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Important - 4x4 Suzuki

1. AIR BAG warning lamp DTC flashing pattern Diagnosis NO MODE 1041 41 UU Resistance high B1042 42 UUU Driver preten Resistance low B1043 43 UUL sioner circuit Short to ground B1044 44 UU Short to power circuit B1045 45 JUUL Resistance high Diagnose trou B1046 46 Passenger Resistance low ble according to pretensioner diagnostic flow B1047 47 circuit Short to ground able conos B1048 48 Short to power circuit sponding to _ P Coch dodo No 1051 51 Frontal crash detected n AIR BAG warming lamp cir post er UUU cuit failure 1071 71 SDM Internal fault Specifications different 1013 13 between air bag system and SDM NOTE When 2 or more codes are indicated the lowest numbered code will appear first 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 or even one of them is a current DTC AIR BAG warning lamp remains on after igi ion 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 Abnorm
2. ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6f System Flow Jo SEH nose Toor M my aes wes Doe I Qe jouir oo Some n tomos Lenmar SOS DT Cee cel anna Be EX ES ES woo 9o amos lt ganyn System Diagram ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 5 1 Airceaner 22 Fuel level sensor 39 AIC controller if equipped 2 Intake air temp sensor 23 Monitor connector if equipped 40 Data link connectorimmobilizer control mod it equipped 3 Mass airflow sensor 291 Diag switch terminal 1 ABS co
3. Sus 17 6 45 i est PPLYEL ach eu ORNIGRN C51 1 7 Qc 86120 WHTIBLK RED C51 1 6 E E6121 GRY BLU E YELIGRN C51 1 18 ET C51 1 28 MZ ORN BLU GRNBLU 081127 c gt aes sara iov E S GRNIRED i war 2 L PPLRED E61 13 13 BLU BLK 7 51377 BLKORN X 23 05127 BLXIGRN E esa ers pau sp PSE LEE 285 232221 20 19 18 17 16 15 14 13 12 11 10 9 17 16l15 9 8 7 1918 17 16 15 14 1312 11 10 9 8 20 19 18 17 14 19 14 13 12 11 10 9 8 3534333213130 29282726 2524 2625 24 23 2221 520 19 18 2827 262524 x 23 22 x21 2030 2928 x 27 26 5 24 23 2221 1 3 Transmission range sensor T7 MIL SERVICE ENGINE SOON lamp 2 VSS 10 Shift solencid A 18 off switch 3 CMP sensor 11 Shifsolenoid B 38 PIN change switch 4 TP sensor 12 solenoid 20 WD low switch sensor 13 Dalalink connector 21 Main relay amp _Stop lamp switch 14 Cruise control module 22 ignition switch 7 Input shaft speed sensor 15
4. 2 1 7 6 5 212 13 12 11 10 91 S pis rara pa n 0 po rez eps ra 9 5 12 1 10 MZ W WAS NZ ora ah i a ar See x Ep 4 Fuel injector No 4 18 2 4WD air pump assembly 4WD 37 Rear defogger switch if equipped 4 1 Fuel injector No 5 19 4WD switch 4WD 38 Heater blower motor if equipped Ai eer ER MEE Tope ERUNT 6 Idle air control 21 1 4WD low switch 4WD 41 Heated oxygen sensor 1 Bank if equipped 7 EVAP canister purge valve 22 Main relay 41 1 Heated oxygen sensor 1 Bank if equipped 8 Ignition coil for No 1 23 Transmission range switch Park Neutral 42 Heater oxygen sensor 2 Bank1 if equipped ERAS DAR 8 1 ignition coil for No 2 24 Starter magnetic switch 42 1 Heater oxygen sensor 2 Bank2 if equipped E T VE MU Eco lem 10 1 Ignition coil for No 6 27 Data link connector 46 CO adjusting resistor if equipped Se ae oe equipped en DE Rd rA emer et Eee UT 8 Ra San TUER 15 Knock sensor 32 input speed sensor A T 51 Monitor connector if equipped un D BED uc AM if equipped a E Throttle opening signal E61 5 Duty output terminal if equipped 61 17 signal if equipped E61 29 Diag switch terminal if equipped 61 6 Tachometer 61 18
5. T Armatura pate bat 5 Sim 7 Compressor body assembly 2 Amature plato Magnet sich 8 Magnet ea 3 Magwiduchamemby INSPECTION Check the following items Check no sigh of compressor oil leakage Check magnet clutch pulley bearing for noise and grease leakage Check magnet clutch operation as follows Connect battery 1 and ammeter 2 to compressor 3 as shown b Check that steadily locks between armature plate 4 and magnet clutch pulley 5 c Check that ammeter 2 indicates specified current Specified current of magnet clutch 4A MAX at 12V If any detects are found repair or replace magnet clutch assem bly REMOVAL 1 Remove compressor from vehicle Refer to COMPRESSOR ASSEMBLY in this section 2 Fix armature plate 1 with special tool and remove armature plate bolt Special tool A 09920 53740 NOTE Do not reuse armature plate bolt 3 Remove armature plate 1 4 Remove shims from shaft 18 42 AIR CONDITIONING OPTIONAL 5 Using special tool remove circlip Special tool A 09900 06107 6 Remove magnet clutch lead wire clamp screw and remove SS A magnet clutch read wire ground terminal lt 7 Remove magnet clutch with puller NOTE Be careful not to damage pulley when tapping magnet clutch T Puler 2 Compressor 8 Remove circlip using special tool Special
6. 2 m Drive bevei pinion Drive bevel gear 1 Universal Joint flange PINo 27110 60A00 Pinion dummy height Attachment height 2 Nut 7b Axe dummy radius 3 Frontbearing 7 Mounting dummy size 110 00 mmy4 3307 in 4 Differential carier V Measured dimension 5 Rearbearing d Drive bevel pinion mounting distance 110 00 3307 in 6 Spacer 797 Shim size for mounting distance adjustment c 7 8 7F 14 DIFFERENTIAL REAR 1 Install special tools with bearings and universal joint flange 2 to differential cartier 1 NOTE This installation requires no spacer or oil seal Special tool E 09951 46010 F 09926 78311 002 2 Tighten flange nut 1 so that specified bearing preload is obtained NOTE Before taking measurement with spring balance 2 or torque wrench 3 check for rotation by hand and apply small amount of differential oil to bearings On measuring preload rotate the drive bevel pinion about 1 rotation per 2 seconds Special tool C 09922 75222 F 09926 78311 002 Pinion bearing preload 0 9 1 7 Nem 9 0 17 0 kg cm 7 8 14 7 Ib in Spring measure reading with special tool 18N 34N 1 8 3 4 kg 4 0 7 5 Ib 4 Socket with adapter DIFFERENTIAL REAR 7F 15 3 Set dial gauge to mou
7. T Upper anchor 4 Buse 9 Z Lower anchor 5 Retractor assembly upper mounting TA Removal Afer tightening lower bot upper bolt 3 Retractor assembly 5 Yalow connector Tor seat balt pretensioner T8 Insialaton equipped 10A 4 SEAT BELT REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system referring to DISABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS under ON VEHICLE SERVICE in Section 10B if necessary 3 Remove front pillar lower trim 4 Disconnect Yellow connector for seat belt pretensioner if necessary a Release locking of lock lever b After unlocking disconnect to connector 5 Remove front seat belts from the vehicle INSPECTION WARNING Never 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 30 cm 1 ft or more it should be replaced 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 The seat belt webbing or strap should be free from damage Fully extend the seat belt to make sure there are no twists or tears in it Retractor assembly 1 Let the seat belt retract fully to confirm its easy retraction
8. ENGINE MECHANICAL H27 ENGINE 6A2 19 5 Install cylinder head to block After applying oil to cylinder head bolts tighten them gradu ally as follows Tighten all bolts to 53 N m 5 3 kg m 38 5 Ib ft according to numerical order in the figure b In the same manner as in a tighten them to 84 Nm 8 4 kg m 61 0 Ib ft Loosen alll bolts until tightening torque is reduced to 0 in reverse order of tightening d In the same manner as in a tighten them to 53 Nm 5 3 kg m 38 5 6 0 In the same manner as in a again tighten them to speci fied torque Tightening torque Cylinder head bolt a 105 N m 10 5 kg m 76 0 Ib ft Cylinder head bolt hex hole bolt b 11 Nem 1 1 kg m 7 5 Ib ft NOTE Don t forget to install b bolts as shown in the figure Hex hole bolt 2 Crankshaft pulley side 3 Flywheel side TA RH bank IB LHbank 6 Install water outlet cap 7 Check timing mark on crankshaft as shown in the figure 3 Crank timing pulley key 2 8 Install valve lash adjuster camshaft CMP sensor and RH bank 2nd timing chain Refer to CAMSHAFT AND VALVE LASH ADJUSTER and RH NO 2 BANK 2ND TIMING CHAIN AND CHAIN TEN SIONER in this section For CMP sensor refer to CMP SENSOR in Section 6F2 Install 1st timing chain Refer to 1ST TIMING CHAIN AND CHAIN TENSIONER in this section Install LH ba
9. BODY SERVICE 9 19 Exterior and Interior Trim Floor Carpet X Front oor carpet 2 Dash panal insulation 3 Rear floor carpet Front floor carpet REMOVAL 1 Remove front and second seats 2 Remove third seat cushion if equipped 3 Remove front and second seat belt lower anchor bolts 4 Remove dash side trims 1 front side sill scuffs 2 center pillar inner lower trims 3 rear side sill scuffs 4 and rear quarter lower trims 5 5 Remove parking brake lever cover console box and console box front extension 6 Remove front floor carpet INSTALLATION Reverse removal sequence to install front floor carpet noting the following point Tighten seat belt anchor bolts as specified torque referring to Section 10A 9 20 BODY SERVICE Rear floor carpet without third seat vehicle REMOVAL 1 Remove rear luggage mat end garish 1 rear side sill scuff and rear quarter lower trims 2 2 Remove luggage hook plate nut 3 3 Remove rear floor carpet INSTALLATION Reverse removal procedure for installation noting the following Head Lining REMOVAL 1 Remove front side sill scuffs 1 rear side sill scuffs 2 cen ter pillar lower trims 3 center pillar upper trims 4 front pil lar upper trims 5 rear luggage mat end gamish 6 rear luggage box 7 rear quarter lower trims 8 and
10. TERMINALS CIRCUIT STANDARD CONDITION RESISTANCE E61 9 and E61 2 Main relay 79 950 E61 22 and C51 3 20 fan motor relay if equipped 75 1100 disconnected and ignition switch ON E61 23 and C51 3 20 Fuel pump relay 79 950 51 3 6 and Body ground Ground Continuity C51 8 17 and Body ground Ground Continuity C51 1 1 and Body ground solenoid B A T 11 150 C51 1 2 and Body ground Shift solenoid A T 51 1 4 51 3 4 IAG valve stepper motor coil 2 255 3850 51 1 5 and C51 3 4 IAC valve stepper motor coil 1 C51 1 8 and Body ground solenoid A T 11 150 51 1 15 and 51 3 4 EVAP canister purge valve 28 350 51 1 16 and 51 3 4 valve stepper motor coil 4 255 3850 51 1 17 and 51 3 4 valve stepper motor coil 3 C51 2 1andC51 34 Fuelinjector No 2 13 160 C51 2 2andC51 34 Fuelinjector No 1 C51 2 4 C51 2 5 and E61 9 Heater of HO2S 1 50 64Q 51 2 7 and Body ground Ground Continuity 51 2 8 and C51 3 4 Fuel injector No 4 13 162 51 2 9 and C51 3 4 Fuelinjector No 3 51 2 12 51 3 4 EGR valve stepper motor coil 4 20 240 51 2 13 and 51 3 4 valve stepper motor coil 3 51 2 14 and 51 3 4 valve stepper motor coil 2 51 2 15 51 3 4 EGR valve stepper motor coil 1 C51 2 16 C51 2 17and Heater of HO2S 2 117 1430 E61 9 C5i 2 21andC51 3
11. 1n 12 13 14 15 16 Terminal arrangement of ECM E61 esta 51 2 2 els aJa 2 T ORGE 3 322 b lpohiehe pepe papa ro 218 S es palapa est apa z i A C CONTROLLER VOLTAGE VALUES TABLE AIR CONDITIONING OPTIONAL 18 17 Terminal Wire Circuit Measurement Normal value Condition ground BLK Controllermain Ground to Ignition switch ON with engine ACA WHT power supply engine Fig B stopped BLK Controller Ground to body ACA YEL ground Fg A 04 0V Engine running Refrigerant pressure within 225 gcn kpa 2 3 kg cm 32 7 psi to 2548 26 kg cm 370 psi Refrigerant Ground to with dida AC A 4 ORN dual pressure tas ang g P engine Fig B Refrigerant pressure below 196 switch input 2 qo KP 2 0 kg cm 28 psi or above 3140 32 kglcm 455 psi with engine running Blower fan motor switch or A C or 8 14V defroster switch OFF with engine ACA GRN e anor found to running BLK Ovitchinput engine Fig B Blower fan molor switch and A C P 0 15V ordefroster switch ON with engine running Signal input from 10 14V Approve of AC ON Ac Ag GRY ECM CON Ground to WHT permission sig engine Fig B 0 1V A CON forbid nal Blower fan motor switch and A C or defro
12. Dual A G model 1 Suction hose 4 Condenser outlet pipe 7 Front suction pipe Apply compressor refrigerant to O ring 2 Dischargehose 5 Expansion valve 8 Rear liquid pipe 3 Frontiquidpipe 6 Dual refrigerant pressure switch 9 Rear suction pipe 18 26 AIR CONDITIONING OPTIONAL Never use heat for bending pipes When bending a pipe try to make its bending radius as slight as possible Keep internal parts of air conditioning free from moisture and dirt When disconnecting any line from system install a blind plug or cap to the fitting immediately When tightening or loosening a fitting use two wrenches one for turning and the other for support Tighten flared nuts to specified torque Tightening torque 8 mm 0 31 in pipe 13 N m 1 3 kg m 9 5 Ib ft 12 7 mm 0 5 in pipe 22 Nm 2 2 kg m 16 0 Ib ft 16 mm 0 63 in pipe 33 N m 3 3 kg m 24 0 Ib ft Route drain hose so that drained water does not make any contact to vehicle components Handling refrigerant HFC 134a R 134a When handling refrigerant always wear goggles to protect your eyes Avoid you direct contact to liquid refrigerant Do not heat refrigerant container higher than 40 C 104 F Do not discharge refrigerant into atmosphere Do not allow liquid refrigerant to touch bright metals Refrigerant combined with moisture is corrosive and will tamish surfaces of
13. AUTOMATIC TRANSMISSION 4 A T 781 21 Step Action Yes No 5 _ 4WD LOW switch signal inspection Go to Step 6 Faulty LOW switch With ignition switch ON check voltage between or its circuit C51 1 26 terminal of PCM coupler and ground If OK substitute a known 4WD LOW switch specification good PCM and recheck Transfer gear position 4L or N 0 V Transfer gear position 4H or 2H Battery voltage Is the result as specified 6 _ Is vehicle equipped with cruise control system Go to Step 7 Substitute a known good PCM and recheck 7 Cruise control signal inspection Substitute a known good Faulty cruise control mod With ignition switch ON check voltage between PCM and recheck ule or its circuit E61 35 terminal of PCM coupler and ground If OK substitute a known Is it battery voltage good PCM and recheck 781 22 AUTOMATIC TRANSMISSION 4 A T Table B 1 O D OFF Light Circi Ignition Switch ON But Engine Starts Up Check O D OFF Light Doesn t Light at WIRING DIAGRAM 5 ues aoa Tues 7 Glo er ys E 2 WHTBLK cmviu YEURED ORN BLU tola Sep BLKWHT 902 RE mo m sods njen E 1 amp 8 8 any 21 20 E61 51 3 51 1 51 2 tH LR Wii W
14. T Ignition swich 3 ABS hydrauic unicontrol module assembly 2 Main fuse 4 ABShydruicun contomoddeconmdor DESCRIPTION The ABS control module monitors the power source voltage at terminal E136 18 When the power source volt age becomes extremely high or low this DTC will be set As soon as the voltage rises or lowers to the specified level the set DTC will be cleared INSPECTION Step Action Yes No 1 1 Connect a voltmeter between battery posi tive 4 terminal and body ground 2 Startthe engine and measure the maximum voltage when racing the engine Is it over 18V Check charging system to Step 2 referring to CHARGING SYSTEM section 1 Disconnect ABS hydraulic unit control mod ule connector 2 Keep the engine idling measure the voltage between terminal 136 18 of ABS control module and body ground 15 it always under 9V Check charging system Poor connection of termi referring to CHARGING nal E136 18 or E136 SYSTEM section 24 of the ABS control Imperfect short between module wire GRN ORN and Ifthe above are in good ground condition substitute a known good ABS hydrau lic unit control module and recheck 52 26 ANTILOCK BRAKE SYSTEM ABS DTC C1061 DTC 61 ABS Pump Motor Circuit WHT BLU E1362 13823 En 136 25 136 23 6196 22
15. ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 89 DTC P0400 Exhaust Gas Recirculation Flow Malfunction SYSTEM WIRING DIAGRAM 5 cse Eee TE gum E122 2 rx Dos cse n S eiue BLU BLK C5 R iT erngl 051245 2 1 zur cs1 2 14 Grivel 4 051 243 0 Lr GhNIRED s lt sew ess gt 51 325 a 5 651 34 051 38 carers LI NM S lt NI SZ 051325 651 24 651 213 1 EGR valve 5 ECM PO 2 Intake manifold MAP sensor 3 Exhaust gas Mainfuse 4 Sensed information 8 Main relay 6 1 90 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA During deceleration engine speed high with closed EGR valve throttle position in which fuel cut is involved difference EGR passage in intake manifold pressure between when EGR valve is Manifold absolute pressure sensor opened and when it is closed is smaller than specified PCM value 2 driving cycle detection logic DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place whe
16. 3 Remove drive bevel gear hypoid gear differential gears differential pinions and pinion shafts a With aluminum plates 2 placed on vise first grip differen tial case with it and remove drive bevel gear hypoid gear 8 by removing its bolts 1 DIFFERENTIAL REAR 7F 7 b Remove differential left case 2 from differential right case 1 c Remove pinion shafts differential gears washers differen tial pinions spring washers thrust washers 4 Using special tools pull out differential side bearings 1 Special tool C 09913 85230 D 09913 61510 5 Remove drive bevel pinion hypoid gear assembly a Hold universal joint flange with special tool and then remove flange nut by using power wrench 4 10 magnifica tion 2 Special tool 09922 66021 1 Socket wrench 7F 8 DIFFERENTIAL REAR b Make mating marks 1 on drive bevel pinion and compan ion flange CAUTION Don t make mating mark on the coupling surface of the flange c Remove companion flange from drive bevel pinion Use special tool if it is hard to remove Special tool F 09913 65135 d Remove drive bevel pinion with rear bearing shim spacer from carrier If it is hard to remove screw an used nut into drive bevel pinion and hammer on that nut with a plastic hammer but never directly on drive bevel pinion
17. yevorn n 3 RED BLK RED BLU 10 LN 5 M vevewu m slk T Font lower motormainrelay 19 Compressor relay Te Baty 2 Blower molor Ti Compressor 29 29 Fear blower molor roy Front ower mdr redi 12 Condenser cocing Tan ator zi Ignition 50 90 ear Bower molor resistor molore 8 Condensar cooing molar 22 HesieUAC main ase 80 Si Faar Bower moter 5 AC controler 34 Fuse box 23 IGMETER fuse 208 32 Rearblowermolor suc 5 ECM PCM 38 AC fuse 24 REAR DEFGT uso 25A 33 Roar main swich 7 Heater mode corr sw 16 Ignition swich 25 REAR BLOW use 20A 34 Fear AC evaporator temperare co 8 Dua agoran pressure swich T7 Main fusa bor 26 FRONT BLOW use 30A 35 Rear AIG evaporator termparatura sensor 9 evaporator thermistor 18 Battery main fuse 100 A 27 Solenoid valve A Rear A C wiring circuit if equipped evaporator temperature sensor Fig A AIR CONDITIONING OPTIONAL 18 15 Inspection of A C Controller and Its Circuits CAUTION controller and ECM cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to A C controller and ECM with couplers disconnected from it AIC Controller 1 and its circuits can be checked at A C controller wiring couplers by measuring voltage Voltage check 1 Remove A C control
18. 09950 78220 Flare nut wrench 10 mm 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE A Mass storage cartridge for Tech 1A gt gt 09931 76030 16 14 pin DLC cable for Tech 1A ANTILOCK BRAKE SYSTEM ABS 5E2 35 Tech 2 kit SUZUKI scan tool See NOTE B NOTE A This kit includes the following items and substitutes for the Tech 2 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 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 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 52 36 ANTILOCK BRAKE SYSTEM ABS ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 SECTION 6 1 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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
19. T PIN change swich 2 Fuse 506 2 0 off switch TROUBLESHOOTING Step Action Yes No 1 O D OFF light circuit check 1 With ignition switch OFF disconnect cou plers from PCM 2 Using service wire connect E61 20 termi nal of disconnected PCM coupler and ground Does O D OFF light turn ON at ignition switch ON Poor E61 20 terminal con nection If OK substitute a know good PCM and recheck Bulb burned out or faulty WHT BLK BLK WHT wire AUTOMATIC TRANSMISSION 4 A T 7B1 23 Table B 2 O D OFF Light Circuit Check OFF Light Comes ON Steadily WIRING DIAGRAM Refer to TABLE B 1 in this section TROUBLESHOOTING Step Action Yes No T Check O D off switch status Goto Step 2 System is OK Press O D off switch button 1 Does O D OFF lamp come ON steadily 2 Check lamp circuit for short WHT BLK circuit Go to Step 3 1 Tum ignition switch OFF and disconnect shorted to ground PCM connectors 2 Tum ignition switch ON Does O D OFF lamp come ON steadily 3 Check O D off switch circuit Go to Step 4 Check PCM ground circuit 1 Check resistance between terminal E61 33 for open of disconnected PCM connector and body If ground circuit is OK ground with O D off switch button 1 substitute a known good released PCM and recheck Is continuity indicated 4 Check O D off switch for operation YE
20. 5208888888 c3 CogBBSBBBBEB 3 ABS hydraulic uniicontrol module assembly 3 ABS pump motor 5 ABS hydraulic uniicontrol module connector 2 ABS pump motor relay 4 ABS fail sale relay DESCRIPTION The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the igni tion switch turned ON It sets this DTC when the voltage at the monitor terminal does not become high low according to ON OFF commands to the motor relay of the module does not follow these commands INSPECTION Step Action Yes No T 1 Check pump motor referring to ABS HYDRAULIC UNIT OPERATION CHECK in this section Is it in good condition Check terminals E136 25 and E136 23 con nection If connections OK substitute a known good ABS hydraulic unit control module assembly and recheck Go to Step 2 1 Ignition switch OFF 2 Disconnect ABS hydraulic unit control mod ule connector 3 Check for proper connection to ABS hydraulic unit control module connector at terminal 136 23 4 If OK then measure voltage between termi nal E136 23 of module connector and body ground Isit10 14 V Go to Step 3 WHT BLU circuit open Measure resistance between terminal E136 22 of ABS hydraulic unit control module con nector and body ground Is it infinite BLK circuit open
21. 6 1 32 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Condition Possible Cause Correction Improper engine idling or engine fails to idle Faulty spark plug Spark plugs in Section 6F2 Faulty ignition coil with ignitor Ignition coil in Section 6F2 Fuel pressure out of specification DIAG FLOW TABLE B 3 in this section Engine overheating Refer to OVERHEATING in this table Maladjusted TP sensor installation angle if adjustable TP sensor in Section 6E2 Faulty idle air control system DIAG FLOW TABLE B 4 in this section Faulty FIA fast idle air valve FIA valve in Section 6E2 Faulty evaporative emission control system EVAP control system in Section 6E2 Faulty EGR system DTC P0400 DIAG FLOW TABLE in this section Faulty injector Fuel injection in Section 6E2 Faulty ECT sensor TP sensor or MAF sensor ECT sensor TP sensor or MAF sensor in Section 6E2 Faulty ECM PCM Inspection of ECM PCM and its circuit in this section Low compression Refer to the same item in HARD STARTING of this table Malfunctioning PCV valve PCV system inspection in Section 6E2 Engine hesitates Momentary lack of response as the accel erator is depressed Can occur at all vehi cle speeds Usually most severe when first trying to make the vehicle move as from a stop sign Spa
22. ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 61 DTC P0135 HO2S 1 Bank 1 Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0130 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when 25 heateris HO2S 1 heater circuit electrically live 2 driving cycle detection logic HO2S 1 heater Current of HO2S heater is 5 3 or more or less than PCM 0 09 A or 25 heater relay Voltage of HO2S heater is 14 0 V or higher or lower than 11 7 V DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 5 min 3 Check pending DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE formed DIAG FLOW TABLE in this section 2 25 1 heater check Go to Step 3 Replace HO28 1 1 Disconnect HO2S 1 coupler with ignition switch OFF 2 Check resistance between 3 and
23. Ignition control Ignition coil with igniter O O MIL control MIL EVAP purge control ese canister purge e EGR control EGR valve if equipped OJO JO O O HOZS heater control HO2S if equipped AIC amplifier AIC control it equipped JOJO condensor fan condensor fan o control relay if equipped Diagnosis ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 13 On Vehicle Service 6 v 2 T Brake booster hose pipe 8 EGR pipe f equipped 15 _EVAP cantor 2 Vacuum hose for fuel pressure regulator 9 Exhaust manifold 16 Tank pressure contol valve 3 Fuel pressure regulator 0 Healad oxygen sensor 37 Tofusl ani 4 MAP sensor equipped 1 EGR valve equipped 18 Cap 5 Engine coolant hose 32 POV hose TAF Vehicle without mentor connector 6 _EVAP canister purge vav 13 IAC valve TBI Vehicle with monitor connector 7 Breather hose 34 IAC hose General When hoses are disconnected and system components are removed for service reinstall components properly and route and connect hoses correctly after service Refer to figure on previous page for proper routing of hoses 62 14 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE Accelerator Cable Adjustment 1 With throttle valve close
24. Substitute a known good ABS hydraulic unit con trol module assembly and recheck ANTILOCK BRAKE SYSTEM ABS 5E2 27 DTC C1063 DTC 63 ABS Fail Safe Relay Circuit BLKeLu ono ETE 1 WHT BLU esas Ca0HBBHHBHH CEOSSSSSHHBHO CogBHBBBBBHB lgnition switch 3 ABS hydraulic uniticontrol module connector 5 Failsafe relay 2 ABS hydraulic un controhmodule assembly 4 To solenoid valves DESCRIPTION ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned ON Also immediately after ignition switch is turned ON perform initial check as follows Switch fail safe relay in the order of OFF ON and check if voltage changes to Low High If anything faulty is found in the initial check and when the voltage is low with ignition switch turned ON this DTC will be set INSPECTION Step Action Yes No 1 Check battery voltage Is it about 11 V or Go to Step 2 Check charging system higher referring to CHARGING SYSTEM section 2 ABS main fuse and connection Go to Step 3 Repair and or replace Is it in good condition fuse 3 1 Ignition switch OFF Substitute known good WHT BLU circuit open 2 Disconnect ABS hydraulic unit control mod ABS hydraulic short to ground ule connector trol module assembly and 3 Check p
25. NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Increase vehicle speed to 80 90 km h 50 56 mph 4 Keep above vehicle speed for 5 min or more Throttle valve opening is kept constant in this step 5 Stop vehicle and check if pending DTC exists by using scan tool If not check if catalyst monitoring test has completed by using scan tool If not in both of above checks i e no pending DTC and catalyst monitoring test not completed check vehicle condition environmental and repeat Step 3 through 5 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 Exhaust system visual inspection Go to Step 3 Repair or replace 1 Check exhaust system for leaks damage and loose connection Is it in good condition 3 HO2S 2 output voltage check Replace warm up three Check RED YEL and 1 Check output voltage of HO2S 2 referring way catalytic converter l GRY YEL wires for open Step 2 of DTC P0156
26. level leakage SECTION 0B Air cleaner element dirt clogging SECTION 0B Battery fluid level corrosion of terminal SECTION 0B Water pump belt and or cooling fan belt Accelerator cable play installation tension damage SECTION 6C A T throttle cable play installation SECTION 6E2 Vacuum hoses of air intake system SECTION 6E2 disconnection looseness deterioration bend SECTION 6A2 Connectors of electric wire harness disconnection friction looseness deformation SECTION 8 Other parts that can be checked visually Also check following items at engine start if possible Malfunction indicator lamp operation Charge warning lamp operation Engine oil pressure warning lamp operation Engine coolant temp meter operation SECTION 6 1 Fuel lever meter operation SECTION 6H Abnormal air being inhaled from air intake system SECTION 8 6A2 Exhaust system leakage of exhaust gas noise SECTION 8 Other parts that can be checked visually SECTION 8 STEP 5 TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 CUSTOMER COMPLAINT ANALYSIS and Step 2 DTC FREEZE FRAME DATA CHECK confirm trouble symptoms Also reconfirm DTC according to DTC CONFIRMATION PROCEDURE described in each DTC FLOW TABLE 6 1 14 ENGINE GENERAL INFORMATION
27. Is check result as specified Intermittent trouble or faulty ECM PCM Recheck referring to INTERMITTENT AND POOR CONNECTION in Section 0A BLU BLK LT GRN LT GRNWHT LT GRN YEL or LT GRN RED circuit open or shorted to ground 6 1 94 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0420 Catalyst System Efficiency Below Threshold Bank 1 SYSTEM DIAGRAM RED p GRY YEL 1 i 513 25 1 25 1 Banici 4 TWO 2 252 Banki 5 ECM POM 3 CIRCUIT DESCRIPTION Exhaust oxygen concentration at the pre catalyst and the post catalyst of WU TWC is detected from HO2S 1 and HO2S 2 respectively and accordingly ECM PCM controls the closed loop which then controls the fuel injection volume Refer to Section 6E2 While the above control is going on and if WU TWC is in good condi tion the output voltage of HO2S 2 is maintained at specified level As WU TWC becomes deteriorated even when the above control is going on the exhaust gas which has passed WU TWC then passes HO2S 2 at the exhaust oxygen concentration similar to that of the pre catalyst without being oxygenated or converted Thus waveforms of HO2S 1 and HO2S 2 output voltages become alike ECM PCM judges deterioration of WU TWC by comparing waveforms of
28. 0 GYEUGAN 051 1 12 GRYIVEL 4y 51 3 26 Wie WAEN W 511 13 0511 12 C513 26 1 sensor 2 To main relay 3 ECM POM SYSTEM DESCRIPTION CMP sensor detects REF signal and POS signal REF signal 4 pulses 1 revolution of camshaft There 2 different kinds of wavelength Based on REF sig nal ECM PCM judges which cylinder is at TDC POS signal 6 pulse 1 revolution of camshaft Each of POS signals has equivalent wavelength Based on POS signal ECM PCM judges the wavelength of REF signals engine speed and piston posi REFERENCE Connect oscilloscope between terminals C51 1 13 POS or C51 1 12 REF and C51 3 26 ground of ECM PCM connector connected to ECM PCM and check CMP sensor signal Pos 45 m m 2 seal asaj asah ssal dasal asa 07 180405 240 sos 360 10 5 10 molh 157 201 20 18 204 15 20 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 87 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA sensor signal is not inputted for 3 sec even though CMP sensor circuit engine start signal is being inputted CM
29. Centerinecfwhes Foward IB Front view Body center On Vehicle Service Reference Information SIDE SLIP For inspecting front wheel side slip with side slip tester Side slip limit IN 4 mm m OUT 2 mm m IN 0 158 in 3 3 ft OUT 0 078 in 3 3 ft If side slip exceeds above limit toe in or front wheel alignment may out not be correct 3A 2 FRONT END ALIGNMENT POWER STEERING P S SYSTEM 3B1 1 SECTION 3B1 POWER STEERING P S SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 syste
30. General Description Two universal non constant velocity joints which are called cardan joints are provided on front propeller shaft and one universal non constant velocity joint two universal constant velocity joints and a rubber mounting cen ter support are provided on rear propeller shaft On the front end of rear propeller shaft cardan joint same as that of front propeller shaft is provided On the rear end of rear propeller shaft ball fixed type constant velocity joint BJ is provided On the middle of rear propeller shaft double offset type constant velocity joint DOJ is provided just behind the center support Most universal joints require no maintenance They are lubricated for life and can not be lubricated on the vehi cle If a universal joint becomes noisy or worn it must be replaced The propeller shaft is a balanced unit Handle it carefully so that balance can be maintained 2 3 Front propeller shaft 2 Rear propeller shaft 48 2 PROPELLER SHAFTS On Vehicle Service Propeller Shaft For the descriptions other than those mentioned below refer to the same item in the same section of the Service Manual men tioned in the FOREWORD of this manual INSTALLATION Tightening torque Tightening Torque Specifica Front propeller shaft flange nuts a 50 N m 5 0 kg m 36 5 Ib ft Rear propeller shaft flange nuts a 60 N m 6 0 kg m 43 5 Ib ft n Use the fol
31. disconnection friction Section 6 1 or 7B1 Fuses burning SECTION 8 Parts installation damage bolt looseness Other parts that can be checked visually Also check following items at engine start if possible O D OFF lamp SECTION 7B1 POWER lamp SECTION 7B1 Malfunction indicator lamp SERVICE ENGINE SOON lamp Section 6 1 Operation Charge warning lamp Operation SECTION 6H SECTION 8C SECTION 6A2 for pres sure check A T Basic Check This inspection is important for troubleshooting when PCM ECM has detected no DTC and no abnormality has been noted in visual inspection Follow flow table carefully Step Action Yes No 1 Was AUTOMATIC TRANSMISSION DIAGNOSTIC Go to Step 2 Go to AUTOMATIC FLOW TABLE performed TRANSMISSION DIAG NOSTIC FLOW TABLE 2 Perform MANUAL ROAD TEST in this section Go to Step 3 Go to Step 4 Is it OK 3 Proceedto TROUBLE DIAGNOSIS TABLE 1 in this Repair or replace Step 5 section defective parts Is trouble identified AUTOMATIC TRANSMISSION 4 A T 781 15 Step Action Yes No 4 Perform stall test engine brake test time rag test line pressure test and P range test referring to STALL TEST LINE PRESSURE TEST ENGINE BRAKE TEST and RANGE TEST in this section Are the test results satisfactory Go to St
32. 4 8 Fuel evaporative emission con Vehicle without HO2S TrqT T trol system Vehicle with HO2S NOT R Replace or change I Inspect and correct replace or lubricate if necessary For Sweden item 2 1 4 2 and 4 3 should be performed by odometer reading only For Item 2 1 Nickel spark plugs replace every 50 000 km if the local law requires kel spark plug BKR6E 11 or K20PR U11 idium spark plug IFR5J11 or SK16PR11 MAINTENANCE AND LUBRICATION 0B 3 Km x 1 000 15 30 45 60 75 90 Interval Miles x 1 000 9 18 27 36 45 54 Months 12 24 36 48 60 72 CHASSIS AND BODY 6 1 Clutch pedal and fluid level 6 2 Brake discs and pads thickness wear damage T Brake drums and shoes wear damage 6 3 Brake hoses and pipes leakage damage clamp 6 4 Brake fluid R R R 6 5 Brake lever and cable damage stroke operation Inspect at first 15 000 km 9 000 miles only 6 6 Tires wear damage rotation Ip qr Tre 6 7 Wheel discs damage 6 8 Suspension system tighteness damage rattle breakage T r T Tr 6 9 Propeller shafts and drive shafts 6 10 Manual transmission oil leakage level I 1st 15 000 only 1 R R 6 11 Automatic transmission Fluid level 1 Fluid change Replace every 165 000 km 99 000 miles Fluid hose R 6 12 Transfer
33. CHECK in this sec Go to applicable DTC to Step 2 tion Diag Flow Table Is there any malfunction DTC 2 1 Check condenser fan for operation Thissystemisin Go to Step 3 condenser fan should be operated under follow good condition ing condition A or B only When engine is running and is operating B When engine coolant temp is 113 C 235 F or more with ignition switch ON Is check result as specified 3 1 Remove ECM PCM cover Fuse blown RED YEUGRN circuit 2 Check voltage between E61 22 terminal of ECM RED BLK or RED open YEL BLU cir PCM connected coupler and ground BLU circuit open cuitopen or short Other than conditions A and B in Step 2 malfunction ofcon relay malfunction 10 14V denser fan motor or If above are OK sub Under condition A or B in Step 2 relay stitute a known good 0 1V ECM PCM and Is check result as specified recheck ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 Special Tool 125 09912 58441 Pressure gauge 09912 58431 Pressure hose sU 09912 58490 3 way joint amp hose 09912 58421 Checking tool set See NOTE 09917 47011 Vacuum pump gauge 09930 88521 Injector test lead 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE Mass storage cartridge for Tech 1A 09931 76030 14 16 pin
34. VSS coupler 2 BLUIYEL 020 1 terminal BLKIYEL 020 2 terminal 4 BLUIBLK 20 3 terminal Fig for Step 5 VSS coupler 2 VSS driven gear 3 VSS drive gear 6 1 108 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0505 Idle Air Control System Malfunction SYSTEM WIRING DIAGRAM unen 1 H E59 C52 MP ppp csraas 75 7 GRNBLK 1 75 d C514 17 moe e 0514 5 C51 1 4 AANA W gt 51107 T Throtie body 3 ECM PCM 5 FIA valve 7 Main relay 2 die air control valve 4 Sensed information 6 Mainfuse DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Engine idle speed is 100 r min or more lower than target idle IAC valve or its circuit speed for longer than 20 sec continuously Abnormal air drawn in air intake system or FIA fast idle air valve Engine idle speed is 200 r min or more higher than target idle speed for longer than 20 sec continuously 2 driving cycle detection logic ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 DTC CONFIRMATION PROCEDURE NOTE 109 Check to mak
35. ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 43 Fuel cut operation INSPECTION spection check to make sure that gear shift lever is in Neutral position with A T model selector lever in P range and that parking brake lever is pulled all the way up 1 Warm up engine to normal operating temperature 2 While listening to sound of injector by using sound scope 1 or such increase engine speed to higher than 3 000 r min 3 Check to make sure that sound to indicate operation of injec tor stops when throttle valve is closed instantly and it is heard again when engine speed is reduced to less than about 2 000 r min 6E2 44 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 86 EGR 6 COOLANT TEMP 18 F EGR 6 Emission Control System EGR system if equipped EGR SYSTEM INSPECTION USING SUZUKI SCAN TOOL 1 Connect SUZUKI scan tool to data link connector DLC 1 with ignition switch OFF Special tool A SUZUKI scan tool NOTE For operation procedure of cartridge refer to its car tridge operator s manual 2 Start engine and warm up it to normal operating tempera ture 3 With engine idling without depressing accelerator pedal open EGR valve by using MISC TEST mode In this state according as EGR valve opening increases engine idle speed drops If not possi
36. REMOVAL 1 Disconnect negative cable at battery 2 Drain cooling system 3 Remove strut tower bar 4 Disconnect accelerator cable 1 and or A T throtlle cable 2 from throttle body 5 Disconnect water hoses from throttle body ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 19 6 Remove surge tank cover Remove intake air pipe 1 and surge tank pipe 2 7 Disconnect connectors of TP sensor and IAC valve 8 Disconnect ground wire at connector 9 Remove clamp bracket 1 and harness clamps from intake collector 10 Disconnect connectors of EVAP canister purge valve 1 MAP sensor and EGR valve 5 11 Disconnect PCV valve 6 from cylinder head with hose con nected breather hose 3 from cylinder head and EVAP can ister purge valve hose 2 12 Detach EGR pipe 4 from intake air collector 13 Remove throttle body 3 and intake collector 2 from intake manifold 1 14 Disconnect hoses of PCV from throttle body 15 Remove throttle body from intake collector NOTE TP sensor 4 or other components containing rubber must not be placed in a solvent or cleaner bath A chemical reaction will cause these parts to swell harden or get distorted Don t put drills or wires into passages for cleaning It causes damages in passages 62 20 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENG
37. freeze frame freeze frame zu detected detection detection data data P0171 Fuel sys Data at PO171 DataatPO110 at P0171 freeze frame detected detection detection detection data 3 P0300 Misfire Data at PO171 DataatP0110 DataatPO171 Data at P0300 58 detected detection detection detection detection S iG Poaot Misfire Data at POT7T DataatP0110 DataatPOi7i Data at P0300 A 4 detected detection detection detection detection Freeze Frame Data Clearance The freeze frame data is cleared at the same time as clearance of DTC 2 E DATA LINK CONNECTOR DLC DLC 1 is in compliance with SAEJ1962 in its installation posi tion the shape of connector and pin assignment 36 15 14 13 12 11 10 9 line of ISO 9141 is used for SUZUKI scan tool generic scan tool to communicate with ECM PCM ABS control module and Air bag SDM SUZUKI serial data line is used for SUZUKI scan tool to communicate with Immobilizer control module Be i SUZUKI Serial data tine i Kline 011509141 ground ground ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 9 On Board Diagnostic System Vehicle with Monitor Connector ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is running and indi
38. 1A 1 Install injector 1 and fuel pressure regulator 2 to special tool injector checking tool NOTE Remove grommet from injector then install injector to special tool and tighten bolts by hand Special tool A 09912 58421 2 Connect special tools hoses and attachment to pipes of vehicle Special tool B 09912 58431 3 Connect special tool test lead to injector Special tool C 09930 88521 4 Install suitable vinyl tube onto injector 3 nozzle to prevent fuel from splashing out when injecting 5 Put graduated cylinder under injector as far apart as possi ble 6 Disconnect fuel pump relay 7 To operate fuel pump and apply fuel pressure to injector using wire harness 2 as thick as the one used for fuel pump circuit connect two terminals of relay connector 1 as shown in the figure Apply battery 4 voltage to injector for 15 seconds and mea sure injected fuel volume with graduated cylinder Test each injector two or three times If not within specification replace injector 8 Injected fuel volume 56 60 cc 15 sec 1 89 1 97 2 02 2 11 US Imp 02 15 sec TAY Lefthand steering vehicle 18 Righthand steering vehicle 9 Check fuel leakage from injector 1 nozzle Do not operate injector for this check but fuel pump should be at work If fuel leaks more than following specifications replace Fuel leakage Less t
39. A Sealant 99000 31110 4 Install differential carrier assembly to axle housing and tighten carrier bolts to specified torque Tightening torque Differential carrier bolt a 55 N m 5 5 kg m 40 0 Ib ft 3E 6 REAR SUSPENSION 5 Apply thread lock cement to thread of propeller shaft flange bolt if reused Install propeller shaft to joint flange aligning match marks and torque flange nuts to specification A Cement 99000 32110 Tightening torque Propeller shaft nut a 60 N m 6 0 kg m 43 5 Ib ft Tightening Torque Specification Tightening torque Fastening part ER Shock absorber nut 29 29 210 Shock absorber lower nut 85 85 61 5 Lower rod bolt and nut 100 10 0 725 Upper rod bolt and nut 100 10 0 725 Lateral rod bolt 100 10 0 725 Differential carrier bolt 55 55 40 0 Propeller shaft nut 60 6 0 43 5 Brake pipe flare nut 16 16 115 Bearing retainer nut 50 50 365 Differentiation gear oil filler amp drain plug filler plug 50 50 365 Differentiation gear oil filer amp drain plug drain plug 27 27 16 0 Wheel nut 100 10 0 725 Wheel speed sensor bolt 21 21 155 Required Service Material ewe Recommended SUZUKI product m Part Number Lithium grease SUZUKI SUPER GREASE Oil seal lip 99000 25010 Brake fluid 0073 Brake reservoir tank Sealant SUZUKI BOND NO 1215 Joint seam of axle and brak
40. AIR BAG SYSTEM 108 65 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 Undeployed air bag inflator module 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 Do not dispose of the live undeployed air bag inflator modules and seat belt pretensioners The method employed depends upon the final disposition of the particular vehicle as noted in DEPLOYMENT ACTIVATION OUTSIDE VEHICLE and DEPLOYMENT ACTIVATION INSIDE VEHICLE Deployment Activation Outside Vehicle Follow this procedure when disposing of the air bag inflator module s and seat belt pretensioner s only i e the vehicle itself will be used again Deployment Activation Inside Vehicle Follow this procedure when scrapping the entire vehicle including the air bag inflator modules and seat belt pretensioners WARNING Following precautions must be observed for this work Failure to observe any of them may result in personal injury The procedure should be followed strictly as described here Be s
41. AUTOMATIC TRANSMISSION 4 A T 7B1 19 Step Action Yes No 5 _ 4WD LOW switch signal inspection Go to Step 6 Faulty 4WD LOW switch With ignition switch ON check voltage between or its circuit C51 1 26 terminal of PCM coupler and ground If OK substitute a known 4WD LOW switch specification good PCM and recheck Transfer gear position 4L or N 0 V Transfer gear position 4H or 2H Battery voltage Is the result as specified 6 _ Is vehicle equipped with cruise control system Go to Step 7 Substitute a know good PCM and recheck 7 Cruise control signal inspection Substitute a known good Faulty cruise control mod With ignition switch ON check voltage between PCM and recheck ule or its circuit E61 35 terminal of PCM coupler and ground If OK substitute a known 15 it battery voltage good PCM and recheck 781 20 AUTOMATIC TRANSMISSION 4 A T Table A 2 No Gear Shift to O D SYSTEM DESCRIPTION PCM does not shift to O D gear under any of the following conditions O D off switch ON 4WD LOW switch ON Cruise control module OFF command signal is output if equipped ECT lt 30 C 86 F TROUBLESHOOTING WARNING When performing a road test select a place where there is no traffic or possibility of a traffic dent and very careful during testing to avoid occurrence of an accident Road
42. PCV HOSE Check hoses for connection leakage clog and deterioration Replace as necessary 1 EVAP canister purge vave _ 4 FGRpipe 2 canister purge valve hose 5 EGR valve 3 Breather hose PCV hose Tightening Torque Specification A Tightening torque Fastening part Mm kom ite Heated oxygen sensor 45 45 325 Fuel pressure regulator bolts 10 10 75 Fuel pipe union bolts 30 30 220 Engine coolant temp sensor 15 15 110 Special Tool 09912 58441 09912 58431 Pressure gauge Pressure hose 09912 58490 3 way joint amp hose 09912 58421 Checking tool set See NOTE ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 49 09917 47010 Vacuum pump gauge 09930 88521 Injector test lead 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE Mass storage cartridge for Tech 1A 09931 76030 14 16 pin DLC cable for Tech 1A Tech 2 kit SUZUKI scan tool See NOTE C NOTE A This kit includes the following items 1 Tool body amp washer 2 Body plug 3 Body attachment 1 4 Holder 5 Return hose amp clamp 6 Body attachment 2 amp washer 7 Hose attachment 1 8 Hose attachment 2 B This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4
43. WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road of a traffic NOTE Check to make sure that following condition is satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 6 1 112 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and warm up engine completely 3 Run engine at idle speed for 1 min engine coolant temp becomes 76 C 169 F or more 4 Increase vehicle speed to 80 km h 50 mph 5 Keep driving above vehicle speed for 1 min Change of vehicle speed is permitted in this step 6 Stop vehicle and check pending DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per formed Go to Step 2 Go to ENGINE DIAG FLOW TABLE in this section 1 Disconnect connector from MAP sensor 2 Check for proper connection to MAP sensor at each terminal 3 If OK ch
44. 4 termi nal of HO2S 1 coupler HO2S 1 heater resistance 5 0 6 4 Q at 20 C 68 F Is it within above specification 3 25 heater power supply check Go to Step 4 2 and or IG 1 With ignition switch ON leaving engine OFF METER fuse blown check voltage between E139 3 and ground If OK faulty BLK WHT 139 1 and ground See Fig wire or BLU WHT wire 15 each voltage 10 14 V 6 1 62 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Step Action Yes No 4 25 heater control circuit check Substitute a known good Faulty HO2S heater relay 1 With ignition switch OFF install 25 PCM and recheck or BLK wire open BLU heater relay wire open or shorted to 2 With ignition switch ON leaving engine OFF ground circuit check voltage between C51 2 4 and or ground GRY wire open or Is the voltage 10 14 V shorted to ground circuit f OK substitute a known good ECM PCM and recheck Fig for STEP 3 a 190 1 Ol eus 3 HOZS heater relay ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 63 DTC P0136 HO2S 2 Bank 1 Circuit Malfunction WIRING DIAGRAM HORS warek cs1 216 naa G E 2 1 651 322 i jene tg 05325 EE J TO O iG METER 004 513 2
45. Crankshaft position sensor REMOVAL AND INSTALLATION Refer to Section 6A4 INSPECTION Refer to Section 6 1 Main relay INSPECTION 1 Disconnect negative cable at battery 2 Remove main relay 1 from its connector Fuel pump relay 3 Fuse box 4 instrumen panel Left hand steering vehicle BI Right hand steering vehicle 6 2 42 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 3 Check resistance between each two terminals as in table below If check results are as specified proceed to next operation check If not replace Main relay resistance TERMINALS RESISTANCE Between A and Infinity Between D 79 95 Q at 20 C 68 F 4 Check that there is continuity between terminals A when battery is connected to terminals and I If malfunction is found replace Fuel pump relay INSPECTION 1 Disconnect negative cable at battery 2 Remove fuel pump relay 2 from connector 3 Structure of fuel pump relay is the same as that of main relay Check its resistance and operation using the same proce dure as that for main relay If malfunction is found replace T Main relay 3 Fuse box 4 Instrument panel afchand steering valide ight hand steering vehicle
46. ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 75 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 HO2S 2 heater check Go to Step 3 Replace HO2S 2 1 Disconnect HO2S 2 coupler with ignition Switch OFF 2 Check resistance between 3 and 4 termi nal of HO2S 2 connector HO2S 2 heater resistance 11 7 14 3 at 20 C 68 F Is it within above specification 3 HO2S heater power supply check Go to Step 4 Fuse HO2S and or IG 1 With ignition switch ON leaving engine OFF METER blown check voltage between E139 3 and ground If OK faulty BLK WHT 139 1 and ground See Fig wire or BLU WHT wire Is each voltage 10 14 V 4 HO2S heater control circuit check Substitute a known good Faulty HO2S heater relay 1 With ignition switch OFF install HO2S ECM PCM and recheck or BLK wire open BLU heater relay wire open or shorted to 2 With ignition switch ON leaving engine OFF ground circuit PNK check voltage between C51 2 17 and WHT wire open ground shorted to ground circuit Is the voltage 10 14 V If OK substitute a known good ECM PCM and recheck Fig for STEP 2 3 a HO2S heater relay 6 1 76 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0171 P0172 Fuel System Too Lean Rich Bank 1
47. Transmission Range Sensor Switch Circuit Mal function WIRING DIAGRAM 2 1 m n 051 3 E28 AD E59 C52 sims s Tie Te Jer Eu ORN GRN GRNIORN 23 E D YEUGRN GRN BLU do As 511 051 2 1 4 WZ W WM a Z Fue 4 Tansmissonrange sensor ih DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Transmission range switch signal P R N D 2 or L is not inputted for 25 sec at 60 km h 38 mile h or higher vehicle speed or Multiple signals are inputted simultaneously for 25 sec 2 driving cycle detection logic Transmission range sensor switch maladjusted Transmission range sensor switch or its circuit malfunction PCM AUTOMATIC TRANSMISSION 4 A T 7B1 27 DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road ity of a traffic 1 Connect scan tool to DLC with ignition switch OFF if available 2 Clear DTC pending DTC and freeze frame data in PCM memory by using scan tool and start engine 3 Shift A T selector lever to each of L 2 D N R and P rang
48. Voltage detected at C51 1 1 terminal is specified volt age or lower when shift solenoid valve B is ON or specified voltage or higher when it is OFF Shift solenoid valve B Shift solenoid valve B circuit PCM DTC CONFIRMATION PROCEDURE AUTOMATIC TRANSMISSION 4 A T 7B1 37 WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident ity of a traffic acci Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition switch OFF if available 2 Clear DTC pending DTC and freeze frame data in PCM memory by using scan tool 3 Start engine and shift transfer lever to 2H or 4H range 4 Shift selector lever in D range and keep it for 10 seconds 5 Drive vehicle about 30 km h 20 mile h with 2nd gear in D range for 10 seconds 6 Increase vehicle speed to about 80 km h 50 mile h with 4th gear in D range and keep it for 10 seconds 7 Release accelerator pedal decrease vehicle speed and stop vehicle 8 Check DTC and or pending DTC TROUBLESHOOTING Step Action Yes No 1 Was A T DIAGNOSTIC FLOW TABLE in this to Step 2 Go to AT DIAGNOSTIC section performed FLOW TABLE in this sec tion 2 shift solenoid circuit for short Go to Step 3 or GRN RED cir 1 Tu
49. connector ASSEMBLY in Sec 4 If OK then connect Special Tool to Q05 con tion 3C1 nector With ignition switch ON is DTC B1024 current A Fig for STEP 1 and 2 B Fig for STEP 2 Fig for STEP a OF COLUMN Special tool A B NOTE 09932 75020 09932 75010 Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected 10B 32 AIR BAG SYSTEM DTC B1025 Step Action Yes No 1 1 With ignition switch OFF disconnect contact coil con to step 2 Go to step 3 nector located near the base of the steering column 2 Check proper connection to contact coil at terminals in 006 connector 3 If OK then connect Special Tool to contact coil connector disconnected at step 1 With ignition switch ON is DTC B1025 current 2 1 With ignition switch OFF disconnect Special Tool B Substitute a known Repair short from and SDM connector good SDM and GRN or BRN RED 2 Measure voltage from 001 9 terminal to body recheck wire circuit to power ground and from 001 10 terminal to body ground circuit With ignition switch ON are they 1 V or less 3
50. 09921 57810 NOTE If inner race of wheel bearing is left in axle shaft remove it from axle shaft with the same procedure as above mentioned CAUTION Do not reuse wheel bearing REAR SUSPENSION 3E 3 6 Remove stud bolt s 1 by using hydraulic press 2 INSTALLATION Install removed parts in reverse order of removal procedure not ing the following 1 Aligning serrations between new stud bolt s 1 and flange 4 install new stud bolt s 1 by tightening nut 2 as shown in the figure S Washer 2 Install bearing retainer 2 to axle shaft 1 3 Press fit new wheel bearing 1 and new retainer ring 2 using press 3 NOTE Use care not to cause any damage to outside of retainer ring 2 Seal side 4 of wheel bearing must face bearing retainer 5 side 4 Install circlip to axle shaft 4 REAR SUSPENSION 5 Apply grease A to axle shaft inner oil seal lip as shown in the figure Grease 99000 25010 T Rs housing 6 Apply water tight sealant B to mating surfaces of brake back plate and rear axle hub 2 B Water tight sealant 99000 31110 7 Install rear axle shaft to rear axle housing and tighten bear ing retainer nuts to specified torque Rear axle shaft length L Left side 700 5 mm 27 6 in Right side 769 5 mm 30 3 in NOTE When installing re
51. 6 1 108 Internal Control 6 1 110 n 6 1 111 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 3 General Information Statement of Cleanliness and Care An automobile engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter ten thousands of inch Accordingly when any internal engine parts are serviced care and cleanliness are important Throughout this section it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surface on initial operation Whenever valve train components pistons piston rings connecting rods rod bearings and crankshaft jour nal bearings are removed for service they should be retained in order At the time of installation they should be installed in the same locations and with the same mating surfaces as when removed Battery cables should be disconnected before any major work is performed on the engine Failure to discon nect cables may result in damage to wire harness or other electrical parts Throughout this manual the 6 cylinders of the engine are identified by numbers No 1 No 2 No 3 No 4 No 5 a
52. 7 Remove steering column 1 mounting bolts 2 pieces 2 and nuts 2 pieces 3 8 If equipped with shift key interlock cable 1 remove shift key interlock cable screw 2 and then disconnect its cable 1 from ignition switch 9 Remove steering column from vehicle INSPECTION Check steering column for damage and operation referring to CHECKING STEERING COLUMN AND STEERING UPPER SHAFT FOR ACCIDENT DAMAGE later in this section INSTALLATION CAUTION After tightening steering column mounting bolts steer ing shaft joint bolts should be tightened 1 Be sure that front wheels and steering wheel are in straight ahead position 2 If equipped with shift key interlock cable 1 install shift key interlock cable 1 to ignition switch Tightening torque Shift key interlock cable screw a 2 2 N m 0 22 kg m 1 6 Ib ft 3 1 6 AIR BAG STEERING WHEEL AND COLUMN 3 Install steering column assembly 1 with contacting upper side of lower bracket slits to mounting bolts Tighten steering column lower mounting nuts 3 first and then upper mount ing bolts 2 to specified torque Tightening torque Steering column mounting bolts and nuts b 25 N m 2 5 kg m 18 0 Ib ft 4 Align cutting point A of steering column assembly 1 with bolt hole B of steering upper shaft upper joint as shown in the figure Then connect steering upper shaft upper joint 5 Insta
53. Actuator assembly faulty Replace actuator assembly Vehicle set speed is unstable Actuator cable play maladjusted or actua tor cable faulty Refer to CRUISE CABLE PLAY INSPECTION AND ADJUSTMENT in this section VSS circuit faulty Refer to VSS CIRCUIT CHECK in this section Throttle valve opening signal circuit faulty Referto THROTTLE VALVE OPENING SIGNAL CIRCUIT CHECK in this sec tion Actuator assembly faulty Replace actuator assembly Actual vehicle speed deviates above or below set speed Actuator cable play maladjusted or actua tor cable faulty Refer to CRUISE CABLE PLAY INSPECTION AND ADJUSTMENT in this section Throttle valve opening signal circuit faulty Refer to THROTTLE VALVE OPENING SIGNAL CIRCUIT CHECK in this sec tion Actuator assembly faulty Replace actuator assembly Acceleration or decel eration by using RESUME ACCEL or switch is not attained Main switch COAST SET RESUME ACCEL and CANCEL switch circuits faulty Refer to CRUISE MAIN SWITCH COAT SET RESUME ACCEL AND CANCEL SWITCHES CIRCUITS CHECK in this section Actuator assembly faulty Replace actuator assembly Cruise control is not cancelled even when CANCEL switch is operated Main switch RESUME ACCEL and CANCEL switch circuits faulty Refer to CRUISE MAIN
54. Engine Stall when Poor fast idle Immediately after start Abnormal idling speed Accel pedal is depressed Low r min Accel pedal is released Unstable Load is applied Hunting r min to r min C A C Electric load O P S Other Other 0 Other OTHERS VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Fair O Cloudy C Rain O Snow O Always O Other Temperature Hot O Warm O Cool O Cold F O Always Frequency O Always C Sometimes times day month Only once O Under certain condition Road Urban O Suburb C Highway C Mountainous O Uphill Downhill C Tarmacadam Gravel O Other Vehicle Condition Engine T Cold Warming up phase C Warmed up 1 Always LJ Other at starting Condition C Immediately after start Racing without load O Engine speed r min Vehicle During driving Lj Constant speed Accelerating Decelerating condition Right hand corner C left hand corner O When shifting Lever position At stop O Vehicle speed when problem occurs km h _ Mile h O Other Malfunction indicator lamp condition Always ON Sometimes ON O Always OFF 7 Good condition Diagnostic trouble First check O No code Normal code O Malfunction code code Second check No code Normal code O Malfunction code NOTE The above form is a stand
55. Fill up inside of boot with joint grease A Joint Grease about 90 100 g 3 2 3 5 oz Black 10 Fitting boot to outer race adjust so that measurements b and c become as shown in the figure Differential side RH boot installation position Length b 196 8 206 8 mm 7 75 8 14 in Differential side LH boot installation position Length c 127 5 137 5 mm 5 02 5 41 in 11 Before fixing boot band insert screwdriver into boot on joint side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure 12 Clamp boot band Check boots for distortion or dent TA Differentia side RH IB Differential side CH 4A2 4 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL Required Service Material Material Recommended SUZUKI product Part Number Use Lithium grease SUZUKI SUPER GREASE A Drive shaft oil seal 99000 31090 99000 25010 Wheel spindle part of differential side drive shaft RH Sealant SEALING COMPOUND 366E Axle shaft drive flange PROPELLER SHAFTS 4B 1 SECTION 4B PROPELLER SHAFTS NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS Tightening Torque Specification Required Service Material 4B 2 4B 2 General Description On Vehicle Service Propeller Shaft
56. T S round Tor air bag CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 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 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 initia
57. above specification or HO2S 1 cir No 13 activity detected tus cycles cycles ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 19 MiL MIL vehicle vehicle DETECTING CONDITION DTC NO DETECTED ITEM without with DTC will set when detecting k monitor monitor connector connector HO2S circuit slow response Response time of HO2S 1 output 5 driving Not P0183 Bank 1 Sensor 1 age between rich and lean is longer vn MUR than specification y Terminal voltage is lower than x P0135 Mond e M cation at heater OFF or it is higher at pud M heater ON m 2 circuit malfunction Mex voltage of HO2S 2 is lower than 3 driving Not 20136 Bank 1 Sonsor2 specification or its min voltage is higher than specification en Terminal voltage is lower than specifi P0141 Nici T cation at heater OFF or it is higher at 2 aa Ne heater ON SPP Min output vollage of HO28 1 is higher than specification HO2S circuit malfunction Min output voltage of HO2S 1 is 2 driving Not PO150 Le Bank 2 sensor 1 lower than specification cycles applicable Output voltage of HO28 1 fails to go above specification Output voltage of HO28 1 fails t P0150 HO2S Bank 2 Sensor 1 no Pul 101899 0 8151099 driving 2 driving a above specification or HO2S 1 cir No 26 activ
58. after ignition switch ON 2 Fuel pump circuit check Go to Step 3 BLU BLK PNKJBLK or BLK circuit open or fuel pump malfunction 1 Check fuel pump relay referring to FUEL PUMP RELAY INSPECTION in Section 6E2 Is it in good condition GRN circuit open or poor E61 23 connection If wire and connection are OK substitute a known good ECM PCM and recheck ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 117 Step Action Yes No 3 Fuel pump relay check BLKWHT or WHT Replace fuel pump relay Fig for Step 2 pump relay connector Table B 2 Fuel Injectors and Circuit Inspection WIRING DIAGRAM 1 METER 051 920 P ou EI N n on gt 3 001 58 bot Cn 10 petu 52 051 22 D Di Kenn 7 prema uec 051 222 Cem X 051 221 0521 1 KU LATH JE AWA A 7 139 cor b20 cs1221 C828 T To onion switch amp
59. for 1 min or longer after warmed up 51 3 03 Heated oxygen sensor 2 bank 2 Deflects between over While engine running at 2 000 r min if equipped and under 0 45 V for 1 min or longer after warmed up C51 8 24 Ground for ECT sensor Ground for IAT sensor MAP sensor Ground for CMP sensor C51 1 Shif solenoid AT vehicle 0 1V Ignition switch ON 5121 2 Shift solenoid A A T vehicle 1014 Tgnition switch ON 51 1 3 51 1 4 valve stepper molor coll 2 51 1 5 valve stepper motor coil 1 Ignition switch ON selector lever D 10 14V gn 1 Transmission range switch range AIT vehicle m Ignition switch ON selector lever Other than Ignition switch ON selector lever Exe 10 14V p gt cgi Transmission range switch P range AIT vehicle em Ignition switch ON selector lever Other than P range C51 8 solenoid A T vehicle 0 1V Ignition switch ON AUD gion wich ON Transfer lever C51 1 9 4WD air pump assembly rd Tang civ Ignition switch ON Transfer lever 2H range 6 1 40 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION AIT input speed sensor 051 110 vehicle About 2 5 V Ignition switch ON C51 1 11 hag sens
60. 1 Check for DTC including pending DTC Is there any DTC s Print DTC and freeze frame data or write them down and clear them by referring to DTC CLEAR ANCE in this section Go to Step 3 Go to Step 4 Visual Inspection 1 Perform visual inspection referring to the next page Is there any faulty condition Visual Inspection 1 Perform visual inspection referring to the next page Is there any faulty condition Repair or replace mal function part Go to Step 11 Go to Step 5 Go to Step 8 Trouble Symptom Confirmation 1 Confirm trouble symptom referring to the next page Is trouble symptom identified Go to Step 6 Go to Step 7 Rechecking and Record of DTC Freeze Frame Data 1 Recheck for DTC and freeze frame data referring to Check in this section Is there any DTC s Go to Step 9 Go to Step 8 Rechecking and Record of DTC Freeze Frame Data 1 Recheck for DTC and freeze frame data referring to Check in this section Is there any DTC s Go to Step 9 Go to Step 10 Automatic Transmission Basic Inspection and Trouble 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 diag flow Table Are check and repair complete Goto Step 11 Check an
61. 1 for a guide during reinstallation 4 After removing bolt 4 on upper shaft assembly 1 side of shaft joint 2 and loosening bolt 5 on its lower shaft assem bly 3 side move shaft joint 2 to lower shaft assembly 3 side in arrow direction in the figure 5 Remove steering upper shaft upper joint bolt 1 and nut 2 and disconnect steering upper shaft upper joint removing in arrow direction in the figure 6 Remove steering upper shaft mounting bolts 4 pieces 7 Remove steering upper shaft assembly from vehicle 3C1 8 AIR BAG STEERING WHEEL AND COLUMN INSPECTION Check steering shaft damage and operation referring to CHECK STEERING COLUMN AND STEERING UPPER SHAFT FOR ACCIDENT DAMAGE later in this section INSTALLATION 1 Be sure that front tires and steering wheel are in straight ahead position 2 Install steering upper shaft assembly to dash panel Tighten steering upper shaft mounting bolts 1 to specified torque Tightening torque Steering upper shaft mounting bolts a 23 N m 2 3 kg m 17 0 Ib ft 3 Install steering shaft joint 1 to steering upper shaft 2 by matching it to marks 3 made before removal 4 Install shaft joint bolt upper shaft assembly side 2 to steering shaft joint 1 Tighten shaft joint bolt upper shaft assembly side 2 to specified torque first and then shaft joint bolt lower shaft assembly side 3 to specified torque Tightenin
62. 2 Vehicle stops monitor for 4 A T TCC SOL for 4 A T Ignition switch ON CON Torque converter Selector lever is shifted at P clutch solenoid command 2 or L range UN 5 signal Vehicle stops MON Torque converter clutch solenoid monitor TRANS RANGE Ignition switch ON selector lever is at P for 4 A T ND range RoR Np DAA ont BRAKE SW Ignition switch ON Brake pedal is released OFF Brake stop lamp switch Ignition switch ON Brake pedal is ox for 4 AT depressed OFF SW ignition switch ON Overdrive cut switch OFF OFF 5 Overdrive cut switch lgnition switch ON Overdrive cut switch ON ON MODE SELECT SW ignition switch ON P N change switch is at S NORMAL Power Normal change normal position switch for 4 A T Ignition switch ON P N change switch is at POWER power position 4WD LSW Ignition switch ON Transfer lever is shifted 4WD low switch at 4H or 2H position Ignition switch ON Transfer lever is shifted an ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 27 Scan tool data det ions COOLANT TEMP Engine Coolant Temp C F Itis detected by engine coolant temp sensor INTAKE AIR TEMP C F It is detected by intake air temp sensor DESIRE IDLE Desired Idle Speed RPM The desired idle speed is an ECM PCM internal parameter which indicates the ECM PCM requested idle If the engine is not running the number is not vali
63. 2 coupler disconnected and ground 3 2 Turn ignition switch ON and check that voltage is battery volt age If not check if wire hamess is open or connection is poor 3 Turn ignition switch OFF and remove ECM PCM cover 1 from bracket 4 Connect MAF sensor coupler to MAF sensor 5 Turn ignition switch ON and check voltage at MAF sensor output terminal of ECM PCM connector 1 MAF sensor output voltage Voltage 1 0 1 6 V 6 Start engine and check that voltage is lower than 5 V and it rises as engine speed increases Reference data 1 7 2 0 V at specified idle speed If check result is not as specified above cause may lie in wire hamess coupler connection MAF sensor or ECM PCM ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 33 REMOVAL 1 Disconnect negative cable at battery and coupler 1 from MAF sensor 3 2 Remove air cleaner outlet hose 2 from throttle body and MAF sensor 3 3 Remove MAF sensor from air cleaner case CAUTION Don t disassemble MAF sensor Do not expose MAF sensor to any shock Do not blow compressed air by using air gun or the like Do not put finger or any other object into MAF sensor Malfunction may occur INSTALLATION 1 Check MAF sensor seal 1 for deterioration and damage 2 Install MAF sensor to air cleaner case 3 Install air cleaner outlet hose 4 Connect MAF sensor coupler
64. 4 781 31 Step Action Yes No 4 _ Check visually input speed sensor and over Intermittent trouble Clean repair or replace drive clutch drum for the followings faulty PCM No damage Check for intermittent No foreign material attached referring to INTERMIT Correct installation TENT AND POOR CON Are they in good condition NECTION in Section OA REFERENCE Connect oscilloscope between C51 1 11 and C51 1 10 of PCM connector connected to PCM and check input speed sensor signal TA Osciloscope waveforms at specified idle speed in p range 781 32 AUTOMATIC TRANSMISSION 4 A T DTC P0720 DTC NO 75 Output Speed Sensor Circ WIRING DIAGRAM Malfunction E61 c51 3 csi este WZ Wi 25 22 POM 2 Output shaft speed sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA With 4WD LOW switch OFF no output shaft speed sensor signal is inputted while vehicle speed sensor signal are inputted or With 4WD LOW switch OFF no output shaft speed sensor signal is inputted while engine running at higher than specified engine speed with D range 2 driving cycle detection logic Output speed sensor or its circuit PCM DTC CONFIRMATION PROCEDURE WARNING When performing a road test
65. BLU 3 If OK then check voltage between 001 4 BLK 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 connector from combina Substitute a known good BLU wire between com tion meter Refer to COMBINATION SDM and recheck bination meter and SDM METER in SECTION 8C connector short to 2 Check resistance between Q01 2 termi ground nal of SDM connector and body ground Is circuit open A Fig for STEP 2 B Fig for STEP 3 Special tool A 09932 75020 108 18 AIR BAG SYSTEM NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected Table B Step Action Yes No 1 1 Set parking brake Go to step 2 BLK BLU wire BLK 2 Note combination meter when ignition WHT wire and IG Switch is turned ON METER fuse between Does the BRAKE indicator warning lamp ignition switch and combi come ON nation meter open or short to ground 2 1 With ignition switch OFF disconnect SDM Go to step 3 Repair electrical connec connector tion check mechanism 2 Check electrical connection check mecha nism Is it in good condition 3 1 Disconnect SDM
66. CLUTCH 761 1 SECTION 7C1 CLUTCH 701 NOTE The clutch of this model is the same as that of H25 engine in the construction and operation Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for ser vice procedure 701 2 CLUTCH DIFFERENTIAL FRONT 7E 1 SECTION 7E DIFFERENTIAL FRONT NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS General Description 2 7E 2 7E 2 7E 3 Differential Assembly Diagnosis Table 7 3 AWD Control System Diagnostic Flow Table 7E 3 Notes on system circuit inspection 7E 3 Flow table 7E 4 AWD Control System Circuit Inspection 7 5 Voltage check 7E 5 AWD Control System Inspection On Vehicle Service Differential Mountings Rear Mounting for Front Differential Carrier 7E 8 Front Differential Assembly Unit Tightening Torque Specification Special Tool 7E 2 DIFFERENTIAL FRONT General Description 4WD Control System System circuit 2 1 3WD switch 4 Release valve 7 Front differential 30 To ignition switch 2 Air pump assembly 5 Pressure switch 8 Airhose and pipe 11 ECM or POM 3 Pump motor 6 Transfer 9 4WD indicator lamp Diagnosis Differential Assembly Diagnosis Table DIFFERENTIAL F
67. Following conditions are detected for 5 sec continuously Engine running TROUBLE AREA sensor circuit TP sensor Signal voltage low or signal voltage high ECM PCM NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 10 sec or more 3 Check DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 55 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE 2 Check TP sensor and its circuit Go to Step 3 Intermittent trouble 1 Connect scan tool to DLC with ignition Check for intermittent Switch OFF and then turn ignition switch referring to Intermittent ON and Poor Connection in 2 Check throttle valve opening percentage Section 0A displayed on scan tool Is it displayed 3 or less 3 Check throttle valve opening percentage displayed on scan tool while opening throttle valve from idle position to full open position Is it
68. INTERMITTENT AND POOR CONNECTION in GENERAL INFORMA TION section and related circuit of trouble code recorded in Step 2 2 Perform FINAL CONFIRMATION TEST after cleared diagnostic trouble code Does trouble recur Go to Step 7 End 1 Perform Diagnostic Trouble Code Check Record and Clearance Is there any malfunction code Go to Step 2 Go to Step 5 ANTILOCK BRAKE SYSTEM ABS 5E2 7 1 MALFUNCTION ANALYSIS a 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 Customer s name Model VIN Date of issue Date of Reg Date of problem Mileage ABS warning lamp abnormal fails to turn on fails to go off flashes Abnormal noise while vehicle is running from motor from valve other Problem Symptoms Wheel is locked at braking Pump motor does not stop running Braking does not work Other Frequancy of occurrence times a day a month Conditions for Vehicle at stop amp ignition switch ON When starting at initial start only at every start Other Vehicle speed while accelerating while decelerating at stop while turning while running at consta
69. Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Start engine and run it for 10 sec 4 Check DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 93 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per formed Go to Step 2 Go to ENGINE DIAG FLOW TABLE in this section EGR valve check 1 With ignition switch OFF disconnect connec tor from EGR valve 2 Check for proper connection to EGR valve at each terminal 3 If OK check EGR valve for resistance refer ring to EGR VALVE INSPECTION in Sec tion 6E2 Is check result as specified Go to Step 3 EGR valve malfunction Wire harness check 1 Connect connector to EGR valve 2 Remove ECM PCM cover and disconnect connector from ECM PCM 3 Check for proper connection to ECM PCM at system related terminals 4 If OK check for resistance between the fol lowing terminals of ECM PCM connector disconnected EGR valve resistance 20 24 Q at 20 C 68 F C51 2 13 and ground C51 2 14 and ground C51 2 15 and ground C51 2 12 and ground Infinity s
70. PCM cover good PCM and _ If wire and connection are 3 With ignition switch ON leaving engine OFF recheck OK substitute a known check voltage between C51 3 10 and C51 good MAF sensor and 3 5 terminal recheck Is voltage 1 0 1 6 V 6 1 50 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0110 DTC No 23 25 Intake Air Temp IAT Circuit Malfunction WIRING DIAGRAM 6145 sias Flos S GRY YEL c51 3 1 W NII NWZ 651325 sensor 2 ECM POM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the conditions are detected for 5 sec con IAT sensor circuit tinuously IAT sensor Low intake air temperature high voltage high resis ECM PCM malfunction tance High intake air temperature Low voltage low resis tance DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed and engine coolant temp 110 C 230 F or lower for 10 sec or more 3 Check DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGI
71. POWER lamp 23 Battery Output shaft speed sensor 16 ODD OFF lamp 24 PCM ECM connector terminal viewed from harness side AUTOMATIC TRANSMISSION 4 A T 7B1 5 Automatic gear shift diagram Automatic shift schedule as a result of shift control is shown below In case that select lever is shifted to L at a higher than 55 km h or 34 mile h speed 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that No up shift is available in L The same as the select lever is shifted to 2 at a higher than 105 km h 65 mile h speed 3rd gear is operated and then down shifts to 2nd at a speed lower than that POWER MODE Shift 152 253 354 453 352 251 Throttle Full throttle km h mileh 46 93 160 150 83 36 opening 29 58 100 94 62 23 Closed throttle km h mile h 16 30 45 38 24 7 19 19 28 16 11 4 GEAR SHIFT DIAGRAM A AND TCC LOCK UP DIAGRAM B a st aes Upshit H Downshift 5 NN EJ 700 iem c2 Vehicle spoed 18 100 8 1 E 55 100 750 m EJ 700 Thien Vehicle speed 781 6 AUTOMATIC TRANSMISSION 4 A T NORMAL MODE Shift 152 253 354 453 352 251 Throttle Full throttle km h 46 98 160 150 88 36 opening 29 58 100 94 62 23 Closed throttle km h mie h 11 2
72. PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 20 sec or more 3 Check DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 sensor check Intermittent trouble Go to Step 3 1 Connect scan tool to DLC with ignition Check for intermittent Switch OFF referring to INTERMIT 2 Start engine and check MAF value dis TENT AND POOR CON played on scan tool Refer to SCAN TOOL NECTION in Section DATA in this section for normal value 15 normal value indicated 3 sensor power supply check Go to Step 4 Faulty BLU BLK wire 1 With ignition switch OFF disconnect MAF sensor coupler 2 With ignition switch ON check voltage between E154 3 of MAF sensor coupler and ground Is voltage 10 14 V 4 sensor output voltage check Poor C51 3 10 or C51 3 5 Faulty PPUWHT wire 1 With ignition switch OFF connect MAF sen terminal connection Poor E154 coupler termi sor coupler If OK substitute a known nal connection 2 Remove ECM
73. Priority of Freeze Frame Data ECM PCM has 4 frames where the freeze frame data can be stored The first frame stores the freeze frame data of the malfunction which was detected first However the freeze frame data stored in this frame is updated according to the priority described below If malfunction as described in the upper square 1 below is detected while the freeze frame data in the lower square 2 has been stored the freeze frame data 2 will be updated by the freeze frame data 1 PRIORITY FREEZE FRAME DATA IN FRAME 1 Freeze frame data at initial detection of malfunction among misfire detected PO300 P0306 fuel system too lean P0171 P0174 and fuel system too rich P0172 P0175 2 Freeze frame data when a malfunction other than those in 1 above is detected 1 In the 2nd through the 4th frames the freeze frame data of each malfunction is stored in the order as the mal function is detected These data are not updated regardless of the priority Shown in the table below are examples of how freeze frame data are stored when two or more malfunctions are detected FRAME 1 FRAME 2 FRAME 3 FRAME 4 FREEZE FRAME 1st FREEZE 2nd FREEZE 3rd FREEZE DATA to be updated FRAME DATA FRAMEDATA FRAME DATA No freeze frame No freeze frame freeze frame No malfunction No freeze frame data data data data Pono IAT Data at PO110 DataatP0110
74. Replace TP sensor Fig for Steps 4 and 5 sotoa Voltage Throttle opening At idie position Fully open 6 1 58 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0130 DTC No 13 HO2S 1 Bank 1 Circuit Malfunction or No Activity Detected WIRING DIAGRAM E139 HOAS ot suwer h RY ob HUI o M e METER j AS ouem HO NE d pe C513 j 4 GRY YEL i j one ee 051 24 ST Coes i 1 md i OM LZ NU Wi 051325 1 HOZS heater relay 2 ECM PCM 3 HO28 1 Bani DTC DETECTING CONDITION AND TROUBLE AREA NOTE For vehicle with monitor connector DTC will set when following only mark condition is detected DTC DETECTING CONDITION TROUBLE AREA Any one of the following conditions are detected in idle state while running HO2S 1 or its circuit under driving conditions described for DTC CONFIRMATION PROCEDURE Fuel system 4 5 V or more HOS circuit voltage is detected when 5 V power is con ECM PCM nected to HO2S circuit in ECM PCM or Max output vol
75. Sensor Circuit Malfunction 7B1 32 DTC P0743 DTC NO 65 66 TCC Lock Up Solenoid Electrical DTC P0753 DTC NO 61 62 Shift Solenoid A 1 Electrical DTC P0758 DTC NO 63 64 Shift Solenoid B 2 Electrical 7B1 34 7B1 36 7B1 7B1 2 AUTOMATIC TRANSMISSION 4 A T Stall Test 7B1 38 Line Pressure Test 7B1 39 Road Test 7B1 40 Manual Road Tes Time Lag Test Engine Brake Test P Range Test On Vehicle Service Maintenance Service 7B1 41 7B1 41 7B1 42 7B1 42 7B1 43 7B1 43 Fluid level 7B1 43 Fluid change 7B1 44 A T Throttle Cable 7B1 45 Solenoid Valves Shift Solenoid Valves and TCC Solenoid Valve 781 45 MANUAL SELECTOR SELECT CABLE Unit Repa Sub Assembly Repair Overdrive case side Forward clutch Front upper valve Unit Assembly Tightening Torque Specification Special Tool AUTOMATIC TRANSMISSION 4 A T 7B1 3 General Description Item Specifications Torque Type 3 element 1 step 2 phase type with TCC lock up mechanism converter Stall torque ratio 2 0 Oilpump Type Trochoid type oil pump Drive system Engine driven Gear Forward 4 step reverse 1 step planetary gear type change Shift position P range Gear in neutral output shaft fixed engine start device range Reverse N range Gear in neutral en
76. 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 procedures are not followed parts or system damage could result CONTENTS On Vehicle Service 10 2 Disposal 10A 2 Service Precautions 10A 2 Front Seat Beli 10A 3 Service and diagnosis 10A 2 Second Rear Seat Belt 10A 6 Disabling air bag system 104 2 Third Rear Seat Belt If Equipped 10A 7 Enabling air bag system 10A 2 Tightening Torque Specification 10A 8 Handling and storage 104 2 10A 2 SEAT BELT On Vehicle Service Service Precautions Service and diagnosis WARNING If replacing seat belt is necessary replace buckle and ELR or webbing 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 reason SUZUKI will supply only the spare buckle and ELR or webbing in a set part Before servicing or replacing seat belts refer to following precautionary items Sea
77. When measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 B1035 and B0137 The voltage measured at forward sensor circuit terminal Q01 18 Q01 14 is below a specified value for speci fied time DTC B1036 and B0138 The voltage measured at forward sensor circuit terminal Q01 18 Q01 14 is above a specified value for speci fied time TABLE TEST DESCRIPTION DTC B1035 and B1037 STEP 1 Check whether malfunction is in forward sensor STEP 2 Check if forward sensor circuit is open STEP 3 Check if forward sensor circuit is shorted to ground B1036 and B1038 STEP 1 Check whether malfunction is in forward sensor STEP 2 Check if forward sensor circuit is shorted between two wires STEP 3 Check if forward sensor circuit is shorted to power circuit DIAGNOSTIC FLOW TABLE DTC B1035 and B1037 AIR BAG SYSTEM 108 37 Step Action Yes No 1 1 Ignition switch OFF 2 Disconnect driver air bag inflator module connector passenger air bag inflator mod ule connector driver pretensioner
78. While engine running and A C switch and or sensor Engine start sig heater blower switch OFF nal inputted or ampli AIC is not operating 0 1 5 fier malfunction While engine running at idle speed and both A If none of the above C switch and heater blower switch ON exists substitute a AIC is operating 10 14 V known good ECM PCM Are check result as specified and recheck 6 1 124 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Table B 6 A C Condenser Fan Motor Relay Control System Inspection If Equipped WIRING DIAGRAM 1 REAR DEFG E114 2 803 Boe E14 1 3 YELGRN veers CO WAY vemu veuses 1 n H 4 E120 Ens Bot Py ed or oN nto amp nto EM 22 5 3 i 7 a LS KA MILL oe eh ati aes dr hine EG PCM INSPECTION WARNING Keep hands tools and clothing away from A C condenser fan to help prevent personal injury This fan is electric and can come on whether or not the engine is running The fan can start automatically in response to the ECT sensor with the ignition switch in the ON position Step Action Yes No 1 1 Check DTC referring to
79. be sure NOT to face its exhaust hole provided side down It must face up Refer to SERVICE PRECAUTIONS for details 25 Contact your local distributor for further assistance 108 76 AIR BAG SYSTEM 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 following points should be noted 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 activated seat belt pretensioner to cool it off and be careful so that water oil etc does not get on the deployed air bag infl
80. e Remove drive bevel pinion rear bearing 2 by using bear ing puller 3 and press Drive bevel pinion ES Component Inspection Check companion flange for wear or damage Check bearings for wear or discoloration Check differential carrier for cracks Check drive bevel pinion and drive bevel gear for wear or cracks Check differential gears pinions and pinion shafts for wear or damage Check differential gear spline for wear or damage DIFFERENTIAL REAR 7F 9 6 Using a hammer and brass bar 1 drive out front bearing outer race with bearing 2 and oil seal 3 7 Drive out rear bearing outer race in the same way as in the step 6 Sub Assembly 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 Drive bevel gear and pinion must be replaced as a set when either replacement becomes necessary When replacing taper roller bearing replace as inner race amp outer race assembly 7F 10 DIFFERENTIAL REAR Differential carrier For press fitting drive bevel pinion bearing outer races use spe cial tools as shown in the figure Special tool A 09924 74510 B 09926
