolt 8 24 BODY ELECTRICAL SYSTEM Wiper and Washer REPAIR 1 Use white gasoline for cleaning 2 Apply masking tape 1 at both upper and lower sides of heat wire to be repaired 3 Apply commercially available repair agent 4 with a fine tip brush 4 Two to three minutes later remove masking tapes previously applied 5 Leave repaired heat wire as it is for at least 24 hours before operating defogger again 2 Wood spatula 3 Broken wire A Front wiper 1 Wiper blade 4 Front washer pump 7 Washer hose B Rear wiper 2 Wiper arm 5 Rear washer pump 8 Washer nozzle C Washer 3 Wiper motor 6 Washer tank 9 Wiper link BODY ELECTRICAL SYSTEM 8 25 Front wiper washer switch INSPECTION 1 Disconnect negative cable at battery 2 Disconnect combination switch lead wire coupler 3 Use a circuit tester to check the continuity at each switch position as shown below Terminal Wiper SW BI OFF O O INT O_O LO Oo O H OS Terminal B3 Ww Wire Color Washer SW Y BI BI B OFF ON O O REMOVAL AND INSTALLATION Refer to Combination Switch Contact Coil and Combination Switch Assembly in Section 3C for details 1 Combination switch lead wire coupler terminal viewed from
312. oves and safety glasses should be worn e Wash your hands with mild soap and water after com pleting the work Refer to the procedure described under Deployed Air Bag Infla tor Module and Activated Seat Belt Pretensioner Disposal in this section 10B 54 AIR BAG SYSTEM Disposal Do not dispose of the live undeployed air bag inflator modules and the live inactivated seat belt pretensioners When disposal is necessary be sure to deploy activate the air bag and seat belt pretensioner according to deployment activation procedure described in Air Bag Inflator Module and Seat Belt Pretensioner Disposal in this section WARNING Failure to follow proper air bag inflator module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which could cause personal injury Undeployed air bag inflator mod ule and inactivated seat belt pretensioner must not be disposed of through normal refuse channels The undeployed air bag inflator module and inactivated seat belt pretensioner contain substances that can cause severe illness or personal injury if the sealed container is damaged during disposal Air bag wire harness and connector in instrument panel harness floor harness and pretensioner har ness Air bag wire harness 1 is included in instrument panel harness floor harness and pretensioner harness The air bag wire harness
313. ply primer BODY SERVICE 9 9 5 Install new molding 1 to glass 2 6 Clean glass surface to be adhered to body with clean cloth If cleaning solvent is used let it dry for more than 10 minutes Cleaning area for distance from the edge of glass or mold ing a 30 50 mm 1 18 1 97 in 7 Install new spacer 1 to glass 4 2 Ceramic printing 3 Cutting section of ceramic printing 8 Using new brush apply sufficient amount of primer for glass along glass surface to be adhered to body NOTE e Be sure to refer to maker s instruction for proper han dling and drying time e Do not apply primer on outside of ceramic coated sur face es Do not touch primer coated surface e Width b 15 mm 0 59 in 9 Apply primer for molding 1 along molding surface all around as shown in figure Width applied primer for windshield b 15 mm 0 59 in 2 Fastener 9 10 BODY SERVICE 10 Apply adhesive referring to the figure NOTE Start from bottom side of glass Be careful not to damage primer Height of adhesive applied to lower side should be higher than that of other three sides Upper right and left sides Press glass against body quickly after adhesive is applied Use of rubber sucker grip is helpful to hold and carry glass after adhesive is applied Perform steps 8 to 9 with
314. posite preload of drive bevel pinion bearings and differential side bearings 19 Tighten flange nut gradually with special tools so that pre load of drive bevel pinion is in specification Tightening torque Flange nut 100 400 N m 10 40 kom 72 289 Ib ft Preload of drive bevel pinion bearings Starting torque of drive bevel pinion when measuring by torque wrench 0 9 1 7 N m 9 0 17 0 kg cm 7 8 14 7 Ib in Preload of drive bevel pinion bearings Starting torque of drive bevel pinion when measuring by spring balance 18 34 N 1 8 3 4 kg 4 0 7 5 Ib Special tool A 09900 23107 B 09915 24550 C 09922 75222 D 09922 66020 1 Power wrench 4 10 magnification 2 Socket wrench 3 Spring balance FRONT DIFFERENTIAL 7E 19 Differential Assembly 1 Place differential side bearing outer races on their respective bearings Used left and right outer races are not inter changeable 2 Install differential case assembly in differential carrier 3 Install differential side bearing adjusters on their respective carrier making sure adjuster are threaded properly NOTE Screw in each adjuster till it contacts bearing outer race so that outer race is prevented from inclining 4 Align match marks 1 on differential side bearing cap and carrier Screw in two side bearing cap bolts two or three turns and press down bearing cap by h
315. position OFF Selector lever is in D position ON Selector lever is in 2 position ON Selector lever is in L position ON THROTTLE POSI Ignition switch Accelerator pedal is released 0 TION ON Accelerator pedal is depressed 0 100 Varies depending on depressed value COOLANT TEMP Engine coolant temperature is 60 C 140 F or HIGH more and engine running Engine coolant temperature is below 60 C LOW 140 F and engine running 7B 54 AUTOMATIC TRANSMISSION 4 A T NORMAL CONDITION SCAN TOOL DATA VEHICLE CONDITION REFERENCE VALUES A C SWITCH Ignition switch ON and air conditioner switch OFF OFF BRAKE SWITCH Ignition switch Brake pedal is depressed ON ON Brake pedal is released OFF SCAN TOOL DATA DEFINITIONS GEAR POSITION Current gear position computed by throttle position coming from ECM and vehicle speed REQUIRED GEAR Gear position to which TCM is going to shift according to calculation by throttle position coming from ECM and vehicle speed INPUT SHAFT REVOLUTION RPM Input shaft revolution computed by reference pulses coming from input shaft speed sensor on transmission case OUTPUT SHAFT REVOLUTION RPM Output shaft revolution computed by reference pulses coming from output shaft speed sensor on transmission case BATTERY VOLTAGE V Battery voltage read by TCM as analog input signal by TCM ATF TEMPERATURE C F ATF temperature decided by
316. pper bolt Be sure to tighten lock nut 4 after adjustment Clutch pedal height a 140 mm 5 51 in 1 Clutch pedal free position 2 Fully depressed position 3 Clutch pedal stopper bolt Clutch pedal free travel 1 Depress clutch pedal 1 stop the moment clutch resistance is felt and measure distance clutch pedal free travel Free travel should be within the following specification Clutch pedal free travel a 10 20 mm 0 4 0 8 in 2 If free travel is out of specification adjust it with clutch cable adjust nut 1 Release fork free travel 2 4mm 0 08 0 16 in 2 Release fork 3 Cap Clutch cable routing 1 For left hand side steering vehicle CLUTCH 7C 5 Wi af 8 o l VW Dik FAN 6 d y x NTN A dp Ly Zo oy 4 10 12 E Q 1 Clutch housing cap 4 Clutch cable clamp No 2 2 Clutch cable 5 Clutch pedal 11 SH A 9 bpe sl siet al Oz 7 Dash panel 3 Clutch cable clamp No 1 8 Radiator stay 6 Pedal bracket 10 Clutch cable bracket 11 9 Cross member Air cleaner bracket 2 For right hand side steering vehicle 12 Clutch cable clamp No 3 1 Clutch housing cap 4 Clutch pedal 7 Air cleaner outlet hose 10 Steering lower shaft 2 Clutch cable 5 Pedal bracket 8 Radiator stay 11 Clutch cable bracket 3 Clutch cable
317. press B1 amp B2 brake return spring seat 2 then remove snap ring 1 Special tool A 09926 96010 NOTE Do not compress wave spring more than necessary 24 Remove spring seat and B1 brake piston 3 from B2 brake piston 4 25 Remove B2 brake piston To remove B2 brake piston force low pressure compress air 1 kg cm 15 psi 100 kPa max into hole shown in figure and pop out piston into a rag 5 O ring 7 Airgun INSPECTION Clutch and Brake Discs Dry and inspect them for pitting burn flaking wear glazing cracking charring and chips or metal particles imbedded in lining If discs show any of the above conditions replacement is required NOTE e If disc lining is exfoliated or discolored replace all discs e Before assembling new discs soak them in A T fluid for at least two hours AUTOMATIC TRANSMISSION 4 A T 7B 85 Clutch and Brake Plates and Flanges Dry plates and check for discoloration If plate surface is smooth and even color smear is indicated the plate should be reused If severe heat spot discoloration or surface scuffing is indicated the plate must be replaced Brake Piston Return Spring Subassembly Measure height of B1 amp B2 and BO brake piston return springs Brake piston return spring height Standard 15 62 mm 6 15 in B1 amp B2 return spring assembly 15 19 mm 5 98 in BO return spring assembly NOTE e Do not apply excessive force
318. put Malfunction a ee eee EIERE he 1 Throttle position TP sensor 4 TCM coupler viewed from harness side 2 ECM viewed from harness side 5 Terminal arrangement of ECM coupler 3 TCM DTC DETECTING CONDITION NO or abnormal throttle opening signal is input Step Action Yes No 1 Check DTC of Engine Diagnosis referring to Inspect and repair refer Go to Step 2 Section 6 ring to DTC flow table of Is there DTC related to throttle position sensor Engine Diagnosis in detected Section 6 2 Ils DTC No 33 Go to Step 4 Go to Step 3 3 Ils DTC No 32 Go to Step 5 Go to Step 6 When DTC is P1700 4 1 Turn ignition switch OFF and disconnect Poor connection of termi B R wire open or poor ECM couplers 2 Turn ignition switch ON and check voltage between terminal E18 21 of disconnected harness side ECM coupler and body ground Is it 10 14 V nal E18 21 of ECM cou pler If connection is OK sub stitute a known good ECM and recheck connection of terminal E22 8 of TCM coupler If wire and connection are OK substitute a known good TCM and recheck 7B 42 AUTOMATIC TRANSMISSION 4 A T Step Action Yes No 5 1 Turn ignition switch OFF and disconnect Go to Step 7 Substitute a known good ECM couplers
319. r FRONT DIFFERENTIAL 7E 23 TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY Irregular patterns If the pattern is not oval it means OF that bevel gear is defective High or low spots on tooth surfaces or on the seat of bevel gear are the cause of irregular patterns appearing on some teeth The rem edy is to replace the pinion and gear set and if the seat is defective so is differential case Tightening Torque Specifications Tightening torque Fastening part Nem kom b fit Front differential oil drain plug 27 2 7 19 5 Front differential oil level filler plug 50 5 0 36 5 Differential carrier bolts 23 2 3 17 0 Propeller shaft bolts 50 5 0 36 5 Drive bevel gear bolts 85 8 5 61 5 Flange nut 100 400 10 40 72 289 Bearing cap bolts 50 5 0 36 5 Lock plate bolts 11 5 1 15 8 5 Required Service Materials Material Recommended SUZUKI product Use Part Number Thread lock cement THREAD LOCK CEMENT 1322 99000 32110 Drive bevel gear bolts Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lip Sealant SUZUKI BOND NO 1215 99000 31110 e Front differential drain plug e Mating surface of differential carrier e Mating surface of front axle housing e Differential carrier bolts 7E 24 FRONT DIFFERENTIAL Special Tools 09900 20607 09900 20701 09900 23107 09913 65135 Dial gauge Magnetic stan
