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1. ANTILOCK BRAKE SYSTEM ABS 5E 13 TERMINAL CIRCUIT Al Idle up signal A2 Stop lamp switch A3 Right front wheel speed sensor A4 Right front wheel speed sensor A5 A6 Right rear wheel speed sensor A7 Right rear wheel speed sensor A8 AQ A10 A11 G sensor signal A12 Diagnosis switch terminal A13 G sensor ground A14 ABS warning lamp A15 Left front wheel speed sensor A16 Left front wheel speed sensor A17 4WD switch for 4WD model only A18 Ignition switch A19 Left rear wheel speed sensor A20 Left rear wheel speed sensor A21 Data link connector A22 Ground for ABS pump motor A23 ABS pump motor power supply A24 Ground for ABS control module A25 Solenoid valve power supply Wire color B Black GW Green White R W Red White B BI Black Blue Lg B Light green Black W BI White Blue BIW Black White Lg R Light green Red W G White Green B Or Black Orange Or Orange WIR White Red BI Blue Or B Orange Black Ne Yellow BIW Blue White P B Pink Black Y B Yellow Black G Green P G Pink Green G B Green Black R BI Red Blue 5E 14 ANTILOCK BRAKE SYSTEM ABS Table A ABS Warning Lamp Circuit Check Lamp Does Not Come ON at Ignition Switch ON
2. CONNEC TERMINAL WIRE COLOR CIRCUIT CONNEC TERMINAL WIRE COLOR CIRCUIT 1 B Ground for ECM 7 WwW Backup power source pier Immobilizer indicator lamp 2 B R Ground for drive circuit sa if equipped An Duty output terminal vehicle without 3 B R Ground for drive circuit immobilizer indicator lamp 4 BI G Canister purge valve 9 fa Power steering pressure switch 5 BI Or if equipped 10 BI Main relay 6 G Y IAC valve 11 B W Ignition switch 7 P B Heater of HO2S 1 if equipped 12 R W Rear defogger switch 8 W B No 4 fuel injector 13 Diagnosis switch terminal 9 R W No 1 fuel injector 14 W BI vehicle without immobilizer indicator lamp Test switch terminal 10 B BI Ground for sensor circuit E18 15 P vehicle without immobilizer indicator lamp 11 w CMP sensor 16 G W A C SW signal if equipped 12 17 R Y Lighting switch R Heated oxygen sensor 1 13 if equipped 18 P B A C condenser fan relay if equipped R BI CO adjusting resistor w o HO2S 14 G B ECT sensor 19 W G Fuel pump relay E19 15 Lg B IAT sensor 20 B a Engine start signal 16 Lg TP sensor 21 G W Stop lamp switch 17 Gr BI Saar stepper motor coil 3 if 22 Y Vehicle speed sensor EGR valve stepper motor coil 1 if _ 18 Gr equipped 23 19 Br B Pagal assembly for No 2 and 3 spark 24 _ _ 20 Br W bree assembly for No 1 and 4 spark 21 R G No 2 fuel injector 1 W R A C evaporat
3. H AoT i E19 21 E19 31 INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check Injector for Operating Sound Using sound scope check each injector for operating sound at engine cranking Do all 4 injector make operating sound Fuel injector circuit is in good condition Go to Step 3 3 Dose none of 4 injectors make operating sound at Step 2 Go to Step 4 Check coupler connec tion and wire harness of injector not making oper ating sound and injector itself Refer to Section 6E 4 Check power circuit of injectors for open and short Is it normal Check all 4 injectors for resistance respectively If resistance is OK substi tute a known good ECM and recheck Power circuit open or short 6 110 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table B 2 Fuel Pump and Its Circuit Check IG COIL METER ENER E18 24P EV Fy E mjg E18 19 1 Ignition switch 3 Main relay 5 Fuel pump relay A Case of TYPE A is shown See NOTE 2 Main relay 4 Main fuse 6 Fuel pump B Case of TYPE B is shown See NOTE NOTE For TYPE A and TYPE B refer to th
4. L Engar a LU AE LJ I E17 07P LI LET TT eK ELE pa E17 12 DTC DETECTING CONDITION POSSIBLE CAUSE e ABS signal input is low when engine start e ABS signal circuit short to ground e ABS control module DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 1 With the ignition switch ON position check Intermittent trouble Go to Step 3 voltage between E17 12 terminal of ECM If OK substitute a known coupler and ground good ECM and recheck Is voltage within 10 14 V 3 1 Check Q wire for shorted to ground circuit Go to Step 4 Repair or replace Is G wire in good condition 4 1 Disconnect coupler of ABS control module Substitute a known good Substitute a known good 2 Clear DTC ECM and recheck ABS control module and 3 Start engine and check DTC recheck Is DTC P1570 No 21 detected ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 105 DTC P1600 Serial Communication Problem Between ECM and TCM CIRCUIT DESCRIPTION IG1 Ae ECM GIR E19 31P Lf E18 24P T E17 01
5. E18 20 E17 14 1 Heated oxygen sensor 2 HO2S 2 A Case of TYPE A is shown See NOTE B Case of TYPE B is shown See NOTE NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model DTC DETECTING CONDITION POSSIBLE CAUSE Engine is warmed up and HO2S 2 voltage is 4 5 V or more circuit open 2 driving cycle detection logic monitoring once 1 driving Exhaust gas leakage W or B BI circuit open or short Heated oxygen sensor 2 malfunction Fuel system malfunction DTC CONFIRMATION PROCEDURE WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester on a level road b Turn ignition switch OFF Clear DTC with ignition switch ON check vehicle and environmental condition for Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower No exhaust gas leakage and loose connection 2 Warm up engine to normal operating temperature 3 S wm trim with Data List mode on scan tool and write it down 4 Stop vehicle don t turn ignition switch OFF Altitude barometric pressure 2400 m
6. 4 Fuel cut valve 6 To EVAP canister 12 To intake manifold vacuum passage 5 Fuel tank pressure control valve 7 Fuel feed line Fuel pump An in tank type electric pump has been adopted for the fuel pump 1 Incorporated in the pump assembly are e Tank pressure control valve 2 which keeps the pressure in the fuel tank constant and prevents the fuel from spouting and tank itself from being deformed e Relief valve 3 which prevents the pressure in tank from ris ing excessively e Fuel cut valve 4 which closes as the float rises so that the fuel will not enter the canister when the fuel level in the tank rises high depending on the fuel level in the tank and the vehicle tilt angle Also a fuel filter 5 is included and a fuel level gauge 6 is attached ENGINE AND EMISSION CONTROL SYSTEM 6E 7 Electronic Control System The electronic control system consists of 1 various sensors which detect the state of engine and driving condi tions 2 ECM which controls various devices according to the signals from the sensors and 3 various controlled devices Functionally it is divided into the following sub systems e Fuel injection control system e Idle speed control system e Fuel pump control system e A C control system if equipped e A C condenser fan control system e EGR system if equipped e Evaporative emission control system e Oxygen sensor heater control system e Igni
7. AIR CONDITIONING OPTIONAL 1B 43 4 Remove circlip 1 using special tool Special tool A 09900 06107 5 Remove magnet clutch lead wire clamp screw and discon nect magnet clutch lead wire 6 Remove magnet clutch pulley 1 by using a puller 2 NOTE e Be careful not to damage pulley part 7 Remove snap ring 1 using special tool Special tool A 09900 06107 8 Remove magnet clutch coil 2 from compressor body assembly 3 INSTALLATION 1 Install magnet clutch coil 1 NOTE e Protrusion on under side of magnet clutch coil 1 must match hole in compressor body assembly 2 2 Install snap ring 3 to proper direction as show using special tool Special tool A 09900 06107 1B 44 AIR CONDITIONING OPTIONAL 3 Install magnet clutch 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 4 Install snap ring 1 using special tool Special tool A 09900 06107 CAUTION Be careful not to scratch bearing seal 5 Adjust clearance between clutch plate 1 and magnet clutch coil 2 by putting shim on compressor shaft Standard clearance between clutch plate and magnet clutch coil a 0 3 0 6 mm 0 012 0 024 in 6 Tighten new clutch plate bolt
8. Disconnect accelerator cable 1 from throttle body Disconnect the following hoses Brake booster hose 2 from intake manifold Canister purge hose 3 from EVAP canister purge valve Fuel feed and return hoses 4 from each pipe Water hose from thermostat case 5 e Heater inlet hose from its pipe e Vacuum hose to check valve 6 11 Remove canister purge hose bracket from intake manifold 10 lt 12 Remove intake manifold stiffener 1 13 Remove oil pan referring to Oil Pan and Oil Pump Strainer in this section 14 Remove cylinder head cover referring to Cylinder Head Cover in this section 15 Remove timing chain cover referring to Timing Chain Cover in this section 16 Remove timing chain referring to Timing Chain and Chain Tensioner in this section 17 Remove intake and exhaust camshafts referring to Cam shaft Tappet and Shim in this section 18 Disconnect exhaust pipe 1 from exhaust manifold ENGINE MECHANICAL M13 ENGINE 6A1 51 19 Remove exhaust manifold stiffener 1 20 Loosen cylinder head bolts in such order as indicated in fig reep ure by using a 12 corner socket wrenches and remove them FX ANa INIIAI NOTE OEA OOA OOOO COLA f a 6 6 Don t forget to remove bolt M8 1 as shown in figure o o o OSs S AY KOKO CKONG WOL oe iGe ae a ee 1 g