81. for damage and deterioration Replace as necessary 2 Arrange 3 new 1 5 V batteries 2 in series and connect its positive terminal to Vin terminal of MAP sensor 1 and negative terminal to Ground terminal Then check voltage between Vout and Ground Also check if voltage reduces when vacuum is slowly applied up to 400 mmHg by using vacuum pump 3 If check result is not satisfactory replace manifold absolute pressure sensor CAUTION As connection to wrong terminal will cause damage to manifold absolute pressure sensor make absolutely sure to connect properly as shown in the figure MAP sensor output voltage Vin voltage 4 5 5 5 V ambi ent temp 20 30 C 68 86 F ALTITUDE BAROMETRIC OUTPUT Reference PRESSURE VOLTAGE m mmHg kPa v 0 0 760 100 94 33 43 2000 610 707 2001 611 E yin 94 85 30 41 5000 1524 5001 1525 E 85 76 27 37 8000 2438 8000 2439 pisei 76 70 25 33 10000 3048 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 41 INSTALLATION 1 Confirm that vacuum passage on intake manifold is free from clog 2 Apply engine oil to O ring of sensor 3 Install sensor 1 to intake manifold 2 4 Connect connector to sensor 1 securely Fuel level sensor sender gauge Refer to Section 8C
82. ing the following points Take off bleeder plug cap from brake pipe and connect pipe or pipes to wheel cylinder 1 just enough to prevent fluid from leaking Tighten wheel cylinder to brake back plate 1 to specified torque Tightening torque Wheel cylinder bolt for non sealed type a 13 5 N m 1 35 kg m 10 0 Ib ft Brake pipe flare nut b 16 N m 1 6 12 0 Ib ft Brake Back Plate INSTALLATION 1 Install brake back plate 3 to rear axle shaft 1 2 Wheel bearing 2 Apply sealant to joint seam of rear axle housing 1 and brake back plate A Sealant 99000 31110 NOTE Make sure to remove old sealant before applying it anew 3 Install rear axle shaft to rear axle housing 5C 6 PARKING AND REAR BRAKE 4 Tighten brake back plate nuts to specified torque Tightening torque Brake back plate nut 50 N m 5 0 kg m 36 5 Ib ft 5 Install wheel cylinder and tighten wheel cylinder bolts and brake pipe flare nut or nuts to specified torque Tightening torque Wheel cylinder bolt 13 5 N m 1 35 kg m 10 0 Ib ft Brake pipe flare nut 16 N m 1 6 kg m 12 0 Ib ft 6 Install parking brake cable 3 to brake back plate 1 and tighten parking brake cable nut 2 to specified torque Tightening torque Parking brake cable nut a 10 N m 10 kg m 7 5 Ib ft 7 Install brake shoes referring to steps 1 to 4 of I
83. noid valve gasket low coast modulator valve spring 2 inter coast modulator valve spring 3 and 2 intermediate coast modulator valves 4 7 Pressing TCC lock up control sleeve with finger and using magnet 1 remove locating pin and then remove TCC lock up control sleeve TCC lock up control valve and TCC lock up control valve spring 8 Check which step of primary regulator valve sleeve 1 how many steps down from its tip contacts primary regulator valve sleeve retainer 2 9 Pressing primary regulator valve sleeve 1 with finger and using magnet remove primary regulator valve sleeve retainer and then remove primary regulator valve sleeve 1 spacer 2 primary regulator valve plunger 3 primary regu lator valve spring 4 and primary regulator valve 5 781 58 AUTOMATIC TRANSMISSION 4 A T ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points Coil outer diameter and free length of each valve spring should be as listed below Be sure to use each one of correct size Coil outer diameter and free length of each valve spring Name of spring Outer diameter Free length Pressure relief valve spring 13 14 mm 0 517 in 32 14 mm 1 265 in TCC Lock up control valve spring 11 40 mm 0 449 in 32 60 mm 1 283 in Valve damping spring 4 95 mm 0 195 in 20 00 mm 0 787 in Low coast modulator valve spr
84. the botom valve sping sont de 6A2 18 ENGINE MECHANICAL H27 ENGINE INSPECTION Valve guides Using a micrometer and bore gauge take diameter readings on valve stems and guides to check stem to guide clearance Be sure to take reading at more than one place along the length of each stem and guide If clearance exceeds limit replace valve and valve guide Valve stem to guide clearance Standard Limit Valve stem Intake 5 965 5 980 mm diameter 0 2348 0 2354 in Exhaust 5 940 5 955 mm 0 2339 0 2344 in Valve guide In amp Ex 5 985 6 010 mm 1 0 0 2356 0 2366 Stem to guide Intake 0 035 0 045 mm 0 07 mm clearance 0 0014 0 0018 in 0 0027 in Exhaust 0 060 0 070 mm 0 09 mm 0 0024 0 0028 in 0 0035 in INSTALLATION 1 Clean mating surface on cylinder head and cylinder block Remove oil old gasket and dust from mating surface 2 Install knock pin 4 to cylinder block 3 Apply sealant A to cylinder head gasket 1 as shown in the figure A Sealant 99000 31150 Sealant amount Width w 4 mm 0 158 in 4 Install new cylinder head gasket 1 to cylinder block as shown in the figure carved lot number 5 on cylinder head gasket 1 should face up toward cylinder head side IA RH No2 bank 18 LH bank 2 Crankshaft pulley side 3 Fiywheel side
85. the bulb of the MIL When PCM detects a malfunction in A T control system and or a malfunction which gives an adverse effect to vehi cle emission while the engine is running it makes the mal function indicator lamp in the meter cluster of the instrument panel turn ON and stores the malfunction area If it detects that continuously 3 driving cycles are normal after detecting a malfunction however it makes MIL 1 tum OFF although DTC stored in its memory will remain It is possible to communicate through DLC 3 by using not only SUZUKI scan tool 2 Diagnostic information can be accessed by using a scan tool 2 2 DRIVING CYCLE DETECTION LOGIC Refer to Section 6 1 for details PENDING DTC Refer to Section 6 1 for details FREEZE FRAME DATA Refer to Section 6 1 for details 781 8 AUTOMATIC TRANSMISSION 4 A T On Board Diagnostic System Vehicle with monitor connector For automatic transmission control system PCM ECM has fol lowing functions Refer to Section 6 6 1 for details When the ignition switch is tumed ON with the engine at stop malfunction indicator lamp MIL turns ON to check the bulb of the MIL When PCM detects a trouble in electronic shift control sys tem it stores its trouble code in ECM back up memory The memory is kept as it is even if the trouble was only tempo rary and disappeared immediately And it is not erased unless the power to PCM is shut off for 30 seconds or l
86. 007 in Special tool A 09930 40120 B 09930 40113 C 09900 20701 1 Bearing bolt DIFFERENTIAL REAR 7F 19 7 Measure preload of pinion bearing with spring balance 1 or torque wrench 2 and check composite preload of pinion bearing and side bearing NOTE Before taking measurement with spring balance 1 or torque wrench 2 check for smooth rotation by hand On measuring preload rotate the drive bevel pinion about 1 rotation per 2 seconds Composite preload of pinion bearing and side bearing 11 1 2 0 Nem 11 0 20 0 kg cm 9 5 17 4 Ib in Spring measure reading with special tool 9 5 35 5 1 95 3 55 kg 4 30 7 83 Ib Special tool D 09922 76560 3 Universal joint flange 4 Socket with adapter 8 Torque bearing cap bolts 2 to specification and install bear ing lock plates Tightening torque Lock plate bolt b 12 N m 1 2 kg m 9 0 Ib ft Bearing cap bolt c 85 N m 8 5 kg m 61 5 Ib ft 3 Lock plate boit 9 As final step check gear tooth contact as follows a After cleaning 10 drive bevel gear teeth paint them with gear marking compound evenly by using brush or sponge etc b gear to bring its painted part in mesh with 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 re
87. 14 V Is the check result satisfactory 4 Check air pump assembly circuit Goto step 5 Check air pump 1 Check for proper connection to air pump assem assembly referring to bly at all terminals ON VEHICLE SER 2 Turn ignition switch ON VICE and then 3 Check voltage between C51 3 18 and C51 3 17 PNK circuit ground The check result should be as follows If OK substitute a When transfer shift lever is in 2HorN 0 1V known good ECM When transfer shift lever is in 4L or 4H more than PCM and recheck 4 seconds after shifted to 4L or 4H 10 14 V Is the check result satisfactory 5 Check 4WD indicator lamp circuit AWD control system is Check DRN BLK cir 1 Turn ignition switch ON 2 Check voltage between E61 19 and C51 3 17 ground The check result should be as follows When transfer shift lever is in 2H or N 10 14 V When transfer shift lever is in 4L or4H 0 1V Is the check result satisfactory in good condition cuit including indica tor lamp and combination meter If OK substitute a known good ECM PCM and recheck DIFFERENTIAL FRONT 7E 5 4WD Control System Circuit Inspection Voltage check Check for input or output voltage voltage between each circuit and body ground of ECM PCM with ECM PCM connector connected and ignition switch tuned ON TER WIRE NORMAL MINAL CIRGUIT COLOR VOLTAGE CONDITION opn __10 14
88. 2 Install tachometer 3 Start engine with select lever shifted to P 4 Depress brake pedal fully 5 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 the following specification Stall speed 2 460 2 760 r min TROUBLESHOOTING Condition Possible cause Lower than standard level Faulty engine output Defective torque converter Slippery O D clutch Slippery forward clutch Malfunctioning O D one way clutch Malfunctioning one way clutch No 2 Low line pressure Slippery direct clutch Slippery reverse brake Low fluid pressure Slippery O D clutch Defective O D one way clutch Higher than standard level in D range Higher than standard level in R range AUTOMATIC TRANSMISSION 4 A T 781 39 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 to 80 C 158 176 F Fluid is filled to proper level between FULL HOT and LOW HOT on dipstick 1 Apply parking brake securely and place checks against wheels 2 Attach oil pressu
89. 26010 B 09951 16080 7E 8 DIFFERENTIAL FRONT zw 6 Position slit in each bush 2 as shown when press itting it Bush instillation position angle A 45 slit alignment 1 Froni mounting bracket L 3 Front mounting bracket 7 Position each bush to bracket as shown in the figure Bush installation position length a 3 0 mm 0 12 in Froni mounting bracket 2 Front mounting bracket L 8 Tighten differential front mounting and bracket bolt to speci fied torque for reinstallation Tightening torque Front mounting bolt a 85 N m 8 5 kg m 61 5 Ib ft Front mounting bracket bolt b 50 N m 5 0 kg m 36 5 Ib ft Rear Mounting for Front Differential Carrier REMOVAL AND INSTALLATION 1 Lift up vehicle and remove rear mounting bracket 3 by removing rear mounting bolt 1 and rear mounting bracket bolts 2 2 Check mounting rubber for damage or deterioration and replace as necessary 3 Tighten rear mounting bolts 1 and rear mounting bracket bolts 2 to specified torque for reinstallation Tightening torque Rear mounting bolt a 85 N m 8 5 kg m 61 5 Ib ft Rear mounting bracket bolts b 50 N m 5 0 kg m 36 5 Ib ft DIFFERENTIAL FRONT 7E 9 Front Differential Assembly DISMOUNTING 1 Lift up vehicle
90. 2nd ring in thickness shape and color of surface contacting cylinder wall Distinguish 1st ring from 2nd ring by referring to the figure When installing oil ring install spacer first and then 2 rails 1 tating 2 2nding 3 Ollting 4 After installing three rings 1st 2nd and oil rings distribute their end gaps as shown in the figure Arrow mark Tst ring end gap Znd ring end gap and ring spacer gap Oil ring upper gap Oil ring lower rail gap Intake sido Exhaust side 6A2 26 ENGINE MECHANICAL H27 ENGINE Unit Repair Overhaul Engine Assembly REMOVAL 1 Release fuel pressure in fuel feed line Refer to FUEL PRESSURE RELIEF PROCEDURE in Section 6 2 Disconnect negative cable at battery 3 Remove engine hood 4 Drain engine oil 5 Drain coolant 6 Remove radiator radiator fan shroud cooling fan and radia tor reservoir Refer to COOLING FAN AND FAN CLUTCH and RADIATOR in Section 6B 7 Disconnect accelerator cable 1 and A T throttle cable for vehicle 2 from throttle body 8 Remove strut tower bar and surge tank cover 9 Disconnect IAT sensor coupler and MAF sensor coupler then remove air cleaner upper case intake air hose intake air pipe and surge tank pipe as a component 10 Remove engine oil level gauge guide and A T fluid level gauge guide for A T vehicle 11 Remove ign
91. 3 Front bumper side installation hole rd mounting installation hole Tst mounting installation hole Lower rod installation hole Suspension frame front installation hole Upper rod installation inside hole Front strut installation outside hole Lateral rod installation hole Suspension arm installation rear side hole Rear shock absorber installation hole Znd mounting installation hole ath mounting installation hole 9 92070 hole Fuel tank instalation rear right sida hola hihi Jig hole 3 Fuel tank installation rear left side hole Hole to hole distance 1363 mm 53 66 in 200 mm 7 87 in 1770 mm 69 68 in 1574 mm 61 97 in 928 mm 36 54 in 1078 mm 42 24 in 1291 mm 50 83 in 1488 mm 58 58 in 1029 mm 40 51 in 1554 mm 61 18 in 1225 mm 48 23 in 970 mm 38 19 in 1854 mm 53 31 in 181 mm 7 13 in 1353 mm 53 27 in 1084 mm 42 68 in 606 mm 23 86 in 1477 mm 58 15 in 1339 mm 52 72 in 1004 mm 39 53 in 1876 mm 73 86 in 918 mm 35 94 in 1781 mm 70 12 in 569 mm 22 40 in 1633 mm 64 29 in 1664 mm 65 51 in 881 mm 34 68 in i k 1 1110 mm 43 70 in o 1660 mm 65 35 in 9 4 BODY SERVICE Body Dimensions
92. 3 Rear expansion valve 1 Compressor 4 Receiveridryer 7 evaporator 10 Rear AIC evaporator 2 Magnet clutch 5 Dual pressure switch 8 Solenoid valve 18 4 AIR CONDITIONING OPTIONAL Major Components And Location TA Dual AIC model 6 Recelverldryer 18 Suction pipe 20 Ventiation air IB Single AIC model 7 Front expansion vave 34 Discharge pipe 21 Rear AIC air 1 Frentcooling unit 8 Heater unit 15 Recirculation air 22 Room air 2 Front AIG evaporator 9 Rear AIC unit 16 Fresh air 23 Solenoid valve 3 Frontblower fan motor 10 Rear blower fan molor T7 Defroster air 24 Rear evaporator 4 Compressor Ti Rear expansion valve 18 Demister air 5 Condenser assembly 12 Liquid pipe 38 Foot air AIR CONDITIONING OPTIONAL 18 5 TA Dual AIC LH steering model 4 Condenser T1 Low pressure charge valve 18 Dual AC RH steering model 5 Sight glass 12 Floor liquid pipe IC Single LH steering model 6 _Refrigerant dual pressura sensor 13 Floor suction pipa ID Single RH steering model 7 Discharge pipe 34 Rear AIC unit 1 Front cooling unit 8 Liquid pipe 18 Rear AIC duct No 1 2 Heater unit 9 Suction pipe 16 Rear AIG duct No 2 3 Compressor 1
93. 5 Remove direct clutch piston return spring 781 54 AUTOMATIC TRANSMISSION 4 A T 6 Install direct clutch cylinder to center support Remove direct clutch piston by blowing air into the second hole from the left as shown in the figure Also remove direct clutch inner piston by blowing air into hole at the extreme right And then remove O rings from pistons Front upper valve body ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points Coil outer diameter and free length of each valve spring should be as listed below Be sure to use each one of correct size Coil outer diameter and free length of each valve spring Name of spring Outer diameter Free length Secondary regulator 17 43 mm 71 27 mm valve spring 0 681 in 2 806 in Cut back valve spring 6 85 mm 23 0 mm 0 259 in 0 906 in Throttle valve 8 56 mm 18 86 mm secondary spring 0 337 in 0 743 in Throttle valve 10 90 mm 39 55 mm primary spring 0 429 in 1 557 in Install as many throttle valve compensating rings as written down when disassembled Tighten throttle cam bolt 1 to specified torque Tightening torque Throttle cam bolt a 7 5 Nm 0 75 kg m 5 5 Ib ft Tighten pressure relief valve bolts 1 to specified torque Tightening torque Pressure relief valve bolt b 5 5 N m 0 55 kg m 4 0 Ib ft AUTOMAT
94. 6 2 14 Special Tool 6 2 36 Valves and Cylinder Heads 6A2 17 Piston Piston Rings Connecting Rods 6A2 2 ENGINE MECHANICAL H27 ENGINE On Vehicle Service Throttle Body and Intake Manifold T Ar cleaner box Intake manifold T1 Gasket 16 Throtlie body boit 2 Intake air hose 7 Intake manifold gasket 12 sensor V oTo 3 Intake air pipe Throttle body assembly 13 MAF sensor DELLI 4 Surge tank pipe 8 Throttle body gasket 34 MAP sensor 5 Gasket 10 Intake collector 35 Throttle body nut ENGINE MECHANICAL H27 ENGINE 6A2 3 REMOVAL 1 Release fuel pressure in fuel feed line by referring to Section 6 CAUTION This work must not be done when engine is hot If done it may cause adverse effect to catalyst 2 Disconnect negative cable at battery 3 Drain coolant WARNING To help avoid danger of being burned do not remove drain plug and radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon 1 Radiator 2 Radiator drain plug 4 Remove strut tower bar 2 5 Disconnect coupler from intake air temp sensor and MAF sensor 6 Remove surge tank cover 1 7 Remove air cleaner upper case intake air hose intake air pipe 1 and surge tank pipe 2 as one component Do not disassemble them
95. 6E2 Faulty ECM PCM Inspection of ECM PCM and its circuit in this section Excessive detonation The engine makes sharp metallic knocks that change with throt tle opening Sounds like pop corn pop ping Engine overheating Refer to OVERHEATING in this table Faulty spark plug Spark plugs in Section 6F2 Improper ignition timing Ignition timing in Section 6F2 Clogged fuel filter and fuel lines Fuel pressure check in Section 6E2 Faulty EGR system DTC P0400 DIAG FLOW TABLE in this section Faulty ECT sensor or MAF sensor ECT sensor or MAF sensor in Sec tion 6E2 Faulty injector Fuel injector in Section 6E2 Faulty ECM PCM Inspection of ECM PCM and its circuit in this section Excessive carbon deposits in combustion chamber Piston and cylinder head cleaning in Section 6A2 Poor knock sensor performance DTC P0325 DIAG FLOW TABLE in this section Overheating Inoperative thermostat Thermostat in Section 6B Poor water pump performance Water pump in Section 6B Clogged or leaky radiator Radiator in Section 6B Improper engine oil grade Engine oil and oil filter change in Section 0B Clogged filter or oil strainer Oil pressure check in Section 6A2 Poor oil pump performance Oil pressure check in Section 6A2 Dragging brakes Diagnosis in Section 5 Slipping clu
96. 7 4WD switch 4 iocum Ignition switch ON Transfer lever 2H range 51 3 8 Manifold absolute pressure sensor 33 48V Ignition switch ON and engine stops ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 39 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION EET en ON Throttle valve at CSTO Throtls postion sensor Ignition switch ON Throttle valve at full open position 7 10 16V Ignition switch ON and engine stops Mass alr flow gensor 17 20V With engine running at idle speed csi Heated oxygen sensori bank T Defects between While engine running at2 000 r min if equipped over and under 0 45 V for 1 min or longer after warmed up Ground for TP sensor Power source for TP sensor Power source Tor sensor 4 75 5 25V lgnition switch ON Power source 10 i4V Ignition switch ON Ground NET Ignition switch ON Transfer lever Pressure switch in 4WD air pump 4H or 4L range 51 3 18 assembly FE Ignition switch ON Transfer lever 2H range 51 3 19 51 3 20 Ignition switch 10 14V Ignition switch ON Heated oxygen sensor T bank2 between over While engine running at 2 000 r min if equipped and under 0 45 V for 1 min or longer after warmed up 51 322 Heated oxygen sensor 2 bank 1 Deflects between over While engine running at 2 000 r min if equipped and under 0 45 V
97. 8 Self test adapter 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 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loop back connector 11 Storage case 12 Power supply 6F2 14 IGNITION SYSTEM FOR H27 ENGINE CHARGING SYSTEM 6H 1 SECTION 6H CHARGING SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in Section 10B before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activa tion 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 Sens
98. 8 E ER 1 Airbag hamess 7 Passenger air bag inflator module 18 Grommet 2 AIR BAG fuse box SOM 14 Instrument panel harness 3 AIR BAG monitor coupler 8 Seat belt pretensioner retractor assembly equipped 15 Main hamess 3 DLC 10 Prelensioner harness 16 Forward sensor 5 Contact coil assembly TI Ground for air bag system 5 Driver airbag module 32 Connector GOs E12 AIR BAG SYSTEM 108 5 a P eue 7A muunen at 2 wen 4 m aw 5 IP i aa ermen erme FE omen Lonny a ommu A omma Tome ed H mr ADR Noe ep e m coe hk ow m n IG oor 0127 000 oz ev Shorting bar 6 Connection detection 14 Passenger air bag inflator module 18 Airbag hamess 7 To ECM TCM if equipped and ABS control 15 Driver seat belt pretensioner if equipped module if equipped Ck Connector 8 To data link connector DLC 16 Passenger seat belt pretensioner if equipped 1 Fran mai fus 3 HR BAG morior cogar 37 For
99. 99 mm 3 4638 3 4642 in 87 97 87 98 mm 3 4634 3 4638 in No 1 cylinder Mi eoo 2 I al Cylinder Number on cylinder block mark Outer diameter 1 88 01 88 02 mm 3 4650 3 4653 in 88 00 88 01 mm 3 4646 3 4650 in Piston to cylinder clearance 0 02 0 04 mm 0 0008 0 0015 in 2 Install piston pin to piston and connecting rod After applying engine oil to piston pin and piston pin holes in piston and connecting rod fit connecting rod to piston as shown in the figure and insert piston pin to piston and con necting rod and install piston pin circlips 86F NOTE 86F mark on connecting rod must face toward crank shaft pulley side 1 Piston 2 mark 3 Connecting rod ENGINE MECHANICAL H27 ENGINE 6A2 25 NOTE Install circlip with its cut part facing as shown the figure Install so that circlip end gap comes within such range as indicated by arrow A Circlip 1 Piston 2 Arrow mark 3 Connecting rod 4 E Oil hole Crankshaft pulley side 3 Install piston rings to piston As shown in the figure 1st and 2nd rings have RN or R mark respectively When installing these piston rings to pis ton direct marked side of each ring toward top of piston st rings differs from
100. AND DIAGNOSIS H27 ENGINE STEP 6 AND 7 RECHECKING AND RECORD OF DTC Refer to DTC Check in this section for checking procedure STEP 8 ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE Perform basic engine check according to the ENGINE BASIC INSPECTION FLOW TABLE first When the end of the flow table has been reached check the parts of the system suspected as a possible cause referring to ENGINE DIAGNOSIS TABLE and based on symptoms appearing on the vehicle symptoms obtained through steps of customer complaint analysis trouble symptom confirmation and or basic engine check and repair or replace faulty parts if any Engine Basic Inspection Flow Table Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 Check battery voltage Go to Step 3 Charge or replace battery Is it 11 V or more 3 5 engine cranked Go to Step 4 Go to DIAGNOSIS in Section 6H 4 Does engine start Go to Step 5 Go to Step 7 5 Check engine idle speed IAC duty referring to to Step 6 Go to ENGINE DIAGNO IDLE SPEED IAC DUTY INSPECTION in SIS TABLE in this sec Section 6E2 tion Is check result as specified 6 Check ignition timing referring to IGNITION Go to ENGINE DIAGNO Adjust ignition timing TIMING INSPECTION in Section 6F2 SIS TABLE in this sec Is check result as specified tion 7
101. Arbaghamess Z non sch 3 oW Y From nain fuse AR BAG usc S Ground torar bag yem CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 B1031 The power source voltage to SDM is above specified value for specified time DTC B1032 The power source voltage is below an approx 8 V for specified time TABLE TEST DESCRIPTION DTC B1031 STEP 1 Check if voltage applied to SDM is within normal range STEP 2 Check if DTC B1031 still exists DTC B1032 STEP 1 Check if voltage applied to SDM is within normal range STEP 2 Check if DTC B1032 still exists 108 34 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1031 Step Action Yes No 1 1 With ignition switch OFF disconnect SDM connector 2 Check proper connection to SDM at 001 4 terminal 3 If OK then ignition switch ON and then check voltage from Q01 4 terminal on SDM connector to body ground Is voltage 14 V o
102. Between Two Wires or Short to Power Circuit 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 10B 40 DTC B1045 Passenger Pretensioner 0B 36 10B 36 10B 40 10B 40 10B 40 Initiator Circuit Resistance High 10B 40 DTC B1046 Passenger Pretensioner Initiator Circuit Resistance Low 10B 40 DTC B1047 Passenger Pretensioner Initiator Circuit Short to Ground DTC B1048 Passenger Pretensioner Initiator Circuit Short to Power Circuit DTC B1051 Frontal Crash Detected System Activation Command Outputted 10B 46 10B 40 10B 40 B1061 AIR BAG Warning Lamp Circuit Failure DTC B1071 Internal SDM Fau DTC B1013 System Specifications Different from SDM Specifications On Vehicle Service Service Precautions Service and diagnosis Disabling air bag syster Enabling air bag system Handling and storage Repairs and Inspections Required after an Accident t Accident with deployment activation component replacement Accident with or without deployment activation component inspection SDM Forward Sensor Seat Belt Pretensione Air Bag Inflator Module and Seat Belt Pretensioner Disposal
103. Check fuel supply as follows Goto Step 9 Go to Step 8 1 Check to make sure that enough fuel is filled in fuel tank 2 Turn ON ignition switch for 3 seconds and then OFF Repeat this a few times Is fuel return pressure returning sounds felt from fuel return hose when ignition switch is turned ON 8 Check fuel pump for operating Go to DIAG FLOW Go to DIAG FLOW 1 Was fuel pump operating sound heard from TABLE B 3 in this sec TABLE B 1 in this sec fuel filler for about 3 seconds after ignition _ tion tion switch ON and stop 9 Check ignition spark referring to IGNITION Go to Step 10 Go to DIAGNOSIS in SPARK TEST in Section 6E2 Section 6F2 Is it in good condition 10 Check fuel injector referring to Fue INJECTOR Go to ENGINE DIAGNO Go to DIAG FLOW INSPECTION in Section 6E2 SIS TABLE this sec TABLE B 2 in this sec Is it in good condition tion tion ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 15 STEP 9 TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag flow table in this section locate the cause of the trouble namely in a sensor switch wire harness connector actuator ECM PCM or other part and repair or replace faulty parts STEP 10 CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur e g wire harness connector etc referring to INTERMITTENT AND PO
104. 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 o 3 az Te ahy dia es gt E wets e BU 601 17 fand z Chess ae o FE a01 Qu A Shorting bar 2 Ignition switch 5 Driver seat belt pretensioner 18 Airbag hamess 3 AIR BAG fuse 6 Passenger seat belt pretensioner CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 AIR BAG SYSTEM 108 41 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 s
105. Compressor oil refrigerant oil 99000 27080 COMPRESSOR OIL ND OIL8 250 cc Each component Tightening Torque Specification Tightening torque Fastening part Num mE Refrigerant pipe 8 mm 0 31 in 18 13 95 Refrigerant pipe 12 7 mm 0 5 in 22 22 16 0 Refrigerant pipe 16 mm 0 63 in 33 33 24 0 Armature plate nut 18 18 13 0 Special Tools 09900 06107 Snap ring pliers Opening type 09920 53740 Armature plate holder 09990 06010 Manifold gauge set See NOTE below 09990 86011 Gas leak detector 09991 06010 Magnet clutch pulley installer NOTE This kit includes the following items 1 Manifold gauge 2 Changing hose 3 Quick connector 4 Refrigerant container tap valve 5 Refrigerant container T joint 6 Packing set FRONT END ALIGNMENT 3A 1 SECTION 3A FRONT END ALIGNMENT NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS On Vehicle Service Reference Information General Information Alignment Service Data without Load General Information Alignment Service Data without Load Toe in Toe in gauge measurement 1 2 0 04 0 08 in Camber angle C 0 1 30 Caster 2 30 1
106. Connect fuel filler hose to fuel filler neck with match the match marks And then clamp the securely 6 Connect fuel filler hose to fuel tank and breather hose to fuel filler neck Clamp them securely Tightening torque Breather hose clamp b 2 0 N m 0 2 kg m 2 0 Ib ft Fuel filler hose clamp c 4 0 N m 0 4 kg m 3 0 Ib ft 7 Install fuel filler hose protector Fuel tank S Fuel tank protector 2 Fuel pump with fuel level gauge 10 3 Fuel fiter 11 Filer neck 4 Fuel filer cap 12 Breather pipe 5 Breather hose 13 Filer hose 6 Fuel feed line to delivery pipe 14 Tank inlet valve 7 Fuel retum line delivery pipe 15 Fuel cut valve 8 Fuel vapor ine to EVAP canister 8 Connect fuel vapor hose 1 and return hose 2 to fuel pipe and clamp them securely 9 Connect fuel filter inlet hose to fuel filter 1 Fuel fiter 2 Fuel fiter outlet hose 3 Fuel fitrinit hose 10 Connect coupler to fuel pump assembly 11 Connect negative cable to battery 12 Upon completion of installation check fuel system for leak age ENGINE FUEL 6C 5 Fuel Lines Due to the fact that fuel feed line is under high pressure this sys tem requires special consideration for service The feed pipe uses screw couplings and hose clamps INSPECTION Visually inspect fuel lines for evidence of fuel leakage hose cracking a
107. DLC cable for Tech 1A Tech 2 kit SUZUKI scan tool See NOTE NOTE A This kit includes the following items 1 Tool body amp washer 2 Body plug 3 Body attachment 1 4 Holder 5 Return hose amp clamp 6 Body attachment 2 amp washer 7 Hose attachment 1 8 Hose attachment 2 B 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 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 6 1 126 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE ENGINE MECHANICAL H27 ENGINE 6A2 1 SECTION 6A2 ENGINE MECHANICAL H27 ENGINE WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 obse
108. DTC 56 Rear Outlet Solenoid Circuit yt 4 E eux 3 ABS hydraulic uniicontrol module assembly 3 ABS control module 5 Fai safe relay 2 ABS hydraulic uniticontrol module assembly connector 4 Signal DESCRIPTION The ABS control module monitors the output from the valve When the output of each valve exceeds the specified value compared with the signal sent from ABS control module this DTC is set INSPECTION Step Action Yes No 1 1 Check solenoid operation referring to item ABS Checkterminal E136 25 Go to Step 2 HYDRAULIC UNIT OPERATION CHECK in this connection If connection is section OK substitute a known good Is it in good condition ABS hydraulic unit control module assembly and recheck 2 1 Ignition switch OFF Substitute known good WHT BLU or 2 Disconnect ABS hydraulic unit control module con ABS hydraulic unit control___ BLK circuit nector module assembly and open 3 Check for proper connection to ABS hydraulic unit recheck control module connector at terminal E136 25 4 If OK then measure voltage between terminal E19 25 of module connector and E136 24 Isit10 14 V ANTILOCK BRAKE SYSTEM ABS 5E2 25 DTC C1057 DTC 57 Power Source Circuit BLK BLU O O BL KWHT L 24 m i 136 24 Ei38 18
109. DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data in ECM memory by using scan tool and start engine 3 Increase vehicle speed to 50 60 km h 30 40 mph 4 Keep driving above vehicle speed for 5 min Change of vehicle speed is permitted in this step 5 Stop vehicle and check if pending DTC exists by using scan tool If not check if oxygen sensor heater moni toring test has completed by using scan tool If not in both of above checks i e no pending DTC and oxy gen sensor heater monitoring test not completed check vehicle conditions environmental and repeat Steps 3 through 5 6 1 66 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE TROUBLESHOOTING Step Action Yes No 1 ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 HO2S 2 heater check Go to Step 3 Replace HO2S 2 1 Disconnect HO2S 2 coupler with ignition switch OFF 2 Check resistance between 3 and 4 termi nal of HO2S 2 connector HO2S 2 heater resistance 117 14 3 Q at 20 C 68 F Is it within above specification 3 HO2S
110. DTC DETECTING CONDITION AND POSSIBLE CAUSE DTC DETECTING CONDITION TROUBLE AREA When running after engine warmed 2 driving cycle Vacuum leaks air inhaling detection logic Exhaust gas leakage Short term fuel trim exceeding 15 or long term fuel Fuel pressure out of specification trim exceeding 20 and total trim exceeding 43 is Heated oxygen sensor malfunction detected EGR system malfunction Fuel system too lean MAF sensor poor performance Short term fuel trim less than 11 or long term fuel ECT sensor poor performance trim less than 11 and total trim less than 30 is Fuel level sensor detected Fuel trim too rich DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp at start 8 60 C 18 140 F Engine coolant temp at start 8 95 C 18 203 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Intake air temp 8 C 18 F or higher Engine coolant temp 110 C 20 F or lower 1 Connect scan tool to DLC with
111. Deployment Activation Outside Vehicle Deployment Activation Inside Vehicle Deployed Air Bag Inflator Module and Activated Seat Belt Pretensioner Disposal Tightening Torque Specifica Special Tool AIR BAG SYSTEM 108 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 if equipped the sag of the seat belt is taken up for seat belt with pretensioner 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 airbag 2 Passenger side air bag 3 Seal belt pretensioner equipped The air bag system is designed to activate 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 108 4 AIR BAG SYSTEM System Components and Wiring Location View and Connectors CONNECTOR 0277 CONNECTOR Quz CONNECTOR 005 CONNECTOR Qo CONNECTOR 201 f CONNECTOR cav
112. Diag Flow Table and short and connec 15 check result satisfactory tions for poor connection If wires and connections are OK replace HO2S 2 6 1 98 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction SYSTEM WIRING DIAGRAM 1 ur fee S BD 1 ASau BLUIBLK NS 2 1 3 Roz AUN GRNIBLK c51 1 15 gt gt 22 WLLL NM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Monitor signal of EVAP canister purge valve is different from command signal Circuit open or short 2 driving cycle detection logic EVAP canister purge valve and its circuit ECM PCM DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following con dure Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F n is satisfied when usin
113. Disconnect CPP switch connector with ignition switch OFF 2 Remove CPP switch from pedal bracket 1 switch for cruise control 2 Stop lamp switch CPP switch for starter f equipped INSPECTION Check for resistance between terminals under each condition below If check result is not satisfactory replace CPP switch resistance When switch shaft is free Continuity When switch shaft is pushed No continuity 1 Push 2 Free INSTALLATION 1 Install CPP switch to pedal bracket 2 With clutch pedal released adjust switch position so that clearance between end of thread and clutch pedal bracket is within specification Clearance a between end of thread and clutch pedal bracket 1 5 2 0 mm 0 06 0 08 in 3 Tighten lock nut to specified torque Tightening torque CPP switch lock nut a 7 5 N m 0 75 kg m 5 5 Ib ft 4 Connect connector to CPP switch securely 3 Clutch pedal 2 CPP switch for cruise control 3 Locknut 8E 22 CRUISE CONTROL SYSTEM Stop Lamp Switch with Pedal Posi Switch INSPECTION 1 Disconnect negative cable at battery 2 Disconnect stop lamp switch connector and remove stop 2 lamp switch from pedal bracket 3 Check switch 2 contacts for resistance under each of the following each conditions If check result is not satisfactory replace stop lamp switch Stop lamp switch specification Between terminals
114. Ignition coil assembly For No 5 cylinder 5 Noise suppressor 32 Ignition assembly For No 6 cylinder Ignition coil assembly For No 1 cylinder 13 To main relay 7 Ignition coll assembly For No 2 cylinder 14 Sensed information 6F2 4 IGNITION SYSTEM FOR H27 ENGINE 1 Substitute a known good ignition coil assembly and then repeat Step 2 Is check result of Step 2 satisfactory assembly Diagnosis Condition Possible Cause Correction Engine cranks but will Blown fuse for ignition coil assembly Replace notstartorhardto Loose connection or disconnection of lead wire Connect securely start No spark Faulty spark plug 5 Replace Faulty ignition coil assembly s Replace Faulty CMP sensor Replace Faulty ECM or PCM Replace Maladjusted ignition timing Adjust Poor fuel economy or Incorrect ignition timing Adjust engine performance Faulty spark plug s Replace Faulty ignition coil assembly s Replace Faulty CMP sensor Replace Faulty ECM or PCM Replace Faulty knock sensor Replace Diagnostic Flow Table Step Action Yes No 1 Was ENGINE DIAGNOSTIC FLOW TABLE in to Step 2 Go to ENGINE DIAG Section 6 1 performed NOSTIC FLOW TABLE in Section 6 1 2 _ Ignition Spark Test Go to Step 8 Go to Step 3 1 Check all spark plug for condition and type referring to SPARK PLUG in this section 2 If OK perform
115. MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 21 14 Install strut tower bar 1 and tighten bolts 15 Refill cooling system 16 Connect negative cable at battery 17 Adjust accelerator cable and A T throttle cable refer to ACCELERATOR CABLE ADJUSTMENT and A T THROT TLE CABLE ADJUSTMENT in this section Idle air control valve IAC valve REMOVAL 1 Disconnect negative cable at battery 2 Disconnect IAC valve connector 3 Remove IAC valve 1 from throttle body INSPECTION 1 Disconnect connector from IAC valve 2 Check each coil of IAC valve for resistance If resistances is out of specification replace IAC valve resistance Terminals Resistance Between 1 and 2 Between 3 and 2 Between 4 and 5 Between 6 and 5 25 5 33 59 62 22 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 3 Remove air cleaner outlet hose and remove IAC valve from throttle body 4 Connect connector to IAC valve 5 Check that plunger 1 of IAC valve moves once and then stops as soon as ignition switch 2 is tumed OFF after cranking engine for 2 sec It plunger 1 of IAC valve does not operate at all check wire harnesses for open and short If wire harnesses are in good condition replace IAC valve and recheck NOTE This check should be perf
116. N m 2 3 kg m 17 0 Ib ft 4 Lower vehicle and fill proper amount of an equivalent of DEXRON III 5 Check fluid level referring to LEVEL CHECK NORMAL OPERATING TEMPERATURE of FLUID LEVEL in this section Fluid specification An equivalent of DEXRON III Fluid capacity When draining from drain plug hole 2 5 liters 5 28 4 40 US Imp pt When overhauling 6 8 liters 14 37 11 97 US Imp pt ost 42 lesa AUTOMATIC TRANSMISSION 4 A T 7B1 45 A T Throttle Cable ADJUSTMENT 1 Pull inner cable 3 by force of 2 N 0 2 kg 0 45 Ib or less to be no slack of inner cable with A T throttle cable 1 curved as shown in the figure 2 Fix stopper 2 to inner cable 3 with clearance c AIT throttle cable adjusting position clearance c 0 8 1 5 mm 0 03 0 06 in 3 Warm up engine and transmission to normal operating tem perature 4 Make sure that accelerator cable is adjusted as specified 5 With throttle valve closed check clearance which should be within the following specification of A T throttle cable 1 If it is out of specification adjust it by turning cable adjusting nut 2 AIT throttle cable adjusting position clearance c 0 8 1 5 mm 0 03 0 06 in 6 Tighten lock nut 3 securely Solenoid Valves Shift Solenoid Valves and TCC Solenoid Valve INSPECTION With PCM couplers disconnected and using service wir
117. OFF disconnect HO2S 1 connec GRY YEL circuit tor open or short 2 Check for proper connection to HO2S 1 at each termi If wire and connec nal tions are OK sub 3 I OK connect voltmeter 1 and 2 terminal of HO2S 1 stitute a known connector good ECM PCM 4 Start engine and check voltmeter while repeating rac and recheck ing engine Is over 0 6 V and below 0 3 V indicated ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 69 on scan tool 15 it within 20 to 20 tion OA Check for intermit tent referring to INTERMITTENT AND POOR CON NECTION in Sec Step Action Yes No 4 Shortterm fuel trim check Intermittent trouble Go to DTC 0174 1 Run engine at 2000 r min for 60 sec or faulty ECM P0175 Diag Flow 2 With engine idling check short term fuel trim displayed PCM Table Fig for Step 2 T Normal gt P0153 HO2S 1 Bank 2 Circuit Slow Response WIRING DIAGRAM CIRCUIT DESCRIPTION Refer to DTC P0150 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected in idle state while running under driving conditions described for DTC CONFIRMATION PROCEDURE Hi Lo cycle TRANS TIME displayed on scan tool of HO2S 1 output voltage is longer than specification or response rates of Hi Lo and Lo Hi TRANS TIME displaye
118. Oil pressure gauge Q 09916 14510 09916 14910 09916 34541 09916 37810 Reamer 11 mm Valve guide remover Valve guide installer han dle Valve lifter Valve lifter attachment Reamer handle Reamer 6 mm 09916 38210 09916 44910 09916 58210 09916 77310 Piston ring compressor ENGINE MECHANICAL H27 ENGINE 6A2 37 09916 84511 09917 68221 09917 87810 09917 98221 Forceps Camshaftlockholder Valve guide installer Valve stem seal installer 09918 08210 09919 28610 09924 17810 09926 58010 Vacuum gauge hose joint Protective sleeve Flywheel holder Bearing puller attachment 09944 36011 09911 97710 09915 76510 Steering wheel remover Oil seal guide Oil pressure gauge attachment 6A2 38 ENGINE MECHANICAL H27 ENGINE ENGINE COOLING 68 1 SECTION 6B ENGINE COOLING NOTE For the descriptions items not found in this section refer to the descriptions of H25 engine in the same section of service manual mentioned in the FOREWORD of this manual CONTENTS 6B 2 Coolant Maintenance 68 2 ENGINE COOLING Coolant Anti freeze proportioning chart Freezing temperature L EIS 595 iaa F 3 33 Antifreeze Anticorrosion coolant concentration 30 50 itr 27 64 4 6 4 6 Ratio of compound to cooling water US pt 58 137 9 8 9 8 imp pt 48 13 8 1 8 1 Coolant capacity Engins radiator Reservoir T
119. P0100 DTC No 33 34 Mass Air Flow Circ WIRING DIAGRAM Malfunction 3 Eua BLKRED z BLU BLK BLU 05135 i i SA SWW 1 Main fuse 2 Main relay 3 ECWPCM 4 Mass airflow sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Switch ON and less than 0 64 mA MAF sensor out put current continues for 100 msec Engine running and more than 3 sec after ignition Switch ON and more than 4 90 mA MAF sensor out put current continues for 100 msec Any one of the following conditions are detected for 5 MAF sensor circuit sec continuously MAF sensor Engine running and more than 3 sec after ignition e ECM PCM ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 49 DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 person a driver and a tester on a level road ity of a traffic NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION
120. P0150 Diag Flow Table in Section 6 1 If malfunction is found replace 6 2 38 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE HEATER INSPECTION 1 Disconnect HO2S 1 or 2 coupler 2 Using ohmmeter measure resistance between terminals VB and GND of HO2S coupler 1 If found faulty replace HO2S NOTE Temperature of HO2S affects resistance value largely Make sure that HO2S heater is at correct temperature Resistance of HO2S heater 11 7 14 3 Q at 20 C 68 F for HO2S 2 5 0 6 4 Q at 20 C 68 F for HO2S 1 3 Connect HO2S coupler securely Heated oxygen sensor sensor 2 REMOVAL WARNING To avoid danger of being burned do not touch exhaust system when system is hot Oxygen sensor removal should be performed when system is cool 1 Disconnect negative cable from battery 2 Disconnect coupler 3 of oxygen sensor s 3 Remove oxygen sensor s 2 from exhaust manifold s 1 NOTE Be careful not to expose it to excessive shock INSTALLATION Reverse removal procedure noting the followings Tighten oxygen sensor s to specified torque Tightening torque Heated oxygen sensor 2 a 45 Nm 4 5 kg m 32 5 Ib ft Connect connector of oxygen sensor s and clamp wire har ness securely After installing oxygen sensor s start engine and check that no exhaust gas leakage ex
121. Precaution Piping Handling refrigeran Refrigerant recovery 1B 26 Refrigerant charge Replenishing compressor oil Rear A C Unit Rear A C Evaporator Rear Expansion Valve Rear A C Evaporator Temperature Controller Refrigerant Pipes and Hoses Solenoid Valve Rear Blower Motor Assembly Rear Blower Motor Relay and Solenoid 1B 34 1B 34 1B 35 1B 36 1B 37 Rear Blower Motor Resistor Rear Blower Motor Switch Rear A C No 1 and No 2 Duct Rear A C No 1 duct 1B 37 Rear A C No 2 duct 1B 37 Compressor Assembly 1B 38 Magnet Clutch 18 41 Required Service Materials 18 44 Tightening Torque Specification 18 44 Special Tools 18 44 AIR CONDITIONING OPTIONAL 18 3 General Description Refrigerant Type Whether the A C in the vehicle being serviced uses HFC 134a R 134a or CFC 12 R 12 is indicated on LABEL on the com pressor Also it can be checked by the shape of the service charge valve Tal 1 4 IB OFO 12 8 12 T Compressor label 2 Service valve Refrigerant Flow of Conditioning System NOTE For single A C model refer to the same section of the Service Manual mentioned in FOREWORD of this manual Vapor ZZZZZZ7 Vuid iy Superheated Vapor 1 VA Dual AC model 3 Condenserassembly 6 Expansion valve
122. Q 2 4 V Required A C ON terminal AC A13 at engine running with nor Sigil Stents 10 14V mal condition refer to INSPEC TION OF ECM AND ITS GRY controller Ground to a acy E61 8 Mp CIRCUIT in Section 6E WHT A C ON permis engine Fig phis Except the above mentioned with sion signal h oiy engine running In this case compressor should be stop Signal input from 0 15V__ Require ON Egiaz YEY AVC controller Ground to BLK A C ON request engine Fig C 10 14V Tum off the signal Blower fan motor switch and or defroster switch ON with engine running at A C evaporator temperature sensor temperature input more than approx 2 5 C yer Condenser cool dto 0 1V than 2 5 V 5840 Q refrig 61 22 Bry ingtanmotor ongie Fig C erant pressure switch ON and relay output 9 9 signal input from ECM ON Engine coolant temperature sen sor more than 113 C 236 F with engine running Except the above mentioned with engine running AIR CONDITIONING OPTIONAL 18 19 Refrigerant Recovery Evacuation and Charging WARNING Your eyes should not be exposed to refrigerant liquid Any liquid Refrigerant 134a escaping by accident shows a temperature as low as approx 6 C 21 2 F below freezing point Should liquid HFC 134a R 134a get into your eyes it may cause a serious injury To protect your eyes against such accident it is necessary
123. SWITCH COAT SET RESUME ACCEL AND CANCEL SWITCHES CIRCUITS CHECK in this section Actuator assembly faulty Replace actuator assembly CRUISE CONTROL SYSTEM 8E 7 Condition Possible Cause Correction RESUME ACCEL switch fails to resume preset vehicle speed after cruise control is cancelled Main switch COAST SET RESUME ACCEL and CANCEL switch circuits faulty Refer to CRUISE MAIN SWITCH COAT SET RESUME ACCEL AND CANCEL SWITCHES CIRCUITS CHECK in this section Actuator assembly faulty Replace actuator assembly Cruise control is not cancelled even when brake pedal is depressed Stop lamp switch circuit faulty Refer to STOP LAMP SWITCH WITH PEDAL POSITION SWITCH CIRCUITS CHECK in this section Actuator assembly faulty Replace actuator assembly Cruise control is not cancelled even when clutch pedal is depressed Clutch pedal position switch circuit faulty Refer to CLUTCH PEDAL POSITION SWITCH CIRCUIT CHECK in this Sec tion Actuator assembly faulty Replace actuator assembly Cruise control is not cancelled even when selector lever is shifted to N posi tion Transmission range switch circuit 4 A T model only faulty Refer to TRANSMISSION RANGE SWITCH CIRCUIT CHECK in this sec tion Actuator assembly faulty Replace actuator assembly 4 speed A T gear shift ing is f
124. Step3 Substitute a known good ECM PCM and recheck 3 sensor check Substitutea sensor or its circuit mal 1 Check MAP sensor and its circuit referring to known good function Steps 2 and 3 of DTC P1408 Diag Flow Table ECM PCM and Is check result satisfactory recheck 6 1 114 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P1500 Engine Starter Signal Circuit WIRING DIAGRAM ee m 51 4 EE oa aE jr PYEL mun i 20 aie C52 E60 ET Cottae T Engine sar swich in onion ain wich 2 Surngmotr 3 Transmission range sensor swich 4 ECM POM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Engine starts even though vehicle is at stop and engine start signalis Engine start signal circuit not inputted ECM PCM or Engine start signal is inputted continuously for specified time while engine is running 2 driving cycle detection logic DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following condition is satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temp 8 C 18 F or
125. The retractor assembly should lock webbing when pulled quickly The retractor assembly should lock webbing even when tilted approx 15 toward the fore and aft or right and left directions 2 Check retractor assembly with seat belt pretensioner appearance visually for following symptoms and if any one of them is applicable replace it with a new one as an assembly Pretensioner has activated There is a crack in seat belt pretensioner retractor assembly Wire harness or connector is damage Seat belt pretensioner retractor assembly is damaged or a strong impact e g dropping was applied to it Anchor bolt Inspect all seat belt anchor bolts to verify that they are secure All anchor bolts should be secure and torqued to specification Belt latch Belt latch should be secure when latched Inspect the seat belt buckle ensuring that it locks and unlocks easily After buckling the seat belt tug sharply on the belt checking that the buckle remains locked SEAT BELT 10 5 Seat belt switch Check driver side seat belt strap switch for continuity by using 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 0 1 Buckle tongue Buckle catch INSTALLATION Install in reverse order of removal noting the f
126. Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 5 min 3 Check pending DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE formed DIAG FLOW TABLE in this section 2 HO2S 1 heater check Go to Step 3 Replace HO28 1 1 Disconnect HO2S 1 coupler with ignition Switch OFF 2 Check resistance between 3 and 4 termi nal of HO2S 1 coupler HO2S 1 heater resistance 5 0 6 4 Q at 20 C 68 F Is it within above specification 3 HO2S heater power supply check Go to Step 4 HO2S and or IG 1 With ignition switch ON leaving engine OFF METER fuse blown check voltage between E139 3 and ground If OK faulty BLKWHT 139 1 and ground See Fig wire or BLU WHT wire Is each voltage 10 14 V ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 71 Step Action Yes No 4 HO2S heater control circuit check Substitute a known good Faulty HO2S heater relay 1 With ignition switch OFF install HO2S ECM PCM and recheck or BLK wire open BLU heater relay wire open or shorted to 2 With ignition switch ON leaving engine OFF ground circuit BLK RED check voltage between C51 2 4 and wire open or shorted to ground ground circuit 15 the voltage 10 14 V If OK substitute a known good ECM PCM and rec
127. Use of any other bolts than that specified is prohibited A Cement 99000 32110 Tightening torque Bevel gear bolts a 105 N m 10 5 kg m 76 0 Ib ft 7F 12 DIFFERENTIAL REAR 9 Install special tool to differential case assembly and check that preload is within specification below If preload exceeds specified value check if foreign matter is caught or gear is damaged Special tool B 09928 06510 Side gear preload Max 2 5 N m 0 25 kg m 1 8 Ib ft Torque wrench Differential case assembly Aluminum plate Vise Differential side bearing 1 Press fit side bearing 1 with special tool and press Special tool A 09944 66020 2 Hold bearing press fitted in Step 1 with holder and press fit 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 DIFFERENTIAL REAR 7F 13 Drive bevel pinion To engage drive bevel pinion and gear correctly it is pre required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings Shown below is relative positions of drive bevel pinion differential carrier and mounting dummy Special tool A 09900 20606 B 09926 78320 C 09922 75222 D 09922 76570 E 09951 46010 F 09926 78311 002
128. WHT circuit between IG METER fuse and combi nation meter or poor cou pler connection at combination meter 6 1 44 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Step Action Yes No 2 ECM power and ground circuit check Does engine start Go to Step 3 Go to TABLE A 3 ECM PCM POWER AND GROUND CIRCUIT CHECK in this section If engine is not cranked go to DIAGNOSIS in Section 6G MIL circuit check 1 Tum ignition switch OFF and disconnect connectors from ECM 2 Check for proper connection to ECM at ter minal E61 7 3 If OK then using service wire ground termi nal E61 7 in connector disconnected Does MIL turn on at ignition switch ON Substitute a known good ECM PCM and recheck Bulb burned out or PPL YEL wire circuit open Table 2 Malfunction Indicator Lamp Circuit Check Lamp Remains ON after Engine Starts WIRING DIAGRAM CIRCUIT DESCRIPTION Refer to TABLE A 1 INSPECTION Step Action Yes No 1 DTC check 1 With ignition switch OFF install scan tool 2 Start engine and check DTC Is there any malfunction DTC s Go to Step 2 of ENGINE DIAG FLOW TABLE in this section Go to Step 2 MIL circuit check 1 With ignition switch OFF disconnect cou plers from ECM PCM Does MIL turn ON at ignition switch ON PPLIYEL wire shorted to
129. Wear of hydraulic valve lash adjuster Check adjuster for pitting scratches or damage If any malcondition is found replace Measure cylinder head bore and adjuster outside diameter to determine cylinder head to adjuster clearance If clearance exceeds limit replace adjuster or cylinder head Hydraulic valve lash adjuster O D Standard 30 959 30 975 mm 1 2188 1 2194 in Cylinder head bore Standard 31 000 31 025 mm 1 2205 1 2214 in Cylinder head to adjuster clearance Standard 0 025 0 066 mm 0 0010 0 0025 in Limit 0 15 mm 0 0059 in ENGINE MECHANICAL H27 ENGINE 6A2 17 Valves and Cylinder Heads T Gyinder beck Exhaust valve Ti Valve som ol seal 15 Gyiindor head bat fex holo Poin ZRH bank cyinder head T take valve T2 Vae sig eur U Torque LH bark cyinder head 8 Vaive sping soat T3 Valve cater Q ras bank head gasket S Ouer valve sping 19 Valve gue Apply engine Mad arvoc iot number on cyindor hess Se sure to positon spring in pace wih Sking surfaco of gasket seul fae up foward oyindor fe bottom end email pid and facing ach par Fead the botom valve sping seat ste 5 LH bank cylinder haad gaskat 16 Inner valve spring 16 Oyinder head bot Carved it number on cyinder ead Bo sure to paston spring in place with gasket shuld up oyindor fe bottom facing fead
130. and Q04 2 terminal of AIR BAG monitor cou pler terminals 3 If OK then measure resistance between Q01 15 terminal and Q04 2 terminal Is circuit open Check PPL wire termi nals If OK repair open in PPL wire circuit Substitute a known good SDM and recheck Fig for STEP 2 100r 1 AIR BAG monitor coupler 2 wire terminal Y NOTE Special tool A 09932 75020 Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected AIR BAG SYSTEM 108 21 Table E SDM Cannot Communicate through The Serial Data Circuit WIRING DIAGRAM BLU BLK BLURED 81 4 j 2 Biewer BLK WHT CN sw nnd pPUnED CES 4 Tow Xen PPURED 10 e o7 17 GND gt E l lA TAR Airbag 5 BAG fuse 10 BAG monitor coupler 1 From main fusa 6 Connection detection pin T1 Ground for air bag system 2 Ignition switch 7 SDM 32 Ground on body 3 IG METER fuse 3 13 Ground on Engi
131. and drain oil 2 Disconnect air hose and breather hose from differential housing 3 Before removing propeller shaft give match marks 1 on joint flange and propeller shaft as shown in the figure 4 Remove propeller shaft flange by removing its 4 bolts and suspend it with cord or the like NOTE If pull out propeller shaft transfer oil must be drained before pulling out 5 Remove bolts 1 for left mounting bracket and bolts and nuts 2 for drive shaft flange to set left side of differential free 6 Remove bolts 1 2 and rear mounting bracket 3 7 Remove bolts 4 and rear mounting bracket No 2 5 8 With differential housing assembly held with transmission jack remove front mounting bracket 2 bolts 1 on right end of housing 3 7E 10 DIFFERENTIAL FRONT 9 Using 2 large screwdrivers 4 as levers pull out right side drive shaft joint 1 from differential 2 and dismount housing assembly from vehicle CAUTION During above work use care not to cause damage to drive shaft boot REMOUNTING For remounting reverse dismounting procedure and use the fol lowing tightening torque Tightening torque Front drive shaft flange bolts a 50 N m 5 0 kg m 36 5 Ib ft Propeller shaft flange bolts a 50 N m 5 0 36 5 Ib ft Front mounting bracket bolts a 50 N m 5 0 kg m 36 5 Ib ft Rear mounting bracket bolts a 50 N m 5 0 kg
132. at present the past history DTCs 5 For procedure to clear all DTC s refer to DIAGNOSTIC TROUBLE CODE CLEARANCE in this section 3 Ground terminal 4 Service wire Also ABS control module turns ON EBD warning lamp brake warning lamp depending on the trouble that detected by the module and EBD warning lamp does not indicate DTC Fail safe function When an abnormality occurs an abnormal DTC is detected ABS control module turns OFF the fail safe relay which supplies power to ABS hydraulic unit Thus with ABS not operating brakes function just like the brake system of the vehicle without ABS ANTILOCK BRAKE SYSTEM ABS 5E2 5 Diagno To ensure that the trouble diagnosis is done accurately and smoothly observe PRECAUTIONS IN DIAGNOSING TROU BLES and follow ABS DIAGNOSTIC FLOW TABLE Precautions in Diagnosing Troubles If the vehicles was operated in any of the following ways ABS warning lamp may light momentarily but this does not indicate anything abnormal in ABS The vehicle was driven with parking brake pulled The vehicle was driven with brake dragging The vehicle was stuck in mud sand etc Wheel spin occurred while driving Wheel s was rotated while the vehicle was jacked up Be sure to read PRECAUTIONS FOR ELECTRONIC CIR CUIT SERVICE in Section OA before inspection and observe what is written there Be sure to use the trouble dia
133. canister Fuel vapor inside EVAP canister is harmful 6E2 46 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 1 Disconnect vacuum hoses from EVAP canister and remove EVAP canister 2 When air is blown into tank pipe there should be no restric tion of flow through purge pipe and air pipe If operation differs from above description EVAP canister must be replaced 3 Install EVAP canister and connect hoses to canister Tank pipe Purge pipe Air pipe Blow air Vacuum passage INSPECTION Start engine and run it at idle speed Disconnect vacuum hose from EVAP canister purge valve With finger placed against hose disconnected check that vacuum is applied It itis not applied clean vacuum passage by blowing compressed air TANK PRESSURE CONTROL VALVE INSPECTION 1 Remove tank pressure control valve installed around EVAP canister 2 Air should pass through valve smoothly from black side 3 of tank pressure control valve 1 to orange side 2 when blown hard 3 From orange side even when blown softly air should come out of black side 4 If air doesn t pass through valve in Step 2 or hard blow is required in Step 3 replace tank pressure control valve WARNING DO NOT SUCK air through tank pressure control valve Fuel vapor inside the valve is harmful 5 Plug orange nozzle and apply 26 kPa 20 cmHg vacuum to black
134. connector Substitute a known good to step 4 2 Check proper connection to SDM at termi SDM and recheck nal Qo1 2 3 If OK then check voltage from Q01 2 ter minal of SDM connector to body ground with ignition switch ON Is it8 V or more 4 1 Remove combination meter Refer to COM Go to step 5 Repair high resistance or BINATION METER in SECTION 8 open in BLU wire circuit 2 Check proper connection to combination between combination meter at BLU terminal for AIR BAG meter and SDM warning lamp and to SDM at terminal Q01 7 3 If OK then check resistance between BLU wire terminal of combination meter connec tor 16 pin connector and 001 2 terminal of SDM connector Is circuit short 5 1 Measure voltage from 001 2 terminal of Repair short from BLU Go to step 6 SDM connector to body ground with ignition wire circuit between com Switch ON bination meter and SDM Is it8 V or more to power circuit 6 1 Remove and inspect AIR BAG bulb Substitute a known good Replace bulb Is bulb good combination meter and recheck AIR BAG SYSTEM 108 19 A Fig for STEP 2 B Fig for STEP 3 and 5 C Fig for STEP 4 1 T6gin connector for combination meter 2 BLU wire terminal Special tool A 09932 75020 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ens
135. displayed 96 or higher 3 Check wire harness Go to Step 4 GRY RED wire open 1 Disconnect connector from TP sensor with GRY RED wire shorted ignition switch OFF to ground circuit or power 2 Check for proper connection to TP sensor at circuit or RED GRN GRY RED RED GRN and GRY YEL wire GRY YEL wire wire terminal open or shorted to ground 3 If OK then with ignition switch ON check circuit or poor C51 3 13 or voltage between each of GRY RED or 51 3 9 connection RED GRN wire terminals and body If wire and connection are ground OK substitute a known Is voltage about 4 6 V at each terminal good ECM and recheck 4 Check TP sensor RED GRN wire shorted Replace TP sensor 1 Check resistance between terminals of TP to power circuit sensor referring to TP SENSOR in Section If wire is OK substitute a 6E2 known good ECM PCM Are measured values within specifications and recheck 6 1 56 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0121 Throttle Position Circuit Range Performance Problem WIRING DIAGRAMICIRCUIT DESCRIPTION Refer to DTC P0120 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Throttle opening change is smaller than specification TP sensor while intake air volume changes and engine is running at PCM constant speed 2 driving cycle detection logic DTC CONFIRMATION PROCED
136. dogs can not be fitted into the slots turn the CMP sensor shaft by 180 degree and try again 1 CMP sensor 2 CMP sensor coupling 3 Camshaft A Slot offset 3 Tighten CMP sensor bolt 3 Tightening torque sensor bolt a 15 N m 1 5 11 0 Ib ft 4 Connect CMP sensor coupler 2 to CMP sensor 1 5 Install A T fluid level gauge and filler tube Tightening torque AIT filler tube bolt a 85 N m 8 5 kg m 61 5 Ib ft 6F2 12 IGNITION SYSTEM FOR H27 ENGINE Noise Suppressor REMOVAL 1 Disconnect coupler of noise suppressor 1 2 Remove noise suppressor 1 from hamess 2 INSPECTION Using ohmmeter check to be sure that capacitor condenser in Noise suppressor is not conductive If check result is not satisfactory replace noise suppressor INSTALLATION For installation reverse removal procedure Spec IGNITION SYSTEM FOR H27 ENGINE 6F2 13 ial Tool 09930 76420 Timing light Dry cell type 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE T 09931 76030 16 14 pin DLC cable for Tech 1A Mass storage cartridge for Tech 1A Tech 2 kit SUZUKI scan NOTE A This kit includes the following items and substitutes for the Tech 2 kit tool See NOTE B 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
137. good Step 1 of this table cause engine low idle ECM PCM and recheck Check FIA valve Air inhaling from between throttle body and MAF sensor EGR valve malfunction leakage from valve seat accessory engine load clog of idle air passage and etc ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 123 Table B 5 A C Signal Circuits Inspection If Equipped WIRING DIAGRAM X core ge o E6117 gt s EI r1 F mi LH Cee aaa M WM te 1 NC conta 2 ECM PCM INSPECTION Step Action Yes No 1 Check Signal Circuit Go to Step 2 YEUBLK circuit open or 1 Check voltage at terminal E61 17 with ignition short Evaporative tem Switch ON perature is below 1 AIC signal circuit specification 34 F or faulty A C sys AIC switch and or heater blower switch OFF A tem C is not operating 10 14 V Both A C switch and heater blower switch ON 0 15V Are check result as specified 2 Check Cut Signal Circuit control signal cir GRY WHT circuit open 1 Check voltage at terminal E61 8 cuits are in good con or short Poor perfor AIC cut signal specification dition mance of ECT sensor TP
138. heater 9 Connect hoses of PCV breather and water 3 EVAP canister purge valve 6 POV hose 2 EGR vave 7 Water hose 3 pipe 8 Breather hose 4 canister purge valve hose 9 Earth terminal coupler E Heater hose 10 Connect couplers of manifold absolute pressure MAP sen sor EVAP canister purge valve and EGR valve Fix wire harness with clamps 11 Install clamp bracket 4 to intake collector 12 Connect earth terminal 3 to intake collector 13 Connect couplers of TP sensor 1 and IAC valve 2 14 Connect brake booster hose 2 to intake manifold 15 Connect injector wire 1 coupler 6A2 8 ENGINE MECHANICAL H27 ENGINE 16 Connect water hoses 3 to throttle body 17 Connect accelerator cable 1 and A T throttle cable 2 for vehicle to throttle body 18 Install surge tank pipe 2 to intake manifold with new gas kets and intake air pipe 1 to throttle body 19 Install surge tank cover 1 20 Install air cleaner upper case 21 Connect coupler to intake air temp sensor and MAF sensor 22 Install strut tower bar 1 23 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled 24 Refill cooling system refering to COOLING SYSTEM FLUSH AND REFILL in Section 6B 25 Connect negative cable at battery
139. heater power supply check Go to Step 4 Fuse 25 and or IG 1 With ignition switch ON leaving engine OFF METER blown check voltage between E139 3 and ground If OK faulty BLK WHT E139 1 and ground See Fig wire or BLU WHT wire Is each voltage 10 14 V 4 HO2S heater control circuit check Substitute a known good Faulty HO2S heater relay 1 With ignition switch OFF install HO2S PCM and recheck or BLK wire open BLU heater relay wire open or shorted to 2 With ignition switch ON leaving engine OFF ground circuit WHT check voltage between C51 2 16 and BLK wire open or shorted ground to ground circuit Is the voltage 10 14 V If OK substitute a known good ECM PCM and recheck Fig for STEP 2 3 a Le a 1991 L e1302 e Momma 1 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 67 DTC P0150 DTC No 26 HO2S 1 Bank 2 Circuit Malfunction or No Activity Detected WIRING DIAGRAM E139 025 oop ever 651 25 513 21 0519 25 i 65138 e METER AAO p euewer d AN H LL i 7 Y Fe A Y 100 2 EOM PON S FORST DTC DETECTING CONDITION AND TROUBLE ARE
140. ignition spark test referring to IGNITION SPARK CHECK in this sec tion Is spark emitted from all spark plugs 3 Diagnostic Trouble Code DTC Check Goto applicable flow table Go to Step 4 1 Check DTC stored in ECM or PCM refer corresponding to that ring to DIAGNOSTIC TROUBLE CODE code in Section 6E2 DTC CHECK in Section 6E2 Is DTC stored 4 Electrical Connection Check Go to Step 5 Connect securely 1 Check ignition coil assemblies for electrical connection Are they connected securely 5 Ignition Coil Assembly Power Supply Ground Go to Step 6 Repair or replace and Trigger Signal Circuits Check 1 Check these circuits for open and short Are circuits in good condition 6 _ Ignition Coil Assembly Check Malfunction of ignition coil Go to Step 7 IGNITION SYSTEM FOR H27 ENGINE 6F2 5 Step Action Yes No 7 CMP Sensor Check Substitute a known good Tighten CMP sensor bolt 1 Check CMP sensor ECM or PCM and then or replace CMP sensor Refer to Step 6 or 7 of DTC P0340 DIAG repeat Step 2 FLOW TABLE in Section 6 1 Is check result satisfactory 8 lgnition Timing Check System is in good condi Adjust ignition timing or 1 Check initial ignition timing and ignition tim tion check ECM PCM input ing advance referring to IGNITION TIM signals related to this sys ING CHECK AND ADJUSTMENT in this tem section Is check result satisfactory REFER
141. ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and warm up engine completely 3 Increase vehicle speed to 50 60 km h 30 40 mph 4 Keep driving above vehicle speed for 3 min or more 5 Stop vehicle and check pending DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 77 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 lsthere DTC s other than PO171 Goto applicable DTC Go to Step 3 P0172 FLOW TABLE 3 Check intake system and exhaust system for to Step 4 Repair or replace leakage Are intake system and exhaust system in good condition 4 Checkfuel pressure referring to TABLE B 3 in to Step 5 Repair or replace this section Is check result satisfactory 5 Check fuel injectors referring to FUEL INJEC to Step 6 Faulty injector s TOR INSPECTION in Section 6E2 Is check result satisfactory 6 Checkfuel level sensor referring to FUEL Go to Step 7 Faulty fuel level sensor or LEVEL SENSOR in Section 6E2 its circuit Is check result satisfactory 7 Check MAF sensor for performance referring to Go to Step 8 Faulty MAF sensor or its MASS AIR FLOW SENSOR in Section 6E2 circuit Is check result satisfactory 8 Check ECT sensor r
142. in D range for 2 sec or more 6 Increase vehicle speed and keep it at higher than 20 km h 13 mile h with 2nd gear in D range for 2 sec or more 7 Increase vehicle speed and keep it at higher than 30 km h 20 mile h with 3rd gear in D range for 2 sec or more 8 Stop vehicle 9 Check DTC and or pending DTC TROUBLESHOOTING Step Action Yes No 1 A T DIAGNOSTIC FLOW TABLE in this Go to Step 2 Go to A T DIAGNOSTIC section performed FLOW TABLE in this sec tion gt Input shaft speed sensor circuit check Go to Step 4 Go to Step 3 1 Remove PCM cover 2 With ignition switch OFF disconnect PCM connectors 3 Check for proper connection to input shaft speed sensor at C51 1 10 and C51 1 11 terminals 4 If OK check resistance of sensor circuit Input shaft speed sensor resistance Resistance between C51 1 10 and C51 1 11 530 650 Q at 20 C 68 F Resistance between C51 1 10 C51 1 11 and ground 1 MQ or more Are check results satisfactory 3 shaft speed sensor check BLU GRN or BLU YEL Replace input shaft speed 1 With ignition switch OFF disconnect input open orshortedto sensor shaft speed sensor connector ground 2 Check for proper connection to input shaft speed sensor at each terminals 3 If OK then check resistance of input shaft speed sensor Are measured values as specified in Step 2 AUTOMATIC TRANSMISSION
143. indicated by flashing of the lamp if a current malfunction DTC is not detected at that point although a history malfunction DTC is stored in memory INSPECTION Step Action Yes No 1 Is diagnosis switch terminal connected to Go to Step 3 Go to Step 2 ground via service wire 2 Is it 10 14 V 1 Ignition switch ON 2 Measure voltage between diagnosis switch terminal and ground Substitute a known good ABS hydraulic unit con trol module assembly and recheck PNK wire circuit shorted to ground 3 1 Ignition switch ON DTC 2 Does flashing of ABS warning lamp indicate Go to Step 7 of ABS DIAGNOSTIC FLOW TABLE in this section Substitute a known good ABS hydraulic unit con trol module assembly and recheck 52 18 ANTILOCK BRAKE SYSTEM ABS Table D Code DTC Is Not Outputted Even with Diagno Connected to Ground Switch Terminal BLKWHT ET3618 i BLU ORN 136 14 BLKWHT 1 6 12 1 ABS waming lamp in combination meter 3 Diagnosis monitor coupler 32 Diagnosis ground terminal 2 ABS hydraulic uniticontrol module assembly 3 1 Diagnosis switch terminal 4 ABS hydraulic uniticontrol module connector CIRCUIT DESCRIPTION When diagnosis switch terminal is connected to ground with ignition switch turned ON the ABS c
144. ment 3 Check depth of piston rod i e distance between piston rod and mating surface of booster to master cylinder Depth c of piston rod for check 15 8 16 6 mm 0 623 0 653 in e BRAKES PIPE HOSE MASTER CYLINDER 5 9 4 If measured depth is out of above specifications adjust to specifications below by turning adjusting screw of piston rod Special tool F 09952 16021 Depth d of piston rod for adjustment 16 3 16 6 mm 0 642 0 653 in 5A 10 BRAKES PIPE HOSE MASTER CYLINDER Tightening Torque Specifica n Tightening torque Fastening part Nem kg m lb ft Brake flexible hose bolt Brake caliper 2 way joint 23 2 3 17 0 Brake hose pipe bracket bolt 10 1 0 7 5 ABS actuator bracket bolt 10 1 0 7 5 Master cylinder attaching nut 13 1 3 9 5 Booster nut 13 1 3 95 Clevis nut 25 25 18 0 2 way joint mounting bolt 10 10 75 Brake pipe flare nut 16 1 6 12 0 Brake bleeder plug Front caliper M8 8 0 8 6 0 Brake bleeder plug Wheel cylinder 7 5 0 75 Wheel nut 100 10 0 72 5 Special Tool 09952 16021 09950 78220 Booster piston rod Flare nut wrench adjuster 10 mm PARKING AND REAR BRAKE 5C 1 SECTION 5C PARKING AND REAR BRAKE WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components
145. not occur Never use air bag system parts from another vehicle Do not attempt to service the parts below Service of these parts is by replacement only Driver Passenger air bag inflator modules Driver Passenger seat belt pretensioners Forward sensors SDM Contact coil and combination switch assembly Air bag wire harness Proper operation of the sensors and air bag system requires that any repairs to the vehicle struc ture return it to its original production 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 when checking the SDM Accident with deployment activation component replacement Certain air bag system components must be replaced Those components are Driver and passenger air bag inflator modules Replace with new one Driver and Passenger seat belt pretensioners Replace with new one SDM affer detecting such collision as to meet deployment conditions Replace with new one Forward sensors Replace with new one AIR BAG SYSTEM 108 57 Accident with or without deployment activation component inspections Certain air bag and restraint system components must be inspected after any crash whether the air bag system activated or not Those components are Steering column and shaft joints Check for length dam
146. 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 WARNING After deployment activation the metal surfaces of the air bag inflator module and the seat belt pretensioner will be very hot Do not touch the metal areas of them for about 30 minutes after deployment activation Do not apply water oil etc to deployed air bag infla tor module and activated seat belt pretensioner Fail ure to follow procedures may result in fire or personal injury AIR BAG SYSTEM 108 75 14 Separate the two banana plugs on the deployment harness 15 Connect 1 the deployment harness to the power source 12 V vehicle battery 2 to immediately deploy activate the air bag or the pretensioner 16 Disconnect the deployment harness from the power source 12 V vehicle battery 2 and short 4 the two deployment harness leads together by fully seating one banana plug into the other Put on a pair of shop gloves to protect your hands from pos sible irritation and heat when handling the deployed air bag inflator module and the activated seat belt pretensioner Disconnect the deployment harness from the air bag infla tor module and the seat belt pretensioner as soon after deployment activation as possible This will prevent damage to the deployment harness due to possible contact with the hot
147. oil leakage level 1 1 6 13 Differential oil leakage level R 1st 15 000 km only Rorl 1 6 14 Steering system tighteness damage breakage rattle 6 15 Power steering if equipped T 6 16 All latches hinges and locks 6 17 Air conditioning filter if equipped NOTE R Replace or change I Inspect and correct replace or lubricate if necessary 08 4 MAINTENANCE AND LUBRICATION Maintenance Recommended under Severe Driving Conditions If the vehicle is usually used under the conditions corresponding to any severe condition code given below it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below Severe condition code A Repeated short trips E Repeated short trips in extremely cold weather B Driving on rough and or muddy roads F Leaded fuel use C Driving on dusty roads G D Driving in extremely cold weather Trailer towing if admitted and or salted roads muon di Maintenance eer Maintenance Interval Every 15 000 km ITEM t 9 000 miles or 12 months Drive belt V rib belt Every 45 000 km 27 000 miles or 36 months ITEM 1 4 Every 5 000 km ARCODEEEH Engine oil and oil filter 3 000 miles or 4 months ITEM 1 6 i Every 15 000 km Exhaust pipe mountings 9 000 miles o
148. opening 8E 16 CRUISE CONTROL SYSTEM Overdrive and TCC off Command Signal Circuit Check Step Action Yes No 1 Overdrive off Command Signal Circuit Check This signal circuitis Check PNK 1 Disconnect connector from cruise control module with BLU wire for ignition switch OFF 2 Check for proper connection to cruise control module at terminal E132 3 open and short If OK substitute known good 3 If OK turn ignition switch ON PCM and 4 Check voltage between terminal E132 3 and ground recheck Is it 10 14 V Fig for Step 1 E1329 Cruise Control Module Power and Ground Circuits Check Step Action Yes No 1 Power and Ground Circuits Check Power and ground BLU BLK or 1 Disconnect connector from cruise control module with ignition switch OFF 2 Check for proper connection to cruise control module at terminals E132 12 and E132 11 3 If OK turn ignition switch ON Does voltmeter indicate 10 14 V 4 Check voltage between terminals E132 12 and E132 11 circuits are OK BLK circuit is open Fig for Step 1 E132 11 E132 12 CRUISE CONTROL SYSTEM 8E 17 Cruise Control Module and Its Circuit Inspection CAUTION Cruise control module can not be checked by itself It is strictly prohibited to
149. or cylinder head with housing Never replace cylinder head without replacing hous ings Check clearance by using gaging plastic The procedure is as fol lows 1 Clean housings and camshaft journals 2 Make sure that all valve lash adjusters are removed and install camshaft to cylinder head 3 Place a piece of gaging plastic the full width of journal of camshaft parallel to camshaft 4 Install camshaft housing 5 Tighten camshaft housing bolts in such order A 1 gt 17 B 1 19 as shown in the figure a little at a time till they are tightened to specified torque NOTE Do not rotate camshaft while gaging plastic is installed RH bank 18 LH bank 6A2 16 ENGINE MECHANICAL H27 ENGINE 6 Remove housing and using scale 2 on gaging plastic 1 envelop measure gaging plastic 1 width at its widest point Camshaft journal clearance Standard 0 045 0 099 mm 0 0018 0 0039 in Limit 0 12 mm 0 0047 in If measured camshaft journal clearance exceeds limit measure journal housing bore and outside diameter of camshaft journal Replace camshaft or cylinder head assembly whichever the differ ence from specification is greater Camshaft journal bore dia IN amp Standard 26 000 26 033 mm 1 0236 1 0249 in Camshaft journal O D IN amp EX Standard 25 934 25 955 mm 1 0210 1 0218 in
150. or damage in special tool deployment harness If any faulty is found do not use it and be sure to use new deployment harness Special tool A 09932 75030 3 Short 1 the two deployment harness leads together by fully seating one banana plug into the other WARNING Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed and seat belt pretensioner is to be activated 4 Remove air bag inflator module s and seat belt preten sioner s from vehicle referring to SECTION 3C1 10B and 10A WARNING Always carry live air bag inflator module with trim cover away from you When storing a live air bag inflator module or when leaving a live air bag inflator module unattended on a bench or other surface always face the bag and trim cover up and away from the surface As the live pas senger air bag inflator module must be placed wit bag trim cover facing up place it on the workbench with a slit 1 or use the workbench vise 2 to hold it securely at its lower mounting bracket 3 This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment Failure to follow procedures may result in personal injury AIR BAG SYSTEM 108 67 WARNING For handing and storage of a live seat belt preten sioner select a place where the ambient tempe
151. or failure to clear the DTC in this step may result in an faulty diagnosis trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unneces sary STEP 3 and STEP 4 VISUAL INSPECTION As a preliminary step be sure to perform visual check of the items that support proper function of the A T and engine referring to Visual Inspection section STEP 5 TROUBLE SYMPTOM CONFIRMATION Check trouble symptoms based on information obtained in Step 1 CUSTOMER COMPLAINT ANALYSIS and Step 2 DTC FREEZE FRAME DATA CHECK Also recheck DTC according to DTC CONFIRMATION PROCEDURE described in each DTC FLOW TABLE STEP 6 and STEP 7 RECHECKING AND RECORD OF DTC FREEZE FRAME DATA Refer to CHECK in this section for checking procedure STEP 8 A T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE Perform A T basic check according to the A T Basic Check Flow Table first When the end of the flow table has been reached check the parts of the system suspected as a possible cause referring to TROUBLE DIAGNO SIS TABLE and based on symptoms appearing on the 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 STEP 9 DIAGNOSTIC TROUBLE CODE FLOW TABLE Based on the DTC indicated in Step 6 and 7 and referring to DIAGNOSTIC TROUBLE CODE FLOW TABLE in this section locate the cause of the troub
152. 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 NOTE For the descriptions items not found in this section refer to the same section of the Service Man ual mentioned in the FOREWORD of this manual All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal CONTENTS General Description Master Cylinder Assembly 5 7 Master Cylinder Assembly 5 2 Brake Booster BAB Tightening Torque Speci 5 3 Special Tool On Vehicle Service Front Brake Hose Pipe Master Cylinder Reservoir 5A 2 BRAKES PIPE HOSE MASTER
153. 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 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 For the descriptions items not found in this section refer to the same section of the Service Man ual mentioned in the FOREWORD of this manual All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque
154. rear quarter upper trims 9 2 Remove rear A C No 1 duct 1 3 Remove sliding roof switch and sliding roof trim if equipped 4 Remove sun visor assembly 1 5 Remove map lamp 2 dome lamp 3 and luggage lamp 4 6 Remove assistant grips 5 7 Disconnect rear washer hose and roof harness 8 Remove head lining 6 NOTE For without sunroof model Adhesive is used in head lining Clear adhesive from head lining and roof after removing roof lining BODY SERVICE 9 21 CAUTION Do not remove rear A C No 2 duct 1 from head lining 2 If perform this prohibited service head lining 2 will be broken INSTALLATION Reverse removal procedure to install head lining noting the follow ing instructions Set roof harness 1 and rear washer hose 2 to head lining 3 with adhesive tape as shown For without sunroof model Apply double coated tape 4 to head lining as shown Tighten seat belt anchor bolt as specified torque referring to Section 10A 9 22 BODY SERVICE RESTRAINT SYSTEM 10 1 SECTION 10 RESTRAINT SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to co
155. removal procedure to install rear seat noting the following instruction Tighten third seat mounting bolts as specified torque 9 10 BODY SERVICE Sealant Application Area Paint and Coatings N N Side body inner panel 6 Cenier floor panel TI Main fior extension panel 2 Rear wheel housing outer rear panel 7 Frontfioor panel 32 Rear floor cap 3 Rear wheal housing panel 8 Center floor member Apply sealant 4 Rear oor panel Side sil inner panel Brush treatment 5 Talllower member 10 Side outer panel C Apply sealant between and panel VIEW Z dom LED 7 9 12 BODY SERVICE l E i 526222 Ze 5 _Roof panel Front pilar upper reinforcement 7 Rear wheel housing panel 4 Front pilar inner panal 8 Fuslinlet box BODY SERVICE 9 13 VIEW V RH Side body outer panel 3 Genter floor gusset Apply sealant 2 Rear wheel housing outer panel 4 Center floor panel 787 Brush treatment 9 14 BODY SERVICE VIEW BB e C 1520 mm 059 079 in Apply sealant 7 Sealant with more than 5 mm 0 20 in between a and b Wipe off sealant in this section Be free from protrude of sealant outside from this line Smooth ou
156. satisfactory Go to Step 3 Adjust Stop Lamp Switch With Pedal Position Switch Check 1 Disconnect connector from stop lamp switch 2 Check for proper connection to stop lamp switch at all ter minals 3 If OK check stop lamp and pedal position switches for operation referring to STOP LAMP SWITCH in this sec tion Is this switch in good condition YEL GRN or GRNAWHT circuit is open or short Replace Fig for Step 1 Transmission Range Switch Circuit Check CRUISE CONTROL SYSTEM 8E 13 Step Action Yes No 1 Transmission Range Switch Circuit Check 1 Disconnect connector from cruise control module with ignition switch OFF 2 Check for proper connection to cruise control module at terminal E132 9 3 If OK connect ohmmeter between terminal E132 9 and ground 4 Check for continuity under each condition below Transmission range switch circuit specification Selector lever at P or N range Continuity D 2 or 1 range Infinity Is check result satisfactory Transmissionrange Switch circuit is OK Go to Step 2 Transmission Range Switch Check 1 Disconnect transmission range switch connector 2 Check for proper connection to transmission range switch at disconnected connector terminals 3 If OK check transmission range switch for operation refer
157. sealants etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product infor mation available at the time of publication approval And used as the main subject of description is the vehicle of standard specifications among others Therefore note that illustrations may differ from the vehicle being actually serviced The right is reserved to make changes at any time without notice RELATED MANUAL Manual Name Manual No Q416 SQ420 SQ625 Service Manual 99500 65D10 01E Q416 SQ420 SQ625 Unit Repair Manual for Manual Transmis sion Automatic Transmission Transfer and Differential GRAND VITARA XL 7 Wiring Diagram Manual 99512 52D00 015 99501 65D01 01E SUZUKI MOTOR CORPORATION OVERSEAS SERVICE DEPARTMENT COPYRIGHT SUZUKI MOTOR CORPORATION 2001 Table of Contents GENERAL INFORMATION TRANSMISSION CLUTCH AND General Information 0A DIFFERENTIAL Maintenance and Lubrication 0B Manual Transmission 1 HEATING AND AIR CONDITIONING Automatic Transmission 7B1 Heater and Ventilation Clutch 7 1 Air Conditioning 1B Transfer 7D STEERING SUSPENSION WHEELS Differential Front 7E AND TIRES Differential Rear 7F Steering Suspension Wheels and Tires 3 ELECTRICAL SYSTEM Front End Alignment 3A Electrical System 8 Po