320. r Control Mod ule and ECM by executing RECORD ECU RECORD ECM PCM ICM command in SELECT MODE menu 6 Make sure that following indicator lamp lights when ignition switch is turned OFF once and then turned ON e Vehicle not equipped with immobilizer indicator lamp malfunction indicator lamp MIL e Vehicle equipped with immobilizer indicator lamp immobilizer indicator lamp 7 H any other Transponder code for ignition key with a built in transponder needs to be registered repeat above steps 2 4 and 6 NOTE es Up to 4 Transponder codes for ignition key with a built in transponder can be registered e It is not possible to register the same Transponder code for ignition key with a built in transponder as the one already registered in Immobilizer Control Module Procedure After ECM Replacement When ECM was replaced including when replaced because rechecking by using a known good ECM was nec essary during trouble diagnosis register ECM Immobilizer Control Module code in ECM by performing follow ing procedure 1 Perform steps 1 and 2 described in How To Register Ignition Key in this section And then turn ignition switch ON 2 Using SUZUKI scan tool register ECM Immobilizer Control Module code in ECM by executing RECORD ECU RECORD ECM ICM command in SELECT MODE menu NOTE For operation procedure of SUZUKI scan tool refer to SUZUKI scan tool operator s manual 3 Make sure that following in
321. r high resistance or 2 Check proper connection between Q60 open in PNK or WHT wire 11 and Q60 12 or Q60 6 and Q60 5 circuit 3 If OK measure resistance with connected DTC B1045 special tools B and D Repair high resistance or e DTC B1041 between Q60 12 and Q60 open in BRN or LT GRN 11 terminals wire circuit e DTC B1045 between Q60 5 and Q60 6 terminals Is resistance 4 5 Q or less A Fig for STEP 1 C Fig for STEP 3 E For DTC B1045 B Fig for STEP 2 and 3 D For DTC B1041 Special tool A 09932 76010 B 09932 75010 C 09932 78310 D 09932 78340 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected 10B 40 AIR BAG SYSTEM DTC B1042 DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW DTC B1046 PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW Step Action Yes No 1 1 With ignition switch OFF remove quarter Go to step 2 Ignition switch OFF and lower trim of applicable side replace seat belt preten 2 Disconnect connector Q08 or Q10 con sioner referring Fr
322. r inserting release tool 1 included in special tool A 3 Measure resistance between Q60 7 terminals and body ground Is resistance 1 MQ or more 3 1 Measure resistance between Q60 8 terminal and Substitute a Repair short from YEL wire circuit to ground A Fig for STEP 1 2 and3 B Fig for STEP 2 and 3 Special tool A 09932 76010 B 09932 75010 C 09932 78340 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected AIR BAG SYSTEM 10B 27 DTC B1019 PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT ground With ignition switch ON is voltage 1 V or less good SDM and recheck Step Action Yes No 1 1 With ignition switch OFF disconnect passenger Go to step 2 Ignition switch OFF air bag inflator module connector G61 behind Replace passenger air the glove box bag inflator module 2 Check proper connection to passenger air bag referring to Passenger inflator module at terminals in G61 connector Air Bag Inflator Module 3 If OK then connect special tools B and C to in this s
323. r kit e When a check for proper connection is required refer to Intermittent and Poor Connections in this section e If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly 10B 16 AIR BAG SYSTEM AIR B TABLE STEP 1 STEP 2 STEP 3 AG warning lamp comes on steady TEST DESCRIPTION Check AIR BAG fuse Check power source circuit Check AIR BAG warning lamp circuit DIAGNOSTIC FLOW TABLE Step Action Yes No 1 1 Ignition switch OFF Go to step 2 BLU RED wire short to 2 Remove and inspect AIR BAG fuse ground Is fuse good After repair replace AIR BAG fuse 2 1 Disconnect SDM connector Q60 Go to step 3 BLU RED wire between 2 Check proper connection to SDM at termi AIR BAG fuse and SDM nal Q60 4 connector open BLK 3 If OK then check voltage between Q60 4 BLU wire between igni terminal of SDM connector and body tion switch and AIR BAG ground with ignition switch ON fuse open or short to Is it 8 V or more ground 3 1 Disconnect 16 pin combination meter con Substitute a known good BLU wire between com nector G24 from combination meter refer SDM and recheck bination meter and SDM ring to Combination Meter in Section 8 connector short
324. r replace 2 Disconnect connectors from Immobilizer Immobilizer Control Module Control Module and recheck 3 Check for proper connection to Immobilizer See NOTE Control Module at all terminals Are they in good condition NOTE After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM and Transponder code and ECM Immobilizer Control Module code in Immobi lizer Control Module by performing procedure described in Procedure After Immobilizer Control Mod ule Replacement in this section 8G 22 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED DTC13 No Transponder Code Transmitted or Coil Antenna Opened Shorted 1 Main fuse 3 1 Immobilizer Control Module Vehicle not equipped with air bag system 4 Coil antenna 2 Main relay 3 2 Immobilizer Control Module Vehicle equipped with air bag system 5 ToECM DESCRIPTION Immobilizer Control Module energizes the coil antenna when the ignition switch is ON and reads Transponder code from the ignition key When Immobilizer Control Module cannot read Transponder code from the ignition key even when the coil antenna is energized this DTC is set INSPECTION Vehicle not equipped with air bag system Step Action Yes No 1 Check that knob shape and color for igni tion key are as shown below e Knob color Black e Knob shape the same as shown in Fig 1
325. rance by blowing compressed air 4 kg cm psi as shown in figure Rear clutch disc clearance 1 10 1 85 mm 0 051 0 073 in If the clearance is out of specification use clutch flange of differ ent thickness to match the clearance to specification Follow 5 types of clutch flanges are available as spare parts Available clutch flange thickness 2 750 mm 0 108 in 2 900 mm 0 114 in 3 050 mm 0 120 in 3 200 mm 0 126 in 3 350 mm 0 132 in 3 500 mm 0 138 in 3 650 mm 0 144 in 3 Air gun 10 Attach special tool C to dial gauge 4 and set them on the lowest clutch plate 2 Special tool C 09952 06010 Measure piston stroke by blowing compressed air 4 kg cm2 psi as shown in figure Rear clutch piston stroke 1 60 1 85 mm 0 063 0 073 in If the piston stroke is out of specification use clutch flange of dif ferent thickness to match the piston stroke within specification Following 7 types of clutch flanges are available as spare parts Available clutch flange thickness 2 750 mm 0 108 in 2 900 mm 0 114 in 3 050 mm 0 120 in 3 200 mm 0 126 in 3 350 mm 0 132 in 3 500 mm 0 138 in 3 650 mm 0 144 in 1 Rear clutch assembly 3 Air gun AUTOMATIC TRANSMISSION 4 A T 7B 99 Planetary set 7 6 1 Rear ring gear 4 Thrust needle roller bearing 7 Snap ring 2 Rear carrier assembly 5 Front car
326. re described in Procedure after ECM Replacement in this section A Fig 1 for step 1 B Fig 2 for step 1 C Fig 3 for step 2 and step 5 A A Diagnosis switch terminal B Ground terminal 8G 10 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Fig 4 for step 3 Malfunction indicator TIME sec Vehicle Equipped with Immobilizer Indicator Lamp Step Action Yes No tion switch is ON but without starting engine See Fig 1 Does immobilizer indicator lamp flash 1 1 Check immobilizer indicator lamp while igni Go to Step 3 If immobilizer indicator lamp remains ON go to Step 2 If immobilizer indicator lamp remains OFF go to Immobi lizer Indicator Lamp Check in this section this section Is there any DTC s in this section Is there any DTC s 2 1 Check DTC stored in ECM referring to Diagnostic Trouble Code Check ECM in 3 1 Check DTC stored in immobilizer control module referring to Diagnostic Trouble Code Check Immobilizer Control Module Go to Immobilizer Indicator Lamp Check in this section Go to flow table for DTC No Immobilizer control system is in good condition Go to Step 4 this section tem 4 1 Check DTC stored in ECM referring to Diagnostic Trouble Code Check ECM in Is there any DTC s for immobilizer control sys Go to flow tabl
327. re is no activity and provide sufficient ventilation Ensure no loose or flammable objects are within activation area f Place wheel installed tire 4 with seat belt pretensioner 2 on ground in step e 10B 66 AIR BAG SYSTEM A C A Vf 10 m 33 ft 2 7 Stretch deployment harness A from air bag inflator mod ule or seat belt pretensioner to its full length 10 m 33 ft Special tool A 09932 75031 8 Place 12 volts vehicle battery 1 near shorted end of deploy ment harness A 9 Verify that area around air bag inflator module or seat belt pretensioner is clear of all people and loose or flammable objects 10 Connect adapter cable B or C as follows Special tool B 09932 78332 C 09932 78320 For driver air bag inflator module Verify that driver air bag inflator module is resting with its vinyl trim cover facing up and connect adapter cable B to driver air bag inflator module For passenger air bag inflator module Verify that passenger air bag inflator module is firmly and properly secured on deployment fixture special tool and connect adapter cable B to passenger air bag inflator module e For seat belt pretensioner a Connect adapter cable C to seat belt pretensioner b Pile 2 wheel installed tires 2 on top of tire with seat belt pretensioner 3 and tie them with wire harness 4 as shown
328. regard less of the condition of the engine and emission control system ECM indicates whether a trouble has occurred in the immobilizer control system or not by causing the immobilizer indicator lamp to flash or turn ON Immobilizer indicator lamp is ON No trouble exists in the immobilizer control system Immobilizer indicator lamp is flashing ECM or Immobilizer Control Module has detected some trouble in the immobilizer control system NOTE As soon as the ignition switch is turned ON ECM and Immobilizer Control Module diagnose if a trouble has occurred in the immobilizer control system While the diagnosis is being made the immobilizer indicator lamp stays ON and if the diagnosis result is abnormal 2 it immediately changes to flashing but if the result if nor mal 1 it remains ON Diagnosis takes about 3 seconds at maximum When ECM and Immobilizer Control Module detects a trouble which has occurred in the above areas it stores DTC correspond ing to the exact trouble area in ECM and Immobilizer Control Module memory DTCs stored in memory of each controller Immobilizer Control Module and ECM can be read by using the procedure described in Diagnostic Trouble Code Check Immobilizer Control Module and Diagnostic Trouble Code Check ECM in this section 8G 8 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Diagnosis Precautions in Diagnosing Troubles Precautions in identifying diagnostic trouble
329. reload of drive Bes Composite pre Sp ential side bear bevel pinion load ings bearings If preload of differential side bearings is specification shown below adjust preload by tightening or loosening side bearing adjusters Preload of differential side bearings Starting torque of drive bevel pinion when measuring by torque wrench 0 2 0 3 N m 2 0 3 0 kg cm 1 7 2 6 Ib in Preload of differential side bearings Starting torque of drive bevel pinion when measuring by spring balance 4 0 6 0 N 0 4 0 6 kg 0 9 1 3 Ib Special tool A 09900 23107 B 09915 24550 C 09922 75222 3 Socket 9 Torque bearing cap bolts to specified torque and install bear ing lock plates Tightening torque Bearing cap bolts a 50 N m 5 0 kg m 36 5 Ib ft Lock plate bolts b 11 5 N m 1 15 kg m 8 5 Ib ft FRONT DIFFERENTIAL 7E 21 10 As final step check gear tooth contact as follows CAUTION When applying red lead paste to teeth be sure to paint tooth surfaces uniformly The paste must not be too dry or too fluid a After cleaning tooth surface of about 10 teeth in A range paint them with gear marking compound evenly by using brush 1 or sponge etc NOTE Be careful not to turn drive bevel gear more than one full revolution for it will hinder accurate check b Turn gear to bring its painted part in mesh wi