9. STEERING GEAR BOX MANUAL TYPE AND LINKAGE 3B 5 3 Measure worm shaft starting torque from its position in straight forward state as described in Step 2 Starting Torque for Worm shaft a 50 100 N cm 5 0 10 0 kg cm 0 4 0 7 Ib ft Special tool A 09944 18211 1 Adjusting bolt If measured torque is not within specification carry out adjust ment with adjusting bolt 1 to meet specification and check to confirm it again Tightening torque Steering gear box adjusting bolt lock nut a 30 N m 3 0 kg m 22 0 Ib ft 2 Lock nut 4 If worm shaft starting torque is checked all right another check should be carried out on worm shaft operating torque in its entire operating range by turning worm shaft all the way to the right and left Worm Shaft Including sector shaft Operating Torque a Under 120 N cm 12 0 kg cm 10 9 Ib ft Special tool A 09944 18211 If measured torque does not conform to specification readjust worm shaft starting torque in straightforward state by means of adjusting bolt 1 and then recheck worm shaft operating torque Tightening torque Steering gear box adjusting bolt lock nut b 30 N m 3 0 kg m 22 0 lb ft If specified value is not attained even after readjustment it is advisable to replace gear box with new gear box assembly 3B 6 STEERING GEAR BOX MANUAL TYPE AND LINKAGE On Vehicle Service Steering Gear Box
10. DIAGNOSIS ABS SYSTEM CONDITION SWITCH WARNING TERMINAL LAMP No trouble in the past Open OFF In good ee dian Grounded DTC 12 at present Trouble occurred in Open OFF the past Grounded History DTC No trouble in the past Open ON Abnormal Grounded Current DTC ity exists Trouble occurred in Open ON at present the past Current and crotunees history DTC NOTE The current code and the history code are displayed without any classification For procedure to clear all DTC s refer to the item Diagnostic Trouble Code DTC Clearance in this section ABS control module Sensed information Output Lamp driver module 1 Ignition switch 2 ABS warning lamp 3 Monitor connector 3 1 Diag switch terminal 3 2 Ground terminal N OO oy A Fail safe function When an abnormality occurs an abnormal DTC is detected ABS control module turns OFF the fail safe transistor which sup plies power to ABS hydraulic unit Thus with ABS not operating brakes function just like the brake system of the vehicle without ABS 5E 6 ANTILOCK BRAKE SYSTEM ABS To ensure that the trouble diagnosis is done accurately and smoothly observe Precautions in Diagnosing Trou Diagnosis bles and follow ABS Diagnostic Flow Table Precaution in Diagnosing Troubles e If the vehicles was operated in any of the following ways ABS warning lamp may light mo
11. TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 9 Ignition switch 10 14V_ Ignition switch ON 10 14V Ignition switch OFF a 0 4 1 5V lIgnition switch ON 11 Ignition switch 10 14V_ Ignition switch ON 10 14 V Ignition switch ON and rear defogger 12 Rear defogger switch if equipped aw oN 0 13V Ignition switch ON and rear defogger switch OFF 13 TO ease ae E ay 4 5V Ignition switch ON immobilizer indicator lamp 15 Test switch terminal without immo 4 5V Ignition switch ON bilizer indicator lamp 10 14 V Ignition switch ON A C switch OFF 16 A C input signal gt 0 2V Ignition switch ON a 10 14V caning a om ON ree f 7 ighting switc Te egning swp 0 1 3V Lighting switch OFF 18 A C condenser fan motor relay 0 1 0V_ A Cis operating if equipped 10 14V_ A Cis not operating 19 Fuel pump relay 0 1V For 2 seconds after ignition switch ON 10 14V_ After the above time 20 Engine start signal 6 14V While engine cranking ov Ignition switch ON 21 Stop lamp switch Slop amp ewiten 10 14V Ignition switch ON Stop lamp switch ON deflect f between Ignition switch ON and rear right wheel Bo aA SPOR SENSEI O0 1 6 and turned slowly with rear left wheel locked 4 14V 23 24 For TYPE A See NOTE NOTE See NOTE in ECM TERMINAL VOLTAGE VALUES TABLE for applicable model TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 1 10
12. OUTPUT VOLTAGE INSPECTION 1 Turn ignition switch OFF 2 Hoist vehicle a little 3 Disconnect connector of wheel speed sensor 4 5 Connect voltmeter between connector terminals While turning wheel at a speed of approximately 1 full rota tion to 1 1 3 rotation per second check AC voltage of sensor wa lt x Output AC voltage at 1 to 1 1 3 rotation per second 120 mV or more at 42 54 Hz If measured voltage is not as specified check sensor rotor and their installation conditions 1 Wheel speed sensor coupler 2 Right wheel sensor terminals 3 Left wheel sensor terminals 100 mv Div pes mS Div ANTILOCK BRAKE SYSTEM ABS 5E 33 Reference When using oscilloscope for this check check if peak to peak voltage 1 meets specification and waveform is complete Peak to peak voltage at 1 to 1 1 3 rotation per second 340 mV or more at 42 54 Hz REMOVAL 1 Disconnect negative cable at battery 2 3 4 Disconnect front wheel speed sensor coupler 3 Hoist vehicle and remove wheel Remove harness clamp bolts 2 and front wheel speed sen sor 1 from knuckle xw rer wa CAUTION Do not pull wire harness when removing front wheel speed sensor e Do not cause damage to surface of front wheel speed sensor and do not allow dust etc to enter its installa tion hole SENSO
13. BRAKES 5 27 INSPECTION Check disc surface for scratches in wearing parts Scratches on disc surface noticed at the time of specified inspection or replace ment are normal and disc is not defective unless they are serious But when there are deep scratches or scratches all over disc sur face replace it When only one side is scratched polish and cor rect that side Brake disc thickness a Standard 10 mm 0 394 in Limit 8 0 mm 0 315 in Use wheel nuts 1 and suitable plain washers 2 to hold the disc securely against the hub then mount a dial indicator as shown and measure the runout at 10 mm 0 39 in from the outer edge of the disc Disk deflection Limit 0 15 mm 0 006 in NOTE Check front wheel bearing for looseness before measure ment INSTALLATION NOTE See NOTE at the beginning of this section 1 Install disc to wheel hub 2 Install caliper assembly to steering knuckle 3 Torque caliper carrier bolts to specification Tightening torque Brake caliper carrier bolts a 85 N m 8 5 kg m 61 5 Ib ft 4 Install wheel and torque front wheel nuts to specification 5 Upon completion of installation perform brake test 5 28 BRAKES CHECK FOR FRONT BRAKE AFTER INSTALLATION Mount tires and make certain that they rotate smoothly with a force of less than 3 0 kg 6 6 Ib NOTE For above check the following must be observed e Jack up front wheels both r
14. INSPECTION Brake Drum Inspect drum for cleanliness Check wear of its braking surface by measuring its inside diameter Drum inner diameter a Standard 220 mm 8 66 in Service Limit 222 mm 8 74 in Whenever brake drums are removed they should be thoroughly cleaned and inspected for cracks scores deep grooves 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 worn and drum is grooved drum should be polished with fine emery cloth but should not be turned NOTE When drum is removed visually inspect wheel cylinder for brake fluid leakage Correct leaky point if any BRAKES 5 31 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 Brake shoe thickness lining shoe rim a Standard lining rim 6 5 mm 0 26 in Service limit 3 0 mm 0 12 in NOTE 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 correc
15. 1 Front axle housing FRONT SUSPENSION 3D 33 5 Remove oil seal 1 from axle housing for 4WD 6 Drain out kingpin bearing outer race 1 from front axle hous ing 2 INSTALLATION 1 Install kingpin bearing outer race 1 to front axle housing by using special tools Special tool A 09944 68510 B 09924 74510 2 Press fit oil seal 1 until it becomes flush with inner surface of front axle housing 2 by using special tool Special tool A 09951 76010 3 Apply grease to oil seal lip A Grease 99000 25010 3 Body center 3D 34 FRONT SUSPENSION 4 Install axle shaft 2 to front axle housing 1 for 4WD 5 Install knuckle to front axle housing For details refer to Steering Knuckle Wheel Spindle in this section 6 Refill front axle differential housing with new specified gear oil for 4WD Refer to Maintenance Service in Section 7E for refill 7 After servicing check that no oil leakage exists Steering Knuckle Seal REMOVAL 1 Hoist vehicle 2 Remove knuckle seal cover bolts and seal cover 1 3 Cut oil seal in place with scissors or knife and take it off INSTALLATION 1 Cut replacement oil seal at one place with scissors or a knife A B FRONT SUSPENSION 3D 35 2 Apply grease to oil seal
16. Fuel filter Replace every 210 000 km 126 000 miles Fuel tank EMISSION CONTROL SYSTEM Crankcase ventilation hoses and connections Vehicle without HO2S PCV valve Vehicle without HO2S l Vehicle with HO2S Fuel evaporative emission Vehicle without HO2S control system Vehicle with HO2S z NOTE R Replace or change I Inspect and correct replace or lubricate if necessary e For Sweden items with asterisk should be performed by odometer reading only e For spark plugs replace every 50 000 km if the local law requires e Nickel spark plug BKR6E 11 NGK or K20PR U11 DENSO e Iridium spark plug IFR5E11 NGK or SK16PR A11 DENSO MAINTENANCE AND LUBRICATION OB 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 Clutch pedal height and travel Brake discs and pads thickness wear damage Brake drums and shoes wear damage Brake hoses and pipes leakage damage clamp Brake fluid R Brake lever and cable damage stroke operation Inspect at first 15 000 Tires wear damage rotation Wheel discs damage Suspension system tightness damage rattle breakage Propeller shafts R 00 miles only l l l o
17. TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE Ignition switch ON 1 A C evaporator temp sensor 2 0 2 3V_ A C evaporator temp sensor at 25 C 77 F i 10 14V E ON and shift select switch E TTRI RINAL Ignition switch ON and shift select switch 0 1 3 V in other than R range 3 Blank 4 Blank 7 6 40 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 0 1 0V o switch ON and ECT less than 2 Cues cur signal Ignition switch ON and ECT more than 10 14V 60 C Ignition switch ON and shift select switch 10 14V 6 D range idle up signal A T in other than P and N range g aN Ignition switch ON and shift select switch O0 16V in P and N range 7 Data link connector 4 5V Ignition switch ON 8 eee 10 14V_ Engine running Malfunct tor 3 AUNE NON EROT AMR 0 1 0V Ignition switch ON leaving engine OFF sa ee 11 Data link connector 10 14V ignition switch ON 12 ABS signal if equipped 10 14V__ Ignition switch ON 0 20V Ignition switch ON and heater blower switch ON 13 Heater blower switch 10 14V Ignition switch ON and heater blower switch OFF 14 Sensor ground 7 Indication Throttle opening signal for deflection st tch ON 15 tom ArT fepeatediony On switio and 10 14 V 16 Tachometer 7 17 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6
18. Tightening torque Connecting rod bearing cap nuts a 15 N m 1 5 kg m 11 0 Ib ft and extra tightening 45 twice 5 Remove cap and using a scale 1 on gauging plastic 2 envelope measure gauging plastic width at the widest point clearance If clearance exceeds its limit use a new standard size bear ing and remeasure clearance Connecting rod bearing clearance Standard 0 029 0 047 mm 0 0011 0 0019 in Limit 0 065 mm 0 0026 in ENGINE MECHANICAL M13 ENGINE 6A1 69 6 If clearance can not be brought to within its limit even by using a new standard size bearing regrind crankpin to undersize and use 0 25 mm undersize bearing NOTE After checking the rod bearing clearance make sure to check connecting rod bolt diameter Refer to Inspection of Connecting Rod ASSEMBLY 1 Install piston pin to piston 1 and connecting rod 2 a After applying engine oil to piston pin and piston pin holes in piston and connecting rod b Fit connecting rod as shown in figure c Insert piston pin to piston and connecting rod d Install piston pin circlips 3 NOTE Circlip should be installed with its cut part facing as shown in figure Install so that circlip end gap comes within such range as indicated by arrow 2 Install piston rings to piston a As indicated in figure 1st and 2nd rings have T mark respectively When i
19. 2 Steering lower shaft 3C 18 STEERING WHEEL AND COLUMN Checking Steering Column 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 CHECKING PROCEDURE 1 Check that two capsules 1 are attached to steering column bracket 2 securely Check clearance between capsules 1 and steering column bracket 2 Clearance should be 0 0 mm 0 0 in on both sides If found loose or clearance replace steering column assem bly 2 Check two plates 3 for any damages such as crack or breakage If anything is found faulty replace as steering column assem bly 3 Take measurement a as shown If it is shorter than specified length replace column assem bly 1 with new one Steering column assembly length a 733 2 734 8 mm 28 87 28 93 in 4 Check if steering lower shaft 1 is with in specified length If it is out of specified length replace it with new one Steering lower shaft length b 478 3 480 3 mm 18 83 18 91 in For LH steering vehicle without P S system 438 3 440 3 mm 17 26 17 33 in For RH steering vehicle without P S system 393 6 395 6 mm 15 50 15 57 in For LH steering vehicle with P S system 434 2 436 2 mm 17 09 17 17 in For RH steering vehicle with
20. When cold When hot Coolant temperature Coolant temperature P A Fa A is 15 25 C or is 60 68 C or 7 OF fo Sar ae Arn 59 77 F 140 154 F ie ime nae 0 18 0 22 mm 0 21 0 27 mm p gt spaa eE sji 0 007 0 009 in 0 008 0 011 in R ONG Exhaust 028 0 32 mm 0 30 0 36 mm N oe aN 0 011 0 013 in 0 012 0 014 in wai mM ils mi l ire Quy etr tore EOR ROP ar wal yy REPLACEMENT OF SHIM 1 Close the valve whose shim 2 is to be replaced by turning crankshaft then turn tappet 3 till its cut section 1 faces inside as shown in figure 6A1 10 ENGINE MECHANICAL M13 ENGINE 2 Lift valve by turning crankshaft and then remove camshaft housing bolts 1 where the shim to be replaced 2 Plug hole 3 Install special tool with camshaft housing bolts as shown in figure Special tool A 09916 67020 Tightening torque Camshaft housing bolts for tightening of special tool a 8 N m 0 8 kg m 6 0 Ib ft NOTE e Check the special tools carved seal as shown and then install special tool in accordance with the location of each camshaft housing e If special tool is holding down the shim adjust special tool position so as not to hold down the shim by loos ening camshaft housing bolt Special tool selection table Embossed mark No on camshaft housing i on speci
21. 0 3B1 21 bole Poy Stet CHECK fotene ii DE Special MOOlS tecscecsecsicn decade macnn 3B1 21 Power Steering Fluid Leakage Check 3B1 7 3B1 2 POWER STEERING P S SYSTEM If equipped General Description The power steering system in this vehicle reduces the driver s effort needed in turning the steering wheel by uti lizing the hydraulic pressure generated by the power steering P S pump which is driven by the engine It is an integral type with the mechanical gear unit hydraulic pressure cylinder unit and control valve unit all housed in the gear box EL N S gt io ont Q Sy r TO eal S y KA Ty 1 Steering gear box 2 Power steering P S pump 3 P S fluid reservoir C7 1 Power steering gear box 3 Spool valve 5 P S fluid reservoir 2 Control valve section 4 Power steering P S pump Diagnosis Table POWER STEERING P S SYSTEM If equipped 3B1 3 Diagnosis Condition Possible Cause Correction Steering wheel feels heavy at low speed Fluid deteriorated low viscosity different type of fluid mixed Change fluid Pipes or hoses deformed air entering through joint Correct or replace Insufficient air bleeding from piping Bleed air Belt worn lacking in tension Adjust belt tension or replace belt as necessary Tire inflation pressure too low Inflate tire Wheel
22. 8 ABS hydraulic unit control module connector of harness Main fuse 6 Monitor connector Blue Ignition switch 6 1 Diag switch terminal 8 1 Lock position IG fuse 6 2 Diag ground terminal 8 2 Unlock position ABS warning lamp in combination meter Combination meter A P ory ABS hydraulic unit control module assembly 1 ABS lamp driver module CIRCUIT DESCRIPTION Operation ON OFF of the ABS warning lamp is controlled by the ABS control module and ABS lamp driver module If the Antilock brake system is in good condition the ABS control module turns the ABS warning lamp ON at the ignition switch ON keeps it ON for 2 seconds only and then turns it OFF If an abnormality in the system is detected the lamp is turned ON by ABS control module Also it is turned ON by ABS lamp driver module when the connector of the ABS control module was disconnected INSPECTION Step Action Yes No 1 1 Turn ignition switch ON Go to step 2 Go to step 4 Do other warning lamp come ON module connector switch ON 2 1 Disconnect ABS hydraulic unit control Does ABS warning lamp light with ignition Replace ABS hydraulic unit Go to step 3 control module assembly ANTILOCK BRAKE SYSTEM ABS 5E 15 tion meter or poor connection Step Action Yes No 3 1 Remove combination meter R BI circuit shorted to ground
23. INSPECTION 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 CHECKING PROCEDURE 1 Check that two capsules 1 are attached to steering column bracket 2 securely Check clearance between capsules and steering column bracket Clearance should be 0 0 mm 0 0 in on both sides If found loose or clearance replace steering column assem bly 2 Check two plates 3 for any damages such as crack or breakage If anything is found faulty replace as steering column assembly 3C 14 STEERING WHEEL AND COLUMN 3 4 Take measurement a as shown If it is shorter than specified length replace column assem bly 1 with new one Steering column assembly length a 733 2 734 8 mm 28 87 28 93 in Check steering shaft joints and shaft for any damages such as crack breakage malfunction or excessive play If anything is found faulty replace as lower joint assembly or column assembly 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 Check steering column lower seal 1 for breakage or defor mation If found defective replace INSTALLATION CAUTION After tightening steering column mounting bol
24. 3 Remove parking brake shoe lever 5 from brake back plate INSPECT e Inspect lever for free movement against brake shoe web If defective correct or replace Inspect ratchet or thread rod part for wear sticking and cor rosion Inspect for damage or weakening e Inspect each part with arrow for rust If found defective replace INSTALLATION Assemble parts as shown in reverse order of removal 1 Apply rubber grease to brake back plate and parking brake shoe lever as shown in the figure 1 Apply rubber grease BRAKES 5 33 2 Install shoe hold down springs 2 by pushing them down in place and turning hold down pins 1 3 Install shoe return spring and parking brake shoe lever spring 4 For procedure hereafter refer to Brake Drum in this sec tion Shoe return spring lower Adjuster lever 3 4 Spring and rod assembly 5 6 Adjuster spring Wheel Cylinder REMOVAL 1 Remove brake drum referring to Brake Drum in this sec tion 2 Remove brake shoe referring to Brake Shoe in this section 3 Loosen brake pipe flare nut or nuts but only within the extent that fluid does not leak 4 Remove wheel cylinder mounting bolts Disconnect brake pipe or pipes from wheel cylinder and put wheel cylinder breather plug cap 1 onto pipe to prevent fluid from spilling INSPECTION Inspect wheel cylin