158. securely 11 With engine OFF and ignition switch ON check for fuel leaks Fuel pump ON VEHICLE INSPECTION CAUTION When fuel filler cap is removed in any procedure work must be done in a well ventilated area keep away from any open flames and without smoking 1 Remove filler cap and turn ON ignition switch 2 Then fuel pump operating sound should be heard from fuel filler 1 for about 3 seconds and stop Be sure to reinstall fuel filler cap after checking If above check result is not satisfactory advance to DIAG NOSTIC FLOW TABLE B 1 in Section 6 1 2 Fuel pressure should be felt at fuel return hose 1 for 3 sec onds after ignition switch ON If fuel pressure is not felt advance to DIAGNOSTIC FLOW TABLE B 3 in Section 6 1 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6 2 25 REMOVAL Remove fuel tank from body according to procedure described in Section 6C and remove fuel pump from fuel tank INSPECTION Check fuel pump filter for evidence of dirt and contamination If present clean and check for presence of dirt in fuel tank INSTALLATION Install fuel pump to fuel tank and then install fuel tank to body according to procedure described in Section 6C Fuel pressure regulator REMOVAL 1 Relieve fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCEDURE in Section 6 1 2 Disconnect negative cable from ba
159. 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 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 instrument panel or any other air bag system component on or around air bag system components or wiring Modifications can adversely affect air bag system performance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process remove the air bag system components air bag inflator modules forward sensor s SDM and or seat belt pretensioners beforehand to avoid component damage or unintended activa tion Foreword This manual contains only different service information of the following applicable model as compared with Q416 SQ420 SQ625 SERVICE MANUAL Applicable model GRAND VITARA XL 7 Therefore whenever servicing the above applicable model consult this manual first And for any section item or description not found in this manual refer to the related manual below When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricant
160. signal voltage too high or cycle applicable too low Exhaust gas recirculation flow sive or insufficient EGR flow 2 Sing Not malfunction detected cycles applicable P0403 EGR valve circuit malfunction EGR valve electrical circuit open or 1 driving 1 driving No 51 shot to ground cycle cycle Output waveforms of HO2S 1 and Catalyst system efficiency 28 2 are similar 2 driving Not P0420 below threshold Bank 1 Time from output voltage change of cies applicable 25 1 to that of HO2S 2 is shorter than specification Output waveforms of HO2S 1 and Catalyst system efficiency 28 2 are similar 2 driving Not P0430 below threshold Bank 2 Time from output voltage change of Case applicable HO2S 1 to that of HO2S 2 is shorter PP than specification Purge control valve circuit Purge control valve circuit is open or 2 driving Not P0443 malfunction shorted to ground cycles applicable P0500 Vehicle speed sensor mal signal while running in Drange 2drving 1 driving No 24 function or during fuel cut at decelerating cycles cycle ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 21 vehicle vehicle DTC NO DETECTED ITEM DETECTING CONDITION without with will set when detecting monitor monitor connector connector Difference between desired idle speed Id
161. status of breather hoses Differential Gear Oil Change NOTE Hypoid gear oil must be used for differential Itis highly recommended to use SAE 80W 90 viscosity 1 Before oil change or inspection be sure to stop engine and lift up vehicle horizontally 2 Check oil level and existence of leakage If leakage is found correct its cause 3 Drain old oil and pour proper amount of gear oil as specified roughly up to level hole 4 Torque drain plug 3 and level filler plugs 2 to specification Sealant 99000 31110 Tightening torque Differential oil level filler plug a 50 N m 5 0 kg m 36 5 Ib ft Differential oil drain plug b 28 N m 2 8 kg m 20 5 Ib ft Hypoid gear oil API GL 5 SAE 75W 85 80W 90 or 90 Oil capacity Viscosity chart SAE 2 5 liters 5 3 4 4 US Imp pt 5 sc 30 20 10 0 10 2 30 40 68 104 Temperature DIFFERENTIAL REAR 7F 5 Rear Differential Assembly Dismounting 1 Lift up vehicle and drain oil from rear differential housing 2 Remove rear brake drums and pull out right and left rear axle shafts Refer to REAR AXLE SHAFT REMOVAL of Section 3E 3 Before removing propeller shaft give match marks 1 on joint flange and propeller shaft as shown 4 Remove propeller shaft by removing its flange bolts and nuts 5 Remove differential assembly b
162. than 10 sec onds PIS uid reservoir Gauge valve shut Oil pressure gauge PIS pump PIS gear box b Next open gauge valve fully and increase engine speed to about 1500 r min rpm Then turn steering wheel to the left or right fully and take reading of relief pressure When it is higher than specified values possible cause is malfunction of relief valve When it is lower than specified values possible cause is failure in steering gear box Replace gear box Relief pressure when gauge valve is opened 7650 8350 kPa 76 5 83 5 kg cm 1088 1187 psi CAUTION Be sure not to hold steering wheel at fully turned position for longer than 10 seconds PIS fluid reservoir Gauge valve open 1 2 3 Oilpressure gauge 4 PIS pump E PIS gear box AIR BAG STEERING WHEEL AND COLUMN 3C1 1 SECTION 3C1 AIR BAG STEERING WHEEL AND COLUMN WARNING Service on and 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 air bag system section before performing service on or around the air bag sys tem 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 injur
163. the outside of the compressor should be cleaned before any On vehicle repair or before removal of the compressor The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichloromethane naphtha kerosene or equivalent solvent and dried with dry air Use only lint free cloths to wipe parts The operations described are based on bench overhaul with compressor removed from the vehicle except as noted They have been prepared in order of accessibility of the components When compressor is removed from the vehicle for servicing the oil remaining in the compressor should be discarded and new refrigerant oil added to the compressor Minor repair procedures may be done on the vehicle without discharging the system Major repair pro cedures require that the system be discharged of refrigerant INSPECTION 1 Install manifold gauge set 1 as shown in the figure 2 Close Hi 4 and Lo 5 side valves 2 High pressure side Delivery side hose 3 Low pressure side Suction side pipe 3 Run engine at fast idle 4 Check compressor for the following items If any of the above checks indicated a defect repair com pressor High pressure gauge reading is not low and low pressure gauge reading is not higher than normal Metallic sound Leakage from compressor AIR CONDITIONING OPTIONAL 18 39 REMOVAL 1 Run engine at idle with A C ON for 10 m
164. to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Start engine and run it at idle if possible 4 Check DTC by using scan tool TROUBLESHOOTING Substitute a known good ECM PCM and recheck ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 111 DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction WIRING DIAGRAM gt RED WHT 1 GRYIYEL sv 72 m TET iN 1 51 3 14 GRY RED t CS1 3 14 estae 1 I z T EE FEDT oi EXT TI J HW L Lt rt f H cot LV SMI 51325 1 MAP sensor 2 ECM PCM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA While engine is running after being warmed up and Manifold absolute pressure sensor with throttle opening smaller than specification e Manifold absolute pressure sensor vacuum pas higher than 4 6 V manifold absolute pressure sen sage sor output voltage is detected for specified time ECM PCM with throttle opening larger than specification lower than 0 2 V manifold absolute pressure output volt age is detected for specified time 2 driving cycle detection logic DTC CONFIRMATION PROCEDURE
165. to step 2 to 8 of Interlock cable installation of the service manual men tioned in FOREWORD of this manual if necessary Confirm that brake key interlock system operates properly if equipped CO COCOm m FNZ 7 eO Shift the select mp lover with its button pushed in Shift the select gt lever without pushing its button AUTOMATIC TRANSMISSION 4 A T 781 47 INSPECTION Check select lever for smooth and clear cut movement and position indicator for correct indication For operation of select lever refer to left figure 781 48 AUTOMATIC TRANSMISSION 4 A T SELECT CABLE 1 Selector lever assembly 6 Washer TI Transmission range switch assembly 2 Selector lever assembly mounting 7 Clip 12 Transmission range switch mounting bolt 3 Selector cable 8 Manual select lever nut transmission range switch side 18 Manual select lever nui selector cable side 4 Cablebracket 9 Lockwasher 14 Selector cable 5 Cable bracket mounting bolt Manual select lever 9 ADJUSTMENT 1 Loosen manual shift lever select cable side nut 1 2 Shift select lever to N range 3 Align center line 2 on manual valve shaft 3 to N refer ence line 4 as shown 4 Tighten manual shift lever nut selector cable side 1 as specified torque Tightening torque Manu
166. to vehicle CAUTION Ensure that arrow on the SDM is pointing toward the front of the vehicle 3 Tighten SDM bolts to specified torque Tightening torque SDM bolt a 6 N m 0 6 kg m 4 5 Ib ft 4 Connect SDM connector 1 to SDM 2 securely 5 Install tuner assembly clock assembly 5 tuner pocket radio hole cover 4 etc and ashtray 3 6 Install center gamish panel 2 7 Install front and rear center console box 1 8 Connect negative cable to battery 9 Enable air bag system Refer to ENABLING AIR BAG SYS TEM in this section 108 62 AIR BAG SYSTEM Forward Sensor WARNING During service procedures be very careful when han dling a sensor Never strike or jar a sensor Under some circumstances it could cause improper operation of the air bag system A sensor and mount ing bracket bolts must be carefully torqued to assure proper operation REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system Refer to DISABLING AIR BAG SYSTEM in this section 3 Remove front grill referring to RONT BUMPER in Section 9 4 Disconnect forward sensor connector sliding connector outer 1 as shown 5 Remove forward sensor bolts 1 and forward sensor 2 from front panel 3 AIR BAG SYSTEM 108 63 INSPECTION CAUTION Never disassemble forward s
167. tool Refer to DTC CHECK condition at some place Is NO CODES displayed on Check the connector harness etc SUZUKI scan tool related to the sensed DTC Refer to INTERMITTENT AND POOR CONNECTIONS in this sec tion Then clear DTC Refer to DTC CLEARANCE and repeat this table 7 1 Check DTC using monitor cou Air bag system is in good An intermittent trouble has occurred pler Refer to DTC CHECK condition at some place Is flashing pattern no 12 indicated Check the connector harness etc on AIR BAG warning lamp related to the sensed DTC Refer to INTERMITTENT AND POOR CONNECTIONS in this sec tion Then clear DTC Refer to DTC CLEARANCE and repeat this table 8 Doyouhave SUZUKI scan tool Goto step 9 Goto step 10 9 1 Check DTC using SUZUKI scan Substitute known good Check and repair according to Flow tool Refer to DTC CHECK SDM and recheck Table corresponding to that DTC Is NO CODES displayed on SUZUKI scan tool 10 1 Check DTC using monitor cou Substitute a known good Check and repair according to Flow pler Refer to DTC CHECK SDM and recheck Table corresponding to that DTC Is flashing pattern no 12 indicated on AIR BAG warning lamp AIR BAG SYSTEM 108 11 DTC Check Using SUZUKI scan tool 1 Tum ignition switch to OFF position 2 After setting cartridge to SUZUKI scan tool connect it to data link connector DLC located on underside of instru m
168. tor diaphragm While doing so does fuel come out return hose ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 Table B 4 Idle Air Control System Inspection 121 WIRING DIAGRAM 3 lt gt E59 O52 IG METER BLKWHT 651 320 E122 7i a 22 BLA RED FSI BLU E61 9 card esce NP BLUIBLK os1 3 15 LJ C5134 6 51 1 5 2 2 3 B onu os1 117 fh Pure es 65115 C544 Win 05141 17 051 1 16 even with headlights turned ON T body 3 EMF 5 Man fuse 2 ide ar control valve 4 Sensed information 5 Main relay INSPECTION Step Action Yes No 1 Check engine idle speed and IAC duty Go to Step 2 Go to Step 3 referring to IDLE SPEED IAC DUTY INSPECTION in Section 6E2 Is idle speed IAC duty within specifica tion 2 engine idle speed kept specified speed System is in good condition Go to Step 3 6 1 122 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Step Action Yes No 3 Check IAC valve referring to VALVE Go to Step 4 TAC valve malfunction BLU INSPECTION in Section 6E2 BLK LT GRN BLK PPL Is check result as specified BLK GRY BLU or PPL YEL wire open or short poor coupler connection If all ab
169. trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected B1044 and 1048 AIR BAG SYSTEM 108 45 Step Action Yes No 1 7 With ignition switch OFF remove center pillar inner gamish of applicable side then disconnect seat belt pretensioner connec tor 2 Q11 or Q12 connector 3 nected at the step 1 With ignition switch ON is DTC B1044 or B1048 still current Check proper connection to applicable seat belt pretensioner at terminals in If OK then connect Special Tool B to seat belt pretensioner connector discon Go to step 2 Ignition switch OFF Replace seat belt preten sioner Refer to Section 10 1 With ignition switch OFF disconnect Spe Substitute a known cial Tool B and SDM 2 Measure voltage from Q01 12 or Q01 5 terminal to body ground With ignition switch ON is voltage 1 V or less good SDM and recheck DTC B1044 Repair short PNK or WHT wire circuit to power circuit DTC B1048 Repair short from BRN or LT GRN wire circuit to power circuit Fig for STEP 1 and 2 STEERING WHEEL 1 Prelensioner harness 108 46 AIR BAG SYSTEM Fig for STEP 2 For DTG B1044 For DTC B1048 1 Special tool A 09932 75020 B 09932 75010 NOTE Upon
170. values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal CONTENTS General Description Brake Drum 50 3 Drum Brake Assembly Wheel Cylinde 5C 5 Brake Back Plate Tightening Torque Specification 50 5 5C 7 On Vehicle Service Parking Brake Cable 5C 2 PARKING AND REAR BRAKE General Description Drum Brake Assembly The drum brake assembly has a self shoe clearance adjusting system so that drum to shoe clearance is main tained appropriate at all times Rear brake is a drum type It uses leading trailing operation when brake pedal is depressed and when parking brake is applied on level road It also uses duo servo operation when parking brake is applied on gradient road and load is applied in longitudi nal direction of vehicle NOTE Replace all components included in repair kits to service this drum brake Lubricate parts as speci fied WARNING If any hydraulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlubricated fasteners o5 1 Brake back plate 6 Adjuster lever 2 Brake shoe 7 Adjuster spring 32 Brake strut 3 Shoe retum upper spring 8 Shoe hold down spring V 79 tore Adjuster Shoe return lower spring E Shoe hold down pin W
171. vise b Connect battery to rear blower motor assembly 1 as shown c Check that there is smoothly operates and no noise d Check that ammeter indicates specified current If measure current is incorrect replace blower motor assembly Rear blower fan motor specified current at 12V 16 A maximum INSTALLATION Reverse removal procedure for installation 18 34 AIR CONDITIONING OPTIONAL Rear Blower Motor Relay and Solenoid Valve Relay INSPECTION 1 Disconnect negative cable at battery 2 Remove rear blower motor relay 1 and or solenoid valve relay 2 from vehicle 3 Check that there is no continuity between terminal c and d If there is continuity replace relay 4 Connect battery positive terminal to terminal a of relay 5 Connect battery negative terminal b of relay 6 Check continuity between terminal and d If there is no continuity when relay is connected to the bat tery replace relay Rear A C Main Switch REMOVAL 1 Remove rear console box 1 2 Remove front console box mounting screws 2 and clips 3 3 Disconnect console box wire coupler 4 Remove rear console box 4 5 Disconnect rear A C main switch connector 6 Remove A C main switch 5 from front console box 4 Mo L ML AIR CONDITIONING OPTIONAL 18 35 INSPEC
172. when none of the other codes is identified Fail Safe Table When any of the following DTCs is detected ECM PCM enters fail safe mode as long as malfunction continues to exist but that mode is canceled when ECM PCM detects normal condition after that ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 23 DTC NO TROUBLE AREA FAIL SAFE OPERATION Injector drive time fuel injection volume is determined according to P0100 throttle valve opening and engine speed No 33 34 SENSOR EGR valve stops Air flow of IAC valve is limited P0110 pm No 23 25 SENSOR Each control is performed on the basis of 22 1 C intake air temp Each control except 4 A T is performed on the basis of 29 9 C engine P0115 coolant temp No 14 15 SENSOR 4 A T control is performed assuming 31 C engine warmed up higher after 15 min from engine start Each control except 4 AT is performed on the basis of 124 5 throttle P0120 No 21 22 SENSOR valve opening 4 A T control is performed on the basis of 0 throttle valve opening P0460 FUEL LEVEL SENSOR Each control is performed in the basis of full fuel level VEHICLE SPEED num 20500 SENSOR Air flow of IAC valve is limited BAROMETRIC i P1450 SENSOR E2h control is performed based on 760 mmHg barometric pressure P0705 TR SWITCH ATT control is performed in priority order o
173. when removing and reinstalling 6A2 4 ENGINE MECHANICAL H27 ENGINE 8 Disconnect accelerator cable 1 and A T throttle cable 2 for A T vehicle from throttle body 9 Disconnect water hoses 3 from throttle body 10 Disconnect injector wire 1 coupler 11 Disconnect brake booster hose 2 from intake manifold 12 Disconnect couplers of TP sensor 1 and IAC valve 2 13 Disconnect earth terminal 3 from intake collector 14 Remove clamp bracket 4 from intake collector 15 Disconnect couplers from manifold absolute pressure MAP sensor EVAP canister purge valve earth terminal and EGR valve 16 Disconnect PCV hose from cylinder head cover Disconnect breather hoses from throttle body or cylinder head cover 17 Disconnect hoses of EVAP canister purge valve and heater 18 Remove EGR pipe EVAP canister purge valve EGR valve 1 POV hose 2 3 EGR pipe D 5 Water hose Breather hose Earth terminal coupler i EVAP canister purge valve hose i Heater hose ENGINE MECHANICAL H27 ENGINE 6A2 5 19 Disconnect hoses of heater EVAP canister fuel feed and fuel return Heater hose Fuel feed hose Fuel return hose EVAP canister hose 20 Remove throttle body 1 and intake collector 2 from intake manifold 3 21 Disconnect hoses of PCV valve and EVAP canister purge valve from i
174. 0 High pressure charge valve 18 6 AIR CONDITIONING OPTIONAL General Diagnosis Main A C system front A C system Condition Possible Cause Correction Cool air does not come out A C system does not operative No refrigerant Perform recover evacuation and charging Fuse blown Check IG METER REAR DEFG and A C fuses and check for short circuit to ground AIC switch faulty Check A C switch Blower motor switch faulty Check blower motor switch AIC evaporator temperature sensor A C evap orator thermistor faulty Check A C evaporator tempera ture sensor A C evaporator ther mistor Refrigerant dual pressure switch faulty Check refrigerant dual pressure switch Wiring or grounding faulty Repair as necessary ON permission signal in ECM faulty Check A C ON permission signal controller and its circuit faulty Check A C controller and its circuit Cool air does not come out A C com pressor does not operative won t rota tive Magnet clutch faulty Check magnet clutch Compressor relay faulty Check compressor thermal switch Compressor relay faulty Check compressor relay Drive belt loose or broken Adjust or replace drive belt Compressor faulty Check compressor ON permission signal in ECM faulty Check A C ON permission signal controll
175. 0 11 Ib 17 64 1 76 oz Check system for refrigerant leaks and refrigerant charging quantity Performance test 18 20 AIR CONDITIONING OPTIONAL Recovery NOTE When discharging refrigerant out of A C system always recover it by using refrigerant recovery and recycling equipment 1 Discharging it into atmo sphere would cause adverse effect to environments When handling recovery and recycling equipment be sure to follow the instruction manual for the equip ment AIR CONDITIONING OPTIONAL 18 21 Evacuating Evacuating procedure CAUTION Do not evacuate before recovering refrigerant in system NOTE Whenever opened exposed to atmospheric air air con ditioning system must be evacuated by using a vacuum pump The A C system should be attached with a mani fold gauge set and should be evacuated for approx 20 minutes 1 Connect high charging hose 1 and low charging hose 2 of manifold gauge set 3 respectively as follows High Charging Hose 1 High pressure charging valve 4 on Discharge Hose Low Charging Hose 2 Low pressure charging valve 5 on Suction Pipe 2 Attach center charging hose 6 of manifold gauge set 3 to vacuum pump 7 3 Operate vacuum pump 7 and then open discharge side valve 9 Hi of manifold gauge set 3 If there is no blockage in the system there will be an indica tion on high pressur
176. 0 1V turning steering wheel to the right or left as far as it stops ignition switch ON Transfer lever ery AWD low range 51 1 26 4WD low switch diary ignition switch ON Transfer lever 4H or 2H range Ignition switch ON selector lever Transmission range switch L L range C51 1 27 AIT vehicle ERO Ignition switch ON selector lever Other than L range Ignition switch ON selector lever e Pane 10 14V Transmission range switch 2 2 range C51 1 28 i AT vehicle PEEN ignition switch ON selector lever Other than 2 range ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 41 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C512 1 Fuelinjector No 2 FEM C51 2 2 Fuel injector 10 14V Ignition switch ON C5123 Heater of HO2S 1 bank 1 10210 sien ON 7 C5124 At specified idle speed after engine if equipped 0 2 warmed up 10 14V Ignition switch ON Heater of HO2S 1 bank 2 anon Swe 51 25 At specified idle speed after engine if equipped 0 2V warmed up C5126 C5127 Ground C518 Fuel injector No 4 prx C512 Fuel injector No 10 14V Ignition switch ON C512 12 ECR valve stepper motor coil 4 nV it equipped Be Gd FoR wae epar motor coil 3 EI i Ignition switch ON ECR valve stepper motor 2 it equipped EGR v
177. 03 mm 0 0984 0 0985 in 2 502 2 506 mm Yellow 0 0985 0 0986 in Bus 2 505 2 509 mm 0 0986 0 0987 in Pink 2 508 2 512 mm 0 0987 0 0988 in 1 Paint 4 From number stamped on crank webs at its center and alphabets stamped on crankcase lower side determine new standard bearing to be installed to journal by referring to table shown below For example if number stamped on crank webs is 1 and alphabet stamped on crankcase is B install a new standard bearing painted in Black to its journal New standard size bearing specification Number stamped on crank web Journal diameter 1 2 3 Alphabet stamped A Black Colorless Yellow on lower crankcase B Colorless Yellow Blue Cap bore dia C Yellow Blue Pink 5 Using gaging plastic check bearing clearance with newly selected standard bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance 6 When replacing crankshaft or cylinder block and crank case due to any reason select new standard bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new crankcase lower side 6A2 34 ENGINE MECHANICAL H27 ENGINE UNDERSIZE BEARING 0 25 mm 0 25 mm undersize bearing is available in 5 kinds varying in thickness To distinguish them each bearing is painted i
178. 1 and 3 Contact for stop lamp FREE 2 Continuity PUSH 1 No continuity Between terminals 2 and 4 Contact for brake pedal position FREE 2 No continuity PUSH 1 Continuity 4 Install stop lamp switch and adjust its position referring to Section 5 CRUISE CONTROL SYSTEM 8E 23 Cruise Control Actuator Assembly with Con trol Module CAUTION Never disassemble cruise control actuator assembly Disassembly will spoil its original function REMOVAL 1 Disconnect negative cable at battery 2 Disconnect connector from actuator assembly 2 with con trol module 3 Remove actuator cap 1 from actuator assembly 2 4 Disconnect cruise cable 3 from actuator assembly 2 5 Remove actuator assembly 2 from vehicle INSPECTION Move actuator lever 1 by hand and check its operation as described below 1 Actuator lever 1 should not tum clockwise 2 Actuator lever 1 should turn smoothly by about 1 3 rotation counterclockwise and contact internal stopper 3 When hand is taken off from actuator lever 1 at the position in 2 above it should return to its original position 2 by return spring force If actuator lever 1 does not operate as described above replace it INSTALLATION Install actuator assembly by reversing removal procedure noting the following point Adjust cruise cable play to specification referring to CR
179. 1 Check MAP sensor for performance refer EGR valve malfunction ring to Section 6E2 If all above are OK inter Is check result satisfactory mittent trouble or faulty ECM PCM Check for intermittent referring to INTERMIT TENT AND POOR CON NECTION in Section 6 1 92 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0403 DTC No 51 Exhaust Gas Recirculation Circuit Malfunction WIRING DIAGRAM 59 c52 BLKWHT 51 320 lomerer n Exod neo Ly T E59 _ c52 51 3415 om m BLU e619 LT GRN d 51 215 a LT GRNIWHT 51 2 14 LT GRNYEL 051 2 13 z SUT GANRED 61081242 051 215 51 2414 51 2 13 m zs N SE i AVANI NNI W esto Twas 2 Main lay EGR val DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA High voltage is detected at EGR valve stepping motor _ EGR valve stepping motor or its circuit electrical circuit for specified time continuously PCM Circuit open or short DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following condition is satisfied when using this DTC CONFIRMATION PRO CEDURE
180. 1 With ignition switch OFF disconnect Special Tool B Ignition switch OFF Ignition switch OFF then reconnect contact coil connector located near Replace contact coil Replace driver air the base of the steering column assembly Referto bag inflator module 2 Remove driver air bag inflator module from steering COMBINATION Refer to DRIVER wheel Refer to DRIVER AIR BAG INFLATOR SWITCH CON AIR BAG INFLA MODULE in Section 3C1 TACTCOILAND TOR MODULE in 3 Check proper connection to driver air bag inflator COMBINATION Section 3C1 module at terminals in 005 connector SWITCH ASSEM 4 If OK then connect Special Tool B to Q05 connec BLY in Section tor 3C1 With ignition switch ON is DTC B1025 current A Fig for STEP 1 and 2 B Fig for STEP 2 C Fig for STEP 3 a ul BASE OF COLUMN Special tool A 09932 75020 B 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected AIR BAG SYSTEM 108 33 DTC B1031 Power Source Voltage High DTC B1032 Power Source Voltage Low WIRING DIAGRAM 2 BLK 991 17 69 Fa
181. 1019 Passenger Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM ci mize es a oor ie Wm 3 RI FE Shoring bar T From main fase 3 AIRBAG fase 5 Passenger air bag inflaton module 18 Airbag hamess 2 Ignition switch 4 SDM 6 Ground for air bag system CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adaptor from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 va
182. 2400 COAST SET switch ON rotated RESUME ACCEL No continuity RESUME ACCEL switch OFF switch released 820 1000 RESUME ACCEL switch ON rotated 132 9 E132 11 Clutch pedal position No continuity Clutch pedal released position switch only M T Switch M T only Continuity Clutch pedal depressed fully 132 9 E132 11 Transmission range Continuity Selector lever in or range A T switch Park neutral No continuity Selector lever in R D 2 or L range CRUISE CONTROL SYSTEM 8E 19 Cruise Cable Play Inspection and Adjustment INSPECTION AND ADJUSTMENT 1 Remove actuator cap 2 With actuator lever 1 returned at original position 2 Where lever does not move clockwise any further check cruise cable for play If itis out of specification adjust it as follows Cruise Cable play a 1 2mm 0 04 0 08 in 3 Loosen cable lock nut 3 4 Adjust cable play to specified value by tuming adjusting nut 4 5 Tighten lock nut 3 securely after adjustment On Vehicle Service Cruise Main Switch REMOVAL 1 Disconnect negative cable at battery 2 Remove meter cluster hood 1 by removing its mounting screws 2 3 Remove cruise main switch 3 from instrument panel 4 Disconnect connector from cruise main switch 3 INSPECTION 1 Check for resistance between IG and LOAD terminals If c
183. 29 EGR VALVE This parameter indicates opening rate of EGR valve which controls the amount of EGR flow A C SWITCH ON OFF ON Command for operation being output from A C amplifier to compressor OFF Command for operation not being output PSP SWITCH ON OFF ON PSP switch detects P S operation high P S pressure OFF PSP switch not detects P S operation PNP SIGNAL Transmission Range Switch P N or D range Whether the transmission range switch P N position switch at P or range or at R D 2 or L range is displayed If at P or N range P N range is displayed and if at D 2 or L range D range is displayed FUEL TANK LEVEL This parameter indicates approximate fuel level in the fuel tank As the detectable range of the fuel level sensor is set as 0 to 100 however with some models whose fuel tank capacity is smaller the indicated fuel level may be only 70 even when the fuel tank is full ELECTRIC LOAD ON OFF ON Small light switch ON or rear window defogger switch ON OFF Small light switch OFF and rear window defogger switch OFF VSS 4 A T km h MPH It is computed by using pulse signals from vehicle speed sensor on 4 speed automatic transmission THROT POS LEVEL Throttle Position Level For 4 A T 0 1 2 3 4 5 6 or 7 This parameter indicates which level zone the throttle valve opening is in The throttle opening is divided into 8 level
184. 3 To combination switch GRNRED 9 AT vehicle ony WHIBLK S To combination switch 10 To air bag SDM BLU 10 ECT sensor YELWHT 10 To ignition switch BLURED T1 To main fuse WHT BLU 11 To fuel level gauge BLUNT 12 To fuse box WHT 12 To ground BLUNEL 18 To combination switch RED 18 combination switch GRNIYEL 14 To immobilizer control module PPL equipped 18 To POM for AIT vehicle PPUYEL 16 To POM for vehicle ORNIBLK 8C 4 INSTRUMENTATION DRIVER INFORMATION On vehicle Service Fuel Meter Fuel Gauge Unit Fuel level sensor sender gauge INSPECTION Remove fuel pump assembly referring to Section 6C Use an ohmmeter to confirm that resistance of sender gauge unit changes with change of float position If measured value is out of specification replace fuel sender gauge Fuel level sensor specification Float Position Resistance 0 53 6 mm 8 2 11 p 143 1 mm 28 36 5 63 in 1 256 9 mm 90 100 10 11 in Fuel pump assembly Fuel level gauge terminal i Fuel level gauge 1 terminal Float INSTRUMENTATION DRIVER INFORMATION 8 5 Engine Coolant Temperature ECT Meter and Sensor Engine coolant temperature sensor REMOVAL AND INSTALLATION Refer to ECT SENSOR in Section 6E2 Oil Pressure Light Oil pressure switch REMOVAL AND INS
185. 4 Fuelinjector No 6 EE 51 2 22 C51 9 4 Fuelinjector No 5 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 43 Table 1 Malfunction Indicator Lamp Circuit Check Lamp Does Not Come ON or Dims at Ignition Switch ON But Engine at Stop WIRING DIAGRAM leuETER ones peu 2 faro awir PPUYEL Spas erue 4 ee E61 29 3 veL hs H waristu _ ples E59 c52 te p padro bror Suv se BU WT 5 320 eers T E122 051 27 Denon Ep oec aw E619 P a freue oss osia Deuconn 1 E617 C513 65 34 051315 65127 SWZ 1 0 Soon S iter i 6 Monitor connector if equipped CIRCUIT DESCRIPTION When the ignition switch is tumed ON ECM causes the main relay to turn ON close the contact point Then ECM being supplied with the main power tums ON the malfunction indicator lamp MIL When the engine starts to run and no malfunction is detected in the system MIL goes OFF but if a malfunction was or is detected MIL remains ON even when the engine is running INSPECTION Step Action Yes No 1 MIL power supply check Go to Step 2 IG METER fuse blown 1 Tum ignition switch ON main fuse blown Ignition Do other indicator waming lights in combination Switch malfunction BLK meter comes ON
186. 42 Camshaft Position Sensor Circuit Malfunctio DTC P0400 Exhaust Gas Recirculation Flow Malfunction 6 1 89 DTC P0403 DTC No 51 Exhaust Gas Recirculation Circuit Malfunction DTC P0420 Catalyst System Efficiency Below Threshold Bank 1 DTC P0430 Catalyst System Efficiency Below Threshold Bank 2 DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction Evap canister purge system inspection Vacuum passage inspectior Vacuum hose inspection Evap canister purge valve and its circuit inspection Evap canister purge valve inspection DTC P0460 Fuel Level Sensor Circuit High Input DTC P0500 DTC No 24 Vehicle Speed Sensor Malfunctio DTC P0505 Idle Air Control System Malfunction DTC P0601 lo Module Memory Check Sum Error DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction DTC P1450 P1451 Barometric Pressure Sensor Circuit Malfunction Performance Problem 6 1 113 P1500 Engine Starter Signal Circuit Malfunction DTC P1510 Ecm Back Up Power Supply Malfunction Table B 1 Fuel Pump Circuit Inspection Table B 2 Fuel Injectors and Circuit Inspection Table B 3 Fuel Pressure Inspection Table B 4 Idle Air Control System Inspection Table B 5 A C Signal Circuits Inspection If Equipped Table B 6 A C Condenser Fan Motor Relay Control System Inspection If Equipped Special Tool 6 1 92 n 6 1 94 6 1 105
187. 43 powertrain control module PCM 6E2 31 Emission Control Syste 6E2 44 Mass air flow sensor MAF 6E2 32 EGR system if equipped 6E2 44 Intake air temperature IAT sensor 6E2 34 EVAP canister 6E2 45 Throttle position sensor TP sensor 6E2 35 Vacuum passage 6E2 46 Engine coolant temperature sensor PCV System 6E2 47 ECT sensor 6E2 36 PCV hose 6E2 47 Heated oxygen sensor sensor 1 6 2 37 PCV valve 6E2 47 Heated oxygen sensor sensor 2 6 2 38 PCV system 6E2 48 Vehicle speed sensor VSS 6E2 39 Tightening Torque Specification 6E2 48 Manifold absolute pressure sensor 6E2 39 Special 6E2 48 Fuel level sensor sender gauge 6E2 41 Crankshaft position sensor 6E2 41 General Description The engine and emission control system has 4 major sub systems air intake system fuel delivery system elec tronic control system and emission control system Air intake system includes air cleaner mass air flow sensor throttle body idle air control valve and intake man ifold Fuel delivery system includes fuel pump delivery pipe fuel pressure regulator fuel injectors etc Electronic control system includes ECM PCM various sensors and controlled devices Emission control system includes EGR EVAP and PCV systems x
188. 5 cs1 3 22 C51246 EA 1 HOZS heater relay 2 ECM PCM 3 HO28 2 Banket DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when any one of following conditions is detected 2 driving HO2S 2 its circuit cycle detection logic Fuel system 4 5 V or more HO2S circuit voltage is detected when 5 V power is con PCM nected to HO2S circuit in ECM PCM While running with A F feed back average output voltage during speci fied time is too high or too low or While running with A F feed back max output voltage during specified time is lower than specified value or min output voltage during speci fied time is higher than specified value DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road of a traffic acci 6 1 64 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Conne
189. 68310 C 09913 75510 1 Differential carrier Differential case 1 After applying differential oil to differential gear 4 pinions 6 pinion shafts 6 thrust washer 2 and spring washer 1 install them in differential right case 3 For correct installing direction of thrust washer 2 and spring washer 1 refer to the figure 2 When installing pinion shaft No 2 2 shorter into differential case and pinion insert its side into pinion joint 1 NOTE a is longer than b gt b 3 Check differential pinion gear 1 for smooth rotation DIFFERENTIAL REAR 7F 11 4 In the same manner as described in Step 1 install thrust washer 2 spring washer 1 and differential gear 4 3 Diferential laf case 5 Diferential pinion 5 Install differential left case 1 and then tighten screws to specified torque A Cement 99000 32110 Tightening torque Differential case screw a 9 N m 0 9 kg m 6 5 Ib ft 3 Differential right 6 Clean and degrease mating surface of drive bevel gear hypoid gear 1 7 Apply thread lock cement to hatched part of drive bevel gear 1 as shown in the figure A Cement 99000 32110 8 Put drive bevel gear 3 on differential case 1 and fasten them with bolts 2 by tightening them to specified torque Use thread lock cement for bolts 2 CAUTION
190. 7 40 35 21 7 7 17 25 22 13 4 GEAR SHIFT DIAGRAM A AND TCC LOCK UP DIAGRAM 1 3 4 400 E sol 1 M 150 km h L L 1 L 1 L 1 1 5 50 39 mem od Vehicle speed 400 sob fi 50 L 1 1 1 5 50 T00 iem Vehicle speed AUTOMATIC TRANSMISSION 4 7B1 7 Diagno This vehicle is equipped with an electronic transmission control system which control the automatic shift up and shift down timing TCC operation etc suitably to vehicle driving conditions PCM ECM has an On Board Diagnosis system which detects a malfunction in this system and abnormality of those parts that influence the engine exhaust emission When diagnosing a trouble in the transmission including this system be sure to have full understanding of the outline of ON BOARD DIAGNOSTIC SYSTEM and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diagnosis according to AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE to obtain correct result smoothly C Vlas CHECK ENGINE Y On Board Diagnostic System Vehicle without monitor connector For automatic transmission control system PCM ECM has fol lowing functions Refer to Section 6 1 for details When the ignition switch is turned ON with the engine at a stop malfunction indicator lamp MIL 1 turns ON to check
191. 7 55 Manual selector assembly bolts 18 18 185 Transmission to engine bolts and nuts 85 85 615 Engine rear mounting bolts 50 50 36 5 Engine rear mounting member bolts Universal joint flange bolts and nuts 50 5 0 365 Torque converter mounting bolts 65 65 470 Adapter case or extension case bolts 42 42 30 0 Transmission range switch lock bolt 55 0 55 40 Oil pipe union bolts 35 35 225 Drive plate bolts 78 78 56 5 Interlock cable clamp screw 22 022 15 Interlock cable outer mounting nut 18 13 95 AUTOMATIC TRANSMISSION 4 781 61 Special Tool 09925 37811 001 09931 76030 09931 76011 Oil pressure gauge 16 14 pin DLC cable for Mass storage cartridge for Tech 1A kit SUZUKI scan Tech 1A Tech 1A tool See NOTE A 09940 53111 Bearing installer Tech 2 kit SUZUKI scan tool See NOTE NOTE A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Suzuki scan tool 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter 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 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 781 62 AUTOMATIC TRANSMISSION 4 A T
192. 8 BODY SERVICE Seat Second Seat d s 0 35 Nm 8 5 ka ra U Head restraint 6 Rod 3i Seatadjster cover 36 Rod belt f equipped 2 Head restraint guide 7 Seat reclining assembly cover 12 Cover V Tena orae 3 Seat back 8 Seatcushion 38 Adjuster extension bracket 4 Tether anchor hook 9 Aduster handie back side 14 Adjster handle front side 5 Seat reclining assembly 10 Seat adjuster 18 Second seat mounting bolt REMOVAL 1 Remove adjuster extension cover 2 Remove adjuster extension bracket 3 Remove front and rear adjuster inside covers 4 Remove adjuster outside covers 5 Remove second seat mounting bolts 6 Disassemble and repair seat as necessary INSTALLATION Reverse removal procedure to install rear seat noting the following instruction Tighten second seat mounting bolts as specified torque Third Seat If Equipped BODY SERVICE 9 9 1o 8 35 Nm 3 5 kg m Head restraint Reclining supporter 9 reina terme 2 Head restraint guide 7 Seat reclining assembly 3 Seatback Seat reclining assembly cover 4 Sealrecining knob 9 Seat cushion 5 Seat reclining rod 10 Third seat mounting bolt REMOVAL 1 Raise the front portion of seat cushion to remove rear seat cushion 2 Remove 6 mounting bolts to remove seat back 3 Disassemble and repair seat if necessary INSTALLATION Reverse
193. A NOTE For vehicle with monitor connector DTC will set when following only mark condition is detected DTC DETECTING CONDITION TROUBLE AREA Any one of the following conditions are detected in idle state while running HO2S 1 or its circuit under driving conditions described for DTC CONFIRMATION PROCEDURE Fuel system 4 5 V or more HO2S circuit voltage is detected when 5 V power is con PCM nected to HO2S circuit in ECM PCM or Max output voltage of HO2S is 0 6 V or lower on average and its minimum voltage on average is 0 3 V or lower Min output voltage of HO2S is over 3 0 V or Max output voltage of HO2S is 0 74 V or higher on average and its min voltage on average is 0 33 V or higher Output voltage of HO2S 1 does not exceed 0 45 V for specified time 2 driving cycle detection logic 6 1 68 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F A
194. A C ON signal circuit and idle air control sys tem ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 17 Idle mixture inspection adjustment vehicle without heated oxygen sensor All vehicles not equipped with heated oxygen sensor are shipped with their CO factory adjusted as follows Engine idle mixture CO 0 8 1 3 at specified idle speed Idle mixture adjustment should never be changed from the origi nal factory setting However if during diagnosis the check indi cates idle mixture to be the cause of a driver performance complaint or emission failure the idle mixture can be adjusted using the following procedures NOTE For this inspection and adjustment exhaust gas tester CO meter and engine tachometer are necessary 1 Check idle speed according to Idle Speed Idle Air Control Duty Inspection in this section 2 Using exhaust gas tester check that idle mixture CO is within above specification If it is out of specification adjust it to specification by turning resistor knob 1 3 If idle mixture has been adjusted confirm that idle speed is within specification 62 18 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE Air Intake System Throttle body body 4 Water hose 2 Intake collector 5 sensor 3 Breatherhose TP sensor
195. ABS hydraulic unit control module assembly do not disconnect connectors of sensors and turn ignition switch ON Then DTC will be set in ABS control mod ule ABS Hydraulic Unit Operation Check Using SUZUKI Scan Tool 1 Connect SUZUKI scan tool to data link connector DLC 1 with ignition switch OFF Special tool A SUZUKI scan tool 2 Tum ignition switch to ON position and check actuator opera tion using HYDRAULIC CONTROL TEST under miscella neous test MISC TEST mode of SUZUKI scan tool ABS Hydraulic Unit Operation Check Not Using Suzuki Scan Tool 1 Check that basic brake system other than ABS is in good condition 2 Check that battery voltage is 11V or higher 3 With ABS warning lamp check that no abnormality is detected in ABS Refer to DIAGNOSTIC TROUBLE CODE DTC CHECK in this section 4 Lift up vehicle 5 Set transmission to neutral and release parking brake 6 Tum each wheel gradually by hand to check if brake drag ging occurs If it does correct 7 With diag switch terminal 2 of diagnosis connector 1 con nected to ground by using service wire 4 turn ignition Switch to ON position and check that ABS warning lamp indicates normal DTC DTC 12 referring to DIAGNOSTIC TROUBLE CODE DTC TABLE in this section 8 Tum ignition switch to OFF position 52 30 ANTILOCK BRAKE SYSTEM ABS 9 Perform following checks with he
196. AGRAM glo ORNIBLK 651 32 051 324 M N A NM IM mI Z Tombmal ET maar 3 EO DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the conditions are detected for 5 sec continu ECT sensor circuit ously ECT sensor Low engine coolant temperature high voltage high ECM PCM resistance High engine coolant temperature low voltage low resistance DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 10 sec or more 3 Check DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 53 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 Check ECT sensor and its circuit Go to Step 3 Intermittent trouble 1 Connect scan tool with ignition switch OFF Check for intermittent 2
197. AND REAR BRAKE ANTILOCK BRAKE SYSTEM ABS 5E2 1 SECTION 5E2 ANTILOCK BRAKE SYSTEM ABS WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 For the descriptions items not found in this section refer to Section 5E1 of the Service Manual mentioned in the FOREWORD of this manual All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and
198. Action Yes No connector With ignition switch ON is DTC B1032 current 3 1 With ignition switch OFF reconnect SDM __ Substitute a known good SDM and recheck Check Charging System and repair as necessary Refer to DI Section 6H IAGNOSIS in Fig for STEP 2 NOTE Special tool A 09932 75020 Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected 10B 36 AIR BAG SYSTEM DTC B1035 RH Forward Sensor Circuit Open or Short to Ground DTC B1036 RH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit DTC B1037 LH Forward Sensor Circuit Open or Short to Ground DTC B1038 LH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit WIRING DIAGRAM oor er 1 ORN GRN ORN GRN ORN GRN HL YEUGRN H YEL GRN M xm DD f I 2 EJ T Airbag harness 2 RH Forward sensor 3 LH Forward sensor 3 S0M CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table
199. B 09915 77420 2 Check each connection for fluid leakage and bleed air Refer to AIR BLEEDING PROCEDURE in this section PIS fd reservoir Attachment Gasket Union boit High pressure side Low pressure side 3 With engine idling turn steering wheel and warm up engine till temperature of fluid in P S fluid reservoir rises to 50 60 C 122 140 F 4 Check back pressure by measuring hydraulic pressure with engine idling and hands off steering wheel When back pressure is higher than specified values check control valve and piping for clogging Back pressure Lower than 1000 kPa 10 kg cm 142 psi 1 PIS fud reservoir 4 PIS gear box 2 Gauge valve open 5 High pressure side 3 PIS pump Low pressure side 381 4 POWER STEERING P S SYSTEM 5 Check relief pressure a Increase engine speed to about 1500 r min rpm Close gauge valve gradually while watching pressure increase indicated by gauge and take reading of relief pressure maximum hydraulic pressure When it is higher than specified values possible cause is malfunction of relief valve When it is lower than specified values possible cause is either failure of P S pump or settling of relief valve spring Relief pressure when gauge valve is closed 7650 8350 kPa 76 5 83 5 kg cm 1088 1187 psi CAUTION Be sure not to close gauge valve for longer
200. BLE 1 Tum ignition switch OFF 2 Disconnect TP sensor connector 3 Check for proper connection to TP sensor at each terminal 4 If OK check TP sensor for resistance referring to TP SENSOR in Section 6E2 Is check result satisfactory RED RED GRN or GRY YEL circuit If wire and connection are OK substitute a known good ECM PCM and recheck in this section 2 5 there a DTC related to TP sensor DTC P0120 Go to applicable DTC Go to Step 3 Diag Flow Table 3 you have SUZUKI scan tool Go to Step 4 Go to Step 5 4 Check TP sensor and its circuit using SUZUKI Substitute a known good Go to Step 6 scan tool ECM PCM and recheck 1 Tum ignition switch OFF and connect SUZUKI scan tool to DLC 2 Tum ignition switch ON and check TP sensor output voltage when throttle valve is at idle posi tion and fully opened Does voltage vary within specified value linearly as shown in the figure 5 Check TP sensor and its circuit not using SUZUKI If voltmeter was used Go to Step 6 scan tool check terminal C51 3 9 for 1 Tum ignition switch ON poor connection 2 Check voltage at terminal C51 3 9 of ECM con If OK substitute a known nector connected when throttle valve is at idle good PCM and position and fully opened recheck Does voltage vary within specified value linearly as shown in the figure 6 Check TP sensor High resistance in GRY
201. CKP sensor and circuit resistance check Go to Step 4 Go to Step 3 1 With ignition switch OFF disconnect ECM PCM coupler C51 2 2 Check for proper connection to ECM PCM at C51 2 19 and C51 2 20 terminals 3 If OK check resistance of followings CKP sensor resistance between C51 2 19 and C51 2 20 terminals 484 656 Q at 20 C 68 F CKP sensor resistance between each terminal and ground 1 or more Is check result satisfactory 3 sensor resistance check Faulty NHT BLU wire Faulty sensor 1 With ignition switch OFF disconnect sen or ORN BLU wire sor coupler 2 Check resistance between terminals of CKP sensor coupler See Fig Were measured resistance values as specified in Step 2 4 CKP sensor visual inspection Intermittent trouble Replace or reinstall Check visually sensor and signal rotor for the faulty PCM followings See Fig Recheck for intermit Damage tent referring to No foreign material attached INTERMITTENT AND Correct installation POOR CONNEC Are they in good condition TION in Section 0A A Fig for Step 3 B Fig for Step 4 1 Sensor plate 6 1 86 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0340 DTC No 42 Camshaft Position Sensor Circuit Malfunction WIRING DIAGRAM 2 BLU BLK 3 1 sv os t t rer
202. CM PCM has an On Board Diagnostic system which detects a malfunction in this system and abnormality of those parts that influ ence the engine exhaust emission When diagnosing engine troubles be sure to have full understanding of the outline of ON BOARD DIAGNOSTIC SYSTEM and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diagnosis according to ENGINE DIAGNOSTIC FLOW TABLE in this section There is a close relationship between the engine mechanical engine cooling system ignition system exhaust system etc and the engine and emission control system in their structure and operation In case of an engine trouble even when the malfunction indicator lamp MIL doesn t tum ON it should be diagnosed according to ENGINE DIAGNOSTIC FLOW TABLE in this section On Board Diagnostic System Vehicle without Monitor Connector ECM PCM in this vehicle has following functions ENGINE detection data When the igniti n switch is tumed ON with the engine at a stop malfunction indicator lamp MIL 1 turns ON to check the bulb of the malfunction indicator lamp 1 KC When ECM detects a malfunction which gives an adverse effect to vehicle emission while the engine is running it makes the malfunction indicator lamp 1 in the meter cluster of the instrument panel tum ON or flash flashing only when CHECK detecting a misfire which can caus
203. CONFIRMATION PROCEDURE Intake air temp at start 8 60 C 18 140 F Engine coolant temp at start 8 95 C 18 203 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Intake air temp 8 C 18 F or higher Engine coolant temp 110 C 230 F or lower 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and warm up engine completely 3 Increase vehicle speed to 50 60 km h 30 40 mph 4 Keep driving above vehicle speed for 3 min or more 5 Stop vehicle and check pending DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 79 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 lsthere DTC s other than 0174 Goto applicable DTC Go to Step 3 P0175 FLOW TABLE 3 Checkintake system and exhaust system for to Step 4 Repair or replace leakage Are intake system and exhaust system in good condition 4 _ Check fuel pressure referring to TABLE B 3 in to Step 5 Repair or replace this section Is check result satisfactory 5 Check fuel injectors referring to FUEL INJEC to Step 6 Faulty injector s TOR INSPECTION in Section 6E2 Is ch
204. CONTENTS On Vehicle Service 3D 1 Tightening Torque Specification Suspension Control Arm Bushings 30 2 On Vehicle Service Suspension Control Arm Bushings INSTALLATION For the details refer to the same item of the same section in the Service Manual mentioned in the FOREWORD of this manual noting following point Install control arm to chassis Tighten suspension arm nuts to specified torque after lower ing hoist and vehicle in non loaded condition Tightening torque Front suspension arm nut a 85 N m 8 5 kg m 61 5 Ib ft Front suspension arm nut b 100 N m 10 0 kg m 72 5 Ib ft NOTE Don t reuse front suspension arm nut b 30 2 FRONT SUSPENSION Tightening Torque Specification 5 95 Nm 0 300Nm m te Nm 55Nm i E 55Nm pa ili i 85Nm SW 100Nm REAR SUSPENSION 3E 1 SECTION 3E REAR SUSPENSION NOTE For the descriptions items not found in this section refer to the same section of the Service Man ual mentioned in the FOREWORD of this manual All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same p
205. CYLINDER General Description Master Cylinder Assembly The master cylinder has two pistons and three piston cups Its hydraulic pressure is produced in the primary a in the figure below and secondary b chambers The hydraulic pressure produced in the primary chamber a acts on the rear wheel brakes Also the hydraulic pressure produced in secondary chamber b acts on the front wheel brakes WARNING Brake master cylinder cannot be disassembled When anything faulty is found in it it must be replaced as an assembly CAUTION Brake master cylinder cannot be disassembled in principle Should primary piston have come off from cylinder while dismounting or handling it wash it in the same specified fluid as that in reservoir and place it back in cylinder 1 Piston cup 4 Sleeve 7 Secondary piston return spring 2 Primary piston 5 Ring guide 8 Oring 3 Secondary piston 6 Primary piston return spring Master cylinder body BRAKES PIPE HOSE MASTER CYLINDER 5A 3 On Vehicle Service Front Brake Hose Pipe REMOVAL 1 Raise and suitably support vehicle Remove tire and wheel This operation is not necessary when removing pipes connecting master cylinder and flexible hose 2 Clean dirt and foreign material from both hose end or pipe end fittings Remove brake hose or pipe INSTALLATION 1 Reverse removal procedure for brake hose and pipe installation proce
206. Check if pending DTC exists by using scan tool If not check if oxygen sensor monitoring test has completed by using scan tool If not in both of above checks i e no pending DTC and oxygen sensor monitoring test not completed check vehicle condition environmental and repeat step 3 through 6 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE in this sec tion 2 25 1 output voltage check Go to Step 4 Go to Step 3 1 Connect scan tool to DLC with ignition switch OFF 2 Warm up engine to normal operating temperature and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously to enrich A F mixture and take foot off from pedal to enlean and check HO2S output voltage displayed on scan tool See Fig Is over 0 6 V and below 0 3 V indicated 3 HO28 check RED or GRY HO28 1 1 With ignition switch OFF disconnect HO2S 1 connec YEL circuit open or tor short 2 Check for proper connection to HO2S 1 at each termi If wire and connec nal tions are OK sub 3 If OK connect voltmeter 1 and 2 terminal of HO2S 1 stitute a known connector good ECM PCM 4 Start engine and check voltmeter while repeating rac and recheck ing engine Is over 0 6 V and below 0 3 V indicated 6 1 60 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGIN
207. Code DTC The AIR BAG DIAGNOSTIC SYSTEM CHECK must always be the starting point of any air bag system diagno sis The AIR BAG DIAGNOSTIC SYSTEM CHECK checks for proper AIR BAG warning lamp operation and checks for air bag diagnostic trouble codes DTCs 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 TOOLS 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 Connector Test Adapter Kit and the Digital Multimeter Special tool A 09932 75020 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 The adapter will also give an idea of whether contact tension is sufficient helping to find
208. Crankpin and connecting rod bear ing inspection in Section 6A2 Worn crankpin Crankpin and connecting rod bear ing inspection in Section 6A2 Loose connecting rod nuts Connecting rod installation in Sec tion 6A2 Low oil pressure Refer to LOW OIL PRESSURE of this table Wom crankshaft journal bearing Crankshaft and bearing inspection in Section 6A2 Worn crankshaft journal Crankshaft and bearing inspection in Section 6A2 Loose lower crankcase bearing cap bolts Crankshaft installation in Section 6A2 Excessive crankshaft thrust play Crankshaft inspection in Section 6A2 6 1 36 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Inspection of PCM ECM and its Circuits PCM ECM and its circuits can be checked at PCM ECM wiring couplers by measuring voltage and resistance CAUTION PCM ECM cannot be checked by itself It is strictly pro hibited to connect voltmeter or ohmmeter to PCM ECM with couplers disconnected from it VOLTAGE CHECK 1 Remove PCM ECM cover from bracket referring to PCM ECM REMOVAL 2 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 61 321 STZ ANI SCRE 564 zsjez es
209. D 7B1 20 Diagnosis 7B1 7 On Board Diagnostic System Vehicle without monitor connector On Board Diagnostic System Vehicle with monitor connector Precaution in Diagnosing Trouble Automatic Transmission Diagnostic Flow Table Malfunction Indicator Lamp MIL Check O D OFF Lamp Check POWER Lamp Check Diagnostic Trouble Code DTC Check Diagnostic Trouble Code Clearance Diagnostic Trouble Code Tabl Fail Safe Table Visual Inspection AIT Basic Check Trouble Diagnosis Table 1 Trouble Diagnosis Table 2 Trouble Diagnosis Table 3 Scan Tool Data Inspection of PCM and Its Circuit 7B1 7 7B1 8 7B1 9 7B1 10 7B1 13 7B1 13 7B1 13 7B1 13 7B1 13 7B1 14 7B1 14 7B1 14 7B1 14 7B1 15 7B1 15 7B1 16 7B1 17 7B1 17 Table B 1 O D OFF Light Circuit Check O D OFF Light Doesn t Light at Ignition Switch ON But Engine Starts Up 7B1 22 Table B 2 O D OFF Light Circuit Check O D OFF Light Comes ON Steadily 7B1 23 Table B 3 POWER Light Circuit Check POWER Light Doesn t Light at Ignition Switch ON But Engine Starts Up Table B 4 POWER Light Circuit Check POWER Light Comes ON Steadily 71 25 DTC P0705 DTC NO 72 Transmission Range Sensor Switch Circuit Malfunction7B1 26 DTC P0715 DTC NO 76 Input Turbine 7B1 24 Speed Sensor Circuit Malfunction 7B1 29 DTC P0720 DTC NO 75 Output Spee
210. DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor 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 6E2 50 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE IGNITION SYSTEM FOR H27 ENGINE 6F2 1 SECTION 6F2 IGNITION SYSTEM FOR H27 ENGINE WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 Technical service work must be started at least 90 seconds afte
211. E Step Action Yes No 4 Short term fuel trim check Intermittent trouble Go to DTC 0171 1 Run engine at 2000 r min for 60 sec or faulty ECM P0172 Diag Flow 2 With engine idling check short term fuel trim displayed PCM Table on scan tool Check for intermit Is it within 20 to 420 tent referring to INTERMITTENT AND POOR CON NECTION in Sec tion OA Fig for Step 2 1 Normal gt DTC P0133 HO2S 1 Bank 1 Circuit Slow Response WIRING DIAGRAMICIRCUIT DESCRIPTION Refer to DTC P0130 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected in idle state while running under driving HO2S 1 conditions described for DTC CONFIRMATION PROCEDURE ECM PCM Hi Lo cycle TRANS TIME displayed on scan tool of HO2S 1 output voltage is longer than specification or response rates of Hi Lo and Lo gt Hi TRANS TIME displayed as L threshold V or L gt R threshold V on scan tool are longer than specification 2 driving cycle detection logic DTC CONFIRMATION PROCEDURE Refer to DTC P0130 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 1 Replace HO28 1 and recheck Substitute known good HO28 1 malfunction Is DTC P0133 detected ECM PCM and recheck
212. E61 30 ABS control module if equipped E61 7 MIL SERVICE INGINE SOON lamp E61 19 4WD lamp E61 31 Power Normal change switch A T EE CER EIL M 61 11 E61 23 Fuel pump relay E61 35 Cruise control module if equipped equipped ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 11 TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT C51 3 1 Intake air temp AT sensor 51 3 13 Power source for TP sensor 51 3 25 GroundforlAT sensor MAP sensor and oxygen sensor if equipped 51 3 2 Engine coolant temp ECT sensor CST3 4 Power source for MAP sensor f 1051 8 28 Ground for CMP sensor equipped 51 33 Knock sensor CSL3 15 Power source 1051134 Power source 651316 51 35 Ground for MAF sensor 1 51317 Ground 51 36 Ground Pressure switch in 4WD air pump assembly CSS 4WD switch GE C51 3 8 Manifold absolute pressure MAP 51 3 20 Ignition switch sensor f equipped 651 39 Throttle position TP sensor 51 3 21 Heated oxygen sensor t Bank if equipped 51 310 Mass air MAF sensor 0513 22 Heated oxygen sensor2 Banki i equipped 05152 11 Heated oxygen sensor 1 Bank if 1051 23 Heated oxygen Bank if equipped equipped CS13 12 Ground for TP sensor 051 524 Ground for ECT sensor TERMINAL CIRCUIT TERMI
213. EHICLE SERVICE in Section 10B Enabling air bag system Refer to ENABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS under ON VEHICLE SERVICE in Section 10B Handling and storage Refer to HANDLING AND STORAGE of SERVICE PRECAUTIONS under ON VEHICLE SERVICE in Sec tion 10B Disposal Refer to DISPOSAL of SERVICE PRECAUTIONS under ON VEHICLE SERVICE in Section 10B SEAT BELT 10A 3 Front Seat Belt INSPECTION ON VEHICLE Seat belts with ALR As to seat belts with ALR other than driver side seat belt check them as follows in addition to above check With vehicle at stop pull seat belt all the way out let it retract a little and try to pull it It should not be pulled out that is it should be locked where retracted Let seat belt retract to its original state Next pull it half way out let it retract a little and try to pull it again It should be pulled out smoothly that is it should not be locked at this time WARNING Never attempt to disassemble or repair the seat belt pretensioner retractor assembly If any abnor mality is found be sure to replace it with new one as an assembly Be sure to read SERVICE PRECAUTIONS before starting to work and observe every precaution during work Neglecting them may result in personal injury or unactivation of the seat belt preten sioner if necessary Bhasnmasiom 2554 4 3 onmi
214. ENCE Oscilloscope waveforms of CMP sensor REF signal and No 1 ignition trigger signal are as shown in figure when connecting oscilloscope between terminal C51 1 13 of ECM PCM connec tor connected to ECM PCM and ground and between terminal C51 2 28 and ground 3 REF signal of CMP sensor 2 ignition trigger signal 3 Primary current flow time 6F2 6 IGNITION SYSTEM FOR H27 ENGINE Ignition Spark Check WARNING Without disconnection of injector coupler combustible gas may come out from spark plug holes during this test and may get ignited in engine room 1 Remove surge tank cover 2 Disconnect injector coupler 1 3 Remove spark plug and check it for condition and type refer ring to SPARK PLUG in this section 4 If OK connect ignition coil coupler to ignition coil assembly and connect spark plug to ignition coil assembly Ground spark plug Crank engine and check if each spark plug sparks If no spark is emitted inspect the related parts as described under DIAGNOSIS in this section After checking install spark plug referring to SPARK PLUG in this section 7 Connect injector coupler 1 8 Install surge tank cover 5 6 Ignition Timing Check and Adjustment NOTE Before starting engine place transmission gear shift lever in Neutral shift selector lever to P ra
215. ENGINE MECHANICAL H27 ENGINE 6A2 9 26 Upon completion of installation verify that there is no fuel leakage at each connection according to procedure described in Section 6 Exhaust Manifold WARNING To avoid danger of being burned do not service exhaust system while it is still hot Service should be performed after system has cooled off Left No 1 exhaust manifold Right No 2 exhaust manifold Exhaust manifold cover Exhaust No 1 pipe Without WU TWC With WU TWG REMOVAL 1 Disconnect negative cable at battery 2 Remove air cleaner upper case and intake air hose if right side exhaust manifold is removed 3 Detach couplers from their bracket and disconnect oxygen sensor lead wires at couplers 3 25 1 Green connector 2 HO2S 2 Black connector 6A2 10 ENGINE MECHANICAL H27 ENGINE 4 Disconnect EGR pipe from right No 2 bank exhaust mani fold if right side exhaust manifold is removed 5 Remove oil level gauge guide 3 if left side exhaust manifold is removed 6 Detach P S pump assembly as following if left side exhaust manifold is removed a Loosen P S pump drive belt by loosening tensioner bolt b Remove P S pump mounting bolts c Detach P S pump assembly 4 with its hoses from cylinder block 7 Remove exhaust manifold covers 2 from exhaust manifolds 1 8 Hoist vehicle 9 For 4WD vehi
216. Front bumper instalation hole 9 Genter member installation hole b 07 Front bumper installation hole RW Fender installation reference hole c Headlight installation hole 1 _ Fender installation hole d d Headight installation resin nut hole _ 10 Fenderinstalation reference hole s Headight installation bolt hole Cowitop panel center hole 66 1 Front fender installation bolt hole 1 Mounting installation hole Hole to hole distance 276 mm 10 87 in 1302 mm 51 26 in 677 mm 26 65 in 1000 mm 39 37 in 189 mm 744 in 1504 mm 59 21 in 1370 mm 53 94 in 672 mm 26 46 in 927 mm 36 50 in 780 mm 28 74 in 968 mm 38 11 in 1344 mm 62 91 in 668 mm 26 30 in 1456 mm 57 32 in 391 mm 15 39 in 414 mm 16 30 in 1550 mm 61 02 in 760 mm 29 92 in 406 mm 15 98 in 299 mm 1177 in 1348 mm 53 07 in 1029 mm 40 51 in 811 mm 37 93 in j k 676mm 26 61 in 1000 mm 39 37 in 854 mm 33 62 in I j 961mm 87 83 in 1016 mm 40 00 in 1339 mm 62 72 in I k 1018 mm 40 08 in Garish installation hole 10 Hole in rear door lower hinge in lower part b Frontend of front windshield lower installation section 10 Rear scuff installation hole at front end Front end of front windshield upper installa
217. HO2S 1 equipped 51 216 Heater of HO2S 2 f equipped CST 2 28 Ignition coll assembly for No 1 051 25 Heater of HO2S 1 Bank2 if equipped 051 27 Heater of HO2S 2 Bank2 if equipped 51 2 29 55128 51 2 30 Ground for sensor shield wire equipped 51 27 Ground 10512 19 sensor f equipped 051258 Fuel injector No 4 10512 20 sensor if equipped C51 2 9_ Fuel injector No 3 10512221 Fuel injector No 6 651210 CST222 Fuel injector No 5 C51 2 23_ Ignition coll assembly for No 6 EGA valve stepper motor coll 4 if CS1 2 24 Ignition coil assembly for No 5 equipped 62 12 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE Engine and Emission Control Input Output Table Refer to Section 6 1 55 58 Input 818 5 8 55 HHE 2g Function sig 581559 89 226 le 58 2 HABBE 5 188 18g zx 5 2 35 355 585 288 55 Guil 3152852 zi g ES 852853558 3 53 80 55 3 8 3 8 8512052 0826 5 lt Main relay control Main relay Fuel pump control Fuel pump relay O Oo Injection control Injectors Jol Idle air control IAC valve Olojololo
218. HO2S 1 and HO2S 2 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA While running under conditions described for DTC CON FIRMATION PROCEDURE output waveform of HO2S 1 becomes similar to that of HO2S 2 2 driving cycle detection logic Exhaust gas leakage Warm up three way catalytic converter Heated oxygen sensor 2 or its circuit ECM PCM ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 95 DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road ity of a traffic acci NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Increase vehicle speed to 80 90 km h 50 56 mph 4 Keep above vehicle speed for 5 min or more Throttle valve opening is kept constant in this step 5 Stop vehicle and check if pending DTC
219. IC TRANSMISSION 4 A T 7B1 55 LOWER VALVE BODY T Lower valve body 7 Lock up control valve plato 38 Primary regulator valve sleeve 2 Spring 8 TOC Lockup control valve gasket _ 14 Primary regulator valve plunger 3 Pressure relie valve 9 Lockup control sleeve 18 Primary regulator valve 4 Pressure relief valve retainer 10 Lock up control valve 16 Spacer 5 Lower valve body piate Ti Pin 6 Lower valve body gasket 12 Retainer 781 56 AUTOMATIC TRANSMISSION 4 A T DISASSEMBLY 1 Remove bypass valve 1 bypass valve spring check ball valve damping spring valve body ball 2 and ball valve spring 3 Checkball 4 Primary regulator valve sleeve retainer 5 Locating pin 2 Remove lower valve body plate 1 and lower valve body plate gasket 3 Remove TCC lock up control valve plate 2 and TCC lock up control valve gasket 4 With pressure relief valve retainer 1 pressed with finger remove pressure relief valve bolt and then remove pressure relief valve retainer 1 pressure relief valve spring and pres sure relief valve ball 5 Remove TCC lock up solenoid valve 1 and Then remove O ring 2 from TCC solenoid valve 1 e AUTOMATIC TRANSMISSION 4 A T 7B1 57 6 After removing shift solenoid valve A amp B 1 remove sole
220. ILL SET WHEN The voltage at the AIR BAG waming lamp circuit terminal 001 2 does not match the commanded state of the warning lamp driver for specified time 108 48 AIR BAG SYSTEM TABLE TEST DESCRIPTION STEP 1 This test rechecks AIR BAG warning lamp operation STEP 2 This test rechecks whether an abnormality is in SDM DTC B1061 Step Action Yes No 1 1 This DTC is set when there is a trouble in Go to step 2 Repair AIR BAG waming AIR BAG warning lamp circuit Failure to lamp circuit properly perform AIR BAG DIAGNOSTIC SYSTEM CHECK may also result in mis diagnosis Therefore check AIR BAG warning lamp circuit again according to AIR BAG DIAGNOSTIC SYSTEM CHECK Is AIR BAG warning lamp circuit in good condition 2 1 Clear DTC Refer to DTC CLEARANCE Substitute a known Recheck air bag system 2 Check DTC Refer to DTC CHECK good SDM and recheck Refer to AIR BAG DIAG Is DTC B1061 set NOSTIC SYSTEM CHECK NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1071 Internal SDM Fault DTC WILL SET WHEN An internal SDM fault is detected by SDM NOTE DTC B1071 can never be cleared once it has been set 1 Ignition switch OFF 2 Replace SDM 3 Rep
221. INE CLEANING CAUTION Do not blow compressed air through bypass air pas sage with IAC valve installed to throttle body This will cause IAC valve to malfunction TP sensor idle air control valve or other components containing rubber must not be places in a solvent or cleaner bath A chemical reaction will cause these parts to swell harden or get distorted Clean throttle body bore and bypass air passages 1 by blowing compressed air INSTALLATION 1 Clean mating surfaces and install throttle body gasket to intake collector 1 with new gasket 2 2 Install throttle body to intake collector and tighten bolts 3 Connect PCV hose 4 Install throttle body and intake collector to intake manifold with new intake collector gaskets 5 Install EGR pipe with new gaskets 6 Connect breather hose and EVAP canister purge valve hose and install PCV valve to cylinder head 7 Connect connectors of EVAP canister purge valve MAP sensor and EGR valve Fix wire harness with clamps 8 Install clamp bracket to intake collector 9 Connect ground wire connector 10 Connect connectors of TP sensor ground and IAC valve 11 Install surge tank pipe to intake manifold with new gaskets and intake air pipe to throttle body Install surge tank cover 12 Connect engine coolant hoses to throttle body 13 Connect accelerator cable and A T throttle cable A T ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL
222. INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 91 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 lsthere DTC P0403 EGR circuit malfunction Goto DTC P0403 Diag Go to Step 3 Flow Table 3 you have SUZUKI scan tool Go to Step 4 Go to Step 6 4 EGR valve operation check Go to Step 5 Go to Step 6 1 With ignition switch OFF install SUZUKI scan tool 2 Check EGR system referring to Section 6E2 Is it in good condition 5 sensor check Intermittent trouble or Repair or replace 1 Check MAP sensor for performance refer faulty ECM PCM Check ring to Section 6E2 tor intermittent referring to Is check result satisfactory INTERMITTENT AND POOR CONNECTION in Section 0A 6 valve power supply circuit check Go to Step 7 Faulty BLU BLK wire 1 With ignition switch OFF disconnect EGR valve coupler 2 With ignition switch ON check voltage between 04 2 and ground C04 5 and ground Is each voltage 10 14 V 7 EGR valve stepper motor coil circuit check Go to Step 8 Faulty EGR valve 1 With ignition switch OFF connect EGR valve coupler and disconnect ECM PCM couplers 2 Check resistance between C51 3 4 and C51 2 12 C51 2 13 C51 2 14 C51 2 15 Is each resistance 20 24 at 20 68 F 8 MAP sensor check EGR passage clogged or Repair or replace
223. INGS 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 When body servicing if shock may be applied to air bag system component parts remove those parts beforehand Refer to Section 10B NOTE For the descriptions items not found in this section refer to the same section of the Service Man ual mentioned in the FOREWORD of this manual Fasteners are important attaching parts in that they could affect the performance of vital compo nents 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 proper retention of these parts CONTENTS Sealant Application Area Undercoating Anti corrosion Compound Application Area Exterior and Interior Trim Floor Carpet Front floor carpet Rear floor carpet without third seat vehicle Head Lining Glass Windows and Mirror Quarter Window Body Struct
224. ION ALWAYS CHARGE THROUGH LOW PRESSURE SIDE of A C system at after the initial charging is performed from the high pressure side with the engine stopped NEVER CHARGE TO HIGH PRESSURE SIDE of A C system with engine running Do not charge while compressor is hot When installing tap valve to refrigerant container to make a hole there through carefully follow directions given by manufacturer A pressure gauge should always be used before and during charging The refrigerant container should be emptied of refrigerant when discarding it The refrigerant container should not be heated up to 40 C 104 F or over Refrigerant container should not be reversed in direction during charging Reversing in direction causes liquid refrigerant to enter compressor causing troubles such as compression of liquid refrigerant and the like NOTE The air conditioning system contains HFC 134a R 134a Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service container When charging refrigerant recovered by using the refrigerant and recycling equipment when recy cling refrigerant follow the procedure described in the equipment manufacturer s instruction manual AIR CONDITIONING OPTIONAL 18 23 The initial charging of the A C system is performed from the high pressure side with the engine stopped And next this method must be followed by charging f
225. Ib ft ENGINE MECHANICAL H27 ENGINE 62 29 3 Tighten bolts and nuts fastening cylinder block and transmis sion to specified torque Tightening torque Transmission to cylinder block bolt and nut b 85 N m 8 5 kg m 61 5 Ib ft 1 Bolt short 2 Bolt Long 4 Remove lifting device 5 Tighten torque converter bolts to specified torque for A T vehicle Tightening torque Torque converter bolt c 65 N m 6 5 kg m 47 0 Ib ft 6 Tighten bolts and nuts of exhaust No 1 pipe 1 to specified torque Tightening torque Exhaust No 1 pipe bolt and nut d 50 N m 5 0 kg m 36 5 Ib ft 7 Install front differential housing with differential to chassis if removed Refer to REMOUNTING in Section 7E 8 Install steering shaft lower assembly Refer to STEERING LOWER SHAFT ASSEMBLY in Section 3C1 9 Install A C compressor assembly Refer to COMPRESSOR ASSEMBLY in Section 1B 10 Install P S pump assembly Refer to POWER STEERING PUMP in Section 3B1 11 Connect hoses cables and electric wires 12 Adjust accelerator cable play and A T throttle cable play for AIT vehicle Refer to ACCELERATOR CABLE ADJUST MENT and A T THROTTLE CABLE ADJUSTMENT A T VEHICLE in Section 6E2 13 Refill engine with engine oil referring to ENGINE OIL CHANGE in Section OB 14 Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL in Sect
226. Important WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instructions clearer WARNING This service manual is intended for authorized Suzuki dealers and qualified service mechanics only Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver and passengers WARNING For vehicles equipped with a Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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
227. Md ui BAN L 4 524 La Em a EG csv BRNBLK ipee wosa ln eee eria ama o TX ost 322 i T ES weren os1 2 16 H 0512 25 ene RED YEL 051 3423 51 224 BnNRED Y PNOWHT Tii s e L PNU E81 35 1 Eers gt nom L E61 30 61 23 FA 2 x GE s ps 3 2 em pmo OT a Lew ss 2 B 15 x y csi 19 BLKRED 51 15 pm genos Lo veL T ei ES up sers Ewer pelas REDNEL era 16 BLUIORN Jcs t25 WHT C51 1 23 18 123 g w ena V BH i 19 onnek en t GENTES x o 6 y 051 3 48 51 128 ost onl GANBLU estar EBTT LORNBLU zem Estas 5 i a E os1 1 28 ORNWHT or E GRNRED T cst a 20 aucwerr Pu LR E612 WHT ZEE melee 162 1 gigas Bueu z EAEE i 24 T 26 BRN 25 BLIJGRN sv BLUIYEL 051 1 14 44 51 317 BLKIORN A ov 62 10 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE TERMINAL ARRANGEMENT OF ECM PCM CONNECTOR VIEWED FROM HARNESS SIDE
228. Measure voltage from 001 8 terminal to body Substitute a known Repair short from YEL ground With ignition switch ON is voltage 1 V or less good SDM and recheck wire circuit to power cir cuit A Fig for STEP 1 2 and 3 B Fig for STEP 2 C Fig for STEP 3 STEERING WHEEL Special tool A B NOTE 09932 75020 09932 75010 Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected 108 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 to Ground DTC B1025 Driver Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM aor BLU BLK BLURED eap Qo amp wo D o01 10 S REDI 06 Yd Co aora 98 A gt BLK 01 17 GND ji i Ni A Shorting bar 2 Ignition switch 5 Contact coil assembly B Airbag hamess 8 AIR BAG fuse 6 Driver air bag inflator module
229. N SYS FAULT Open loop due to detected system fault CLOSED ONE 028 Closed loop but fault with at least one oxygen sensor may be using single oxygen sensor tor fuel control CALC LOAD Calculated Load Value Engine load displayed as a percentage of maximum possible load Value is calculated mathematically using the formula actual current intake air volume maximum possible intake air volume x 100 TOTAL FUEL TRIM The value of total fuel trim is obtained by putting values of short term fuel trim and long term fuel trim together This value indicates how much correction is necessary to keep the air fuel mixture stoichiometrical CANIST PRG DUTY EVAP Canister Purge Flow Duty This parameter indicates valve ON valve open time rate within a certain set cycle of EVAP canister purge valve which controls the amount of EVAP purge VEHICLE SPEED km h MPH It is computed based on pulse signals from vehicle speed sensor on transfer or transmission FUEL CUT ON OFF ON Fuel being cut output signal to injector is stopped OFF Fuel not being cut MAP Manifold Absolute Pressure mmHg kPa This parameter indicates the pressure in the intake manifold absolute pressure A C CONDENSER FAN ON OFF This parameter indicates the state of the A C Condenser Fan control signal BLOWER FAN ON OFF This parameter indicates the state of the blower fan motor switch ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1
230. NAL CIRCUIT TERMINAL CIRCUIT CS1 I 1 Shift solencid B NT CS1 1 13 sensor 51 1 25 Power steering pressure switch CST T2 Shift solenoid A AT CST 14 Vehicle speed sensor 51 126 4WD Low switch crs 10511 15 EVAP canister purge valve 10517127 Transmission range switch 1 AT CS1 1 4 TAC valve stepper motor 2 CS1 1 16 IAC valve stepper motor coil 4 10517128 Transmission range switch 2 AT 651 1 5 valve stepper motor 1 CS1 1 17 valve stepper motor coil 3 10517156 Transmission range switch R 051 1 18 Transmission range switch D A T C51 1 7_Transmission range switch P A T C51 1 19_ Transmission range switch N A T C5118 TCC solenoid NT 10517220 Shield wire ground for A T output speed sensor 51 1 9 4WD air pump assembly CST 21 Shield wire ground for A T input speed sensor CS1 1 10 input speed sensor CS1 1 22 output speed sensor 51 1 11 input speed sensor 51 1 23 AIT output speed sensor 51 1 12 sensor 105171 24 Engine start signal TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT 0512 1 Fuel injector No 2 EGR vale ool 51 2 25 Ignition coll assembly for No 4 051 22 Fuel injector No 1 EG vale appr mito ool 05112228 ignition assembly for No 3 55123 512 15 EGR valve stepper motor coil 1 f 51 2 27 ignition assembly for No 2 equipped CST24 Heater of
231. NE 6 1 51 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section gt Check IAT sensor and its circuit Go to Step 3 Intermittent trouble 1 Connect scan tool with ignition switch OFF Check for intermittent 2 Tum ignition switch ON referring to INTERMIT 3 Check intake air temp displayed on scan TENT AND POOR CON tool NECTION in Section Is 40 C 40 F or 165 C 329 F indicated 3 Check wire hamess Go to Step 4 LT BLU wire open or 1 Disconnect IAT sensor connector with igni short or poor C51 3 1 tion switch OFF connection 2 Check for proper connection to IAT sensor If wire and connection are at LT BLU and GRY YEL wire terminals OK substitute a known If OK then with ignition switch ON is voltage good ECM PCM and applied to LT BLU wire terminal about 4 6 V recheck 4 Check wire harness Replace IAT sensor GRY YEL wire open or 1 Using service wire connect IAT sensor con nector terminals 2 Tum ignition switch ON and check intake air temp displayed on scan tool Is 165 C 329 F indicated poor C51 3 25 connec tion If wire and connection are OK substitute a known good ECM PCM and recheck 6 1 52 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0115 DTC No 14 15 Engine Coolant Temp Circuit Malfunction WIRING DI
232. NING OPTIONAL Performance Diagnosis 1 Confirm that vehicle and environmental conditions as fol lows Vehicle is not exposed to direct sun Ambient temperature is within 15 35 C 59 95 F 2 Make sure that high pressure valve 1 and low pressure valve 2 of manifold gauge 3 are firmly closed Connect high pressure charging hose 4 to high pressure service valve 5 on vehicle and connect low pressure charging hose 6 to low pressure service valve 7 on vehi cle Bleed the air in charging hoses 3 4 by loosening their respective nuts on manifold gauge utilizing the refrigerant pressure When a hiss is heard immediately tighten nut 3 4 CAUTION Do not interchange high and low pressure charging hoses by mistake 5 Warm up engine to normal operating temperature engine coolant temperature at 80 90 C 176 194 F and keep it at specified idle speed 6 Operate A C at the following conditions Main front A C switch at ON position Rear A C main switch at ON position if equipped Front blower motor switch at max position Rear blower motor switch at max position if equipped Air outlet control button at face position Temperature control lever at max cool position Vehicle door at all open Air inlet door at recirculation position 7 Keep all windows doors and engine food open 8 With about 20 mm 0 8 in of dry bulb thermom
233. NSTALLA TION under BRAKE SHOE in this section 8 Install brake drum Refer to steps 1 to 2 of INSTALLA TION under BRAKE DRUM in this section 9 Refill differential housing with new specified gear oil Refer to ON VEHICLE SERVICE in Section 7F for refill 10 Fill reservoir with brake fluid and bleed brake system For bleeding operation refer to BLEEDING BRAKE in Section 5 11 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nut b 100 N m 10 0 kg m 72 5 Ib ft 12 Upon completion of all jobs depress brake pedal with about 30 kg 66 Ibs load 3 to 10 times so as to obtain proper drum to shoe clearance Adjust parking brake cable For adjustment refer to PARK ING BRAKE CHECK AND ADJUSTMENT in Section 5 13 Tighten parking brake lever cover screws 14 Check to ensure that brake drum is free from dragging and proper braking is obtained Then remove vehicle from hoist and perform brake test foot brake and parking brake 15 Check each installed part for oil leakage PARKING AND REAR BRAKE 5C 7 Tightening Torque Specification Tightening torque Fastening part Tn kgm BE Wheel cylinder bleeder plug 75 0 75 55 Parking brake lever bolt 23 23 17 0 Wheel cylinder boit 135 135 10 0 Brake pipe flare nut 16 16 12 0 Brake back plate nut 50 50 365 Wheel nut 100 10 0 725 Parking brake cable nut 10 10 75 5C 8 PARKING
234. OK Go to Step 4 Circuit open or shorted to ground 1 Remove applicable ABS wheel speed sensor 2 Check sensor for damage or foreign material attached Is it in good condition Go to Step 5 Clean repair or replace Check front and or rear sensor ring for the following remove rear drum as necessary Rotor serration teeth neither missing nor damaged No foreign material being attached Rotor not being eccentric Wheel bearing free from excessive play Are they in good condition Go to Step 6 Clean repair or replace 1 Install ABS wheel speed sensor to knuckle 2 Tighten sensor bolt to specified torque and check that there is no clearance between sensor and knuckle Is it OK Go to Step 7 Replace ABS wheel speed sensor Referring to Reference of FRONT WHEEL SPEED SEN SOR and or Reference of REAR WHEEL SPEED SEN SOR in this section check output voltage or waveform Is specified voltage and or waveform obtained Substitute a known good ABS hydrau lic unit control mod ule assembly and recheck Replace sensor and recheck 52 24 ANTILOCK BRAKE SYSTEM ABS DTC C1041 DTC 41 Right Front Inlet Solenoid Circuit DTC C1045 DTC 45 Left Front Inlet Solenoid Circuit DTC C1055 DTC 55 Rear Inlet Solenoid Circuit DTC C1042 DTC 42 Right Front Outlet Solenoid Circuit DTC C1046 DTC 46 Left Front Outlet Solenoid Circuit DTC C1056
235. OR CONNECTION in Section and related circuit of DTC recorded in step 2 STEP 11 FINAL CONFIRMATION TEST Confirm that the problem symptom has gone and the engine is free from any abnormal conditions If what has been repaired is related to the DTC clear the DTC once perform DTO confirmation procedure and confirm that no malfunction DTC a normal code is indicated 6 1 16 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Malfunction Indicator Lamp MIL Check 1 Turn ON ignition switch but the engine at stop and check that MIL 1 lights If MIL does not light up go to Diagnostic Flow Table A 1 for troubleshooting 2 Start engine and check that MIL turns OFF 3 If MIL remains ON and no DTC is stored in ECM PCM go to Diagnostic Flow Table A 2 for troubleshooting Diagnostic Trouble Code DTC Check Using SUZUKI scan tool 1 Prepare generic scan tool or SUZUKI scan tool 2 2 With ignition switch OFF connect it to data link connector DLC 3 located on underside of instrument panel at driver s seat side Special tool A SUZUKI scan tool 3 Turn ignition switch ON and confirm that MIL lights 4 Read DTC and freeze frame data according to instructions displayed on scan tool and print them or write them down Refer to scan tool operator s manual for further details If communication between scan tool and ECM PCM is not possible check if sca