330. rier assembly Apply automatic transmission fluid 3 Planetary oil receiver No 2 6 Planetary oil receiver No 1 DISASSEMBLY 1 Remove snap ring Remove front carrier assembly 2 Remove planetary oil receiver No 1 from rear carrier assem bly Remove rear carrier assembly Remove needle roller bearing and planetary oil receiver No 2 from planetary gear assembly No 2 fo INSPECTION Planetary Oil Receiver No 1 and No 2 Inspect the seal and the claw for deterioration damage or cut If found faulty replace 1 Planetary oil receiver No 1 2 Planetary oil receiver No 2 7B 100 AUTOMATIC TRANSMISSION 4 A T 1 ASSEMBLY Reverse removal procedure for installation noting following points e Note the direction of needle roller bearing e Take care not to break the claw of oil receiver e Oil receiver has installation position Make sure that all claws are aligned with holes before insert ing them e Note the location of the ends of the snap ring 1 2 Planetary ring gear No 2 Valve body AUTOMATIC TRANSMISSION 4 A T 7B 101 31 Q 8 N m 0 8 kg m U 8 N m 0 8 kom 1 Upper valve body 13 Plug 25 Key 2 Gasket for upper valve body 14 Lock up control valve 26 Steel ball 3 Valve body plate 15 Lock up control valve spring 27 Oil strainer 4 Gasket for lower valve body 16 Plug 28 Shift solenoid valve No 2
331. ring to Combination Switch Contact Coil and Combination Switch Assembly in Section 3C Ignition switch OFF Replace driver air bag inflator module refer ring to Driver Air Bag Inflator Module in Section 3C TA Fig for STEP 1 and 2 B Fig for STEP 2 C Fig for STEP 3 Special tool A B C 09932 76010 09932 75010 09932 78340 NOTE Upon completion of inspection and repair work perform the following items AIR BAG SYSTEM 10B 33 e Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected DTC B1025 DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT Step Action Yes No 1 1 With ignition switch OFF disconnect con tact coil connector G62 located near the base of the steering column 2 Check proper connection to contact coil at terminals in contact coil connector G62 3 If OK then connect special tools B and C to contact coil connector G62 With ignition switch ON does DTC B1025 still exist Go to step 2 Go to step 3 1 With ignition switch OFF disconnect special tools B and C from G62 connector and SDM connector Q60 from SDM re
332. rk FULL COLD line LOW COLD line oja A ow Pp AUTOMATIC TRANSMISSION 4 A T 7B 59 LEVEL CHECK AT ROOM TEMPERATURE The fluid level check at room temperature 20 30 C 68 86 F performed after repair or fluid change before test driving is just preparation for level check of normal operating temperature The checking procedure itself is the same as that described previ ously If the fluid level is between FULL COLD and LOW COLD proceed to test drive And when the fluid temperature has reached the normal operating temperature check fluid level again and adjust it as necessary 1 Dipstick 4 FULL COLD line 2 FULL HOT mark 5 LOW COLD line 3 LOW HOT mark Fluid change 1 Lift up vehicle 2 When engine has cooled down remove drain plug 1 from oil pan and drain A T fluid 3 Install drain plug Tightening torque A T fluid drain plug a 22 N m 2 2 kg m 16 0 Ib ft 7B 60 AUTOMATIC TRANSMISSION 4 A T 4 Lower vehicle and fill proper amount of an equivalent of DEXRON IIE or DEXRON III 5 Check fluid level according to procedure described under LEVEL CHECK AT NORMAL OPERATING TEMPERA TURE Automatic transaxle fluid An equivalent of DEXRON III or DEXRON IIE Automatic transaxle fluid capacity When draining from drain plug hole 1 0 liters 2 11 1 76 US Imp pt
333. rmality exists at present History DTC is set only Faulty condition occurred once in the past but normal condition is restored at present AIR BAG warning lamp after ignition switch ON Flashing 6 times and turns on Flashing 6 times and turns off AIR BAG warning lamp when grounding diagnosis switch Current DTC is displayed History DTC is displayed AIR BAG SYSTEM 10B 15 AIR BAG Warning Lamp Circuit Trouble Diagnosis Table WIRING DIAGRAM 4 6 BLK BLU BLK RED Fen BLU A ta Seas D za 7 9 G24 BLU RED PPL PNK GRN G63 PNK GRN BLK 12 14 Q60 1 From main fuse 6 AIR BAG warning lamp in combination meter 11 Ground on engine block 2 Ignition switch 7 Connection detection pin 12 To ECM TCM and ABS control module if equipped 3 Circuit fuse box 8 Data link connector 13 AIR BAG monitor coupler 4 METER fuse 9 To circuit fuse box 14 Ground for air bag system 5 AIR BAG fuse 10 Ground on body 15 SDM CAUTION e Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to flow table e When measurement of resistance or voltage is required in this table use a specified digital multim eter described in Special Tool in this section along with a correct terminal adapter from special tool Connector test adapte
334. rminal E21 15 of Poor E21 2 or E21 15 B wire open TCM coupler and body ground with ignition connection switch ON If all above are OK sub AUTOMATIC TRANSMISSION 4 A T 7B 31 DTC P0715 DTC No 14 Input Turbine Speed Sensor Circuit Lg R Lg B 1 Input shaft speed sensor 2 Terminal arrangement of TCM coupler viewed from harness side 3 TCM DTC DETECTING CONDITION Input shaft speed sensor signal voltage is too high or too low Step Action Yes No 1 Was Automatic Transmission Diagnostic Flow Chart Go to Step 2 Go to Automatic Trans performed mission Diagnostic Flow Chart 2 1 Turn ignition switch OFF and disconnect output shaft Go to Step 3 Replace input shaft speed speed sensor input shaft speed sensor coupler sensor 2 Measure resistance between terminals of the discon nected sensor side coupler Is it 160 200 Q See figure 3 1 Connect output shaft speed sensor input shaft Go to Step 4 Lg R or Lg B wire open speed sensor coupler then disconnect TCM couplers or shorted each other 2 Measure resistance between terminal E22 7 and E22 15 of disconnected harness side coupler Is it 160 200 Q 4 1 Turn ignition switch OFF and connect input shaft Short in Poor connection of termi speed sensor coupler then disconnect TCM couplers between Lg R
335. rning lamp comes ON when igni tion switch is turned to ON position If it does not come ONT proceed to AIR BAG Warning Lamp Does Not Come On in this section 2 Using service wire 1 ground diagnosis switch terminal 2 in monitor coupler 3 3 Read DTC from flashing pattern of AIR BAG warning lamp referring to DTC TABLE in this section If lamp does not indicate DTC proceed to AIR BAG Warn ing Lamp Can Not Indicate Flashing in this section After completing the check turn ignition switch to OFF posi tion and disconnect service wire from AIR BAG monitor coupler GE 10B 12 AIR BAG SYSTEM EXAMPLE When driver air bag initiator circuit resistance high DTC B1021 is set C C C Time sec A AIR BAG warning lamp is turned ON B AIR BAG warning lamp is turned OFF C Code No 21 DTC Clearance Using SUZUKI Scan Tool 1 Turn ignition switch to OFF position 2 Connect SUZUKI scan tool to data link connector DLC in the same manner as when making this connection for DTC check Special tool A SUZUKI scan tool 3 Turn ignition switch to ON position 4 Erase DTC according to instructions displayed on SUZUKI scan tool Refer to SUZUKI scan tool operators manual for further details 5 After completing the check turn ignition switch to OFF posi tion and disconnect SUZUKI scan tool from DLC 6 Perform DTC Check
336. rol lever Gear shift control shaft bushes SUZUKI SUPER GREASE 99000 25210 Input shaft spline front end Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain and filler plug Mating surface of transmission case Mating surface of extension case Mating surface of input shaft bear ing retainer Mating surface of gear shift lever case Thread lock cement THREAD LOCK CEMENT 1322 99000 32110 Reverse gear shift limit bolt Gear shift rear arm bolt 7A 32 MANUAL TRANSMISSION Special Tool 09951 16080 Bearing installer 09913 65135 Bearing puller 09922 8581 1 Spring pin remover 09925 18011 Bearing installer 09925 78210 Spring pin remover 09913 60910 Bearing puller fon 09927 08210 Shaft remover 09913 80113 Bearing installer 09913 84510 Bearing installer AUTOMATIC TRANSMISSION 4 A T 7B 1 SECTION 7B AUTOMATIC TRANSMISSION 4 A T WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under
337. rom the tester may deploy the air bag Never attempt disassembly of the air bag inflator modules If any abnormality is found be sure to replace it with new one as an assembly When an abnormality is noted as existing in the live unde ployed air bag inflator module be sure to deploy it before discarding it When grease cleaning agent oil water etc got on the air bag inflator modules driver and passenger wipe it off immediately with a dry cloth If air bag inflator module was dropped from a height of 90 cm 3 ft or more it should be replaced with a new one as an assembly WARNING For handling and storage of a live air bag inflator module select a place where the ambient temperature below 65 C 150 F without high humidity and away from electric noise When carrying a live air bag inflator module make sure the bag opening is pointed away from you In case of an accidental deployment the bag will then deploy with minimal chance of injury Never carry the air bag inflator module by the wires or connector on the underside of the module Otherwise personal injury may result 10B 52 AIR BAG SYSTEM WARNING When placing a live air bag inflator module on bench or other surface always face the bag up away from the sur face As the live passenger air bag inflator module must be placed with its bag trim cover facing up place it on the work
338. rror heater coupler 2 3 Check for continuity between terminals a and b if not continuity replace outside mirror A B BODY ELECTRICAL SYSTEM 8 45 Front Seat Heater If Equipped Seat heater switch driver and passenger side INSPECTION 1 Remove seat heater switch from instrument panel 2 Check for continuity between terminals at each switch posi tion as show below If check result is not as specified replace switch Terminal BS a b e d e Position FREE o0 O O PUSH otoo gt 00 Seat heater wire INSPECTION 1 Confirm that seat heater switch is OFF position 2 Disconnect two couplers of seat heater under the seat cush ion 3 Check for continuity between terminals as show below If not continuity replace faulty seat heater Seat heater circuit in seat back Between a and b Between b and c Between b and d Seat heater circuit in seat cushion Between e and f A Seat heater circuit in seat back B Seat heater circuit in seat cushion 1 Heater wire 2 Thermostat 8 46 BODY ELECTRICAL SYSTEM IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 1 SECTION 8G IMMOBILIZER CONTROL SYSTEM IF EQUIPPED WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system compo
339. rs R G Y Q W B Y or Substitute a known good 2 Measure the resistance between terminal __ P BI wire shorted to TCM and recheck E21 26 E21 25 E21 24 E21 23 or ground E21 22 of the disconnected harness side TCM coupler and body ground Is it about 0 Q See figure 5 1 Disconnect TCM couplers R G Y Q W B Y or Go to Step 6 2 Measure the resistance between terminal P BI wire shorted to E21 26 E21 25 E21 24 E21 23 or ground E21 22 of the disconnected harness side TCM coupler and body ground Is it about 0 Q See figure 6 1 Connect solenoid coupler then disconnect Go to Step 7 R G Y Q W B Y or TCM couplers P BI wire open or poor 2 Measure the resistance between each sole connection of shift sole noid terminal of the disconnected harness noid coupler side TCM coupler and body ground Is it11 15 QO 7 Turn ignition switch ON then measure voltage Poor connection at termi R G Y G W B Y or P BI wire or shift sole noid lead wire shorted to power source circuit Solenoid Terminal Number Lead Wire Color E es ei ST eae Coupler shift solenoid side Shift solenoid A No 1 E21 26 R G 3 Shift solenoid B No 2 E21 25 Y G 4 Shift solenoid C No 3 E21 24 VW 5 Shift solenoid D No 4 E21 23 B Y 6 TCC l