25. Clearance d or e between brake pedal and wall LH steering vehicle clearance d Over 55 mm 2 17 in RH steering vehicle clearance e Over 76 mm 2 99 in 4 If clearance d or e is less than specification the most pos sible cause is either rear brake shoes are worn out beyond limit or air is in lines Should clearance d or e remain less than specification even after replacement of brake shoes and bleeding of sys tem other possible but infrequent cause is malfunction of rear brake shoe adjusters or booster push rod length out of adjustment Bleed brake system Refer to Air Bleeding of Brake Sys tem in this section Remove brake drums for adjuster inspection Refer to Rear Brake in this section If defective correct or replace A LH steering vehicle B RH steering vehicle Front Brake Disc Check Refer to item Front Disc Brake in this section for inspection point and procedure Front Brake Pad Check Inspect pad linings 3 periodically according to maintenance schedule whenever wheels are removed for tire rotation or other reason Take a look through each end or hole of caliper and check lining thickness of outside and inside pads If lining is worn and its thickness a in figure is less than limit all pads must be replaced at the same time Front brake pad thickness a lining thickness Li
26. 5E 12 ANTILOCK BRAKE SYSTEM ABS System Circuit DTC DTC displayed on indicated by ABS warning light flashing SUZUKI scan ABS warn pattern BRON EMS tool ing lamp 5 7 C1057 57 UL ULL Power source 6 1 C1061 61 MiNi ABS pump motor circuit 6 3 C1063 63 ULL UT ABS solenoid valve circuit 7 1 C1071 71 ULL ABS control module Or BIW 9 T Fp OOOOOO 410 4 Lg B delign Y 17 Y B P B 12 PAO POOKY A1 A183 A21 At pocco cdi q ATANI i9 LAL A24 A14 R BI A17 LZ N VAVAVA gt pare N N ERRBEEE gt gt a gS N H Hii N 3 gt nN a Bll gt 1 Battery 5 5 Solenoid valves 14 Stop lamp switch 2 Main fuses 6 Combination meter 15 ECM 3 Ignition switch 7 Right rear wheel speed sensor 16 G sensor 4 Circuit fuses 8 Left rear wheel speed sensor 17 4WD switch for 4WD model only 5 ADS hydraulic unit control module assem 9 Right front wheel speed sensor 18 4WD indicator lamp for 4WD model only y 5 1 Terminal arrangement for ABS hydraulic unit 10 Left front wheel speed sensor 19 4WD controller for 4WD model only control module assembly 5 2 ABS fail safe transistor 11 Data link connector 20 ABS warning lamp 5 3 ABS pump motor transistor 12 Monitor connector 21 ABS lamp driver module 5 4 Pump motor 13 Stop lamp
27. Immerse temperature sensing part of ECT sensor 1 in water or ice and measure resistance between terminal A and B while heating water gradually If measured resistance doesn t show such characteristic as shown in left figure replace ECT sensor 1 kQ _ for reference 5 74 RESISTANCE 2 297 2 595 J gt X 1 15 fo elas 0 584 f i D O 20 40 60 80 C 32 68 104 140 176 F TEMPERATURE INSTALLATION Reverse removal procedure noting the following e Clean mating surfaces of ECT sensor 1 and water outlet cap e Check O ring for damage and replace if necessary ENGINE AND EMISSION CONTROL SYSTEM 6E 33 e Tighten ECT sensor 1 to specified torque Tightening torque ECT sensor a 15 N m 1 5 kg m 11 5 Ib ft e Connect connector to ECT sensor 1 securely e Refill coolant referring to Cooling System Flush and Refill in Section 6B Heated oxygen sensor Sensor 1 and sensor 2 OXYGEN SENSOR HEATER INSPECTION 1 Disconnect sensor connector 2 Using ohmmeter measure resistance between terminals Vg and GND of sensor connector If found faulty replace oxygen sensor NOTE Temperature of sensor affects resistance value largely Make sure that sensor heater is at correct temperature Resistance of oxygen sensor heater HO2S 1 5 0 6 4 Q at 20 C 68 F HO2S 2 11 7 14 3 Q at 20 C 68 F 1 Viewed from termina
28. Noise high pitched squeak without brake applied Front lining worn out Replace brake pads Rear brake locked pre maturely Maladjusted sensor spring length of LSPV Check or adjust Malfunctioning LSPV assembly Replace assembly Brake locked For vehicles equipped with ABS Malfunctioning ABS if equipped Check system and replace as nec essary 5 6 BRAKES Condition Possible Cause Correction Excessive pedal travel Pedal stroke too large Partial brake system failure Check brake systems and repair as necessary Insufficient fluid in master cylinder reservoirs Fill reservoirs with approved brake fluid Check for leaks and air in brake systems Check warning light Bleed system if required Air in system pedal soft spongy Bleed system Rear brake system not adjusted malfunctioning auto adjusting mechanism Repair auto adjusting mechanism Adjust rear brakes Bent brake shoes Replace brake shoes Worn rear brake shoes Replace brake shoes Dragging brakes A very light drag is present in all disc brakes immediately after pedal is released Master cylinder pistons not returning correctly Repair master cylinder Restricted brake tubes or hoses Check for soft hoses or damaged tubes and replace with new hoses and or new brake tubes Incorrect parking brake adjustment on rear brakes Check and adju
29. cccceceeeesesseeeeeeeeeeeeees 5 33 Master Cylinder and Brake Fluid Level Brake back plate eeen 5 34 GEC r AEE EE E arent hes eh Ae BA 5 10 Master Cylinder NEE ESERE AE IATE E PAEA 5 36 Rear Drum Brake Shoe Adjustment 5 11 Master Cylinder Reservoir cccccceeeeeeees 5 36 Parking Brake Inspection and Adjustment 5 11 f Master Cylinder Assembly ceee 5 37 Booster Operation Check ccccccccseeeeeees 5 12 5 2 BRAKES Master Cylinder cccceccceeeeeeeeeeeteeeeeeees 5 38 Fill Reservoir 0 0 ceceeeececeeeceeeeeeeeeeeeeeeeeeeetees 5 40 LSPV Load Sensing Proportioning Valve Assembly If Equipped cccseseceeeseee 5 42 LSPV Assembly ccecceeeeeeeeeeeeeetteeeeeees 5 43 P Proportioning Valve cccceeeseseeeeees 5 44 Brake Booster ccccccccccccceeeceseeseessseeseseeseees 5 45 Inspection and adjustment 5 46 Brake HoSe Pipe ccccccceeceeeeeeeeseeeeeeees 5 48 Front brake hoSe pipe ccccceeeeeeeeees 5 48 Rear Brake Hose Pipe cccceceseeeeeeees 5 51 Parking Brake Lever Cable c eeeee 5 52 Parking brake lever 5 52 Parking Brake Cable 5 53 Tightening Torque Specifications 5 54 Required Service Material ccssssesesees 5 54 Special TOON iciccsie c ecstees cg csict enced segeentecietessesace 5 55 BRAKES 5 3 General Description When the foot brake pedal i
30. WATER PUMP AND GENERATOR DRIVE BELT INSPEC TION 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 Water pump and generator belt tension a 4 5 5 5 mm 0 18 0 22 in deflection under 100 N 10 kg 22 Ib pressure NOTE When replacing belt with a new one adjust belt tension to 3 4 mm 0 12 0 16 in 3 If belt is too tight or too loose adjust it to specification by adjusting alternator position 4 Tighten alternator adjusting bolts and pivot bolt 5 Connect negative cable to battery REPLACEMENT Replace belt Refer to Water Pump Belt and Cooling Fan in Sec tion 6B for replacement procedure of pump belt POWER STEERING PUMP AND OR A C COMPRESSOR DRIVE BELTS INSPECTION IF EQUIPPED 1 Disconnect negative cable at battery 2 Inspect belt for cracks cuts deformation wear and cleanli ness If any defect exists replace 0B 6 MAINTENANCE AND LUBRICATION 3 Check belt for tension Power steering pump and or A C compressor drive belt tension a 6 9 mm 0 24 0 35 in deflection under 100 N 10 kg 22 Ib pressure 4 If belt tension is out of above specification adjust it referring to Compressor Drive Belt in Section 1B or Power Steering Belt Check in Section 3B1 1 P S pump pulley 2 Ca
31. ccccccssscsseseessseeeseseeeaes 4B 3 4B 2 PROPELLER SHAFTS General Description Components U 50 N m 5 0 kg m Wy 3 gt T 50 N m 5 0 A U 33 N m 3 3 kg m F 50 N m 5 0 kg m 1 Propeller shaft No 1 2 Propeller shaft No 2 3 Propeller shaft No 3 m Tightening Torque Diagnosis Diagnosis Table Condition Possible Cause Correction Abnormal noise e Loose universal joint bolt Tighten universal joint bolt e Spider bearing worn out or stuck Replace e Wear spider Replace propeller shaft Vibration e Performed propeller shaft Replace Propeller Shaft Joint Check If universal joints are suspected of producing chattering or rattling dex noise inspect them for wear Check to see if cross spider rattles in yokes or if splines are worn down and replace defective propel ler shaft with new one Noise coming from universal joint can be easily distinguished from other noises because rhythm of chattering or rattling is in step with cruising speed Noise is pronounced particularly on standing start or in coasting condition when braking effect of engine is showing in the drive line PROPELLER SHAFTS 4B 3 On Vehicle Service Propeller Shafts REMOVAL 1 Hoist vehicle 2 Drain transmission oil only when servicing propeller shaft No 1 3 Before removing propeller shaft 2 give match marks 1 on each joint flange 3
32. 6 62 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0135 DTC No 14 Heated Oxygen Sensor HO2S Heater Circuit Mal function Sensor 1 CIRCUIT DESCRIPTION ECM B W m th BIP l i ey L o a U 1 Heated oxygen sensor 1 HO2S 1 heater DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is met e HO2S 1 heater circuit open or shorted to ground A e ECM malfunction e Low voltage at terminal E19 7 when engine is running at high load B e High voltage at terminal E19 7 when engine is running under condition other than above 2 driving cycle detection logic Continuous monitoring DTC CONFIRMATION PROCEDURE WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON start engine and keep it at idle for 1 min 3 Start vehicle and depress accelerator pedal fully for 5 sec or longer 4 Stop vehicle 5 Check DTC in DTC mode and pending DTC in ON BOARD TEST or PENDING DTC mode INSPECTION ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 63 Step A
33. 6 84 ENGINE GENERAL INFORMATION AND DIAGNOSIS A Fig 1 for Step 3 B Fig 2 for Step 6 C Fig 3 for Step 6 A B B R C Fig 4 for Step 7 Ee a ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 85 DTC P0400 Exhaust Gas Recirculation Flow Malfunction CIRCUIT DESCRIPTION B ECM BI B N A A E19 18 E19 17 E19 3 E19 2 rl E19 31P E18 24P Tet 017P LI L LIIITI SG E E O A EA E J LITLI HLL LIL Pa E19 29 E19 28 1 EGR valve DTC DETECTING CONDITION POSSIBLE CAUSE e While running at specified vehicle speed after engine warm up e EGR valve or its circuit e During deceleration engine speed high with closed throttle position e EGR passage ON in which fuel cut is involved difference in intake manifold absolute e ECM pressure between when EGR valve is opened at specified value and when it is closed is larger or smaller than specified value 2 driving cycle detection logic monitoring once 1 driving DTC CONFIRMATION PROCEDURE WARNING e When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful d