236. Output Voltage min or longer after warming up 025 B2 1 When engine is running at 2000 r min for 3 PE HO2S 2 Output Voltage or longer after warming up O28 B2 82 When engine is running at 2000 r min for 3 array HO2S 2 Output Voltage min or longer after warming up FUEL SYSTEM B1 At specified idle speed after warming up Fuel System Status 4 Closed FUEL SYSTEM B2 At specified idle speed after warming up God Fuel System Status CALC LOAD At specified idle speed with no load after TREE Calculated Load Value warming up At 2500 r min with no load after warming up 14 23 TOTAL FT TRIM B1 At specified idle speed after warming up 80 480 TOTAL FT TRIM B2 At specified idle speed after warming up 30 30 MAP At specified idle speed after warming up 25 35 kPa CANIST PRG DUTY At specified idle speed after warming up EVAP Canister Purge 0 Flow Duty VEHICLE SPEED At stop O km h 0 MPH FUEL CUT When engine is at fuel cut condition ON Other than fuel cut condition OFF EGR VALVE At specified idle speed after warming up 0 BLOWER FAN Ignition switch ON blower fan switch ON ON Ignition switch ON blower fan switch OFF OFF CONDENSER ignition switch ON not operating OFF Ignition switch ON A C operating ON PSP SWITCH Engine running at idle speed and steering OFF wheel at straight ahead position Engine running at idle speed and steering wheel turned to the right or left as far as it ON stop
237. P AWAY FROM LOOSE OBJECTS 1 Sion workbench 2 Lower mounting bracket 3 Workbench vise 0A 4 GENERAL INFORMATION WARNING SDM Never strike or jar the SDM During service procedures be very careful when handling a Sensing and Diagnostic Module SDM Never power up the air bag system when the SDM is not rigidly attached to the vehicle All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury WARNING Driver and Passenger Seat Belt Pretensioners 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 Never carry seat belt pretensioner by wire or connec tor of pretensioner When placing a live seat belt pre tensioner on the workbench or some place like that 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 or to put a seat belt pre tensioner on top of another Otherwise personal injury may result Never dispose of live inactivated seat belt pretension ers drive and passenger If disposal is nece
238. P sensor or Engine starter signal circuit REF signal pattern is incorrect while POS signal varies ECM PCM or POS signal voltage too high or too low DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following condition is satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Crank engine for 3 seconds or more and keep it at idle for 1 min 4 Check DTC by using scan tool TROUBLESHOOTING NOTE If starter circuit is open i e starter signal circuit is OK but starter fails to run this DTC is stored in memory at starter switch ON even through CMP sensor is in good condition When starter motor fails to run and this DTC appears check starter circuit first Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE performed to Step 2 Go to ENGINE DIAG FLOW TABLE in this section 2 5 engine cranked Go to Step 3 Go to Section 6G 3 there DTC P1500 Engine starter signal circuit Go to P1500 Diag to Step 4 Flow Table 4 CMP sensor power supply voltage check Go to Step 5 Faulty BLU BLK wire 1 With ignitio
239. PE in this section When replenishing or changing refrigerant and compressor oil and when replacing parts make sure that the material or the part to be used is appropriate to the A C installed in the vehicle being serviced Use of incorrect one will result in leakage of refrigerant damage in parts or other faulty condition NOTE For the descriptions items not found in this section refer to the same section of the Service Man ual mentioned in FOREWORD of this manual For basic servicing method of the air conditioning system that is not described in this section refer to AIR CONDITIONING BASIC MANUAL 99520 02130 CONTENTS General Description 1B 3 temperature within 30 35 C Refrigerant Type 18 3 85 95 F 1B 13 Refrigerant Flow of Air Conditioning System 1B 3 Wiring Circuit 1B 14 Major Components And Location 1B 4 Inspection of A C Controller and Its Diagnosis 1B 6 Circuits 1B 15 General 18 6 Voltage checi 1B 15 Main A C system front A system 18 6 Refrigerant Recovery Evacuation and Rear A C system 1B 8 Charging 1B 19 Quickly Checking of Refrigerant Charge If Equipped with Sight Glass 18 9 1B 19 Performance Diagnosi B 10 1B 20 Performance diagnosis tabl 1B 12 1B 21 Detail diagnosis table at ambient Evacuating procedure 1B 21 Checking system for pressure leaks 1B 22 18 2 AIR CONDITIONING OPTIONAL Charging On Vehicle Service
240. PTION Battery voltage is supplied to keep DTC memory values that ECM has learned to control engine etc in ECM even when ignition switch is turned OFF DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Back up circuit voltage lower than specification is detected POM back up circuit while engine is running DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following condition is satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 1min 3 Check DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE in this section 2 Battery voltage supply circuit check Poor E61 2 connection or WHT circuit open or short 1 Remove ECM PCM cover intermittent trouble 2 While engine running check voltage between E61 Check for intermittent referring 2 and ground to INTERMITTENT AND Is voltage 10 14 V POOR CONNECTION in Section If wire and connecti
241. R Lamp Check 1 Check that Power Normal change switch button is at Normal position 2 Tum ignition switch ON 3 Check that POWER lamp lights for about 2 4 sec and then goes OFF If anything faulty is found advance DIAGNOSTIC FLOW TABLE B 3 or B 4 POWER LAMP CIRCUIT CHECK Diagnostic Trouble Code DTC Check Refer to the same item in Section 6 1 for checking procedure Diagnostic Trouble Code Clearance Refer to the same item in Section 6 1 for clearance procedure 781 14 AUTOMATIC TRANSMISSION 4 A T Diagnostic Trouble Code Table Refer to the same item in Section 6 1 Fail Safe Table Refer to the same item in Section 6 1 Visual Inspection Visually check following parts and systems Engine oil pressure warning lamp Operation Engine coolant temp meter Operation Other parts that can be checked visually INSPECTION ITEM REFERRING SECTION AMT fluid Tevel leakage color SECTION 0B AIT fluid hoses disconnection looseness deterioration SECTION 7B1 Throttle accelerator cable play installation SECTION 6E2 AIT throttle cable play installation SECTION 7B1 select cable installation operation SECTION 7B1 Engine oil level leakage SECTION 0B Engine coolant level leakage SECTION 0B Battery fluid level corrosion of terminal Connectors of electric wire harness
242. RONT 7E 3 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 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 and replenish Constant noise Inadequate or insufficientlubricant Repair and replenish Noise while coasting Damaged bearing s of bevel pinion Replace Noise while turning Damaged differential side bearing s Replace or axle bearing s Oil leakage Worn or damaged oil seal Replace Excessive oil Adjust oil level Loose differential carrier bolts Replace or retighten 2WD AWD Defective actuator Replace switching error Abnormality in 4WD control system Inspect referring to 4WD CONTROL SYSTEM DIAG NOSTIC FLOW TABLE 4WD Control System Diagnostic Flow Table Before performing the trouble diagnosis check that the transfer and front differential are in good condition and there is no air leakage from air hoses and the actuator Refer to 4WD CONTROL SYSTEM INSPECTION in this section for air leakage Notes on system circ
243. S RANGE Transmission Range P R N D 2 or L It indicates transmission range according to transmission range switch signal BRAKE SW Brake Stop Lamp Switch ON OFF OFF Brake pedal is released ON Brake pedal is depressed O D OFF SW Overdrive Cut Switch ON OFF OFF Overdrive cut switch OFF ON Overdrive cut switch ON MODE SELECT SW Power normal Change Switch Power normal POWER Switch button is at POWER position NORMAL Switch button is at NORMAL position 4WD L SW 4WD LOW Switch ON OFF ON Transfer lever is shifted to 4L position OFF Transfer lever is shifted to 4H or 2H position ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 31 Engine Diagnosis Table Perform troubleshooting referring to following table when ECM PCM has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously Condition Possible Cause Correction Hard starting Engine cranks OK Faulty idle air control system DIAG FLOW TABLE 4 in this section Faulty ECT sensor or MAF sensor ECT sensor or MAF sensor in Sec tion 6E2 Faulty ECM PCM Inspection of ECM PCM and its circuit in this section Low compression Compression check in Section 6A2 Faulty hydraulic valve lash adjuster Valve lash adjuster in Section 6A2 Compression leak from valve seat Valves inspection in Section 6A2 Sticky valv
244. S o c edid 61 23 Fuel pump relay After 3 sec from ignition switch ON 10 14V infe with engine stopped reg Ground for CO adjusting resistor x if equipped 1 25 E E61 26 5 E61 27 E61 28 Fuel level sensor 0 6V Jorio switon ON Voltage depends on fuel level 61 29 10180 90108 terminal 10 14 Ignition switch ON vehicle with monitor connector E61 30 ABS control module 10 14V Ignition switch ON vuv Ignition switch ON P N change Egg Powet Normal change switch switch POWER mode AIT vehicle mur Ignition switch ON P N change Switch NORMAL mode Ignition switch ON lighting switch gaty OFF E61 32 Lighting switch Ignition switch ON lighting switch 10 14V ON docu tion Ld OR overdrive cut 61 33 Overdrive cut switch A T vehicle 7 eV Ignition switch ON overdrive cut switch pressed Brake pedal released swilch OFF ony Ignition switch ON 61 34 Stop itch are NOW Brake pedal depressed witch ON Ignition switch ON E61 35 Cruise control module if equipped 10 14V Ignition switch ON z Ignition switch ON Sensor ambient 51 3 1 Intake air temp sensor 22 80V emp 20 C T Ignition switch ON Engine coolant 51 3 2 Engine coolant temp sensor 05 09V emp cap CHE Gack bance Abouasv With engine running at idis after warned up 51 34 Power source 10 14V Ignition switch ON 51 3 5 Ground for MAF sensor 51 3 6 Ground Ignition switch ON Transfer lever ped 4H or 4L range C51 9
245. STEM CHECK to confirm that the trouble has been corrected AIR BAG SYSTEM 108 31 DTC B1024 Step Action Yes No 1 1 With ignition switch OFF disconnect contact coil connector located near the base of the steering col umn 2 Check proper connection to contact coil at terminals in 006 connector 3 If OK then connect Special Tool B to contact coil connector disconnected at step 1 With ignition switch ON is DTC B1024 current Go to step 2 Go to step 3 2 1 With ignition switch OFF disconnect Special Tool Substitute a known Repair short from B and SDM connector good SDM and GRN or GRN RED 2 Measure resistance between Q01 9 terminal and_ recheck wire circuit to ground body ground and between 001 10 terminal and body ground Are circuits open 3 1 With ignition switch OFF disconnect Special Tool lgnition switch OFF Ignition switch OFF B then reconnect contact coil connector located contact coil Replace driver air bag near the base of the steering column assembly Refer to nflator module 2 Remove driver air bag inflator module from steer COMBINATION Refer to DRIVER AIR ing wheel Refer to DRIVER AIR BAG INFLATOR SWITCH CONTACT BAG INFLATOR MODULE in Section 3C1 COIL AND COMBI MODULE in Section 3 Check proper connection to driver air bag inflator NATION SWITCH 3 1 module at terminals in Q05
246. SYSTEM ABS ABS 63 ABS Hydraulic Unit control Module Assembly ABS control module is a component of ABS hydraulic unit control module assembly and has the following functions Self diagnosis function ABS control module diagnoses conditions of the system compo nent parts whether or not there is any abnormality all the time and indicates the results warning of abnormality occurrence and DTC through the ABS warning lamp as described below 1 When ignition switch is turned ON ABS warning lamp lights for 2 seconds to check its bulb and circuit 2 When no abnormality has been detected the system is in good condition ABS warning lamp turns OFF after 2 sec onds 3 When an abnormality in the system is detected ABS war ing lamp lights and the area where that abnormality lies is stored in the memory of EEPROM in ABS control module 4 When Diag switch terminal 2 of diagnosis connector 1 monitor connector is grounded the abnormal area is output as DTC It is indicated by flashing of ABS waming lamp Refer to the table below ABS WARNING LAMP Diag switch Diag switch terminalis terminal is notgrounded grounded SYSTEM CONDITION Ingood Notroubleinthe past OFF DTC 12 condition Trouble occurred in at present the past OFF History DTC Abnormal No trouble in the past Current DTC ity exists Trouble occurred in Current and
247. Special Tool B Is resistance 1 4 Q or more cuit to other wire circuit A Fig for STEP 1 and 2 B Fig for STEP 2 Special tool A B 09932 75020 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected 108 26 AIR BAG SYSTEM DTC B1018 Step Action Yes No 1 1 With ignition switch OFF disconnect passenger air step 2 bag inflator module connector behind the glove box 2 Check proper connection to passenger air bag infla tor module at terminals in Q07 connector 3 If OK then connect Special Tool B to passenger air bag inflator module connector disconnected at the step 1 With ignition switch ON is DTC B1018 current Ignition switch OFF Replace passenger air bag inflator module Refer to PASSENGER AIR BAG INFLATOR MODULE in this section 2 1 With ignition switch OFF disconnect Special Tool Goto step 3 Repair short from YEL and SDM connector RED wire circuit to 2 Measure resistance between Q01 7 terminals and ground body ground Is circuit open 3 1 Measure resistance between 001 8 terminal and Subsi
248. Step Action Yes No T Customer Complaint Analysis Go to Step 2 Perform customer com 1 Perform customer complaint analysis plaint analysis Was customer complaint analysis performed 2 DTC syFreeze Frame Data Check RecordDTC s Freeze Go to Step 4 1 Check DTC s Freeze frame data frame data Is there any malfunction DTC s Clear DTC s Go to Step 3 3 Visual Inspection Repair or replace Go to Step 5 1 Perform visual inspection function part 15 there any faulty condition Go to Step 11 4 Visual Inspection Repair or replace mal Go to Step 8 1 Perform visual inspection function part 15 there any faulty condition Goto Step 11 5 Trouble Symptom Confirmation Goto Step 6 Go to Step 7 1 Confirm trouble symptom based on cus tomer complaint analysis DTC s freeze frame data in Step 1 15 trouble symptom identified 6 DTO Freeze Frame Data Recheck Go to Step 9 Go to Step 8 1 Recheck DTO freeze frame data Is there any malfunction DTC s 7 DTO Freeze Frame Data Recheck Go to Step 9 Go to Step 10 1 Recheck DTO freeze frame data Is there any malfunction DTC s 8 Engine Basic Inspection Goto Step 11 Check and repair mal 1 Check and repair according to ENGINE function part s BASIC INSPECTION FLOW TABLE and Go to Step 11 ENGINE DIAGNOSIS TABLE in this sec tion Are check and repair complete 9 DTC Trouble Shooting Go to Step 11 Check and repair mal 1 Check and repai
249. T MUFFLER FRONT FLANGE EXHAUST SYSTEM 6K 3 E 10f 4 8 45 4 5 im 33 Exhaust manifold without WU TWO 4 Heated oxygen if equipped 7 Exhaust pipe bolt 12 Muffler gasket 12 Exhaust manifold with WU TWO 5 _ Exhaust pipe gasket 8 18 Exhaust pipe stiffener 2 Sealing 6 1 Exhaust 2 pipe without WU TWO 9 Muffler mounting S Te 3 1 Exhaust No 1 pipe without WU TWO 62 Exhaust No 2 pipe with WU TWO 10 Heated oxygen sensor Do not reuse equipped e 32 Exhaust No pipe with WU TWC 6 3 ExhaustNo 2 pipe without TWO Muffler tall pipe 6 4 EXHAUST SYSTEM MANUAL TRANSMISSION 7A1 1 SECTION 7A1 MANUAL TRANSMISSION E NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS 7 1 1 Unit Repair NOTE This manual transmission for H27 engine is not equipped with C ring of countershaft rear bearing Therefore it is not necessary to disassemble or reassemble this C ring from or to countershaft rear bearing For the descriptions items other than mentioned above refer to the same section of UNIT REPAIR MANUAL mentioned in the FOREWORD of this manual 7A1 2 MANUAL TRANSMISSION AUTOMATIC TRANSMISSION 4 A T 7B1 1 SECTION 7B1 AUTOMATIC TRANSMISSION 4 A T WARNING c
250. TALLATION Refer to OIL PRESSURE CHECK in Section 6A2 Brake Warning Light Brake fluid level switch INSPECTION Use an ohmmeter to check switch for continuity If found defective replace switch reservoir Brake fluid level switch specification OFF position float up No continuity ON position float down Continuity 8C 6 INSTRUMENTATION DRIVER INFORMATION WINDOWS MIRRORS SECURITY AND LOCKS 8D 1 SECTION 8D WINDOWS MIRRORS SECURITY AND LOCKS WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 Othe
251. TC refer to DTC TABLE Example When right front wheel speed sensor circuit opens DTC 21 pre 21 pre 21 DTC 21 488 waning le poy phe EE i Mx 5 1 5 After completing the check turn ignition switch off discon nect service wire from monitor coupler ANTILOCK BRAKE SYSTEM ABS 5E2 11 Diagnostic Trouble Code DTC Check Using SUZUKI Scan Tool 1 After setting cartridge for ABS to SUZUKI scan tool connect SUZUKI scan tool to data link connector Special tool A SUZUKI scan tool 2 Tum ignition switch ON 3 Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down Refer to SUZUKI scan tool operator s manual for further details 4 After completing the check turn ignition switch off and dis connect SUZUKI scan tool from DLC Diagnostic Trouble Code DTC Clearance WARNING When performing a driving test select a safe place where there is neither any traffic nor any traffic accident possi bility and be very careful during testing to avoid occur rence of an accident After repair or replace malfunction part s clear all DTCs by per forming the following procedure 1 Tum ignition switch OFF 2 Using service wire 4 connect diagnosis switch terminal 2 of diagnosis monitor coupler 1 to ground terminal 3 3 With connectio
252. TION Check rear A C main switch for each terminal to terminal continuity If check results are not specified replace rear A C main Switch posit e dj e ON INSTALLATION Reverse removal procedure for installation Rear Blower Motor Resistor REMOVAL 1 Remove rear A C unit referring to REAR A C UNIT in this section 2 Disconnect rear blower motor resistor connector 1 3 Remove rear blower motor resistor 2 from rear A C unit 3 INSPECTION Measure each terminal to terminal resistance If measured resistance is incorrect replace rear blower motor resistor 1 Rear blower motor resister resistance Mo L Approx 2 4 Q Mo ML Approx 1 2 Q Mo MH Approx 0 6 Q INSTALLATION Reverse removal procedure to install rear blower motor resistor 18 36 AIR CONDITIONING OPTIONAL Rear Blower Motor Switch Roar blower motor swich 5 Rar ai ower holder Install proper direction as shown in figure Rear AC air louver Bub Bracket 7 Knob Fear A G air louver case INSPECTION Check rear blower motor switch for each terminal to terminal continuity If check results are not specified replace rear blower motor Switch POSITION Terminal a b d Low obo Middle m o High ERES d i Check rear blower motor switch bulb come ON when con batter
253. Tnjector NoT T njectorNod 10 EM POM 2 Main fuse 5 inecorNo2 3 injecorla 3 Main reay Injector No3 3 Injector Nos 6 1 118 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE INSPECTION Step Action Yes No 1 Check injector for operating sound Go to Step 2 Go to Step 3 Using sound scope check each injector for operating sound at engine cranking Do all 6 injectors make operating sound 2 Wire harness check Fuel injector circuit is PNK BLK PNK 1 Remove ECM PCM cover and disconnect good condition GRN PNK BLU GRY connectors from ECM PCM GRN and GRY BLK 2 Check for resistance between following ter shorted each other minals of ECM PCM connector discon nected Fuel injector and its circuit resistance C51 2 1 C51 3 4 C51 2 2 51 3 4 C51 2 8 C51 3 4 C51 2 9 C51 3 4 51 2 21 C51 3 4 and C51 2 22 51 3 4 14 2 14 8 Q at 20 C 68 F Is check result as specified 3 none of 6 injectors make operating sound Go to Step 4 Check coupler connec atStep 1 tion and wire harness of injector not making oper ating sound and injector itself Refer to FUEL INJECTOR INSPEC TION in Section 6E2 4 Check power circuit of injectors for open and Checkall6 injectors for Power circuit open or short resistance respectively short Is it normal It resistance is OK substi tute a known good ECM PCM and r
254. Torque Specificati Special Tool 5E2 25 5E2 26 5E2 27 5E2 28 5E2 29 5E2 29 5E2 29 5E2 29 5E2 31 5E2 33 5E2 34 5E2 34 ANTILOCK BRAKE SYSTEM ABS 5E2 3 General Description Components Parts Location The ABS Antilock Brake System controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied This ABS has also the following function While braking is applied but before ABS control becomes effective braking force is distributed between the front and rear so as to prevent the rear wheels from being locked too early for better stability of the vehicle The main component parts of this ABS include the following parts in addition to those of the conventional brake sys tem Wheel speed sensor which senses revolution speed of each wheel and outputs its signal ABS warning lamp which lights to inform abnormality when system fails to operate properly ABS hydraulic unit control module assembly is incorporated ABS control module ABS hydraulic unit actua tor assembly fail safe relay and pump motor relay ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure applied to each wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking ABS hydraulic unit which operates according to s
255. Tum ignition switch ON referring to INTERMIT 3 Check engine coolant temp displayed on TENT AND POOR CON scan tool NECTION in Section Is 40 C 40 F or 164 C 327 F indicated 3 Check wire hamess Go to Step 4 ORN BLK wire open or 1 Disconnect ECT sensor connector with igni short or poor C51 3 2 tion switch OFF connection 2 Check for proper connection to ECT sensor If wire and connection are at ORN BLK and GRY YEL wire termi OK substitute a known nals good ECM PCM and If OK then with ignition switch ON is voltage recheck applied to ORN BLK wire terminal about 4 6 v 4 Check wire harness Replace ECT sensor GRY YEL wire open or 1 Using service wire connect ECT sensor connector terminals 2 Tum ignition switch ON and check engine coolant temp displayed on scan tool Is 164 C 327 F indicated poor C51 tion If wire and connection are OK substitute a known good ECM PCM and recheck 23 connec 6 1 54 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0120 DTC No 21 22 Throttle Position Circuit Malfunction WIRING DIAGRAM c30 RYIRED C512 13 fs 1 REDIGAN 4d csias EN 2 051 313 11 q Sii 051312 3 Throtie position sensor 2 ECM PCM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION
256. UISE CABLE PLAY INSPECTION AND ADJUSTMENT in this section 8E 24 CRUISE CONTROL SYSTEM Cruise Cable T Actuator cap 4 Crise cable 7 Clamp at member 2 Actuator assembly 5 Clamp 8 Accelerator pedal 3 Screw 6 Grommet 3 Member REMOVAL 1 Disconnect cruise cable from cruise control arm and accelerator bracket 2 Remove actuator cap and disconnect cruise cable from actuator 3 Release cable from all clamps 4 Remove cable from vehicle INSTALLATION Install cruise cable by reversing removal procedure noting the following points Refer to the figure for proper clamp location and cable routing Adjust cable play to specification referring to CRUISE CABLE PLAY INSPECTION AND ADJUSTMENT in this section BODY SERVICE 9 1 SECTION 9 BODY SERVICE WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 WARN
257. URE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and start engine 3 Increase vehicle speed to 60 km h 40 mph 4 Keep driving above vehicle speed for 5 min Change of vehicle speed is permitted in this step 5 Stop vehicle and run engine at idle speed for 1 min 6 Increase vehicle speed till engine speed is reached 2 000 3 000 r min in proper gear 7 Keep driving at that engine speed for 30 sec or more Engine speed is kept constant in this step 8 Stop vehicle 9 Repeat step 6 to 8 10 Check pending DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 57 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TA
258. URED circuit shorted Replace O D switch 1 Remove console box to ground 2 Disconnect O D off switch connector 3 Check continuity between switch terminals under each condition below O D switch operation With O D off switch button 1 released No continuity With O D off switch button 1 pressed Continuity Is check result satisfactory A for Step 1 B for Step 4 1 781 24 AUTOMATIC TRANSMISSION 4 A T Table B 3 POWER Light Ignition Switch ON But Engine Starts Up WIRING DIAGRAM Check POWER Light Doesn t Light at 5 rx aoa rs fey 57 Glo a 2 WHT BLK cmvimu YEURED ORN BLU tola Sep 2 BLKWHT 902 ey m m sods je 4 amp 8 8 ay 21 20 E61 51 3 51 1 51 2 tH ERG XX W T POM 4 PIN change switch 2 Fuse 5 Jc 3 OID off switch TROUBLESHOOTING Step Action Yes No 1 POWER light circuit check 1 With ignition switch OFF disconnect cou plers from PCM 2 Using service wire connect E61 21 termi nal of disconnected PCM coupler and ground Does POWER light turn ON at ignition switch ON Poor E61 21 terminal con Bulb burned out or faulty nection GRY BLU BLK WHT If OK substi
259. V Transfer shift lever ZH or N E61 19 4WD Indicator lamp 4 seconds after transfer shift lever shifted BLK 0 1V to 4H or 4L Air pump assembly O 1V Transfer shift lever 2H or N C51 1 9 Pump motorandrelease RED seconds after transfer shift lever shifted 10 14V valve to 4H or 4L BLK 10 14V Transfer shift lever 2H or N Color ORN O 1V Transfer shift lever 4H or 4L C51 3 17 Ground oan 0 1V p i O 1V Transfer shift lever 2H or N 51 3 18 Pump assembly PNK 4 seconds after transfer shift lever shifted pressure switch 10 14V to 4H or 4L toto 51317 C53 651 38 connector terminal arrangement viewed from harness side DIFFERENTIAL FRONT AWD Control System Inspection 1 Install special tool to air hose connecting between air pump assembly and differential actuator as shown in figure Tighten adjusting screw 2 of special tool as far as it stops Close air check side opening by using fuel hose 1 as blind plug Special tool A 09918 18110 SUZUKI GENUINE PARTS B 09367 04002 NOTE Use care not to bend any part of hose 2 Turn ON ignition switch and shift transfer lever from 2H to 4H range 3 Check that motor starts running a sound can be heard within 1 second and it stops when gauge of special tool indi cates specified pressure value Chec
260. age and bend according to CHECK ING STEERING COLUMN FOR ACCIDENT DAMAGE in Section 3C1 Steering column bracket and capsules Check for damage and bent If any faulty condition is found in above checks replace faulty part 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 tightness If any faulty condition is found in above checks replace faulty part Contact coil and combination switch assembly Check wire harness and connectors for damage or tight ness Check contact coil case for damage If any faulty condition is found in above checks replace 108 58 AIR BAG SYSTEM Instrument panel member reinforcement and knee bolster amp panel 1 passenger Check for any distortion bending cracking or other dam age If any faulty condition is found in above checks replace 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 SDM 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 The
261. age indicated only when select lever is shifted to 2 range and 0 V for other ranges as shown in figure Check voltage at other terminals likewise referring to figure Are check results satisfactory 5 Check select cable for adjustment referring to Go to Step 6 Adjust SELECT CABLE ADJUSTMENT in this section 15 it adjusted correctly 781 28 AUTOMATIC TRANSMISSION 4 A T Step Action Yes tion line on shaft are aligned Are they aligned 1 Shift select lever to N range 2 Check that N reference line on switch and center 6 Check transmission range switch for installation posi Go to Step 7 Adjust Are check results satisfactory 7 Checktransmission range switch sensor referring to TRANSMISSION RANGE SWITCH in this section YEL ORN GRN RED ORN BLU YELIGRN GRN ORN or GRN BLU circuit open or short If wires and connec tions are OK substi tute a known good PCM and recheck range switch Replace Transmission Fig for Step 2 Terminal C51 1 7 C51 1 6 C51 1 19 C51 1 18 C51 1 28 C51 1 27 Select lever position P B V ov ov 0v ov R B V ov ov 0v ov N ov B V ov ov ov D ov B V 2 ov ov ov ov B V ov L ov ov ov ov ov B V AUTOMATIC TRANSMISSION 4 A T 7B1 28 DTC P0715 DTC NO 76 Input Turbine Speed Sensor Circuit Malf
262. ai storey 13 Ground For G sensor For 4WD vehicle only Table A ABS Warning Lamp Circ Ignition Switch ON ANTILOCK BRAKE SYSTEM ABS 5E2 15 Check Lamp Does Not Come ON at BLKWHT E1318 BLUJORN 5196 14 E136 10 E136 24 E136 25 E13818 136 14 196 23 on GET WHT BLU HE 4 T Man fase S ABS waring lamp 3 Brake fui evel switch 2 Ignition switch 8 Brake waring lamp 0 ASS hydraulic univcontrol modulo assembly 3 tse 7 Lamp driver module 1 ABS hydraulic unticontrol module connector 4 Combination meter 3 Parking brake switch CIRCUIT DESCRIPTION Operation ON OFF of ABS warning lamp is controlled by ABS control module through lamp driver module in combination meter If the Antilock brake system is in good condition ABS control module turns ABS warning lamp ON at the ignition Switch ON keeps it ON for 2 seconds and then turns it OFF If an abnormality in the system is detected ABS warning lamp is turned ON continuously by ABS control module Also it is turned ON continuously by lamp driver module when the connector of ABS control module is disconnected INSPECTION Step Action Yes No 1 1 Tum ignition switch ON Go to Step 2 Go to Step 4 Do other wamin
263. air bag inflator module and seat belt pretensioner The deployment hamess are designed to be reused They should however be inspected for damage after each deployment activation and replaced it if necessary 19 Carefully remove drop cloth 3 from vehicle and clean off any fragments or discard it entirely 20 Repeat Steps 2 through 19 to deploy activate air bag infla tor modules and seat belt pretensioners which has not been deployed activated if any In the unlikely event that the air bag inflator module and the seat belt pretensioner proceed immediately with Steps 23 through 25 If the air bag inflator module and the seat belt pretensioner did deploy activate proceed with Steps 22 17 18 21 22 With air bags deployed and pretensioners activated the vehi cle may be scrapped in the same manner as a non air bag system equipped vehicle 23 Remove the undeployed air bag inflator module s and the inactivated seat belt pretensioner s from the vehicle For driver air bag inflator module refer to SECTION 3C1 for passenger air bag inflator module refer to ON VEHICLE SERVICE for seat belt pretensioner refer to SECTION 10A 24 For air bag inflator module Temporarily store the air bag inflator module with its vinyl trim cover facing up away from the surface upon which it rests Refer to SERVICE PRECAUTIONS for details For seat belt pretensioner When temporarily strong the seat belt pretensioner
264. al entrance of for eign material which could follow intake passage into cylinder and cause extensive damage when engine is started 6 1 4 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE When disconnecting couplers don t pull wire harness but make sure to hold coupler itself With lock type coupler be sure to unlock before disconnection Attempt to disconnect coupler without unlocking may result in damage to coupler When connecting lock type coupler insert it till clicking sound is heard and connect it securely Precaution on Fuel System Service Work must be done with no smoking in a well ventilated area and away from any open flames As fuel feed line between fuel pump and fuel pressure regulator is still under high fuel pressure even after engine was stopped loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected Before loosening or disconnecting fuel feed line make sure to release fuel pressure according to FUEL PRESSURE RELIEF PROCEDURE in this section A small amount of fuel may be released after the fuel line is disconnected In order to reduce the chance of personal injury cover the fitting to be disconnected with a shop cloth Put that cloth in an approved container when disconnection is completed Never run engine with fuel pump relay disconnected when engine and exhaust system are hot Fuel or fuel vapor hose connectio
265. al shift lever nut a 23 2 3 kg m 17 0 Ib ft 5 After select cable was installed check for the following Push vehicle with selector lever shifted to P range Vehicle should not move Vehicle can not be driven in N range Vehicle can be driven in D 2 and L ranges Vehicle can be backed in R range AUTOMATIC TRANSMISSION 4 A T 7B1 49 Unit Repair NOTE The service procedure to be described in this item is the same as that of H25 engine model except the following description Refer to the same section of the Unit Repair Manual mentioned in FOREWORD of this manual for the description not found in this item Sub Assembly Repair Overdrive case side DISASSEMBLY 1 Measure clearance between retaining ring 1 and brake backing plate 2 with thickness gauge If itis not within standard range replace brake disc or brake plate Clearance between retaining ring and brake backing plate Standard 0 40 0 90 mm 0 016 0 035 in 2 Remove retaining ring 1 brake backing plate 2 brake disc 3 brake plate 4 cushion brake plate 5 in that order Then remove planetary ring gear thrust bearing race and thrust rear bearing 3 Remove retaining ring 1 retainer 2 and piston retum spring 3 781 50 AUTOMATIC TRANSMISSION 4 A T Forward clutch 4 Blow air into fluid hole in O D case 2 and remove brake pis ton 1 5 Remove b
266. ality 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 10B 16 AIR BAG SYSTEM Table A AIR BAG Warning Lamp Comes ON Steady Table B AIR BAG Warning Lamp Does Not Come ON Table C AIR BAG Warning Lamp Flashes Table D AIR BAG Warning Lamp Cannot Indicate Flashing Pattern of DTC WIRING DIAGRAM BLU BLK BLU RED Turm sucer gt eum eects 2 PPL Gore NS gt ix B T PA EA T From main fuse 5 AIRBAG fuse 8 To ECM TOM if equipped and ABS control module it equipped 2 Ignition switch 6 Connection detection pin 16 AIR BAG monitor coupler 3 IG METER fuse 7 SDM 3i Ground for air bag system 4 AIR BAG waring lamp in combination meter 8 ToDLC TAI Airbag CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table u
267. allation in Section 6 2 Worn or damaged valve stem seal Valves and cylinder head in Sec tion 6A2 Worn valve stem Valves inspection in Section 6A2 Low oil pressure Improper oil viscosity Engine oil and oil filler change in Section 0B Malfunctioning oil pressure switch Oil pressure switch inspection in Section 8 Clogged oil strainer Oil pan and oil pump strainer clean ing in Section 6A2 Functional deterioration of oil pump Oil pump in Section 6A2 Worn oil pump relief valve Oil pump in Section 6A2 Excessive clearance in various sliding parts INSPECTION for each parts in Section 6A2 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 35 Condition Possible Cause Correction Engine noise Note Before check ing the mechanical noise make sure the followings Ignition timing is properly adjusted Specified spark plug is used Specified fuel is used Faulty hydraulic valve lash adjuster Hydraulic valve lash adjuster in Section 6A2 Worn valve stem and guide Valves inspection in Section 6A2 Weak or broken valve spring Valve springs inspection in Section 6A2 Warped or bent valve Valves inspection in Section 6A2 Loose camshaft housing bolts Camshafts in Section 6A2 Wom piston ring and cylinder bore Pistons and cylinders inspection in Section 6A2 Worn crankpin bearing
268. als d Y d throttle valve opening 1 Ground terminal 2 Output voltage terminal 3 Reference voltage terminal 3 Connect TP sensor coupler securely 4 Connect negative cable to battery REMOVAL 1 Disconnect negative cable at battery 2 Disconnect coupler from TP sensor 3 Remove TP sensor from throttle body INSTALLATION 1 Install TP sensor 1 to throttle body 2 m l Fit sensor 1 to throttle body 2 in such way that its holes little away from TP sensor screw holes as shown in the figure and turn TP sensor 1 clockwise so that those holes align Tightening torque TP sensor screw a 3 5 Nem 0 35 kg m 2 5 Ib ft 2 Connect coupler to TP sensor securely 3 Connect battery negative cable to battery 6 2 36 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 674 Mor reference RESISTANCE 228 281 1 15 0 584 0303 0328 27 157 0 20 40 60 80 32 6B 104 140 176 F TEMPERATURE Engine coolant temperature sensor ECT sensor REMOVAL 1 Disconnect negative cable from battery 2 Drain cooling system 3 Disconnect coupler from ECT sensor 1 4 Remove ECT sensor from water outlet cap 2 INSPECTION Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water g
269. alve stepper motor coil 1 0 1V it equipped Heater of HO2S 2 bank 1 do 51 2 16 At specified idle speed after engine if equipped 0 1V warmed up Heater of HO2S 2 bank 2 lonmen See 51 2 17 At specified idle speed after engine if equipped 0 1V warmed up 51 2 18 cg 1 2 19 Crankshaft position sensor if equipped Crankshaft position sensor 2 if equipped Fue injector No 6 10 14V Ignition switch ON Fuel injector No 5 Ignition coil assembly for No 6 Ignition coil assembly for No 5 Ignition coil assembly for No 4 Ignition coil assembly for No 3 Ignition coil assembly for No 2 Ignition coil assembly for No 1 Ground for CKP sensor shield wire if equipped 6 1 42 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE RESISTANCE CHECK 1 Disconnect couplers 1 from ECM PCM with ignition switch OFF CAUTION Never touch terminals of ECM PCM itself or connect volt meter or ohmmeter 2 2 Check resistance between each pair of terminals of discon nected couplers 1 as listed in following table CAUTION Be sure to connect ohmmeter 2 probe from wire har ness side of coupler Be sure to turn OFF ignition switch for this check Resistance in table represents that when parts temper ature is 20 C 68 F
270. an open or intermittent open due to poor terminal contact BASE OF COLUMN PASSENGER INFLATOR STEERING WHEEL BAG SYSTEM 108 7 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 followings Driver air bag inflator module when it is connected at the top of the column to the contact coil assembly Passenger air bag inflator module when it is connected to the air bag harness connector for passenger air bag inflator module Each of driver and passenger seat belt pretensioners when it is connected to air bag hamess connector for driver and pas senger seat belt pretensioner if equipped 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
271. and disconnect service wire from monitor coupler Diagnostic Trouble Code DTC Clearance Using scan tool 1 With ignition switch OFF connect generic scan tool or SUZUKI scan tool to data link connector DLC 2 ignition switch ON 3 Erase DTC according to instructions displayed on scan tool Freeze frame data is cleared with the DTC Refer to scan tool operator s manual for further details 4 After completing the clearance turn ignition switch off and disconnect scan tool from data link connector NOTE DTC and freeze frame data stored in ECM PCM memory are also cleared in following cases Be careful not to clear them before keeping their record When power to ECM PCM is cut off by disconnecting battery cable removing fuse or disconnecting ECM PCM connectors When the same malfunction DTC is not detected again during 40 engine warm up cycles refer to WARN UP CYCLE of ON BOARD DIAGNOSTIC SYS TEM in this section Vehicle without monitor connec tor 6 1 18 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Without using scan tool 1 Turn the ignition switch OFF position 2 Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM memory and reconnect it Time required to erase DTC Ambient Time to cut power to ECM temperature Over 0 C 32 F 30 sec or longer Under 0 C Not specifiable 32 F Select a place with hig
272. ansion valve 34 5 Rear AIC evaporator 10 Rearsuction pipe 15 Packing 2 Recover refrigerant by using recovery and recycling equip ment Be sure to follow the instruction manual for the equip ment The amount of compressor oil removed must be measured and the same amount added to the system 3 Remove rear luggage mat end garish 1 rear luggage box 2 if equipped rear side sill scuff 3 rear quarter lower trim 4 and rear quarter upper trim 5 AIR CONDITIONING OPTIONAL 18 28 4 Loosen floor suction pipe and floor liquid pipe mounting bolt 1 2 Matfer 5 Remove rear A C No 1 duct 1 6 Disconnect rear A C unit wire couplers 2 7 Remove rear A C unit mounting bolts 3 and then remove rear A C unit 4 NOTE Cap open fitting immediately to keep moisture out of sys tem INSPECTION Check the following Clog of rear A C evaporator fins If any clogs are found rear A C evaporator fins should be washed with water and should be dried with compressed air Rear A C evaporator fins for leakage and breakage If any defects are found repair or replace rear A C evapora tor INSTALLATION Reverse removal procedure to install rear A C unit noting the fol lowing points Evacuate and charge system Refer to RECOVERY and EVACUATING in this section When the rear A C evaporator thermistor temperature sen sor removed i
273. ar axle shaft be careful not to cause damage to oil seal lip in axle housing Tightening torque Bearing retainer nut a 50 N m 5 0 kg m 36 5 Ib ft 8 Tighten wheel speed sensor bolt to specified torque if equipped with ABS Tightening torque Wheel speed sensor bolt b 21 N m 2 1 kg m 15 5 Ib ft 9 Refill rear axle housing with new specified gear oil Refer to MAINTENANCE SERVICE in Section 7F 10 Install brake drum Refer to BRAKE DRUM in Section 5 REAR SUSPENSION 3E 5 Rear Axle Shaft Inner INSTALLATION Seal 1 Using special tool drive in oil seal until it contacts oil seal pro tector in axle housing NOTE Make sure that oil seal is free from inclination as it is installed Refer to the figure so that oil seal is installed in proper direction Special tool 9924 74510 A Grease 99000 25010 B Sealant 99000 31110 1 Hammer 4 soal 2 Rod 5 Body center 3 seal protector 2 For procedure hereafter refer to steps 6 to 11 of INSTAL LATION under REAR AXLE SHAFT in the service manual mentioned in the FOREWORD of this manual Rear Axle Housing INSTALLATION For Step 1 to 4 7 and 9 to 30 refer to the same section in the Service Manual mentioned in the FOREWORD of this manual 3 Clean mating surfaces of axle housing 1 and differential carrier and apply sealant A to housing side
274. ard sample It should be modified according to conditions character each market ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 13 STEP 2 DIAGNOSTIC TROUBLE CODE DTC FREEZE FRAME DATA CHECK First check DTC referring to DIAGNOSTIC TROUBLE CODE CHECK in this section If DTC is indicated record DTC and freeze frame data After that clear DTC referring to DIAGNOSTIC TROUBLE CODE CLEARANCE in this section DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now To check which case applies check the symptom in question according to Step 5 and recheck DTC according to Step 6 7 Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC including pending DTC in this step will lead to incorrect diagnosis trouble diagnosis of a normal circuit or difficulty in troubleshooting NOTE For vehicle if only DTC P0705 P0715 P0720 P0741 P0743 P0751 P0753 P0756 P0758 or P1875 is indicated in this step proceed to DIAGNOSIS in SECTION 7B1 STEP 3 and 4 VISUAL INSPECTION Be sure to perform visual check of the following items that support proper function of the engine INSPECTION ITEM REFERRING SECTION Engine oil level leakage SECTION 0B Engine coolant level leakage SECTION 0B Fuel level leakage SECTION 0B AIT fluid
275. arefully torqued and the arrow must be pointed toward the front of the vehicle to ensure proper operation of the air bag system 108 52 AIR BAG SYSTEM 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 from 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 tempe
276. art number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as speci fied during reassembly to assure proper retention of this part Never attempt to heat quench or straighten any suspension part Replace it with a new part or damage to the part may result CONTENTS On Vehicle Service 3E 1 Tightening Torque Specification 6 Rear Axle Shaft and Wheel Bearing 1 Required Service Material 6 Rear Axle Shaft Inner Oil Seal 3E 5 Special Tool 3E 7 Rear Axle Housing On Vehicle Service Rear Axle Shaft and Wheel Bearing REMOVAL 1 Remove axle shaft from axle housing according to Step1 to 6 in the same section in the service manual mentioned in the FOREWORD of this manual noting following points 3E 2 REAR SUSPENSION 2 Remove circlip from axle shaft 3 In order to remove retainer ring 1 from axle shaft 3 grind with a grinder two portion 2 of bearing retainer ring as illus trated till it becomes thin CAUTION Be careful not to grind axle shaft TAY Vehicle with ABS IBI Vehicle without ABS 4 Break with a chisel 1 the thin ground sensor rotor and retainer ring and it can be removed 5 Remove wheel bearing 1 and bearing retainer 2 using special tools as shown in figure Special tool A 09927 18411 B
277. as to what functions are available and how to use it Priorities for diagnosing troubles Vehicle without monitor connector If two or more diagnostic trouble codes DTCs are stored proceed to the flow table of the DTC which was detected earliest in the order and follow the instruction in that table If no instructions are given troubleshoot diagnostic trouble codes according to the following priorities Diagnostic trouble codes DTCs other than DTC P0171 P0172 P0174 P0175 Fuel system too lean too rich P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire detected and DTC P0400 EGR flow malfunction DTC P0171 P0172 P0174 P0175 Fuel system too lean too rich and DTC P0400 EGR flow malfunction DTC P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire detected Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE in Section 0A before inspection and observe what is written there ECM PCM Replacement When substituting a known good ECM PCM check for following conditions Neglecting this check may cause damage to a known good ECM PCM Resistance value of all relays actuators is as specified respectively MAF sensor MAP sensor and TP sensor are in good condition and none of power circuits of these sen sors is shorted to ground ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 11 Engine Diagnostic Flow Table Refer to following pages for the detail of each step
278. ass air flow sensor INJ PULSE WIDTH B1 Fuel Injection Pulse Width Bank 1 msec INJ PULSE WIDTH B2 Fuel Injec tion Pulse Width Bank 2 msec This parameter indicates time of the injector drive valve opening pulse which is output from ECM PCM THROTTLE POS Absolute Throttle Position When throttle position sensor is fully closed position throttle opening is indicated as 0 and 100 for full open position 6 1 28 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE TP SENSOR VOLT TP Sensor Output Voltage V Throttle Position Sensor reading provides throttle valve opening information in the from of voltage 025 B1 1 HO2S Bank 1 Sensor 1 Output Voltage V 025 B2 1 HO2S Bank 2 Sensor 1 Output Voltage V It indicates output voltage of HO2S SENSOR 1 installed on exhaust manifold pre catalyst 025 B1 S2 HO2S Bank 1 Sensor 2 Output Voltage V 025 B2 S2 HO2S Bank 2 Sensor 2 Output Voltage V If indicates output voltage of HO2S SENSOR 2 installed on exhaust pipe post catalyst It is used to detect cat alyst deterioration FUEL SYSTEM B1 Fuel System Bank 1 Status Fuel System B2 Fuel System Bank 2 Status Air fuel ratio feedback loop status displayed as one of the followings OPEN Open loop has not yet satisfied conditions to go closed loop CLOSED Closed loop using oxygen sensor s as feedback for fuel control OPEN DRIVE COND Open loop due to driving conditions Power enrichment etc OPE
279. at the same time apply parking brake 2 After stopping engine depress brake pedal and release paring 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 to make sure no one is around vehicle or down on a slope and keep watchful for safety during test 4 48 us D OO m 92 15 FULL HOT LOW HOT AUTOMATIC TRANSMISSION 4 A T 71 43 On Vehicle Service Maintenance Service Fluid level LEVEL CHECK AT NORMAL OPERATING TEMPERATURE 1 Stop vehicle and place it level 2 Apply parking brake and place chocks against wheels 3 With selector at P position start engine 4 Warm up engine till fluid temperature reaches normal oper ating temperature 70 80 C 158 176 F As a guide to check fluid temperature warm up engine till engine coolant temperature meter indicated around 1 unit above C point 5 Keep engine idling and shift selector slowly to L and back to P position VA Shift the select lever with its button pushed in IB Shift the select lever without pushing button 6 With engine idling pull out dipstick wipe it off with a clean cloth and put it back into place 7 Pull out dipstick agai
280. ation Switch under Rear Wiper and Washer If Equipped in the same section of the Service Manual mentioned in FOREWORD of this manual Rear Wiper Intermittent Relay INSPECTION Refer to Rear Wiper Intermittent Relay under Rear Wiper and Washer If Equipped in the same section of the Service Manual mentioned in FOREWORD of this manual when service vehicle without cruise control sys tem CRUISE CONTROL SYSTEM 8E 1 SECTION 8E CRUISE CONTROL SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 Oth
281. ator 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 comstarch 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 When disposing of the deployed air bag inflator module and the activated seat belt pretensioner be sure to seal it in a vinyl bag 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 Be sure to wash your hands with mild soap and water after handling it Tightening Torque Specification AIR BAG SYSTEM 108 77 Fastening part Tightening torque Nem kg m Ib ft SDM boit 6 06 45 Passenger air bag inflator module screw 55 0 55 40 Passenger air bag inflator module bolt 23 23 165 Forward sensor bolt 10 1 0 72 Driver air bag inflator module bolt Refer to Section 3C1 Seat belt pretensioner retractor assembly bolt Refer to Section 10A Special Tool 09932 75010 Air bag driver passenger load tool 09932 75030 Air bag deployment har ness 09932 75041 Passenger air bag infla tor module deployment fixture 09932 75020 Connector test adapter kit Digital multimeter S
282. ator module or the seat belt preten sioner did deploy activate proceed with Steps 16 through 19 16 Put on a pair of shop gloves to protect your hands from pos sible irritation and heat when handling the deployed air bag inflator module and the activated seat belt pretensioner Disconnect the deployment harness from the air bag infla tor module and the seat belt pretensioner as soon after deployment activation as possible This will prevent damage to the deployment harness due to possible contact with the hot air bag inflator module and seat belt pretentioner The deployment harness are designed to be reused They should however be inspected for damage after each deployment activation and replaced it if necessary 17 AIR BAG SYSTEM 108 71 18 Dispose of the deployed air bag inflator module and the activated seat belt pretensioner through normal refuse chan nels after it has cooled for at least 10 minutes and tightly seal the air bag inflator module and the seat belt pretensioner in a strong vinyl bag Refer to DEPLOYED AIR BAG INFLA TOR MODULE AND ACTIVATED SEAT BELT PRETEN SIONER DISPOSAL in detail 19 Wash your hands with mild soap and water afterward NOTE The remaining steps are to be followed in the unlikely event that the air bag inflator module did not deploy the seat belt pretensioner did not activate after following these procedures 20 Ensure that the deployment harness
283. bag wire hamess 5 Contact ooi 2 Passenger air bag inflaton module 8 Driver air bag inflator module 3 SOM 7 Forward sensors 4 Seat belt pretensioners Diagnosis When troubleshooting air bag system be sure to follow DIAGNOSIS in SECTION 10B Bypassing these proce dures may result in extended diagnostic time incorrect diagnosis and incorrect parts replacement Never use electrical test equipment other than that specified in this manual WARNING Never attempt to measure the resistance of the air bag inflator modules driver and passenger and seat belt pretensioners driver and passenger It is very danger ous as the electric current from the tester may deploy the air bag or activate the pretensioners GENERAL INFORMATION 0A 3 Servicing and handling WARNING Many of service procedures require disconnection of AIR BAG fuse and all air bag inflator module s from initiator circuit to avoid an accidental deployment Driver and Passenger Air Bag Inflator Modules 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 mo
284. 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 T Gonnectorfor contact and driver air bag inflaton module Located near the base of the steering column 2 Connector for diver passenger air bag inflaton module and driver and passenger seat belt pretensioners 3 Notused 108 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 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 adapte
285. ble cause is clogged EGR gas passage stuck or faulty EGR valve 1 SUZUKI scan tool display 2 EGR valve opening 0 Close 100 Full Open REMOVAL 1 Disconnect negative cable at battery 2 Disconnect EGR valve coupler 3 Remove wire harness bracket from intake collector 4 Remove EGR valve 5 and gasket from intake collector 1 EVAP canister purge vave 4 EGRpipe EVAP canister purge valve hose PCV hose Breather hose ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 45 INSPECTION 1 Check resistance between following terminals of EGR valve 1 in each pair If found faulty replace EGR valve assembly EGR valve resistance Terminals Standard resistance AL A B 20 24 Q at 20 C 68 F D E B valve body E valve body infinity e 2 Remove carbon from EGR valve gas passage NOTE Do not use any sharp edged tool to remove carbon Be careful not to damage or bend EGR valve valve seat and rod 3 Inspect valve 2 valve seat 3 and rod for fault cracks bend or other damage If found faulty replace EGR valve 1 assembly INSTALLATION Reverse removal procedure noting the followings Clean mating surface of valve and intake manifold Use new gasket EVAP canister INSPECTION WARNING DO NOT SUCK nozzles on EVAP
286. bright metals including chrome After recovering refrigerant from system the amount of compressor oil removed must be measured and the same amount added to the system Refrigerant recovery When discharging refrigerant out of A C system always recover it by using refrigerant recovery and recycling equipment Discharging refrigerant HFC 134a R 134a into atmosphere would cause adverse effect to environ ments NOTE When handling recovery and recycling equipment be sure to follow the instruction manual for the equipment Refrigerant charge Charge a proper amount of refrigerant to A C system according to charging procedure described in recovery evacuation and charging CAUTION Do not perform an additional refrigerant charging to A C system This cause it to overcharge AIR CONDITIONING OPTIONAL 18 27 Replenishing compressor oil CAUTION Be sure to use HFC 134a R 134a compressor oil When replacing air conditioning parts with new ones it is neces sary to replenish oil by the amount supposedly remaining in each part WHEN CHANGING GAS ONLY When it is unavoidable to change gas without replacing any com ponent part for engine removal and installation or for some other reason replenish 20 cm 20 oil When replenishing gas only oil replenishment is not necessary WHEN REPLACING COMPRESSOR Compressor oil is sealed in each new compressor by the amount required for air condit
287. by prod ucts of the chemical reaction 108 70 AIR BAG SYSTEM WARNING After deployment activation the metal surfaces of the air bag inflator module and the seat belt pretensioner Will be very hot Do not touch the metal areas of them for about 30 minutes after deployment activation Do not place the deployed air bag inflator module and the activated seat belt pretensioner near any flamma ble objects Do not apply water oil etc to deployed air bag infla tor module and activated seat belt pretensioner If the deployed air bag inflator module and the acti vated seat belt pretensioner must be moved before it is cool wear gloves and handle it by using nonmetal material such as the air bag webbing and vinyl trim Failure to follow procedures may result in fire or per sonal injury 12 Separate 1 the two banana plugs on the deployment har ness 13 Connect the deployment harness to the power source 12V vehicle battery 2 to immediately deploy activate the air bag or seat belt pretensioner 14 Disconnect the deployment harness from power source 12V vehicle battery 2 and short 3 the two deployment har ness leads together by fully seating one banana plug into the other 15 In the unlikely event that the air bag inflator module or seat belt pretensioner did not deploy activate after following these procedures proceed immediately with Steps 20 through 23 If the air bag infl
288. cates the result by turning on of flashing mal function indicator lamp 1 Heated oxygen sensor if equipped ECT sensor TP sensor IAT sensor CMP sensor MAF sensor Knock sensor EGR if equipped VSS CPU Central Processing Unit of ECM and malfunction indicator lamp 1 operate as follows Malfunction indicator lamp 1 light when the ignition switch is tumed ON but the engine at stop with the diagnosis switch terminal ungrounded regardless of the condition of Engine and Emission control system This is only to check the malfunction indicator lamp 1 bulb and its circuit If the above areas of Engine and Emission control system is free from any trouble after the engine start while engine is running malfunction indicator lamp 1 tums OFF When ECM detects a trouble which has occurred in the above areas it makes malfunction indicator lamp 1 turn ON while the engine is running to warn the driver of such occur rence of trouble and at the same time it stores the trouble area in ECM back up memory The memory is kept as it is even if the trouble was only temporary and disappeared immediately And it is not erased unless the power to ECM is shut off for specified time ECM also indicates trouble area in memory by means of flashing of malfunction indicator lamp 1 at the time of inspection Le when diagnosis switch terminal 2 is con nected to ground terminal 3 with a service wire and ignition switch is
289. ck Go to Step 5 Go to Step 6 1 With ignition switch ON leaving engine OFF check voltage between C20 1 and C20 2 terminal of VSS coupler Is voltage 4 V or more ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 107 1 With ignition switch OFF disconnect G11 coupler from combination meter 2 With ignition switch ON leaving engine OFF check voltage between C20 1 and C20 2 terminal of VSS coupler 15 voltage 4 V or more Step Action Yes No 5 VSS visual inspection Poor VSS connection or VSS Replace VSS 1 Remove VSS referring to TRANSFER malfunction section If connection is OK substi 2 Check VSS drive and driven gears for tute a known good VSS and damage and excessive wear recheck Are they in good condition 6 _ Speedometer circuit che Substitute aknown good Goto Step 7 combination meter and recheck 7 Cruise control module circuit check if equipped 1 With ignition switch OFF disconnect E132 coupler from cruise control mod ule 2 With ignition switch ON leaving engine OFF check voltage between C20 1 and C20 2 terminal of VSS coupler 15 voltage 4 V or more Substitute a known good cruise control module and recheck BLU YEL wire short or faulty ECM PCM If wire and connection are OK substitute a known good ECM PCM and recheck A Fig for Step 3 B Fig for Step 4 6 7
290. ck Flow Table 10B 10 DTC Checl 10B 11 DTC Clearance 10B 12 DTC Table Table A AIR BAG Warning Lamp Comes ON Steady Table B AIR BAG Waming Lamp Does Not Come ON xi Table C AIR BAG Warning Lamp Flashes Table D AIR BAG Warning Lamp Cannot Indicate Flashing Pattern of DTC 108 16 Table E SDM Cannot Communicate through The Serial Data Circuit DTC B1015 Passenger Air Bag Initiator Circuit Resistance Hig 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 10B 21 10B 23 10B 23 10B 23 Circuit Short to Power Circuit 10B 23 DTC B1021 Driver Air Bag Initiator Circuit Resistance High 10B 28 DTC B1022 Driver Air Bag Initiator Circuit Resistance Low 10B 28 DTC B1024 Driver Air Bag Initiator Circuit Short to Ground DTC B1025 Driver Air Bag Initiator Circuit Short to Power Circuit 10B 28 10B 28 10B 2 AIR BAG SYSTEM DTC B1031 Power Source Voltage High 10B 33 DTC B1032 Power Source Voltage Low 10B 33 DTC B1035 RH Forward Sensor Circuit Open or Short to Ground 1 DTC B1036 RH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit DTC B1037 LH Forward Sensor Circuit Open or Short to Ground DTC B1038 LH Forward Sensor Circuit Short
291. ck charge of refrigerant Air in system Replace condenser dryer and then perform evacuation and charging Drive belt slipping Adjust or replace drive belt Compressor faulty Check compressor Cool air does not comes out only at high speeds Excessive charge of refrigerant Check charge refrigerant evaporator frosted Check evaporator Check A C thermistor Insufficient velocity of cooled air AIC evaporator clogged or frosted Check evaporator Air leaking from cooling unit or air duct Repair as necessary Blower motor faulty Check blower motor Wiring or grounding faulty Repair as necessary 18 8 AIR CONDITIONING OPTIONAL Rear A C system Condition Possible Cause Correction Cool air dose not come out Rear blower motor normal operative Solenoid valve relay faulty Check solenoid valve relay and then replace if necessary Solenoid vaive faulty Check solenoid valve and then replace if necessary Diode in rear harness faulty Check diode and then replace rear hamess if necessary Rear evaporator temperature controller faulty Check rear A C evaporator temperature controller and then replace if necessary Rear blower motor switch faulty Check rear blower motor switch and then repair rear A C evaporator and check rear A C evaporator temperature contro
292. cle before disconnecting front propeller shaft put match mark 1 on joint flange and propeller shaft to facil itate their installation as shown in the figure 10 For 4WD vehicle disconnect propeller shaft from front differ ential 11 Remove exhaust manifold stiffeners 1 2 Exhaust No 1 pipe Without WU TWC B Wih WU TWC 12 Remove stabilizer bar mounting bolt and pull down stabilizer bar if right side exhaust manifold is removed 13 Remove exhaust manifolds and their gaskets from cylinder heads ENGINE MECHANICAL H27 ENGINE 6A2 11 INSTALLATION 1 Install new manifold gaskets to cylinder heads and No 1 pipe gasket to exhaust No 1 pipe 2 Install exhaust manifolds Always install new bolts with pre coated adhesive to the locations with mark Tighten both manifold nuts and bolts to specified torque Tightening torque Exhaust manifold bolt and nut a 30 N m 3 0 kg m 21 5 Ib ft 3 Left No 1 exhaust manifold 2 Right No 2 exhaust manifold 3 Install stabilizer bar if it was removed Refer to STABILIZER BAR BUSHINGS in Section 3D 4 Install exhaust manifold stiffeners if removed 5 Install exhaust No 1 pipe 1 Tighten exhaust No 1 pipe bolts to specified torque Tightening torque Exhaust No 1 pipe bolt b 50 N m 5 0 kg m 36 5 Ib ft 2 Exhaust No 2 pipe 6 Tighten exhaust No 1 pipe nuts to
293. completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1051 Frontal Crash Detected System Activation Command Output ted 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 NOTE Before executing items in this table be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK Step Action Yes No 1 1 Ignition switch OFF Replace components Goto step 2 Has air bag deployed perform inspections as directed in REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT AIR BAG SYSTEM 108 47 Step Action Yes No 2 1 Inspect front of vehicle and undercar Replace components and Substitute a known good riage for signs of impact perform inspections as SDM and recheck Are there signs of impact directed in REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT in this section NOTE Upon completion of inspection and repair work perform following items Reconnect all a
294. components leave steer ing wheel installed on steering column REMOVAL WARNING Never rest a steering column assembly on the steering wheel with air bag inflator module face down and column vertical Otherwise personal injury may result CAUTION Never turn steering wheel while steering column with steering wheel is removed Turning steering wheel more than about two and a half turns will break contact coil 1 Disconnect negative cable at battery 2 Disable air bag system Refer to DISABLING AIR BAG SYSTEM under SERVICE PRECAUTIONS in Section 10B 3 Remove steering wheel and contact coil and combination switch assembly if necessary Refer to STEER ING WHEEL and CONTACT COIL AND COMBINATION SWITCH ASSEMBLY in this section Perform the following procedure if not removing steering wheel and or combination switch a Tum steering wheel so that vehicle s front tires are at straight ahead position b Tum ignition switch to LOCK position and remove key Wy 4 Remove steering column hole cover 1 MN VL 5 Disconnect all connectors for the following parts Contact coil and combination switch Ignition switch AIR BAG STEERING WHEEL AND COLUMN 3C1 5 6 Remove steering upper shaft upper joint bolt 1 and nut 2 and disconnect steering upper shaft upper joint removing in arrow direction in the figure
295. connect voltmeter or ohmmeter to cruise control module with coupler disconnected from it VOLTAGE CHECK Check for input or output voltage of control module voltage between each circuit and body ground with cruise control module connector connected CIRCUIT NORMAL VOLTAGE CONDITION Vehicle speed sensor Indicator deflection repeated between 0 1Vand3 5V Ignition switch ON and cruise main switch ON Vehicle hoisted and rear left tire turned slowly with rear right tire locked Stop lamp switch 0 2V Brake pedal released 10 14V Brake pedal depressed Overdrive and TCC off signal 10 14V Ignition switch ON 4 only CRUISE indicator light 10 14V Ignition switch ON Ground Brake pedal position switch 10 14V Ignition switch ON and brake pedal released in stop lamp switch ov Ignition switch ON and brake pedal depressed Throttle valve opening signal from PCM 4A T only Ignition switch ON Voltage varies as specified by graph in THROTTLE VALVE OPENING SIG NAL CIRCUIT CHECK in this section Cruise main switch 7 9V Ignition switch ON and cruise main switch released 3 5V ignition switch ON and cruise main switch pressed CANCEL switch 0 1V Ignition switch ON and CANCEL switch pressed COAST SET switch 1 2V Ignition switch ON and COAST SET switch rotated RESUME ACCEL switch 25 4V Ignition switch ON and RESUME ACCEL switch rotate
296. control system consists of 1 various sensors which detect the state of engine and driving condi tions 2 ECM PCM which controls various devices according to the signals from the sensors and 3 various controlled devices Functionally it is divided into the following sub systems Fuel injection control system Heated oxygen sensor heater control system if equipped Idle air control system Fuel pump control system Evaporative emission control system Ignition control system EGR system if equipped Also with A T model PCM controls A T INFORMATION SENSORS CONTROLLED DEVICES OTHERS sensor A G condenser fan motor relay f equipped A Main fuse box 2 MAP sensor if equipped b ignition assemblies B PCM 3 Heated oxygen sensor sensor 1 equipped c EVAPcanister purge valve Data link connector 4 ECT sensor d valve if equipped D Combination meter 5 TP sensor 1 air control valve E Fuse box MAF sensor f Injectors EVAP canister 7 Camshaft position sensor sensor 9 Malfuncton indicator lamp 8 ABS control module h Fuel pump relay 8 Crankshaft position sensor sensor equipped i Main relay 10 Power steering pressure switch PSP switch Oxygen sensor heater relay f equipped 11 CO adjusting resistor f equipped 12 Monitor connector f equipped 18 Transmission range switc
297. ct ABS hydraulic unit control module assembly con nector 1 by pulling up lock 2 52 32 ANTILOCK BRAKE SYSTEM ABS 3 Using special tool loosen flare nuts 1 and disconnect brake pipes 2 from ABS hydraulic unit control module assembly 3 Special tool 09950 78220 NOTE Put bleeder plug cap onto pipe to prevent fluid from spill ing Do not allow brake fluid to get on painted surfaces 4 Remove three bolts and take out ABS hydraulic unit control module assembly 1 from bracket using flat end rod or the like 2 CAUTION Do not give an impact to hydraulic unit Use care not to allow dust to enter hydraulic unit Do not place hydraulic unit on its side or upside down Handling it in inappropriate way will affect its original performance INSTALLATION 1 Install hydraulic unit control module assembly by reversing removal procedure Tightening torque Brake pipe flare nut a 16 N m 1 6 kg m 11 5 Ib ft ABS hydraulic unit control module assembly bolt b 9 N m 0 9 kg m 6 5 Ib ft Bracket bolt c 10 N m 1 0 kg m 6 5 Ib ft 2 Bleed air from brake system referring to BRAKES section 3 Check each installed part for fluid leakage and perform ABS HYDRAULIC UNIT OPERATION CHECK in this section NOTE For new ABS hydraulic unit control module assembly if ABS HYDRAULIC UNIT OPERATION CHECK procedure has not been performed ABS warning
298. ct scan tool with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data in ECM memory by using scan tool and start engine 3 Increase vehicle speed to 55 km h 40 mph or more 4 Keep driving above vehicle speed till engine is warmed up completely Changed of vehicle speed is permit ted in this step 5 Keep driving 50 60 km h 30 40 mph for 8 min or more 6 Stop vehicle and check if pending DTC exists by using scan tool If not check if oxygen sensor heater moni toring test has completed by using scan tool If not in both of above checks i e no pending DTC and oxy gen sensor heater monitoring test not completed check vehicle conditions environmental and repeat Steps 3 through 6 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 HO28 2 output voltage check Go to Step 4 Go to Step 3 1 Connect scan tool to DLC with ignition Switch OFF 2 Drive vehicle about 35 mph 55 km h for 2 min or more 3 Stop vehicle and check HO2S 2 output volt age displayed on scan tool while repeating racing engine Is over and below 0 3 V indicated 3 HO2S2 check RED BLK or GRY YEL Replace HO2S 2 1 With ignition switch OFF disconnect HO2S circuit open short 2 coupler If wire and connection are 2 Connect voltmeter between 2 and 1 of substitute a kn
299. cuit Malfunction DTC P0120 DTC No 21 22 Throttle Position Circuit Malfunction DTC P0121 Throttle Position Circuit Range Performance Problem 6 1 56 DTC P0130 DTC No 13 HO2S 1 Bank 1 Circuit Malfunction or No Activity Detected 6 1 58 DTC P0133 HO2S 1 Bank 1 Circuit Slow Response E DTC P0135 HO2S 1 Bank 1 Heater Circuit Malfunction DTC P0136 HO2S 2 Bank 1 Circuit Malfunction 6 1 63 P0141 Circuit Malfunction 6 1 65 DTC P0150 DTC No 26 HO2S 1 Bank 2 Circuit Malfunction or No Activity Detected 6 1 67 P0153 HO2S 1 Bank 2 Circuit Slow Response 6 1 69 DTC P0155 HO2S 1 Bank 2 Heater Circuit Malfunction DTC P0156 HO2S 2 Bank 2 Circuit Malfunction DTC P0161 HO2S 2 Bank 2 Heater Circuit Malfunction DTC P0171 P0172 Fuel System Lean Rich Bank 1 DTC P0174 P0175 Fuel System Lean Rich Bank 2 P0300 P0301 P0302 P0303 P0304 P0305 P0306 Random Misfire Cylinder 1 Misfire Cylinder 2 Misfire Cylinder 3 Misfire Cylinder 4 Misfire Detected Cylinder 5 Misfire Detected Cylinder 6 Misfire Detected DTC P0325 DTC No 43 Knock Sensor 6 1 45 6 1 46 6 1 48 6 1 50 6 1 52 6 1 54 6 1 60 6 1 61 6 1 70 6 1 72 6 1 74 6 1 76 6 1 78 6 1 80 Circuit Malfunction i DTC P0335 Crankshaft Position Sensor Circuit Malfunction DTC P0340 DTC No
300. cuit or Sensor Ring DTC C1031 DTC 31 DTC C1032 DTC 32 Right Rear Wheel Speed Sensor Circuit or Sensor Ring DTC C1035 DTC 35 DTC C1036 DTC 36 Left Rear Wheel Speed Sensor Circuit or Sensor Ring BLKWHT GESE GANIBLK GESAG ETE ui BLU BLK EGET Gem LT GRN BLK LTGRN E3827 i GESENG Ei3648 138 15 w w E YEUBLK 51905 10 Ene ad E1397 es 6 E1364 E1963 3 Ignition switch 4 Rightiront wheel speed sensor 7 ABS hydraulic uniticontrol module connector 2 ABS control module hydraulic unit assembly 5 Leftrear wheel speed sensor 3 Lefkiront wheel speed sensor 6 Rightrear wheel speed sensor DESCRIPTION The ABS control module monitors the voltage at the terminal of each sensor while the ignition switch is ON When the voltage is not within the specified range an applicable DTC will be set Also when no sensor signal is inputted at starting or while running an applicable DTC will be set NOTE When the vehicle was operated in any of the following ways one of these DTCs may be set even when the sensor is in good condition If such possibility is suspected repair the trouble dragging of brake etc of the vehicle clear DTC once and then after performing the driving test as described in Step 2 of ABS DIAGNOSIS FLOW TABLE check whether o
301. d CLOSED THROT POS Closed Throttle Position ON OFF This parameter will read ON when the throttle valve is fully closed Or OFF when the throttle is not fully closed IAC FLOW DUTY This parameter indicates IAC valve opening rate which controls bypass air flow ENGINE SPEED RPM It is computed by reference pulses from the Camshaft Position Sensor SHORT FT B1 Short Term Fuel Trim Bank 1 SHORT FT B2 Short Term Fuel Trim Bank 2 Short term fuel trim value represents short term corrections to the air fuel mixture computation A value of 0 indi cates no correction a value greater than 0 means an enrichment correction and a value less than 0 implies an enleanment correction LONG FT B1 Long Term Fuel Trim Bank 1 LONG FT B2 Long Term Fuel Trim Bank 2 Long term fuel trim value represents long term corrections to the air fuel mixture computation A value of 0 indi cates no correction a value greater than 0 means an enrichment correction and a value less than 0 implies an enleanment correction IGNITION ADVANCE Ignition Timing Advance For No 1 Cylinder Ignition timing of No 1 cylinder is commanded by ECM PCM The actual ignition timing should be checked by using the timing light BATTERY VOLTAGE V This parameter indicates battery positive voltage inputted from main relay to ECM PCM MAF Mass Air Flow Rate g s Ib min It represents total mass of air entering intake manifold which is measured by m
302. d Clutch pedal position switch 10 14V Ignition switch ON and clutch pedal released M T only 0 1V Ignition switch ON and clutch pedal depressed fully Transmission range switch ov Ignition switch ON and selector lever in P or Park Neutral position switch range only 10 i4V Ignition switch ON and selector lever in F D 2 or L range Cruise main switch indicator 0 1V Ignition switch ON lamp 10 14V Ignition switch ON and after input main switch ON sig nal 18 CRUISE CONTROL SYSTEM RESISTANCE CHECK 4 Disconnect cruise control module connector from cruise con trol module with ignition switch OFF CAUTION Never touch terminals of cruise control module itself or connect voltmeter or ohmmeter 5 Check resistance between each pair of terminals of discon switch in stop lamp nected connectors as shown the following table _ T Crase conma module connector 162 STANDARD TERMINALS CIRCUIT RESISTANCE CONDITION E132 11 body ground Ground Continuity 132 6 E132 12 Brake pedal position Continuity Brake pedal released No continuity Brake pedal depressed switch 132 8 E132 5 CANCEL switch No continuity CANCEL switch OFF released Continuity CANCEL switch ON pressed COAST SET switch No continuity COAST SET switch OFF released 200
303. d check accelerator pedal play which should be within following specification If measured value is out of specification adjust accelerator cable 1 to specification with cable adjusting nut 2 Accelerator pedal play a 2 5 mm 0 08 0 20 in 2 With accelerator pedal depressed fully check clearance between throttle lever 2 and lever stopper 1 throttle body which should be within following specification If measured value is out of specification adjust it to specifi cation by changing height of pedal stopper bolt 3 Clearance b between throttle lever and lever stopper throttle body with accelerator pedal depressed fully 0 5 2 0 mm 0 02 0 07 in A T Throttle Cable Adjustment A T Vehicle 1 Make sure that accelerator cable is adjusted as specified 2 With throttle valve closed check clearance c which should be within the following specification If it is out of specification adjust A T throttle cable 1 by turning cable adjusting nut 2 throttle cable installing position specification clear ance c 0 8 1 5 mm 0 03 0 06 in ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 15 a Idle Speed Idle Air Control IAC Duty Inspec tion Before idle speed IAC duty check make sure of the following Lead wires and hoses of engine emission control systems are connecte
304. d 4 Hose bolt Top side 5 Brake caliper Front side 2 way joint 5A 6 BRAKES PIPE HOSE MASTER CYLINDER Master Cylinder Reservoir REMOVAL 1 Disconnect reservoir lead wire at coupler 2 Clean outside of reservoir 1 3 Take out fluid with syringe or such 4 Remove reservoir stopper 3 2 Master cylinder 5 Remove reservoir 1 NOTE Do not allow brake fluid to get on painted surfaces 2 Stopper 3 Grommets INSTALLATION NOTE See NOTE at the beginning of this section 1 When using new grommets lubricate them with the same fluid as the one to fill reservoir 1 with Then press fit grom mets to master cylinder 2 Grommets must be seated in place 2 Install reservoir 1 and then insert stopper 3 3 Connect reservoir lead wire 4 Fill reservoir 1 with specified fluid 5 Upon completion of installation check for fluid leakage BRAKES PIPE HOSE MASTER CYLINDER 5A 7 Master Cylinder Assembly REMOVAL NOTE Do not allow brake fluid to get on painted surfaces 1 Disconnect reservoir lead wire 1 at coupler 2 Clean around reservoir cap 2 and take out fluid with syringe or such 3 Disconnect brake pipes from master cylinder 3 and ABS actuator 4 INSPECTION Inspect distance A to be the following Distance 57 4 mm 2 26 in or more If mea
305. d as L threshold V or L gt R threshold V on scan tool are longer than specification 2 driving cycle detection logic HO28 1 ECM PCM DTC CONFIRMATION PROCEDURE Refer to DTC P0150 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per formed Go to Step 2 Go to ENGINE DIAG FLOW TABLE in this section 1 Replace HO28 1 and recheck Is DTC P0153 detected Substitute a known good HO2S 1 malfunction ECM PCM and recheck 6 1 70 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0155 HO2S 1 Bank 2 Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0150 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S heateris HO2S 1 heater circuit electrically live 2 driving cycle detection logic HO2S 1 heater Current of HO2S heater is 5 3 A or more or less than ECM PCM 0 09 A or Voltage of HO2S heater is 14 0 V or higher or lower than 11 7 V DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool with ignition switch OFF 2
306. d repair mal function part s Go to Step 11 Check for Intermittent Problems 1 Check for intermittent problems referring to the next page Is there any faulty condition Repair or replace mal function part s Go to Step 11 Go to Step 11 AUTOMATIC TRANSMISSION 4 781 11 Step Action Yes No 11 Final Confirmation Test Goto Step 6 End 1 Clear DTC if any 2 Perform final confirmation test referring to the next page Is there any problem symptom DTC or abnor mal condition STEP 1 CUSTOMER COMPLAINT ANALYSIS Record details of the problem failure complaint and how it occurred as described by the customer For this purpose use of such a inspection form will facilitate collecting information to the point required for proper analysis and diagnosis STEP 2 DIAGNOSTIC TROUBLE CODE DTC FREEZE FRAME DATA CHECK RECORD AND CLEARANCE First referring to DTC check section check DTC including pending DTC If DTC exists print or write down DTC and freeze frame data and then clear them by referring to DTC clearance section DTC indicates malfunc tion in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and normal condition has been restored In order to know that check symptom in question according to Step 5 and then recheck DTC according to Step 6 Diagnosing a trouble based on the DTC in this step only
307. d securely Accelerator cable is adjusted Ignition timing is within specification All accessories wipers heater lights A C etc are out of service Air cleaner has been properly installed and is in good condi tion ECM PCM does not detect any malfunction DTC After above items are all confirmed check idle speed and IAC duty as follows NOTE Before starting engine place transmission gear shift lever in Neutral shift selector lever to P range for A T vehicle and set parking brake and block drive wheels Using SUZUKI scan tool 1 Connect SUZUKI scan tool to DLC with ignition switch OFF Special tool A SUZUKI scan tool 2 Warm up engine to normal operating temperature 3 Check IAC duty and idle speed by using Data List mode of SUZUKI scan tool Engine idle speed AIC OFF 700 50 r min AIC ON 750 50 r mi IAC duty at specified idle speed 5 40 at A C OFF 4 If duty and or idle speed is out of specifications check idle air control system referring to DIAG FLOW TABLE B 4 in Section 6 1 5 Check that specified engine idle speed is obtained with A C ON if vehicle is equipped with A C If not check A C ON sig nal circuit and idle air control system 62 16 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE Not using SUZUKI scan tool vehicle with monitor connector 1 Disconnect scan tool from DLC if connected 2 Warm
308. d sensor and SDM or from YEL GRN wire cir cuit between forward sensor and SDM to YEL BLU wire circuit between forward sensor and SDM AIR BAG SYSTEM 108 39 Step Action Yes No 1 Measure voltage from Q01 13 terminal to body ground 001 14 terminal to body ground or from Q01 18 terminal to body ground and 001 19 terminal to body ground With ignition switch ON are they 1V or less Substitute a known good SDM and recheck Repair short from ORN GRN or ORN BLU wire circuit between forward sensor and SDM to power circuit or from YEL GRN or YEL BLU wire circuit between for ward sensor and SDM to power circuit A Fig for STEP 1 B Fig for STEP 2 C Fig for STEP 3 5 Special tool A 09932 75020 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected 108 40 AIR BAG SYSTEM 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
309. dal position switch M T vehicle only When the clutch pedal is depressed the clutch pedal position switch closes and provides a ground signal to cruise control module The cruise control module cancels cruise control accelerator pedal control when this signal is inputted Transmission range switch Park Neutral position switch AT vehicle only When the selector lever is places in either P or N position the transmission range switch closes and provides a ground signal to cruise control module The cruise control module cancels cruise control accelerator pedal control when this signal is inputted PCM Throttle opening sig nal 4 A T vehicle only Throttle opening signal is inputted from PCM From this signal the cruise control module detects the throttle opening and uses it as one of the factors to output the overdrive and TCC OFF command sig nal to PCM CRUISE CONTROL SYSTEM 8E 5 Component Function PCM Overdrive and When the throttle opening for the vehicle speed exceeds the specified value off command signal output during cruise control the cruise control module sends this signal to PCM PCM uses this signal as one of signals to control 4 A T Cruise main switch indicator In the state with the ignition switch ON and the cruise control system OFF lamp pressing this switch once and releasing it will activate the cruise control system and the cruise contr
310. dule by the wires or connector on the underside of the module When placing a live air bag inflator module on a bench or other surface always face the bag up away from the surface As the live passenger air bag inflator module must be placed with its bag trim cover facing up place it on the work bench with a slit or use the workbench vise to hold it securely at its lower mounting bracket This is neces sary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment Otherwise personal injury may result Never dispose of live undeployed air bag inflator modules driver and passenger If disposal is neces sary be sure to deploy them according to deployment procedures described in SECTION 10B before dis posal The air bag inflator module immediately after deploy ment is very hot Wait for at least half an hour to cool it off before proceeding the work 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 gloves and safety glasses should be worn ALWAYS CARRY AIR BAG INFLATOR MODULE WITH TRIM COVER AIR BAG OPENING AWAY FROM BODY 18 ALWAYS PLACE AIR BAG INFLATOR MODULE ON WORKBENCH WITH TRIM COVER AIR BAG OPENING U