340. rse order of removal noting the following e Seat belt anchor bolts should have an unified fine thread 7 16 20 UNF Under no circumstances should any differ ent sized or metric screw threads be used e Be sure to tighten seat belt anchor bolts to specified torque referring to previous figure Front Seat Belt with Pretensioner WARNING e Do not attempt to disassemble or repair the seat belt pretensioner retractor assembly If any abnormality is found be sure to replace it with new one as an assem bly e Be sure to read Service Precautions in this section before starting to work and observe every precaution during work Neglecting them may result in personal injury or unactivation of the seat belt pretensioner when necessary INSPECTION BEFORE REMOVAL When checking seat belt with pretensioner refer to Inspection before Removal under Front Seat Belt without Pretensioner in this section RESTRAINT SYSTEM 10 7 REMOVAL 1 Disconnect negative battery cable from battery 2 Disable air bag system referring to Disabling Air Bag Sys tem in Section 10B 3 Disconnect Yellow connector for seat belt pretensioner 4 Remove front seat belts from vehicle referring to Front Seat Belt without Pretensioner in this section INSPECTION When checking seat belt with pretensioner use the following check items in addition to those specified for seat belt withou
341. s TT KY y oo 8 1 Input shaft 8 Countershaft 5th gear 15 Main shaft reverse gear 22 Reverse gear shift fork 2 Main shaft 9 Low speed synchronizer hub 16 Upper case 23 Low speed gear shift shaft 3 Main shaft low gear 10 High speed synchronizer hub 17 Lower case 24 High speed gear shift shaft 4 Main shaft 2nd gear 11 5th speed synchronizer hub 18 Extension case 25 Reverse gear shift shaft 5 Main shaft 3rd gear 12 Reverse gear shaft 19 Input shaft bearing retainer 26 Gear shift front shaft 6 Main shaft 5th gear 13 Reverse idle gear 20 Low speed gear shift fork 27 Gear shift front arm 7 Countershaft 14 Countershaft reverse gear 21 High speed gear shift fork 28 Select guide pin MANUAL TRANSMISSION 7A 3 On Vehicle Service Maintenance Service 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 or repair it 80W 90 75W 85 75W 90 C 30 20 10 0 10 20 30 40 a O O a F 22 4 14 32 lt 50 68 86 104 Temperature 3 Drain old oil and pour new specified oil as shown below by specified amount roughly up to level hole NOTE e Itis highly recommended to use SAE 75W 90 gear oil e Whenever vehicle is hoisted for any service work other than oil change also be sure to check for oil leakage e
342. s noted to exceed service limit Backlash here is a circular displace ment as measured with a dial indicator Backlash limit in serration fit of clutch disc 0 8 mm 0 03 in 7C 10 CLUTCH Clutch Cover Inspect clutch cover for evidence of diaphragm spring rivets get ting loose If rivets are loose or are getting loose replace cover assembly as such cover makes rattling noise when clutch pedal is depressed Inspect tips of tapering fingers for wear If tips are worn exces sively replace cover assembly 1 Spring wear 2 Rivet Release Bearing Replace release bearing if it sticks rattles or makes abnormal noise when spun and turned by hand Input Shaft Bearing Replace input shaft bearing if it sticks rattles or makes abnormal noise when spun and turned by hand Flywheel Check surface contacting clutch disc for any wear or damage CLUTCH 7C 11 INSTALLATION NOTE e Before installing flywheel clutch disc and clutch cover hoist vehicle and lift transmission by jack up to trans mission installation position e Before assembling make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly 1 Before installing retainer apply grease to release bearing 1 inner surface and release fork 2 A Grease 99000 25010 2 Install input shaft bearing 1 to flywheel using special tool Special
343. s no oper ation METER fuse blown After checking short circuit replace fuse ECT meter faulty Check ECT meter ECT sensor faulty Check ECT sensor Wiring or grounding faulty Repair circuit 8 6 BODY ELECTRICAL SYSTEM Oil Pressure Light Condition Possible Cause Correction Oil pressure warning Bulb in combination meter blown Check bulb light does not light up when ignition switch METER fuse blown After checking short circuit replace fuse is on at engine off Combination meter wiring circuit faulty Check combination meter wiring circuit Oil pressure switch faulty Check oil pressure switch Wiring or grounding faulty Repair circuit Brake and Parking Brake Warning Light Condition Possible Cause Correction Brake warning light Bulb in combination meter blown Check bulb does not light up when fluid low level METER fuse blown After checking short circuit replace fuse Combination meter wiring circuit faulty Check combination meter wiring cir cuit Brake fluid level switch faulty Check brake fluid level switch Wiring or grounding faulty Repair circuit Brake warning light Ignition switch faulty Check ignition switch does not light up when cranking when Combination meter wiring circuit faulty Check combination meter wiring
344. shift shaft 5 and then remove limit spring 6 limit yoke 7 and shift front arm 8 NOTE Ball 9 and spring 10 will jump out when disconnecting gear shift shaft 5 Remove boot 12 and oil seal 13 Extension case 1 Remove select return spring bolts 1 return springs and select guide pins 5 2 Remove bolts securing extension case to transmission case and then take off extension case 3 Remove extension case seal 6 as necessary 2 Low select return spring 4 Reverse select return spring outer 3 Reverse select return spring inner Transmission case 1 Remove clutch release bearing 1 and release fork 2 2 Remove input shaft bearing retainer bolts and pull out retainer 3 Take out oil seal from input shaft bearing retainer as neces sary MANUAL TRANSMISSION 7A 11 4 Remove bolts fastening upper and lower cases together separate the two and take out main shaft assembly 2 Using a screwdriver or the like can be used to pry two cases apart as shown In such a case do not stick screwdriver too far into between two mating faces or faces may get dam aged 1 Pry Point EB E et SS eo W IS SS Countershaft 1 Remove reverse idle gear shaft 1 with gear 2 Remove outside circlip of countershaft front bearing 3 Using plastic hammer drive countershaft 1 rearward CAUTION Be sure to set flat face
345. spec tively 2 Release shorting bar in SDM connector inserting release tool 1 included in special tool A 3 Measure voltage from Q60 9 terminal to body ground and from Q60 10 terminal to body ground With ignition switch ON are they 1 V or less Substitute a known good SDM and recheck Repair short from GRN or GRN RED wire cir cuit to power circuit 1 With ignition switch OFF disconnect special tools B and C from G62 connector then reconnect contact coil connector G62 located near the base of the steering col umn as it was 2 Remove driver air bag inflator module from steering wheel referring to Driver Air Bag Inflator Module in Section 3C Check proper connection to driver air bag inflator module at terminals in G70 con nector 4 If OK then connect special tools B and C to G70 connector With ignition switch ON does DTC B1025 still exist LA Ignition switch OFF Replace contact coil assembly referring to Combination Switch Contact Coil and Combi nation Switch Assembly in Section 3C Ignition switch OFF Replace driver air bag inflator module referring to Driver Air Bag Inflator Module in Section 3C 10B 34 AIR BAG SYSTEM A A Fig for STEP 1 and2 B Fig for STEP 2 C Fig for STEP 3 Special tool A 09932 76010 B 09932 7501
346. spection and repair work perform the following items es Reconnect all air bag system components ensure all components are properly mounted e Clear diagnostic trouble codes referring to DTC Clearance in this section if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected AIR BAG SYSTEM 10B 37 DTC B1041 Driver Pretensioner Initiator Circuit Resistance High DTC B1042 Driver Pretensioner Initiator Circuit Resistance Low DTC B1043 Driver Pretensioner Initiator Circuit Short to Ground DTC B1044 Driver Pretensioner Initiator Circuit Short to Power Circuit DTC B1045 Passenger Pretensioner Initiator Circuit Resistance High DTC B1046 Passenger Pretensioner Initiator Circuit Resistance Low DTC B1047 Passenger Pretensioner Initiator Circuit Short to Ground DTC B1048 Passenger Pretensioner Initiator Circuit Short to Power Circuit WIRING DIAGRAM BLK BLU 1 From main fuse 4 SDM 7 Ground for air bag system 2 Ignition switch 5 Driver seat belt pretensioner A Shorting bar 3 AIR BAG fuse 6 Passenger seat belt pretensioner CAUTION e Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to flow table e When measurement of resistance or voltage is required in this table use a specified digital multim eter des
347. ssible Cause Correction Cigarette lighter shows no operation CIGAR fuse blown After checking short circuit replace fuse Ignition switch faulty Check ignition switch Cigarette lighter faulty Check cigarette lighter Wiring or grounding faulty Repair circuit 8 10 BODY ELECTRICAL SYSTEM Interior Lights Condition Possible Cause Correction Interior lights do not Bulbs blown Replace light up Dome fuse blown After checking short circuit replace fuse Interior light switch faulty Check switch Door switch faulty Check switch Wiring or grounding Repair One of interior light Bulb blown Replace does not light up Interior light switch faulty Check switch Door switch faulty Check switch Wiring or grounding Repair Headlight On Vehicle Service BODY ELECTRICAL SYSTEM 8 11 i Headlight assembly 3 Turn signal light soc ket 5 Socket cover 7 Position light bulb PASS 2 Disconnect combination switch lead wire couplers from junc 2 Halogen bulb 4 Position light socket 6 Turn signal light bulb Headlight switch INSPECTION 1 Disconnect negative cable at battery tion fuse block HI 3 Use a circuit tester to check the continuity at each switch position shown below f Terminal HU HL RF Switch Position R
348. stem components ensure all components are properly mounted e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected SDM Serial Data Circuit Toruble Diagnosis Table WIRING DIAGRAM AIR BAG SYSTEM 10B 21 BLK RED Oy PNK GRN From main fuse AIR BAG warning lamp in combination meter 11 Ground on engine block according to flow table this section 1 6 2 Ignition switch 7 Connection detection pin 12 To ECM TCM and ABS control module if equipped 3 Circuit fuse box 8 Data link connector DLC 13 AIR BAG monitor coupler 4 METER fuse 9 To circuit fuse box 14 Ground for air bag system 5 AIR BAG fuse 10 Ground on body 15 SDM CAUTION e Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis e When measurement of resistance or voltage is required in this table use a specified digital multim eter described in Special Tool in this section along with a correct terminal adapter from special tool Connector test adapter kit e When a check for proper connection is required refer to Intermittent and Poor Connections in e If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly TABLE TEST DESCRIPTION STEP
349. stics and paint ability after it s applied to repair areas For the sealer to fill open joints use caulking material Select a sealer in conformance with the place and pur pose of a specific use Observe the manufacturer s label stand instructions when using the sealer In many cases repaired places require color painting When this is required follow the ordinary techniques specified for the finish preparation color painting and undercoating build up Rust proof wax a penetrative compound is applied to the metal to metal surfaces door and side sill insides where it is difficult to use ordinary undercoating material for coating Therefore when selecting the rust proof wax it may be the penetrative type During the undercoating vinyl coating application care should be taken that sealer is not applied to the engine related parts and shock absorber mounting or rotating parts Following the under coating make sure that body drain holes are kept open The sequence of the application steps of the anti corrosion materials are as follows 1 Clean and prepare the metal surface 2 Apply primer 3 Apply sealer all joints sealed originally 4 Apply color in areas where color is required such as hem flanges exposed joints and under body compo nents 5 Apply anticorrosion compound penetrative wax 6 Apply undercoating rust proof material 9 26 BODY SERVICE When the welding or heating operation causes the original ga