34. 8 94 in RH steering vehicle 217 223 mm 8 54 8 78 in 2 Check measurement between booster mounting surface and center of clevis pin hole When booster push rod clevis has been reinstalled it is important that the measurement is adjusted Refer to Brake Booster Inspection and Adjust ment in this section 3 Check stop light switch position Adjust it if it is out of specifi cation Brake Pedal Play Check Pedal play should be within specification below If out of specification check stop light switch for proper installation position and adjust if necessary Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defective Brake pedal play a 1 8 mm 0 04 0 31 in Stop Light Switch Adjustment Adjustment should be made as follows when installing switch Pull up brake pedal toward you and while holding it there adjust switch position so that clearance between end of thread and brake pedal is specified Then tighten lock nut to specified torque Clearance between brake pedal and stop light switch c 1 5 2 0 mm 0 06 0 08 in Tightening torque Stop light switch lock nut a 6 5 N m 0 65 kg m 4 7 Ib ft BRAKES 5 9 Excessive Pedal Travel Check 1 Start engine 2 Depress brake pedal a few times 3 With brake pedal depressed with approximately 30 kg 66 lbs load measure brake pedal to wall clearance d or e
35. Lithium grease SUPER GREASE A 99000 25010 e Oil seal lip of P S pump pulley shaft Special Tools 09915 77411 Oil pressure gauge 09915 77420 Oil pressure gauge attachment amp hose set 09944 18211 Torque check socket 09945 35010 Air bleeding hose set 3B1 22 POWER STEERING P S SYSTEM If equipped STEERING WHEEL AND COLUMN 3C 1 SECTION 3C STEERING WHEEL AND COLUMN WARNING severe injury repairs For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer 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 e The procedures in this section must be followed in the order listed to temporarily disable the air bag system and prevent false diagnostic codes from setting Failure to follow procedures could result in possible air bag system activation personal injury or otherwise unneeded air bag system CAUTION When fasteners are removed always reinstall them at the same location from which they were removed If a faste
36. Malfunctioning oil pressure switch Oil pressure switch in Section 8 Clogged oil strainer Oil pan and oil pump strainer in Sec tion 6A1 Functional deterioration of oil pump Oil pump in Section 6A1 Worn oil pump relief valve Oil pump in Section 6A1 Excessive clearance in various sliding parts Refer to Section 6A1 Engine noise Improper valve lash Valve lash in Section 6A1 See NOTE below Worn valve stem and guide Valves and cylinder head in Section 6A1 Weak or broken valve spring Valve springs in Section 6A1 Warped or bent valve Valves and cylinder head in Section 6A1 Loose camshaft housing bolts Camshaft in Section 6A1 Worn piston ring and cylinder bore Pistons and cylinders in Section 6A1 Worn crankpin bearing Crankpin and connecting rod bearing in Section 6A1 Worn crankpin Crankpin and connecting rod bearing in Section 6A1 Loose connecting rod nuts Connecting rod in Section 6A1 Low oil pressure Previously outlined Worn crankshaft journal bearing Main bearings Crankshaft and cylin der block in Section 6A1 Worn crankshaft journal Main bearings Crankshaft and cylin der block in Section 6A1 Loose lower crankcase bearing cap bolts Main bearings Crankshaft and cylin der block in Section 6A1 Excessive crankshaft thrust play Main bearings Crankshaft and cylin der
37. ON BOARD TEST DTC flow table Is DTC or pending DTC displayed 2 Set scan tool to READINESS TESTS mode No DTC is detected Repeat DTC confirmation and check if testing has been completed Confirmation test is com procedure Is test completed pleted INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 1 Turn ignition switch ON Go to Step 3 Go to Step 6 2 Does EGR stepper motor operation for 0 6 second after ignition switch OFF 3 With ignition switch at OFF check voltage Go to Step 4 Go to Step 8 between E19 28 17 29 18 terminals of ECM and body ground See Fig 2 Is voltage about 0 V ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 87 Step Action Yes No 4 With ignition switch at ON check voltage Go to Step 5 Go to Step 8 between E19 28 17 29 18 terminals of ECM and body ground See Fig 2 Is voltage within 10 14 V 5 Do you have SUZUKI scan tool Go to Step 6 Stuck or faulty EGR valve or clogged EGR gas pas sage If all above are OK sub stitute a known good ECM and recheck 6 Check EGR system referring to EGR System Substitute a known good Stuck or faulty EGR valve in Section 6E ECM and recheck or clogged EGR gas pas Is check result satisfactory sage 7 1 Disconnect EGR valve connector with igni Go to Step 3 BI B wire open
38. VACUUM SWITCH 1 Disconnect coupler from vacuum switch and check resis tance between two terminals of vacuum switch If resistance is out of specification replace Resistance of vacuum switch More than 1 MQ 2 Connect vacuum pump gauge and apply vacuum more than 40 kPa 0 40 kg cm 5 70 Psi then check resistance between terminals of vacuum switch If resistance is out of specification replace Vacuum switch resistance Less than 0 8 Q Special tool A 09917 47910 4WD SWITCH Refer to 4WD Switch in Section 7D VACUUM HOSE PIPE Inspect vacuum hoses for leaks or cracks vacuum pipes for cracks dents or corrosion If defective replace FRONT SUSPENSION 3D 13 CHECK VALVE lt Remove check valve 1 2 Close B side of check valve with finger as shown and apply 50 cmHg vacuum by means of vacuum pump Then check that vacuum is applied Apply vacuum to another side of check valve and check that vacuum is not applied Replace if defective Special tool A 09917 47910 A Intake manifold side B Vacuum switching valve side Stabilizer bar bushing check BAR Inspect for damage or deformation If defective replace BUSHING Inspect for damage wear or deterioration If defective replace 3D 14 FRONT SUSPENSION Shock Absorber and or Coil Spring Check 1 Inspect shock absorber for oil leakage If shock absorber is found faulty re
39. DTC mode on scan tool and check DTC 6 80 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table Check CKP Sensor and connector for proper installation Is CKP sensor installed properly and connector connected securely Go to Step 3 Correct Check Wire Harness and Connection 1 Disconnect connector from CKP sensor 2 Check for proper connection to CKP sensor at each terminal 3 If OK turn ignition switch ON and check for voltage at each terminal of sensor connector disconnected See Fig 1 Terminal B 10 14 V Terminal Vout 4 5 V Terminal GND 0 V Is check result satisfactory Go to Step 5 Go to Step 4 Was terminal Vout voltage out of specification in Step 3 check G R wire open short or poor connection If wire and connection are OK substitute a known good ECM and recheck BI B or B R wire open short or poor connection Check Ground Circuit for Open 1 Turn ignition switch OFF 2 Check for continuity between GND terminal of CKP sensor connector and engine ground Is continuity indicated Go to Step 6 B R wire open or poor ground connec tion Check CKP Sensor for Operation 1 Remove CKP sensor from sensor case 2 Remove metal particles on end face of CKP
40. Investigate leaky point correct it and add brake fluid Brake warning light circuit faulty Repair circuit BRAKES 5 7 Condition Possible Cause Correction Brake warning light turns on when brake is applied Brake fluid leaking from brake line Investigate leaky point correct it and add brake fluid Insufficient amount of brake fluid Add brake fluid Faulty P amp Differential valve Differential switch Replace Brake warning light fails to turn on even when parking brake is applied Bulb burnt out Replace bulb Brake warning light circuit open Repair circuit ABS warning light does not turn on for 2 sec after ignition switch has turned ON Bulb burnt out Replace bulb ABS warning light circuit open if equipped with ABS including check relay Check system referring to TABLE A in Section 5E ABS warning light remains on after igni tion switch has turned on for 2 sec Malfunctioning ABS if equipped with ABS Check system referring to TABLE B in Section 5E 5 8 BRAKES q q i 1 I 4 t t 1 I i t N Brake Pedal Free Height Adjustment 1 Check brake pedal free height If it is not within specification check and adjust following item 2 and 3 Brake pedal free height a from wall LH steering vehicle 221 227 mm 8 70
41. Replace bulb Is bulb of ABS warning lamp in good condition If OK replace ABS warning cir cuit lamp driver module 4 jls IG fuse in good condition Open in B W wire to combina Repair and replace 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 F 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 Is malfunction DTC other than code No 12 exists at step 1 Go to step 7 of ABS diag nostic flow table in this section Go to step 3 1 Disconnect ABS hydraulic unit control module connector 2 Check for proper connection to ABS hydrau lic unit control module connector at termi nals A14 and A18 3 If OK turn ignition switch ON and mea sure voltage at terminal A18 of connector Is it 10 14 V Go to step 4 B W circuit open 1 With ABS control module connector discon nected turn ignition switch ON and light ABS warning lamp 2 Connect terminal A14 of disconnected connector to ground using service wire Does ABS warning lamp turn off Go to step 5 R BI circuit open If wire and connection are OK replace ABS lamp driver module 1 Measure resistance from conn