311. dure For installation make sure that steering wheel is in straightforward position and hose has no twist or kink Check to make sure that hose doesn t contact any part of suspension both in extreme right and extreme left tum conditions If it does at any point remove and correct Fill and maintain brake fluid level in reservoir Bleed brake system 2 Perform brake test and check installed part for fluid leakage Tightening torque Brake pipe flare nut a 16 N m 1 6 12 0 Ib ft Brake flexible hose bolt brake caliper 2 joint b 23 N m 2 3 kg m 17 0 Ib ft 2 way joint mounting bolt c 10 N m 1 0 kg m 7 5 Ib ft Brake hose pipe bracket bolt c 10 N m 1 0 kg m 7 5 Ib ft ABS actuator bracket bolt c 10 N m 1 0 kg m 7 5 Ib ft ABS actuator mounting bolt d 9 N m 0 9 kg m 6 5 Ib ft NOTE Insert E ring ti its end surface is flush with or lower than bracket end surface 4 BRAKES PIPE HOSE MASTER CYLINDER For RH steering vehicle ViewD 1 Ering Tak Clampa 2 Flexible hose bk Clampb 3 Hose washer ck Clampd 4 Hose bolt T Top side 5 Brake caliper F Front side 8 Zwayjoint For LH steering vehicle BRAKES PIPE HOSE MASTER CYLINDER 5 5 TDF View D 1 Ering ak Clamp a 2 Flexible hose Clamp b 3 Hose washer 19 Clamp
312. e If any abnormality is found replace them with specified new plug Spark plug air gap a 10 11 mm 0 039 0 043 in Spark plug type DENSO K20PR U11 SK16PR11 NGK BKR6E 11 IFRSJ11 NOTE Under 25 C 13 F it is highly recommended to use the spark plugs with an asterisk for better engine starting performance INSTALLATION 1 Install spark plug 3 and tighten them to specified torque Tightening torque Spark plug a 25 N m 2 5 kg m 18 0 Ib ft 2 Install ignition coil assembly 2 securely 3 Tighten ignition coil bolt 1 and then connect ignition coil coupler 4 Install ignition coil cover 872 10 IGNITION SYSTEM FOR H27 ENGINE CMP Sensor CAUTION Disassembly is prohibited If anything faulty is found replace as an assembly unit REMOVAL 1 Disconnect CMP sensor coupler 2 2 Remove A T fluid level gauge and filler tube 3 Remove CMP sensor 1 by removing bolt 3 INSTALLATION NOTE After installing CMP sensor adjust ignition timing Refer to IGNITION TIMING CHECK AND ADJUSTMENT in this section 1 Install a new O ring 2 with engine oil applied to CMP sen sor 1 IGNITION SYSTEM FOR H27 ENGINE 6F2 11 2 Install CMP sensor to camshaft Fit the dog of CMP sensor coupling into the slots of cam shaft when installing The dogs of CMP sensor coupling are offset Therefore if the
313. e REMOVAL 1 Remove rear A C unit referring to REAR A C UNIT in this section 2 Disconnect solenoid valve connector 1 3 Loosen solenoid valve flared nuts 2 4 Remove solenoid valve bracket mounting screws 3 and then remove rear liquid pipe 4 and rear suction pipe 5 from rear expansion valve 5 Remove rear liquid pipe 4 rear suction pipe 5 and sole noid valve bracket 6 from solenoid valve 7 NOTE Cap open fitting immediately to keep moisture out of sys tem INSPECTION 1 Connect special tool to solenoid valve 1 Special tool A 09917 47910 2 Check that solenoid valve is closed when vacuum is applied to solenoid valve If solenoid valve is opened replace solenoid valve 3 Check that solenoid valve 1 is opened when connect bat tery to solenoid valve as shown in figure NOTE Solenoid valve terminal is polarity INSTALLATION Reverse removal procedure to install solenoid valve AIR CONDITIONING OPTIONAL 18 33 Rear Blower Motor Assembly REMOVAL 1 Remove solenoid valve referring to SOLENOID VALVE in this section 2 Disconnect rear blower motor coupler 1 3 Remove rear blower motor assembly 2 from rear A C unit 3 INSPECTION 1 Check continuity between two terminal as shown If check results are no continuity replace rear blower motor assembly 1 2 Check operate and current a Fix rear blower motor assembly 1 by using
314. e are measured in thrust direction at 2 positions 3 268mm 1 04 in Ring groove clearance Before checking piston grooves must be clean dry and free of carbon Fit new piston ring 1 into piston groove and measure clear ance between ring and ring land by using thickness gauge 2 If clearance is out of specification replace piston Ring groove clearance Top 0 03 0 07 mm 0 0012 0 0027 in 2nd 0 02 0 06 mm 0 0008 0 0023 in 6A2 24 ENGINE MECHANICAL H27 ENGINE ASSEMBLY 1 2 sizes of piston are available as standard size spare part so as to ensure proper piston to cylinder clearance When installing a standard size piston make sure to match piston with cylinder as follows a Each piston has stamped number 1 or 2 on its piston head It represents outer diameter of piston b There are also stamped numbers of 1 and 2 on the cylinder block as shown in the figure c Stamped number on piston and cylinder block must corre 4 spond That is install number 2 stamped piston to cylinder Er which is stamped also number 2 and a number 1 piston to cylinder with number 1 Also a letter A B or C is stamped on piston head but ordi narily it is not necessary to distinguish each piston by this letter No 2 cylinder Piston to cylinder clearance Piston Number at the top mark Outer diameter 3 87 98 87
315. e as shown in the figure check each solenoid valve for clicking sound Shift solenoid valve A 1 C51 1 2 Shift solenoid valve B 2 C51 1 1 TCC Lock up solenoid valve C51 1 8 PER VAS m een 781 46 AUTOMATIC TRANSMISSION 4 A T MANUAL SELECTOR ASSEMBLY 8 8 18 Nm 1 8 kom T _Manual over assembly 4 Bub fior 7 Shit Tock solenoid equipped 2 Seleclindicalor assembly 5 Bub 3 Manual selector assembly mounting boit 3 Wuminaton assembly 6 knob assembly eniro REMOVAL 1 Disconnect negative cable at battery 2 Remove console box 3 Disconnect connector for illumination lamp shift lock sole noid if equipped and overdrive OFF switch if equipped 4 Remove selector assembly mounting bolts 5 Disconnect selector cable 1 from manual selector assem bly 2 expanding selector cable clip 3 INSTALLATION Reverse removal procedure to install manual selector assembly noting the following instructions Make sure that selector cable clip 3 hold selector cable 1 manual selector assembly 2 securely Tighten manual selector assembly mounting bolts as speci fied torque Tightening Torque Manual selector assembly mounting bolts 18 Nem 1 8 kg m 13 5 Ib ft Connect interlock cable end to cam referring
316. e back plate 99000 31110 Joint seam of bearing retainer and brake back plate Joint seam of differential carrier and axle housing Drain plug Mating surface of oil seal and axle housing Gear oil For gear oil information refer to Section 7F Differential gear Rear axle housing Thread lock THREAD LOCK CEMENT SUPER 1322 Rear propeller shaft flange bolts cement 99000 32110 Special Tool REAR SUSPENSION 3E 7 09921 57810 Counter shaft holder 09924 74510 Bush remover handle 09926 88310 Oil seal installer 09927 18411 Universal puller 09942 15510 Sliding hammer 09943 35512 Brake drum remover 09944 88210 Bearing installer 3E 8 REAR SUSPENSION WHEELS AND TIRES 3F 1 SECTION 3F WHEELS AND TIRES NOTE For the descriptions items not found in this section refer to the same section of the Service Man ual mentioned in the FOREWORD of this manual All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and wea
317. e damage to the catalyst YN and stores the malfunction area in its memory If it detects that continuously 3 driving cycles are normal after detecting a malfunction however it makes MIL 1 turn OFF although DTC stored in its memory will remain As a condition for detecting a malfunction in some areas in the system being monitored by ECM PCM and tuming ON the malfunction indicator lamp 1 due to that malfunction 2 driving cycle detection logic is adopted to prevent erroneous When a malfunction is detected engine and driving condi tions then are stored in ECM PCM memory as freeze frame data For the details refer to description on Freeze frame Itis possible to communicate by using not only SUZUKI scan tool 2 but also generic scan tool Diagnostic information can be accessed by using a scan tool TROUBLE CODE COOLANT TEMP ENGINE SPEED SHORT FT Bt SHORT FT B2 LONG FT Bi LONG FT B2 CALC LOAD FUEL SYSTEM B1 FUEL SYSTEM B2 MAP VEHICLE SPEED 750 RPM 08 04 13 15 205 CLOSED CLOSED 306 KPa 1st ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 7 WARM UP CYCLE A warm up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22 C 40 F from engine starting and reaches a minimum temperature of 70 C 160 F DRIVING CYCLE A Driving Cycle consists of engine startup driving mode where a malfunction w
318. e fuel leakage from fuel feed line hose Fuel leakage from hose to Step 10 pipe or joint pipe or joint 5 Was fuel pressure higher than spec in Step 1 Go to Step Goto Step 7 6 1 Disconnect fuel return hose from fuel pipe Restricted fuel return Faulty fuel pressure regu and connect new hose to it hose or pipe lator 2 Put the other end of new return hose into approved gasoline container 3 Operate fuel pump Is specified fuel pressure obtained then 7 no fuel pressure applied in Step 17 Go to Step 8 Go to Step 9 Low pressure is mea sured 8 With fuel pump operated and fuel return hose Faulty fuel pressure regu Shortage of fuel or fuel blocked by pinching it is fuel pressure applied lator pump or its circuit defec tive Refer to TABLE B 1 9 1 Operate fuel pump Faulty fuel pressure regu Clogged fuel filter 2 With fuel return hose blocked by pinching it lator restricted fuel feed hose check fuel pressure or pipe faulty fuel pump Is it 450 kPa 4 5 kg cm 64 0 psi or more or fuel leakage from hose connection in fuel tank 10 1 Disconnect fuel return hose from fuel pipe _ Faulty fuel pressure regu Fuel leakage from injec and connect new hose to it lator tor faulty fuel pump 2 Put the other end of new return hose into faulty check valve in fuel approved gasoline container pump or fuel leakage 3 Check again if specified fuel pressure is from fuel pressure regula retained
319. e gauge 10 When this occurs open the other side valve 8 Lo of the set Approx 10 minutes later low pressure gauge 11 should show 10 kPa 1 0 kg cm 760 mmHg 14 2 psi provid ing no leakage exists 4 NOTE If the system does not show 10 kPa 1 0 kg cm 760 mmHg 14 2 psi close both valves stop vacuum pump and watch movement of low pressure gauge Increase in the gauge reading suggests existence of leakage In this case repair the system before continu ing its evacuation If the gauge shows a stable reading suggesting no leakage continue evacuation 5 Evacuation should be carried out for a total of at least 20 minutes 6 Continue evacuation until low pressure gauge indicates 10 kPa 1 0 kg cm 760 mmHg 14 2 psi and then close both valves 8 9 7 Stop vacuum pump 7 Disconnect center charging hose 6 from pump inlet Now the system is ready for charging refrig erant 18 22 AIR CONDITIONING OPTIONAL Checking system for pressure leaks After completing the evacuation close manifold gauge high pres sure valve and low pressure valve LO and wait 10 minutes Verify that low pressure gauge reading has not changed CAUTION If the gauge reading moves closer to 0 there is a leak somewhere Inspect the tubing connections make nec essary corrections and evacuate system once again making sure that there are no leaks Charging CAUT
320. e manifold 8 Intake air pipe 34 TP sensor 5 Intake collector 10 Throttle body 15 IAC valve ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 7 Fuel Delivery System The fuel delivery system consists of the fuel tank fuel pump fuel filter fuel pressure regulator delivery pipe and fuel injectors The fuel in the fuel tank is pumped up by the fuel pump filtered by the fuel filter and fed under pressure to each injector through the delivery pipe As the fuel pressure applied to the injector the fuel pressure in the fuel feed line is always kept a certain amount higher than the pressure in the intake manifold by the fuel pressure regulator the fuel is injected into the intake port of the cylinder head when the injector opens according to the injection signal from ECM PCM The fuel relieved by the fuel pressure regulator returns through the fuel return line to the fuel tank ea un S81 Fuel T Fueltank 5 Fuel return ine 3 Fuel injector 18 Air 2 Fuel pump 6 _Fuel pressure regulator 30 Fuel delivery pipe 3 Fuel fiter 7 Vacuum hose for fuel pressure regulator 11 valve 4 Fuclfeedine 8 Intake manifold surge tank 62 8 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE Electronic Control System The electronic
321. e second symbol represents the color of the stripe YEL in the figure INSTRUMENTATION DRIVER INFORMATION 8C 1 SECTION 8C INSTRUMENTATION DRIVER INFORMATION WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS 8C 2 Engine coolant temperature sensor 8C 2 Oil Pre
322. e 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 For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual Wiring System Harnesses Connectors Fuses Relay Switches Grounds System Circuit Diagram Lighting System Instrumententation and Driver Information Windows Mirrors Security and Locks Immobilizer Control System CONTENTS General Description 8 3 8 2 BODY ELECTRICAL SYSTEM WIRE COLOR SYMBOLS General Description _ GPN Base Color GAN Base Color SYEL Stripe Color Symbol Wire Color Symbol Wire Color B BLK Black 0 Or ORN Orange Bl BLU Blue R RED Red Br BRN Brown W WHT White G GRN Green Y YEL Yellow Gr GRY Gray P PNK Pink LT BLU Light blue PPL Violet lg LT GRN Light green There are two kinds of colored wire used in this vehicle One is single colored wire and the other is dual colored striped wire The single colored wire uses only one color symbol i e GRN The dual colored wire uses two color symbols i e GRN YEL The first symbol represents the base color of the wire in the figure and th
323. e stem Valves inspection in Section 6A2 Weak or damaged valve springs Valves spring inspection in Section 6A2 Compression leak at cylinder head gasket Cylinder head inspection in Section 6A2 Sticking or damaged piston ring Piston ring inspection in Section 6A2 Wom piston ring or cylinder Cylinders pistons and piston rings inspection in Section 6A2 Malfunctioning PCV valve PCV system inspection in Section 6E2 Engine has no power Engine overheating Refer to OVERHEATING in this table Defective spark plug Spark plugs in Section 6F2 Faulty ignition coil with ignitor Ignition coil in Section 6F2 Fuel pressure out of specification dirty fuel filter dirty or clogged fuel hose or pipe malfunctioning fuel pressure regulator malfunctioning fuel pump DIAG FLOW TABLE 3 in this section Maladjusted TP sensor installation angle TP sensor in Section 6E2 Faulty EGR system DTC P0400 DIAG FLOW TABLE in this section Faulty injector Fuel injector in Section 6E2 Faulty TP sensor ECT sensor or MAF sensor TP sensor ECT sensor or MAF sensor in Section 6E2 Faulty ECM PCM Inspection of ECM PCM and its circuit in this section Low compression Refer to the same item in HARD STARTING of this table Dragging brakes Diagnosis in Section 5 Slipping clutch Diagnosis in Section 7C1
324. e sure that following condition is satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and warm up engine completely 3 Run engine at idle speed for 1 min 4 Check pending DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 speed check Intermittent trouble Goto Step 3 1 Check engine idle speed referring to IDLE faulty ECM PCM SPEED IDLE AIR CONTROL DUTY Check for intermittent INSPECTION in Section 6E2 referring to INTERMIT 15 engine idle speed within specification TENT AND POOR CON NECTION in Section 3 valve check Go to Step 6 Go to Step 4 1 Check IAC valve referring to IAC VALVE INSPECTION in Section 6E2 Is check result as specified 4 valve circuit check Go to Step 5 LT GRNBLK PPL7 1 With ignition switch OFF disconnect ECM BLK GRY BLU or PCM couplers PPL YEL wire open or 2 Check for proper connection to IAC valve at short C51 1 4 C51 1 5 C51 1 16 and C51 1 17 I
325. e to pos sibility of fire or explosion 9 Disconnect fuel filter inlet hose from filter 1 Fuel fit 2 Fuel fiter outlet hose 3 Fuel fiter inlet hose ENGINE FUEL 6C 3 10 Disconnect fuel vapor hose and return hose from pipes 11 Remove fuel tank protector if equipped from vehicle 12 Lower fuel tank gradually while holding it horizontally and pull out coupler at fuel pump 3 Fuel pump 2 Coupler INSPECTION After removing fuel tank check hoses and pipes connected to fuel tank for leaks loose connections deterioration or damage Also check fuel pump and level gauge gaskets for leaks visually inspect fuel tank for leaks and damage Replace any damaged or malconditioned parts 6 4 ENGINE FUEL INSTALLATION 1 Install fuel pump assembly fuel cut valve and vapor control valve to fuel tank Refer to FUEL PUMP in this section 2 Connect fuel hoses to fuel tank fuel cut valve and vapor control valve check valve and fuel pump assembly After connecting clamp hoses securely 3 Install inlet valve to fuel tank If deformed or damaged in any other way replace with a new one 4 Install fuel tank by using fuel tank belts and then install pro tector to vehicle Tightening torque Fuel tank bolt a 50 N m 5 0 kg m 36 5 Ib ft Fuel tank protector bolt a 50 N m 5 0 kg m 36 5 Ib ft 5
326. e vehicle Remove front differential housing with differential from chas sis if equipped Refer to DISMOUNTING in Section 7E Remove exhaust No 1 pipe Refer to EXHAUST MANI FOLD in this section Remove exhaust manifold stiffener from transmission 6A2 28 ENGINE MECHANICAL H27 ENGINE 24 Remove A T fluid hose clamps 1 from engine mounting bracket 2 for A T vehicle 25 Remove clutch housing lower plate 26 Remove torque converter bolts for A T vehicle 27 Remove starter motor 28 Lower vehicle 29 Support transmission For A T vehicle don t jack under A T oil pan to support transmission 30 Remove bolts and nuts fastening cylinder block and trans mission 31 Install lifting device 32 Disconnect engine side mounting brackets 1 to engine mountings 33 Before lifting engine check to ensure all hoses wires and cables are disconnected from engine 34 Remove engine assembly from chassis and transmission by sliding toward front and then carefully hoist engine assem bly INSTALLATION Reverse removal procedure for installation noting the following points 1 Lower engine assembly into engine compartment Connect engine to transmission and engine side mounting brackets to engine mountings 2 Tighten nuts fastening engine side mounting brackets and engine mountings Tightening torque Engine side mounting bracket nut a 50 N m 5 0 kg m 36 5
327. eat AIR BAG DIAGNOSTIC SYSTEM CHECK DTC B1013 System Specifications Different from SDM Specifications DTC WILL SET WHEN Specifications of the air bag system differ from those of SDM NOTE Before executing items below be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK 1 Ignition switch OFF 2 Replace SDM 3 Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK AIR BAG SYSTEM 108 49 On Vehicle Service Service Precautions Service and diagnosis WARNING CAUTION labels are attached on each part of air bag system components 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
328. echeck ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 Table B 3 Fuel Pressure Inspection SYSTEM DIAGRAM 119 T Inector 3 Fusifior 2 Deive ps 5 Fuel pump 3 Fuel pressure regulator Special tool A B 09912 58441 09912 58431 09919 58421 INSPECTION NOTE Before using the following flow table check to make sure that battery voltage is higher than 11 V If battery voltage is low pressure becomes lower than specification even if fuel pump and line are in good condition Step Action Yes No 1 7 Install fuel pressure gauge referring to FUEL PRESSURE INSPECTION in Sec tion 6E2 2 Operate fuel pump Is fuel pressure then 270 310 kPa 2 7 3 1 kg m 38 4 44 0 psi Go to Step 2 Go to Step 5 Is 200 kPa 2 0 kg cm 28 4 psi or higher fuel pressure retained for 1 minute after fuel pump is stopped at Step 1 Go to Step 3 Go to Step 4 6 1 120 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Step Action Yes No 3 1 Start engine and warm it up to normal oper Normal fuel pressure Clogged vacuum passage ating temperature for fuel pressure regula 2 Keep it running at specified idle speed tor or faulty fuel pressure Is fuel pressure then within 210 260 kPa regulator 2 1 2 6 kg cm 29 8 37 0 psi 4 Isther
329. eck 6 1 100 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Evap canister purge system inspection 1 Warm up engine to normal operating temperature 2 Hoist vehicle so that all wheels rotate freely 3 Set M T in Neutral or A T in position and parking brake 4 Disconnect purge hose 1 from EVAP canister 5 Place finger against the end of disconnected hose 1 and check that vacuum is not felt there when engine is running at idle speed 6 Release parking brake lever set transfer in 2H and M T in 4st or AT in L WARNING Make sure that transfer is set to 2H range position for this check If it is set to 4H or 4L position front and rear wheels turn at high speed and a very dangerous sit uation may occur 7 Also check that vacuum is felt when engine speed is increased to higher than about 1 500 r min and keep it for 3 min or more If check result is not described in steps 5 and 7 check EVAP canister purge valve wire harness and vac uum passage Vacuum passage inspection Start engine and run it at idle speed With finger placed against vacuum nozzle 1 check that vacuum is applied If itis not applied clean vacuum passage by blowing compressed air ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 101 Vacuum hose inspection Check hoses for connection leakage clog and de
330. eck GRN RED wire cir 3 If OK then measure resistance between Q01 9 and cuit or from GRN Q01 10 terminals with connected Special Tool B GRN RED wire cir Is resistance 1 7 Q or more cuit to other wire cir cuit 3 1 With ignition switch OFF disconnect Special Tool B Ignition switch OFF Ignition switch OFF then reconnect contact coil connector located near Replace contact coil Replace driver air the base of the steering column assembly Referto bag inflator module 2 Remove driver air bag inflator module from steering COMBINATION Refer to DRIVER wheel Refer to DRIVER AIR BAG INFLATOR SWITCH CON AIR BAG INFLA MODULE in Section 3C1 TACTCOILAND MODULE in 3 Check proper connection to driver air bag inflator Section 3C1 module at terminals in 005 connector SWITCH ASSEM 4 If OK then connect Special Tool B to Q05 connec BLY in Section tor 3C1 With ignition switch ON is DTC B1022 current A Fig for STEP 1 and 2 B Fig for STEP 2 C Fig for STEP 3 I OF COLUMN Special tool A 09932 75020 B 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SY
331. eck MAP sensor for performance referring to MAP SENSOR INSPECTION in Section 6E2 Is check result satisfactory or GRY RED circuit open short If wire and connections are OK substitute a known good ECM PCM and recheck 2 sensor signal check Intermittent trouble Go to Step 3 1 Remove ECM PCM cover faulty ECM PCM 2 Check voltage between C51 3 8 and C51 Check for intermittent 3 25 under following conditions referring to INTERMIT With ignition switch ON leaving engine OFF TENT AND POOR CON 0 2 V or higher NECTION in Section 0A At idling 4 6 V or lower Is check result as specified 3 sensor check RED WHT GRY YEL Replace MAP sensor ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 113 DTC 1450 1451 Barometric Pressure Sensor Circuit Malfunction Perfor mance Problem SYSTEM DESCRIPTION Barometric pressure sensor is installed in ECM PCM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P1450 Barometric pressure sensor in ECM Barometric pressure out of specification is detected PCM DTC P1451 Manifold absolute pressure sensor While running under conditions described for DTC CONFIRMATION performance problem PROCEDURE barometric pressure value compared with intake Barometric pressure sensor in ECM manifold vacuum value in fuel cut state is not as specified PCM 2 driving c
332. eck result satisfactory 6 Checkfuel level sensor referring to FUEL Go to Step 7 Faulty fuel level sensor or LEVEL SENSOR in Section 6E2 its circuit Is check result satisfactory 7 Check MAF sensor for performance referring to Go to Step 8 Faulty MAF sensor or its MASS AIR FLOW SENSOR in Section 6E2 circuit Is check result satisfactory 8 Check ECT sensor referring to Section 6E2 to Step 9 Faulty ECT sensor Is check result satisfactory 9 Check HO2S 1 referring to P0150 DIAG Substitute a known good Faulty HO2S 1 FLOW TABLE ECM PCM and recheck Is check result satisfactory 6 1 80 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0300 P0301 P0302 P0303 P0304 P0305 P0306 Random Misfire Cylinder 1 Misfire Cylinder 2 Misfire Cylinder 3 Misfire Cylinder 4 Misfire Detected Cyl inder 5 Misfire Detected Cylinder 6 Misfire Detected SYSTEM DESCRIPTION ECM PCM measures the angle speed of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder If it detects a large change in the angle speed of the crankshaft it concludes occurrence of a misfire When the number of misfire is counted by the ECM PCM beyond the DTC detecting condition it determines the cylinder where the misfire occurred and outputs it as DTC DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P0300 Ignition system Misfire which causes catal
333. eck to make sure that following con CEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more ion is satisfied when using this DTC CONFIRMATION PRO 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and warm up engine completely 3 Increase vehicle speed to 100 110 km h 60 70 mph 4 Release accelerator pedal and with engine brake applied keep vehicle coasting for 5 seconds or more and then stop vehicle 5 Check pending DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 Does speedometer indicate vehicle speed Faulty BLU YEL wire Go to Step 3 poor C51 1 14 connection If wire and connection are OK intermittent trouble or faulty ECM PCM Check for intermittent refer ring to INTERMITTENT AND POOR CONNECTION in Section 0A 3 VSS power supply voltage check Go to Step 4 BLK BLU or BLKYEL 1 With ignition switch OFF remove VSS wire open short coupler 2 With ignition switch ON leaving engine OFF check voltage between C20 3 and C20 2 terminal of VSS coupler Is voltage 10 14 V 4 55 signal harness che
334. ectors 10 Install throttle body and intake collector refer to THROTTLE BODY in this section 11 With engine OFF and ignition switch ON check for fuel leaks around fuel line connection ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 31 Electronic Control System Engine control module ECM powertrain control module PCM CAUTION As ECM PCM consists of precision parts be careful not to expose it to excessive shock REMOVAL 1 Disconnect negative cable from battery 2 Disable air bag system if equipped referring to DIS ABLING THE AIR BAG SYSTEM in Section 10B 3 Remove ECM PCM cover 1 from bracket 4 Disconnect connectors from ECM PCM 1 5 Remove ECM PCM 1 with bracket 2 INSTALLATION 1 Install ECM PCM with bracket to vehicle 2 Connect connectors to ECM PCM securely 3 Install ECM PCM cover to bracket 4 Enable air bag system if equipped referring to ENABLING AIR BAG SYSTEM in Section 10B 5 Connect negative cable to battery 6 2 32 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE MILI Mass air flow sensor MAF sensor INSPECTION NOTE Use voltmeter with high impedance 10 kO V minimum or digital type voltmeter 1 Connect voltmeter 1 to B terminal of MAF sensor
335. ed amp Blue Red amp Yellow Red amp Blue Red amp Pink ENGINE MECHANICAL H27 ENGINE 642 35 INSPECTION Honing or reboring cylinders 1 When any cylinder needs reboring all other cylinders must also be rebored at the same time 2 Select oversized piston according to amount of cylinder wear Oversize piston specification Size Piston diameter Standard 87 970 87 990 mm 3 4634 3 4642 in Oversize 0 25 88 220 88 240 mm 3 4732 3 4740 in Oversize 0 50 88 470 88 490 mm 3 4831 3 4839 in 3 Using micrometer measure piston diameter 4 Calculate cylinder bore diameter to be rebored as follows D A B C Cylinder bore diameter to be rebored A Piston diameter as measured Piston clearance 0 02 0 04 mm 0 0008 0 0015 in C Allowance for honing 0 02 mm 0 0008 in 5 Rebore and hone cylinder to calculated dimension NOTE Before reboring install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores 6 Measure piston clearance after honing 6A2 36 ENGINE MECHANICAL H27 ENGINE Special Tool 09911 97810 Oil seal installer 09913 75510 Bearing installer v 09915 47310 Oil filter wrench 09915 64510 Compression gauge 09915 64530 Compression gauge hose 09915 67010 Compression gauge attachment c 09915 67310 Vacuum gauge 09915 77310
336. ee NOTE B and WARNING 09931 76030 16 14 pin DLC cable for 1 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE Mass storage cartridge for Tech 1A Tech 2 kit SUZUKI scan tool See NOTE C 108 78 AIR BAG SYSTEM WARNING Be sure to use the specified digital multimeter Otherwise air bag deployment or personal injury may result NOTE 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 B Digital multimeter specification The maximum test current is 10 mA or less at the minimum range of resistance measurement 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 Prepared by SUZUKI MOTOR CORPORATION Overseas Service Department 1st Ed June 2001 2nd Ed Oct 2001 Printed in Japan Printing January 2002 652
337. eferring to Section 6E2 to Step 9 Faulty ECT sensor 15 check result satisfactory 9 Check HO28 1 referring to P0130 DIAG Substitute a known good Faulty HO2S 1 FLOW TABLE ECM PCM and recheck Is check result satisfactory 6 1 78 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0174 P0175 Fuel System Too Lean Rich Bank 2 DTC DETECTING CONDITION AND POSSIBLE CAUSE DTC DETECTING CONDITION TROUBLE AREA When running after engine warmed 2 driving cycle Vacuum leaks air inhaling detection logic Exhaust gas leakage Short term fuel trim exceeding 15 or long term fuel Fuel pressure out of specification trim exceeding 20 and total trim exceeding 43 is Heated oxygen sensor malfunction detected EGR system malfunction Fuel system too lean MAF sensor poor performance Short term fuel trim less than 11 or long term fuel ECT sensor poor performance trim less than 11 and total trim less than 30 is Fuel level sensor detected Fuel trim too rich DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this DTC
338. ehicle speed at that moment is stored in memory and vehicle starts constant cruising ACCEL RESUME switch When this switch is rotated ON during constant cruising vehicle speed keeps increasing as long as it is ON When it is released OFF vehicle speed at that moment is stored in memory and vehicle starts constant cruising If vehicle speed is higher than 40 km h 25 mile h after cruise control is cancelled tum ing this switch ON momentarily will resume the speed at which vehicle was run ning before cancellation CANCEL switch When this switch is pressed ON cruise control accelerator pedal control is cancelled Vehicle speed sensor VSS The vehicle speed sensor VSS is mounted on the transfer or transmission VSS converts vehicle speed into pulse signal and send it to the cruise con trol module Stop lamp switch The stop lamp switch has 2 contact points One contact point closes when the brake pedal is depressed to light the stop lamp and provides a voltage signal to the cruise control module This signal when inputted cancels cruise control sets the accelerator pedal free The other contact point brake pedal position switch opens when the brake pedal is depressed to shut off the power to the magnetic clutch in the actuator thereby cancelling cruise control setting the accelerator pedal free This switch is installed to cancel cruise control constant cruising without fail Clutch pe
339. elieved pressure shown below Relieved pressure 7850 kPa 78 5 kg cm 1116 psi Diagnosis Power Steering Pump Drive Belt Belt inspection Check P S pump drive belt 1 is free from any damage and prop erly fitted in pulley groove Belt tension check Check belt tension by measuring how much it deflects when pushed at arrow point 2 between pulleys with about 10 kg 22 Ib force Deflection of P S belt 4 7 mm 0 16 0 28 in Belt tension adjustment 1 To adjust P S pump drive belt 1 tension loosen tension pulley bolts 3 and tum tension pulley 4 using hexagon wrench 2 Adjust belt tension to above specification Then tighten tension pulley bolts 3 to specified torque Tightening torque Tension pulley bolts a 25 N m 2 5 kg m 18 5 Ib ft PIS pump pulley AIG compressor pulley f equipped Crankshaft pulley 1 With AC 18 Without AIC c 450c 122 F POWER STEERING P S SYSTEM 3 1 3 Hydraulic Pressure in P S Circuit Hydraulic pressure check 1 After cleaning joint of high pressure hose and P S pump thoroughly disconnect hose from pump and install special tool oil pressure gauge attachment and hose CAUTION Take care not to cause damage to A C condenser during service operation if equipped Special tool A 09915 77410
340. ength replace steering upper shaft assembly with new one Steering upper shaft assembly length b 419 0 1 0 mm 16 50 0 04 in Tightening Torque Specification Tightening torque Fastening part is BK Driver air bag inflator module bolt 9 09 65 Steering shaft nut 33 33 235 Steering column mounting bolt and nut 25 25 18 0 Steering shaft joint bolt 25 25 18 0 Steering lower shaft assembly lower joint bolt 25 25 18 0 Shift key interlock cable screw 22 022 16 Steering upper shaft mounting bolt 23 23 17 0 Steering upper shaft upper joint nut 23 23 17 0 FRONT SUSPENSION 3D 1 SECTION 3D FRONT SUSPENSION CAUTION All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as speci fied during reassembly to assure proper retention of this part Never attempt to heat quench or straighten any front suspension part Replace it with a new part or damage to the part may result NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual
341. ensor Sensor should be replaced when it was dropped from a height of 90 cm 3 ft or more Check sensor 1 and its bracket 2 for dents cracks defor mation or rust Check sensor connector sensor side and harness side or lock mechanism for damage or crack Check connector terminals for bent corrosion or rust Check sensor for resistance Sensor resistance 738 905 Q INSTALLATION CAUTION Proper operation of forward sensor requires sensor be rigidly attached to vehicle structure and that the arrow on sensor bracket be pointing toward the front of the vehi cle 1 Check that none of following faulty conditions exists Bend or deformity of sensor bracket 1 and front panel Foreign matter on mating surface of sensor bracket 1 with sensor or excessive rust 2 Apply thread lock cement to mounting bolts thread Install forward sensor 1 on front panel 2 and tighten mounting bolts 3 to specified torque A Thread lock cement 1332B 99000 32100 Tightening torque 10 N m 1 0 kg m 7 2 Ib ft 10B 64 AIR BAG SYSTEM 3 Connect forward sensor connector pushing connector inner 1 as shown 4 Connect negative cable at battery 5 Enable air bag system Refer to ENABLING AIR BAG SYS TEM in this section Seat Belt Pretensioner Refer to FRONT SEAT BELT in Section 10A for removal inspection and installation
342. ent panel at driver s seat side Special tool A SUZUKI scan tool 3 Tum ignition switch to ON position 4 Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down Refer to SUZUKI scan tool operator s manual for further details If communication between scan tool and SDM is not possi ble proceed to Diagnostic Flow Table E Serial data check circuit 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 DLO 5 Not using SUZUKI scan tool 1 Check that malfunction indicator lamp AIR BAG warning lamp comes ON when ignition switch is turned to ON posi tion If it does not come ON proceed to Diagnostic Flow Table B AIR BAG warning lamp circuit 2 Using service wire ground diagnosis switch terminal in mon itor coupler 3 Read DTC from flashing pattem of malfunction indicator lamp AIR BAG warning lamp Refer to DTC TABLE If lamp does not indicate DTC proceed to Diagnostic Flow Table D Diagnosis switch terminal circuit check After completing the check tum ignition switch to OFF posi tion and disconnect service wire from AIR BAG monitor coupler 4 1 AIR BAG monitor coupler 2 Body ground 3 Diagnosis switch terminal 4 Service wire 108 12 AIR BAG SYSTEM EXAMPLE When driver air bag initiator circuit resista
343. ep 5 Proceed to TROUBLE DIAGNOSIS TABLE 3 in this section section 5 to TROUBLE DIAGNOSIS TABLE 2 in this Is trouble identified Repair or replace defective parts Proceed to TROUBLE DIAGNOSIS TABLE 3 in this section Trouble Diagnosis Table 1 Condition Possible Cause Correction TCC does not operate Brake pedal stop lamp switch or its circuit faulty H25 engine only 4WD low switch or its circuit faulty Engine coolant temp sensor or its circuit faulty Cruise control signal circuit faulty if equipped Refer to DIAGNOSTIC FLOW TABLE A 1 in this section Gear does not change O D off switch or its circuit faulty to 4th AWD low switch or its circuit faulty Engine coolant temp sensor or its circuit faulty Cruise control signal circuit faulty if equipped Refer to DIAGNOSTIC FLOW TABLE 2 in this section Trouble Diagnosis Table 2 TRANSMISSION FLUID Condition Possible Cause Correction Low fluid pressure Clogged oil pump strainer Wash strainer Malfunction of pressure regulator valve Overhaul valve body High fluid pressure Pressure regulator valve Overhaul valve body RUNNING CONDITION Condition Possible Cause Correction Unable to run in all Regulator valve stick Replace range Clogged oil strainer Was
344. er both low and high pressure tem Improperly evacuated Inspect quantity of compres sides sor oil and presence of con Low pressure side tubing is taminants in oil not cold when touched Evacuate system and Air bubbles are visible recharge with fresh refriger through sight glass ant 0 45 0 55 High pressure reading _ Faulty expansion valve Replace expansion valve 45 5 5 both low and high pressure Refrigerant flow is not regu 64 78 sides lated properly Large amount of frost or dew on the low pressure side tubing 18 14 AIR CONDITIONING OPTIONAL Wiring Circuit 4 2 jn sucwer 3 E sem IE 5 xp Lewes i PNK GRN re LM lt po Pene f REDBLK il as 1 RA BLK 1 2 i i 7 8 i BLUWHT i 2 J ai 15 e p e j 21 Pele j 5 32 s T i 4 i i 5 i 9 H imo pe eaten esac PEN A NEUGRN PNK
345. er bolts first following the order shown in the figure then tighten 8 mm thread diameter bolts Tightening torque Thrust and journal bearing cap bolt 8 mm thread diame ter 60 N m 6 0 kg m 43 5 Ib ft Thrust and journal bearing cap bolt 10 mm thread diame ter b 27 Nm 2 7 kg m 19 5 Ib ft NOTE Do not rotate crankshaft while gaging plastic is installed 1 Lower crankcase 2 Bolt 10 mm thread diameter 3 8 mm thread diameter 4 Long 8 mm thread diameter 5 Remove crankcase and using scale 2 on gaging plastic 1 envelop measure gaging plastic 1 width at its widest point If clearance exceeds its limit replace bearing Always replace both upper and lower inserts as a unit A new standard bearing may produce proper clearance If not it will be necessary to regrind crankshaft journal for use 0f 0 25 mm undersize bearing After selecting new bearing recheck clearance Main Bearing Clearance Standard 0 024 0 044 mm 0 0009 0 0017 in Limit 0 060 mm 0 0023 in 6A2 32 ENGINE MECHANICAL H27 ENGINE Selection of main bearings STANDARD BEARING If bearing is in malcondition or bearing clearance is out of specification select a new standard bearing according to the following procedure and install it 1 First check journa
346. er faulty Check A C controller Cool air does not come out A C con denser cooling fan motor does not opera tive Condenser cooling fan motor relay faulty Check condenser cooling fan motor relay Wiring or grounding faulty Repair as necessary AIC condenser fan motor relay signal in ECM faulty Check A C condenser cooling fan motor relay signal Condenser cooling fan motor faulty Check condenser cooling fan motor Cool air does not come out Blower motor does not opera tive Fuse blown Check FRONT BLOW and REAR DEFG fuses and check for short circuit to ground Blower motor relay faulty Check blower motor relay Blower motor resistor faulty Check blower motor resistor Blower motor switch faulty Check blower motor switch Wiring or grounding faulty Repair as necessary Blower motor faulty Check blower motor AIR CONDITIONING OPTIONAL 18 7 Condition Possible Cause Correction Cool air does not come out or insuffi cient cooling A C sys tem normal operative Insufficient or excessive charge of refrigerant Check charge of refrigerant Refrigerant leak in system Check system for leaks Condenser clogged Check condenser evaporator clogged or frosted Check evaporator evaporator temperature sensor A C evap orator thermistor faulty Check A C evaporator
347. ere is no traffic or possibility of a traffic acci iccident Road test should be carried out with 2 persons a driver and a tester on a level road ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 73 NOTE Check to make sure that following conditions are sati PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more ied when using this DTC CONFIRMATION 1 Connect scan tool with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data in ECM memory by using scan tool and start engine 3 Increase vehicle speed to 55 km h 40 mph or more 4 Keep driving above vehicle speed till engine is warmed up completely Changed of vehicle speed is permit ted in this step 5 Keep driving 50 60 km h 30 40 mph for 8 min or more 6 Stop vehicle and check if pending DTC exists by using scan tool If not check if oxygen sensor heater moni toring test has completed by using scan tool If not in both of above checks i e no pending DTC and oxy gen sensor heater monitoring test not completed check vehicle conditions environmental and repeat Steps 3 through 6 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this secti
348. erminal is found replace wire harness connectors and terminals as an assembly 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 Never use air bag system component parts from another vehicle When using electric welding be sure to temporarily disable air bag system referring to DIS ABLING AIR BAG SYSTEM in SECTION 10B Never expose air bag system component parts directly to hot air drying or baking the vehicle after painting or flames WARNING CAUTION labels are attached on each part of air bag system components Be sure to fol low the instructions After vehicle is completely repaired perform AIR BAG DIAGNOSTIC SYSTEM CHECK in SEC TION 10B 6 GENERAL INFORMATION Identi Vehicle Identification Number ation Information The vehicle body number is on the left side of instrument panel and punched on the chassis inside the tire housing on the right front side H 27 100001 L Sequential Number Engine Displacement 27 2 7 Liter Engine Type GENERAL INFORMATION 0A 7 Engine Identification Number The number is punched on the cylinder block Engine Identification Number Speci Transmission Identification Number The A T manufacture s identification number is located on the transmission case as shown However the M T identifica
349. erwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CONTENTS General Descriptio Cautions in Servicing Symbols and Marks Abbreviations Wiring Color Symbols Joint Connector Fuse Box and Relay Power Supply Diagram Cruise Control System Cruise control system circuit Components and function Cancel Conditions Diagnosis Diagnosis Table Note on System Circuit Inspection Cruise Main Switch Indicator Lamp Circuit Check Cruise Indicator Lamp Circuit Check Cruise Main Switch Coast Set Resume Accel and Cancel Switches Circuits Check VSS Circuit Stop Lamp Switch with Pedal Position Switch Circuits Check 8E 2 8E 2 8E 2 8E 2 8E 2 8E 2 8E 2 8E 3 8E 3 8 4 8E 5 8E 5 8E 5 8E 7 8 8 8E 9 8E 10 8E 11 8E 12 8E 2 Transmission Range Switch Circuit Check 8E 13 Clutch Pedal Position Switch Circuit Check 8E 14 Throttle Valve Opening Signal Circuit Check Overdrive and TCC off Command Signal Circuit Check 2 Cruise Control Module Power and Ground Circuits Check Cruise Control Module and Its Circuit Inspection Cruise Cable Play Inspection and Adjustment On Vehicle Service Cruise Main Switc Coast Set Resume Accel and Cancel Switches Vehicle Speed Sensor VSS Transmission Range Switch Clutch Pedal Position Switc Stop Lamp Switch with Pedal Positi
350. es for 30 seconds each 4 Increase vehicle speed to about 70 km h 45 mile h in D range 5 Keep driving above vehicle speed for 30 seconds 6 Release accelerator pedal decrease vehicle speed and stop vehicle 7 Check DTC and or pending DTC TROUBLESHOOTING Step Action Yes No 1 Was A T DIAGNOSTIC FLOW TABLE in this section to Step 2 Go to A T DIAGNOS performed TIC FLOW TABLE in this section 2 Doyou have SUZUKI scan tool Go to Step 3 Go to Step 4 3 Check Transmission range switch sensor circuit for Intermittent trouble Go to Step 5 operation Check for intermittent Check by using SUZUKI scan tool referring to INTER 1 Connect SUZUKI scan tool to DLC with ignition MITTENT AND POOR Switch OFF CONNECTION in 2 Tum ignition switch ON and check transmission Section 0 range signal P R N D 2 or L on display when shifting select lever to each range Is applicable range indicated Are check results satisfactory 4 Check Transmission range switch sensor circuit for Intermittent trouble Go to Step 5 operation Check for intermittent Check by not using SUZUKI scan tool referring to INTER 1 Tum ignition switch ON MITTENT AND POOR 2 Check voltage at terminals C51 1 6 C51 1 7 CONNECTION in C51 1 18 51 1 19 C51 1 27 and 51 1 28 Section 0A respectively with select lever shifted to each range Taking terminal C51 1 28 as an example is battery volt
351. ess forward clutch piston return spring and remove retaining retum spring Special tool A 09926 98310 CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform 8 Remove forward clutch piston return spring 9 Install forward clutch to O D case Blow low pressure air into fluid hole at the right of cut in O D case to remove forward clutch piston AUTOMATIC TRANSMISSION 4 A T 781 53 DIRECT CLUTCH DISASSEMBLY 1 Install direct clutch assembly 1 to center support 2 and with 4 8 kg cm air pressure applied to second fluid hole from the left measure stroke of direct clutch piston as shown in figure If it is not within standard range use 3 55 mm 3 75 mm or 4 0 mm 0 140 in 0 147 in or 0 157 in clutch backing plate to adjust it to standard stroke Standard direct clutch piston stroke 0 90 1 30 mm 0 035 0 051 in 2 Remove direct clutch assembly from center support and then remove retaining ring 3 Remove clutch backing plate 1 and then remove clutch disc 3 and clutch plate 2 4 Using special tool and hydraulic press 1 compress direct clutch piston return spring 3 and remove retaining return spring ring 2 Special tool A 09926 98310 CAUTION Be careful when applying pressure for overpressure will cause plate section of piston return spring to deform
352. eter 1 inserted into center face air outlet 2 rear A C air outlet 3 dual A C model only and near A C evaporator air inlet read temperature indicated on each thermometer AIR CONDITIONING OPTIONAL 18 11 9 Check for each pressure of low side and high side if it is 2844 2000 20 within shaded range of graph 2 If each gauge reading is out of specified pressure correct 2560 1800 18 ty or Le defective part referring to PERFORMANCE DIAGNOSIS 275 emo TABLE 2193 1600 15 n t Example Poe p Gauges should read as follows isa non when ambient temperature is 30 C 86 F Pressure high pressure 1400 1750 kPa 25100 aoe gauge HI 14 0 17 5 kg cm 199 1 248 9 psi P Pressure on high pressure 230 350 kPa urn e gauge LO 2 3 3 5 kg cm HERT E 33 ow m 327 49 8 psi 3 284 200 2 NOTE EE 4 v 4 Pressure registered gauge varies with ambient tem m XT perature Therefore use the graphs when determining if n ae vag pressures are normal or not 10 Check inlet port temperature to outlet port temperature rela e tionship using graph PS For example if A C evaporator inlet port temperature is 25 gen C 77 F and center face air outlet temperatu
353. eter between terminals of injector and check resistance If resistance is out of specification replace Fuel injector resistance 14 2 14 8 at 20 C 68 F 3 Connect connector to injector securely ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 27 REMOVAL 1 Relieve fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCEDURE in Section 6 1 2 Remove throttle body intake collector refer to THROTTLE BODY in this section 3 Disconnect fuel feed hose 1 and fuel return hose 2 4 Disconnect vacuum hose 4 and fuel return hose from fuel pressure regulator 5 5 Remove fuel feed pipe 8 and fuel connect pipe 7 from delivery pipes 6 right and left CAUTION A small amount of fuel may be released when it is from delivery pipe Place a shop cloth under delivery pipe so that released fuel is absorbed in it 6 Disconnect connector 3 from each injector 7 Remove delivery pipes 1 right and left from intake mani fold 8 Remove fuel injector s INSPECTION WARNING As fuel is injected in this inspection perform in a well ventilated area and away from open flames Use special care to prevent sparking when connecting and disconnecting test lead to and from battery 62 28 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE
354. exists by using scan tool If not check if catalyst monitoring test has completed by using scan tool If not in both of above checks i e no pending DTC and catalyst monitoring test not completed check vehicle condition environmental and repeat Step 3 through 5 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 Exhaust system visual inspection Go to Step 3 Repair or replace 1 Check exhaust system for leaks damage and loose connection Is it in good condition 3 HO2S 2 output voltage check Replace warm up three Check RED BLK and 1 Check output voltage of HO2S 2 referring way catalytic converter l GRY YEL wires for open Step 2 of DTC P0136 Diag Flow Table and short and connec 15 check result satisfactory tions for poor connection If wires and connections are OK replace HO2S 2 6 1 96 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0430 Catalyst System Efficiency Below Threshold Bank 2 SYSTEM DIAGRAM i REDIGAN 51 3 21 j i 1 25 1 Bank 2 HO282 Bank 2 3 4 TWG 5 ECM POM CIRCUIT DESCRIPTION Exhaust oxygen concentration at the pre catalyst and the post catalyst of WU TWC is detected fro
355. 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 The AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE must be the starting point of any air bag sys tem diagnosis The AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE checks for proper AIR BAG waming lamp operation through AIR BAG warning lamp and whether air bag diagnostic trouble codes exist 2 Refer to the proper diagnostic table as directed by the AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE The AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE will lead you to the correct table to diagnose any air bag system malfunctions Bypassing these procedures may result in extended diagnostic time incor rect diagnosis and incorrect parts replacement Repeat the AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE after any repair or diagnostic proce dures have been performed Performing the AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE after all repair or diagnostic pro cedures will ensure that the repair has been made correctly and that no other malfunctions exist 3 FLOW TABLE TEST DESCRIPTION STEP 1 Check that AIR BAG warning lamp lights STEP 2 Check that AIR BAG warning lam
356. f L 2 N D and P OUTPUT SPEED P0720 SENSOR CIRCUIT A T control is performed by using signal from VSS MALFUNCTION control using Srd gear is performed when D range 1st or 2nd 20753 gear is used TCC solenoid OFF AIT control using 4th gear is performed when D range 2nd or 3rd gear is used P0758 i eO SOLENOID When both shift solenoids A 1 and B 2 failed simultaneously control using 4th gear is always performed in D range TCC solenoid OFF Lock up P0743 SOLENOID TCC Lock up solenoid OFF 6 1 24 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 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 judgment as abnormal should not be made by checking with these data alone Also conditions in the below table that can be checked by the scan tool are those output from ECM PCM as Commands and there may be cases where the engine or actuator is not operating in the condition as indicated by the scan tool Be sure to use the timing light to check the ignition timing referring to Section 6F2 NOTE For asterisk marked item in OTHER column item can be read only SUZUKI sca
357. f necessary Rear A C evaporator temperature controller faulty Check rear A C evaporator temperature controller and then replace if necessary Wiring or grounding faulty Check and repair Cool air dose not come out at only high speed Rear evaporator frosted Check rear A C evaporator temperature evaporator drain hose and then replace if necessary Insufficient velocity of cooled air Rear evaporator clogged or frosted Check rear A C evaporator and then repair rear evaporator or check rear AIC evaporator temperature if necessary Air leaking from rear unit or air duct Check rear A C unit and air duct and then repair if necessary Rear blower motor faulty Check rear blower motor and then replace if necessary Wiring or grounding faulty Check and repair AIR CONDITIONING OPTIONAL 18 9 Quickly Checking of Refrigerant Charge If Equipped with Sight Glass The following procedure can be used for quickly checking whether the A C system has a proper charge of refrigerant or not 1 Run engine at fast idle 2 Operate A C at the following conditions for a few minutes Main front A C switch at ON position Rear A C main switch at ON position if equipped Front blower motor switch at max position Rear blower motor switch at max position if equipped Air outlet control button at face position Temperature co
358. f wire and connections terminals are OK replace IAC 3 If OK check resistance between C51 1 4 valve and C51 1 5 C51 1 16 and C51 1 17 Is each resistance 51 67 Q 5 valve power supply voltage check TAC valve or ECM PCM Open BLU BLK wire 1 Connect ECM PCM couplers malfunction 2 With ignition switch OFF disconnect C29 coupler of IAC valve 3 With ignition switch ON check voltage between C29 2 and ground C29 5 and ground Is each voltage 10 14 V 6 1 110 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Step Action Yes No 6 Was idle speed higher than specification in FIA valve for mal _ Check parts or system Step 2 function which can cause engine Check abnormal air inhal low idle ing from intake manifold Check FIA valve for stuck throttle body PCV valve Air inhaling from between and EVAP canister purge throttle body and MAF control system sensor EGR valve mal function leakage from valve seat accessory engine load clog of idle air passage engine mechanical engine over heat and etc DTC P0601 DTC No 71 Internal Control Module Memory Check Sum Error SYSTEM DESCRIPTION Internal control module is installed in ECM PCM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Data write error or check sum error ECM PCM DTC CONFIRMATION PROCEDURE 1 Connect scan tool
359. ferring to following chart If contact pattern is not normal readjust or replace as necessary according to instruction in chart NOTE Be careful not to turn drive bevel gear more than one full revolution for it will hinder accurate check 1 Brush Paint gear marking compound evenly 7F 20 DIFFERENTIAL REAR TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY NORMAL Outer end Healy Drive side side Inner end Toe HIGH CONTACT Pinion is positioned too far from the center of drive bevel gear 4 Increase thickness of pinion height adjusting shim and position pinion closer to gear center 5 Adjust drive bevel gear backlash to specifica tion Gear Pinion LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height adjusting shim and position pinion farther from gear cen ter 2 Adjust drive bevel gear backlash to specification If adjustment is impossible replace differential carrier 1 Check seating of bevel gear or differential case d Check bevel gear for runout 2 If adjustment is impossible replace drive bevel gear amp pinion set or differential cartier Replace drive bevel gear amp pinion set or differential case DIFFERENTIAL REAR 7F 21 10 Upon completion of gear tooth contact check in Step 9 caul
360. ffered by the driver and front passenger seat belts the driver air bag inflator module is deployed from the center of the steering column the passenger air bag inflator module from the top of the instrument panel in front of the front passenger seat For more information refer to Section 10B Air Bag System SEAT BELT 10A 1 SECTION 10A SEAT BELT WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 CAUTION
361. fic or possibility of a traffic acci dent and very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 person a driver and tester on a level road Step Action Yes No 1 Was AUTOMATIC TRANSMISSION DIAG Step 2 Go to AUTOMATIC NOSTIC FLOW TABLE performed TRANSMISSION DIAG NOSTIC FLOW TABLE in this section 2 check Go to Step 3 Faulty ECT sensor its cir 1 Warm up engine to normal operating tem cuit or engine cooling sys perature tem 2 Check ECT using scan tool If OK substitute a known Is ECT more than 30 C 86 F good PCM and recheck 3 Perform running test under the following condi Faulty TCC solenoid Go to Step 4 tions and check voltage between C51 1 8 termi valve its circuit or trans nal of PCM coupler and ground mission Normal mode in D range Transfer 2H position Cruise control is not operated if equipped Brake pedal released Drive vehicle with TCC ON condition refer ring to TCC LOCK UP DIAGRAM in this section Is it battery voltage 4 switch signal inspection Go to Step 5 Faulty brake pedal switch With ignition switch ON check voltage between or its circuit E61 34 terminal of PCM coupler terminal and If OK substitute a known ground good PCM and recheck Brake switch specification Brake pedal released 0 V Brake pedal depressed Battery voltage Is the result as specified
362. filter properly it is important to accurately identify the position at which filter O ring first contacts the mounting surface 5 Tighten the filter 3 4 turn from the point of contact with the mounting surface using an oil filter wrench Tightening torque For reference Oil filter b 14 N m 1 4 kg m 10 5 Ib ft T Ol fier 2 Ollfiter wrench 08 8 MAINTENANCE AND LUBRICATION gt gt o4 ao sw e Temperature 6 Replenish oil until oil level is brought to FULL level mark on dipstick oil pan and oil filter capacity The filler inlet is at the top of the cylinder head cover It is recommended to use engine oil of SE SF SG SH or SJ grade NOTE Select the appropriate oil viscosity according to the proper engine oil viscosity chart A TAF Proper engine oll viscosity chart Engine oil specification H27 engine pan capacity liters US Imp pt About 5 0 10 6 8 8 Oil filter capacity liters US Imp pt About 0 5 1 1 0 9 Others Titers US Imp pt About 0 7 1 5 1 2 Total liters US Imp pt About 6 2 13 1710 9 NOTE Engine oil capacity is specified However note that the amount of oil required when actually changing oil may somewhat differ from the data in the table depending on various conditions temperature viscosity etc 7 Chec
363. firm that the trouble has been corrected 108 44 AIR BAG SYSTEM DTC B1043 and B1047 Step Action Yes No 1 With ignition switch OFF remove center pil lar inner garnish of applicable side then dis connect seat belt pretensioner connector 2 Check proper connection to applicable seat belt pretensioner at terminals in Q11 0127 connector 3 If OK then connect Special Tool B to seat belt pretensioner connector disconnected at the step 1 With ignition switch ON is DTC B1043 or B1047 still current Go to step 2 Ignition switch OFF Replace seat belt pretensioner Refer to Section 10 1 With ignition switch OFF disconnect Spe cial Tool B and SDM 2 Measure resistance between 001 11 Q01 6 and body ground Is circuit open Substitute a known good SDM and recheck DTC B1043 Repair short PNK or WHT wire circuit to ground DTC B1047 Repair short from BRN or LT GRN wire circuit to ground Fig for STEP 1 and 2 T Prelensioner harass STEERING WHEEL Fig for STEP 2 For DTC B1043 1B For DTC B1047 Special tool A B 09932 75020 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic
364. found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS General Description 14 2 Rear Duct 14 3 1A 2 HEATER AND VENTILATION General Description The heater an in and out air selectable type hot water heater is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides right and left of the instrument panel the hot air outlet at a place close to the feet and the defroster air outlets at places right and left along the windshield glass The heater and ventilation consist of the following parts 1 Side ventilator culler 4 Healer unit 7 Heater control lever assembly 10 Rear duct 2 Side defroster outlet 5 Defroster duct 8 Heater mode control switch Center ventilator outlet Ventilator duct 3 Blowerunit HEATER AND VENTILATION 1A 3 Rear Duct 1 Heater unit 2 Rear duct REMOVAL 1 Disconnect negative cable at battery 2 Remove front and second seats 3 Remove console box 4 Take off carpet till rear duct is totally exposed 5 Remove rear duct INSTALLATION Reverse removal sequence to install rear duct 1A 4 HEATER AND VENTILATION AIR CONDITIONING OPTIONAL 18 1 SECTION 1B AIR CONDITIONING OPTIONAL WARNING For vehicles equipped with Supplemental Restraint Air Bag Sy
365. g SUZUKI Scan 5E2 11 AT Ca Claes Cee roule vene 22 Right Front Wheel Speed Sensor Circuit or Sensor Ring 5E2 22 Diagnostic Trouble Code DTC Table System DTC C1025 DTC 25 DTC C1026 26 Left Front Wheel Speed 52 2 ANTILOCK BRAKE SYSTEM ABS 5E2 22 Sensor Circuit or Sensor Ring DTC C1031 DTC 31 DTC C1032 DTC 32 Right Rear Wheel Speed Sensor Circuit or Sensor Ring DTC C1035 DTC 35 DTC C1036 DTC 36 Left Rear Wheel Speed Sensor Circuit or Sensor Ring 5 DTC C1041 DTC 41 Right Front Inlet 5E2 22 5E2 22 Solenoid Circuit 5E2 24 DTC C1045 DTC 45 Left Front Inlet Solenoid Circuit 5E2 24 DTC C1055 DTC 55 Rear Inlet Solenoid Circuit 5E2 24 DTC C1042 light Froni Outlet Solenoid Circuit 5E2 24 DTC C1046 DTC 46 Left Front Outlet Solenoid Circuit 5E2 24 DTC C1056 DTC 56 Rear Outlet Solenoid Circuit 5E2 24 DTC C1057 DTC 57 Power Source Circuit 2 DTC C1061 DTC 61 ABS Pump Motor Circuit DTC C1063 63 ABS Fail Safe Relay Circuit DTC C1071 DTC 71 ABS Control Module On Vehicle Service Precautions ABS Hydraulic Unit Operation Check Using SUZUKI Scan Tool ABS Hydraulic Unit Operation Check Not Using Suzuki Scan Tool ABS Hydraulic Unit Control Module Assembly Rear Sensor Rotor Retainer Ring Tightening
366. g air may reduce its durability 1 Fully apply joint grease to wheel side joint Use joint grease in the tube included in spare part Joint Grease about 85 95 g 3 0 3 4 oz Yellow TA Wheel side 2 Fit wheel side boot 1 on shaft Fill up inside of boot 1 with joint grease Before fixing boot band 2 insert screwdriver into boot 1 on joint side and allow air to enter boot so that air pressure in boot 1 becomes the same as atmospheric pressure 3 Fixing boot band 2 4 Install boot 1 onto drive shaft till small diameter side fits to shaft groove and fix there with boot band 2 5 Install cage 1 to shaft CAUTION Install cage 1 directing smaller outside diameter side to shaft end 18 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL 442 3 6 Install circlip 1 by using snap ring plier 7 Apply grease to entire surface of cage Use joint grease in tube included in spare part 8 Insert cage into outer race and fit circlip 1 into groove of outer race CAUTION Position opening of circlip a so that it will not be lined up with a ball 9 Apply grease in tube included in spare part to inside of outer race and fit boot to outer race
367. g lamp come ON 2 1 Disconnect ABS hydraulic unit control mod Substitute a known good ABS Go to Step 3 ule connector hydraulic unit control module Does ABS warning lamp light with ignition assembly and recheck switch ON 3 1 Remove combination meter BLU ORN circuitshortedto Replace bulb Is bulb of ABS warning lamp in good condition ground If OK replace combina tion meter lamp driver module 4 516 fuse in good condition Openin BLK WHT wireto Repair and replace combination meter or poor con nection 2 16 ANTILOCK BRAKE SYSTEM ABS Table B ABS Warning Lamp Circuit Check Lamp Comes ON Steady Refer to TABLE A for System Circuit Diagram and Circuit Description INSPECTION Step Action Yes No 1 Perform diagnostic trouble code check Is there any DTC including code No 12 NO CODES on SUZUKI scan tool exists Go to Step 2 Go to Step 3 Does malfunction DTC other than code No 12 exist at Step 1 Go to Step 7 of ABS DIAGNOSTIC FLOW TABLE in this section Go to Step 3 1 Disconnect ABS hydraulic unit control mod ule connector 2 Check for proper connection to ABS hydraulic unit control module connector at terminals E136 14 E136 18 and E136 24 3 If OK then ignition switch ON and measure voltage at terminal E136 18 of connector Isit10 14 V Go to Step 4 BLK WHT circuit open 1 With ABS hydrau
368. g service procedures be very careful when han dling a Sensing and Diagnostic Module SDN 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 Refer to DISABLING AIR BAG SYSTEM in this section 3 Remove rear and front center console box 1 by removing screw and clips 4 Remove center gamish panel 2 5 Remove ashtray 3 and tuner assembly clock assembly 5 tuner pocket radio hole cover 4 etc 6 Disconnect SDM connector 1 from SDM 2 7 Remove SDM 2 from vehicle FORWARD e ZA AIR BAG SYSTEM 108 61 INSPECTION CAUTION Do not connect a tester whatever type it may be Never repair or disassemble SDM If SDM has been dropped it should be replaced Check SDM and SDM plate for dents cracks or deformation Check SDM connector for damage cracks or lock mecha nism Check SDM terminal for bent corrosion or rust If any faulty condition is found in above checks replace INSTALLATION 1 Check that none of following faulty conditions exists Bend scratch deformity in vehicle body mounted on SDM Foreign matter or rust on mating surface of vehicle body mounted on SDM 2 Install SDM 2
369. g the DTC Confirmation Proce Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 99 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Start engine and warm up it completely 4 Increase vehicle speed to 55 km h 35 mph or more 5 Keep driving above vehicle speed for 20 min or more Change of vehicle speed is permitted in this step 6 Release accelerator pedal stop vehicle and run engine at speed for 2 min 7 Check DTC and pending DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 canister purge system for opera Intermittent trouble or Go to Step 3 tion referring to EVAP CANISTER PURGE faulty PCM SYSTEM INSPECTION in this section Check for intermittent Is check result satisfactory referring to INTERMIT TENT AND POOR CON NECTION in Section 0A 3 Check EVAP canister purge valve for resistance GRN BLK or BLU BLK Replace EVAP canister referring to EVAP CANISTER PURGE VALVE circuit open or short purge valve INSPECTION in this section If wire and connections Is resistance as specified are OK substitute a known good ECM PCM and rech
370. g torque Steering shaft joint bolt c 25 N m 2 5 kg m 18 0 Ib ft 5 Align cutting point A of steering column assembly 1 with bolt hole B of steering upper shaft upper joint as shown in the figure Then connect steering upper shaft upper joint AIR BAG STEERING WHEEL AND COLUMN 3C1 9 6 Install steering upper shaft upper joint bolt 2 and nut 1 Tighten steering upper shaft upper joint nut 1 to specified torque Tightening torque Steering upper shaft upper joint nut a 23 N m 2 3 kg m 17 0 Ib ft Steering Lower Shaft Assembly CAUTION Never turn steering wheel while steering lower shaft assembly is removed Should it have been turned and contact coil on combina tion switch have got out of its centered position it needs to be centered again Also turning steering wheel more than about two and a half turns will break contact coil REMOVAL 1 Tum steering wheel so that vehicle s front tires are at straight ahead position 2 Tum ignition switch to LOCK position and remove key 3 After removing bolt 4 on upper shaft assembly 1 side of shaft joint 2 and loosening bolt 5 on its lower shaft assem bly 3 side move shaft joint 2 to lower shaft assembly side 3 in arrow direction in figure 4 Remove lower shaft assembly lower joint bolt 2 and then remove lower shaft assembly 1 5 Remove shaft joint bolt lower shaft assembly side from
371. gauge 7 Fuel retum line from delivery pipe 3 Fuel iter 8 Fuel vapor ine to EVAP canister Fuel iter cap Fuel tank protector 5 Breather hose 10 Bet 6C 2 ENGINE FUEL On Vehicle Service Fuel Tank REMOVAL 1 Relieve fuel pressure in fuel feed line referring to Section 6 or Section 6 1 CAUTION This work must not be done when engine is hot If done it may cause adverse effect to catalyst 2 Disconnect negative cable at battery 3 Before disconnecting fuel filler hose give match marks on fuel filler hose and fuel filler neck 4 Disconnect fuel filler hose from fuel filler neck 5 Insert hose of a hand operated pump into fuel filler hose and drain fuel in space A in the figure drain fuel through it till fuel stops CAUTION Do not force hose of a hand operated pump into fuel tank Doing so can damage inlet valve Fuel filer hose 2 Fuel tank inlet check valve 6 Remove fuel tank filler hose protector Disconnect filler hose from fuel tank and breather hose from fuel filler neck 7 Remove fuel tank inlet valve Use care not to damage inlet valve when removing Tank Breather hose Filler hose net valve 8 Drain fuel tank by pumping fuel out through fuel tank filler Use hand operated pump device to drain fuel tank CAUTION Never drain or store fuel in an open container du
372. ged 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 DIFFERENTIAL REAR 7F 3 On Vehicle Service 15 4B 24 F 12 Ok at P amp um on lt 0 d D HG O a F 23 58 8 95 N m 9 5 kom 2a 0 12 Nm 12 i lt T ot 25 8 s5 Nm 7 as go Universal ont Tange Dice carter aonb 2 Hypo goar sot 19 Diferential pinion 8 Tock piate 25 Bo WE Bove pon space Ti Derental gear 18 Prion sha NO ppl thread lock cement Apply thread lock pum DIFFERENTIAL CASE in fad part of bo 3 Sm TE Pirin sa 3 ion it d em E Fear boarng Diferenta a aso Ti ping washer 9 E Font baring TK Doria ight caso 7 Os E Tus washer Esse ABH Reply crease 99000 25010 Apply inroad oc profer of bok S Fagen 6 side beating E ale cauk nur eure 4 DIFFERENTIAL REAR Precaution for Maintenance Service When having driven through water check immediately if water has entered if so oil is cloudy Water mixed oil must be changed at once Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage and
373. gic ECM PCM Current of HO2S 2 heater is more than 11 4 A or less than 0 32 A or Voltage of HO2S 2 heater is more than 13 8 V or less than 8 7 V DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data in ECM memory by using scan tool and start engine 3 Increase vehicle speed to 50 60 km h 30 40 mph 4 Keep driving above vehicle speed for 5 min Change of vehicle speed is permitted in this step 5 Stop vehicle and check if pending DTC exists by using scan tool If not check if oxygen sensor heater moni toring test has completed by using scan tool If not in both of above checks i e no pending DTC and oxy gen sensor heater monitoring test not completed check vehicle conditions environmental and repeat Steps 3 through 5
374. gine start range Forward 1st lt gt 2nd lt gt 3rd lt gt 4th O D O D ON automatic gear change range Forward 1st lt gt 2nd lt gt 3rd O D OFF automatic gear change 2 range Normal mode Forward 1st lt gt 2nd lt 3rd auto matic gear change Power mode Forward 2nd lt 3rd automatic gear change and fixed at 2nd gear L range Forward 1st lt 2nd lt 3rd reduction and fixed at 1st gear Gear 1st 2 826 ratio low gear 2nd 1 493 second gear 3rd 1 000 top gear 4th 0 689 overdrive gear Reverse 2 703 reverse gear Control elements Wet type multi disc clutch 3 sets Wet type multi disc brake 4 sets One way clutch 3 sets Transfer 1 000 Lo 1 816 4WD model only Final gear reduction 5 125 ratio Differential Lubrication Lubrication system Force feed system by oil pump Cooling Cooling system Radiator assisted cooling water cooled Fluid used equivalent of DEXRONPIII 781 4 AUTOMATIC TRANSMISSION 4 A T Electronic Shift Control System sume osa E 1i HE SEEE 1 3 4 cst 2 GRY RED I REDIGRN ORNBLU e 31120 gt
375. gnosis procedure as described in the flow table Failure to follow the flow table may result in incorrect diagnosis Some other diagnosis trouble code may be stored by mistake in the memory of ABS control module during inspection When disconnecting ABS hydraulic unit control module con nector 1 pull up lock 2 of connector When connecting set the connector on ABS hydraulic unit control module assembly and push the lock 2 down D Disconnect Connect 52 6 ANTILOCK BRAKE SYSTEM ABS ABS gnostic Flow Table Refer to the following pages for the details of each step Step Action Yes No 1 1 Perform Customer Complaint Analysis 2 Perform Problem Symptom Confirmation 3 Perform Diagnostic Trouble Code Check Record and Clearance Is there any malfunction DTC Go to Step 2 Go to Step 5 1 Perform DRIVING TEST Is trouble symptom identified Go to Step 3 Go to Step 6 1 Check diagnostic trouble code Is it malfunction code Go to Step 4 Go to Step 5 1 Inspect and repair referring to applicable diagnostic trouble code table in this section 2 Perform FINAL CONFIRMATION TEST after cleared DTC Does trouble recur Go to Step 7 End 1 Inspect and repair referring to DIAGNOSIS in BRAKES section 2 Perform FINAL CONFIRMATION TEST 1 Check intermittent troubles referring to
376. ground circuit Substitute a known good ECM PCM and recheck ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 45 Table A 3 Malfunction Indicator Lamp Check MIL Flashes at Ignition Switch ON Vehicle with Monitor Connector WIRING DIAGRAM CIRCUIT DESCRIPTION Refer to TABLE A 1 TROUBLESHOOTING Step Action Yes No 1 MIL Flashing Pattern check Go to Step 2 Go to Diagnosis in Sec 1 Tum ignition switch ON tion 8G Does lamp flashing pattern indicate diagnostic trouble code 2 Diag Switch Circuit check System is in good condi circuit shorted to 15 diag switch terminal connected to ground via tion ground If circuit is OK service wire substitute a known good ECM PCM and recheck Table A 4 Malfunction Indicator Lamp Check MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Terminal Vehicle with Monitor Connector WIRING DIAGRAM CIRCUIT DESCRIPTION Refer to TABLE A 1 TROUBLESHOOTING Step Action Yes No 1 Circuit check PPL YEL circuit shorted to Step 2 1 Tum ignition switch OFF and disconnect to ground connectors from ECM PCM Does MIL turn ON at ignition switch ON 2 ECM PCM Connection check Go to Step 3 1 Tum ignition switch OFF Is connector E61 29 connection connected to ECM PCM properly 3 Diag switch Terminal Circuit check YEL or BLK circuit Substitute a known go
377. h A T 14 Knock sensor NOTE Above figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the side of symmetry ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 9 so GE rm E E YeUGAN fost 1 12 GRVIGEN E 49 jJ YEUBLU 1651113 GRY BLK Eu 1651326 5 B PPLIWHT CS1 3 10 GRY YEL 4 51 3 5 a z GRNAVET 27 RED WHT 51 3 8 E LTGRNYEL T GRYRED 651 34 ae ELT GRNMED do s E m ere a E 5 irene SEDAN E133 GRYRED C51 3 19 zc Sg aic e ORNBLK 51 2 LLL fosis2s i cS1 1 18 1061325 o2 HTARLY EX pres RED Js
378. h OFF terminal E132 1 Is check result satisfactory 2 Check for proper connection to cruise control module at 3 If OK check for continuity between terminals E132 1 and E59 2 terminals C52 2 and C20 1 referring to CRUISE CONTROL SYSTEM in Section 8A Step Action Yes No 1 Vehicle Speed Sensor Circuit Check VSS circuit is l BLU YEL cir 1 Disconnect connector from cruise control module with cuit is open Fig for Step 1 522 8 12 CRUISE CONTROL SYSTEM Stop Lamp Switch with Pedal Position Switch Circuits Check Step Action Yes No 1 Stop Lamp Switch With Pedal Position Switch Circuits Check 1 Disconnect connector from cruise control module with ignition switch OFF 2 Check for proper connection to cruise control module at terminals E132 2 and E132 6 3 If OK turn ignition switch ON 4 Check Voltage between each terminal and ground under each condition below Stop lamp switch circuit specification Brake pedal released terminal E132 2 0 V Brake pedal released terminal E132 6 10 14 V Brake pedal depressed terminal E132 2 10 14 V Brake pedal depressed terminal E132 6 0 V Is check result satisfactory Stop lamp switch with pedal position Switch circuits are OK Go to Step 2 Stop Lamp Switch Position Check 1 Check stop lamp switch for installation position referring to STOP LAMP SWITCH in Section 5 Is check result
379. h ignition switch ON is DTC B1042 or B1046 still current Ignition switch OFF Replace seat belt preten sioner Refer to Section 10 AIR BAG SYSTEM 108 43 Step Action Yes No 2 1 With ignition switch OFF disconnect SDM Substitute a known good DTC B1042 2 Check proper connection to SDM at termi SDM and recheck Repair short from PNK nals 001 11 and 001 12 or Q01 6 and wire circuit to WHT wire Q01 5 circuit or from PNK or 3 If OK then measure resistance between WHT wire circuit to other Q01 11 and 001 12 terminals or QO1 wire circuit 06 and 001 05 terminals with connected DTC B1046 Special Tool B Repair short from BRN Is resistance 1 4 or more wire circuit to LT GRN wire circuit or from BRN or LT GRN wire circuit to other wire circuit Fig for STEP 1 and2 Protonsioner hamess STEERING WHEEL Fig for STEP 2 a 181 5001 5 901 8 901 11 7001 12 ForDTC B1042 IB ForDTC B1046 Special tool A 09932 75020 B 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to con
380. h strainer Seized or broken planetary gear Repair or replace Faulty manual valve Replace Poor ist speed run ning or excessive slip page in D or 2 Faulty 1 2 shift valve Replace 781 16 AUTOMATIC TRANSMISSION 4 A T GEAR SHIFT Condition Possible Cause Correction Poor 1 2 shift exces Regulator valve sticking Replace sive slippage 1 2 shift valve sticking Replace Shift solenoid valve B sticking Replace Intermediate coast modulator valve sticking Replace Poor 2 3 shift exces 2 3 shift valve sticking Replace sive slippage Shift solenoid vaive A sticking Replace Poor start or surging _ Regulator valve sticking Replace in D range Poor 3 4 shift exces 3 4 shift valve sticking Replace sive slippage Shift solenoid valve B sticking Replace Excessive shock on Regulator valve sticking Replace 1 2 shift Faulty accumulator second brake piston Replace Excessive shock on _ Regulator valve sticking Replace 2 3 shift Faulty accumulator direct clutch piston Replace Excessive shock on Regulator valve sticking Replace 3 4 shift Non operate lock up Lock up control valve sticking Replace system Solenoid valve No 2 TCC solenoid valve stick Replace ing Trouble Diagnosis Table 3 TRANSMISSION FLUID Condition Possible Cause Correction Low fluid p
381. han 1 drop min ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 29 NS Ne 1 T A VP oS ote P INSTALLATION 1 Replace injector O ring 1 with new one using care not to damage it Install grommet 2 to injector 2 Check if insulator 1 is scored or damaged If it is replace with new one Install insulators and cushions 2 to intake manifold 3 Apply thin coat of fuel to O rings 1 and then install injectors into delivery pipes right and left and intake manifold Make sure that injectors rotate smoothly If not probable cause is incorrect installation of O ting or grommet 2 Replace O ring with new one 4 Tighten delivery pipe bolts 3 and make sure that injectors rotate smoothly 6 2 30 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 5 Install fuel connect pipe 1 and tighten union bolts to speci fied torque with new gaskets 3 Tightening torque Fuel connect pipe union bolt b 30 N m 3 0 kg m 22 0 Ib ft 6 Install fuel feed pipe 2 and tighten union bolt to specified torque with new gaskets Tightening torque Fuel feed pipe union bolt a 30 N m 3 0 kg m 22 0 Ib ft 7 Connect vacuum hose 5 and fuel return hose 4 to fuel pressure regulator 8 Connect fuel feed hose 1 and fuel retum hose 2 9 Connect connectors of injector wire 3 to inj
382. has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other 21 Disconnect the deployment harness from the air bag infla tor module and the seat belt pretensioner 22 Temporarily store air bag inflator module or seat belt pre tensioner For driver air bag inflator module Temporarily store the air bag inflator module with its vinyl trim cover facing up away from the surface upon which it rests Refer to SERVICE PRECAUTIONS for details For seat belt pretensioner When temporarily strong the seat belt pretensioner be sure NOT to face its exhaust hole provided side down It must face up Refer to SERVICE PRECAUTIONS for details 23 Contact your local distributor for further assistance 108 72 AIR BAG SYSTEM Deployment Activation Inside Vehicle Use this procedure when scrapping the entire vehicle including the air bag inflator modules and seat belt pretensioners CAUTION When vehicle itself will be used again deploy activate the air bag and pretensioner outside vehicle according to DEPLOYMENT ACTIVATION OUTSIDE VEHICLE for deploying activating it inside will cause the instrument panel glove box and their vicinity to be deformed Failure to observe this CAUTION may require unneeded vehicle inspection and repair 1 Tum ignition switch to LOCK position remove key and put
383. he ground about 185 cm 6 ft 4 in diameter where the seat belt pretensioner retractor assem bly 1 is to be activated A paved outdoor location where there is no activity is preferred If an outdoor location is not available a space on the shop floor where there is no activ ity and sufficient ventilation is recommended Ensure no loose or flammable objects are within the activa tion area Place the seat belt pretensioner retractor assembly 1 as shown in the figure on the ground in the space just cleared c TA AIR BAG SYSTEM 10B 69 6 Stretch the deployment from the driver or passenger air bag inflator module to its full length 10 m 33 ft 1 Special tool A 09932 75030 7 Place a power source 3 near the shorted end of the deploy ment harness Recommended application 12 Volts mini mum 2 amps minimum A vehicle battery is suggested 8 Verify that the area around the air bag inflator module or seat belt pretensioner is clear of all people and loose or flam mable objects 9 Verify setting condition of air bag inflator module or preten sioner as follows In case of driver air bag inflater module Verify that the driver air bag inflator module is resting with its vinyl trim cover facing up In case of passenger air bag inflator module Verify that the passenger air bag inflator module is firmly and properly secured in passenger air bag inflator m
384. he 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 Never attempt to disassemble the seat belt pretensioners retractor assembly If any abnormality is found be sure to replace it with new one as an assembly When an abnormality is noted as existing in the live 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 immedi ately with a dry cloth If seat belt pretensioner was dropped from a height of 30 cm 1 ft or more it should be replaced with a new one as an assembly 108 54 AIR BAG SYSTEM WARNING 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 Never carry the seat belt pretensioner by the wire or connector of the pretensioner 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 Othe
385. heck Fig for STEP 2 3 a HOZS heater olay 6 1 72 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0156 HO2S 2 Bank 2 Circuit Malfunction WIRING DIAGRAM E139 HO2S 7 ia METER 0204 C51247 051 923 C51325 1 o W 513 23 W 051325 81217 1 HOZS heater relay 2 ECM POM 3 HO282 Bank 2 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when any one of following conditions is detected 2 driving cycle detection logic 4 5 V or more HO2S circuit voltage is detected when 5 V power is con nected to HO2S circuit in ECM PCM While running with A F feed back average output voltage during speci fied time is too high or too low or While running with A F feed back max output voltage during specified time is lower than specified value or min output voltage during speci fied time is higher than specified value HO28 2 or its circuit Fuelsystem ECM PCM DTC CONFIRMATION PROCEDURE WARNING dent and be very careful during testing to avoid occurrence of an a When performing a road test select a place where th
386. heck result is not satisfactory replace Cruise main switch specification Switch button released Infinity Switch button pressed About 3 9 INSTALLATION Reverse removal procedure for installation 8E 20 CRUISE CONTROL SYSTEM Coast Set Resume Accel and Cancel Switches CAUTION Never disassemble combination switch assembly Disas sembly will spoil its original functions These switches are built in the combination switch assembly REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH in Section 3C1 INSPECTION 1 Disable air bag system referring to DISABLING AIR BAG SYSTEM in Section 10B 2 Disconnect connector 1 of COAST SET RESUME ACCEL and CANCEL switches 3 Check for resistance between SW and GND terminals of disconnected switch connector 1 under each condition below If check result is not satisfactory replace combination switch assembly COAST SET RESUME ACCEL and CANSEL switch speci fication All switches released OFF Infinity CANCEL switch pressed ON About 0 Q COAST SET switch rotated ON 200 240 Q RESUME ACCEL switch rotated ON 820 1000 Q Vehicle Speed Sensor VSS INSPECTION Refer to Section 6E2 Transmission Range Switch Refer to Section 7B1 for inspection removal installation and adjustment CRUISE CONTROL SYSTEM 8E 21 Clutch Pedal Position CPP Switch REMOVAL 1
387. heel cylinder Parking Brake Cable PARKING AND REAR BRAKE 5C 3 On Vehicle Service 15 14 eaim 14 S io nm oem 15 re 21 V 10 1 0 N Y Parking brake swich Ti Goor ing 36 Crossmember 2i Parking brake cable nut 2 Parking brake lever 7 Pin 12 Cable 37 Chassis rame 3 Parking brake lovor bot amp Equalizer 13 Grommet 38 Hanger 4 Fior 9 Adustrod 14 Bol 19 Rear axle 5 Locking nut 10 Coupler 15 Clamp if equipped 20 G sensor if equipped Brake Drum INSPECTION Brake drum Inspect drum for cleanliness Check wear of its braking surface by measuring its inside diameter Whenever brake drums are removed they should be thoroughly cleaned and inspected for cracks scores deep grooves Brake dram inside diameter a Standard 254 mm 9 99 in Service Limit 256 mm 10 07 in 5 4 PARKING AND REAR BRAKE Cracked scored or grooved drum A cracked drum is unsafe for further service and must be replaced Do not attempt to weld a cracked drum Smooth up any slight scores Heavy or extensive scoring will cause excessive brake lining wear and it will probably be neces sary to resurface drum braking surface If brake linings are slightly wo