350. t 6 Disc gt 7 Flange NOTE Before assembly new discs should be soaked in auto matic transmission fluid for at least 2 hours 7B 92 AUTOMATIC TRANSMISSION 4 A T 6 Install snap ring 1 NOTE Make sure that the ends of the snap ring do not come to the opening of the front clutch No 1 drum 7 Place special tool B on soft jawed vise 1 and install 2 oil seal rings on special tool Special tool B 09926 26030 SUZUKI GENUINE PARTS C Clutch oil seal set 22860 81ATO NOTE e Clutch oil seal set has two oil seal rings in a set e Do not use the oil seal rings removed from oil pump assembly It is not necessary to remove oil seal rings from special tool once installed D AUTOMATIC TRANSMISSION 4 A T 7B 93 8 Place front clutch assembly 1 on special tool B 9 Set dial gauge 4 on the top of clutch flange 2 and mea sure clearance by blowing compressed air 4 kg cm psi as shown in figure Front clutch disc clearance 0 65 1 20 mm 0 026 0 047 in If the clearance is out of specification use clutch flange of differ ent thickness to match the clearance to specification Follow 5 types of clutch flanges are available as spare parts Available clutch flange thickness 2 750 mm 0 108 in 2 875 mm 0 113 in 3 000 mm 0 118 in 3 125 mm 0 123 in 3 250 mm 0 128 in 3 375 mm 0 133 in 3 500 mm 0 138 in
351. t 99000 32110 5 Retighten differential case bolts to specified torque Tightening torque Differential case bolts a 41 N m 4 1 kg m 30 0 Ib ft CAUTION Use specified bolts Use of any other bolts than specified may cause loosening of bolts and damage to drive bevel gear 6 Put drive bevel gear 1 on differential case 2 and fasten them with 10 bolts 3 by tightening them to specified torque Use thread lock cement for 10 bolts A Cement 99000 32110 Tightening torque Drive bevel gear bolts a 85 N m 8 5 kg m 61 5 Ib ft 7F 14 REAR DIFFERENTIAL 7 Press fit differential side bearing 1 with special tool and hydraulic press Special tool A 09944 66020 8 Hold bearing press fitted in previous step with holder and press fit differential side bearing on the other side NOTE Be sure to use bearing holder for the purpose of protect ing lower bearing Special tool A 09944 66020 B 09951 16060 REAR DIFFERENTIAL 7F 15 Differential Carrier and Drive Bevel Pinion To engage drive bevel pinion and gear correctly it is prerequired to install drive bevel pinion to differential car rier properly by using adjusting shim B A 4 So BID c C A D 1 F G H 0 A Dummy height of pinion form dummy 40 mm 1 575 in F Shim thickness for mounting distance adjustment D 6 Fron
352. t Matched DESCRIPTION Immobilizer Control Module checks if Transponder code transmitted from ignition key and that registered in Immobilizer Control Module match when ignition switch is ON If they do not DTC 11 and or 32 are set INSPECTION Register ignition key with built in transponder by using SUZUKI scan tool and performing following steps 1 Register Transponder code in Immobilizer Control Module by performing procedure described in How To Register Ignition Key 2 Turn ignition switch OFF then turn it ON and check that DTC11 and or 32 are not set DTC31 Transponder Code Not Registered DESCRIPTION Immobilizer Control Module checks if Transponder code transmitted from ignition key and that registered in Immobilizer Control Module match when ignition switch is ON If there is no Transponder code registered in Immobilizer Control Module this DTC is set INSPECTION Register ignition key with built in transponder by using SUZUKI scan tool and performing following steps 1 Register Transponder code in Immobilizer Control Module by performing procedure described in How To Register Ignition Key 2 Turn ignition switch OFF then turn it ON and check that DTC31 is not set DTC12 Fault in Immobilizer Control Module DESCRIPTION This DTC is set when an internal fault is detected in Immobilizer Control Module INSPECTION Step Action Yes No 1 1 Ignition switch OFP Substitute a known good Repair o
353. t bearing B Radius of bearing form dummy with dummy shaft 40 1 Pinion form dummy 7 Differential carrier mm 1 575 in C Block dummy thickness 14 mm 0 5512 in 2 Bearing form dummy with dummy shaft 8 Rear bearing A B C Mounting distance adjusting dummy total size 94 mm 3 Block dummy 9 Spacer 01 in D Measured dimension 4 Dial gauge 10 Drive bevel pinion E Drive bevel pinion mounting distance 94 mm 1 575 in 5 Drive bevel gear Special tool A 09922 76120 B 09922 76240 C 09922 76550 D 09922 76140 E 09922 76410 F 09922 76310 G 09922 76340 H 09922 76320 I 09922 76150 7F 16 REAR DIFFERENTIAL esi 1 Assemble bearing form dummy with dummy shaft using spe cial tools Special tool A 09922 76120 B 09922 76240 2 Install dial gauge 1 to bearing form dummy with dummy shaft as shown in figure Dial gauge rod tip set distance C 2 3 mm 0 079 0 118 in NOTE This installation requires no spacer or oil seal 3 Apply differential oil to drive bevel pinion front and rear bear ings 4 Install pinion form dummy 1 the other special tools and drive bevel pinion bearings to differential carrier 2 Special tool A 09922 76140 B 09922 76410 C 09922 76310 D 09922 76340 E 09922 76320 F 09922 76150 REAR DIFFERENTIAL 7F 17 NOTE Before taking
354. t deploy or seat belt pretensioner did not activate 22 Ensure that deployment harness has been disconnected from 12 volts vehicle battery and that its two banana plugs have been shorted together by fully seating one banana plug into the other 23 Disconnect deployment harness and adapter cable from air bag inflator module or seat belt pretensioner A AIR BAG SYSTEM 10B 69 24 Temporarily store undeployed air bag inflator module or unactivated seat belt pretensioner referring to Service Pre cautions for details 25 Contact your local distributor for further assistance Deployment Activation Inside Vehicle When the vehicle will be destroyed or salvaged for component parts deploy the air bag modules and activate seat belt preten sioners installed on vehicle 1 Turn ignition switch to LOCK position remove key and put on safety glasses 2 Remove all loose objects from front seats and instrument 3 lt panel Disconnect air bag inflator module or seat belt pretensioner connector as follows For driver air bag inflator module Disconnect contact coil connector 1 located near base of steering column For passenger air bag inflator module Remove glove box from instrument panel and disconnect passenger air bag inflator module connector 2 For seat belt pretensioner Remove both side driver and passenger side quarter lower trims and disconnect se
355. t of windshield Adhesive 470 g 15 7 oz Primer for glass 30 g 1 0 oz Primer for body 30 g 1 0 oz Primer for molding 30 g 1 0 oz Eyeleteer Piano string Windshield knife Brush for primer application 2 pcs Knife Rubber sucker grip Sealant gun for filling adhesive Putty spatula for correcting adhered parts BODY SERVICE 9 7 REMOVAL 1 Clean both inside and outside of glass and around it 2 Remove wiper arms and garnish 3 Using tape cover body surface around glass to prevent any damage 4 Remove rear view mirror sunvisor and front pillar trims right amp left 5 If necessary remove instrument panel Refer to Instrument Panel in this section 6 If necessary remove head lining 7 Remove or cut windshield molding all around until wind shield edge comes out 8 Drill hole with eyeleteer 1 through adhesive and let piano string through it 9 Cut adhesive all around windshield 2 with piano string 1 When using tool to cut adhesive be careful not to cause damage to windshield Use wire to cut adhesive along lower part of windshield NOTE Use piano string as close to glass as possible so as to prevent damage to body and instrument panel 3 Windshield knife 10 Using knife 1 smoothen adhesive 2 remaining on body 3 side so that it is 1 to 2 mm thick all around NOTE Before using knife clean knife
356. t pre tensioner described in Inspection under Front Seat Belt without Pretensioner in this section WARNING Do not measure resistance of pretensioner or disassem ble it Otherwise personal injury may result CAUTION If seat belt pretensioner retractor assembly was dropped from a height of 90 cm 3 ft or more it should be replaced Check retractor assembly with seat belt pretensioner appearance visually for the following symptoms and if any one of them is applicable replace it with a new one as an assembly e Seat belt pretensioner has activated e There is a crack in seat belt pretensioner retractor assem bly e Wire harness or connector is damaged e Seat belt pretensioner retractor assembly is damaged or a strong impact e g dropping was applied to it INSTALLATION 1 Install front seat belts to vehicle referring to Front Seat Belt without Pretensioner in this secton 2 Connect Yellow connector for seat belt pretensioner securely 3 Connect negative battery cable to battery 4 Enable air bag system referring to Enabling Air Bag Sys tem in Section 10B 10 8 RESTRAINT SYSTEM Rear Seat Belt WARNING caution during work Be sure to read Service Precautions in this section before starting to work and observe every pre E 35 N m 3 5 kg m 1 Upper anchor 3 Retractor assembly 2 Lower anchor 4
357. tch plate Aton D ring Apply grease 99000 25030 to all over surface 8 Clutch disc SCH Front clutch piston Apply grease 99000 25030 to the lip of the piston 9 Clutch flange Front clutch return spring seat 10 Snap ring Front clutch balancer Apply automatic transmission fluid Shaft snap ring x lt Do not reuse fe NS DISASSEMBLY 1 Remove snap ring 2 Remove flange 1 discs and plates 3 Remove shaft snap ring 1 Compress piston return springs and remove shaft snap ring Place special tool clutch spring compressor on spring seat and compress spring with a press 2 and then remove shaft snap ring using a screwdriver 3 CAUTION Do not push down return spring more than necessary Special tool A 09926 96010 7B 90 AUTOMATIC TRANSMISSION 4 A T 4 Remove front clutch balancer 1 and front clutch return spring seat 2 5 Remove front clutch piston 3 Blow compressed air through input shaft oil hole to remove piston If piston does not pop out take it out with long nose pliers 6 Remove D ring 4 from front clutch No 1 drum 5 INSPECTION Clutch Discs Plates and Flange Check that sliding surfaces of discs plates and flanges are not worn or burnt If necessary replace NOTE e If disc lining is exfoliated or discolored replace all d
358. tem circuit check 1 Turn signal and hazard warning relay connector G34 viewed from harness side equipped circuits Terminal Wire Circuit Specification Condition G34 1 BLK RED Ignition switch circuit eee 0 1V Ignition switch is ON position G34 4 WHT BLU Power supply for turn signal ig i4y and hazard warning lights f f Continuity Turn signal light switch is R position Right t light G34 5 GRN YEL ace e Se Turn signal light switch is N or L posi switch circuit No continuity d Continuity Turn signal light switch is L position Left t light G34 6 GRN RED ie oe S ST Turn signal light switch is N or R posi switch circuit No continuity tion G34 7 BLK Ground 0 1V Hazard warning switch is ON position Approx 1 2 sec after pushing Hazard warning switch and Continuity UNLOCK button on transmitter G34 8 YEL BLU keyless entry system if Approx 0 6 sec after pushing LOCK button on transmitter No continuity Hazard warning switch is OFF posi tion 8 16 BODY ELECTRICAL SYSTEM Turn signal light switch INSPECTION 1 Disconnect negative cable at battery 2 Disconnect combination switch lead wire coupler 3 Use a circuit tester to check the continuity at each switch position shown below Terminal TL TB TR Switch Wire Color Position G R G GIY L O