42. Valve lash clearance out of specification much and how often crankshaft revolution speed e Manifold absolute pressure sensor malfunction changes is higher than specified value e Engine coolant temp sensor malfunction e PCV valve malfunction e EVAP control system malfunction e EGR system malfunction DTC CONFIRMATION PROCEDURE NOTE Among different types of random misfire if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2 simultaneously it may not possible to reconfirm DTC by using the following DTC confirmation proce dure When diagnosing the trouble of DTC P0300 Random misfire detected of the engine which is apparently misfiring even if DTC P0300 cannot be reconfirmed by using the following DTC confirma tion procedure proceed to the following Diag Flow Table WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Check vehicle and environmental condition for Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower Engine coolant temp 10 110 C 14 230 F 4 Start engine and kee
43. W wire open shorted to ground circuit or poor E19 25 connection If wire and connection are OK substitute a known good ECM and recheck 6 78 ENGINE GENERAL INFORMATION AND DIAGNOSIS A Fig 1 for Step 2 B Fig 2 for Step 3 A E19 25 E19 GIP Eia aP E17 017P ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 79 DTC P0335 DTC No 23 Crankshaft Position CKP Sensor Circuit Malfunction CIRCUIT DESCRIPTION ECM B T i BI B GIR B R th E19 31P Mm E18 24P E17 17P cI LT tH CITITTT CONC LT yt TJ CELL A E19 23 DTC DETECTING CONDITION POSSIBLE CAUSE e NO CKP sensor signal for 2 seconds at engine crank e CKP sensor circuit open or short ing e Signal teeth damaged e CKP sensor malfunction foreign material being attached or improper installation e ECM malfunction REFERENCE Connect oscilloscope between terminals E19 23 of ECM connector connected to ECM and body ground and check CKP sensor signal A 2V DIV 2V DIV 2ms DIV 1 2 2ms DIV B C 1 10 signal A Oscilloscope Waveforms C Waveforms at 2000 rpm 2 30 signal B Waveforms at idle speed DTC CONFIRMATION PROCEDURE 1 Clear DTC and crank engine for 2 sec 2 Select
44. e Check sliding surface of relief valve for wear and damage POWER STEERING P S SYSTEM If equipped 3B1 15 e Check free length of relief valve spring 1 Replace pump assembly if any defective is found Relief valve spring free length Standard 36 5 mm 1 44 in Limit 33 5 mm 1 32 in ASSEMBLY Reverse disassembly procedure for assembly noting the follow ing 1 Apply power steering fluid to shaft 2 outer surface and grease to oil seal lip 1 and insert it from oil seal side A Grease 99000 25010 2 Apply power steering fluid to O rings and fit them to pump body 3 Install side plate 2 to pump body NOTE Carefully align the dowel pins 3 on the side plate 2 at bolt hole 1 as shown in figure 4 Apply power steering fluid to sliding surface of rotor 1 5 Install rotor 1 to shaft directing dot 2 marked side of rotor toward pump cover facing up 6 Install new snap ring to shaft then make sure to fit snap ring into shaft groove securely NOTE Never reuse the removed snap ring 3B1 16 POWER STEERING P S SYSTEM If equipped 7 Apply power steering fluid to sliding surface of cam ring 1 8 Install cam ring 1 to pump body The tapered end of cam ring 1 should face the side plate 2 9 Apply power steering fluid to each vane 2 10 Install vanes 10 pipes 2 to
45. e 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 e Road test should be carried out with 2 persons a driver and a tester 1 Turn ignition switch OFF Clear DTC with ignition switch ON check vehicle and environmental condition for Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower Warm up engine to normal operating temperature Drive vehicle at 30 40 mph 50 60 km h for 2 min Stop vehicle and run engine at idle for 2 min Check DTC in DTC mode and pending DTC in ON BOARD TEST or PENDING DTC mode 2 3 4 5 x wr wa 6 60 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Is there DTC s other than HO2S 1 Go to applicable DTC Go to Step 3 DTC P0130 Diag Flow Table 3 1 Connect scan tool to DLC with ignition Intermittent trouble Check R and B BI switch OFF See Fig 1 2 Warm up engine to normal operating tem perature and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from ped
46. netic switch Lead wire coupler loose in place Retighten Open circuit between ignition switch and magnetic Repair switch Open circuit in pull in coil Replace magnetic switch Brushes are seating poorly or worn down Repair or replace Poor sliding of plunger and or pinion Repair Motor not running Operating sound of magnetic switch heard Battery run down Recharge battery Battery voltage too low due to battery deteriora tion Replace battery Loose battery cable connections Retighten Burnt main contact point or poor contacting action of magnetic switch Replace magnetic switch Brushes are seating poorly or worn down Repair or replace Weakened brush spring Replace Burnt commutator Replace armature Layer short circuit of armature Replace Crankshaft rotation obstructed Repair Starting motor running but too slow small torque If battery and wiring are satisfac tory inspect starting motor Insufficient contact of magnetic switch main con tacts Replace magnetic switch Layer short circuit of armature Replace Disconnected burnt or worn commutator Repair commutator or replace armature Worn brushes Replace brush Weakened brush springs Replace spring Burnt or abnormally worn end bush Replace bush Starting motor run ning but not cranking engine Worn pinion tip Replace over runnin
47. 16 N m 1 6 kg m 11 5 Ib ft 9 Tighten wheel speed sensor bolt to specified torque if equipped with ABS Tightening torque Wheel speed sensor bolt c 10 N m 1 0 kg m 7 5 Ib ft 1 Wheel speed sensor 10 Install parking brake cable 3 to brake back plate 1 2 Cable stopper ring 11 Install brake shoes referring to Brake Shoe in Section 5 12 Install brake drum Refer to Rear Brake Drum in Section 5 13 Refill differential housing with new specified gear oil Refer to Maintenance Service in Section 7E for refill 14 Fill reservoir with brake fluid and bleed brake system For bleeding operation refer to Bleeding Brakes in Section 5 15 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 5 Ib ft REAR SUSPENSION 3E 17 16 Upon completion of all jobs depress brake pedal with about 30 kg 66 Ibs load over ten times so as to obtain proper drum to shoe clearance Adjust parking brake cable For adjustment refer to Parking Brake Check and Adjustment in Section 5 17 Tighten parking brake lever cover screws 18 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 19 Check each installed part for oil leakage Rear Axle Shaft Inner Oil Seal
48. 5 ECM Power Circuit Check Check Go to Step 6 1 Using service wire ground terminal E18 10 and measure voltage ground cir between terminal E18 5 and ground at ignition switch ON cuits B and Is it 10 14 V B P for open If OK then substitute a known good ECM and recheck 6 Is operating sound of main relay heard in Step 1 Go to Step 7 BI B or B PR wire open 7 Main Relay Check Or or BI B Replace main 1 Check main relay according to procedure in Step 2 wire open relay A Fig 1 for Step 2 and 3 B Fig 2 for Step 2 C Fig 3 for Step 2 B C 2 F1 fuse 6 48 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0105 DTC No 11 Manifold Absolute Pressure MAP Circuit Malfunc tion CIRCUIT DESCRIPTION ECM Lg R B BI GIP un 4P l 7P E E19 22 DTC DETECTING CONDITION POSSIBLE CAUSE e MAP sensor signal is 0 19 V or lower e B BI circuit open Low pressure High vacuums Low voltage e Lg R circuit open or shorted to ground e MAP sensor signal is 4 5 V or higher e Q circuit open or shorted to ground High pressure Low vacuums High voltage e MAP sensor malfunction e ECM malfunction NOTE e When DTC P0120 is indicated together it is possible that Lg R circui
49. 7 Chain tensioner mounting bolt 4 Timing chain tensioner 8 Chain guide mounting bolt REMOVAL SS Q o wo oN le a i EEX o oo Q k D N amp J ar 4 ee oer 0 e lt a OII y 50 5 ooo 090 0 1 Remove timing chain cover referring to Timing Chain Cover 2 Align both intake and exhaust camshaft timing sprocket marks 1 with notches 2 of cylinder head respectively by turning crankshaft 3 Remove timing chain tensioner adjuster assembly 3 4 Remove timing chain tensioner 4 5 Remove timing chain No 1 guide 5 6 Remove timing chain 6 with crankshaft timing sprocket 7 CAUTION After timing chain is removed never turn crankshaft and camshafts independently more than its allowable turning range described in INSTALLATION section If turned interference may occur between piston and valves and valves themselves and parts related to piston and valves may be damaged 6A1 38 ENGINE MECHANICAL M13 ENGINE INSPECTION Timing chain tensioner e Check shoe 1 for wear or damage Crankshaft timing sprocket e Check teeth of sprocket for wear or damage Timing chain e Check timing chain for wear or damage Timing chain tensioner adjuster e Check that tooth surface 1 are free from damage Timing chain No 1 guide e