388. her than 0 C 32 F temperature Diagnostic Trouble Code DTC Table MIL ML vehicle vehicle DTC NO DETECTED ITEM DETECTING CONDITION without with DTC will set when detecting monitor monitor connector connector P0100 No 34 Mass air flow circuit SS0F output too low 1 driving 1 driving ass don Sensor output too high cycle Intake air temp circuit low input No 25 Intake air temp circuit mal P P 1 driving 1 driving eas function Intake air temp circuit high input ele cycle P0115 fas aaa a ate Jee No 15 Engine coolant temp circuit 19 Coolant temp circuit low input 4 driving 1 driving oe Engine coolant temp circuit high cycle P0120 22 Throttle position circuit Throttle position circuit low input 1 driving 4 driving functi i een Throttle position circuit high input 996 Poi Trote positon circuit perior poor performance of TP sensor 2 diving Not mance problem cycles applicable Min output voltage of HO2S 1 is higher than specification poigo 25 circuit malfunction output voltage of HO2S T is 2 driving Not Bank 1 Sensor 1 lower than specification cycles applicable Output voltage of HO2S 1 fails to go above specification PO130 HO2S Bank 1 Sensor 1 no Put voltage of HO2S 1 fails to 0 5 2 driving
389. hicles Equipped with A Vehicle Identification Numbei Supplemental Restraint Engine Identification Number Air Bag System 0 2 Transmission Identification Numbei Diagnosis 0A 2 Warning Caution and Information Labels 0A 8 Servicing and handling 0A 3 0A 2 GENERAL INFORMATION Precau ns Precaution for Vehicles Equipped with A Sup plemental Restraint Air Bag System WARNING The configuration of air bag system parts are as shown in the figure When it is necessary to service remove reinstall and inspect these parts be sure to follow procedures described in SECTION 10B Failure to fol low proper procedures could result in possible air bag system activation personal injury damage to parts or air bag system being unable to activate when neces sary If the air bag system and another vehicle system both need repair SUZUKI recommends that the air bag sys tem be repaired first to help avoid unintended air bag system activation Do not modify the steering wheel dashboard or any other air bag system components Modifications can adversely affect air bag system performance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking pro cess remove the air bag system components before hand to avoid component damage or unintended air bag system activation 1 Air
390. higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC by using scan tool then start engine and run it for 3 min or more 3 Check pending DTC by using scan tool TROUBLESHOOTING Step Action Yes No 1 ENGINE DIAG FLOW TABLE per Goto Step 2 Goto ENGINE DIAG FLOW TABLE formed in this section 2 Check for voltage at terminal C51 1 24 of Poor C51 1 24 connection BLK YEL circuit open PCM connector connected under fol intermittent trouble lowing condition Check for intermittent referring to Engine starter signal specification INTERMITTENT AND POOR While engine cranking 6 14 V CONNECTION in Section 0A After starting engine 0 1 V If wire and connections are OK Is voltage as specified substitute a known good ECM PCM and recheck 115 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 DTC P1510 Ecm Back Up Power Supply Malfunction WIRING DIAGRAM 1 E121 DOME z WHEL WHT WHT E612 E612 T Nanti 3 EME O 2 Te DLC CIRCUIT DESCRI
391. ide bearing 7 12 Drive bevel pinion 7 13 Assembling Unit 7 17 7 20 7F 20 7F 21 Tightening Torque Speci Required Service Mater Special Too 2 DIFFERENTIAL REAR General Description The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle It is set in the conven tional type axle housing 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 Diagnosis Diagnosis Table Condition Possible Cause Correction Gear noise Deteriorated or water mixed lubricant Repair and replenish Inadequate or insufficient lubricant Repair and replenish Maladjusted backlash between drive bevel pin Adjust as prescribed ion and gear Improper tooth contact in the mesh between Adjust or replace drive bevel pinion and gear Loose drive bevel gear securing bolts Replace or retighten Damaged differential gear s or differential pin Replace ion s Bearing noise Constant noise Deteriorated or water mixed Repair and replenish lubricant Constant noise Inadequate or insufficient Repair and replenish lubricant Noise while coasting Damaged bearing s of Replace drive bevel pinion Noise while turning Dama
392. ig for STEP 2 C Fig for STEP 3 5 Special tool A NOTE Upon completion of inspection and repair work perform following items 09932 75020 Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1036 and B1038 Step Action Yes No 1 1 Ignition switch OFF 2 Disconnect driver air bag inflator module connector passenger air bag inflator mod ule connector driver pretensioner module connector and passenger pretensioner module connector 3 Disconnect forward sensor 4 Check proper connection to forward sensor connector at ORN GRN and ORN BLU terminals or YEL GRN and YEL BLU ter minals 5 If OK then measure resistance between ter minals of forward sensor Is resistance 738 905 Q Go to step 2 Replace forward sensor 1 Disconnect SDM connector 2 Check proper connection to SDM connector at terminals Q01 13 and 001 14 or ter minals 001 18 and Q01 19 3 If OK then measure resistance between ter minal 001 13 and Q01 14 or terminal Q01 18 and 001 197 Is circuit open Go to step 3 Repair short from ORN GRN wire circuit between forward sensor and SDM to ORN BLU wire circuit between for war
393. igerant HFC 134a R 134a strike your eye s consult a doctor immediately DO NOT USE YOUR HAND TO RUB AFFECTED EYE S Instead use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point Obtain proper treatment as soon as possible from a doctor or eye specialist Should liquid refrigerant HFC 134a R 134a get on your skin such affected part should be treated in the same manner as when skin is frostbitten or frozen CAUTION None of refrigerant compressor oil and component parts is interchangeable between two types of AIC one using CFC 12 R 12 and the other using HFC 134a R 134a For identification between these two types refer to REFRIGERANT TYPE in this section When replenishing or changing refrigerant and compressor oil and when replacing parts make sure that the material or the part to be used is appropriate to the A C installed in the vehicle being serviced Use of incorrect one will result in leakage of refrigerant damage in parts or other faulty condition Precaution When servicing air conditioning system the following rules must be observed Piping When connecting hoses and pipes apply a few drops of compressor oil refrigerant oil to seats of coupling nuts and O ring NOTE Single A C model is the same as SQ625 H25 engine model Refer to the same section of the Service Manual mentioned in FOREWORD of this manual
394. ignal from ABS control module to control fluid pressure applied to wheel cylinder of each 4 wheels Fail safe relay solenoid valve relay which supplies power to solenoid valve in ABS hydraulic unit and pump motor relay Pump motor relay which supplies power to pump motor in ABS hydraulic unit G sensor which detects body deceleration speed For 4WD model only This ABS is equipped with Electronic Brake force Distribution EBD system that controls a fluid pressure of rear wheels to best condition which is the same function as that of proportioning valve by the signal from wheel sen sor independently of change of load due to load capacity and so on And if the EBD system fails to operate prop erly the brake warning lamp lights to inform abnormality 3 Wheel speed sensor Right ront Wheel speed sensor Left rear 31 G sensor For 4WD model only 2 Stop lamp switch 7 Ground 12 Wheel speed sensor rotor ing Data link connector 8 Diagnosis connector Black connector 38 switch For 4WD model only 4 ABS warning lamp 8 Wheel speed sensor Lef ront 14 EBD warning lamp Brake warning lamp 5 Wheel speed sensor Rightrear 10 ABS hydraulic unilicontrol module assembly with ABS pump motor relay and fail safe relay NOTE Above figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the side of symmetry 52 4 ANTILOCK BRAKE
395. imes day month Only Once Road LUrban C Suburb CiHighway TMountainous uphill downhill Paved road L1Gravel DOther Vehicle Condition Transmission range CKPA N D 2 L range Transmission temp 7009 7 up phase OWarmed up Vehicle stop C During driving constant speed accelerating decelerating right hand corner left hand corner ClOther OSpeed km h mile h Engine OSpeed r min OThrottle opening idle about full Brake CiApply LINot apply OID off switch CON OFF P N change switch Malfunction indicator lamp SERVICE ENGINE SOON light condition ClAlways ON Sometimes ON OFF Good condition Diagnostic trouble First check __ code Malfunction code gode Second check code Malfunction code NOTE The above form is a standard sample It should be modified according to conditions characteristic of each market AUTOMATIC TRANSMISSION 4 A T 7B1 13 Malfunction Indicator Lamp MIL Check Refer to the same item in Section 6 1 for checking procedure O D OFF Lamp Check 1 Check that O D off switch button is at OFF position pushed 2 Tum ignition switch ON 3 Check that O D OFF lamp lights for about 2 4 sec and then goes OFF If anything faulty is found advance DIAGNOSTIC FLOW TABLE B 1 or B 2 O D OFF LAMP CIRCUIT CHECK POWE
396. imes _ refrigeration cycle recharge with fresh refriger Ti TL normal pressure Also high ant Abnormal Abnormal pressure side reading fluc Negative 0 7 1 0 tuates between the abnor pressure 7 10 mal and normal pressure 100 142 005 015 07 10 Both iow and high pressure insufficient refrigerant in sys Using a gas leak detector 0 5 1 5 7 10 sides indicate low readings tem Refrigerant leaking check for leaks and repair as 42 213 100 142 Continuous air bubbles are necessary visible through sight glass Recharge refrigerant to Output air is slightly cold specified amount If the pressure reading is almost 0 when the manifold gauges are attached check for any leaks repair ther and evacuate the system 04 05 Pressure on low pressure Internal leak in compressor Inspect compressor and 4 6 side is high repair or replace as neces 56 9 85 3 Pressure on high pressure sary side is low Both pressure becoming equal right after A C is turned OFF 0 35 0 45 2 0 2 5 High pressure reading on Overcharged A C system Adjust refrigerant to specified 35 45 20 25 both low and high pressure Faulty condenser cooling amount 50 64 285 355 sides operation Clean condenser Air bubbles are not visible Faulty condenser fan opera Inspect and repair condenser even when engine rpm is _ tion fan lowered High pressure reading on Presence of air in A C sys Replace condenser dry
397. in the particular vehicle or not depends on specifications Be sure to bear this in mind when performing service work Monitor connector CKP sensor MAP sensor EGR valve Heated oxygen sensor or CO adjusting resistor Three way catalytic converter Warm up three way catalytic converter CONTENTS General Description 6 2 2 Idle Speed Idle Air Control IAC Duty System Flow 6 2 3 Inspection 6E2 15 System Diagram 6 2 4 Using 8 scan tool 6E2 15 Air Intake System 6E2 6 Not using SUZUKI scan tool Fuel Delivery System 6E2 7 Electronic Control System 6 2 8 Engine and Emission Control Input Output Table 6E Diagnosis On Vehicle Service General Accelerator Cable Adjustment 6E2 14 A T Throttle Cable Adjustment AIT Vehicle vehicle with monitor connector 6E2 16 Idle mixture inspection adjustment vehicle without heated oxygen sensor 6E2 17 Air Intake System 6E2 18 Throttle body 6E2 18 Idle air control valve IAC valve 6E2 21 Fast idle air valve 6E2 22 Fuel Delivery System 6 2 23 Fuel pressure inspection 6 2 23 Fuel pump 6E2 24 Fuel pressure regulator 6E2 25 62 2 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE Fuel injector 6E2 26 Main relay 6E2 41 Electronic Control System 6E2 31 Fuel pump relay 6E2 42 Engine control module ECM Fuel cut operatio 6E2
398. ing 10 00 mm 0 394 in 42 35 mm 1 667 in Inter coast modulator valve spring 9 04 mm 0 356 in G16 and J20 engines 27 26 mm 1 073 in G16 and J20 engines 10 00 mm 0 394 in H25 and H27 engine 25 60 mm 1 008 in H25 and H27 engine Ball valve spring 10 5 mm 0 413 in 13 7 mm 0 539 in Bypass valve spring 13 82 mm 0 544 in 28 90 mm 1 138 in Primary regulator valve spring 17 02 mm 0 670 in 50 28 mm 1 980 in Install primary regulator valve sleeve so that its tip is posi tioned as it was before disassembly Use new TCC lock up control valve gasket solenoid gas ket and lower valve body plate gasket Tighten shift solenoid valve bolt to specified torque Tightening torque Shift solenoid valve bolt 10 N m 1 0 kg m 7 5 Ib ft Solenoid valve No 1 Shift solenoid valve 1 2 Low coast modulator valve spring 3 Inter coast modulator valve spring E E Intermediate coast modulator valve Low coast modulator valve AUTOMATIC TRANSMISSION 4 A T 7B1 59 Tighten TCC lock up solenoid valve bolt to specified torque Tightening torque TCC solenoid valve 5 5 N m 0 55 kg m 4 0 Ib ft 1 Solenoid valve No 2 solenoid valve 2 Oring Tighten pressure relief valve bolt to specified torque Tighten
399. ing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS General Description Generator Unit Repair Overhaul Generator Assembly Inspection 6H 6 6H 6 6H 6 6H 6 Tightening Torque Specification 6 2 CHARGING SYSTEM Generator General Description Generator output Battery terminal L Lamp terminal 5 Stator core 10 Rearendirame D Dummy terminal 1 Pulley 6 Field coll 11 Dive end frame E Ground 2 Pulley nut 7 Rectifier F Field coll terminal 3 Rotor fan Brush 1G ignition terminal 4 Stator col 8 Regulator WIRING CIRCUIT 5 5 1 Generator with regulator assembly 3 Stator coll 5 Field rotor coi 7 Main switch 2 1C regulator 4 Diode 6 Charge indicator light 8 Unit Repair Overhaul Generator Assembly CHARGING SYSTEM 6H 3 T Pally aut 8 Diver end bearing Wave washer 36 Regulator Teminal plato 2 Pulley 7 Bearing retainer 32 Roar end frame 37 Brush 3 Dive ond bearing Rolor 18 Soal plato 78 Brush holder 4 Stator 3 Endhousgbeaing 14 Rector 8 Brush holder cover 5 Sud bot 10 Bear
400. ing chain 5 Camshaft sprocket bolt 3 Timing chain tensioner adjuster No 3 bolt 2 Timing chain tensioner adjuster No3 8 Timingchain guide No 4 10 Timing chain tensioner adjuster No 3 nut 3 LH bank intake camshaft sprocket 7 Timing chain guide No 5 11 Timing chain guide No 4 bolt 4 LH bank exhaust camshaft sprocket 8 3 Idler sprocket No 2 V ero Tore 6A2 14 ENGINE MECHANICAL H27 ENGINE Camshaft and Valve Lash Adjuster pom eem oo T HEN m A SS S RH bank intake camshaft holder 10 LH bank camshaft haider Apply engine olto siding surface T ENGINE MECHANICAL H27 ENGINE 642 15 INSPECTION Cam wear Using a micrometer measure cam height If measured height is below its limit replace camshaft Intake cam height Standard 40 402 40 562 mm 1 5906 1 5969 in Limit 40 300 mm 1 3581 in Exhaust cam height Standard 39 428 39 588 mm 1 5523 1 586 in Limit 39 400 mm 1 5512 in Camshaft runout Set camshaft between two V blocks and measure its runout by using a dial gauge If measured runout exceeds below specified limit replace cam shaft Camshaft runout limit 0 04 mm 0 002 in Camshaft journal wear Check camshaft journals and camshaft housings for pitting scratches wear or damage If any malcondition is found replace camshaft
401. ing cover 78 Insulator 20 Rearend cover Inspection Rotor Using ohmmeter check for continuity between slip rings of rotor If there is no continuity replace rotor Standard resistance between slip rings of rotor 1 6 2 0 Q at 20 C 68 F 6H 4 CHARGING SYSTEM Using ohmmeter check that there is no continuity between slip ring and rotor If there is continuity replace rotor Check slip rings for roughness or scoring If rough or scored replace rotor Using a vernier caliper measure the slip ring diameter If the diameter is less than minimum replace the rotor Standard diameter of slip ring 14 2 14 4 mm 0 557 0 567 in Minimum diameter of slip ring 12 8 mm 0 504 in Stator Using ohmmeter check all leads for continuity If there is no continuity replace stator Using ohmmeter check that there is no continuity between coil leads and stator core If there is continuity replace sta tor CHARGING SYSTEM 6H 5 Brush and brush holder Check each brush for wear by measuring its length as shown If brush is found worn down to service limit replace brush Exposed brush length a Standard 10 5 mm 0 413 in Limit 1 5 mm 0 059 in Rectifier Positive Rectifier a Using an ohmmeter connect one tester probe to the B terminal 1 and the other to each rectifier terminal 2 b Reverse the polarity of the tes
402. ing torque Pressure relief valve bolt 5 5 N m 0 55 kg m 4 0 Ib ft Tighten lower valve body plate 1 TCC lock up control valve plate 2 flange bolt to specified torque Tightening torque Lower valve body and TCC control valve Plate bolts 5 5 N m 0 55 kg m 4 0 Ib ft Unit Assembly 1 Apply A T fluid to new O ring and spring and install them to accumulator piston and install accumulator piston to trans mission case 4 Upperspring 781 60 AUTOMATIC TRANSMISSION 4 A T Accumulator piston and spring specification Piston outer Used for E diameter a Spring free length b 31 80 31 85 mm Direct clutch accumulator 2 1 252 1 254 in Upper spring 43 56 mm 1 715 in Lower spring 30 00 mm 1 181 in 31 80 31 85 mm Forward clutch accumulator 1 555 1 254 Upper spring 57 18 mm 2 251 in Lower spring 30 50 mm 1 201 in 34 80 34 85 mm Second brake accumulator 3 4 370 1 372 Upper spring 56 16 mm 2 211 in 18 5 mm 0 728 in Lower spring Tightening Torque Specification Fastening part Tightening torque Nem kg m lb ft Automatic transmission fluid drain plug 23 23 17 0 Transfer oil level filler and drain plugs 23 23 17 0 Transmission case plug 7 17 125 Manual select lever nut 18 13 95 Manual select cable nut 7 0
403. inutes 2 Disconnect negative cable at battery 3 Recover refrigerant from refrigeration system using recovery and recycling equipment NOTE The amount of compressor oil at removed must be mea sured and the same amount must be poured when install ing the compressor 4 Remove P S pump referring to step 4 to 7 of REMOVAL under P S PUMP in Section 3B1 NOTE It is not necessary to drain P S fluid 5 Disconnect magnet clutch connector 6 Disconnect suction hose 1 and discharge hose 2 from compressor NOTE Cap open fitting immediately to keep moisture out of sys tem 7 Remove compressor 1 from its mount 2 NOTE If compressor assembly is replaced Drain oil from com pressor and measure its amount 18 40 AIR CONDITIONING OPTIONAL INSTALLATION CAUTION Be sure to use HFC 134a R 134a compressor oil Reverse removal procedure to install compressor assembly not ing the following instructions If compressor was replaced pour new compressor oil with the same amount as that drained from compressor Refer to REPLENISHING COMPRESSOR OIL in this sec tion 1 New compressor 2 Removed compressor 3 Excess ofl Install P S pump referring to P S PUMP in Section 3B1 Evacuate and charge system Refer to EVACUATING and CHARGING in this section Magnet Clutch AIR CONDITIONING OPTIONAL 18 41
404. ion 6B 15 Check to ensure that all fasteners and clamps are tightened 16 Upon completion of installation verify that there is no fuel leakage coolant leakage P S fluid leakage or exhaust gas leakage at each connection 6A2 30 ENGINE MECHANICAL H27 ENGINE Main Bearings Crankshaft and Cylinder Block 15 23ko Minmi om 27nme7 kgm T Oyfinder book Rear oi saa Ti Ong Sealant application amount 2 Lower crankcase 7 Flywheel W T Drive piate T2 Clutch housing plate 9 Tono Tone Apply sealant 29000 31150 to lower any dlankcase mating surface 3 Crankshaft Water pump 18 Cap bot d em 3 Main bearing 9 Og 74 Lowercranicase bot Apply engine oto siding EP Ss d eac pans E Thrust bearing 10 Timing chain oft 18 Krock sensor Width amm 0127 Set bearing facing grooved side to rank weds WI mm 0 08 in ENGINE MECHANICAL H27 ENGINE 6A2 31 Main bearing clearance Check clearance by using gaging plastic 1 according to the fol lowing procedure 1 Remove crankcase 2 Clean bearings and main journals 3 Place a piece of gaging plastic to full width of bearing paral lel to crankshaft on journal avoiding oil hole 4 Install crankcase to cylinder block Tighten crankcase bolts following sequence in the figure Tighten crankcase bolts to specified torque NOTE Tighten 10 mm thread diamet
405. ion switch to LOCK and remove key 2 Connect Yellow connector 1 of contact coil and combination switch assembly and be sure to lock connector with lock lever a Connect connector b Lock connector with lock lever AIR BAG SYSTEM 10B 51 3 Connect Yellow connector 1 of passenger air bag inflator module and be sure to lock connector with lock lever a Connect connector b Lock connector with lock lever 4 Install glove box 5 Install AIR BAG fuse to AIR BAG fuse box 6 Tum ignition switch to ON 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 SDM 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 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 has been dropped 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 c
406. ioner cycle Therefore when using a new compressor for replacement drain oil from it by the amount calcu lated as follows A C Amount of oil to be drained A Amount of oil sealed in a new compressor B Amount of oil remaining in removed compressor NOTE Compressor assembly supplied from factory is filled up with the following amount of oil Amount of oil in new compressor Dual A C model 140 cm 140 cc Single A C model 100 100 WHEN REPLACING OTHER PART Amount of compressor oil Replaced part Amount of compressor oil to be replenished Evaporator 25 cm 25 cc Rear evaporator 25 cm 25 cc for dual A C model Condenser 15 cm 15 cc Receiver dryer 20 cm 20 cc Hoses 10 cm 10 cc each Pipes 10 cm 10 cc each 3 New compressor 2 Removed compressor 3 Excess oil A B 18 28 AIR CONDITIONING OPTIONAL Rear A C Unit Rear A C Evaporator Rear blower fan cover Rear AIC unit mounting Sclencid valve mounting bracket DELI Rear unit mounting bush 7 Rear blower molor assembly valve Apply compressor REMOVAL 1 Disconnect negative cable at battery refrigerant oil to O ring 3 Rear blower fan resistor 8 Rear AC evaporator temperature controller 38 Rear liquid pipe 4 Rear AIC unit cover 3 Rear exp
407. ir bag system components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1061 AIR BAG Warning Lamp Circuit Failure WIRING DIAGRAM BLUBLK BLUIRED gt M Itl pas 2 4 7 PPURED PPURED Err a9 wr 02 m 1 10 gt e SUS 01 17 oN i 1 7E ie 2 T From main fuse 5 AIRBAG fuse 8 To EGM TCM if equipped and ABS control module if equipped 2 Ignition switch amp Connection detection 10 AIR BAG monitor coupler 3 IG METER fuse 7 SDM Ti Ground for air bag system 4 AIR BAG waring lamp in combination meter 8 ToDLC AY Airbag hamess CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 W
408. is switch in good condition Fig for Step 1 Throttle Valve Opening Signal Circuit Check CRUISE CONTROL SYSTEM 8E 15 1 Disconnect connector from PCM with ignition switch OFF 2 Check for proper connection to PCM at terminal E61 4 3 If OK connect BLU wire terminal of main relay to ground with service wire 4 Tum ignition switch ON 5 Check voltage between E61 4 of PCM connector and ground Is it 10 14 V Step Action Yes No 1 Powertrain Control Module PCM Diagnostic Trouble Code Checkandrepair Go to Step 2 Check TP sensor refer 1 Check PCM for DTC ring to Section 6 1 15 there related to throttle position sensor 2 _ Throttle Valve Opening Signal Circuit Check Throttle valve Go to Step 3 1 Tum ignition switch ON opening signal cir 2 Check voltage between terminal E61 4 of PCM connector cuit is OK connected and ground Does voltage vary linearly according to throttle opening 3 Supply Voltage Check Check TP sensor Check GRY and circuits refer ring to Section 6 1 If OK substitute a known good PCM and recheck wire for open and short If OK proceed to cruise control module power and ground cir cuits check Fig for Step 2 Signal Voltage Characteristic Si Signal N Voltage N POM Close Atidie Full open Throttle
409. ission range switch cir neously or P R N D 2orLrangesig 2 driving Not No 72 cuit malfunction nal not inputted while running at cycles applicable 60km h or more P0715 Input speed sensor circuit speed sensor signal is lower 2 driving Not No 76 malfunction than specification while running cycles applicable P0720 Output speed sensor circuit Output speed sensor signal not input 2 driving Not No 75 malfunction ted while VSS signal being inputted cycles applicable 7 Actual operation does not agree po741 TOC lock up solenoid perfor viue ON OFF control from PCM to 2dning Net mance or stuck off aN cycles applicable P0743 Monitor signal OFF is detected when m No 65 Mu lock up solenoid electri control solenoid is ONormonitor gomg n is No 66 signal ON is detected when itis OFF lt Shift solenoid 1 perfor 998 change control from PCM 3 driving Not P0751 does not agree with actual gear posi mance or stuck off cycles applicable tion of A T 6 1 22 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE vehicle vehicle DTC NO DETECTED ITEM DETECTING CONDITION without with will set when detecting monitor monitor connector connector P0753 Monitor signal OFF is detected when n No 61 Shift solenoid A 1 electrical shift
410. ists ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 39 costa HEATER INSPECTION Refer to HEATED OXYGEN SENSOR SENSOR 1 HEATER INSPECTION Vehicle speed sensor VSS ON VEHICLE INSPECTION 1 Hoist vehicle 2 Release parking brake lever set transmission in neutral and transfer in 2H 3 Remove ECM PCM cover 4 Connector voltmeter between VSS terminal C51 3 1 of ECM PCM connector and body ground 5 Tum ignition switch ON and tum rear right tire slowly with rear left tire locked Voltmeter should indicate deflection between 0 1 V and 8 14 V a few times while tire 1 is turned one revolution If check result is not satisfactory proceed to flow table of DTC P0500 in Section 6 1 TAF Terminal arrangement of ECM coupler viewed trom harness side REMOVAL INSPECTION AND INSTALLATION Refer to VSS Removal Inspection or Installation in Section 7D 1 V8S Manifold absolute pressure sensor REMOVAL 1 Disconnect negative cable at battery 2 Disconnect connector from manifold absolute pressure sen sor 3 Remove manifold absolute pressure sensor from intake manifold 6 2 40 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE INSPECTION 1 Check sensor O ring 1
411. ition coil covers 12 13 14 15 ENGINE MECHANICAL H27 ENGINE 6A2 27 Disconnect the following electric lead wires Injector wire coupler CMP sensor coupler Ignition coil couplers CKP sensor coupler MAP sensor coupler TP sensor 1 coupler IAC valve 2 coupler Earth wire 3 from surge tank EVAP canister purge valve coupler EGR valve coupler Oxygen sensor 1 and 2 couplers referring to Exhaust Man ifold in this section Coolant temperature sensor coupler Knock sensor coupler Generator wires Starter wires Oil pressure wire P S pump wire Earth wire from generator bracket Engine block heater if equipped Remove clamps and brackets Disconnect the following hoses Heater hose from heater water pipe Heater hose from water outlet cap EVAP canister hose from canister pipe Brake booster vacuum hose Remove EVAP canister purge valve 5 4 Clamp bracket EGR valve 16 17 18 19 20 21 22 23 7 Heater hose Disconnect the following hoses at the location shown in the figure Fuel feed hose 1 from fuel feed pipe Fuel return hose from 2 fuel retum pipe Remove P S pump assembly Refer to POWER STEERING PUMP in Section 3B1 Remove A C compressor assembly Refer to COMPRES SOR ASSEMBLY in Section 1B Remove steering shaft lower assembly Refer to STEERING LOWER SHAFT ASSEMBLY in Section 3C1 Fais
412. ition switch OFF 2 Check for proper connection to cruise control module at terminal E132 8 3 If OK check resistance between terminal E132 8 and E132 5 under each condition below Switch circuit specification resistance All switches OFF Infinity switch rotated ON 200 240 Q RESUME ACCEL switch rotated ON 820 1000 Q CANCEL switch pressed ON About 0 4 Tum ignition switch ON and check voltage between termi nal E132 8 and ground under each condition below Switch circuit specification voltage Cruise main switch released OFF 0 V Cruise main switch pressed ON 10 14 V Are check results in above steps 3 and 4 satisfactory 2 Cruise Main Switch Check Go to step 3 Replace 1 Check cruise main switch for operation referring to Cruise Main Switch Inspection in this section Is switch in good condition 3 RESUME ACCEL and CANCEL Switches Check BLK YEL or LT Replace 1 Check COAST SET RESUME ACCEL and CANCEL GRN circuit is switches for operation referring to COAST SET open or short RESUME ACCEL and CANCEL SWITCHES in this sec tion Are all switches in good condition Fig for Step 1 Cruise main switch RESUME ACCEL switch COAST switch CANCEL switch VSS Circuit Check CRUISE CONTROL SYSTEM 8E 11 ignition switc
413. itute a Repair short from VEL body ground known good circuit to ground Is circuit open SDM and recheck A Fig for STEP 1 2 and 3 B Fig for STEP 2 C Fig for STEP STEERING WHEEL Special tool A B 09932 75020 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected AIR BAG SYSTEM 108 27 DTC B1019 Step Action Yes No 1 1 With ignition switch OFF disconnect passenger Goto step 2 Ignition switch OFF air bag inflator module connector behind the Replace passenger air glove box bag inflator module 2 Check proper connection to passenger air bag Refer to PASSENGER inflator module at terminals in 007 connector AIR BAG INFLATOR 3 If OK then connect Special Tool B to passenger MODULE in this section air bag inflator module connector disconnected at the step 1 With ignition switch ON is DTC B1019 current 2 1 With ignition switch OFF disconnect Special Tool Go to step 3 Repair short from YEL B and SDM connector RED wire circuit to power 2 Measure voltage from 001 7 terminal to body circuit ground With ignition switch ON is voltage 1 V or less 3 1
414. ity detected cycles cycles cuit open HO2S circuit slow response 50159 time HO2S 1 output volt 5 driving Not Poles age between rich and lean is longer vn PUE than specification y Terminal voltage i lower than specifi x P0155 cation at heater OFF or it is higher at 2 oe eae heater ON id e HO2S circuit malfunction voltage of HOS 2 is lowerthan une Not 20166 Bank 2 Sensor 2 specification or its min voltage is ae jails higher than specification oy Terminal voltage is lower than specifi P0161 Meo ead cation at heater OFF or it is higher at S heater ON or heater circuit or short Y Short term fuel trim or total fuel trim short and long terms added is larger MS P0171 Fuel system too lean Bank 1 than specification for specified time or ae lalis longer Fuel trim toward rich side is ev large Short term fuel trim or total fuel trim short and long terms added is m P0172 Fuel system too rich Bank 1 smaller than specification for specified 9 cycles applicable time or longer Fuel trim toward lean side is large 6 1 20 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE MIL ML vehicle vehicle DETECTING CONDITION DTC NO DETECTED ITEM without with DTC will set when detecting monitor monitor connector connector Sh
415. k also for air leakage Air pressure specification for 4WD control system inspection 30 0 45 0 kPa 0 30 0 45 kg cm 4 25 6 40 psi 4 Check that pressure value indicated on gauge of special tool drops as soon as transfer lever is shifted to 2H position 5 Start motor by shifting transfer lever to 4H position again Loosen adjusting screw 2 to lower pressure value on gauge Motor should start to run again and stop in about 4 seconds With the adjusting screw 2 of special tool loosened shift transfer shift lever to N or 2H position and then 4L or 4H position Pump motor should stop about 10 seconds after motor starts to run 6 3 pipe air pump assembly 4 Hose to differential carrier 5 Diferential housing DIFFERENTIAL FRONT 7E 7 On Vehicle Service Differential Mountings REMOVAL AND INSTALLATION 1 Lift up vehicle and turn steering wheel all way to the right 2 Separate front mounting bracket R 2 from differential hous ing 3 by removing bolts 1 from its lower part 3 Remove front mounting bracket R 2 by removing mounting front bolt 4 from its upper part 4 Remove front mounting bracket L 3 from differential hous ing 1 by removing upper and lower fastening bolts 2 4 5 Check conditions of each bush If it is damaged or deterio rated drive it out with special tools and press for replace ment Special tool A 09951
416. k flange nut 2 with caulking tool 1 and hammer Tightening Torque Specification Fastening part EU Differential oil level filler plug 50 5 0 36 5 Differential oil drain plug 28 28 20 5 Propeller shaft flange nuts 60 6 0 43 5 Differential carrier bolts 55 5 5 40 0 Bevel gear bolts 105 10 5 76 0 Bearing cap bolts 85 8 5 61 5 Lock plate bolts 12 1 2 9 0 Differential case screws 9 0 9 65 Required Service Material Recommended SUZUKI product Material Part Number Use Thread lock cement THREAD LOCK CEMENT Bevel gear bolts SUPER 1322 Differential case bolts 99000 32110 Bevel gear mating surface Propeller shaft flange bolt Lithium grease SUZUKI SUPER GREASE A Oil seal lips 99000 25010 Sealant SUZUKI BOND NO 1215 Rear differential drain plug 99000 31110 Mating surface of differential housing Mating surface of rear axle housing 7F 22 DIFFERENTIAL REAR Special Tool 09900 20606 09900 20701 09913 61510 09913 65135 Dial gauge Magnetic stand Bearing puller Bearing puller 09922 76570 09913 75510 09913 85230 09922 66021 Attachment Bearing installer Bearing removing jig Flange holder 09922 75222 Preload checking tool 09922 76560 Preload checking tool 09924 74510 Installer attachment 09925 18011 Bearing installer A 09926 68310 Bearing installer 09926 7831 1 002 Pinio
417. k oil filter and drain plug for oil leakage 8 Start engine and run it for 3 minutes Stop it and wait 5 min utes before checking oil level Add oil as necessary to bring oil level to FULL level mark on dipstick 1 Fulllevel mark hole 2 Low level mark hole HEATER AND VENTILATION 1A 1 SECTION 1A HEATER AND VENTILATION WARNING For vehicles equipped with Supplement Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in Section 10B before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activa tion of the system or could render the system inoperative Either or 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 NOTE For the descriptions items not
418. kening of the metal EA CONTENTS 1 Tires Wheels General Description General Description Tires This vehicle is equipped with following tire Tire specification P235 60 R16 or 235 60 R16 The tires are of tubeless type The tires are designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressure Correct tire pressures and driving habits have an important influence on tire life Heavy cornering excessively rapid acceleration and unnecessary sharp braking increase tire wear Wheels Standard equipment wheels are following steel wheels Wheel specification 16x7JJ 3F 2 WHEELS AND TIRES FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL 4A2 1 SECTION 4A2 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS On Vehicle Servic 402 2 Required Service Material Drive Shaft 4A2 2 4A2 2 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL On Vehicle Service al Drive Shaft ASSEMBLY CAUTION To prevent any problem caused by washing solution do not wash joint boots Degreasing of those parts with cloth is allowed Bend each boot band against forward rotation Do not squeeze or distort boot when fastening it with bands Distorted boot caused by squeezin
419. l 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 follow the proce dures listed in the following pages to temporarily disable the air bag system Failure to follow procedures could result in possible air bag system activation personal injury or unneeded air bag system repairs 108 50 AIR BAG SYSTEM Disabling air bag system 1 Tum steering wheel so that vehicle s wheels front tires and pointing straight ahead 2 Tum ignition switch to LOCK position and remove key 3 Remove AIR BAG fuse from AIR BAG fuse box 1 4 Disconnect Yellow connector 2 of contact coil and combina tion switch assembly a Release locking of lock lever b After unlocked disconnect to connector 5 Pull out glove box while pushing its stopper from both right and left sides and disconnect Yellow connector 1 of pas senger air bag inflator module a Release locking of lock lever b After unlocked disconnect to 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 an air bag system malfunction 2 Steering support member Enabling air bag system 1 Tum ignit
420. l diameter As shown in the figure crank web has stamped numbers and alphabet at the center kinds of numbers 1 2 and 3 represent the following journal diameters Journal diameter Stamped numbers Journal diameter 65 000 65 006 mm 2 5590 2 5593 in 64 994 65 000 mm 1 2 5588 2 5590 in 3 64 988 64 994 mm 2 5586 2 5588 in Crankshaft 2 Crank web 2 Next check crankcase bearing cap bore diameter without bearing On lower surface of lower crankcase 4 alphabets are stamped as shown in the figure kinds of alphabets B and C represent the following cap bore diameters Main bearing cap bore diameter Bearing cap bore diameter without bearing 70 000 70 006 mm Stamped numbers 2 7559 2 7561 in B 70 006 70 012 mm 2 7561 2 7563 in c 70 012 70 018 mm 2 7563 2 7566 in Crankshaft pulley side ENGINE MECHANICAL H27 ENGINE 6A2 33 3 There are 5 kinds of standard bearings differing in thickness To distinguish them they are painted in following colors at the position as shown in the figure Each color indicates the following thickness at the center of bearing Standard size Main bearing thickness Color painted Bearing thickness Black 2 496 2 500 mm 0 0983 0 0984 in Colorless no paint 2 499 2 5
421. l tool 16 30 1 6 3 0 kg 3 5 6 6 Ib Special tool C 09922 76560 J 09922 66021 2 Sockel wrench 7F 18 DIFFERENTIAL REAR Assembling Unit 1 Place bearing outer races on their respective bearings Used left and right outer races are not interchangeable 2 Install case assembly in carrier 3 Install side bearing adjusters on their respective carrier making sure adjuster are threaded properly 4 Align match marks 1 on cap and carrier Screw in 2 side bearing cap bolts 2 or 3 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 cap bolts provisional torque Tightening torque Bearing cap bolt Provisional torque a 15 Nem 1 5 kg m 11 0 Ib ft 6 Tighten both bearing adjusters 2 so as to obtain specified gear backlash and at the same time obtain preload of side bearing NOTE Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth As a practical measure the following would be recom mended to obtain specified backlash and side bearing preload at the same time Obtain specified backlash by turning both adjusters inward lightly Tighten both adjusters further by one notch at a time Measure at least 4 points on drive bevel gear periph ery Standard backlash 0 13 0 18 mm 0 005 0
422. lamp may flash when ignition switch is turned ON position Accordingly preform ABS HYDRAULIC UNIT OPERA TION CHECK to stop flashing of ABS warning lamp ap 18 ANTILOCK BRAKE SYSTEM ABS 5E2 33 Rear Sensor Rotor Retainer Ring REMOVAL 1 Remove rear axle shaft assembly Refer to REAR AXLE SHAFT in Section 3E 2 In order to remove sensor rotor retainer ring 2 from shaft 1 grind with a grinder one part A of the sensor rotor retainer ring as shown till it becomes thin CAUTION Cover vinyl sheet 3 or the like over wheel bearing so that fine grains from grinding will not enter there Becareful not to go so far as to grind the retainer ring 3 Break with a chisel 1 the thin ground sensor rotor retainer ring 2 and it can be removed INSTALLATION 1 Press fit sensor rotor retainer ring 1 as shown in the fig ure 2 Install rear axle shaft assembly Refer to REAR AXLE SHAFT in Section 3E 52 34 ANTILOCK BRAKE SYSTEM ABS Tightening Torque Specification Tightening torque Fastening part Brake pipe flare nut 16 16 115 ABS hydraulic unit bolt b 9 09 65 ABS hydraulic unit bracket bolt 10 10 75 Wheel speed sensor bolt Front d 23 23 17 0 Wheel speed sensor bolt Rear e 21 21 155 Parking lever assembly mounting bolt f 23 23 17 0
423. le Scuff installation hole rear end Front seat bett installation hole Hole in rear door upper hinge in upper part Hole to hole distance a d 1155 45 47 in 1140 mm 44 88 in g j 1082 mm 42 60 in a f 1046 mm 41 18 in 1245 mm 49 02 in h j 879mm 3461 in a g 1090 mm 42 91 in 1174 mm 4622 in h k 1282 mm 5047 in b f 1120 mm 44 09 in 1029 mm 40 51 in i k 1485 mm 66 50 in BODY SERVICE 9 7 a Clip hole in the center of head lining rear installation section Installation hole in uppermost par of lower hinge 5 Innermost end of roof panel installation section T f Innermost end of rear floor tail member installation section Installation hole in upper part of back door striker 9 6 Installation hole in outer upper section of rear combination right lamp 9 Installation hole in uppermost part of upper hinge Nut hole Hole to hole distance Zb 448 mm 17 64 in e 837mm 32 95 in 1293 mm 50 90 in f 1054 mm 41 50 in 892 mm 35 12 in 1030 mm 40 55 in 512 mm 20 16 in 1544 mm 60 79 in 888 mm 34 96 in 996 mm 3921 in 806 mm 31 73 in a b a b a g 1050 41 34 in b c 650mm 25 59 in a h 921 mm 36 25 in b f 1314 61 73 in b b b b d 400 mm 15 75 in d 1245 mm 49 02 in 9
424. le Maintenance Schedule under Normal Driving Conditions NOTE This interval should be judged by odometer reading or months whichever comes first This table includes service as scheduled up to 90 000 km 54 000 miles mileage Beyond 90 000 km 54 000 miles carry out the same services at the same intervals respectively Km x 1 000 15 30 45 75 90 Interval Miles x 1 000 9 18 27 36 45 54 Months 12 24 36 48 60 72 ENGINE 1 1 Drive belt Verib belt Flat type 1 4 Engine oil and oil filter 1 5 Engine coolant R T TR 1 6 Exhaust system IGNITION SYSTEM 2 1 Spark plugs When Vehicle without Nickel plug RI TRTI TR unleaded HO2S Iridium plug R fuel is used Vehicle with Nickel plug R HO2S Iridium plug Replace every 105 000 km or 63 000 miles When leaded fuel is used refer to MAINTENANCE RECOMMENDED UNDER SERVER DRIVING CONDITIONS in this section FUEL SYSTEM 3 1 Air cleaner filter TR 3 2 Fuel lines and connections 3 3 Fuel filter Replace every 105 000 km or 63 000 miles 3 4 Fueltank EMISSION CONTROL SYSTEM 4 1 Crankcase ventilation hoses and connections Vehicle without es esl 25 42 PCV valve Vehicle without HO28 Vehicle with 25
425. le namely in a sensor switch wire harness connector actuator PCM or other part and repair or replace faulty parts 781 12 AUTOMATIC TRANSMISSION 4 A T STEP 10 CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur e g wire harness connector etc referring to INTERMITTENT AND POOR CONNECTION in Section 0A and related circuit of DTC recorded in Step 2 STEP 11 FINAL CONFIRMATION TEST Confirm that the problem symptom has gone and the A T is free from any abnormal conditions If what has been repaired is related to the malfunction DTC clear the DTC once set conditions under which DTC was detected and A T and or vehicle was repaired and confirm that no DTC is indicated CUSTOMER PROBLEM INSPECTION FORM EXAMPLE User name Model VIN Date of issue Date of Reg Date of problem Mileage PROBLEM SYMPTOMS CEngine does not start C Engine stops C Vehicle does not move CiTransmission does not shift forward rearward 1st 2nd 3rd 4th Rev gear No lock up TCC clutch operation Automatic shift does not occur CIShitt point too high or too low CiTransmission slipping in 1st 2nd 3rd 4th Rev gear JExcessive gear change shock Other VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather OFair 1Cloudy Rain Snow Always _1Other Temperature JHot LWarm LICool ICold L C 1 Frequency JAlways Sometimes _ t
426. le air control system mal actual idle speed continues to 2 driving Not P0505 a function exceed specified valueforlongerthan cycles applicable specified time 060 Internal control module mem Data write error or check sum idrving 1 driving No 71 ory check sum error when written into ECM cycle cycle Manifold absolute pressure sensor pi4og Manifold absolute pressure output voltage is higher or lower than 2 driving Not sensor circuit malfunction specified value or sensor circuit cycles applicable shorted to ground or open piago Barometric pressure sensor Barometric pressure is lower or higher 1 driving Not circuit malfunction than specification cycle _ applicable lt Difference between intake manifold Barometric pressure sensor 1 2driving Not Fidi DS S robo pressure and barometric pressure is ase eau P P larger than specification v Engine starter signal circuit Engine starts with no starter signal or 5 qiie Not P1500 signal input during long period after malfunction pun cycles applicable pigro back up power supply back up power after starting 1 driving Not malfunction engine cycle _ applicable For A T system Refer to Section 7B1 for diagnosis MIL MIL vehicle vehicle DTC NO DETECTED ITEM DETECTING CONDITION without with DTC will set when detecting monitor monitor connector connector Multiple signals inputted simulta PO705 Transm
427. ler 1 from vehicle referring to A C CONTROLLER in this section 2 Remove ECM 2 from vehicle 3 Connect A C controller couplers to A C controller and con nect ECM couplers to ECM 4 Check each terminal voltage with couplers connected by referring to A C CONTROLLER VOLTAGE VALUES TABLE 3 Teminal ACAD 4 Teminal 51 5 6 NOTE For Fig A Fig B Fig C in the figure refer to A C CONTROLLER VOLTAGE VALUES TABLE 18 16 AIR CONDITIONING OPTIONAL SYSTEM CIRCUIT x A To FRONTBLOW fuse 1 Front blower motor relay 8 Dual refrigerant pressure switch Ti Condenser coaling fan motor To REAR DEFG fuse 2 Front blower motor 7 A Cthemistor evaporator temperature sensor i2 AIC controller C To IGMETER use 3 Frontblowermolorresistr 8 Compressor relay 18 ECM D To AIC fuse 4 Front blower motor switch 9 Compressor 5 AC switch 30 Condenser cooling fan molor relay Terminal arrangement of A C controller AGB ACA n p 2
428. lic unit control module con nector disconnected turn ignition switch ON and light ABS warning lamp 2 Connect terminal E136 14 of discon nected connector to ground using service wire Does ABS warning lamp tum off Goto Step 5 BLU ORN circuit open If wire and connection are OK replace combination meter lamp driver mod ule 1 Measure resistance from connector terminal E136 24 to body ground Is continuity indicated Substitute a known good ABS hydraulic unit con trol module assembly and recheck BLK circuit open ANTILOCK BRAKE SYSTEM ABS 5 2 17 Table C ABS Warning Lamp Circ While Ignition Switch Is ON Check The Lamp Flashes Continuously BLKWHT SEZDI BLKWHT EET 2 JG 136 14 136 18 ABS waming lamp in combination meter 3 Diagnosis monitor coupler 3 2 Diagnosis ground terminal 2 ABS hydraulic uniicontrol module assembly 3 1 Diagnosis switch terminal 4 ABS hydraulic uniicontrol module connector CIRCUIT DESCRIPTION When diagnosis switch terminal is shorted or connected to the ground with ignition switch ON diagnosis trouble code DTC is indicated by flashing of ABS waring lamp only in the following cases Normal DTC 12 is indicated if no malfunction DTC is detected in the ABS A history malfunction DTC is
429. ll steering upper shaft upper joint bolt 2 and nut 1 Tighten steering upper shaft upper joint nut 1 to specified torque Tightening torque Steering upper shaft upper joint nut a 23 N m 2 3 kg m 17 0 Ib ft 6 If contact coil and combination switch assembly is removed install it referring to CONTACT COIL AND COMBINATION SWITCH ASSEMBLY in this section 7 Connect all connectors that have been removed in removal 8 Install steering column hole cover 1 9 If steering wheel is removed install it by referring to STEERING WHEEL in this section 10 Connect negative cable to battery 11 After installing steering column assembly be sure to enable air bag system by referring to ENABLING AIR BAG SYS TEM under SERVICE PRECAUTIONS in Section 10B AIR BAG STEERING WHEEL AND COLUMN 3C1 7 Steering Upper Shaft Assembly CAUTION Never turn steering wheel while steering upper shaft assembly is removed Should it have been turned and contact coil on combina tion switch have got out of its centered position it needs to be centered again Also turning steering wheel more than about two and a half turns will break contact coil REMOVAL 1 Tum steering wheel so that vehicle s front tires are at straight ahead position 2 Tum ignition switch to LOCK position and remove key 3 Make alignment marks 3 on shaft joint 2 and shaft upper shaft assembly side
430. ller if necessary Rear evaporator clogged or frosted Check rear A C evaporator and then replace if necessary Rear expansion valve faulty Check rear expansion valve and then replace if necessary Air leaking from rear A C unit or air duct Check and repair if necessary Insufficient or excessive charge of refrigerant Check charge of refrigerant and then perform recovery evacuation and charg ing if necessary Refrigerant pipe or hose deformed Check pipe hose and then replace if necessary Cool air dose not come out Rear blower motor dose not operative Fuse blown Check and REAR BLOW fuses and then check for short circuit to ground Rear blower motor relay faulty Check rear blower motor relay and then replace if necessary Rear A C main switch faulty Check rear A C main switch and then replace if necessary Rear blower motor switch faulty Check rear blower motor switch and then replace if necessary Rear blower motor resister faulty Check rear blower motor resister and then replace if necessary Wiring or grounding faulty Check and repair Rear blower motor faulty Check rear blower motor and then replace if necessary Cool air dose not come out at only intermittently Loose or poor connected wiring connector Connect connector correctly Rear expansion valve faulty Check rear expansion valve and then replace i
431. lley f equipped Tension pulley Tension pulley 2 E 4 5 3 Connect negative cable to battery POWER STEERING PUMP AND OR A C COMPRESSOR DRIVE BELTS IF EQUIPPED REPLACEMENT Replace belt referring to Section 1B or 3B1 for replacement pro cedure of belt ITEM 1 4 Engine oil and filter replacement WARNING New and used engine oil can be hazardous Be sure to read WARNING in General Precaution in Section 0A and observe what in written there Step 1 7 outlined below must be performed with ENGINE NOT RUNNING For step 8 be sure to have adequate ventilation while engine is running Before draining engine oil check engine for oil leakage If any evi dence of leakage is found make sure to correct defective part before proceeding to the following work MAINTENANCE AND LUBRICATION 0B 7 1 Drain engine oil by removing drain plug 2 After draining oil wipe drain plug clean Reinstall drain plug and tighten it securely as specified below Tightening torque Engine oil drain plug a 50 N m 5 0 kg m 36 5 Ib ft 3 Loosen oil filter by using oil filter wrench special tool Special tool A 09915 47310 NOTE Before fitting new oil filter be sure to oil its O ring Use engine oil for this purpose 4 Screw new filter on oil filter stand by hand until the filter O ring contacts the mounting surface CAUTION To tighten oil
432. lowing specification to torque universal joint flange nuts For rear propeller shaft flange bolt apply thread lock cement to thread part of bolts if reused A Cement 99000 32110 Part Number Tightening torque Fastening part mE mE Front propeller shaft flange nuts 50 5 0 36 5 Rear propeller shaft flange nuts 60 6 0 46 5 Center support bolts 50 5 0 36 5 Required Service Material Material Recommended SUZUKI product Use Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 Rear propeller shaft flange bolts BRAKES 5 1 SECTION 5 BRAKES WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 Technical service work m
433. lp of another person 10 Brake pedal 1 should be depressed a Ignition switch turned to ON position by one person b Wheel should be turned by another person s hand At this time check that Operation sound of solenoid is heard and wheel turns only about 0 5 sec brake force is depressurized Operation sound of pump motor is heard and pulsation is felt E at brake pedal 95 11 If all 4 wheels cannot be checked during one ignition cycle OFF ON repeat Steps 8 and 9 till all 4 wheels are checked If a faulty condition is found in Steps 9 and 10 replace hydraulic unit control module assembly Turn ignition switch to OFF position and remove service wire from diagnosis connector Motor Solenoid RE Rear ANTILOCK BRAKE SYSTEM ABS 5E2 31 ABS Hydraulic Unit Control Module Assembly CAUTION Never disassemble ABS hydraulic unit control module assembly loosen blind plug or remove motor Performing any of these prohibited services will affect original performance of ABS hydraulic unit control module assembly E i6 Nm 1 6 E 10 Nm 1 0 kom Es m 0 9 om T Brake pipe 3 Bracket 2 hydraulic unitcontroi module assembly 4 Connector HYDRAULIC UNIT INSPECTION Check hydraulic unit for fluid leakage If any repair or replace REMOVAL 1 Disconnect negative cable at battery 2 Disconne
434. ltitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and start engine 3 Increase vehicle speed to 55 km h 35 mph or more 4 Keep driving above vehicle speed for 2 min or more Change of vehicle speed is permitted in this step 5 Stop vehicle and run engine at idle speed for 1 min 6 Check if pending DTC exists by using scan tool If not check if oxygen sensor monitoring test has completed by using scan tool If not in both of above checks i e no pending DTC and oxygen sensor monitoring test not completed check vehicle condition environmental and repeat step 3 through 6 TROUBLESHOOTING Step Action Yes No 1 ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE in this sec tion 2 HO2S 1 output voltage check Go to Step 4 Go to Step 3 1 Connect scan tool to DLC with ignition switch OFF 2 Warm up engine to normal operating temperature and Keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously to enrich A F mixture and take foot off from pedal to enlean and check HO2S output voltage displayed on scan tool See Fig Is over 0 6 V and below 0 3 V indicated 3 25 1 check RED BLU or Replace HO28 1 1 With ignition switch
435. lue 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 B1019 only 108 24 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1015 Step Action Yes No 1 1 With ignition switch OFF disconnect passenger air step 2 Ignition switch OFF bag inflator module connector behind the glove box Replace passenger air 2 Check proper connection to passenger air bag infla bag inflator module tor module at terminals in Q07 connector Refer to PASSENGER 3 If OK then connect Special Tool B to passenger air AIR BAG INFLATOR bag inflator module connector disconnected at the MODULE in this sec step 1 tion With ignition switch ON is DTC B1015 current 2 1 With ignition switch OFF disconnect SDM connector Substitute a Repair high resistance 2 Check proper connection to SDM at terminals 001 7 known good SDM or open in YEL RED Q01 8 and recheck YEL wire circuit 3 If OK then measure resistance between 001 7 and Q01 8 terminals with connec
436. m 36 5 Ib ft Rear mounting bolt b 85 N m 8 5 kg m 61 5 Ib ft Rear mounting bracket No 2 bolts b 85 N m 8 5 kg m 61 5 Ib ft After tightening all fasteners properly fill hypoid gear as speci fied and check tightening of plugs with specification Unit Repair DIFFERENTIAL FRONT 7E 11 Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual Tightening Torque Specification Fastening part Tightening torque Nem kg m Ib ft Front mounting bolts 85 85 615 Front mounting bracket bolts 50 50 365 Front drive shaft flange bolts 50 50 36 5 Propeller shaft flange bolts 50 50 365 Rear mounting bolt 85 85 615 Rear mounting bracket bolts 50 50 36 5 Rear mounting bracket No 2 bolts 85 85 615 Special Tool 09918 18110 Air pressure regulator 09951 16080 Bearing installer 09951 26010 Bush remover plate 7E 12 DIFFERENTIAL FRONT DIFFERENTIAL REAR 7F 1 SECTION 7F DIFFERENTIAL REAR CONTENTS General Description Diagnosis Diagnosis Table On Vehicle Service Precaution for Maintenance Service Differential Gear Oil Change Rear Differential Assembly Dismounting 7 5 Remounting 7F 5 Unit Repair 7F 6 Disassembling Unit Component Inspection Sub Assembly Adjustment and Reassembly 7F 9 Differential carrier 7F 10 Differential case 7 10 Differential s
437. m may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of the Service Man ual mentioned in the FOREWORD of this manual Some parts in the Power Steering Gear Box cannot be disassembled or adjusted For detailed infor mation refer to the description of POWER STEERING GEAR BOX ASSEMBLY All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as speci fied during reassembly to assure proper retention of these parts CONTENTS General Descriptio 3B1 2 Belt tension check Power Steering P S Pump 9B1 2 Belt tension adjustment 3B1 2 Diagnosis 1 2 Hydraulic Pressure P S Circui Power Steering Pump Drive Belt Hydraulic pressure check Belt inspection 3B1 2 3B1 2 381 2 POWER STEERING P S SYSTEM General Description Power Steering P S Pump Power steering P S pump specification The specification of this power steering pump is the same as the specification of the same section in the service manual mentioned in this manual except for data of r
438. m HO2S 1 and HO2S 2 respectively and accordingly ECM PCM controls the closed loop which then controls the fuel injection volume Refer to Section 6E2 While the above control is going on and if WU TWC is in good condi tion the output voltage of HO2S 2 is maintained at specified level As WU TWC becomes deteriorated even when the above control is going on the exhaust gas which has passed TWC then passes HO2S 2 at the exhaust oxygen concentration similar to that of the pre catalyst without being oxygenated or converted Thus waveforms of HO2S 1 and HO2S 2 output voltages become alike ECM PCM judges deterioration of WU TWC by comparing waveforms of HO2S 1 and HO2S 2 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA becomes similar to that of HO2S 2 2 driving cycle detection logic While running under conditions described for DTC CON Exhaust gas leakage FIRMATION PROCEDURE output waveform of HO2S 1 Warm up three way catalytic converter Heated oxygen sensor 2 or its circuit ECM PCM ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 97 DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road ity of a traffic acci
439. m ignition switch OFF and disconnect cuit shorted to power cir PCM connectors cuit 2 Check for proper connection to PCM at ter minals C51 1 2 or C51 1 1 3 If OK then turn ignition switch ON and mea sure voltage between terminal C51 1 2 or C51 1 1 of disconnected PCM connector and ground 15 it about 0 V 3 Check shift solenoid circuit for open or short Intermittent trouble GRN or GRN RED cir 1 Tum ignition switch OFF 2 Measure resistance between terminal C51 1 2 or C51 1 1 of disconnected PCM con nector and ground Is it 11 15 Q at 20 C 68 F faulty PCM Check for intermittent referring to INTERMIT TENT AND POOR CON NECTION in Section 0A cuit open or shorted to ground If wire and connections are OK replace malfunc tion shift solenoid 781 38 AUTOMATIC TRANSMISSION 4 A T Stall Test This test is to check overall performance of automatic transmission and engine by measuring stall speed at D and R ranges Be sure to perform this test only when transmission fluid is at normal operating temperature and its level is between FULL and LOW marks CAUTION Do not run engine at stall more than 5 seconds continuously for fluid temperature may rise exces sively high After performing stall test be sure to leave engine running at idle for longer than 30 seconds before another stall test 1 Apply parking brake and block wheels
440. mn and Steering Upper Shaft for Accident Damage NOTE Vehicles involved in accidents resulting in body damage where steering column has been impacted or air bag deployed may have a damaged or misaligned steering column Check that 2 capsules are attached to steering column bracket securely Check clearance between capsules and steering column bracket Clearance should be 0 mm 0 in on both sides If found loose or clearance replace steering column assembly 1 Capsule 2 Steering column bracket Take measurement a as shown in the figure If it is shorter than specified length replace column assembly with new one Steering column assembly length a 490 3 x 1 0 mm 19 30 0 04 in Check steering shaft for smooth rotation If found defective replace as column assembly Check steering shaft and column for bend cracks or defor mation If found defective replace as column assembly Check steering upper shaft lower seal 1 for breakage or deformation If found defective replace Check steering shaft joints and shaft for any damages such as crack breakage malfunction or excessive play If anything is found faulty replace steering upper assembly steering lower shaft assembly or steering column assembly 3C1 12 AIR BAG STEERING WHEEL AND COLUMN Take measurement b as shown in the figure If it is shorter than specified l
441. module connector and passenger pretensioner module connector 3 Disconnect forward sensor 4 Check proper connection to forward sensor connector at ORN GRN and ORN BLU terminals or YEL GRN and YEL BLU ter minals 5 If OK then measure resistance between ter minals of forward sensor Is resistance 738 905 0 Go to step 2 Replace forward sensor 1 Reconnect forward sensor 2 Disconnect SDM connector 3 Check proper connection to SDM connector at terminals Q01 13 and QO1 14 or ter minals Q01 18 and 001 19 4 If OK then measure resistance between ter minal 001 13 and 001 14 or terminal 001 18 and 001 19 Is circuit open Repair open in ORN GRN and ORN BLU wire circuit between for ward sensor and SDM or YEL GRN and YEL BLU wire circuit between forward sensor and SDM Go to step 3 1 Disconnect forward sensor 2 Measure resistance between Q01 13 ter minal and body ground Q01 14 terminal and body ground or between 001 18 ter minal and body ground Q01 19 terminal and body ground Are circuits open Substitute a known good SDM and recheck Repair short from ORN GRN or ORN BLU wire circuit between forward sensor and SDM to ground or from YEL GRN or YEL BLU wire circuit between forward sensor and SDM to ground 108 38 AIR BAG SYSTEM A Fig for STEP 1 B F
442. n Check blower motor and fan Compressor malfunction Check compressor NOTE If ambient temperature is within 30 35 C 85 95 F it is possible to do using DETAIL DIAGNOSIS TABLE in this section for detail diagnosis AIR CONDITIO IG OPTIONAL 18 13 Detail diagnosis table at ambient temperature within 30 35 C 85 95 F Condition Possible Cause Correction MANIFOLD MPa Detail GAUGE kglem psi To Hi 0 23 0 35 1 4 1 75 Normal condition 2 3 3 5 14 17 5 33 50 200 249 Negative 05 06 The low pressure side Dust particles or water drop Clean expansion valve pressure 5 9 reads a negative pressure ets are either stuck or frozen Replace if it cannot be 71 2 85 3 the high pressure side inside expansion valve pre cleaned reads an extremely low venting the refrigerant from Replace condenser dryer pressure flowing Evacuate the A C system and Presence of frost around recharge with fresh refriger tubing to and from receiver ant dryer and expansion valve Normal Normal During operation the Expansion valve is frozen due Replace expansion valve 0 23 0 35 1 4 1 75 low pressure side some to moisture in the system and Replace condenser dryer 2 3 3 5 14 17 5 times indicates negative temporarily shuts off the Evacuate A C system and 33 50 200 249 pressure and somet
443. n connected to this fuse 3 Main relay check Go to Step 4 Replace main relay 1 Turn OFF ignition switch and remove main relay 2 Check for proper connection to main relay at terminal 3 and 4 3 If OK check main relay for resistance and operation referring to MAIN RELAY INSPECTION in Section 6E2 15 check result satisfactory 4 PCM power circuit check Go to Step 5 BLK WHT BLU or 1 Turn OFF ignition switch disconnect con BLK RED circuit open nectors from ECM PCM and install main relay 2 Check for proper connection to ECM PCM at terminals C51 3 20 E61 9 51 3 15 and 51 3 4 3 If OK then measure voltage between termi nal C51 3 20 and ground E61 9 and ground with ignition switch ON Is each voltage 10 14 V 5 ECM power circuit check Check ground circuits to Step 6 1 Using service wire ground terminal E61 9 BLK GRN and BLK and measure voltage between terminal ORN for open C51 8 15 and ground at ignition switch ON If OK then substitute a Is it 10 14 V known good ECM PCM and recheck 6 _ Is operating sound of main relay heard in Step Go to Step 7 BLK RED or BLU BLK 1 wire open 7 Main relay check BLK RED or BLU BLK Replace main relay 1 Check main relay according to procedure in wire open Step 3 15 main relay in good condition 6 1 48 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC
444. n 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 III up to FULL HOT Fluid specification An equivalent of DEXRONC III NOTE DO NOT RACE ENGINE while checking fluid level even after the engine start DO NOT OVERFILL Overfilling can causes foaming and loss of fluid through breather Then slippage and transmission failure can result Bringing the level from LOW HOT to FULL HOT requires 0 3 liters 0 64 0 53 US Imp pt 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 781 44 AUTOMATIC TRANSMISSION 4 A T 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 Fluid change 1 Lift up vehicle 2 With engine is cool remove drain plug 1 from oil pan and drain A T fluid 3 Install drain plug 1 Tightening torque AIT fluid drain plug a 23
445. n described in above Step 2 maintained turn ignition switch ON 52 12 ANTILOCK BRAKE SYSTEM ABS 4 Repeat disconnecting and reconnecting of service wire between diagnosis and ground terminals 5 times or more at about 1sec interval within 10 seconds Open 5 Shot T About 10 seconds 1 2 s 4 5 1 sec 1 sec 5 Turn ignition switch OFF and disconnect service wire from monitor coupler 6 Perform DRIVING TEST Step 2 of ABS DIAGNOSTIC FLOW TABLE in this section and CHECK and con firm that normal DTC DTC 12 is displayed not malfunction DTC NOTE It is also possible to clear DTC by using SUZUKI scan tool Refer to Cartridge Manual for procedure to clear DTC Diagnostic Trouble Code DTC Table CAUTION Be sure to perform ABS DIAGNOSTIC FLOW TABLE before starting diagnosis DTC DTC displayed indicated by ABS warning lamp flashing on SUZUKI ABS warning pattern DIAGNOSTIC TEMS scan tool lamp 1 2 No DTC 12 Normal 1 C1015 15 G sensor circuit and 4WD lamp circuit 21 C1021 21 RF 2 5 C1025 25 LF mn Wheel speed sensor circuit 3 1 C1031 81 RR 3 5 C1035 35 LR ANTILOCK BRAKE SYSTEM ABS 5E2 13 DTC DTC di
446. n mounting dummy See NOTE 09926 78320 Mounting dummy QN 09927 66010 J 23082 01 Oil pump aligner DIFFERENTIAL REAR 7F 23 09928 06510 Differential torque checking tool 09930 40113 Rotor holder 09930 40120 Attachment 09944 66020 Bearing installer 09951 16060 09951 18210 Lower arm bush remover Oil seal remover amp installer No 2 09951 46010 Drive shaft oil seal installer NOTE This tool is constituent of tools with 09926 78311 7F 24 DIFFERENTIAL REAR BODY ELECTRICAL SYSTEM 8 1 SECTION 8 BODY ELECTRICAL SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 Technical service work must b
447. n switch OFF disconnect CMP sen and or GRY YEL wire sor coupler 2 With ignition switch ON check voltage between C09 2 and 09 1 terminal See Fig Is the voltage 10 14 V 6 1 88 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 1 With ignition switch ON and crankshaft turned slowly check voltage between C51 1 12 and C51 3 26 terminal Does voltmeter indicator deflect between 0 1 V and 3 5 25 V 6 times while crankshaft turned two revolutions 51 3 13 terminal of ECM PCM coupler con nection If OK substitute a known good ECM PCM and recheck Step Action Yes No 5 sensor REF signal check Go to Step 6 Faulty YEL GRN wire 1 With ignition switch OFF connect CMP sensor or CMP sensor coupler If OK substitute a 2 Disconnect couplers from ignition coil assembly known good and fuel injectors PCM and recheck 3 With ignition switch ON and crankshaft turned slowly check voltage between C51 1 13 and C51 3 26 terminal Does voltmeter indicator deflect between 0 1 V and 3 5 25 V 4 times while crankshaft turned two revolutions 6 CMP sensor POS signal check Poor C51 1 12 and or Faulty YEL BLU wire or CMP sensor If OK substitute a known good ECM PCM and recheck Fig for Step 4 1 Disconnected sensor coupler 2 BLUIBLK wire C09 2 terminal 3 GRYIVEL wire C09 1 terminal
448. n switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine for 1 min 3 Check pending DTC by using scan tool 6 1 104 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per formed Go to Step 2 Go to ENGINE DIAG FLOW TABLE in this section 1 Tur ignition switch OFF and disconnect fuel level sensor connector L15 R01 2 Check for proper connection to fuel level sensor at L15 4 and L15 3 terminals 3 I OK then check resistance between RO1 4 and RO1 3 terminals Refer to FUEL LEVEL GAUGE SENDER GAUGE in Section 8C Is value close to one of above values indicated circuit open If wire and connection are OK substitute a known good ECM PCM and recheck 2 Does fuel level meter in combination meter indi Replenish fuel tank with Go to Step cate E Empty fuel and go to Step 3 3 Check fuel level sensor and its circuit Go to Step 4 Intermittent trouble or 1 Check voltage between terminal E61 28 and faulty ECM PCM ground with ignition switch ON Check for intermittent Is it about 7 1 V or more referring to INTERMIT TENT AND POOR CON NECTION in Section 0 4 5 voltage in Step 3 9 14 V BLUMHT wire shorted to Step 5 to power circuit or fuel level meter malfunction 5 Check Fuel Level Sensor BLU WHT
449. n the following colors at such position as shown in the figure Each color represents the following thickness at the center of bearing Under size main bearing thickness Color painted Bearing thickness 2 621 2 625 mm Black amp Red 0 1032 0 1033 in a 2 624 2 628 mm 0 1033 0 1034 in 2 627 2 631 mm Red amp Yellow 0 1034 0 1035 in 2 630 2 634 mm Red amp Blue 0 1035 0 1036 in z 2 633 2 637 mm Red amp Pink 0 1036 0 1037 in Pant Under size bearing specification If necessary regrind crankshaft journal and select undersize bearing to use with it as follows 1 Regrind journal to the following finished diameter Finished journal diameter 64 738 64 756 mm 2 5487 2 5494 in 2 Using micrometer measure reground journal diameter Measurement should be taken in 2 directions perpendicular to each other in order to check for out of round 3 Using journal diameter measured above and alphabets stamped on lower crankcase select an undersize bearing by referring to table given below Check bearing clearance with newly selected undersize bearing Measured journal diameter lower crankcase 64750 64756 mm 64744 64750 mm 63738 64744 2 5492 2 5494 in 2 5489 2 5492 2 5487 2 5489 in A Black amp Red Red Red amp Yellow Alphabets stamped 5 Red Red amp Yellow R
450. n tool When checking the data with the engine running at idle or racing be sure to shift M T gear to the neutral gear position and A T gear to the Park position and pull the parking brake fully Also if nothing or no load is indicated turn OFF all electric loads P S and all the other necessary switches NORMAL CONDITION SCAN TOOL DATA CONDITION REFERENCE VaLue OTHER COOLANT TEMP At specified idle speed affer warming up 80 100 C Engine Coolant Temp 176 212 F INTAKE AIR TEMP At specified idle speed affer warming up Environmental temp 20 C 436 F 5 C 9 F DESIRE IDLE At idling with no load after warming up Desired idle speed 700m t CLOSED THROT POS With ignition switch ON accelerator pedal ON Closed Throttle Position released 2 With ignition switch ON accelerator pedal OFF depressed TAG FLOW DUTY At specified idle speed after warming up 5 40 ENGINE SPEED At idling with no load after warming up Desired idle speed 50 rpm SHORT FT 1 At specified idle speed after warming up 15 15 Short term fuel trim SHORT FT B2 At specified idle speed affer warming up Short term fuel trim gt LONG FT Bi At specified idle speed affer warming up 15 15 Long term fuel trim LONG FT B2 At specified idle speed after warning up 15 15 Long term full trim IGNITION ADVANCE specified idle speed wi
451. n tool is communicable by connecting it to ECM PCM in another vehicle If communication is possi ble in this case 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 After completing the check turn ignition switch off and dis connect scan tool from data link connector 5 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 17 Without Using SUZUKI Scan Tool Vehicle with Monitor Connector 1 Check malfunction indicator lamp referring to Malfunction Indicator Lamp Check in this section 2 With the ignition switch OFF position disconnect SUZUKI scan tool if connected and using service wire 4 connect diagnosis switch terminal 1 to ground terminal 2 in moni tor connector 3 3 With the ignition switch ON position and leaving engine OFF read DTC from flashing pattern of malfunction indicator lamp Refer to Diagnostic Trouble Code Table If lamp remains ON go to Diagnostic Flow Table A 4 NOTE I 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 Take a note of diagnostic trouble code indicated first 4 After completing the check turn the ignition switch OFF posi tion
452. n varies with each type of pipe When reconnecting fuel or fuel vapor hose be sure to TL connect and clamp each hose correctly referring to left fig VL tire k After connecting make sure that the hose has no twist or kink TA With short pipe fit hose as far as it reaches pipe joint as shown IB Wih following type pipe fit hose as far as its peripheral projection as shown w E IG With bent pipe fit hoso as far as its bent part as shown or tl pipe s about 20 1030 mm 173 1 18 in into the hose 22222 IO Wim sicht pipe ft hose about 20 30 mm 079 1 181 ins T Hoss 2 Pe Clamp Clamp securely position 3 1o 7 mm 0 12 0 27 in from hose end 1 2010 30mm 0 79 1 18 n When installing fuel union bolt gasket always use new gas ket and tighten union bolt to specified torque according to TIGHTENING TORQUE SPECIFICATION in Section 6 When installing injector fuel feed pipe or fuel pressure regu lator lubricate its O ring with gasoline When connecting fuel pipe flare nut first tighten flare nut by hand and then tighten it to specified torque ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 5 Fuel Pressure Relief Procedure CAUTION This work must not be done when engine is hot If done it may cause adverse effect to catalyst After making sure that engine i
453. nce high DTC B1021 is set B1021 7 7 Time TAY BAG warning lamp is turned ON BI AIR BAG warning lamp is turned OFF IC Code 21 DTC Clearance Using SUZUKI scan tool 1 Turn ignition switch to OFF position 2 Connect SUZUKI scan tool to data link connector DLC 1 in the same manner as when making this connection for DTC check Special tool A SUZUKI scan tool 3 ignition switch to ON position 4 Erase DTC according to instructions displayed on SUZUKI scan tool Refer to SUZUKI scan tool operator s 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 and confirm that normal DTC NO CODES is displayed and not malfunction DTC NOTE DTC B1051 DTC B1071 is stored in SDM it is not possible to clear DTC AIR BAG SYSTEM 108 13 Not using SUZUKI scan tool 1 Tum 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 and confirm that normal DTC DTC 12 is displayed and not malfunction DTC NOTE DTC B1051 DTC B1071 is sto
454. nd No 6 as counted from crankshaft pulley side to flywheel side Figure at the left shows engine with intake manifold removed and viewed from the top LH No 1 bank consists of No 1 No 3 and No 5 cylinders RH No 2 bank consists of No 2 No 4 and No 6 cylinders 6 No S cjinder 77 Q Bunctas tas 2 NoZ cylinder 7 1H No 1 bank E 5 3 No3 cylinder 8 RH No2 bank 4 cylinder 9 Crank shaft pulley side S No S cylinder General Information on Engine Service CAUTION The following information on engine service should be noted carefully as it is important in preventing damage and in contributing to reliable engine performance When raising or supporting engine for any reason do not use a jack under oil pan Due to small clearance between oil pan and oil pump strainer jacking against oil pan may cause it to be bent against strainer result ing in damaged oil pick up unit It should be kept in mind while working on engine that 12 volt electrical system is capable of violent and damaging short circuits When performing any work where electrical terminals could possibly be grounded ground cable of the bat tery should be disconnected at battery Any time the air cleaner air cleaner outlet hose throttle body surge tank pipe intake collector or intake man ifold is removed the intake opening should be covered This will protect against accident
455. nd deterioration or damage Make sure all clamps are secure Replace parts as needed 6 6 ENGINE FUEL ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 1 SECTION 6E2 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 following systems parts are used
456. ne 4 NRSAG wamigimpcombmalniamp 9 To ECM equipped and ABS coim 34 Immoblizercontol module f equipped trol modulo f equipped CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 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 PPL RED circuit in air bag harness 108 22 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE connector 2 Check proper connection at 002 8 PPL RED wire terminal for DLC 3 If OK then check resistance between Q02 8 PPL RED wire terminal and Q01 20 terminal of SDM connector Is circuit short known good SDM and recheck Step Action Yes No 1 1 Make sure that SUZUKI scan tool is free from malfunc Go to step 2 Pr
457. nector 2267 Ignition switch ON E6133 Data link connector 12V 10 14V Scan tool not connected to DLG Test switch terminal EUM E61 14 Vehicle with monitor connector 4014 V Ignition switch ON CHEV Ton ih ON rear defogger 61 15 Rear defogger switch if equipped onion switch ON ear defogger 10 14V switch mou Ignition Switch ON heater Blower switch OFF E6126 Heater blower switch o N Ignition switch ON heater blower i switch ON Ignition switch switch Est erani heater blower switch OFF ee EN ignition switch ON switch ON and heater blower switch ON E6138 gt Ignition switch ON Transfer lever Had 4H or 4L range E61 19 4AWD lamp Ignition switch ON Transfer lever 10 14V 2H range For 4 sec after ignition switch ON or overdrive cut switch ON E6120 O D OFF lamp A T vehicle M After 4 sec from ignition switch ON and overdrive cut switch OFF nm Ignition switch ON P N change 61 21 POWER lamp A T vehicle Sen POWER made No Ignition switch ON P N change Switch NORMAL mode 6 1 38 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ignition switch ON A C not oper 61 22 pit UA Tan motor relay 10 14 V ated and Engine coolant temp equipped less than 113 C 235 F TERI
458. nfirm 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 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 Seat Belt Air Bag System Section 10A Section 10B CONTENTS General Description 10 2 10 2 RESTRAINT SYSTEM General Description Driver side seat belt with ELA and pretensioner 4 Second rear seat belt with A ELA Third rear seat RH with A ELR equipped it equipped Front passenger side seat belt with and pre 5 Second rear seat belt center without ELA and Driver side airbag tensioner if equipped 3 Second rear seat bok LH wih AELA Third rear seat bak CH with AELA F equipped 3 Passenger side air bag SEAT BELT WITH ELR The seat belt with Emergency Locking Retractor ELR is designed so that it locks immediatel
459. nge for A T model and set parking brake 1 Start engine and warm it up to normal operating tempera ture 2 Make sure that all of electrical loads except ignition are switched off 3 Check to be sure that idle speed is within specification Refer to Section 6E2 4 Connect SUZUKI scan tool to DLC 1 with ignition switch OFF restart engine and fix ignition timing by using fixed spark mode of SUZUKI scan tool Special tool A SUZUKI scan tool IGNITION SYSTEM FOR H27 ENGINE 62 7 5 Set timing light to ignition harness for No 1 cylinder 6 Using timing light check that timing observed from viewpoint is within specification Initial ignition timing of viewpoint when itis fixed by SUZUKI scan tool 5 1 BTDC Ignition order 1 6 5 4 3 2 Special tool A 09930 76420 3 Timing mark on crankshaft pulley 7 If ignition timing is out of specification loosen flange bolt adjust timing by turning CMP sensor 1 while engine is run ning and then tighten bolt 2 Tightening torque CMP sensor bolt a 15 N m 1 5 kg m 11 0 Ib ft 8 After tightening bolt 2 recheck that ignition timing is within specification 9 After checking and or adjusting end fixed spark mode of SUZUKI scan tool NOTE In this state ignition timing may vary more or less of ini tial ignition timing but it is nothing abnormal 10 With e
460. ngine idling closed throttle position and vehicle stopped check that ignition timing is about BTDC 12 16 shown in the figure Also check that increasing engine speed advances ignition timing If above check results are not satisfactory check input sig nals related to this system 3 Timing mark on crankshaft pulley 6F2 8 IGNITION SYSTEM FOR H27 ENGINE On Vehicle Service Ignition Coil Assembly Igniter and Ignition Coil REMOVAL 1 Remove ignition coil cover 2 Disconnect ignition coil coupler 3 Remove ignition coil bolt 1 and then pull out ignition coil assembly 2 PA 2 INSPECTION Check ignition coil assembly for the following Damage Deterioration S Terminal for corrosion INSTALLATION Install in reverse order of removal Spark Plug REMOVAL 1 Remove ignition coil cover 2 Disconnect ignition coil coupler 3 Remove ignition coil bolt 1 and then pull out ignition coil assembly 2 4 Remove spark plug 3 IGNITION SYSTEM FOR H27 ENGINE 6F2 9 INSPECTION CAUTION When servicing the iridium platinum spark plugs slender center electrode type plugs do not touch the center electrode to avoid damage to it The electrode is not strong enough against mechanical force as it is slender and its material is not mechanically tough Inspect them for electrode wear carbon deposits and Insulator damag
461. nk 2nd timing chain Refer to LH NO 1 BANK 2ND TIMING CHAIN AND CHAIN TENSIONER in this section Install timing chain cover Refer to TIMING CHAIN COVER in this section 9 10 11 6A2 20 ENGINE MECHANICAL H27 ENGINE 12 Install oil pan and oil pump strainer Refer to OIL PAN AND OIL PUMP STRAINER in this sec tion Install cylinder head cover Refer to CYLINDER HEAD COVER in this section Install exhaust manifold Refer to EXHAUST MANIFOLD in this section 15 Install radiator outlet pipe radiator cooling fan and water hose Refer to COOLING WATER PIPES OR HOSES RADIA TOR and COOLING FAN AND FAN CLUTCH in Section 6B 16 Install throttle body and intake manifold Refer to THROTTLE BODY AND INTAKE MANIFOLD in this section Adjust water pump drive belt tension Refer to COOLING FAN BELT TENSION CHECK AND ADJUSTMENT in Section 6B 18 Adjust power steering pump drive belt tension Refer to POWER STEERING PUMP DRIVE BELT in Sec tion 3B1 19 Adjust accelerator cable play and A T throttle cable play Refer to ACCELERATOR CABLE ADJUSTMENT and A T THROTTLE CABLE ADJUSTMENT A T VEHICLE in Sec tion 6E2 20 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled 21 Refill engine with engine oil referring to ENGINE OIL CHANGE in Section 22 Refill cooling sy
462. nnection to PCM at ter minal C51 1 8 3 If OK then turn ignition switch and mea sure voltage between terminal C51 1 8 of disconnected PCM connector and ground Is it about 0 V 3 Check TCC solenoid circuit for open or short Intermittent trouble or GRN YEL circuit open or 1 Tum ignition switch OFF faulty PCM shorted to ground 2 Measure resistance between terminal C51 Check for intermittent If wire and connections 1 8 of disconnected PCM connector and referring to INTERMIT OK replace TCC ground TENT AND POOR CON solenoid Is it 11 15 Q at 20 C 68 F NECTION in Section 0A 781 36 AUTOMATIC TRANSMISSION 4 A T DTC P0753 DTC NO 61 62 Shift Solenoid A 1 Electrical DTC P0758 DTC NO 63 64 Shift Solenoid B 2 Electrical WIRING DIAGRAM T GRN GRNIRED GRN YEL 2 sks E 4 MI WS POM Shift solenoid A i Shi sclencid solenoid DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P0753 DTC NO 61 62 Voltage detected at C51 1 2 terminal is specified volt age or lower when shift solenoid valve A is ON or specified voltage higher when it is OFF Shift solenoid valve A Shift solenoid valve A circuit PCM DTC P0758 DTC NO 63 64
463. not interfere with other parts Make sure all air bag system grounding points 2 are clean and grounds are securely fastened for optimum metal to metal contact Poor grounding can cause intermittent prob lems that are difficult to diagnose 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 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 108 56 AIR BAG SYSTEM Repairs and Inspections Required after an Accident CAUTION All air bag system components including the electrical harness component mounting points must be inspected after an accident If any components are damaged or bent they must be replaced even if air bag system activation did
464. nown of knock sensor connector See Fig good ECM and recheck 514 52 Fig for Steps 2 and 3 1 Knock sensor 2 Knocksensor connector 6 1 84 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0335 Crankshaft Position Sensor Circuit Malfunction WIRING DIAGRAM jua onwel on ars lsa 3 2 cs 51 2 19 I I MEZ DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CKP sensor signal is not input while 100 pulses of CKP sensor circuit CMP sensor signal are input after engine start CKP sensor ECM PCM DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following cond CEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more is satisfied when using this DTC CONFIRMATION PRO 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 10 sec 3 Check DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 85 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE performed to Step 2 Go to ENGINE DIAG FLOW TABLE in this section 2