359. tempt any repairs on retractor mechanisms or retractor covers Replace defective assemblies with new replacement parts Keep belts dry and clean at all times If there exist any parts in question replace such parts Replace belts whose webbing is cut or otherwise damaged Do not put anything into trim panel opening which seat belt webbing passes through For seat belt with pretensioner Refer to Service and Diagnosis of Service Precautions in Section 10B WARNING When performing service on or around air bag system components or air bag system wiring disable the air bag system referring to Disabling Air Bag System in Section 10B Failure to follow procedures could result in possible air bag activation personal injury or unneeded air bag system repairs Disabling air bag system for vehicle with air bag system Refer to Disabling Air Bag System in Section 10B Enabling air bag system for vehicle with air bag system Refer to Enabling Air Bag System in Section 10B Handling and storage for vehicle with air bag system Refer to Handling and Storage in Section 10B Disposal for vehicle with air bag system Refer to Disposal in Section 10B RESTRAINT SYSTEM 10 5 Front Seat Belt without Pretensioner WARNING Be sure to read Service Precautions before starting to work and observe every precaution during work E 35 N m 3 5 kg m U 35 N m 3 5 kg m
360. tening nut so as rotational torque of drive bevel pinion to be in specified torque caulk nut securely 7E 6 FRONT DIFFERENTIAL Differential Unit DISMOUNTING 1 Lift up vehicle and remove wheels 2 Drain differential oil from front axle housing referring to Oil Change in this section 1 Drain plug 2 Level Filler plug 3 Remove front axle shafts referring to Front Axle Shaft Oil Seal Kingpin Bearing Outer Race or Front Axle Housing in Section 3D 4 Before removing propeller shaft give match marks 1 on companion flange 2 and propeller shaft 3 as shown 5 Remove differential carrier bolts 1 and differential assem bly FRONT DIFFERENTIAL 7E 7 REMOUNTING Reverse removal procedure for installation noting the following Front Differential e Clean mating surface of front axle housing 1 and differen tial carrier and apply sealant to housing side A Sealant 99000 31110 ZZ gt e Apply sealant to carrier bolts and tighten carrier bolts to specified torque A Sealant 99000 31110 Tightening torque Differential carrier bolts a 23 N m 2 3 kg m 17 0 Ib ft e Install propeller shaft to companion flange aligning match marks 2 and tighten propeller shaft bolts to specified torque Tightening torque Propeller shaft bolts b 50 N m 5 0 kg m 36 5 Ib ft Front Axle Shaft For
361. ter from special tool Connector test adapter kit e When a check for proper connection is required refer to Intermittent and Poor Connections in this section e If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC WILL SET WHEN DTC B1015 The combined resistance of the passenger air bag inflator module harness wiring and connector terminal con tact is above a specified value for specified time DTC B1016 The combined resistance of the passenger air bag inflator module harness wiring and connector terminal con tact is below a specified value for specified time DTC B1018 The voltage measured at passenger air bag initiator circuit is below a specified value for specified time DTC B1019 The voltage measured at passenger air bag initiator circuit is above a specified value for specified time TABLE TEST DESCRIPTION DTC B1015 B1016 B1018 and B1019 STEP 1 Check whether malfunction is in passenger air bag inflator module STEP 2 Check passenger air bag inflator module initiator circuit in air bag harness STEP 3 Check passenger air bag inflator module initiator circuit in air bag harness for DTC B1018 and B1019 only 10B 24 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1015 PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH Q60 2 Check proper connection to
362. th Immobi lizer Indicator Lamp Immobilizer Indicator Lamp Does Not Light at Ignition Switch ON Do other indicator warning lights in combina tion meter come ON 1 Main fuse 2 Main relay 3 ECM 4 Immobilizer indicator lamp Step Action Yes No 1 1 Turn ignition switch ON Go to Step 2 IG fuse blown main fuse blown ignition switch mal function B W circuit between IG fuse and com bination meter or poor cou pler connection at combination meter 1 Turn ignition switch OFF and disconnect connectors from ECM 2 Check for proper connection to ECM at ter minal E18 8 3 If OK then using service wire ground termi nal E18 8 in connector disconnected Does immobilizer indicator lamp turn on at igni tion switch ON Substitute a known good ECM and recheck Bulb burned out or BI wire circuit open 8G 18 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Table C Immobilizer Indicator Lamp Check for Vehicle Equipped with Immobi lizer Indicator Lamp Immobilizer Indicator Lamp Remains on After Engine Starts 1 Main fuse 2 Main relay 3 ECM 4 Immobilizer indicator lamp Step Action Yes No 1 1 With ignition switch OFF disconnect cou R G wire shorted to Substitute a known good plers from ECM ground circuit ECM and recheck Does immobilizer indicator lamp turn ON at ignition switch ON
363. th drive bevel pinion and turn it back and forth by hand to repeat their con tact c Bring painted part up and check contact pattern referring to following chart If contact pattern is not normal readjust or replace as necessary according to instruction in chart 11 Upon completion of gear tooth contact check caulk flange nut 2 with caulking tool 1 and hammer 7E 22 FRONT DIFFERENTIAL TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY NORMAL Outer end Heel Drive side Coast side K end Toe HIGH CONTACT Pinion is positioned too fat from the Gear center of drive bevel gear 1 Increase thickness of pinion height adjusting shim and position pinion closer to gear center 2 Adjust drive bevel gear backlash to Pinion specification LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height akan adjusting shim and position pinion farther from gear center 2 Adjust drive bevel gear backlash to specification These contact patterns indicate that the offset of dif or ferential carrier is too much or too little The remedy is d D to replace the carrier with a new one These contact patterns located on toe or heel on both on 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 The remedy is to replace the defective membe
364. tion if any e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected AIR BAG SYSTEM 10B 25 DTC B1016 PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW Step Action Yes No 1 1 With ignition switch OFF disconnect passenger air Go to step 2 Ignition switch OFF bag inflator module connector G61 behind the Replace passenger air glove box bag inflator module 2 Check proper connection to passenger air bag infla referring to Passenger tor module at terminals in G61 connector Air Bag Inflator Module 3 If OK then connect special tools B and C to passen in this section ger air bag inflator module connector G61 With ignition switch ON does DTC B1016 still exist 2 1 With ignition switch OFF disconnect SDM connector Substitute a Repair short from YEL Q60 known good RED wire circuit to YEL 2 Check proper connection to SDM at terminals Q60 7 SDM and wire circuit or from YEL and Q60 8 recheck RED or YEL wire cir 3 If OK release shorting bar in SDM connector inserting cuit to other wire circuit release tool 1 included in special tool A 4 Measure resistance between Q60 7 and Q60 8 ter minals with special tools B and C connected to G61 connector Is resistance 1 4 or more A B A Fig for STEP 1 and 2 B Fig
365. tmeter Indicator Low kk AA besen Ww TIME sec 0 5 0 5 05 0 5 0 5 8G 12 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Vehicle equipped with air bag system 1 Turn ignition switch OFF 2 After setting cartridge to Suzuki scan tool connect it to data link connector DLC 1 located on underside of instrument panel at driver s seat side Special tool A Suzuki scan tool 3 Turn ignition switch ON 4 Read DTC stored in immobilizer control module according to instructions displayed on Suzuki scan tool and print it or write it down Refer to Suzuki scan tool operators manual for further details If communication between Suzuki scan tool and immobilizer control module is not possible go to Diagnostic Flow Table D NOTE When reading DTC stored in immobilizer control module using Suzuki scan tool select BCM from the applica tions menu and IMMOBILIZER from the select system menu displayed on Suzuki scan tool 5 After completing the check turn ignition switch OFF and dis connect Suzuki scan tool from data link connector DLC Diagnostic Trouble Code DTC Check ECM Not using SUZUKI scan tool Except for vehicle equipped with immobilizer indicator lamp 1 Using service wire 6 ground diagnostic switch terminal in monitor coupler 3 ECM Dash side trim 1 2 4 To diagnostic switch 5 To ground ter
366. to Component in Section 6K 6 Remove propeller shaft No 1 and No 2 if equipped for 4WD refer to Propeller Shafts in Section 4B 7 Remove gear shift control joint bolt and extension rod bolt 8 Apply transmission jack and remove rear mounting bracket 3 with gear shift case mounting bracket 4 and engine rear mounting 5 9 Remove rear gear shift control assembly 6 1 Gear shift control joint 2 Extension rod 7A 6 MANUAL TRANSMISSION INSPECTION e Check that gear shift control lever moves smoothly without abnormal noise e Check bushes and boot for damage and deterioration INSTALLATION Install in reverse order of removal procedure noting following points A Grease 99000 25010 B Sealant 99000 31110 C Cement 99000 32110 e Press fit oil seal referring to figure for installing direction e Make breather of boot face downward as shown in figure e Torque bolts to specifications as given below Tightening torque Gear shift control boot cover bolts a 23 N m 2 3 kg m 17 0 Ib ft Transmission rear mounting bolts b 25 N m 2 5 kg m 18 0 Ib ft Control shaft joint nuts c 18 N m 1 8 kg m 13 0 Ib ft Extension rod joint bolt d 35 N m 3 5 kg m 25 5 Ib ft Gear shift lever plate bolts e 5 5 N m 0 55 kg m 4
367. to 2 Check resistance between Q60 2 termi ground nal of SDM connector and body ground Is resistance 1 MQ or more A B A Fig for STEP 2 B Fig for STEP 3 Special tool A 09932 76010 NOTE Upon completion of inspection and repair work perform the following items e Reconnect all air bag system components ensure all components are properly mounted e Repeat Air Bag Diagnostic System Check in this section to confirm that the trouble has been cor rected AIR BAG SYSTEM 10B 17 AIR BAG warning lamp does not come on TABLE TEST DESCRIPTON STEP 1 Check combination meter power feed circuit STEP 2 Check electrical connection check mechanism in SDM connector STEP 3 Check AIR BAG warning lamp circuit STEP 4 Check AIR BAG bulb and combination meter STEP 5 Check open in AIR BAG warning lamp circuit STEP 6 Check short from AIR BAG warning lamp circuit to power circuit DIAGNOSTIC FLOW TABLE Step Action Yes No 1 1 Set parking brake Go to step 2 BLK BLU BLK RED 2 Note combination meter when ignition wire or METER fuse switch is turned ON open or short to ground Does the BRAKE indicator warning lamp come ON 2 1 Disconnect SDM connector Q60 Go to step 3 Repair electrical connec 2 Check electrical connection check mecha tion check mechanism nism Connection detecting pin and L1 and L2 termi