50. 95 F Engine rpm Keep to 1 500 rpm Blower fan motor switch H 3rd position Temperature control Cool Air outlet control Face Vehicle doors All open Air inlet door position Recirculation 7 With dry bulb thermometer 1 inserted into center duct air outlet and another one set near evaporator air inlet read temperature indicated on each thermometer Pressure of High Pressure Gauge Pressure of Low Pressure Gauge psi kPa kg cm 284 4 270 2 256 0 241 7 227 5 213 3 199 1 184 9 170 6 151 4 142 2 128 0 113 8 99 5 85 3 71 1 56 9 427 28 4 14 2 2000 1900 1800 1700 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 20 10 O N O A A QNO O Ambient Temperature 68 66 2 64 4 62 6 60 8 59 57 2 55 4 53 6 51 8 50 48 2 46 4 44 6 42 8 41 0 39 2 37 4 35 6 33 8 Temperature at Center Duct Air Outlet oO N OUO A A Q N G amp D 15 59 Temperature at Evaporator Air Inlet AIR CONDITIONING OPTIONAL 1B 11 8 Check if each pressure on low side and on high side is within shaded range of the graph If each gauge reading is out of specified pressure correct defective part referring to Performance Diagnosis Table in this section NOTE Pressure regi
51. A If it exceeds limit replace with new one B Cylinder head bolt diameter measurement points a 83 5 mm 2 81 in b 115 mm 4 53 in Cylinder head bolt diameter difference deformation Limit A B 0 1 mm 0 004 in a lt Tighten cylinder head bolts 1 10 to 20 N m 2 0 kg m 14 5 lb ft according to numerical order as shown by using a 12 corner socket wrenches b In the same manner as in Step a tighten them to 40 N m 4 0 kg m 29 0 lb ft c Retighten all bolts 60 according to numerical order in fig ure d Repeat Step c e Tighten bolt A to specified torque NOTE Be sure to tighten M8 bolt A after securing the other bolt Tightening torque Cylinder head bolt for M8 a 22 N m 2 2 kg m 16 0 Ib ft Cylinder head bolts for M10 b 40 N m 4 0 kg m 29 0 Ib ft and extra tightening 60 twice ENGINE MECHANICAL M13 ENGINE 6A1 61 6 Install exhaust manifold stiffener and exhaust pipe referring to Exhaust Manifold in this section 7 Install camshafts timing chain and chain cover referring to Camshaft Tappet and Shim Timing Chain and Chain Tensioner and Timing Chain Cover in this section 8 Install cylinder head cover and oil pan referring to Cylinder Head Cover and Oil Pan and Oil Pump Strainer in this sec tion 9 Install intake manifold stiffener and connect each hoses
52. B 6 B R ami B R BR 1 E18 5 E18 2 M 31P M 24P 17P ee ee ee i ae LET yi u CICO Py t i i E18 14 E18 11 E17 9 1 Main fuse 4 Main relay 7 IG fuse A Case of TYPE A is shown See NOTE 2 Ignition switch 5 Malfunction indicator lamp in 8 IG COIL METER fuse B Case of TYPE B is shown combination meter See NOTE 3 Fuse box 6 FI fuse NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model When the ignition switch is turned ON ECM causes the main relay to turn ON close the contact point Then ECM being supplied with the main power turns 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 fuse blown main fuse 1 Turn ignition switch ON blown ignition switch mal Do other indicator warning lights in combina function B W circuit tion meter comes ON between IG fuse and combination meter or poor coupler connection at combination meter 6 44 ENGINE GENERAL INFORMATION AND
53. CKP Sensor Circuit Malfunction 6 79 DTC P0340 DTC No 15 Camshaft Position CMP Sensor Circuit Malfunction 6 82 DTC P0400 Exhaust Gas Recirculation Flow Malfunction aaeain ataa 6 85 DTC P0420 Catalyst System Efficiency below Threshold wc ecececsestessiecccsesssssecsceceestetbiaedeieesees 6 88 DTC P0443 Purge Control Valve Circuit MalfUNCTION Maaa EEE EE EAA 6 91 DTC P0481 A C Condenser Fan Control Circuit Malfunction cccceceeeseseessteeneeees 6 92 DTC P0500 DTC No 16 Vehicle Speed Sensor VSS Malfunction ceeeeee 6 94 DTC P0505 Idle Control System Malfunction cceeceeeeeeeeeesessteeaseeeeeeeeeeeeees 6 96 DTC P0601 Internal Control Module Memory Check Sum Error DTC NO 71 eee 6 98 DTC P1450 Barometric Pressure Sensor Low High INp t eener 6 99 DTC P1451 Barometric Pressure Sensor Performance Problem cccccccccceeeeeeeeeeeees 6 99 DTC P1500 Engine Starter Signal Circuit Malfunction cecceeeeeesstseeteeeeeeeeeeeeeeeeees 6 101 DTC P1510 ECM Back up Power Supply Malfunction ceceeeeseeeeseetteeeeseeeeeeeeeesens 6 103 DTC P1570 DTC No 21 ABS Signal Circuit Malfunction cceceeeeseeesteeeteeeeceeeeeeeeeeeess 6 104 DTC P1600 Serial Communication Problem Between ECM and TOM seeen 6 105 DTC P1717 A T Drive Range Park Neutral Position Signal Circuit Malfunction 6 107 Table B 1 Fuel Injector C
54. Correction AWD Indicator light flashing Hub locking procedure error Shift transfer shift control lever 2WD 4WD once again error Abnormality in 4WD control system Air leakage from vacuum circuit Clogged vacuum hose or pipe Defective check valve or vacuum tank e Defective VSV2 Replace e Defective vacuum switch Replace e Defective check valve or vacuum tank Replace e Air leak from vacuum circuit Check and repair e Clogged vacuum hose or pipe Replace e Faulty 4WD controller Check and replace 2WD 4WD switching Defective air locking hub assembly Replace Inspect referring to 4WD Control System Diagnostic Flow Table Check and replace Replace Replace 4WD CONTROL SYSTEM DIAGNOSTIC FLOW TABLE Before performing the trouble diagnosis check that the air locking hub assemblies are in good condition and there is no air leakage from vacuum hoses and vacuum pipe Refer to 4WD Control System Check in this sec tion for air leakage NOTES ON SYSTEM CIRCUIT INSPECTION e Be sure to read Precautions for Electrical Circuit Service in Section OA before circuit inspection and observe what is written there e For system circuit refer to the figure of System Circuit in this section Step Action Yes No troller at all termi body ground 1 Check ground circuit 1 Disconnect coupler from 4WD controller with ignition switch OFF 2 Check for prope
55. Defective wheel cylinders Repair or replace Malfunctioning caliper assembly Repair or replace Air in system Bleed system Maladjusted sensor spring length of LSPV Check or adjust Broken sensor spring of LSPV Replace Defective collar of LSPV Replace Malfunctioning ABS Antilock brake system if equipped Check system and replace as nec essary Brake pull Brakes not working in unison Pad or shoe linings are wet with water or stained with oil in some brakes Replace Drum to shoe clearance out of adjustment in some brakes Malfunctioning auto adjusting mechanism Check for inoperative auto adjusting mechanism Drum is out of round in some brakes Replace Wheel tires are inflated unequally Inflate equally Malfunctioning wheel cylinders Repair or replace Disturbed front wheel alignment Adjust as prescribed Unmatched tires on same axle Tires with approximately the same amount of tread should be used on the same axle Restricted brake tubes or hoses Check for soft hoses and damaged lines Replace with new hoses and new double walled steel brake tubing Malfunctioning caliper assembly Check for stuck or sluggish pistons and proper lubrication of caliper slide bush Loose suspension parts Caliper should slide Check all suspension mountings Loose calipers Check and torque bolts to specifica tions
56. General Description 0 ecceeeeeeeeeeeeeeeeeeeeees 6 6 On Board Diagnostic System Vehicle with Immobilizer Indicator Lamp ee 6 6 6 2 ENGINE GENERAL INFORMATION AND DIAGNOSIS Diagnostic trouble code DTC table 6 16 Fail safe table ccceeceeeeeeeeseeeeeeeeeeeeees 6 19 Visual inspection 00 cece eee 6 20 Engine basic inspection secc 6 21 Engine diagnosis table eee 6 23 Scan Tool Data cceceeccceeeeeeeeeeeeeeeeeeeees 6 28 Scan tool data definitions ee 6 30 Inspection of ECM and Its Circuits 6 33 Component Location e ceeeeeeeeeeeeeeeees 6 42 Table A 1 Malfunction Indicator Lamp Circuit Check Lamp Does Not Come ON at Ignition Switch ON But Engine at Stop 6 43 Table A 2 Malfunction Indicator Lamp Circuit Check Lamp Remains ON after Engine Table A 3 Malfunction Indicator Lamp Circuit Check Mil Flashes at Ignition Switch ON 6 45 Table A 4 Malfunction Indicator Lamp Circuit Check MIL Does Not Flash Just Remains ON or Just Remains OFF Even with Grounding Diagnosis Switch Terminal 6 45 Table A 5 ECM Power and Ground Circuit Check MIL Doesn t Light at Ignition Switch ON and Engine Doesn t Start Though It Is Cranked Up cccceeceeeceeeeeeeeeeeeeeeeeteeeeneeeeeees 6 46 DTC P0105 DTC No 11 Manifold Absolute Pressure MAP Circuit Malfunction 6 48 DTC P0110 DTC No 1
57. Malfunctioning EGR valve if equipped EGR system in Section 6E Poor performance of knock sensor ECT sensor or MAP sensor Knock sensor in this section ECT sensor or MAP sensor in Section 6E Faulty injector Diagnostic Flow Table B 1 Faulty ECM Inspection of ECM and its circuit in this section Excessive combustion chamber deposits Piston and cylinder head in Section 6A1 Overheating Inoperative thermostat Thermostat in Section 6B Faulty A C condenser fan motor or its cir cuit A C condenser fan control system check in Section 6E Loose or slip water pump belt ITEM1 1 Drive belt inspection and change in Section OB Poor water pump performance Water pump in Section 6B Clogged or leaky radiator Radiator in Section 6B Improper engine oil grade ITEM1 3 Engine oil and oil filter change in Section OB Clogged oil filter or oil strainer Oil pressure check in Section 6A1 Poor oil pump performance Oil pressure check in Section 6A1 Dragging brakes Diagnosis Table in Section 5 Slipping clutch Diagnosis Table in Section 7C Blown cylinder head gasket Valves and cylinder head in Section 6A1 Poor gasoline mileage Faulty ignition coil Ignition coil assembly in Section 6F Fuel pressure out of specification Diagnostic Flow Table B 3 Faulty TP sensor ECT sensor or MAP sensor TP sensor ECT sensor or