465. nozzle Check that vacuum is held at that level there is no leakage If vacuum leaks replace 6 Install tank pressure control valve 4 To canister 5 From fuel tank ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 47 PCV System NOTE Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed IAC duty for obstructed PCV valve or hose hampers its accu rate checking PCV hose INSPECTION Check hoses for connection leakage clog and deterioration Replace as necessary PCV valve ON VEHICLE INSPECTION 1 Disconnect PCV valve from cylinder head cover and plug head cover hole 2 Run engine at idle 3 Place your finger over end of PCV valve 1 to check for vac uum If there is no vacuum check for clogged valve Replace as necessary 4 After checking vacuum stop engine and remove PCV valve 1 Shake valve and listen for the rattle of check needle inside the valve 1 If valve does not rattle replace 5 After checking connect PCV valve 1 PCV hose and clamp securely 6E2 48 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE PCV system NOTE Be sure to check that there is no obstruction in PCV valve or its hoses 6 before checking engine idle speed IAC duty for obstructed PCV valve or hose hampers its accurate checking
466. nsor installed floor securely Go to Step 6 Tighten sensor or bracket screw securely If not using new screw 7 Ignition switch OFF 2 Remove G sensor with bracket 3 Check for proper connection to G sensor 4 If OK then check G sensor referring to INSPECTION of G SENSOR Is it in good condition Go to Step 7 Replace G sensor 7 Disconnect connectors from ABS hydraulic unit control module assembly and G sensor 2 Check for proper connection to ABS control module at terminals E136 11 and E136 13 3 If OK then turn ignition switch and mea sure voltage between BLK WHT terminal of sensor connector and body ground Is it 10 14 V Go to Step 8 BLK WHT circuit open Measure voltage between ORN WHT terminal of sensor connector and body ground Is it v Goto Step 9 ORNAWHT circuit shorted to power circuit 1 Ignition switch OFF 2 Check that ORN WHT circuit is free from open or short to ground and ORN GRN circuit Is it in good condition ORN GRN circuit open If circuit is OK substitute a known good ABS hydraulic unit control module assembly ORNMHT circuit open or shorted to ground or ORN GRN circuit 52 22 ANTILOCK BRAKE SYSTEM ABS DTC C1021 DTC 21 DTC C1022 DTC 22 Right Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1025 DTC 25 DTC C1026 DTC 26 Left Front Wheel Speed Sensor Cir
467. nt speed Diagnostic Trouble Code Occurrence of Problem othe Road surface condition Paved road rough road snow covered road other Chain equipment Environmental Condition Weather fair cloudy rain snow other Temperature F C First check Normal code malfunction code Second check after test drive Normal code malfunction code 5E2 8 ANTILOCK BRAKE SYSTEM ABS b Problem Symptom Confirmation Check if what the customer claimed in CUSTOMER QUESTIONNAIRE is actually found in the vehicle and if that symptom is found whether it is identified as a failure This step should be shared with the cus tomer if possible Check warning lamps related to brake system referring to EBD WARNING LAMP BRAKE WARNING LAMP CHECK and ABS WARNING LAMP CHECK in this section c Diagnostic Trouble Code DTC Check Record and Clearance Perform DIAGNOSTIC TROUBLE CODE CHECK procedure in this section record it and then clear it referring to DIAGNOSTIC TROUBLE CODE CLEARANCE in this section If the malfunction DTC which was once displayed and then cleared cannot be detected indicated again when the ignition switch is tumed ON attempt to diagnose the trouble based on the DTC recorded this step may mislead the diagnosis or make diagnosing difficult Proceed to Step 2 to check control module for proper self diagnosis function If
468. ntake collector 22 Remove throttle body 1 from intake collector 23 Remove EGR valve and EVAP canister purge valve from intake collector 24 Remove intake manifold bolts 8 pc and nuts 4 pc 25 Remove intake manifold 6A2 6 ENGINE MECHANICAL H27 ENGINE INSTALLATION 1 Install new intake manifold gaskets 1 to cylinder heads 2 Install intake manifold 1 Tighten bolts and nuts to specified torque Tightening torque Intake manifold bolt and nut a 23 2 3 kg m 16 5 Ib ft 3 Install throttle body 2 to intake collector 1 with new throttle body gasket Tighten bolts and nuts to specified torque Tightening torque Throttle body bolt and nut b 23 N m 2 3 kg m 16 5 Ib ft 4 Install EGR valve 1 EVAP canister purge valve 2 mani fold absolute pressure MAP sensor and each hoses to intake collector and throttle body if removed Use new gasket when installing IAC valve and EGR valve 3 EVAP canister purge valve hose 5 Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets ENGINE MECHANICAL H27 ENGINE 6A2 7 6 Connect hoses of heater EVAP canister fuel feed and fuel return Heater hose Fuel feed hose Fuel return hose EVAP canister hose 7 Install EGR pipe with new gaskets 8 Connect hoses of EVAP canister purge valve and
469. ntial difference between the sensor signal terminal E136 11 and the sensor ground terminal E136 13 is not within the specified voltage value or if the signal voltage while at a stop does not vary from that while running this DTC is set Therefore this DTC may be set when a vehicle is lifted up and its wheel s is turned In such case clear the DTC and check again When G sensor is installed to 2WD vehicle this DTC is set 4WD lamp When 4WD lamp circuit open or shorted this DTC is set INSPECTION ANTILOCK BRAKE SYSTEM ABS 5E2 21 Step Action Yes No 1 1 Turn ignition switch ON Does 4WD lamp turn ON when 4WD switch turns ON Goto Step 2 Replace bulb or repair its circuit 1 Ignition switch OFF 2 Check for proper connection to ECM PCM and 4WD switch 3 If OK then check 4WD control system refer ring to DIAGNOSIS in SECTION 7E Is it good condition Goto Step 3 Repair 4WD control sys tem 1 Ignition switch OFF 2 Disconnect connector from ABS hydraulic with control module assembly 3 Check for proper connection to ABS control module at terminal E136 17 4 If OK then turn ignition switch ON and 4WD Switch ON 5 Measure voltage between terminal E136 17 of module connector and body ground Is it 10 14 V Go to Step 4 ORN BLK circuit open or short to ground Is G sensor installed to 2WD vehicle Remove G sensor Go to Step 5 Is G se
470. nting dummy and make 0 zero adjustment on surface plate NOTE When setting dial gauge to mounting dummy tighten screw lightly Be careful not to overtighten it which will cause damage to dial gauge With dial gauge set turn dummy back and force by hand a couple of times and attain accurate 0 zero adjustment Itis desirable that short pointer indicates beyond 2 mm when long one is at 0 zero Special tool A 09900 20606 B 09926 78320 1 Surface plate 2 Screw 4 Place zero adjusted mounting dummy and dial gauge set on pinion mounting dummy and take measurement between zero position and extended dial gauge measuring tip NOTE Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accu rately When dial gauge measuring tip extends from 0 zero position pointer turns counterclockwise Measured value may exceed 1 mm Therefore it is also necessary to know reading of short pointer Special tool A 09900 20606 B 09926 78311 D 09922 76570 F 09926 78311 002 5 Obtain adjusting shim thickness by using measured value by dial gauge in previous step Neces R Dialgauge sary shim measured thickness pa value 7F 16 DIFFERENTIAL REAR 6 Select adjusting shim s 2 closest to calculated value from among following available sizes and put it in place and then press fit rear bearing 1 Calc
471. ntrol lever at max cool position Vehicle door at all open Air inlet door at recirculation position 3 Look at the sight glass 1 and compare what is observed with the symptoms listed in the table given below 2 Bubbles Condition Possible Cause Correction Bubbles observed in sight Insufficient charge of refrigerant in system Check system for leaks with a leak tester glass No bubbles observed in No charge or proper or too much charge of refrigerant in Refer to the following items sight glass system No temperature differ Empty or nearly empty system Perform recovery evacuating and charg ence between compressor ing system and then check it for leaks inlet and outlet with a leak tester Noticeable temperature Proper or too much charge of refrigerant in system difference between com pressor inlet and outlet Refer to the following items When is turned OFF much charge of refrigerant in system refrigerant in sight glass clears immediately and remains clear Recharge with specified amount of refrig erant When A C is turned OFF Proper charge of refrigerant in system refrigerant in sight glass once produces bubbles and then clears Perform PERFORMANCE DIAGNOSIS in this section NOTE For specified amount of refrigerant refer to OPERATION PROCEDURE FOR CHARGING A C WITH REFRIGERANT in this section 18 10 AIR CONDITIO
472. ntrol module 4 canister purge valve 232 Test switch terminal 42 Main relay 5 Throtiie position sensor 23 3 Output duty select switch terminal 48 Ignition switch Idie air control valve 234 output terminal 44 ParkiNeutral position switch in TR switch AT 7 Camshaft postion sensor 24 Fuel fiter 25 Battery 8 EGR valve 25 Fuel pressure regulator 46 Starter magnetic switch 9 Manifold absolute pressure sensor 26 Immobilizer indicator lamp f equipped 47 OFF lamp equipped 16 Fuel injector Z7 Tank pressure control valve 48 lamp T1 POV valve 28 EVAP canister 49 Lighting switch AIT 12 Ignition coll assembly 29 Knock sensor 50 Stop lamp switch AT 18 Engine coolant temperature sensor 30 Engine control module Powertrain con 51 cut switch troi module T4 Heated oxygen sensor 31 Malfunction indicator lamp 52 POWERINORMAL change switch bank 1 sensor 1 f equipped 18 Heated oxygen sensor 32 Electric loads rear defogger if equipped lighting 53 4WD low switch ATT bank 2 sensor 1 f equipped 16 Heated oxygen sensor 33 Power steering pressure switch 54 Transmission range switch bank 1 sensor 2 f equipped 17 Heated oxygen sensor 34 Healer Blower fan switch 55 Solenoid valve A ATT bank 2 sensor 2 f equipped T amp Warm up three way catalytic converter 35 Cruise control module 56 Solenoid
473. o 55 rpm it is proper For high speed check connect battery termi nal to terminal and its terminal to Black lead wire 2 If motor rotates at a high revolution speed of 67 to 83 rpm it is proper Testing automatic stop action a Connect 12 V battery terminal to terminal A of wiper motor and terminal to Black lead wire 2 and let the motor turn b Disconnect terminal A from battery and let the motor stop c Connect terminal A and D with a jumper wire 3 and connect terminal C to battery 4 terminal Observe the motor turns once again then stops at a given position d Repeat a through c several times and inspect if the motor stops at the given position every time 80 4 WINDOWS MIRRORS SECURITY AND LOCKS Rear Window Wiper and Washer For Vehicle with Cruise Control System INSPECTION Rear Wiper and Washer Switch 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 If any continuity is not obtained replace switch 1 T Temma n E OFF Rear wiper ON Rear washer T Rear wiper switch 2 Rear washer switch Rear Window Wiper and Washer For Vehicle without Cruise Control System INSPECTION Refer to Rear Wiper and Washer Switch In Combin
474. 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 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 following systems parts are used in the particular vehicle or not depends on specifications Be sure to bear this in mind when performing service work Monitor connector CKP sensor MAP sensor EGR valve Heated oxygen sensor or CO adjusting resistor Three way catalytic converter Warm up three way catalytic converter CONTENTS General Information 643 For A T system Refer to Section 7B1 Statement of Cleanliness and Care 6 1 3 for diagnosis 6 1 21 General Information on Engine Service 6 1 3 For immobilizer control system Refer to Precaution on Fuel System Service 6 1 4 Section 8G for diagnosis 6 1 22 Fuel Pressure Relief Procedure 6 1 5 Fail Safe Table 6 1 23 Fuel Leakage Check Procedure 6 1 5 Scan Tool Data 6 1 24 Engine Diagn
475. od 1 Connect connectors to ECM PCM open ECM PCM and recheck 2 Using service wire ground E61 29 terminal with connectors connected to ECM PCM 3 Tum ignition switch ON Does MIL flash Poor connector connec tion 6 1 46 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Table 5 PCM Power and Ground Circuit Check MIL Doesn t Light at Ignition Switch ON and Engine Doesn t Start Though It Is Cranked Up WIRING DIAGRAM 5 IGMETER ou re 2 foro suw df esr Td 320 cs1 27 feuern E122 07 oop Buen 3 TO BLU E619 T 51 36 H BLKGRN i AES oom cova bs E617 C513 6 51 3 4 51 3 15 51 2 7 WW al A Esto 051317 651320 MI 1 ME 2 To ignition switch 3 Main fuse p E Main relay POM CIRCUIT DESCRIPTION When the ignition switch is turned ON the main relay turns ON the contact point closes and the main power is supplied to ECM PCM ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 47 INSPECTION Step Action Yes No 1 Main relay operating sound check Go to Step 5 Go to Step 2 Is operating sound of main relay heard at igni tion switch ON 2 Fusecheck Go to Step 3 Check for short in circuits Is main FI fuse in good conditio
476. odule deployment fixture special tool In case of seat belt pretensioner Verify that the seat belt pretensioner is placed as shown in the figure on the ground in the space just cleared Connect 2 the air bag inflator module or seat belt preten sioner to the deployment harness connector and lock con nector with lock lever Notify all people in the immediate area that you intend to deploy activate the air bag inflator module or seat belt pre tensioner 10 11 For Driver Air Bag Inflator Module 18 For Passenger Air Bag Inflator Module IC For Seat Belt Pretensioner NOTE When the air bag deploys and the pretensioner acti vates the rapid gas expansion will create a substantial report Wear suitable ear protection Notify all people in the immediate area that you intend to deploy the air bag inflator module or activate the seat belt preten sioner and suitable ear protection should be worn When the driver air bag deploys and the pretensioner activates driver air bag inflator module and preten sioner retractor assembly may jump about 30 cm 1 ft vertically This is a normal reaction of them to the force of the rapid gas expansion inside the air bag and pretensioner After the 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
477. oid coupler 1 valves on transmission WARNING To avoid the danger of being burned do not touch the hot exhaust system when disconnecting shift solenoid cou pler 1 2 With select lever in P start engine and warm it up 3 With select lever in L range start vehicle and accelerate to 20 km h 12 5 mile h Check in this state that 1st gear is being used 4 At 20 km h 12 5 mile h shift select lever to 2 range and accelerate to 40 km h 25 mile h Check in this state that 3rd gear is being used 5 At 40 km h 25 mile h shift select lever to D range and check that O D gear is used when speed is higher than 40 km h 25 mile h 6 After above checks stop vehicle then engine and connect shift solenoids coupler 1 with ignition switch OFF Time Lag Test This test is to check conditions of clutch reverse brake and fluid pressure Time lag means time elapsed since select lever is shifted with engine idling till shock is felt 1 With chocks placed before and behind front and rear wheels respectively depress brake pedal 2 Start engine 3 With stop watch ready shift select lever from to D range and measure time from that moment till shock is felt WARNING To avoid the danger of being burned do not touch the hot exhaust system when connecting shift solenoid coupler 1 7 Clear DTC with scan tool 4 Similarly measure time lag by shifting select lever f
478. ol module will cause the indicator lamp to light up CRUISE indicator lamp It lights up when cruise control accelerator pedal control is functioning Cancel Conditions Constant cruising is cancelled under the following conditions Ignition switch is turned OFF Cruise main switch is turned OFF Vehicle speed has slowed down to lower than minimum operating speed 40 km h 25 mile h Vehicle speed varies beyond cancel speed range 15 km h 9 mile h from preset speed Brake pedal is depressed Stop lamp switch is turned ON Clutch pedal is depressed Clutch pedal position switch is turned ON For M T vehicle Selector lever is shifted to N range Park Neutral position switch in transmission range switch is turned ON CANCEL switch is turned ON NOTE When constant cruising is cancelled under above any condition with asterisk vehicle speed before cancellation can be resumed by operating ACCEL RESUME switch provided that vehicle speed is higher than 40 km h 25 miles h Diagnosis Diagnosis Table Condition Possible Cause Correction Main switch indicator Main switch indicator lamp circuit faulty Refer to CRUISE MAIN SWITCH INDI lamp fails to light up LAMP CIRCUIT CHECK in this or remains ON section Cruise control module power and ground Refer to CRUISE CONTROL MODULE circuits faulty POWER AND GROUND CIRCUIT CHECK in this section Actuator assembly faulty Replace actua
479. ollowings Seat belt anchor bolts should have an unified fine thread 7 16 20 UNF Under no circumstances should any different sized or metric screw threads be used Connect Yellow connector for seat belt pretensioner securely and fit seat belt pretensioner connector onto front pillar lower panel if necessary Connect connector b Lock connector with lock lever Enable air bag system referring to ENABLING AIR BAG SYSTEM under SERVICE PRECAUTIONS in Section 108 if necessary 10A 6 SEAT BELT Second Rear Seat Belt WARNING Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work 25 5 15 1 ff 9735 Nm 3 5 ka 25 5 vn 1 Upper anchor 4 Bucks 2 Lower anchor V 799 3 Retractor assembly REMOVAL Refer to the figure above to remove rear seat belts INSPECTION Check second rear seat belt in the same way as when inspecting front seat belt except pretesioner inspection Refer to FRONT SEAT BELT in this section INSTALLATION Install in reverse order of removal noting the followings Seat belt anchor bolts should have an unified fine thread 7 16 20 UNF Under no circumstances should any different sized or metric screw threads be used SEAT BELT 10A 7 Third Rear Seat Belt If Equipped WARNING Be sure to read SERVICE PRECAUTIONS in this sec
480. ommanded or low while TCC sole noid ON is commanded TCC lock up solenoid valve TCC lock up solenoid valve circuit PCM AUTOMATIC TRANSMISSION 4 A T 7B1 35 DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road ity of a traffic 1 Connect scan tool to DLC with ignition switch OFF if available 2 Clear DTC pending DTC and freeze frame data in PCM memory by using scan tool 3 Start engine warm it up to normal operating temperature and shift transfer lever to 2H or 4H range 4 Shift selector lever in D range and keep it there for 10 seconds 5 Increase vehicle speed to about 80 km h 50 mile h in 4th gear and in D range 6 Keep driving at above speed for 20 seconds 7 Release accelerator pedal decrease vehicle speed and stop vehicle 8 Check DTC and or pending DTC TROUBLESHOOTING Step Action Yes No 1 Was A T DIAGNOSTIC FLOW TABLE in this to Step 2 Go to AT DIAGNOSTIC section performed FLOW TABLE in this sec tion 2 Check TCC solenoid circuit for short Go to Step 3 GRN YEL circuit shorted 1 Tum ignition switch OFF and disconnect to power circuit PCM connectors 2 Check for proper co
481. on 2 HO28 2 output voltage check Go to Step 4 Go to Step 3 1 Connect scan tool to DLC with ignition Switch OFF 2 Drive vehicle about 35 mph 55 km h for 2 min or more 3 Stop vehicle and check HO2S 2 output volt age displayed on scan tool while repeating racing engine Is over and below 0 3 V indicated 1 Run engine at 2000 r min for 60 sec 2 With engine idling check short term fuel trim displayed on scan tool Is it within 20 to 420 95 faulty ECM PCM Check for intermittent referring to INTERMIT TENT AND POOR CON NECTION in Section 0A 3 HO2S 2 check RED YEL or GRY YEL Replace HO2S 2 1 With ignition switch OFF disconnect HO2S circuit open short 2 coupler If wire and connection are 2 Connect voltmeter between 2 and 1 of substitute a known HO2S 2 coupler good ECM PCM and 3 Start engine and check voltmeter while recheck repeating racing engine Is over and below 0 3 V indicated 4 Shortterm fuel trim check Intermittent trouble or Goto DTC 0174 0175 Diag Flow Table 6 1 74 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0161 HO2S 2 Bank 2 Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0156 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S 2 heater operates 2 25 2 heater or its circuit driving cycle detection lo
482. on Switch Cruise Control Actuator Assembly with Control Module Cruise Cable 8E 23 8E 24 8E 2 CRUISE CONTROL SYSTEM General Description Cautions in Servicing Refer to Section 8 Symbols and Marks Refer to Section 8A Abbreviations Refer to Section 8A Wiring Color Symbols Refer to Section 8 Joint Connector Refer to Section 8 Fuse Box and Relay Refer to Section 8A Power Supply Diagram Refer to Section 8A CRUISE CONTROL SYSTEM 8E 3 Cruise Control System The cruise control system is a device which maintains a preset vehicle speed while driving at a high speed e on a highway It allows the driver to drive his vehicle at a constant speed of 40 km h 25 mile h or higher without depressing the accelerator pedal constant cruising The system also has such functions as to change the vehi cle speed without operating the accelerator pedal but using SET COAST and ACCEL RESUME switches can cel cruise control CANCEL switch and resume the speed in memory automatically after cruise control is cancelled ACCEL RESUME switch The system mainly consists of a vehicle speed sensor an actuator assembly incorporated with control module cruise main switch SET COAST switch ACCEL RESUME switch and CANCEL switch etc CRUISE Stop lamp switch with brake pedal position switch Clutch pedal position switch MIT
483. on 10B Disabling air bag system For disabling air bag system refer to DISABLING AIR BAG SYSTEM under SERVICE PRECAUTIONS in Section 10B Enabling air bag system For enabling air bag system refer to ENABLING AIR BAG SYSTEM under SERVICE PRECAUTIONS in Section 10B Handling and storage For handling and storage refer to HANDLING AND STORAGE under SERVICE PRECAUTIONS in Section 10B Disposal For disposal refer to DISPOSAL under SERVICE PRECAUTIONS in Section 10B 3C1 4 AIR BAG STEERING WHEEL AND COLUMN Steering Column CAUTION Once the steering column is removed from the vehicle the column is extremely susceptible to dam age Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length leaning on the column assembly could cause it to bend or deform Any of the above damage could impair the column s collapsible design When loosening steering column mounting bolts and nuts make sure that steering column assembly and steering upper shaft assembly have been separated Loosening them with steering column assembly and steering upper shaft assembly assembled could cause damage to upper joint and mounting bracket in steering upper shaft assembly NOTE When servicing steering column or any column mounted component remove steering wheel But when removing steering column simply to gain access to instrument panel
484. on is WHT circuit open or shorted to ground detected KNOCK sensor malfunction KNOCK sensor voltage is 0 90 V or less or ECM malfunction KNOCK sensor voltage is 3 98 V or more DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Start engine and run it for 10 sec 4 Check DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 83 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 Knock sensor and its circuit check Knock sensor and its cir Go to Step 3 1 With engine running check voltage from cuit are in good condition C51 3 3 terminal of ECM connector to Intermittent trouble or body ground See Fig faulty ECM 15 voltage about 0 90 3 98 V Recheck referring to INTERMITTENT TROU BLE in Section 0A 3 Knock sensor power source circuit check Substitute known good WHT wire open shorted 1 Stop engine knock sensor and to ground circuit or poor 2 With ignition switch at OFF position discon recheck C51 3 3 connection nect knock sensor connector If wire and connection are 3 With ignition switch at ON position check OK substitute a known voltage from WHT to body ground terminal good substitute a k
485. on safety glasses 2 Remove all loose objects from front seats and instrument panel 3 For driver air bag inflator module Disconnect contact coil connector 1 located near the base of the 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 front pillar lower trim and disconnect seat belt pretensioner connectors 4 Confirm that each air bag inflator module is securely mounted TAI For Driver Ar Bag inflaton Module BI For Passenger Air Bag infiator Module IC For Seat Belt Pretensioner AIR BAG SYSTEM 108 73 5 Check that there is no open short or damage in special tool deployment harness If any faulty condition is found do not use it and be sure to use new deployment harness Special tool A 09932 75030 6 Short 1 the two deployment harness leads together by fully seating one banana plug into the other WARNING Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed and seat belt pretensioner is to be activated 7 Connect deployment harness connector to air bag inflator module driver or passenger or seat belt pretensioner driver or passenger and lock connector with lock lever a Connect connector b Lock c
486. onditions may result in severe injury For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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 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 For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS General Description 7B1 3 Wire Harness and Connectors 7B1 17 Electronic Shift Control System 7B1 4 Table A 1 No TCC Lock Up Oceurs 7B1 18 Automatic gear shift diagram 1781 5 Table 2 No Gear Shift to O
487. onger Itis possible to communicate through DLC by using not only SUZUKI scan tool 2 but also generic scan tool Diagnostic information can be accessed by using a scan tool ECM also indicates trouble area in memory by means of flashing of malfunction indicator lamp 1 at the time of inspection i e when diagnosis switch terminal 3 is con nected to ground terminal 4 with a service wire 5 and igni tion switch is turned ON d cii Wide 30 30 7 Time s c 93 os Tiri eee AUTOMATIC TRANSMISSION 4 A T 7B1 9 Precaution in Diagnosing Trouble Don t disconnect couplers from PCM ECM battery cable from battery PCM ground wire harness from engine or main fuse before checking the diagnosis information DTC freeze frame data etc stored in PCM memory Such disconnec tion will clear memorized information in PCM memory Using SUZUKI scan tool or also generic scan tool for vehicle without monitor connector the diagnostic information stored in PCM memory can be checked and cleared as well Before its use be sure to read Operator s Instruction Manual sup plied with it carefully to have good understanding of its func tions and usage Priorities for diagnosing troubles If two or more diagnostic trouble codes DTCs are stored proceed to the flow table of the DTC which was detected earliest in the order and follow the instruction in that table If no instructions are given troubleshoo
488. onnector with lock lever TA For Driver Air Bag Inflator Module 108 74 AIR BAG SYSTEM 8 Route deployment harness out the vehicle 9 Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable objects 10 Stretch the deployment harness to its full length 10 m 33 ft 1 Special tool A 09932 75030 11 Place a power source near the shorted end 3 of the deploy ment harness Recommended application 12 Volts mini mum 2 amps minimum A vehicle battery is suggested Completely cover windshield area and front door window openings with a drop cloth blanket to similar item 2 This reduces the possibility of injury due to possible fragmenta tion of the vehicle s glass or interior Notify all people in the immediate area that you intend to deploy the air bag inflator module or activate the seat belt pretensioner 12 13 TA Driverside for left hand steering vehicle B Driver side for ight hand steering vehicle NOTE When the air bag deploys and the pretensioner acti vates the rapid gas expansion will create a substantial report Wear suitable ear protection Notify all people in the immediate area that you intend to deploy the air bag inflator module or to activate the seat belt preten sioner and suitable ear protection should be worn After the air bag inflator module has been deployed the surface
489. ons are OK substitute a known good ECM PCM and recheck 6 1 116 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Table B 1 Fuel Pump Circuit Inspection WIRING DIAGRAM 61 23 Ei 651 320 F619 6 51315 3 awe 1 Paz ay i K 2 eum suec susc E WHTIGRN 61 23 NS d PNKIBLK 1 With ignition switch OFF remove fuel pump relay from connector 2 Check for proper connection to relay at each terminal 3 If OK using service wire connect terminals 07 7 and 07 8 of relay connector See Fig Is fuel pump heard to operate at ignition switch ON SS ne Em z x RS W T Ta ipion swich amp Foai pup relay S Fuel pump 3 Main relay amp ECM POM INSPECTION CAUTION Check to make sure that connection is made between correct terminals Wrong connection can cause damage to ECM wire harness etc Step Action Yes No 1 Fuel pump operation check Fuel pump circuitisin Step 2 1 Remove fuel filler cap good condition 2 Turn ON ignition switch 15 fuel pump operation sound heard for 3 sec
490. ontrol module outputs diagnostic trouble code by flashing ABS warning lamp INSPECTION Step Action Yes No 1 lsitshorted diagnosis switch terminal and Go to Step 2 Connect service wire ground terminal by service wire properly securely 2 1 Disconnect service wire PNK circuit open Go to Step 3 2 Disconnect ABS hydraulic unit control mod ule connector 3 Measure resistance between diagnosis Switch terminal and connector terminal E136 12 Is it infinite 3 1 Measure resistance between ground termi Go to Step 4 circuit open or poor nal of monitor coupler and body ground connection Is continuity indicated 4 1 Check for proper connection to ABS Substitute a known good Repair ABS warning hydraulic unit control module at terminal E136 12 2 If OK then check ABS warning lamp circuit referring to TABLE A B and C Is itin good condition ABS hydraulic with control module assembly and recheck lamp circuit ANTILOCK BRAKE SYSTEM ABS 5E2 19 Table E EBD Warning Lamp Brake Warning Lamp Check Lamp Comes ON Steady CIRCUIT DESCRIPTION EBD warning lamp brake warning lamp is controlled by parking brake switch brake fluid level switch and ABS control module hydraulic unit assembly through lamp driver module in combination meter Refer to TABLE A tor circuit diagram INSPECTION Step Action Yes No 1 1 Make sure that Go to Ste
491. oper connection to driver air bag inflator COMBINATION 3C1 module at terminals in Q05 connector SWITCH ASSEM 4 If OK then connect Special Tool B to Q05 connec BLY in Section tor 8C1 With ignition switch ON is DTC B1021 current A Fig for STEP 1 and 2 B Fig for STEP 2 Fig for STEP a STEERING WHEEL aen BASE OF COLUMN Special tool A 09932 75020 B 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected 108 30 AIR BAG SYSTEM DTC B1022 Step Action Yes No 1 1 With ignition switch OFF disconnect contact con to step 2 Go to step 3 nector located near the base of the steering column 2 Check proper connection to contact coil at terminals in 006 connector 3 If OK then connect Special Tool B to contact coil connector disconnected at step 1 With ignition switch ON is DTC B1022 current 2 1 With ignition switch OFF disconnect SDM connector Substitute a known Repair short from 2 Check proper connection to SDM at terminals Q01 9 good SDM and wire circuit to 001 10 rech
492. operly connect SUZUKI tion and correct cartridge for air bag system is used scan tool to DLC 2 Ignition switch OFF 3 Check proper connection of SUZUKI scan tool to DLC Is connection in good condition 2 1 Check if communication is possible by trying communi Go to step Repair open in common cation with other control module ECM TCM section of serial data circuit equipped or ABS control module if equipped PPL RED 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 circuit PPL RED wire cir cuit 3 1 With ignition switch OFF disconnect SDM and 002 Substitute Repair high resistance or open in PPL RED wire circuit in air bag harness Fig for STEP 3 1 Airbag hamess side connector 2 PPLIRED wie terminal Special tool A 09932 75020 2 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected AIR BAG SYSTEM 108 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 B
493. or About 2 5 V Ignition switch ON x Defiects between gnition switch ON crankshaft 51 1 12 Camshaft position sensor 1 ict anda 6 V lumed soul Defiects between Ignition switch ON crankshaft 51 1 13 Camshaft position sensor 2 eV lined only Defects between l9nilion switch ON Rear right tire 51 1 14 Vehicle speed sensor turned slowly with rear left tire 0 1 V and over 4V locked 51 1 15 EVAP canister purge valve 10 14V Ignition switch ON C51 1 16 valve stepper motor coil 4 51 1 17 valve stepper motor coil 3 Ignition switch ON selector lever ar 10 14V 51 1 18 Transmission range switch D range vehicle Ignition switch ON selector lever Other than range Ignition switch ON selector lever MEA 10 14V n Transmission range switch range AT vehicle nem ignition switch ON selector lever Other than N range Shield wire ground for A T output Coto speed sensor A T vehicle B Shield wire ground for A T input Copt speed sensor A T vehicle kl AIT output speed sensor 0851 1 22 r vehicle About 2 5 V Ignition switch ON AIT output speed sensor 0851 1 23 vehicle About 2 5 Ignition switch ON 2 10 147 While engine cranking 51 1 24 Engine start signal ocv one 10 14V ignition switch ON C51 1 25 Power steering pressure switch Willtengine running et Ide
494. or BLKYYEL Check BLU WHT and BLK YEL wires between R01 and R02 connections If OK replace fuel level sensor ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 DTC P0500 DTC No 24 Vehicle Speed Sensor Malfunction WIRING DIAGRAM E 1 TY E132 E15 E59 52 BLUNEL 4 2 c20 To main relay 5V BLUIYEL BLUNEL 051 1 UE lt E C51 1 14 i N L 4 NI Speedometer Vehicle speed sensor Cruise control module f equipped POM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Vehicle speed signal not inputted although fuel is kept Vehicle speed sensor circuit open or short cut for longer than 5 seconds Vehicle speed sensor 2 driving cycle detection logic Vehicle speed sensor drive gear or driven gear Speedometer malfunction Cruise control module malfunction if equipped ECM PCM 6 1 106 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Ch
495. or could render the system inoperative Either of these two conditions may result in severe injury 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 NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS General Descriptio System Components and Wiring Location View and Connectors System Wiring Diagram Diagnosis Diagnostic Trouble Code DTC Use of Special Tool Intermittents and Poor Connections 10B 8 Air Bag Diagnostic System Check Air Bag Diagnostic System Che
496. or Open Lamp circuit is OK Go to Step 3 1 Check for proper connection to cruise control module at terminal E132 10 2 If OK connect terminal E132 10 to ground Does indicator lamp turn ON at ignition switch ON 3 Bulb Check LT Replace bulb Fig for Step 2 f L aeo Cruise Indicator Lamp Circuit Check CRUISE CONTROL SYSTEM 8E 9 Step Action Yes No 1 Check Circuit for Short GRN YEL circuit Go to Step 2 1 Disconnect connector from cruise control module with is shorted to ignition switch OFF ground 2 Tum ignition switch ON Does CRUISE indicator lamp tum ON gt Check Circuit for Open Lamp circuit is OK Go to Step 3 1 Check for proper connection to cruise control module at terminal E1324 2 If OK connect terminal E132 4 to ground Does indicator lamp turn ON at ignition switch ON 3 Lamp Bulb Check BLK WHT or Replace bulb 1 Remove combination meter from instrument panel GRN YEL circuit 2 Remove lamp bulb and check it is open Is bulb in good condition Fig for Step 2 8 10 CRUISE CONTROL SYSTEM Cruise Main Switch Coast Set Resume Accel and Cancel Switches Circuits Check Step Action Yes No 1 Switch Circuit Check Switch circuitis Go to Step 2 1 Disconnect connector from cruise control module with ign
497. or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal CONTENTS 5E2 3 5E2 3 General Description Components Parts Location Table A ABS Warning Lamp Circuit Check Lamp Does Not Come ON at Ignition ABS Hydraulic Unit control Module Switch 5E2 15 Assembly 5 2 4 Table B ABS Warning Lamp Circuit Check Self diagnosis function 5 2 4 Lamp Comes ON Steady 5E2 16 Table C ABS Warning Lamp Circuit Check The Lamp Flashes Continuously While Ignition Switch Is ON Table D Code DTC Is Not Outputted Even with Diagnosis Switch Terminal Connected to Grount Table E EBD Warning Lamp Brake Warning Lamp Check Lamp Comes Fail safe function Diagnosis Precautions in Diagnosing Troubles ABS Diagnostic Flow Table ABS Waming Lamp Check EBD Warning Lamp Brake Warning Lamp Check Diagnostic Trouble Code DTC Check 5E2 5 5E2 5 5E2 5 5E2 6 5E2 9 5E2 17 5E2 18 5E2 9 Cena S Waning Lame bre 15 G Sensor Circuit Diagnostic Trouble Code DTC Check 61015 TE 19 BA Usin
498. or leakage repair if necessary and recharge Expansion valve malfunction valve opens too wide Check expansion valve Compressor malfunction Insufficient compression Check compressor LOW PRESSURE GAUGE graph Condition Possible Cause Correction Pressure high Expansion valve malfunction valve opens too wide Check expansion valve C area of low side Compressor malfunction Insufficient compression Check compressor Pressure low D area of low side graph insufficient refrigerant insufficient charge or leakage Check for leakage repair if necessary and recharge Expansion valve malfunction valve opens too narrow Check expansion valve Clogged refrigerant passage crashed pipe Repair or replace THERMOMETER AT CENTER DUCT Condition Possible Cause Correction Outlet air temperature at center duct is high Crossing point is in area insufficient or excessive charge of refrigerant Check refrigerant pressure Dirty or bent A C evaporator fins Clean or repair Air leakage from cooling heater unit or air duct Repair or replace Malfunctioning switch over function of damper in cool Repair or replace ing heater unit Compressor malfunction Check compressor Outlet air temperature at center duct is low Crossing point is in area p Insufficient air volume from center duct Heater blower malfunctio
499. ormed by two people one per son operates ion switch while the other checks plunger operation INSTALLATION 1 Install new O ring to throttle body 2 Install IAC valve to throttle body 3 Tighten IAC valve screws to specified torque Tightening torque IAC valve screw a 3 5N m 0 35 kg m 2 5 Ib ft 4 Connect IAC valve connector securely 5 Connect negative cable to battery Fast idle air valve 1 Disconnect IAC valve coupler with ignition switch OFF 2 Check that with cold engine started as cooling water tem perature rises engine idle speed reduces gradually If check result is as described above fast idle air valve is in good condition If not fast idle air valve air passage or coolant passage is faulty ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 23 Fuel Delivery System Fuel pressure inspection 1 Relieve fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCEDURE in Section 6 1 2 Disconnect fuel feed hose from 3 delivery fuel feed pipe 1 CAUTION A small amount of fuel may be released when fuel feed hose is removed Place container under the fuel feed hose or fuel feed pipe with a shop cloth so that released fuel is caught in container or absorbed in cloth Place that cloth in an approved container 3 Connect special tools and hose 2 between fuel feed hose and fuel feed pipe as sh
500. ort term fuel trim or total fuel trim short and long terms added is larger 5 ving it P0174 Fuel system too lean Bank 2 than specification for specified time or 5 m9 ON longer Fuel trim toward rich side is y large Short term fuel trim or total fuel trim short and long terms added is Zw we P0175 Fuel system too rich Bank 2 smaller than specification for specified g cycles applicable time or longer Fuel trim toward lean side is large P0300 Random misfire detected MIL flashing P0301 1 misfire detected Misfire of such level as to cause dam during mis Not P0302 Cylinder 2 misfire detected to three way catalyst fire detec applicable P0303 Cylinder 3 misfire detected tion P0304 Cylinder 4 misfire detected Misfire of such level as to deteriorate gt ha P0305 Cylinder 5 misfire detected emission but not to cause damage to PAWS Pon P0306 Cylinder 6 misfire detected _ three way catalyst 0325 Knock sensor circuit malfunc Sensor output too low Td ving 1driving 43 Sensor output too high cycle cycle Crankshaft position sensor cir signal during engine running and 1 driving Not 20335 cuit malfunction CMP sensor signal inputting cycle _ applicable No signal for 3 sec during engine PO340 Camshatt position sensor cir cranking REF signal pattem incor 1 driving Not No 42 cuit malfunction rect or POS
501. ose When using refrigerant container tap valve use following procedure to purge air i Once fully tighten refrigerant container tap valve and then loosen open plate nut slightly ii Open low pressure valve of manifold gauge set a little iii As soon as refrigerant comes out with a hiss through a clearance between refrigerant container and tap valve tighten plate nut as well as manifold gauge set low pres sure valve iv Turn handle of tap valve clockwise so that its needle is screwed into the new container to make a hole for refriger ant flow 1T HF 8 After the system has been charged with specified amount of refrigerant or when low pressure gauge 1 and high pres sure gauge 2 must indicated the following specified amount close low pressure side valve 3 of manifold gauge set 4 If equipped with sight glass in this time look into the sight glass 6 of condenser outlet pipe 5 and check that there are no bubbles 7 in it which means that the system is fully charged Low pressure gauge when charged with specified amount About 200 300 kPa 2 3 kg cm 29 43 psi At A C inlet temperature 30 35 C 86 95 F High pressure gauge when charged with specified amount About 1370 1670 kPa 14 17 kg cm 200 244 psi At A C inlet temperature 30 35 C 86 95 F AIR CONDITIONING OPTIONAL 18 25 On Vehicle Service WARNING Should refr
502. osis 6 1 Scan tool data definition 6 1 27 i Engine Diagnosis Table _ 6 1 31 General Description et Inspection of PCM ECM and its Circuits 6 1 36 On Board Diagnostic System Vehicle without Monitor Connector On Board Diagnostic System Vehicle with Monitor Connector Precaution in Diagnosing Trouble Engine Diagnostic Flow Table Malfunction Indicator Lamp MIL Check 6 Diagnostic Trouble Code DTC Check 6 Diagnostic Trouble Code DTC Clearance 6 Diagnostic Trouble Code DTC Table 6 Table A 1 Malfunction Indicator Lamp Circuit Check Lamp Does Not Come ON or Dims at Ignition Switch ON But Engine at Stop Table A 2 Malfunction Indicator Lamp Circuit Check Lamp Remains ON after Engine Starts Table A 3 Malfunction Indicator Lamp Check MIL Flashes at Ignition Switch ON Vehicle with Monitor Connector 6 1 2 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Table A 4 Malfunction Indicator Lamp Check MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Terminal Vehicle with Monitor Connector Table A 5 ECM PCM Power and Ground Circuit Check MIL Doesn t Light at Ignition Switch ON and Engine Doesn t Start Though It Is Cranked Up DTC P0100 DTC No 33 34 Mass Air Flow Circuit Malfunction DTC P0110 DTC No 23 25 Intake Air Temp IAT Circuit Malfunction DTC P0115 DTC No 14 15 Engine Coolant Temp Cir
503. otal and heater itr US Imp pt 82 175 144 0 9 1 9 1 6 9 1 19 4 16 0 NOTE Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time as damage to cooling system could occur Even in a market where no freezing temperature is anticipated mixture of 70 water and 30 ethyl ene glycol antifreeze Antifreeze Anticorrosion coolant should be used for the purpose of corro sion protection and lubrication Hard water if used will foul up the cooling circuit by scale formation Tap water available from city water supply is the best available water in a practical sense for the cooling system Distilled water is ideal but is a luxury in most cases ENGINE FUEL 6C 1 SECTION 6C ENGINE FUEL NOTE For the descriptions items not found in this section refer to the same section of Service Manual mentioned in the FOREWORD of this manual CONTENTS General Description 6C 1 On Vehicle Service 6C 2 Fuel System 6C 1 Fuel Tank 6C 2 Fuel Lines 60 5 General Description Fuel System The main components of the fuel system are fuel tank fuel pump fuel filter and fuel level gauge and it includes three lines fuel feed line fuel return line and fuel vapor line For the details of fuel flow and fuel vapor flow refer to Section 6E2 1 Fuel tank 6 Fuel feed line to delivery pipe 2 Fuel pump with fuel level
504. ould be detected if present and engine shutoff 2 DRIVING CYCLE DETECTION LOGIC The malfunction detected in the first driving cycle is stored in ECM PCM memory in the form of pending DTC but the mal function indicator lamp does not light at this time It lights up at the second detection of same malfunction also in the next driving cycle PENDING DTC Pending DTC means a DTC detected and stored temporarily at 1 driving cycle of the DTC which is detected in the 2 driving cycle detection logic FREEZE FRAME DATA ECM PCM stores the engine and driving conditions in the form of data as shown in the figure at the moment of the detection of a malfunction in its memory This data is called Freeze frame data Therefore it is possible to know engine and driving conditions e g whether the engine was warm or not where the vehicle was running or stopped where air fuel mixture was lean or rich when a malfunction was detected by checking the freeze frame data Also ECM PCM has a function to store each freeze frame data for three different malfunctions in the order as the malfunction is detected Utilizing this function it is possible to know the order of malfunctions that have been detected Its use is helpful when rechecking or diagnosing a trouble 1 Tat 2nd or rd in parentheses hera represents which position in the order the malfunction is detected 6 1 8 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE
505. outdoor location is not available a space on the shop floor where there is no activity and sufficient ventila tion is recommended Ensure that no loose or flammable objects are within the deployment area b Place special tool passenger air bag inflator module deployment fixture on the ground in the space cleared in step a if it has not already been placed there Special tool B 09932 75041 108 68 AIR BAG SYSTEM Fill plastic reservoir in fixture special tool with water or sand This is necessary to provide sufficient stabilization of the fixture during deployment d Attach the passenger air bag inflator module in the fixture special tool using mounting attachment hold down bolts and nuts and M8 bolts and nuts 1 CAUTION Be sure to use the following bolt and nut for fixing passenger air bag inflator module to mounting attachment Size M8 Strength 7T Securely hand tighten all fastener prior to deployment In case of seat belt pretensioner a Pull out the webbing 2 fully as shown in the figure and cut it at the root of the pretensioner retractor assembly 1 as shown in the figure WARNING As the drum 3 of the retractor assembly 1 turns very quickly as soon as the webbing 2 is cut fix the retractor assembly 1 with a vise on the workbench and keep your hands and fingers away from it when cutting the webbing 2 b Clear a space on t
506. ove are OK substi tute a known good ECM PCM and recheck 4 Wasidie speed within specification in Check for following Goto Step 5 Step 1 FIA valve Vacuum leaks air inhal ing EVAP canister purge control system accessory engine load stuck of PCV valve clog of idle air passage MAF sensor TP sensor ECT sensor EGR valve malfunc tion leakage from valve seat A C signal transmission range switch signal and power steering switch signal 5 Was idle speed higher than specification Step Goto Step 8 in Step 1 6 Check input signal circuit referring Go to Step 7 AIC signal circuit open or to Step 1 of Table B 5 A C signal can short or A C system mal be also checked by using SUZUKI scan function tool Is it in good condition 7 Was IAC duty less than about 2 in Step Check FIA valve Check TP sensor closed 1 of this table Check abnormal air inhaling from throttle position and ECT intake manifold throttle body PCV sensor for performance valve and EVAP canister purge If sensors are OK substitute control system a known good ECM PCM and recheck 8 _ Check transmission range switch signal Go to Step 9 Transmission range switch referring to INSPECTION OF ECM malfunction or its circuits PCM AND ITS CIRCUIT in this section open or short Is check result satisfactory 9 WaslAC duty more than about 30 in Check parts or system which can Substitute a known
507. own 25 2 coupler good ECM PCM and 3 Start engine and check voltmeter while recheck repeating racing engine Is over and below 0 3 V indicated 4 Shortterm fuel trim check Intermittent trouble Goto DTC 0171 0172 1 Run engine at 2000 r min for 60 sec faulty ECM PCM Diag Flow Table 2 With engine idling check short term fuel Check for intermittent trim displayed on scan tool referring to INTERMIT Is it within 20 to 420 TENT AND POOR CON NECTION in Section 0A ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 65 DTC P0141 HO2S 2 Bank 1 Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0136 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S 2 heater operates 2 25 2 heater or its circuit driving cycle detection logic ECM PCM Current of HO2S 2 heater is more than 11 4 A or less than 0 32 A or Voltage of HO2S 2 heater is more than 13 8 V or less than 8 7 V DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this
508. own in figure and clamp hose securely to ensure no leaks occur during checking Special tool A 09912 58441 09912 58431 4 Check that battery voltage is above 11 V 5 Tum ignition switch ON to operate fuel pump and after 3 sec onds tum it OFF Repeat this 3 or 4 times and then check fuel pressure 6 Start engine 7 Measure fuel pressure at idling If measure pressure doesn t satisfy specification refer to Diagnostic Flow Table B 3 in Section 6 1 and check each possibly defective part Replace if found defective Fuel pressure specification CONDITION FUEL PRESSURE With fuel pump operating and 270 310 kPa engine stopped 2 7 3 1 kg cm 38 4 44 0 psi At specified idle speed 210 260 kPa 2 1 2 6 kg cm 29 8 37 0 psi With 1 min after engine fuel pump over 200 kPa stop Pressure reduces as time 2 0 kg cm passes 28 4 psi ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 8 After checking fuel pressure remove fuel pressure gauge 1 CAUTION As fuel feed line is still under high fuel pressure make sure to release fuel pressure according to following pro cedures Place fuel container under joint Cover joint with rag and loosen joint nut slowly to release fuel pressure gradually 9 Remove fuel pressure gauge hose and 3 way joint 10 Connect fuel feed hose and clamp it
509. p 2 Release parking brake Parking brake is completely released completely and or replen Brake fluid level is upper than the minimum ish brake fluid level Are the check results OK 2 Does ABS waming lamp come on Perform TABLE B pre Go to Step 3 viously outlined 3 1 Disconnect ABS hydraulic unit control mod Substitute a known good BRN circuit open ule connector ABS hydraulic If wire and connection are 2 Check for proper connection to ABS trol module assembly and OK replace combination hydraulic unit control module connector at recheck meter terminals E136 10 3 If OK apply chocks to wheels and select gear in neutral position P range for A T 4 Keep brake pedal depressed and start engine Release parking brake 5 Connect terminal E136 10 of discon nected connector to ground using service wire Does EBD warning lamp brake warning lamp turn off 52 20 ANTILOCK BRAKE SYSTEM ABS DTC C1015 DTC 15 G Sensor Circuit and 4WD Lamp Circuit EET ORNIBLK SESH E3647 E1368 4 2 EEn lonition switch 3 ABShydrauicuni contohmoduleassemby 5 4WDlamp 7 WD switch 2 G sensor 4 ABS hydraulic unifcontrol module connector 6 PCM DESCRIPTION G sensor While a vehicle is at stop or running if the pote
510. p 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 108 10 AIR BAG SYSTEM Air Bag Diagnostic System Check Flow Table Step Action Yes No 1 1 Make sure that battery voltage is to step 2 Proceed to Diagnostic Flow Table B about 11V or higher AIR BAG warning lamp circuit 2 Note AIR BAG warning lamp as check ignition switch is tuned ON Does AIR BAG warning lamp come ON when ignition switch is tuned ON 2 Does AIRBAG warning lamp come Proceed to Diagnostic Go to step 3 ON steady Flow Table A AIR BAG waming lamp circuit check 3 Does AIR BAG warning lamp keep Proceed to Diagnostic Go to step 4 flashing indicating DTC when igni Flow Table C tion switch is ON AIR BAG warning lamp circuit check 4 Does AIR BAG waming lamp tum Go to step 5 Go to step 8 OFF after flashing 6 times 5 have SUZUKI scan tool Goto step 6 Go to step 7 6 1 Check DTC using SUZUKI scan Air bag system is in good An intermittent trouble has occurred
511. peci 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 1044 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 air bag harness DIAGNOSTIC FLOW TABLE B1041 and 1045 Step Action Yes No 1 1 With ignition switch OFF remove center Go to step 2 Ignition switch OFF pillar inner garnish of applicable side then Replace seat belt preten disconnect seat belt pretensioner connec sioner Refer to Section tor 10A 2 Check proper connection to applicable seat belt pretensioner at terminals in Q11 or Q12 connector If OK then connect Special Tool B to seat belt pretensioner connector discon nected at the step 1 With ignition switch ON is DTC B1041 or B1045 still current 3 2 1 With ignition switch OFF disconnect SDM Substitute a known DTC B1041 connector good SDM and recheck Repair high resistance or 2 Check p
512. r 12 months Every 2 500 km ITEM 3 1 1 5000 miles Air cleaner filter 1 Every 30 000 km 18 000 miles or 24 months Every 10 000 km ITEM 2 1 Nickel plug b 6000 miles or 8 months ABC EF H Spark plugs pm E Every 30 000 km 18 000 miles or 24 months ppe p EMG Every 15 000 km Propeller shafts and drive shafts 9 000 miles or 12 months TEM 19 6 15 6 19 Every 30 000 km Manual transmission R 18 000 miles or 24 months transfer and differential oil ITEM 6 11 Every 30 000 km Automatic transmission fluid 18 000 miles or 24 months ITEM 6 8 E Every 15 000 km Suspension bolts and nuts 9 000 miles or 12 months Bcp u EMe7 Every 15 000 km Wheel bearing 9 000 miles or 12 months TEM eir Every 15 000 km CD Air conditioning filter 2 9 000 miles 12 months Every 45 000 km 27 000 miles or 36 months NOTE I Inspect and correct replace or lubricate if necessary R Replace or change T Tighten to the specified torque 1 Inspect or replace more frequently if necessary lean or replace more frequently if the air from the air conditioning decreases MAINTENANCE AND LUBRICATION 0B 5 Maintenance Service Engine and Emission Control ITEM 1 1 Drive belt inspection and replacement WARNING All inspection and replacement are to be performed with ENGINE NOT RUNNING WATER PUMP AND GENERATOR DRIVE BELT INSPEC TION 1 Disconnect negative cable a
513. r according to applicable function part s DTC Diag flow table in this section Go to Step 11 Are check and repair complete 10 Intermittent Problems Check Repair or replace mal Go to Step 11 1 Check for intermittent problems referring to function part Check for Intermittent Problem GEN Go to Step 11 ERAL INFORMATION section 15 there any faulty condition 11 Final Confirmation Test Go to Step 6 END 1 Clear DTC if any 2 Perform final confirmation test referring to DTC CONFIRMATION PROCEDURE in this section 15 there any problem symptom malfunction DTC or abnormal condition 6 1 12 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE STEP 1 CUSTOMER COMPLAINT ANALYSIS Record details of the problem failure complaint and how it occurred as described by the customer For this purpose use of such an inspection form will facilitate collecting information to the point required for proper anal ysis and diagnosis CUSTOMER PROBLEM INSPECTION FORM EXAMPLE User name Model VIN Date of issue Date of Reg Date of problem Mileage PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire C After fire No combustion Lack of power O Poor starting at Surging cold warm O always Abnormal knocking Other Other C Poor idling
514. r kit special tool If contact tension is not enough reform it to increase contact tension or replace Special tool A 09932 75020 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 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 108 9 Air Bag Diagnostic System Check 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 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
515. r less Go to step 2 Check Charging System and repair as necessary Refer to DIAGNOSIS in Section 6H 1 With ignition switch OFF reconnect SDM connector With ignition switch ON is DTC B1031 current Substitute a known good SDM and recheck Check Charging System and repair as necessary Refer to DIAGNOSIS in Section 6H Fig for STEP 1 Special tool A 09932 75020 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1032 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 Refer to DIAGNOSIS in Section 6H 2 1 With ignition switch OFF disconnect SDM Go to step 3 Possibly faulty points are connector 2 Check proper connection to SDM at Q01 4 terminal 3 If OK then ignition switch ON and then check voltage from Q01 4 terminal on SDM connector to body ground Is voltage 8 V or more as follows Check each of them and repair as neces sary Circuit from battery to Q01 connector Charging System Refer to DIAGNOSIS in Section 6H AIR BAG SYSTEM 108 35 Step
516. r not any abnormality exists The vehicle was driven with parking brake pulled The vehicle was stuck The vehicle was driven with brake dragging Wheel spin occurred while driving Wheel s was turned while the vehicle was jacked up INSPECTION ANTILOCK BRAKE SYSTEM ABS 5E2 23 Step Action Yes No 1 1 Disconnect applicable ABS wheel speed sensor coupler with ignition switch OFF 2 Measure resistance between terminals of ABS wheel speed sensor Refer to FRONT WHEEL SPEED SEN SOR and or REAR WHEEL SPEED SENSOR in this section 15 measured resistance value as specified Go to Step 2 Replace ABS wheel speed sensor assembly 1 Tum ignition switch OFF 2 Disconnect ABS hydraulic unit control module connec tor 3 Check for proper connection to ABS control module at each sensor terminal 4 I OK then turn ignition switch ON and measure voltage between sensor terminal of module connector and body ground Is it OV Go to Step 3 ABS wheel speed sensor circuit shorted to power 1 Turn ignition switch OFF 2 Connect ABS wheel speed sensor coupler 3 Measure resistance between the following points Both ABS hydraulic unit control module connector termi nals of the corresponding sensor This check result should be the same as above Step 1 Either terminal of wheel speed sensor coupler and body ground This check result should be no continuity Are both check results
517. r 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 CONTENTS General Descriptio 6F2 2 On Vehicle Service Components 6 2 2 Ignition Coil Assembly Igniter and Ignition System Wiring 6F2 8 6F2 8 Diagnosis GF2 4 Spark Plug 6F2 8 Diagnostic Flow Table 6F2 4 CMP Sensor GF2 10 Ignition Spark Chec 6 2 6 Noise Suppressor OF 2 12 Ignition Timing Check and Adjustment GF2 6 Special Tool 6F2 13 6F2 2 IGNITION SYSTEM FOR H27 ENGINE General Description The ignition system is a direct ignition system It consists of the parts as described below and has an electronic ignition control system ECM or PCM It detects the engine condition through the signals from the sensors determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter in ignition coil assembly Ignition coil assembly including an igniter and an ignition coil The ignition coil assembly has a built in igniter and ignition coil which turns ON and OFF the primary current of the ignition coil according to the signal from ECM or PCM When the ignition coil primary current is turned OFF a high voltage is induced in the secondary wiring One ignition coil is in charge of ignition of one cylinder onl
518. radually If measured resistance doesn t shown such characteristic as shown in the figure replace ECT sensor INSTALLATION Reverse removal procedure noting the followings Clean mating surfaces of sensor and water outlet cap 1 Use new O ring Tighten ECT sensor to specified torque Tightening torque ECT sensor a 15 N m 1 5 kg m 11 0 Ib ft Connect coupler to sensor securely Refill cooling system ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 37 Heated oxygen sensor sensor 1 REMOVAL WARNING To avoid danger of being burned do not touch exhaust system when system is hot Oxygen sensor removal should be performed when system is cool 1 Disconnect negative cable from battery 2 Disconnect coupler of oxygen sensor s 3 Remove oxygen sensor s from exhaust manifold s NOTE Be careful not to expose it to excessive shock 3 Left No 1 bank oxygen sensor 1 INSTALLATION Reverse removal procedure noting the followings Tighten oxygen sensor s to specified torque Tightening torque Heated oxygen sensor 1 a 45 N m 4 5 32 5 Ib ft Connect connector of oxygen sensor s and clamp wire har ness securely After installing oxygen sensor s start engine and check that no exhaust gas leakage exists INSPECTION Inspect HO2S 1 and its circuit referring to DTC P0130 or
519. rake piston inner ring and brake piston outer ring from brake piston 6 Unsnap seal ring 1 7 Remove 2 seal rings 1 NOTE Be careful not to open seal ring more than necessary SS 4 3 input shaft 5 Retaining ring 8 Clutch disc 2 Piston 6 Bearing race 30 Froward clutch hub 3 Retum spring 7 Bearing 11 Direct clutch input hub 4 Oring 8 Clutch plate AUTOMATIC TRANSMISSION 4 781 51 DISASSEMBLY 1 After removing retaining ring 1 remove direct clutch input hub 2 and forward clutch hub 3 2 Remove bearing race and thrust bearing Thrust bearing No 2 2 Thrustforward clutch bearing 3 Thrust rear race 3 Install direct clutch input hub 1 and retaining ring 2 4 Install forward clutch 2 to O D case 1 Apply 4 8 kg cm air pressure into fluid hole at the right of cut in O D case and measure movement of forward clutch piston If measured value is not within standard range use either 1 8 mm 0 071 in or 2 0 mm 0 079 in clutch disc to adjust it to standard value Standard forward clutch piston movement 1 40 1 70 mm 0 056 0 067 in 781 52 AUTOMATIC TRANSMISSION 4 A T 5 Remove retaining ring 1 and then remove direct clutch input hub 6 Remove retaining ring and then remove all clutch discs 7 Using special tool and hydraulic press compr
520. rature below 65 C 150 F without high humidity and away from electric noise Never carry the seat belt pretensioner by the wire or connector of the pretensioner 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 5 Set air bag inflator module or seat belt pretensioner as fol lows In case of driver air bag inflator module a Clear a space on the ground about 185 cm 6 ft 3 in diameter where the driver air bag inflator module 1 is to be deployed A paved outdoor location where there is no activity is preferred If an outdoor location is not available a space on the shop floor where there is no activity and suffi cient ventilation is recommended Ensure no loose or flammable objects are within the deployment area b Place the driver air bag inflator module 1 with its vinyl trim cover facing up 2 on the ground in the space just cleared In case of passenger air bag inflator module a Clear a space on the ground about 185 cm 6 ft 2 in diameter where the fixture special tool with attached air bag inflator module 1 is to be placed for deployment A paved outdoor location where there is no activity is pre ferred If an
521. rature 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 al 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 AIR BAG SYSTEM 108 53 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 workbench 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 1 is retracted into the retractor assembly 2 quickly Note therefore that if they activate accidentally t
522. re gauge to fluid pressure check hole 1 in transmission case Special tool A 09925 37811 001 CAUTION After attaching oil pressure gauge check that not fluid leakage exists 3 Depress foot brake fully run engine at idle and stall 4 Check fluid pressure in D or R range within the following specification CAUTION Do not continue running engine at stall speed longer than 5 seconds Line pressure D range range Idle speed 4 1 4 6 kg cm 5 4 6 0 kg cm 58 65 psi 77 85 psi Stall speed 120 13 5 kg cm 14 6 17 1 kg cm 171 192 psi 208 243 psi 5 If check result is OK disconnect special tool then tighten transmission case plug to specified torque Tightening torque Transmission case plug 17 N m 1 7 kg m 12 0 Ib ft 781 40 AUTOMATIC TRANSMISSION 4 A T TROUBLESHOOTING Condition Possible cause Line pressure higher than standard level in each Malfunctioning regulator valve range Malfunctioning throttle valve Maladjusted A T throttle cable Line pressure lower than standard level in each Defective O D clutch range Defective oil pump Malfunctioning throttle valve Malfunctioning regulator value Maladjusted A T throttle cable Line pressure lower than standard level only in Fluid leakage from forward clutch D range Defective O D clutch Leakage from D range fluid pressure circuit Line pressure lower than standard le
523. re is 8 C os 46 4 F their crossing point is within acceptable range as shown in graph san 11 If crossing point is out of acceptable range diagnose trouble referring to PERFORMANCE DIAGNOSIS TABLE 8 METE 12 Check that difference in temperature of center face air outlet Pais amp air and rear A C air outlet air are within 5 C 41 F Faso 72 If the rear A C air outlet air temperature is higher over 5 C Bus 41 F than center face air outlet air temperature check rear guo T AC unit us HEN 2 B 7 Temperature at Evaporator Air Inlet asc p 18 12 AIR CONDITIONING OPTIONAL Performance diagnosis table HIGH PRESSURE GAUGE Condition Possible Cause Correction Pressure high A area of high side graph Refrigerant overcharged Recharge Expansion valve frozen or clogged Check expansion valve Clogged refrigerant passage of high side Clean or replace Condenser cooling fan malfunction Insufficient cooling of condenser Check condenser cooling fan Dirty or bent condenser fins Insufficient cooling of con denser Clean or repair Compressor malfunction Insufficient oil etc Check compressor Engine overheat Check engine cooling system Pressure low B area of high side graph insufficient refrigerant Insufficient charge or leakage Check f
524. re 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 SDM connector and terminals for tightness Check SDM sets a diagnostic trouble code Refer to CHECK and the diagnostic table leads to a malfunction ing SDM If any faulty condition is found in above checks replace 1 Air bag wire harness and connections Check for damages deformities or poor connections Refer to INTERMITTENTS AND POOR CONNEC TIONS Check wire harness clamps for tightness If any faulty condition is found correct or replace AIR BAG SYSTEM 108 59 Forward sensor Check sensor 1 sensor bracket 2 and front panel 3 for damage bend or rust Check that connector 4 or lead wire 5 of forward sensor has a scorching melting or damage If any faulty condition is found in above checks replace 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 Seat belts and mounting points Refer to FRONT SEAT BELT WITH PRETENSIONER in SECTION 10A AIR BAG waming lamp After vehicle is completely repaired perform AIR BAG DIAGNOSTIC SYSTEM CHECK 108 60 AIR BAG SYSTEM FORWARD 2g f SDM WARNING Durin
525. re there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and warm up engine completely 3 Increase vehicle speed to 55 60 km h 35 40 mph 4 Keep driving above vehicle speed for 7 min or more 5 Increase vehicle speed to 100 110 km h 60 70 mph 6 Release accelerator pedal and with engine brake applied keep vehicle coasting and then stop vehicle 7 Check if pending DTC exists by using scan tool If not check if EGR system monitoring test has completed by using scan tool If not in both of above checks ie no pending DTC and EGR system monitoring test not completed check vehicle conditions environmental and repeat Steps 3 through 6 100 110 60 70 55 60 85 40 010 1 and 2 3 4 5 9 E 1 Vehicle speed km h mph 2 Step ENGINE GENERAL
526. reakage of O D case seal ring Worn direct clutch bushing Replace Direct clutch slipping Replace Foreign material caught in direct clutch piston Replace check ball Poor start or surging Fluid pressure leakage of forward clutch due to Replace in D range wear or breakage of O D case seal ring Malfunction of forward clutch Replace Poor 3 4 shift exces Faulty overdrive brake Replace sive slippage Faulty overdrive clutch Replace Poor start or juddering Fluid pressure leakage of direct clutch due to Replace in R range wear or breakage of oil center support seal ring Worn direct clutch Replace Excessive shock on Faulty one way clutch Replace 1 2 shift Non operate lock up Faulty torque converter Replace system ABNORMAL NOISE Condition Possible Cause Correction Abnormal noise in Worn oil pump Replace or N range Scan Tool Data Refer to Section 6 1 Inspection of PCM and Its Circuit Refer to Section 6 1 Wire Harness and Connectors Refer to Section 6 1 781 18 AUTOMATIC TRANSMISSION 4 A T Table A 1 No TCC Lock Up Occurs SYSTEM DESCRIPTION PCM tums TCC solenoid OFF under any of the following conditions Brake pedal switch ON 4WD LOW switch ON Cruise control module TCC OFF command signal is output if equipped ECT lt 30 86 F TROUBLESHOOTING WARNING When performing a road test select a place where there is no traf
527. red in SDM it is not possible to clear DTC 1 kk 19 AIRBAG monitor coupler Open 2 Body ground b Short 3 Diagnosis switch terminal 6 10 seconds 4 Semice wire d Abou sec 108 14 AIR BAG SYSTEM DTC Table AIR BAG waming lamp DTC flashing pattern Diagnosis NO MODE c nan Normal 1015 15 Resistance high B1016 16 Passengerair Resistance low 1018 18 bag circuit Sport to ground 1019 19 fL Short to power circuit 1021 21 L Resistance high B1022 22 Driver air bag Resistance low Diagnose trou circuit ble according to 1024 24 Short to ground JUL diagnostic flow 1025 25 UL Short to power circuit table corre sponding to 1031 31 Power source 7 high each code No 1032 32 UL voltage Too low 1035 35 RH Forward OPen or short ground sensor circuit Short between two wires or P1999 98 74 short to power circuit B1037 37 fih Forwara OPen or short to ground sensor circuit Short between two wires or P1095 588731 short to power circuit AIR BAG SYSTEM 108 15
528. requent between 3rd and over drive when driving on uphill road Hunting Throttle valve opening signal circuit faulty Refer to THROTTLE VALVE OPENING SIGNAL CIRCUIT CHECK in this Sec tion Overdrive and TCC off command signal circuit faulty Refer to OVERDRIVE AND TCC OFF COMMAND SIGNAL CIRCUIT CHECK in this section Actuator assembly faulty Replace actuator assembly 4 speed A T is not shifted to overdrive gear even though not on uphill road Throttle valve opening signal circuit faulty Refer to THROTTLE VALVE OPENING SIGNAL CIRCUIT CHECK in this sec tion Overdrive and TCC off command signal circuit faulty Refer to OVERDRIVE AND TCC OFF COMMAND SIGNAL CIRCUIT CHECK in this section Actuator assembly faulty Replace actuator assembly Note on System Circuit Inspection Refer to PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE in Section 0A 8E 8 CRUISE CONTROL SYSTEM Cruise Main Switch Indicator Lamp Circuit Check 1 Remove cruise main switch from instrument panel 2 Remove lamp bulb and check it Is bulb in good condition GRN WHT circuit is open Step Action Yes No 1 Check Circuit for Short LT GRNMHT cir Go to Step 2 3 Disconnect connector from cruise control module with cuitis shorted to ignition switch OFF ground 4 Tum ignition switch ON Does cruise main switch indicator lamp tum ON 2 Check Circuit f
529. ressure Leakage from oil pressure circuit Overhaul RUNNING CONDITION Condition Possible Cause Correction Unable to run in all Wearin oil pump Replace range Seizure in oil pump Replace Fluid pressure leakage to over drive clutch due Replace to wear of oil pump bushing Faulty in torque converter Replace Poor 1st speed run Fluid pressure leakage from forward clutch due Replace ning or excessive slip to wear or breakage of O D case seal ring page in D or 2 Overdrive clutch slipping Replace Unable to run or Fluid pressure leakage of forward clutch due to Replace excessive slippage wear or breakage of O D case seal ring L range Reverse brake disc slipping Replace Broken brake piston O ring Replace Unable to run or Fluid pressure leakage to direct clutch dueto Replace excessive slippage in wear or breakage of center support seal ring R range Worn direct clutch Replace AUTOMATIC TRANSMISSION 4 A T 781 17 GEAR SHIFT Condition Possible Cause Correction Poor 1 2 shift exces Fluid pressure leakage to overdrive clutch due Replace sive slippage to wear or breakage of O D case seal ring Faulty second brake Replace Broken O ring of second brake piston Replace Faulty second coast brake in 2 range Replace Poor 2 3 shift exces Fluid pressure leakage to overdrive clutch due Replace sive slippage to wear or b
530. rformed 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 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 For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS Maintenance Schedule 0B 2 Maintenance Service 0 5 Maintenance Schedule under Normal Engine and Emission Control 0 5 Driving Conditions 0B 2 Drive belt inspection and replacement 0B 5 Maintenance Recommended under Severe Engine oil and filter replacement 0B 6 Driving Conditions OB 4 0B 2 MAINTENANCE AND LUBRICATION Maintenance Schedu
531. ring to TRANSMISSION RANGE SWITCH in Section 7B1 Is check result satisfactory BLK RED or BLK YEL circuitis open or short Adjust or replace Fig for Step 1 14 CRUISE CONTROL SYSTEM Clutch Pedal Position Switch Circuit Check Step Action Yes No 1 Clutch Pedal Position Switch Circuit Check Clutch pedal posi Go to Step 2 1 Disconnect connector from cruise control module with tion switch circuit is ignition switch OFF OK 2 Check for proper connection to cruise control module at terminal E132 9 3 If OK check for resistance between terminal E132 9 and ground under each condition below Clutch pedal position switch circuit specification Clutch pedal released Infinity Clutch pedal depressed Continuity Is check result satisfactory 2 Clutch Pedal Position Switch Position Check Go to Step 3 Adjust 1 Check clutch pedal position switch for installation position referring to CLUTCH PEDAL POSITION SWITCH in this section Is check result satisfactory 3 Pedal Position Switch Check BLU or BLK cir Replace 1 Disconnect connector from clutch pedal position switch cuitis open or 2 Check for proper connection to clutch pedal position short Switch at all terminals 3 If OK check clutch pedal position switch for operation referring to CLUTCH PEDAL POSITION SWITCH in this section Is th
532. rk plug faulty or plug gap as out of adjust ment Spark plugs in Section 6F2 Fuel pressure out of specification clogged fuel filter faulty fuel pressure regula tor clogged fuel filter hose or pipe DIAG FLOW TABLE B 3 in this section Engine overheating Refer to OVERHEATING in this table Faulty EGR system DTC P0400 DIAG FLOW TABLE in this section Faulty injector Fuel injector in Section 6E2 Faulty TP sensor ECT sensor or MAF sensor TP sensor ECT sensor or MAF sensor in Section 6E2 Faulty ECM PCM Inspection of ECM PCM and its circuit in this section Low compression Refer to the same item in HARD STARTING of this table ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 33 Condition Possible Cause Correction Surges Engine power varia tion under steady throttle or cruise Feels like the vehicle speeds up and down with no change in the accelerator pedal Defective spark plug excess carbon deposits improper gap and burned electrodes etc Spark plugs in Section 6F2 Variable fuel pressure clogged fuel filter kinky or damaged fuel hose and line faulty fuel pressure regulator DIAG FLOW TABLE 3 in this section Faulty EGR system DTC P0400 DIAG FLOW TABLE in this section Faulty MAF sensor MAF sensor in Section 6E2 Faulty injector Fuel injector in Section
533. rn and drum is grooved drum should be polished with fine emery cloth but should no be turned NOTE When drum is removed visually inspect wheel cylinder for brake fluid leakage Correct leaky point if any Brake shoe Where lining is worn out beyond service limit replace shoe If one of brake linings is to service limit all linings must be replaced at the same time Rear brake drum shoe thickness a Standard 7 1 mm 0 28 in Service limit 3 6 mm 0 14 in CAUTION Never polish lining with sandpaper If lining is polished with sandpaper hard particles of sandpaper will be deposited in lining and may damage drum When it is required to correct lining replace it with a new one INSTALLATION NOTE See NOTE at the beginning of this section For the details refer to the same item of the same section in the service manual mentioned in the FOREWORD of this manual not ing the following Before installing brake drum check outer diameter of brake shoes 3 If it is not within value as specified below adjust it to specification by turning adjuster 2 Rear brake shoe outer diameter a 253 3 253 7 mm 9 972 9 988 in Pawilever PARKING AND REAR BRAKE 5C 5 Wheel Cylinder INSTALLATION For the details refer to the same item of the same section in the service manual mentioned in the FOREWORD of this manual not
534. rning light turns off Insufficient amount of brake fluid Add brake fluid Brake fluid leaking from brake line Investigate leaky point correct it and add brake fluid Brake waming light circuit faulty Repair circuit Malfunctioning EBD system Check system referring to DIAG NOSIS of Section 5E2 ABS warning light does not turn on for 2 Bulb burnt out Replace bulb ABS waming light circuit open including check Check system referring to DIAG remains on after igni tion switch has turned on for 2 3 sec 3 sec after ignition relay NOSIS in Section 5E2 switch has turned ON ABS warning light Malfunctioning ABS Check system referring to DIAG NOSIS in Section 5E2 BRAKES PIPE HOSE MASTER CYLINDER 5A 1 SECTION 5A BRAKES PIPE HOSE MASTER CYLINDER WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components 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
535. rom to range Specification for time lag NU UD Less than 1 2 sec TN UR Less than 1 5 sec 781 42 AUTOMATIC TRANSMISSION 4 A T NOTE When repeating this test be sure to wait at least minute after select lever is shifted back to N range Engine should be warmed up fully for this test TROUBLESHOOTING Condition Possible cause When gt D time lag exceeds specification Low line pressure Worn forward clutch Low line pressure Worn direct clutch Worn reverse brake When time lag exceeds specification 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 operation when select lever is shifted down to L range 3 If engine brake fails to operate in above tests possible causes for such failure are as follows Check each part which is suspected to be the cause TROUBLESHOOTING Condition Possible cause Fails to operate when shifted down to 2 range Second coast brake defective Fails to operate when shifted down to L range Reverse brake defective P Range Test 1 Stop vehicle on a slope shift select lever to P range and
536. rom the low pressure side with the engine running 1 Check to make sure that hoses are routed properly after evacuating the system 2 Connect Low side hose 1 and High side hose 2 of the manifold gauge set 3 in position Thus open refrigerant container valve 4 to purge the charging line 3 Open the high pressure side valve 6 and charge refrigerant to system 4 After a while open the low pressure side valve 5 and close the high pressure side valve 6 WARNING Make sure that high pressure side valve is closed securely 5 Start engine and keep engine speed at 1500 rpm Then operate air conditioning NOTE Dual A C model must be operated rear A C system too 6 Charge A C system with refrigerant in vapor state At this time refrigerant container should be held upright 7 When refrigerant container 3 is emptied the use following procedure to replace it with a new refrigerant container 3 Close low pressure valve b Replace empty container 3 with a refrigerant container which has been charged with refrigerant When using refrigerant container tap valve 4 use following procedure for replacement i Retract needle 1 and remove refrigerant container tap valve 4 by loosening its plate nut 2 ii Install previously removed refrigerant container tap valve 4 to a new refrigerant container 3 18 24 AIR CONDITIONING OPTIONAL c Purge any air existing in center charging h
537. roper connection to ABS hydraulic recheck unit control module at terminal 136 25 4 If OK then measure voltage between con nector terminal 136 25 and body ground Is it 10 14 V 52 28 ANTILOCK BRAKE SYSTEM ABS DTC C1071 DTC 71 ABS Control Module E9625 WHT BLU 1 196 25 BEA d 19625 pi O cC20BBHHHBH CLL OBHBHHBHHHO CooBBBBBBE 196 23 138 22 3 ABS hydraulic uniicontrol module assembly 3 ABS pump motor 5 ABS hydraulic uniiconirol module connector 2 ABS pump motor relay 4 ABS fail safe relay DESCRIPTION This DTC will be set when an internal malfunction is detected in the ABS control module unit control module connector 2 If OK disconnect ABS hydraulic unit control module connector and check the followings Voltage E136 25 terminal 10 14 V Resistance between E136 22 and body ground Continuity Are the check result as specified above unit control module assembly INSPECTION Step Action Yes No 1 Clear all DTCs and check Go to Step 2 Could be a temporary Is it DTC 71 malfunction of the ABS control module 2 1 Check proper connection of ABS hydraulic Replace ABS hydraulic Repair and recheck ANTILOCK BRAKE SYSTEM ABS 5E2 29 On Vehicle Service Precautions When connector are connected to
538. roper connection to SDM at termi open in PNK or WHT wire nals 001 11 and 001 12 or 001 6 circuit and Q01 5 DTC B1045 3 If OK then measure resistance between Repair high resistance or Q01 11 and 001 12 terminals or Q01 open in BRN or LT GRN 6 and 001 5 terminals with connected wire circuit Special Tool B Is resistance 4 5 or less 108 42 AIR BAG SYSTEM Fig for STEP 1 and 2 1 Prelensioner hamoss STEERING WHEEL Fig for STEP 2 QoS 5001 67 For DTG B104T For DTC B1045 1 Special tool A 09932 75020 B 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1042 and B1046 Step Action Yes No 1 1 With ignition switch OFF remove center pil Go to step 2 lar inner gamish of applicable side then dis connect seat belt pretensioner connector 2 Check proper connection to applicable seat belt pretensioner at terminals Q11 Q12 connector 3 If OK then connect Special Tool B to seat belt pretensioner connector disconnected at the step 1 Wit
539. rve 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 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 For the descriptions items not found in this section refer to the same section of service manual mentioned in the FOREWORD of this manual Whether following systems parts are used in the particular vehicle or not depends on specifica tions Be sure to bear this in mind when performing service work EGR valve Warm up three way catalytic converter Heated oxygen sensor s Three way catalytic converter sensor MAP sensor CONTENTS On Vehicle Service 6A2 2 and Cylinders 6A2 21 Throttle Body and Intake Manifold 6 2 2 Unit Repair Overhaul 6A2 26 Exhaust Manifold 6A2 9 Engine Assembly 6 2 26 LH No 1 Bank 2n Main Bearings Crankshaft and Chain Tensioner 6A2 13 and Cylinder 6A2 30 Camshaft and Valve Lash Adjustei
540. rwise personal injury may result DEPLOYED AIR BAG INFLATOR MODULE AND ACTI VATED SEAT BELT PRETENSIONER WARNING 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 Do not apply water oil etc to deployed air bag infla tor module and to activate seat belt pretensioner 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 gloves and safety glasses should be worn Wash your hands with mild soap and water after com pleting the work Refer to the procedure described under DEPLOYED AIR BAG INFLATOR MODULE AND ACTIVATED SEAT BELT PRETEN SIONER DISPOSAL in this section for disposal AIR BAG SYSTEM 108 55 AIR BAG WIRE HARNESS AND CONNECTOR Air bag wire 1 can be identified easily as it is covered with a yellow protection tube Be very careful when handling it When an open in air bag wire harness 1 damaged wire hamess connector or terminal is found replace wire har ness connectors and terminals as an assembly When installing it be careful so that the air bag wire harness 1 is not caught or does
541. rwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS 8D 2 Rear Window Wiper and Washer 8D 2 For Vehicle with Cruise Control System 80 4 8D 3 Rear Wiper and Washer Switch 80 4 aa Rear Window Wiper and Washer pee For Vehicle without Cruise Control System Rear Wiper Intermittent Rela General Description Rear Wiper and Washer If Equipped On Vehicle Service Windshield Wipers Front wiper and washer 8D 4 8D 4 8D 2 WINDOWS MIRRORS SECURITY AND LOCKS General Description Rear Wiper and Washer If Equipped Rear Wiper Assembly Rear Wiper and Washer Switch For vehicle without cruise control system Rear Wiper Intermittent Relay For vehicle without cruise control system Rear Wiper and Washer Switch For vehicle with cruise control system WINDOWS MIRRORS SECURITY AND LOCKS 8D 3 On Vehicle Service Windshield Wipers Front wiper and washer Wiper motor As shown in the figure use a 12 V battery to connect its terminal to terminal A and its terminal to Black lead wire 2 If motor 1 rotates at a low revolution speed of 45 t
542. s AIC SWITCH When not operating OFF n if equipped When A C operating ON 6 1 26 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE at 41 position NORMAL CONDITION SCAN TOOL DATA CONDITION REFERENCE VALUE OTHER PNP SIGNAL Transmis With igniton switch ON selector lever in DEOR sion Range Switch for 4 position gt With ignition switch ON selector lever in R mm D 2 or L position FUEL TANK LEVEL ignition switch ON 0 100 ELECTRIC LOAD Ignition ON small light OFF OFF Ignition switch ON small ight ON ON VSS Vehicle speed sen At stop Mn Rg 9 P OMPH GEAR POSITION for 4 Ignition switch ON selector lever is shifted at m R D 2 or L range and vehicle stops THROT POS LEVEL 0 about idle position 1 2 3 4 5 6 or 7 about full open Throttle position level for appears according to throttle valve opening 4 SHIFT SOL 1 Tgnition switch ON CON Shift solenoid 1 Selector lever is shifted at P D command signal 2 or L range ON MON Shift solenoid 4 Vehicle stops monitor for 4 A T SHIFT SOL 2 B Tgnition switch ON CON Shift solenoid 2 Selector lever is shifted at P R N D command signal 2 or L range OFF MON Shift solenoid
543. s zones from 0 about idle position to 7 about full open and sig nals are assigned to each opening level zone PCM controls the automatic gear change of the automatic trans mission by using these signals according to the signal from the TP sensor GEAR POSITION 1ST 2ND 3RD or 4TH The gear position is determined on the basis of the command state signals generated from PCM to shift sole noids A and B 1 and 2 and displayed as shown in the table below SHIFT SOLENOID A SHIFT SOLENOID B 15T ON OFF 2ND ON ON DISFUAY 3RD OFF ON 4TH OFF OFF SHIFT SOL 1 CON MON Shift Solenoid 1 A Command monitor ON OFF CON ON ON command being output to shift solenoid 1 A CON OFF ON command not being output MON ON Electricity being passed to shift solenoid 1 A MON OFF Electricity not being passed 6 1 30 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE SHIFT SOL 2 CON MON Shift Solenoid 2 B Command monitor ON OFF CON ON ON command being output to shift solenoid 2 B CON OFF ON command not being output MON ON Electricity being passed to shift solenoid 2 B MON OFF Electricity not being passed TCC SOL CON MON Torque Converter Clutch Solenoid Command monitor ON OFF CON ON ON command being output to TCC solenoid CON OFF ON command not being output MON ON Electricity being passed to TCC solenoid MON OFF Electricity not being passed TRAN
544. s cold relief fuel pressure as fol lows 1 Place transmission gear shift lever in Neutral shift selector lever to P range for A T vehicle set parking brake and block drive wheels 2 Remove fuel pump relay 1 from its connector 3 Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it 4 Start engine and run it till it stops for lack of fuel Repeat cranking engine 2 3 times of about 3 seconds each time to dissipate fuel pressure in lines Fuel connections are now safe for servicing 5 Upon completion of servicing install fuel pump relay to relay box TA hand steering vehicle B Right hand steering vehicle 2 Fusebox Fuel Leakage Check Procedure After performing any service on fuel system check to make sure that there are no fuel leakages as follows 1 Tum ON ignition switch for 3 seconds to operate fuel pump and then tum it OFF Repeat this ON and OFF 3 or 4 times and apply fuel pres sure to fuel line till fuel pressure is felt by hand placed on fuel return hose 2 In this state check to see that there are no fuel leakages from any part of fuel system 6 1 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Engine Diagnosis General Description This vehicle is equipped with an engine and emission control system which are under control of ECM PCM The engine and emission control system in this vehicle are controlled by ECM PCM E
545. s gone and the ABS is free from any abnormal conditions If what has been repaired is related to the malfunction DTC clear the DTC once and perform test driving and confirm that no DTC is indicated ANTILOCK BRAKE SYSTEM ABS 5E2 9 ABS Warning Lamp Check 1 1 Tum ignition switch ON 2 Check that ABS warning lamp 1 comes ON for about 2 sec ABS 6 onds and then goes off If any faulty condition is found advance to Diagnostic Flow Table A B C or D 87 EBD Warning Lamp Brake Warning Lamp Check NOTE Perform this check on a level place 1 Tum ignition switch ON with parking brake applied 2 Check that EBD warning lamp brake warning lamp 1 is turned ON 3 Release parking brake with ignition switch ON and check that EBD warming lamp brake warning lamp goes off If it doesn t go off go to TABLE E in this section 52 10 ANTILOCK BRAKE SYSTEM ABS Diagnostic Trouble Code DTC Check Using ABS Warning Lamp 1 Perform ABS WARNING LAMP CHECK described above 2 Using service wire 4 connect diagnosis switch terminal 2 of monitor coupler 1 to ground 3 3 ignition switch ON 4 Read flashing of ABS waming lamp which represents DTC as shown in example below and write it down When more than 2 DTCs are stored in memory flashing for each DTC is repeated three times starting with the smallest DTC number in increasing order For details of D
546. scribed replace EVAP canister purge valve WARNING Do not suck the air through valve Fuel vapor inside valve is harmful 6 Connect vacuum hoses 7 Connect EVAP canister purge valve coupler securely ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 DTC P0460 Fuel Level Sensor Circuit High Input WIRING DIAGRAM CIRCUIT DESCRIPTION cei s Rot Lis 101 Goi 602 10 _ BLUWHT BLUWHT BLUWHT BLUWHT 7 BLUIWHT 103 E05 59 052 lt amp BLKIVEL 2 up WM W E6128 1 Fusllevel sensor 2 Fuel meter in combination meter 3 ECM PCM DTC DETECTING CONDITION AND TROUBLE AREA TROUBLE AREA Fuel level gauge or its circuit Fuel level sensor or its circuit ECM PCM DTC DETECTING CONDITION Fuel level sensor output voltage higher than specified value is detected for specified time 2 driving cycle detection logic DTC CONFIRMATION PROCEDURE NOTE Check to make sure that following condition is satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignitio
547. se a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section 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 AIR BAG SYSTEM 108 17 TABLE TEST DESCRIPTION Table A STEP 1 Check AIR BAG fuse STEP 2 Check power source circuit STEP 3 Check AIR BAG warning lamp circuit Table B STEP 1 Check combination meter power feed circuit STEP 2 STEP 3 Check AIR BAG warning lamp circuit STEP 4 STEP 5 STEP 6 Check AIR BAG bulb Table C and D STEP 1 Check AIR BAG monitor coupler STEP 2 Check diagnosis switch circuit for air bag system DIAGNOSTIC FLOW TABLE Check electrical connection check mechanism in SDM connector Check open in AIR BAG warning lamp circuit Check short from AIR BAG warning lamp circuit to power circuit Table A 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 Go to step 3 BLU RED wire between 2 Check proper connection to SDM at termi AIR BAG fuse and SDM nal 001 4 connector open
548. securely 5 Connect negative cable to battery 6 2 34 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE RESISTANCE 209 281 0322 0 32 20 40 60 80 68 104 140 176 F TEMPERATURE Intake air temperature IAT sensor REMOVAL 1 Disconnect negative cable at battery 2 Disconnect IAT sensor coupler 3 Remove IAT sensor from air cleaner case INSPECTION Immerse temperature sensing part of IAT sensor in water or ice and measure resistance between sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in the figure replace IAT sensor INSTALLATION 1 Clean mating surface of sensor and seal 2 on air cleaner case 2 Install IAT sensor 1 into seal 3 Connect connector to IAT sensor securely ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE 6E2 35 Throttle position sensor TP sensor INSPECTION 1 Disconnect negative cable at battery and coupler from TP sensor 4 2 Using ohmmeter check resistance between terminals under each condition given in table below If check result is not satisfactory replace TP sensor TP sensor specification TERMINALS RESISTANCE Between 1 and area 3 terminals 79 0 02 6 0 Between 1 and varying linearly according to 2 termin
549. select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition switch OFF if available 2 Clear DTC pending DTC and freeze frame data in PCM memory by using scan tool 3 Start engine and shift transfer lever to 2H or 4H range 4 Drive vehicle at 40 km h 25 mile h or more for longer than 10 sec or higher than 3500 r min engine speed with D range for longer than 10 sec 5 Stop vehicle and check DTC and or pending DTC AUTOMATIC TRANSMISSION 4 A T 7B1 33 TROUBLESHOOTING Step Action Yes No 1 Was A T DIAGNOSTIC FLOW TABLE in this to Step 2 Go to AT DIAGNOSTIC section performed FLOW TABLE in this sec tion 2 Output shaft speed sensor circuit check Go to Step 4 Go to Step 3 1 Remove PCM cover 2 With ignition switch OFF disconnect PCM connectors 3 Check for proper connection to output speed sensor at C51 1 22 and C51 1 23 terminals 4 If OK check resistance of sensor circuit Resistance between C51 1 22 and C51 1 23 387 473 at 20 68 F Resistance between C51 1 22 C51 1 23 and ground 1 or more Are check results satisfactory 3 Output shaft speed sensor check WHT wire Replace outp
550. servicing oM apt Dicebling att Salei Sera Tightening Torque Specification 3C1 12 Enabling air bag system 301 3 m C1 3C1 2 AIR BAG STEERING WHEEL AND COLUMN General Description This double tube type steering column has the following three important features in addition to the steering func tion The column is energy absorbing designed to compress in a front end collision The ignition switch and lock are mounted conveniently on this column With the column mounted lock the ignition and steering operations can be locked to inhibit theft of the vehi cle To insure the energy absorbing action it is important that only the specified screws bolts and nuts be used as designated and that they are tightened to the specified torque When the column assembly is removed from the vehicle special care must be taken in handling it Use of a steering wheel puller other than the one recom mended in this manual or a sharp blow on the end of the steering shaft leaning on the assembly or dropping the assembly could shear the plastic shear pins which maintain column length and position The driver air bag inflator module is one of the supplemental restraint air bag system components and is mounted to the center of the steering wheel During certain frontal crashes the air bag system supplements the restraint of the driver s and passenger s seat belts by deploying the air bags The air bag inflator module should be handled
551. shaft joint 3 and then remove shaft joint 3 from lower shaft assembly 1 3C1 10 AIR BAG STEERING WHEEL AND COLUMN INSTALLATION 1 Be sure that front wheels and steering wheel are in straight ahead position 2 Align flat part A of lower shaft assembly 1 with bolt hole B of shaft joint as shown in the figure Then insert shaft joint 1 into lower shaft assembly 2 3 Install shaft joint bolt lower shaft assembly side to shaft joint 2 Then tighten it by hand 4 Insert pinion shaft into lower shaft assembly lower joint 2 with slit 1 of lower joint marks 4 on pinion shaft 5 and gear case 6 aligned And then install lower shaft assembly lower joint bolt 3 to lower shaft assembly lower joint 2 Tighten it to specified torque Tightening torque Lower shaft assembly lower joint bolt a 25 2 5 kg m 18 0 Ib ft 5 Install steering shaft joint 2 to steering upper shaft 1 NOTE Be sue that front wheels and steering wheel are in straight ahead position 6 Install shaft joint bolt upper shaft assembly side 2 to shaft joint 1 Tighten shaft joint bolt upper shaft assembly side 2 to specified torque first and then shaft joint bolt lower shaft assembly side 3 to specified torque Tightening torque Steering shaft joint bolt b 25 N m 2 5 kg m 18 0 Ib ft AIR BAG STEERING WHEEL AND COLUMN 3C1 11 Checking Steering Colu
552. solenoid 1 is ON or monitor OS applicable No 62 signal ON is detected when it is OFF y pp Shift solenoid B 2 perfor G2ar change control from POM to AFT 2 driving Not P0756 does not agree with actual gear posi mance or stuck off cycles applicable tion of A T P0758 Monitor signal OFF is detected when 4 gryn No 63 Shift solenoid 2 electrical shift solenoid 2 is ON monitor oS applicable No 64 signal ON is detected when it is OFF Difference between vehicle speed AWD low switch circuit mal defected by VSS vehicle speed 5 driving Not P1875 i tion detected by output speed sensor and applicable compensated by 4WD low switch is y larger than specification For immobilizer control system Refer to Section 8G for diagnosis vehicle vehicle DTC NO DETECTED ITEM DETECTING CONDITION without with will set when detecting monitor monitor connector connector P1620 ECU code not registered NO code transmitted P1621 Immobilizer Control Mod 89 ute Refer to Section 8G P1622 P1623 Noa ECU code not matched NOTE DTC NO with is detected only vehicle without monitor connector DTC No with is detected only vehicle with monitor connector For marked No in DTC column it is used for vehicle with monitor connector DTC No 12 appears
553. specified torque Tightening torque Exhaust No 1 pipe nut b 50 N m 5 0 kg m 36 5 Ib ft Exhaust No 1 pipe Exhaust manifold Without WU TWC With WU TWC gt 6A2 12 ENGINE MECHANICAL H27 ENGINE 7 Reverse removal procedure to install front propeller shaft if removed When installing propeller shaft align match mark 1 Use following specification to torque universal joint flange Tightening torque Universal joint flange bolt c 55 N m 5 5 kg m 40 0 Ib ft 8 Connect EGR pipe to left No 1 bank exhaust manifold 1 9 Install exhaust manifold covers 2 10 Install oil level gauge guide 3 using new O ring 11 Install P S pump assembly 4 if it was removed Refer to POWER STEERING PUMP in Section 3B1 Adjust P S pump drive belt tension refer to POWER STEERING BELT CHECK AND ADJUSTMENT in Section 3B1 12 13 Connect oxygen sensor lead wire couplers Be sure to clamp its lead wires 1 HO28 1 Green connector 2 HO28 2 Black connector 14 Connect negative cable to battery Upon completion of installation start engine and check that no exhaust gas leakage exists ENGINE MECHANICAL H27 ENGINE 62 13 LH No 1 Bank 2nd Timing Chain and Chain Tensioner 907 Nm 1 1 kgm a 2 5 f OUI 10 8 45 Nm 4 5 kom A 5 SD mtem T LH bank 2nd tim
554. splayed indicated by ABS warning lamp flashing on SUZUKI ABS waming pattern DIAGNOSTIC ITEMS scan tool lamp 2 C1022 22 RF 2 1026 26 LF 4 L Wheel speed sensor circuit 3 gt or sensor ring 1032 32 RR 3 C1036 36 LR nur C1041 41 Inlet solenoid valve circuit B mam C1042 42 Outlet solenoid valve circuit 5 C1045 45 Inlet solenoid valve circuit LF 4 5 C1046 46 Outlet solenoid valve circuit C1055 55 n n Inlet solenoid valve circuit REAR 5 5 C1056 56 Outlet solenoid valve circuit 5 7 1057 57 Power source 1 C1061 61 ABS pump motor and or motor relay circuit 5 3 1063 63 Fail safe relay 1 C1071 ABS control module 52 14 ANTILOCK BRAKE SYSTEM ABS System Circuit were pee Ce Fl eux BLKIWHT oy Lf 4 m rt aT og i ovem s om 17 ORNIBLK Hz 20 PPUGRN 20 ES H i 1 2 H 14 LL 0 y cm re a0 1 AUN AUN
555. ssary be sure to activate them according to activation proce dures described in SECTION 10B before disposal The seat belt pretensioner immediately after activation is very hot Wait for at least half an hour to cool it off before proceeding the work With many service procedures gloves and safety glasses should be worn to prevent any possible irrita tion of the skin or eyes GENERAL INFORMATION 0A 5 CAUTION Even when the accident was light enough not to cause air bags to activate be sure to inspect sys tem parts and other related parts according to instructions under REPAIR AND INSPECTION REQUIRED AFTER AN ACCIDENT in SECTION 10B When servicing parts other than air bag system if shocks may be applied to air bag system compo nent parts remove those parts beforehand When handling the air bag inflator modules driver and passenger forward sensors 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 91 4 cm 3 feet or more never attempt disassembly or repair but replace it with a new one When grease cleaning agent oil water etc has got onto air bag inflator modules driver and pas senger wipe off immediately with a dry cloth Air bag wire harness can be identified easily as it is covered with a yellow protection tube Be very careful when handling it When an open in air bag wire harness damaged wire harness connector or t
556. ssure Light Oil pressure switc 8C 4 Brake Warning Light c Brake fluid level switch General Description Combination Meter On vehicle Service Fuel Meter Fuel Gauge Unit Fuel level sensor sender gauge Engine Coolant Temperature ECT Meter and Sensor 8C 2 INSTRUMENTATION DRIVER INFORMATION General Descri Combination Meter or 5 13 CHECK T Tachometer 8 Malfunction indicator ight 35 Charge warning light 2 Speedometer 3 Tum signal pilot ight RH 36 Brake fluid level parking brake and EBD waming light 3 Fuel level meter 10 AIR BAG warning light 37 POWER indicator light vehicle only 4 Engine coolant temperature meter 11 O D OFF light NT vehicle only 18 CRUISE indicator light 5 Tum signal pilot ight LH 32 Fasten seat belt light f equipped 39 immoblizer warning light f equipped 4WD indicator 18 High beam light 20 Shift position indicator A T vehicle if equipped 7 ABS warning fight 34 Engine pressure warning light COMBINATION METER INTERNAL CIRCUITS INSTRUMENTATION DRIVER INFORMATION 8 3 Air bag circuit EBD circuit il O2 BMY B10 AMS AS AM CT CHECK pom ENGINE oc BRAKE or ABS ABSci
557. stem 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 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 CAUTION The air conditioning system of this vehicle uses refrigerant HFC 134a R 134a None of refrigerant compressor oil and component parts is interchangeable between two types of AIC one using refrigerant CFC 12 R 12 and the other using refrigerant HFC 134a R 134a Be sure to check which refrigerant is used before any service work including inspection and mainte nance For identification between these two types refer to REFRIGERANT TY
558. stem refering to COOLING SYSTEM FLUSH AND REFILL in Section 6B 23 Refill front differential housing with gear oil if drained refer ring to MAINTENANCE SERVICE in Section 7E 24 Connect negative cable at battery 25 Check ignition timing and adjust as necessary referring to IGNITION TIMING CHECK AND ADJUSTMENT in Section 6F2 26 Verify that there is no fuel leakage water leakage oil leak age and exhaust gas leakage at each connection 27 Check wheel alignment referring to STEERING ANGLE in Section 3A 13 14 17 ENGINE MECHANICAL H27 ENGINE 6A2 21 Piston Piston Rings Connecting Rods and Cylinders T Top ting 5 Gonnecting rod 9 Piston pin circi V Teen Tore Clean bearing instaling surface when install 2 and ving 6 Connecting rod bearing cap 10 Cylinder block ore Clean bearing instaling surface when install 3 iring 7 Connecting rod bearing 11 Bearing cap nut Apply engine oi to siding Clean outer surface when install surface of each parts 4 Piston Piston pin 6A2 22 ENGINE MECHANICAL H27 ENGINE INSPECTION Cylinders Inspect cylinder walls for scratches roughness or ridges which indicate excessive wear If cylinder bore is very rough or deeply scratched or ridged rebore cylinder and use over size piston Using a cylinder gauge measure cylinder bore in thrust and axial directions at 2 positions 1 2 as shown in
559. ster switch ON with engine running at A C evaporator Signal output to 0 1 5V temperature sensor temperature AC A 13 Mp ECM A C ON ici n input more than approx 2 5 request signa 9 9 less than 2 5 V 5840 Q and refrigerant pressure switch is ON EXceptthe above mentioned with engine running Blower fan motor switch and A C or defroster switch ON with engine running at A C evaporator temperature sensor temperature Compressor Ground to input more than approx 2 5 C Maara engine Fig less than 2 5 V 5840 Q refrig youre erant pressure switch ON and signal input from ECM ON Exceptthe above mentioned with engine running BLU Ground to body AC B 4 Ye Sensorground 04 0V Engine running 1B 18 AIR CONDITIONING OPTIONAL Terminal Wire Circuit Measurement Normal value Condition ground E AIC evaporator temperature sen 3520 9 sor temperature at approx 15 C 59 F with engine running AIC evaporator temperature sen sor temperature at approx 4 5 C WHT Ground to 34 F with engine running AC B 2 sensor teras BLK engine Fig B If the temperature is less than evaporator ther 251V approx 4 5 C in this case com mistor input 5 855 0 pressor and condenser fan should be stop come back at more than approx 6 1 C less than 5403
560. surement is out of above specification replace master cyl inder assembly INSTALLATION NOTE See NOTE at the beginning of this section 1 Install master cylinder to brake booster 2 Tighten master cylinder attaching nuts to specified torque Tightening torque Master cylinder attaching nut b 13 Nem 1 3 kg m 9 5 Ib ft 3 Connect hydraulic lines to master cylinder and ABS actuator and tighten flare nuts to specified torque Tightening torque Brake pipe flare nut c 16 N m 1 6 kg m 12 0 Ib ft 4 Connect reservoir lead wire 1 5 Fill reservoir with specified brake fluid 6 After installing check brake pedal play and bleed air from system Refer to BRAKE PEDAL PLAY CHECK and BLEEDING BRAKE in Section 5 7 Perform brake test and check each installed part for fluid leakage 8 BRAKES PIPE HOSE MASTER CYLINDER Brake Booster T Brake master cylinder assembly 4 Push rod clevis 7 2 Brake booster assembly Nut 8 Plate 3 Gasket 6 Clevis pin 9 Seal CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON CHECK AND ADJUSTMENT The length of booster piston rod 1 is adjusted to provide speci fied clearance 0 between piston rod 1 end and master cylinder piston 2 1 Before measuring clearance push piston rod several times as to make sure reaction disc is in place 2 Keep inside of booster at atmospheric pressure for measure
561. t battery 2 Inspect belt for cracks cuts deformation wear and cleanli ness If any defect exists replace Check belt for tension Water pump and generator belt tension a 9 11 mm 0 35 0 43 in deflection under 100 10 kg or 22 Ib pres sure NOTE When replacing belt with a new one adjust belt tension to 7 9 mm 0 28 0 35 in 1 Grankshaft pulley 2 Water pump pulley 3 100N 10kg or 221b 3 If belt is too tight or too loose adjust it to specification by adjusting alternator position 4 Tighten alternator adjusting bolt and pivot bolts 5 Connect negative cable to battery WATER PUMP AND GENERATOR DRIVE BELT REPLACE MENT Replace belt Refer to Section 6B for replacement procedure of pump belt 0B 6 MAINTENANCE AND LUBRICATION POWER STEERING PUMP AND OR A C COMPRESSOR DRIVE BELTS IF EQUIPPED INSPECTION 1 Disconnect negative cable at battery 2 Inspect belt for cracks cuts deformation wear and cleanli ness If any defect exists replace Check belt for tension If belt tension is out of above specification adjust it referring to Section 1B or 3B1 Power steering pump and or A C compressor drive belt tension a 4 7 mm 0 16 0 28 in deflection under 100 N 10 kg 22 Ib pressure HZT engine with PIS system IBI 27 engine with PIS and system Crankshaft pulley PIS pump pulley AIG compressor pu
562. t 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 latch plate and ELR 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 bolt by hand to prevent cross threading Use only the correct seat belt anchor bolts and screws and tighten to the correct torque value Do not attempt 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 under ON VEHICLE SERVICE in Sec tion 10B WARNING When performing service on or around air bag system components or air bag system wiring disable the air bag system Refer to DISABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS under ON VEHICLE SERVICE 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 Refer to DISABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS under ON V
563. t diagnostic trouble codes according to the following priorities Diagnostic trouble codes DTCs other than DTC 0171 P0172 P0174 P0175 Fuel system too lean too rich DTC P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire detected and DTC P0400 EGR flow malfunction DTC P0171 P0172 P0174 P0175 Fuel system too lean too rich and DTC P0400 EGR flow malfunction DTC P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire detected Be sure to read PRECAUTIONS FOR ELECTRICAL CIR CUIT SERVICE in Section before inspection and observe what is written there PCM replacement When substituting a known good PCM check for following conditions Neglecting this check may result in damage to a good PCM All relays and actuators have resistance of specified value MAF sensor MDP sensor TP sensor and fuel tank pres sure sensor are in good condition Also the power circuit of these sensors is not shorted to the ground 781 10 AUTOMATIC TRANSMISSION 4 A T Automatic Transmission Diagnostic Flow Table Refer to the following pages for the details of each step Step Action Yes No 1 Customer Complaint Analysis 1 Perform customer complaint analysis refer ring to the next page Was customer complaint analysis performed according to instruction Goto Step 2 Perform customer com plaint analysis Diagnostic Trouble Code DTC and Freeze Frame Data Check Record and Clearance
564. t sealant with a brush BODY SERVICE 9 15 VIEW KK NN NN 7A Apply sealant 1071 Wipe off sealant in this section 7B Smooth out sealant with a brush 7D Sealant width more than 5 mm 0 20 in between a and Undercoating Anti corrosion Compound Application Area BODY SERVICE 9 17 vel i Y of Tado 5 EPI j 7 Y T a 1 7 VIEW Z 1 Si body or 100 mm 3 94 in 2 Side sill inner pply rust proof wax hot wax 50 3 Frame Apply rust proof wax high viscosity wax 50 um or more 4 Main floor 5 Sie body adir Far wheal housing 9 18 BODY SERVICE PI SOmm ii8in 1 Main floor Extension floor 757 100 mm 394 in 2 Front fender 7 Centerficor A Apply undercoating PVC 400 um or more 3 Front wheel housing 8 Rear floor B Add undercoating POV to cover edges and mating paris 4 Frame Side sil inner Dash panel 10 Side sil outer
565. t should be reinstalled in original position If rear A C unit or rear evaporator is replaced pour 25 25 of refrigerating oil to compressor suction side Rear Expansion Valve INSPECTION Refer to PERFORMANCE DIAGNOSIS in this section 18 30 AIR CONDITIONING OPTIONAL REMOVAL 1 Remove rear A C unit referring to REAR A C UNIT in this section 2 Disconnect solenoid valve connector 1 3 Loosen solenoid valve bracket mounting screws 2 4 Remove rear liquid pipe and rear suction pipe bolt 1 and then disconnect rear liquid pipe 2 and rear suction pipe 3 with solenoid valve and its bracket from rear expansion valve 4 5 Remove rear expansion valve 4 from rear A C unit 5 NOTE Cap open fitting immediately to keep moisture out of sys tem INSTALLATION Reverse removal procedure to install rear expansion valve Rear A C Evaporator Temperature Controller REMOVAL 1 Remove rear A C unit referring to REAR A C UNIT in this section 2 Disconnect rear A C evaporator temperature controller con nector 1 3 Remove rear A C evaporator temperature controller 2 from rear A C unit AIR CONDITIONING OPTIONAL 18 31 INSPECTION 1 Connect battery positive cable to terminal b and battery negative cable to terminal c as shown 2 Using ohmmeter check continuity between terminal a and terminal b at specified
566. tage of HO2S is 0 6 V or lower on average and its minimum voltage on average is 0 3 V or lower Min output voltage of HO2S is over 3 0 V or Max output voltage of HO2S is 0 74 V or higher on average and its min voltage on average is 0 33 V or higher Output voltage of HO2S 1 does not exceed 0 45 V for specified time 2 driving cycle detection logic ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 59 DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road ity of a traffic NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 C 18 F or higher Engine coolant temp 8 110 C 18 230 F Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and start engine 3 Increase vehicle speed to 55 km h 35 mph or more 4 Keep driving above vehicle speed for 2 min or more Change of vehicle speed is permitted in this step 5 Stop vehicle and run engine at idle speed for 1 min 6
567. tch Diagnosis in Section 7C1 Blown cylinder head gasket Cylinder head inspection in Section 6A2 6 1 34 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE Condition Possible Cause Correction Poor gasoline mileage Faulty spark plug improper gap heavy depos its and burned electrodes etc Spark plugs in Section 6F2 Fuel pressure out of specification DIAG FLOW TABLE B 3 in this section Faulty TP sensor ECT sensor or MAF sensor TP sensor ECT sensor or MAF sensor in Section 6E2 Faulty EGR system DTC P0400 DIAG FLOW TABLE in this section Faulty injector Fuel injector in Section 6E2 Faulty ECM PCM Inspection of ECM PCM and its circuit in this section Low compression Refer to the same item in HARD STARTING of this table Poor valve seating Valves inspection in Section 6A2 Dragging brakes Diagnosis in Section 5 Slipping clutch Diagnosis in Section 7C1 Thermostat out of order Thermostat in Section 6B Improper tire pressure Diagnosis in Section 3 Excessive engine oil consumption Sticky piston ring Piston cleaning in Section 6A2 Worn piston and cylinder Cylinders pistons and piston rings inspection in Section 6A2 Worn piston ring groove and ring Pistons and piston rings inspection in Section 6A2 Improper location of piston ring gap Pistons inst
568. ted Special Tool Is resistance 4 5 Q or less A Fig for STEP 1 and 2 B Fig for STEP 2 STEERING WHEEL Special tool A 09932 75020 B 09932 75010 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected AIR BAG SYSTEM 108 25 DTC B1016 Step Action Yes No 1 1 With ignition switch OFF disconnect passenger air Goto step 2 lgnition switch OFF bag inflator module connector behind the glove box Replace passenger air 2 Check proper connection to passenger air bag infla bag inflator module tor module at terminals in 007 connector Refer to PASSENGER 3 If OK then connect Special Tool B to passenger air AIR BAG INFLATOR bag inflator module connector disconnected at the MODULE in this section step 1 With ignition switch ON is DTC B1016 current 2 1 With ignition switch OFF disconnect SDM connector Substitute a Repair short from YEL 2 Check proper connection to SDM at terminals 001 7 known good RED wire circuit to YEL and 001 8 SDM and wire circuit or from YEL 3 If OK then measure resistance between 001 7 recheck RED or YEL wire cir 001 8 terminals with connected
569. tempera ture sensor A C evaporator ther mistor AIC controller faulty Check A C controller Expansion valve faulty Check expansion valve Drive belt slipping Check or replace drive belt Magnetic clutch faulty Check magnetic clutch Cool air does not come out or insuffi cient cooling A C sys tem normal operative Compressor faulty Check compressor Air in system Replace condenser dryer and then perform evacuation and charging Air leaking from cooling unit or air duct Repair as necessary Heater and ventilation system faulty Check air inlet box assembly Check heater control lever assem bly Check heater assembly Blower motor faulty Check blower motor Excessive compressor oil existing in A C sys tem Pull out compressor oil in sys tem circuit and replace compres sor Cool air does not comes out only inter mittently Wiring connection faulty Repair as necessary Expansion valve faulty Check expansion valve Excessive moisture in A C system Replace condenser dryer and then perform evacuation and charging controller faulty Check A C controller Magnetic clutch faulty Check magnetic clutch Excessive charge of refrigerant Check charge of refrigerant Cool air comes out only at high speeds Condenser clogged Check condenser Insufficient charge of refrigerant Che
570. temperature as shown Rear A C evaporator temperature controller specification Approximately 3 5 38 3 F B Approximately 5 0 C 41 F ON Continuity OFF No continuity B INSTALLATION Reverse removal procedure to install rear A C evaporator temper ature controller noting the following instruction When the rear A C evaporator thermistor temperature sen sor removed it should be reinstalled in original position Refrigerant Pipes and Hoses INSPECTION Use a leak tester to check hoses and pipes for any gas leakage Check each hose or pipe clamp for tightness Retighten or replace loose clamp as required if any REMOVAL CAUTION As soon as the above hose or pipe is disconnected cap its opened fitting to prevent moisture and dust from entering 1 Recover refrigerant by using recovery and recycling equipment Be sure to follow the instruction manual for the equipment The amount of compressor oil removed must be measured and the same amount must be added to the sys tem when reinstalling 2 Replace defective hose or pipe NOTE Remove EVAP canister and fuel tank cover if necessary INSTALLATION Reverse removal procedure to install refrigerant line noting the following instruction Evacuate and charge system Refer to EVACUATING and CHARGING in this section 18 32 AIR CONDITIONING OPTIONAL Solenoid Valv
571. ter probes and repeat step a c Check that one shows continuity and the other shows no continuity If there is continuity replace the rectifier Negative Rectifier a Using an ohmmeter connect one tester probe to each neg ative terminal 1 and the other to each rectifier terminal 2 b Reverse the polarity of the tester probes and repeat step a c Check that one shows continuity and the other shows no continuity If there is continuity replace the rectifier 6H 6 CHARGING SYSTEM Battery Battery type 55023 75023 95026 Rated capacity AH SHR 12 Volts 28 52 66 Electrolyte L US Imp pi 3 9 8 24 6 86 3 9 824 686 4 0 8 53 7 04 Electrolyte S G 1 28 when fully charged at 20 C 68 F Generator Type 105A type Rated voltage 12V Nominal output 105A Permissible max speed 18000 r min No load speed 1150 r min rpm Setting voltage 14210148 V Permissible ambient temperature 30 to 90 22 to 194 F Polarity Negative ground Rotation Clockwise viewed from pulley side Tightening Torque Specification Fastening part Tightening torque Nem kg m Ib ft Body ground bolt 8 08 60 Generator mounting bolts and nut 23 23 165 B terminal inner nut 36 0 37 30 B terminal outer nut 8 08 6 0 Generator pulley nut 111 112 815 Rear end frame nuts 45 0 45 35 Rear end cover n
572. terioration Replace as necessary Evap canister purge valve and its circuit inspection 1 Connect SUZUKI scan tool to DLC 1 with ignition switch OFF and disconnect vacuum hoses from each pipe 2 Tum ignition switch ON clear DTC and select MISC TEST mode on SUZUKI scan tool 3 Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool If check result is not described check vacuum hoses purge valve wire harness and connections EVAP canister purge valve Valve OFF A When blowing into hose A air should not come out of hose B Valve ON B When blowing into hose A air should come out of hose B Evap canister purge valve inspection 1 With ignition switch OFF disconnect coupler from canister purge valve 2 Check resistance between two terminals of EVAP canister purge valve 1 If resistance is as specified proceed to next operation check If not replace Resistance of EVAP canister purge valve 28 35 Q at 20 C 68 F 3 Disconnect vacuum hoses from intake manifold and its EVAP canister 4 With coupler disconnected blow into hose A 1 Air should not come out of hose B 2 6 1 102 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 5 Connect 12 V battery to EVAP canister purge valve 3 termi nals In this state blow hose 1 Air should come out of hose B 2 If check result is not as de
573. test should be carried out with 2 person a driver and tester on a level road Step Action Yes No 1 Was AUTOMATIC TRANSMISSION DIAG Go to Step 2 Go to AUTOMATIC NOSTIC FLOW TABLE performed TRANSMISSION DIAG NOSTIC FLOW TABLE in this section 2 ECT check Go to Step 3 Faulty ECT sensor its cir 1 Warm up engine to normal operating tem cuit or engine cooling sys perature tem 2 Check ECT using scan tool If OK substitute a known Is ECT more than 30 C 86 F good PCM and recheck 3 Perform running test under the following condi Faulty shiftsolenoid valve wire or GRN tions and check voltage between C51 1 2 termi its circuit or transmission RED wire shorted to nal of PCM coupler and ground C51 1 1 power circuit terminal of PCM coupler and ground If OK go to Step 4 OID off switch OFF O D OFF lamp OFF Normal mode in range Transfer 2H position Cruise control is not operated if equipped Drive vehicle with 4th gear condition refer ring to Gear shift diagram in this section Is each voltage about 0 V 4 070 off switch signal inspection Go to Step 5 Faulty O D off switch or its With ignition switch ON check voltage between circuit E61 33 terminal of PCM coupler and ground If OK substitute a known O D cut switch specification good PCM and recheck O D cut switch OFF Battery voltage cut switch ON 0 V 15 the result as specified
574. th no load after ra warming up BATTERY VOLTAGE ignition switch ON engine stopped 10 14V MAF Mass Air Flow At specified idle speed with no load after 26 45 95 Rate warming up 0 34 0 59 Ib min At 2500 r min with no load after warming up 10 16 gis 1 32 2 11 Ib min INJ PULSE WIDTH B1 __ At specified idle speed with no load after ae i 2 0 8 8 msec Fuel Injection Pulse warming up Width At 2500 r min with no load after warming up 22 32 msec ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 25 NORMAL CONDITION SCAN TOOL DATA CONDITION REFERENCE VALUE OTHER INJ PULSE WIDTH B2 specified idle speed with no Toad after warming up At 2500 r min with no load after warming up 22 82 msec THROTTLE POS With ignition switch ON warmed up engine Absolute Throttle Posi stopped accelerator pedal released tion With ignition switch ON warmed up engine 72 87 2 stopped accelerator pedal depressed fully TP SENSOR VOLT With ignition switch ON warmed up engine VA CUN TP Sensor Output Volt stopped accelerator pedal released With ignition switch ON warmed up engine 3 76 4 36 V stopped accelerator pedal depressed fully 025 1 51 At specified idle speed after warming up HO2S 1 Output Voltage 005 095 V 025 52 When engine is running at 2000 r min for 3 are HO2S 2
575. the figure It any of the following conditions is noted rebore cylinder Cylinder bore dia exceeds limit Difference of measurements at 2 positions exceeds taper limit Difference between thrust and axial measurements exceeds out of round limit Cylinder bore dia limit 88 050 mm 3 4665 in Taper and out of round limit 0 10 mm 0 004 in NOTE If any one of six cylinders has to be rebored rebore all six to the same next oversize This is necessary for the sake of uniformity and balance 80mm 136 inj 2 95mm 3741 Pistons Inspect piston for faults cracks or other damages Damaged or faulty piston should be replaced Piston diameter As shown in the figure piston diameter should be measured at a position 26 5 mm 1 04 in 1 from piston skirt end in the direction perpendicular to piston pin Piston diameter 87 970 87 990 mm 3 4634 3 4642 in Oversize 88 470 88 490 mm 0 50 mm 0 0196 in 3 4831 3 4839 in Standard ENGINE MECHANICAL H27 ENGINE 642 23 Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance Piston clearance should be within specification as given below If it is out of specification rebore cylinder and use oversize piston Piston clearance 0 02 0 04 mm 0 0008 0 0015 in NOTE Cylinder bore diameters used her
576. the malfunction DTC which was once displayed and then cleared can be detected indicated again when ignition switch is tumed ON proceed to Step 3 2 DRIVING TEST Test drive the vehicle at 40 km h for more than a minute and check if any trouble symptom such as abnor mal lighting of ABS warning light exists If the malfunction DTC is confirmed again at ignition switch ON driving test as described in above is not nec essary Proceed to Step 3 3 DIAGNOSTIC TROUBLE CODE CHECK Recheck diagnostic trouble code referring to DTC CHECK as shown in the following page 4 DIAGNOSTIC TROUBLE CODE FLOW TABLE According to Diagnostic flow table for the diagnostic trouble code confirmation in Step 3 locate the cause of the trouble namely in a sensor switch wire harness connector actuator assembly or other part and repair or replace faulty parts 5 DIAGNOSIS IN BRAKES SECTION Check the parts or system suspected as a possible cause referring to DIAGNOSIS in BRAKES section and based on symptoms appearing on the vehicle symptom obtained through Steps 1 a 1 b and 2 and repair or replace faulty parts if any 6 CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur e g wire harness connector etc referring to INTERMITTENT TROUBLE in GENERAL INFORMATION section and related circuit of trouble code recorded in Step 1 c 7 FINAL CONFIRMATION TEST Confirm that the problem symptom ha
577. 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 correct table to diagnose any air bag malfunctions Bypassing these procedures may result in extended diagnostic time incorrect diagnosis and incorrect parts replacements Never use air bag component parts from another vehicle If the vehicle will be exposed to temperatures over 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 9 SDM is dropped air bag inflator module is dropped from a height of 90 cm 3 ft or more seat belt pretensioner retractor assembly is dropped from a height of 30 cm 1 ft or more never attempt disassem bly 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 wil
578. tion number is not assign 8 GENERAL INFORMATION Warning Caution and Information Labels The figure below shows main labels among others that are attached to vehicle component parts When servicing and handling parts refer to WARNING CAUTION instructions printed on labels If any WARNING CAUTION label is found stained or damaged clean or replace it as necessary 1 Passengerseat belt label f equipped 5 Blank 3 Jacking instruction label 2 Radiator cap label 8 Airbag label on sun visor 10 Transfer label if equipped 3 Airbag label 7 Airbag label on sun visor Back side 1 Armrest abel on strap Air bag label and utiity vehicle label on sun visor Face side 3 Engins cooling fan label 8 Jacking instructions 12 Seat label if equipped Air bag label on driver air bag inflaton module 5 Airbag label on wire hamess Air bag label on combination switch and contact coll assembly 5 Airbaglabelon SOM i Airbag label on steering column cover 7 Pretensioner label on seat ball protensioner i Airbag label on passenger air bag inflator module MAINTENANCE AND LUBRICATION 0B 1 SECTION 0B MAINTENANCE AND LUBRICATION WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be pe
579. tion before starting to work and observe every precaution during work jes Nm 85m jr 25554 X 55 Nm 35 kom 25560 gt main 3 Upper anchor 3 Buckie 2 Lower anchor oes Tore 3 Retractor assembly REMOVAL Refer to the figure above to remove rear seat belts INSPECTION Check third rear seat belt in the same way as when inspecting second rear seat belt Refer to SECOND REAR SEAT BELT in this section INSTALLATION Install in reverse order of removal noting the followings Seat belt anchor bolts should have an unified fine thread 7 16 20 UNF Under no circumstances should any different sized or metric screw threads be used 10A 8 SEAT BELT Tightening Torque Specifica n Fastening part Tightening torque Nem kg m lb ft Upper and lower anchor bolt 35 35 255 Retractor assembly bolt 35 35 255 Retractor assembly screw 55 0 55 40 Buckle bolt 35 35 255 AIR BAG SYSTEM 108 1 SECTION 10B AIR BAG SYSTEM WARNING 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 activation of the system
580. tion section Trim instalation hole Hole in front door lower hinge at rear 10 Rear door striker lower section instalation hole Trim instalation hole mim Trim instalation hole Scuff installation hole at rear end Installation hole for front seat front inside 919 installation hole Installation hole for front seat rear inside h Hole in rear door upper hinge in upper part Hole to hole distance a c 982mm 88 66 in 1511 mm 59 49 in j o 649 mm 25 55 in 1390 mm 54 72 in 620 mm 84 41 in 1095 mm 43 11 in 755 mm 29 72 in 1085 mm 42 72 in 1475 mm 58 07 in 1406 mm 55 35 in 1099 mm 4327 in 1513 mm 59 57 1012 mm 39 84 in 1521 mm 59 88 in 1273 mm 50 12 in 1545 mm 60 83 in 901 mm 35 47 in 1110 mm 43 70 in 800 mm 31 50 in 1547 mm 60 91 in m o 2037 mm 80 20 in 1110 mm 43 70 in 806 mm 37 73 in 1036 mm 40 79 in 1511 mm 69 49 in 9 6 BODY SERVICE Hole in front door upper hinge at rear gt in rear door lower hinge in lower part Hole in front door lower hinge at rear Assistant grip front installation hole Trim installation dip hole Trim installation hole 7 ig hole Door striker ower section installation ho
581. tisfactory 6 lgnition timing inspection Go to Step 7 Adjust or check system 1 Check ignition timing referring to Section related parts 6F2 Is check result satisfactory 7 EGR system inspection Go to Step 8 Repair or replace 1 Check EGR system referring to Section 6E2 Is check result satisfactory 8 Fuellevel sensor inspection Go to Step 9 Repair or replace 1 Check fuel level sensor referring to Section 6E2 Is check result satisfactory 9 Check engine mechanical parts or system Check wire hamess and Repair or replace which can cause engine rough idle or poor per connection of ECM PCM formance ground ignition system Engine compression See Section 6A2 fuel injector for inter Valve lash or lash adjuster See Section mittent open and short 6A2 Valve timing Timing belt or chain installa tion See Section 6A2 Are they in good condition 6 1 82 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DTC P0325 DTC No 43 Knock Sensor Circuit Malfunction CIRCUIT DESCRIPTION rea 651 33 PERS es Z M Knock sensor 2 ECM POM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when one of the following conditi
582. to always wear goggles Should it occur that HFC 134a R 134a strikes your eye s consult a doctor immediately Do not use your hand to rub the affected eye s Instead use quantities of fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point Obtain proper treatment as soon as possible from a doctor or eye specialist Should the 134 R 134a liquid come into contact with your skin the affected area should be treated in the same manner as when skin is frostbitten or frozen Refrigerant must not be handled near where welding or steam cleaning is performed Refrigerant should be kept at a cold and dark place It should never be stored where a high temper ature is anticipated e g where exposed to direct sun light close to fire or inside vehicle including trunk room Avoid breathing fumes produced when HFC 134a R 134a is burned Such fumes may be hazardous to health Operation Procedure for Charging A C with Refrigerant Start evacuating lt 20 minutes Stop evacuating Inspect and repair connections Wait 10 minutes Check system for pressure tightness If gauge shows abnormal conditions J Charge proper amount of refrigerant Charge with refrigerant amp in gas form Amount of refrigerant Dual A C model 750 509 1 6520 11 Ib 26 45 1 76 oz Single A C model 500 509 1 12
583. tool A 09900 06107 9 Remove magnet clutch coil 1 INSTALLATION 1 Install magnet clutch coil 2 NOTE Protrusion on under side of magnet clutch coil 2 must match hole in compressor assembly 3 to prevent move ment and correctly locate lead wire 2 Using special tool install new circlip 1 as shown Special tool A 09990 06107 3 Install clamp portion and ground terminal of lead wire AIR CONDITIONING OPTIONAL 18 43 4 Install magnet clutch 1 a Set magnet clutch squarely over clutch installation boss b Place special tool onto clutch bearing Ensure that edge rests only on inner race of bearing Special tool A 09991 06010 c Install new circlip CAUTION Be careful not to scratch bearing seal 5 Adjust clearance between armature plate 1 and magnet clutch 2 by putting shim s on compressor shaft Standard clearance between armature plate and magnet clutch a 0 35 0 6 mm 0 014 0 023 in 6 Tighten new armature plate nut 1 to specified torque Tightening torque Armature plate nut a 18 N m 1 8 kg m 13 0 Ib ft Special tool A 09920 53740 2 Amature plate 7 Install compressor to vehicle Refer to COMPRESSOR ASSEMBLY in this section 18 44 AIR CONDITIONING OPTIONAL Required Service Materials Material Recommended SUZUKI product Part Number Use
584. tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and start engine 3 Increase vehicle speed to speed recorded as freeze frame data V 5 km h when detecting misfire 4 Keep driving above vehicle speed for 5 min 5 Stop vehicle and check DTC or pending DTC by using scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 81 TROUBLESHOOTING Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed FLOW TABLE in this section 2 lgnition system inspectio Go to Step 3 Faulty ignition coil wire 1 Check spark plug and ignition spark of cylin harness or other system der where misfire occurs referring to IGNI parts TION SYSTEM section Is it in good condition 3 Fuel injector circuit inspection Goto Step 4 Check coupler connec 1 Using sound scope check each injector tion and wire harness of operating sound at engine cranking or injector not making oper idling ating sound and injector Do all injectors make operating sound itself If OK substitute a known good ECM PCM and recheck 4 Fuel pressure inspection Go to Step 5 Repair or replace 1 Check fuel pressure referring to TABLE B 3 in this section Is check result satisfactory 5 _ Fuel injector inspection Go to Step 6 Replace 1 Check fuel injector s referring to Section 6E2 Is check result sa
585. tor assembly CRUISE indicator CRUISE indicator lamp circuit Refer to CRUISE INDICATOR LAMP lamp fails to light up CIRCUIT CHECK in this section or remains ON Cruise control module power and ground Refer to CRUISE CONTROL MODULE circuits POWER AND GROUND CIRCUIT CHECK in this section Actuator assembly faulty Replace actuator assembly 8E 6 CRUISE CONTROL SYSTEM Condition Possible Cause Correction Vehicle speed can not be set Actuator cable play maladjusted or actua tor cable faulty Refer to CRUISE CABLE PLAY INSPECTION AND ADJUSTMENT in this section Main switch COAST SET RESUME ACCEL and CANCEL switch circuits faulty Refer to CRUISE MAIN SWITCH COAT SET RESUME ACCEL AND CANCEL SWITCHES CIRCUITS CHECK in this section VSS circuit faulty Refer to VSS CIRCUIT CHECK in this section Stop lamp switch circuit faulty Refer to STOP LAMP SWITCH WITH PEDAL POSITION SWITCH CIRCUITS CHECK in this section Transmission range switch circuit 4 A T model only faulty Refer to TRANSMISSION RANGE SWITCH CIRCUIT CHECK in this sec tion Clutch pedal position switch circuit faulty Refer to CLUTCH PEDAL POSITION SWITCH CIRCUIT CHECK in this sec tion Cruise control module power and ground circuits faulty Refer to CRUISE CONTROL MODULE POWER AND GROUND CIRCUIT CHECK in this section
586. tor circuit in air bag harness STEP 3 Check whether malfunction is in contact coil or driver air bag inflator module AIR BAG SYSTEM 108 29 DIAGNOSTIC FLOW TABLE DTC B1021 Step Action Yes No 1 1 With ignition switch OFF disconnect contact coil con Go to step 2 Go to step 3 nector located near the base of the steering column 2 Check proper connection to contact coil at terminals in 006 connector 3 If OK then connect Special Tool B to contact coil connector disconnected at step 1 With ignition switch ON is DTC B1021 current 2 1 With ignition switch OFF disconnect SDM connector Substitute a known Repair high resis 2 Check proper connection to SDM at terminals Q01 9 good SDM and tance or open in and 001 10 recheck GRN or GRN RED 3 If OK then measure resistance between 001 9 and wire circuit Q01 10 terminals with connected Special Tool Is resistance 4 5 Q or less 3 1 With ignition switch OFF disconnect Special Tool B Ignition switch OFF Ignition switch OFF then reconnect contact coil connector located near Replace contact coil Replace driver air the base of the steering column assembly Referto bag inflator module 2 Remove driver air bag inflator module from steering COMBINATION Refer to DRIVER wheel Refer to DRIVER AIR BAG INFLATOR SWITCH CON AIR BAG INFLA MODULE in Section 3C1 TACTCOILAND MODULE in 3 Check pr
587. ttery 1 3 Disconnect vacuum hose 1 from fuel pressure regulator 4 Remove fuel pressure regulator 1 from fuel delivery pipe 3 CAUTION A small amount of fuel may be released when it is from delivery pipe Place a shop cloth under delivery pipe so that released fuel is absorbed in it 5 Disconnect fuel return hose 2 from fuel pressure regulator CAUTION A small amount of fuel may be released when hose is dis connected Cover hose to be disconnected with a shop cloth 62 26 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE INSTALLATION For installation reverse removal procedure and note the follow ings Use new O ring Apply thin coat of gasoline to O ring to facilitate installation Tighten fuel pressure regulator 1 bolts to specified torque Tightening torque Fuel pressure regulator bolt a 10 N m 1 0 kg m 7 5 Ib ft With engine OFF and ignition switch ON check for fuel leaks around fuel line connection Fuel injector ON VEHICLE INSPECTION 1 Using sound scope 1 or such check operating sound of injector when engine is running or cranking Cycle of operating sound should vary according to engine speed no sound or an unusual sound is heard check injector cir cuit wire or coupler or injector 2 Disconnect connector from injector connect ohmm
588. tured ON NOTE When a trouble occurs in the above areas and disappears soon while the diagnosis switch terminal is ungrounded and the engine is running malfunction indicator lamp 1 lights and remains ON as the trouble exists but it turns OFF when the normal condition is restored 6 1 10 ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE DATA LINK CONNECTOR DLC 5 DLC 1 is in compliance with SAEJ1962 in its installation posi tion the shape of connector and pin assignment K line of ISO 9141 is used for SUZUKI scan tool to communicate with ECM PCM ABS control module and air bag SDM SUZUKI serial data line is used for SUZUKI scan tool to communicate with Immobilizer control module 16 15 se 13 12 11 10 9 Br gt 3 SUZUKI Serial data ine 4 Kline 01150 9141 5 D Body ground ground Precaution in Diagnosing Trouble Don t disconnect couplers from ECM PCM battery cable from battery ECM PCM ground wire harness from engine or main fuse before confirming diagnostic information DTC freeze frame data etc stored in ECM PCM memory Such disconnection will erase memorized information in ECM PCM memory Diagnostic information stored in ECM PCM memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool Before using scan tool read its Operator s Instruction Manual carefully to have good understanding
589. tute a known wire good PCM and recheck TROUBLESHOOTING AUTOMATIC TRANSMISSION 4 A T 781 25 Table B 4 POWER Light Circuit Check POWER Light Comes ON Steadily WIRING DIAGRAM Refer to TABLE B 3 in this section Step Action Yes No 1 Check Power Normal change switch position Is switch button at Normal position Go to Step 2 Set Power Normal change switch at Nor 1 Remove Power Normal change switch 2 Check continuity between switch terminals 4 and 5 under each condition below Normal position No continuity Power position Continuity Is check result satisfactory mal position 2 Check lamp circuit for short GRY BLU circuit Go to Step 3 1 Tum ignition switch OFF and disconnect PCM _ shorted to ground connectors 2 Tum ignition switch ON Does POWER lamp come ON steadily 3 Check Power Normal change switch circuit Go to Step 4 Check PCM ground 1 Check resistance between terminal E61 31 of dis circuit for open connected PCM connector and body ground with If ground circuit is OK P N change switch OFF substitute a known Is continuity indicated good PCM and recheck 4 Check Power Normal change switch for operation ORN BLU circuit Replace Power Normal shorted to ground change switch A for Step 1 B for Step 4 SS 781 26 AUTOMATIC TRANSMISSION 4 A T DTC P0705 DTC NO 72
590. uit inspection Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE in Section 0A before circuit inspection and observe what is written there For system circuit refer to the figure of GENERAL DESCRIPTION in this section For terminal arrangement refer to amp WD CONTROL CIRCUIT INSPECTION in this section 4 DIFFERENTIAL FRONT Flow table Step Action Yes No 1 Tum ON ignition switch but engine at stop and Go to step 2 Airouble has occurred check malfunction indicator lamp at some place Repair Does lamp light up it referring to MALFUNCTION INDI CATOR LAMP CHECK ENGINE LAMP CHECK in DIAGNOSIS of Sec tion 6 2 Check 4WD switch circuit Go to step 3 Check 4WD switch Turn ignition switch ON and check that voltage refer to Section 7A between terminal C51 3 7 and terminal C51 3 17 BLK ORN and BLK ground is as follows circuits of AWD switch When transfer shift lever is N or 2H 10 14 If OK substitute a When transfer shift lever is in 4L or4H 0 1 V known good ECM Is the check result satisfactory PCM and recheck 3 Check power supply Go to step 4 Check RED circuit If 1 Turn ignition switch ON it is OK substitute a 2 Check voltage between C51 1 9 and C51 3 17 known good ECM ground The check results should be as follows PCM and recheck When transfer shift lever is in Nor2H 0 1V When transfer shift lever is in 4L or 4H 10
591. ulated valve f Closest value to e refer to Step 5 Special tool G 09925 18011 H 09927 66010 Available shim thickness 1 12 1 15 1 18 1 21 1 24 1 27 1 30 and 0 3 mm 0 044 0 045 0 046 0 047 0 048 0 049 0 050 and 0 012 in 3 Drive beval pinion 7 With new pinion spacer 3 inserted as shown in the figure install front bearing 5 to differential carrier 4 NOTE Make sure to use new spacer for reinstallation Apply differential oil to bearings 1 Drive bevel pinion 2 Rear bearing 8 Using special tool and plastic hammer drive oil seal 2 into differential cartier 1 till it becomes flush with carrier end Then apply grease A to oil seal lip Grease 99000 25010 Special tool 1 09951 18210 DIFFERENTIAL REAR 7F 17 9 While tightening flange nut gradually with special tool and power wrench 4 10 magnification 1 set preload of pinion to specification NOTE Before taking measurement with spring balance 3 or torque wrench 4 check for smooth rotation by hand On measuring preload rotate the drive bevel pinion about 1 rotation per 2 seconds Be sure to tighten gradually and carefully till specified starting torque is obtained Turning back overtightened flange nuts should be avoided Pinion bearing preload 9 1 7 Nem 9 0 17 0 kg cm 7 8 14 7 Ib in Spring measure reading with specia
592. unction WIRING DIAGRAM 1 csi r evuvet ewean I a e 2 eet csta 051 2 NUUA NI T 2 shaft speed sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Input speed sensor detected speed is lower than spec ification while vehicle running under all of the following conditions 2 driving cycle detection logic input PCM at higher than 10 km h 7 mile h with 1st gear in D range for 1 sec or more at higher than 20 km h 13 mile h with 2nd gear in D range for 2 sec or more at higher than 30 km h 20 mile h with 3rd gear in D range for 2 sec or more speed sensor and its circuit 781 30 AUTOMATIC TRANSMISSION 4 A T DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition switch OFF if available 2 Clear DTC pending DTC and freeze frame data by using scan tool 3 Start engine and tum O D cut switch ON 4 Shift select lever to D range and start vehicle 5 Keep vehicle speed at higher than 10 km h 7 mile h with 1st gear
593. up engine to normal operating temperature 3 Stop engine and connect duty meter 3 between duty output terminal and ground terminal of monitor connector 1 4 Using service wire 2 ground diagnosis switch terminal in monitor connector 5 Set tachometer 6 Start engine and warm it up completely 7 Check IAC duty and idle air control system referring to Diag nostic Flow Table B 4 IDLE AIR CONTROL SYSTEM CHECK in this section X Output duty select switch terminal B Diagnosis switch terminal C Blank D E F Ground terminal x Test switch terminal Duty output terminal AIC OFF AIC ON Engine idle speed 700 50 r min 750 50 r min duty at specified 5 40 0 7 5 6 V idle speed when battery voltage is 14 NOTE IAC duty can be checked roughly by using voltmeter 1 AC duty to voltage relation is as follows ON DUTY METER OFF DUTY VOLT METER INDICATION INDICATION INDICATION Vv 0 10 0 50 50 0 5x VB 100 0 VB OFF DUTY METER is such duty meter that indicates approx 100 when terminal voltage is approx 0 V represents battery voltage while engine of vehicle being checked is running 8 Remove service wire from monitor connector 9 Install cap to monitor connector 10 Check that specified engine idle speed is obtained with ON if vehicle is equipped with A C If not check
594. urcan TO ae _ i p EJ Php D wv H 1 2 15 1 1 Batey TI ABS fail safe transistor Solenoid valve transistor 21 ECM and SDM if equipped 2 Mai fuss T2 ABS pump anor 22 3 onion wich 5 Pure maior 25 Siop lamp ach 2 Grout fuses 34 Solenoid val 24 G sensor For AWD vein 5 Combination maier 35 Diagnosis monitor pir 25_AWD amp For wail or 6 ABS waring amp 36 speed sensor 26 ECH PCM For D veio on 7 Brake waring np CEBD wamingiamp 17 1 wheel spoed sensor 27 AWD swich For vail 8 Wammgmprvermodie oraBS 18 Fighttont speed sensor 28 ECM PCM S ABS seem 19 speed sensor 30 Terina arrangement E138 for 20 Data irk connector ABS yas incon mode TERMINAL RUT TERMINAL ROUT 7 ideup sonal 34 ABS warning lamp 2 Stop amp swch 15 Lefton whee spoed sena GJ 3 Flo ron whee speed sensor G 38 efron whee speed sensor E 4 Fight rot wheel speed sensor C 17 AWD switch 5 E 18 8 Flgrear whee speed sensor C eras 19 beter whee speed sensor E136 7 Right rear wheel speed sensor 20 Lefrenr wheel speed sensor E g 71 Data Ink connector 9 22 Ground for ABS pump motor T0 Brake waring amp ERD waning amy 23 ABS pump motor reay 11 G sensor For vehicle only 24 Ground for ABS control module 12 Diagnosis switch terminai 25 ABS f
595. ure Under Body Dimensions Body Dimensions Seat Second Seat Third Seat If Equipped Paint and Coatings 9 2 BODY SERVICE Glass Windows and Mirror Quarter Window REMOVAL AND INSTALLATION Refer to WINDSHIELD in this section as removal and installa tion procedures are basically the same However note the follow ings Before applying primer to glass edge install molding accord ing to installing position shown in the figure Observe the following precautions when applying adhesive along glass edge Adhesive should be applied evenly especially in height Be careful not to damage primer Press glass against body quickly after adhesive is applied Adhesive amount specification quarter window Height a 12 mm 0 47 in Width b 8 mm 0 31 in Width c 16 mm 0 63 in for glass front rear and upper section Width c 14 mm 0 55 in for glass bottom section Position d 177 mm 6 97 in for left side glass front section Position d 75 mm 2 95 in for right side glass front section Position d 29 mm 1 15 in for glass rear section Position d 39 mm 1 54 in for glass upper section Position d 22 mm 0 87 in for glass bottom section T Spacer 4 Adhesive 2 Glass 5 Primer 3 Molding amp Ceramic print Under Body Dimensions Body Structure BODY SERVICE 9
596. ure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected Table Step Action Yes No 1 1 Check AIR BAG monitor coupler Remove service wire Go to step 2 15 it connected diagnosis switch terminal in AIR BAG monitor coupler and body ground by ser vice wire 2 1 With ignition switch OFF disconnect SDM Substitute a known good Repair short from PPL connector SDM and recheck wire circuit to ground 2 Measure resistance between 001 15 ter minal of SDM connector and body ground 15 circuit open Fig for STEP 2 Special tool A 09932 75020 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected 108 20 AIR BAG SYSTEM Table D Step Action Yes No 1 1 Inspect connection between diagnostic Go to step 2 Properly connection diag switch terminal on AIR BAG monitor cou pler and body ground by service wire Is it securely connected between them by ser vice wire nostic switch terminal on AIR BAG monitor cou pler and body ground by service wire 2 1 Disconnect SDM connector from SDM 2 Check for proper connection at PPL wire Q01 15 terminal of SDM connector
597. ure to read SERVICE PRECAUTIONS beforehand To avoid an accidental deployment this work should be performed by no more than one person Since the smoke is produced when air bag is deployed and pretensioner is activated select a well ventilated area The air bag inflator module and seat belt pretensioner will immediately deploy activate when a power source is connected to it Wear safety glasses throughout this entire deployment activation and disposal procedure Wear suitable ear protection when deploying air bag activating pretensioner Also advise those who are in the area close to deployment activation 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 power source before connecting deployment harness to the air bag inflator module and seat belt pretensioner Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed and the pretensioner is to be activated 10B 66 AIR BAG SYSTEM Deployment Activation Outside Vehicle Use this procedure when the vehicle itself is used again only the air bag inflator module s and seat belt pretensioner s are dis posed 1 Tum ignition switch to LOCK position remove key and put on safety glasses 2 Check that there is no open short
598. ust 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 For the description items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual When inspecting and servicing vehicle equipped with ABS be sure to refer to section 5E2 first All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal CONTENTS 52 Diagnosis Table Diagnosis 5 2 BRAKES Diagnosis Table For the item not found in this column refer to the same item of the same section in the service manual men Diagnosis tioned in the FOREWORD of this manual Condition Possible Cause Correction Brake warning light turns on after engine start Parking brake applied Release parking brake and check that brake wa
599. ut C C10 96 9 Ede COMBINATION METER COUPLERS a iere ri 18 EEEE EEEE Palas shii NOTE Terminal arrangement of coupler viewed from harness side TAJ CouplerA 18 Coupler B TC Coupier G T To Cruise control module 1 equipped GRYYEL 1 Todoorswitch drive side 1 To ground BUK 2 Blank 2 To transmission range switch GRNIBLU 2 To ECM PCM for A T vehicle BRN AIT vehicle only if equipped L To ignition switch BLXWHT 3 To transmission range switch GRNIORN 3 To ignition switch PPURED vehicle only if equipped 2 4 Bank 4 To transmission range switch YEL GRN 4 To brake fluid level switch AIT vehicle only if equipped D 5 control module f equipped BLUJORN To transmission range switch ORN BLU 5 To parking brake switch PPL vehicle only if equipped 5 POM AIT vehicle only GRY BLU 6 To transmission range switch ORNIGRN 6 To seat belt switch GRYRED AIT vehicle only if equipped P 7 Te ABS control module f equipped 7 Totansmission range switch 7 To generator WHIURED vehicle only if equipped amp Teves BLUVEL 8 Toillumination control module RED GRN 8 To engine oil pressure switch YEL BLK
600. ut shaft 1 With ignition switch OFF disconnect output open or shorted to speed sensor shaft speed sensor connector ground 2 Check for proper connection to output shaft speed sensor at each terminals 3 If OK then check resistance of output shaft speed sensor Are measured values as specified in Step 2 4 visually output shaft speed sensor and Intermittent trouble Clean repair or replace sensor rotor for the followings faulty PCM No damage Check for intermittent No foreign material attached referring to INTERMIT Correct installation TENT AND POOR CON Are they in good condition NECTION in Section REFERENCE Connect oscilloscope between C51 1 23 and C51 1 22 of PCM connector connected to PCM and check output speed sen sor signal TA Oscilloscope waveforms at about 40 km h 25 mile h 5msiDiv 781 34 AUTOMATIC TRANSMISSION 4 A T DTC P0743 DTC NO 65 66 TCC Lock Up Solenoid Electrical WIRING DIAGRAM esca esi 512 CECHRCHEERCIE ai ALA MWK 8 Shift sclencid A i Shift solenoid i solenoid DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Voltage at terminal C51 1 8 of PCM is high while TCC solenoid OFF is c
601. uts 45 0 45 35 Stator stud bolts 98 10 70 Drive end bearing plate screws 3 0 0 30 22 Rectifier screws 30 0 30 22 Regulator and brush holder screws 20 0 20 15 Terminal plate bolt 39 0 39 30 EXHAUST SYSTEM 6K 1 SECTION 6K EXHAUST SYSTEM CAUTION Be sure to use UNLEADED FUEL for the catalytic converter equipped vehicle Use of LEADED FUEL will affect performance of the catalytic converter adversely to a great extent NOTE For the descriptions items not found in this section refer to the same section of service manual mentioned in the FOREWORD of this manual CONTENTS On Vehicle Service 6 2 Components 6 2 EXHAUST SYSTEM On Vehicle Service Components TYPE WITH WELD BOLT AT MUFFLER FRONT FLANGE A U 45 Nm 4 5 kom Mo e we f LA 10 8 45 m 4 5 kg m TA Exhaust manifold without WU TWO 4 Heated oxygen sensor i i equipped 7 Exhaust pipe bolt TI Muflor tail pipe 32 Exhaust manifold with WU TWO 5 Exhaust pipe gasket 8 32 Muffior gasket 2 Seal ring 61 Exhaust No 2 pipe without WU TWO 8 1 Weld bolt 18 Exhaust pipe stiffener 31 Exhaust No 1 pipe without WU TWG 62 Exhaust No 2 pipe wihWU TWC 9 Muffler mounting V eene Tore 32 Exhaust NO pipe win WUTWC 63 Exhaust No2 pipa ioi TWC 10 Heated oxygen sensor2 Do not reuse equipped TYPE WITHOUT WELD BOLT A
602. valve AT equipped 18 Three way catalytic converter 38 Vehicle speed sensor 57 solenoid valve equipped 20 Grankshaft position sensor 37 Combination meter 58 AIT input speed sensor AT equipped 21 Fue pump 38 AIC condenser fan relay f equipped 59 AT vehicle output speed sensor AT 6E2 6 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE Air Intake System The main components of the air intake system are air cleaner mass air flow sensor air cleaner intake air pipe throttle body intake collector idle air control valve and intake manifold The air by the amount corresponding to the throttle valve opening and engine speed is filtered by the air cleaner passes through the throttle body is distributed by the intake manifold and finally drawn into each com bustion chamber When the idle air control valve is opened according to the signal from ECM PCM the air bypasses the throttle valve through bypass passage and is finally drawn into the intake manifold 1 Airdeaner amp _POV hose 11 Breather hose 16 valve and fast idle control system EGR 2 sensor 7 Brake booster 12 MAF sensor T7 valve Engine coolant 3 Resonator 8 Fuel pressure 18 EGR valve 18 Thermo WAX regulator hose 4 Intak
603. vehicle Automatic transmission Transmission range switch ParkiNeutral position switch A T vehicle 1 Cruise main switch 171 Cruise main switch indicator lamp 2 CRUISE Indicator ight 3 SETCOAST ACCEL RESUMEICANCEL switch 4 Vehicle speed sensor 5 Cruise control actuator assembly with control module Cruise control system circuit Refer to Section 8A 8E 4 CRUISE CONTROL SYSTEM Components and functions Component Function Cruise control actuator assembly with control mod ule Cruise control module Executes centralized control by means of a microcomputer over all functions including setting a constant speed resuming it setting coast limiting minimum speed and cancelling cruise control Cruise control actuator stepping motor amp clutch Actuates accelerator pedal through cruise cable and arm according to a signal from cruise control module to control vehicle speed Cruise main switch This switch has a momentary contact type button to tum the cruise control system ON and OFF SET COAST switch When this switch is rotated ON and then released OFF while vehicle is run ning at a speed 40 km h 25 mile h or higher vehicle speed at that OFF moment is stored in memory and it is maintained constant cruising Rotating this switch ON continuously during constant cruising keeps slowing down vehicle speed as long as it is ON When it is released OFF v
604. vel only Fluid leakage from direct clutch R range Defective O D clutch Fluid leakage from reverse brake Fluid leakage from R range fluid circuit Road Test This test is to check if upshift and downshift take place at specified speed while actually driving vehicle on a level road WARNING Carry out test in very little traffic area to prevent an accident Test requires 2 persons a driver and a tester 1 Warm up engine 2 With engine running at idle shift select lever D 3 Accelerate vehicle speed by depressing accelerator pedal gradually 4 While driving in D range check if gear shift occurs properly as shown in GEAR SHIFT DIAGRAM this section TROUBLESHOOTING Condition Possible cause When 1 2 upshift fails to occur 1 2 shift valve stuck When 2 gt upshift fails to occur 2 8 shift valve stuck When gt O D upshift fails to occur 3 4 shift valve stuck When gear shift point is incorrect Maladjusted throttle cable Defective shift solenoid valve or B 1 2 2 3 or 3 4 shift valve not operating properly AUTOMATIC TRANSMISSION 4 A T 781 41 Manual Road Test This test check the gear being used in L 2 or D range when driven with unoperated gear shift control system Test drive vehi cle on a level road NOTE Before this test check diagnostic trouble code DTC 1 Disconnect shift solen
605. ward sensor 2 rin se 19 Ground Tor airbag est 18 RH Forward sensor 3 IGMETER fus T SoM 8 To seat ba euh 4 AIR BAG waring rp cran matr 12 Contad cal asse 5 AR BAG us 13 Driver air bag fao modu TERMINAL ARRANGEMENT OF SDM VIEWED FROM HARNESS SIDE unu 20 19 1 CONNECTOR Q01 SDM CONNECTOR CONNECTOR Q01 SDM connector TEAMINAL CIRCUIT TERMINAL CIRCUIT 001 1 01 11 Driver pretensioner Low Q012 AIRBAG waming lamp Q01 12 if equipped High Q01 3 001 13 High 01 4 lgnition switch power source gorig sensor Low Q01 5 Passenger pretensioner High 00115 Diagnosis switch 0016 _ it equipped Low Q0146 0017 Passenger air bag inflator High 00117 Ground Q0i8 module Low 90118 Forward sensor Low Q019 Driver air bag inflatory Low 001 19 High Q0140 High 90120 Data link connector DLC 108 6 AIR BAG SYSTEM Diagnosis 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 Diagnostic Trouble
606. wer Steering P S System 3B1 WiringDiagram 8A Air Bag Steering Wheel and Column Lightening System 8B Front Suspension Instrumentation Driver Information 8C Rear Suspension 3E Windows Mirrors Security and Lock 8D Wheels and Tires Cruise Control System 8E DRIVE SHAFT AND PROPELLER SHAFT Immobilizer control system if equipped 8G Front Drive Shaft Shaft Bearing 4a2 BODY SERVICE Oil Seal Body Service 9 Propeller Shaft 4B RESTRAINT SYSTEM BRAKE SYSTEM Restraint System 10 Brakes 5 Seat Belt 10A Brake Pipe Hose Master Cylinder 5A Air Bag System 10B Front Brake 5B Parking and Rear Brake 5 Antilock Brake System ABS 5E2 ENGINE General Information and Diagnosis H27 Engine 61 Engine Mechanical H27 Engine 6A2 Engine Cooling 6B Engine Fuel 6 Engine and Emission Control System SFI For H27 Engine Ignition System H27 Engines 6F2 Cranking System 6G Charging System 6H Exhaust System 6K NOTE o D e o El For the screen toned Sections in the above table refer to the same section of the Related Manuals mentioned in FOREWORD of this manual GENERAL INFORMATION 0A 1 SECTION 0A GENERAL INFORMATION NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS Precautions 2 Identification Information Precaution for Ve
607. with care to prevent accidental deployment When servicing be sure to observe all WARN INGS in this section Refer to SERVICE PRECAUTIONS in Section 10B 1 Diiver airbag inflaton module 5 Steering column upper cover 9 Steering column hole cover 13 Steering column lower seal 2 Steering wheel 6 Steering column lower cover 10 Steering shaft joint 34 f equipped 3 Steering wheel nut 7 Steering column assembly 31 Steering lower shaft assembly 15 Steering upper shaft assembly 4 Contact coil and combination 8 Steering lock assembly 12 Adjustable steering column switch assembly release lever AIR BAG STEERING WHEEL AND COLUMN 3C1 3 Diagno For diagnosis of the steering wheel and steering column refer to Section 3 For diagnosis of the air bag system refer to Section 10B Inspection and Repair Required after Accident After an accident whether the air bag has been deployed or not be sure to perform checks inspections and repairs described under CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE in this section as well as REPAIRS AND INSPECTIONS REQUIRED AFTER ACCIDENT in Section 10B On Vehicle Service Service Precautions For service precautions refer to SERVICE PRECAUTIONS under ON VEHICLE SERVICE in Section 10B Diagnosis and servicing For diagnosis and servicing refer to DIAGNOSIS AND SERVICING under SERVICE PRECAUTIONS in Secti
608. y Spark plug and noise suppressor CMP sensor TP sensor ECT sensor IAT sensor VSS knock sensor and MAF sensor For their details refer to Section 6E2 This ignition system does not have a distributor and high tension cords but each cylinder has an ignition coil assembly igniter and ignition coil and the secondary voltage which occurred in the ignition coil is sent to the spark plug directly Also the signal s are sent from the CMP sensor to ECM or PCM so as to control each igni tion coil independently through the igniter in ignition coil assembly Components NOTE For other components not found in this figure refer to Section 6E2 Ignition assembly igniter and ignition coi sensor Noise suppressor or POM Spark plug IGNITION SYSTEM FOR H27 ENGINE 6F2 3 System Wiring NOTE For ECM PCM terminal assignment refer to Section 6E2 BLKWHT 2 BLKWHT 1 2 28 10 BANIBLK C51 2 274 10 BRNWHT C51 228 BRNYEL BRN RED 10 BLKIBRN 1 2 2 BLK ORN YEUGRN 6511 12 BLU BLK YEUBLU 79 C5111430 GRYIYEL 3 To ignition switch 8 ignition coil assembly For No 3 cylinder 2 IG COIL METER fuse 3 Ignition coil assembly For No 4 cylinder 3 or POM 30 Spark plug 4 CMP sensor T1
609. y 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 procedures are not followed parts or system damage could result NOTE For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual CONTENTS General Description 3C1 2 Handling and storage Diagnosis 3 1 3 Disposal Inspection and Repair Required after Steering Column Accident 3C1 3 Steering Upper Shaft Assembly Service 1 3 Steering Lower Shaft Assembly Checking Steering Column and Steering _ Ponies Upper Shaft for Accident Damage 301 11 iagnosis and
610. y to prevent the webbing from being pulled out of the retractor any further when any of the following items is detected as exceeding each set value speed at which the webbing is pulled out of the retractor acceleration or deceleration of the vehicle speed and 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 SEAT BELT WITH PRETENSIONER IF EQUIPPED The seat belt with ELR and a pretensioner has a pretensioner mechanism which operates in linkage with the air bag in addition to the above described ELR The pretensioner takes up the sag of the seat belt in occurrence of a front collision with an impact larger than a certain set value thereby enhancing restraint performance DRIVER AND FRONT PASSENGER SIDE AIR BAGS The driver and front passenger side air bags are components of the air bag system In occurrence of a front col lision with an impact larger than a certain set value they are activated by the ignition signal from SDM to supple ment protection o
611. y positive cable to terminal c and battery negative cable to terminal It A C blower fan switch bulb does not come ON replace it AIR CONDITIONING OPTIONAL 18 37 Rear A C No 1 and No 2 Duct Rear A C No 1 duct REMOVAL 1 Remove rear A C unit referring to REAR A C UNIT in this section 2 Remove rear A C No 1 duct 1 INSTALLATION Reverse removal procedure to install rear A C No 1 duct 1 Rear A C No 2 duct CAUTION Never remove rear A C No 2 duct 2 from head lining Performing this prohibited service will break head lining 18 38 AIR CONDITIONING OPTIONAL Compressor Assembly CAUTION None of refrigerant compressor oil and component parts is interchangeable between two types of AIC one using CFC 12 R 12 and the other using HFC 134a R 134a For identification between these two types refer to page 66 When replenishing or changing refrigerant and compressor oil and when replacing parts make sure that the material or the part to be used is appropriate to the A C installed in the vehicle being serviced Use of incorrect refrigerant or compressor oil will result in leakage of refrigerant damage in parts or other faulty condition When servicing the compressor keep dirt or foreign material away from getting on or into the com pressor parts and system Clean tools and a clean work area are important for proper service The compressor connection and
612. y removing its 8 fastening bolts 1 Remounting 1 Clean mating surfaces of rear axle and differential assembly and apply sealant to axle side evenly A Sealant 99000 31110 2 Install differential assembly to axle and fix it with bolts 1 tightened to specified torque Tightening torque Differential carrier bolts a 55 N m 5 5 kg m 40 0 Ib ft 7F 5 DIFFERENTIAL REAR 3 Install propeller shaft to joint flange aligning match marks and torque flange nuts to specification Apply thread lock cement to thread part of bolt if reused A Cement 99000 32110 Tightening torque Propeller shaft flange nuts a 60 N m 6 0 kg m 43 5 Ib ft 4 Install right and left rear axle shafts and drums Refer to REAR AXLE INSTALLATION of Section 3E and rear brake drum installation of Section 5 5 Install wheels 6 Fill hypoid gear oil as specified and tighten plug to specifica tion 7 Lower lift Unit Rep Disassembling Unit 1 Hold differential assembly securely and put identification marks on differential side bearing caps 6 2 Take off differential side bearing lock plates 4 and differen tial side bearing caps 6 by removing their bolts and then take out bearing adjusters 5 side bearing outer races and drive bevel gear with differential case 1 Differential carrier 2 Drive bevel gear assembly 3 Differential case A Identification mark
613. ycle detection logic DTC CONFIRMATION PROCEDURE For DTC P1450 1 Connect scan tool to DLC with ignition switch OFF 2 Tum ON ignition switch and clear DTC by using scan tool and run engine for 1 min 3 Check DTC by using scan tool For DTC P1451 WARNING When performing a road test select a place where there is no traffic or possi dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road of a traffic acci 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and warm up engine to normal operating temperature 3 Increase engine speed to 3 000 r min in 3rd gear in case of and 2 range in case of A T 4 Release accelerator pedal and with engine brake applied keep vehicle coasting for 5 sec or more keep fuel cut condition for 5 sec or more If fuel cut condition is not kept for 5 sec or more coast down a slope in engine speed 1600 3000 r min for 5 sec or more 5 Stop vehicle and run engine at idle 6 Repeat steps 3 5 2 times 7 Check pending DTC by using scan tool TROUBLESHOOTING DTC P1450 P1451 Step Action Yes No 1 Was ENGINE DIAG FLOW TABLE performed GotoStep2 Go to ENGINE DIAG FLOW TABLE in this section 2 Is DTC P1451 set Goto
614. yst to overheat during 200 engine Fuel injector and its circuit revolutions is detected at 2 or more cylinders MIL flashes as Fuel line pressure long as this misfire occurs continuously Engine compression Misfire which affects exhaust emission adversely during 1000 Abnormal air drawn in engine revolutions is detected at 2 or more cylinders 2 driving e EGR system cycle detection logic Fuel level sensor DTC P0301 P0302 P0303 P0304 P0305 P0306 Valve lash adjuster Misfire which causes catalyst to overheat during 200 engine Valve timing revolutions is detected at 1 cylinder MIL flashes as long as this misfire occurs continuously Misfire which affects exhaust emission adversely during 1000 engine revolutions is detected at 1 cylinder 2 driving cycle detection logic DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE Intake air temp 8 70 C 18 158 F Engine coolant temp 8 C 18 F or higher Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 Connect scan
615. zo pe s 927 1 PCM ECN 2 PCM ECM connector Viewed from harness side ENGINE GENERAL INFORMATION AND DIAGNOSIS H27 ENGINE 6 1 37 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Rover for CO 10 14V Ignition switch ON resistor if equipped E61 2 Power source for back up 10 14V Ignition switch ON and OFF E613 Cruise control module ignition switch ON Voltage varies as specified at figure in E61 4 throttle opening signal cruise control diagnosis of Section 8E while throttle valve is if equipped opened gradually Duty output terminal HR 61 5 Aaa d 0 1V Ignition switch ON vehicle with monitor connector E61 6 Tachometer Ignition switch ON engine stops mgr Malfunction indicator lamp 0 25V Ignition switch ON engine stops SERVICE ENGINE SOON lamp 10 14V Engine running ae 0 15V AIC is not operating 61 8 cut signal if d cut signal if equipped 10 14V AIC is operating 10 14V Ignition switch OFF E61 9 Main relay mem lgnition switch ON or for 4 seconds after ignition switch OFF E6130 adjusting resistor if equipped E6131 Data link connector 6V PER E61 12 Vehicle with monitor con

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