368. tooth contact check caulk flange nut 2 with caulking tool 1 and hammer DIAGNOSIS AND REMEDY NORMAL Outer end Heel Coast side Drive side 7F 24 REAR DIFFERENTIAL TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY HIGH CONTACT Pinion is positioned too fat from the Gear center of drive bevel gear 1 Increase thickness of pinion height adjusting shim and position pinion closer to gear center 2 Adjust drive bevel gear backlash to Pinion specification f LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height SR A adjusting shim and position pinion farther from gear center 2 Adjust drive bevel gear backlash to specification These contact patterns indicate that the offset of dif ferential carrier is too much or too little The remedy is to replace the carrier with a new one 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 The remedy is to replace the defective member AE AK G Irregular patterns If the pattern is not oval it means that bevel gear is defective High or low spots on tooth surfaces or on the seat of bevel gear are the cause of irregular patterns appearing on some teeth The rem edy is to replace the pinion
369. tter G10 5 YEL BLU Hazard warning signal circuit Figure C Push UNLOCK button on transmit g ter A B C 12V 12V 12V OV DV DV 2ms div 0 5 s div 0 5 s div A Figure A B Figure B C Figure C BODY ELECTRICAL SYSTEM 8 41 Transmitter REPLACEMENT OF TRANSMITTER BATTERY If transmitter becomes unreliable replace transmitter battery as follows 1 Remove screw 1 and transmitter cover 2 2 Remove transmitter 3 from transmitter holder 4 3 Put edge of coin or flat blade screwdriver in slot of transmit ter 3 and by pry it open 4 Replace the battery lithium disc type CR1616 or equivalent battery so its terminal faces mark on transmitter 5 Fit together transmitter 3 and install it into transmitter holder 4 6 Install transmitter cover 2 and screw 1 7 Make sure the door locks can be operated with transmitter CAUTION Use care not to allow grease or dirt to be attached on the printed circuit board and the battery NOTE e To prevent theft be sure to break the transmitter before discarding it e Dispose of the used battery properly according to applicable rules or regulations Do not dispose of lith ium batteries with ordinary household trash CODE REGISTRATION PROCEDURE If transmitter or door lock controller replace new one register key code as
370. ubricant Repair and replenish Inadequate or insufficient lubricant Repair and replenish Maladjusted backlash between bevel pinion and gear Adjust and prescribed Improper tooth contact in the mesh between bevel pinion and gear Adjust or replace Loose bevel gear securing bolts Replace or retighten Damaged side gear s or side pinion s Replace Bearing noise Constant noise Deteriorated or water mixed lubricant Repair or replenish Constant noise Inadequate or insufficient lubri cant Repair or replenish Noise while coasting Damaged bearing s of Replace bevel pinion Noise while turning Damaged differential side Replace bearing s or axle bearing s Oil leakage Clogged breather plug Clean Worn or damaged oil seal Replace Excessive oil Adjust oil level Loose differential carrier bolts Replace or retighten 7F 4 REAR DIFFERENTIAL On vehicle Service Viscosity chart SAE c 30 20 10 D 10 20 30 40 Temperature a he GE oF 22 4 14 32 50 68 86 104 Oil Change 1 Before oil change or inspection be sure to stop engine and set vehicle horizontally 2 Check oil level and existence of leakage For checking oil level roughly lower point of level hole can be assumed to be standard point of level If leakage is found correct its cause 3 Remove level filler plug 2 and drain plug 1 then dra
371. uction configuration CAUTION After detecting one time of such collision as to meet deployment conditions the SDM must not be used Refer to Air Bag Diagnostic System Check in this section when checking the SDM Accident with Deployment Activation Com ponent Replacement The following components must be replaced e Driver and passenger air bag inflator modules e Driver and passenger seat belt pretensioners e SDM Accident with or without Deployment Activa tion Component Inspections Certain air bag system components must be inspected after any crash whether the air bag system activated or not Those components are e Steering column and shaft joints Check for length damage and bend according to Checking Steering Column for Accident Damage in Section 3C If any faulty condition is found in above checks replace faulty part e Steering column bracket and capsules Check for damage and bent If any faulty condition is found in above checks replace faulty part 10B 56 AIR BAG SYSTEM e Steering wheel and driver air bag inflator module Check for damage or air bag inflator module fitness Check trim cover pad surface for cracks Check wire harness and connector for damage or tight ness If any faulty condition is found in above checks replace faulty part e Contact coil and combination switch assembly Check wire harness
372. uit PNK GRN wire circuit 3 1 With ignition switch OFF disconnect SDM connector Substitutea Repair high resistance or Q60 known good open in PNK GRN wire 2 Check proper connection at Q60 14 PNK GRN SDM and circuit wire terminal of SDM connector recheck 3 If OK then check resistance between PNK GRN wire terminal of DLC and Q60 14 PNK GRN wire termi nal of SDM connector Is resistance 1 Q or less A B 1 3 A Fig for STEP 1 1 DLC 3 PNK GRN wire terminal B Fig for STEP 3 2 SUZUKI scan tool AIR BAG SYSTEM 10B 23 DTC B1015 Passenger Air Bag Initiator Circuit Resistance High DTC B1016 Passenger Air Bag Initiator Circuit Resistance Low DTC B1018 Passenger Air Bag Initiator Circuit Short to Ground DTC B1019 Passenger Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM G61 YEL RED Ke I 5 YEL I Not 1 From main fuse 3 AIR BAG fuse 5 Passenger air bag inflator module A Shorting bar 2 Ignition switch 4 SDM 6 Ground for air bag system CAUTION e Be sure to perform Air Bag Diagnostic System Check in this section before starting diagnosis according to flow table e When measurement of resistance or voltage is required in this table use a specified digital multim eter described in Special Tool in this section along with a correct terminal adap
373. uit electrical cycle applicable Torque converter clutch lock up T 2 Not P0741 29 UI III clutch circuit performance or stuck arving y off cycles applicable P0720 31 iilii Output shaft speed sensor circuit PSU NOE p H cycle applicable Throttle position signal input mal 1 driving Not P1700 function cycle applicable P0705 34 ANI Transmission range sensor circuit 1 driving Not malfunction cycle applicable 2 drivi Not P0725 35 UL ULL Engine speed input circuit ening e cycles applicable Transmission fluid temperature 2 driving Not P0710 Ee sensor circuit cycles applicable P1709 51 AIL Engine coolant temperature signal 1 driving Not circuit cycle applicable P0702 Transmission control system elec driving Not SS JULI tee cycle applicable P1702 Internal malfunction of TCM y PP P1887 57 LL SUL vss signal circuit A E applicable applicable 7B 30 AUTOMATIC TRANSMISSION 4 A T TCM Power and Ground Circuit Check E21 2 E21 15 B W Is it about 0 V stitute a known good TCM and recheck 1 Battery Circuit fuse IG 7 Terminal arrangement of TCM coupler Viewed from harness side 2 Main fuse TCM 3 Ignition switch Ground Step Action Yes No 1 Check voltage between terminal E21 2 of Go to Step 2 B W wire open TCM coupler and body ground with ignition switch ON Is it 10 14 V 2 Check voltage between te
374. usters 1 so as to obtain specified gear backlash and at the same time obtain preload of differential side bearing Special tool A 09930 40120 B 09930 40113 C 09900 20607 D 09900 20701 Bevel gear backlash 0 10 0 20 mm 0 0039 0 0078 in NOTE e Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth e Measure at least 4 points on drive bevel gear periph ery e As a practical measure following would be recom mended to obtain specified backlash and differential side bearing preload at the same time To increase or decrease backlash for adjustment displace drive bevel gear toward or away from drive bevel pinion by running in one adjuster and running out the other adjuster by equal amount Tighten both adjusters further by one notch ata time 7F 22 REAR DIFFERENTIAL 7 Measure composite preload of drive bevel pinion bearings and differential side bearings with torque wrench 2 or spring balance 1 8 Calculate preload of differential side bearings by using the following equation Preload of differential _ Composite Preload of drive side bearings preload bevel pinion bearings If preload of differential side bearings is specification shown below adjust preload by tightening or loosening side bearing adjusters Preload of differential side bearings Starting torque of drive pinion
375. ut shaft speed sensor termi nals 2 Input shaft speed sensor resistance Standard 160 200 at 20 C 68 F AUTOMATIC TRANSMISSION 4 A T 7B 67 REMOVAL 1 Disconnect negative cable at battery 2 Disconnect output shaft speed sensor input shaft speed sensor coupler 1 3 Remove input shaft speed sensor 2 by removing its bolt INSTALLATION 1 Apply A T fluid to input shaft speed sensor O ring 2 Install input shaft speed sensor to A T case and tighten bolt to specified torque Tightening torque Input shaft speed sensor bolt 8 N m 0 8 kg m 6 0 Ib ft 3 Connect output shaft speed sensor input shaft speed sen sor coupler 4 Connect negative cable to battery Vehicle Speed Sensor Refer to Step 7 of DTC P0500 DTC No 16 Flow Table in Section 6 for inspection Throttle Position Sensor INSPECTION Check throttle position sensor referring to Section 6E Engine Coolant Temperature ECT Sensor INSPECTION Check engine coolant temp sensor referring to Section 6E 7B 68 AUTOMATIC TRANSMISSION 4 A T IA B O D Off Switch INSPECTION 1 Remove console box 2 Disconnect O D off switch coupler 3 Check continuity between O D off switch terminals O D off switch 1 ON OFF Continuity Continuity No continuity 2 Shift lever A O D off switch ON B O D off switch OFF Shift
376. vation of the system or could render the system inoperative Either of these two conditions may result in severe injury e The procedures in this section must be followed in the order listed to disable the air bag system temporarily and prevent false diagnostic trouble codes from setting Failure to follow procedures could result in possible activation of the air bag system personal injury or otherwise unneeded air bag system repairs CAUTION When fasteners are removed always reinstall them at the same location from which they were removed If a fastener needs to be replaced use the correct part number fastener for that application If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above conditions are not followed parts or system damage could result CONTENTS General Description ccccssssssecceeeeeeeseees 10B 3 SDM Serial Data Circuit Toruble System Components and Wiring Location Diagnosis Tables Aviva kk nics 10B 21 View and Connechors ssssieeeeereees 10B 4 DTC B1015 Passenger Air Bag Initiator System Wiring Diagram rere 10B 5 Circuit Resistance Hoh 10B 23 Denge dee Ee 10B 6 DTC B1016 Passenger Air Bag Initiator f Circuit Resistance Low 10B 23 Diagnost
377. ver 1 DCH 2 Cap 2 Remove 4WD switch 1 and take out steel ball 3 Remove locating spring bolt 1 and take out locating spring 2 and steel ball 3 4 Remove vehicle speed sensor 1 TRANSFER 7D 11 5 Remove rear output side flange To lock flange use special tool With flange locked remove flange nut 1 Special tool A 09930 40113 6 Remove 11 rear case bolts and then separate case by using special tool NOTE To separate case use special tool at 2 points in turn and make opening wider evenly Special tool 09912 34501 7 Remove oil seal from rear case by using special tool Special tool A 09913 50121 8 Remove circlip 1 by using special tool and then remove bearing by using special tool Special tool A 09900 06108 B 09913 75830 7D 12 TRANSFER 9 Pull out speedometer sensor rotor 1 10 Remove flanges To lock flange use special tool With flange locked remove flange nut 1 Special tool A 09930 40113 11 Remove drive chain 2 input shaft 1 and ring and sprocket gear assembly 3 as an assembly 12 Remove needle roller bearing 1 13 Pull out bearings 1 from input shaft by using special tool Special tool A 09913 65135 TRANSFER 7D 13 14 Disassemble ring and sprocket gear asse
378. verse brake and fluid pressure Time lag means time elapsed since select lever is shifted with engine idling till shock is felt 1 With chocks placed in front and behind front and rear wheels respectively depress brake pedal 2 Start engine 3 With stop watch ready shift select lever from N to D range and measure time from that moment till shock is felt 4 Similarly measure time lag by shifting select lever from N to R range Gear shifting time lag N D Less than 1 0 sec N R Less than 1 4 sec NOTE e When repeating this test be sure to wait at least minute after select lever is shifted back to N range es Engine should be warmed up fully for this test Troubleshooting Test result Possible cause e Low line pressure e Worn front clutch e Worn 1st amp 2nd brake e Low line pressure e Worn front clutch e Worn reverse brake When N gt D time lag exceeds specification When N gt R time lag exceeds specification 7B 22 AUTOMATIC TRANSMISSION 4 A T 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 158 176 F Fluid is filled to proper level between FU
379. volution of the counter driven gear vehicle speed in the transmission case The pulse generator is a noncontact sensor consisting of a per manent magnet coil and gears As the Output shaft turns the magneflux from the permanent magnet varies and a voltage of the frequency corresponding to the rotor revolution occurs in the coil This voltage is inputted to the TCM where TCM judges the output shaft revolution or the vehicle speed Input shaft speed sensor This sensor is a pulse generator type that detects revolution of torque converter s turbine shaft in the transmission case The principle of operation is the same as the output shaft speed sensor 1 Output shaft speed sensor 2 Input shaft speed sensor Transmission range sensor Shift switch A transmission range sensor 1 is provided so that the engine can be started only when the shift lever is in the P or N posi tion wich Wo BJ ATH C E D G 1 F P O TO OTO R O O N EE et D OTO 2 OTO L O O 2 Transmission range sensor coupler A B O D off switch AUTOMATIC TRANSMISSION 4 A T 7B 9 The gear shift up or shift down to and from the O D gear can be selected with this switch O D off switch 1 O D OFF indicator light ON ON OFF OFF 2 Shift lever A O D off switch ON B
380. when measuring by torque wrench 0 2 0 3 N m 2 0 3 0 kg cm 1 7 2 6 Ib in Preload of differential side bearings Starting torque of drive pinion when measuring by spring balance 4 0 6 0 N 0 4 0 6 kg 0 9 1 3 Ib Special tool A 09900 23107 B 09915 24550 C 09922 75222 3 Companion flange 4 Socket 9 Torque bearing cap bolts to specified torque and install bear ing lock plates Tightening torque Bearing cap bolts a 85 N m 8 5 kg m 61 5 Ib ft Lock plate bolts b 11 5 N m 1 15 kg m 8 5 Ib ft REAR DIFFERENTIAL 7F 23 10 As final step check gear tooth contact as follows CAUTION or too fluid When applying red lead paste to teeth be sure to paint tooth surfaces uniformly The paste must not be too dry NOTE tact a After cleaning tooth surface of about 10 teeth in A range paint them with gear marking compound evenly by using brush 1 or sponge etc Be careful not to turn drive bevel gear more than one full revolution for it will hinder accurate check b Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their con c Bring painted part up and check contact pattern referring to following chart If contact pattern is not normal readjust or replace as necessary according to instruction in chart 11 Upon completion of gear
381. when troubleshooting the air bag system do not use electrical test equipment such as a battery powered or AC powered voltmeter ohmmeter etc or any type of electrical equip ment other than that specified in this manual Do not use a non powered probe type tester Instructions in this manual must be followed carefully otherwise personal injury may result CAUTION The order in which diagnostic trouble codes are diagnosed is very important Failure to diagnose the diagnostic trouble codes in the order specified may result in extended diagnostic time incorrect diag nosis and incorrect parts replacement The diagnostic procedures used in this section are designed to find and repair air bag system malfunctions To get the best results it is important to use the diagnostic flow tables and follow the sequence listed below 1 Perform the Air Bag Diagnostic System Check Flow Table in this section The Air Bag Diagnostic System Check Flow Table must be the starting point of any air bag system diagno sis The Air Bag Diagnostic System Check Flow Table checks for proper AIR BAG warning lamp operation through AIR BAG warning lamp and whether air bag diagnostic trouble codes exist N ed Refer to the proper diagnostic table as directed by the Air Bag Diagnostic System Check Flow Table in this section The Air Bag Diagnostic System Check Flow Table will lead you to the correct table to diagn
382. witch ON G38 5 G38 6 Blank Data link connector Si G38 7 Serial data terminal 4 5V Ignition switch ON G38 8 Ground G38 9 Blank e 0 14V Ignition switch ON G38 10 Diagnosis output Ov ignition switch OFF NOTE When measuring voltage at G38 4 and G38 3 terminals with ignition switch turned ON be sure to turn ignition switch ON before connecting positive probe of voltmeter to G38 4 or G38 3 terminal If it is not turned ON first DTC13 Diagnostic Trouble Code 13 may be indicated lt Vehicle equipped with air bag system gt TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION G38 1 Ground G38 2 pate ink congactor 4 5V Ignition switch ON Serial data terminal S 10 14V Ignition switch ON SES ES 0 0 8V Ignition switch OFF G38 4 Power source 10 14V Ignition switch ON 8G 32 IMMOBILIZER CONTROL SYSTEM IF EQUIPPED Resistance Check Vehicle Not Equipped with Air Bag System SS SR Em TERMINAL CIRCUIT 1 Disconnect Immobilizer Control Module couplers from Immo bilizer Control Module with ignition switch OFF CAUTION Never touch terminals of Immobilizer Control Module itself or connect voltmeter or ohmmeter Check resistance between each terminal of couplers discon nected 1 CAUTION e Be sure to connect ohmmeter 2 probe from wire har ness side of coupler e Be sure to turn OFF ignition switch for this che
383. witch ON select lever other than P range 2 Transmission range sensor 10 14V IG switch ON select lever at R range R range 0 1V IG switch ON select lever other than R range 3 Transmission range sensor 10 14V IG switch ON select lever at N range N range 0 1V IG switch ON select lever other than N range 4 Diagnosis switch 10 14V IG switch ON diagnosis switch terminal not grounded 5 Engine speed signal 0 1V IG switch ON leaving engine OFF 6 Output shaft speed sensor E22 7 Input shaft speed sensor 8 Throttle opening signal 9 Transmission range sensor 10 14V IG switch ON select lever at D range D range 0 1V IG switch ON select lever other than D range 10 Transmission range sensor 10 14V IG switch ON select lever at 2 range 2 range 0 1V IG switch ON select lever other than 2 range 14 Transmission range sensor 10 14V_ IG switch ON select lever at L range L range 0 1V IG switch ON select lever other than L range 12 Serial data link SUZUKI scan tool 10 14V_ IG switch ON 13 Output shaft speed sensor shield 14 Output shaft speed sensor 15 Input shaft speed sensor 7B 58 AUTOMATIC TRANSMISSION 4 A T On Vehicle Service Maintenance Service Fluid level check LEVEL CHECK AT NORMAL OPERATING TEMPERATURE 1 St
384. with the center of groove A on the door as shown NOTE Striker should be moved vertically and placed level Do not adjust door lock Tightening torque Door latch striker screw a 10 N m 1 0 kg m 7 2 Ib ft Door latch screw b 6 N m 0 6 kg m 4 3 Ib ft 1 Door latch 2 Shaft Move door latch striker 1 sideways to adjust door 3 sur face flush with body 2 surface as shown In order to correctly obtain door latch striker position in the Bee el Dee geg EEN oe 3 an AJ fore and aft direction increase or decrease number of shims poi 5 5 inserted between body and striker to adjust it sy Dimension between door surface and body surface gt ial a 13 3 14 8 mm 0 52 0 58 in EN i S Dimension between door latch and door latch striker SS L b 3 2 5 2 mm 0 13 0 2 in 5 T NOTE a Apply oil or grease to striker joints periodically 4 Front side 9 36 BODY SERVICE Back Door Lock Assembly REMOVAL 1 Remove inside lock knob 2 Remove door trim 3 Remove door sealing cover 1 2 Adhesive 4 5 6 7 1 Outside door handle emove door lock control rod 2 isconnect control rod 3 isconnect door lock motor lead wire emove lock assembly DOUUD INSTALLATION Reverse removal procedure to install back door lock assembly noting followin
385. with 09926 37610 REAR DIFFERENTIAL 7F 1 SECTION 7F REAR DIFFERENTIAL CONTENTS General Description c ccsseseecceeeesessereees 7F 2 Differential Unit cc cceeceeeeeeeeeeeeeteeeeeees 7F 6 BET Le CC 7F 3 Tightening Torque Specification 7F 25 On vehicle Service cccceseeseeeceeeeeeeeseneees 7F 4 Required Service Material 7F 25 Oil Change enk 7F 4 Special TOOL sssccccsseecesseeecesseeseesseenenessenes 7F 25 Unit Repair Overhaul cccccsseseseereeeeees 7F 5 7F 2 REAR DIFFERENTIAL General Description The rear differential assembly uses a hypoid bevel pinion and gear The differential assembly is decisive in that the drive power is concentrated there Therefore use of genuine parts and specified torque is compulsory Further because of sliding tooth meshing with high pressure between bevel pinion and gear it is mandatory to lubricate them by hypoid gear oil The hypoid gears have an advantage of preventing gear noise at the same time they require accurate adjust ment of tooth contract and backlash Companion flange 5 Differential pinion Differential carrier 6 Differential side gear Drive bevel gear hypoid gear 7 Differential case PLO PM gt Drive bevel pinion hypoid gear REAR DIFFERENTIAL 7F 3 Diagnosis Condition Possible Cause Correction Gear noise Deteriorated or water mixed l
386. zer Indicator Lamp IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 9 Step Action Yes No 1 1 Make sure that diagnosis switch terminal in Go to Step 3 If malfunction indicator lamp monitor coupler is not grounded by service remains ON go to Step 2 wire See Fig 1 If malfunction indicator lamp 2 Check malfunction indicator lamp while igni remains OFF go to Malfunc tion switch is ON but without starting tion Indicator Lamp Check in engine See Fig 2 Section 6 Does malfunction indicator lamp flash 2 1 Using service wire 2 ground diagnosis Immobilizer control Go to Malfunction Indicator switch terminal in monitor coupler 1 See system is in good con Lamp Check in Section 6 Fig 3 dition Does malfunction indicator lamp flash 3 Does malfunction indicator lamp flash as Fig Go to Step 4 Go to Malfunction Indicator 4 Lamp Check in Section 6 4 1 Check DTC stored in immobilizer control Go to flow table for Go to Step 5 module referring to Diagnostic Trouble DTC No Code Check Immobilizer Control Module in this section Is there any DTC s 5 1 Check DTC stored in ECM referring to Go to flow table for Substitute a known good Diagnostic Trouble Code Check ECM in DTC No ECM and recheck this section See NOTE Is there any DTC s NOTE After replacing with a known good ECM register ECM Immobilizer Control Module code in ECM by performing procedu

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