58. Oil seal mod Cylinder head cover amount 2 Apply engine oil to oil seal lip Apply sealant 99000 31150 to the sealing point for timing chain cover mating surface and cylinder head gasket sealing point Refer to Cylinder Head Cover Installation a 3mm 0 12 in Timing chain cover Tightening torque Apply sealant 99000 31140 to the mating surface of cylinder and cylinder head Apply sealant 99000 31150 to the mating surface of timing chain cover referring to the figure of Step 1 in INSTALLATION b 2 mm 0 08 in Pin Do not reuse 1 Crankshaft pulley bolt Cylinder head cover gasket 2 Crankshaft pulley Timing chain cover mounting bolts 1 Disconnect negative cable at battery 2 Remove A C compressor and or P S pump belt equipped 3 Remove generator belt 4 Drain engine oil if ENGINE MECHANICAL M13 ENGINE 6A1 29 5 Drain coolant WARNING To help avoid danger of being burned do not remove drain plug 1 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 6 Disconnect radiator inlet and outlet hoses from each pipe 7 Disconnect A T fluid hoses 1 vehicle with A T and release its clamps Place some container under radiator to receive A T fluid which will flow out when hose is disconnected 8 Remove fan shroud upper b
59. PENDING DTC mode 2 3 SS wa INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Is SUZUKI scan tool available Go to Step 3 Go to Step 4 3 Check TP Sensor and Its Circuit Substitute a known good Go to Step 5 1 Turn ignition switch OFF and connect ECM and recheck SUZUKI scan tool to DLC See Fig 1 2 Turn ignition switch ON and check TP sen sor output voltage when throttle valve is at idle position and fully opened See Fig 3 Dose voltage vary within specified value linearly as shown in figure 6 58 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1 Turn ignition switch OFF 2 Disconnect TP sensor connector 3 Check for proper connection to TP sensor at each terminal 4 If OK then measure resistance between terminals and check if each measured value is as specified below See Fig 4 TP sensor resistance Between 1 and 2 4 0 6 0 kQ Between 1 and 3 0 02 6 0 KQ varying according to throttle valve opening Are measured values as specified Lg or B BI circuit If wire and connection are OK substitute a known good ECM and recheck Step Action Yes No 4 Check TP Sensor and its Circuit If voltmeter was used Go to Step 5 1 Turn ignition switch ON check terminal E19 16 for 2 Check voltage at terminal E19 16 of ECM poor connection connector con
60. REMOVAL A 2 Disconnect negative cable at battery Disconnect EGR valve connector xw wre re wm 3 Remove EGR pipe 4 Remove EGR valve and gasket from cylinder head INSPECTION 1 Check resistance between following terminals of EGR valve sat 1 in each pair 2 If found faulty replace EGR valve assembly He EGR valve resistance Terminal Standard resistance A B C B F E 20 240 D E 2 Remove carbon from EGR valve 1 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 assembly INSTALLATION Reverse removal procedure noting following e Clean mating surface of valve and cylinder head e Use new gaskets Evaporative emission EVAP control system EVAP CANISTER PURGE INSPECTION NOTE Before inspection 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 6E 40 ENGINE AND EMISSION CONTROL SYSTEM 1 Disconnect purge hose 1 from EVAP canister 2 Place finger against the end of disconnected hose and check that vacuum is not felt there when engine is cool and running at idle speed 3 Connect purge hose to EV
61. Steering wheel play is Loose steering shaft nut Retighten large and vehicle wan Loose linkage or joint Retighten ders Loose gear box fixing bolt Retighten Front wheel bearing worn Replace Fluid leakage Loose joints of hydraulic pressure pipes and Retighten hoses Deformed or damaged pipes or hoses Correct or replace Gear box Replace gear box assembly 3B1 4 POWER STEERING P S SYSTEM If equipped Condition Possible Cause Correction Abnormal noise See NOTE D Air drawn in due to insufficient fluid Replenish fluid Air drawn in through pipe or hose joints Retighten or replace Belt slipping loose Adjust Worn belt Replace Loose steering linkage Retighten Loose gear box fixing bolt Retighten Loose pitman arm Retighten Pipes or hoses in contact with chassis Correct Defective pump vane Replace pump assembly Malfunction of flow control valve Replace gear box assembly Defective pump shaft bearing Replace pump assembly NOTE e C Turn steering wheel 90 at 35 km h 22 mile h and let it free If it returns more than 60 then it is normal e D Some hissing noise may be heard through steering column when turning steering wheel with vehicle halted It is from operation of the valve in the gear box and indicates nothing abnormal POWER STEERING P S SYSTE
62. s paint dot should be aligned with the tire s paint dot as shown in left fig ure Whenever a tire is dismounted from its wheel it should be remounted so that the tire and wheel are matched If the tire s paint dot cannot be located a line should be scribed on the tire and wheel before dismounting to assure that it is remounted in the same position Inflation of Tires The pressure recommended for any model is carefully calculated to give a satisfactory ride stability steering tread wear tire life and resistance to bruises Tire pressure with tires cold after vehicle has set for three hours or more or driven less than one mile should be checked monthly or before any extended trip Set to the specifications on the tire placard located on the driver s side door lock pillar It is normal for tire pressure increase when the tires become hot during driving Do not bleed or reduce tire pres sure after driving Bleeding reduces the Cold Inflation Pressure Higher than Recommended Pressure Can Cause 1 Hard ride 2 Tire bruising or carcass damage 3 Rapid tread wear at center of tire Unequal Pressure on Same Axle Can Cause 1 Uneven braking 2 Steering lead 3 Reduced handling 4 Swerve on acceleration Valve caps should be kept on valves to keep dust and water out WHEELS AND TIRES 3F 7 Lower than Recommended Pressure Can Cause 1 Tire squeal on turns 2 Hard steering 3 Rapid and uneven we
63. 0 18 0 22 in as deflection 10 kg 22 Ibs NOTE When replacing belt with a new one adjust belt tension to 3 4 mm 0 12 0 16 in 3 If belt is too tight or too loose adjust it to proper tension by displacing generator position 4 Tighten generator adjusting bolt and pivot bolts as specified torque Tightening torque Generator adjusting bolt a 23 N m 2 3 kg m 17 0 lb ft Generator pivot bolts b 50 N m 5 0 kg m 36 0 Ib ft 5 Connect negative cable at battery terminal 6B 10 ENGINE COOLING On Vehicle Service CAUTION e Check to make sure that engine coolant temperature is cold before removing any part of cooling system e Disconnect negative cable at battery before removing any part Cooling System Component wee 0 or 1 14 B 25 N m 2 5 kg m a aS 1 Radiator 6 Thermostat 11 Water outlet cap 2 Reservoir 7 Thermostat cap 12 Thermostat case outlet pipe 3 Cooling fan shroud 8 Radiator outlet pipe 13 Thermostat cap bolt 4 Water outlet pipe 9 Heater pipe 14 Thermostat case bolt 5 Thermostat case 10 ECT sensor m Tightening Torque ENGINE COOLING 6B 11 Coolant Draining Remove radiator cap 1 Loosen drain plug on radiator to drain coolant 3 After draining coolant be sure to tighten drain plug securely Fill cooling system Refer to Coolant in this sectio
64. 1 Turn ignition switch OFF 2 Disconnect IAC valve connector 3 Check for proper connection to IAC valve at each terminals 4 If OK disconnect ECM connector 5 Check for proper connection to ECM at E19 6 terminal 6 If OK check BI B G Y and B R circuit for open and short Are they in good condition recheck A Fig 1 for Step 3 B Fig 2 for Step 4 6 98 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0601 Internal Control Module Memory Check Sum Error DTC No 71 DTC DETECTING CONDITION POSSIBLE CAUSE DTC P0601 Data write error or check sum error when written into ECM 2 driving cycle detection logic continuous monitoring ECM DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 3 Start engine and run it at idle if possible Clear DTC with ignition switch ON and then turn ignition switch OFF 4 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode INSPECTION Substitute a known good ECM and recheck ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 99 DTC P1450 Barometric Pressure Sensor Low High Input DTC P1451 Barometric Pressure Sensor Performance Problem WIRING DIAGRAM CIRCUIT DESCRIPTION Barometric pressure sensor is installed in ECM DTC DETECTING CONDITION POSSIBLE CAUSE DTC P1450 1 6 V or lower e ECM barometric pressure sensor malfunc e Ba
65. 99000 31150 To apply to water pump mating surface Tightening Torque Specification Tightening torque Fastening part Nem kg m bt Water pump bolt 23 2 3 17 0 Thermostat cap bolt 11 1 1 8 0 Thermostat case bolt 25 2 5 18 0 Fun clutch bolt 11 1 1 8 0 6B 18 ENGINE COOLING ENGINE FUEL 6C 1 SECTION 6C ENGINE FUEL CONTENTS General Description ccssssssssssesesseeseeeeees 6C 2 Fuel Lines cccceeeeeeeceeeeeeeeeeeeceeeaeessseeeeeees 6C 4 Fuel System cccsessesseseseseessceseversserseesesess 6C 2 Fuel Filler CAD secs cs cntctnsarescauintavneetarnintasceet 6C 4 FUCI Tank cecccccccccccccccccccccceccececccecesettttttttttttees 6C 2 Fuel Tank ccsceeceeeeeeeeeeeeseeeeeeeseeseeeeeees 6C 4 Fuel Pump Assembly s 6C 3 Fuel Pump Assembly seeeeeereeeeeeeees 6C 7 Fuel Filler Cap cccccccscsceeeeeeeseeeeeeeeeeeees 6C 3 Tightening Torque Specification 6C 10 On Vehicle ServiCe cccecseseeeeeeeeeesseeeees 6C 4 Special TOO Msi wcccieececes sth ceeceet a ivcdececencecetestenze 6C 10 CAUTION For vehicles with a catalytic converter be sure to use unleaded fuel only Use of leaded and or low lead fuel can result in engine damage and reduce the effectiveness of the emission control system 6C 2 ENGINE FUEL Fuel System General Description The main components of the fuel system are fuel tank fu
66. ACCELERATOR PEDAL OPERATION Check that pedal operates smoothly without getting caught or interfered by any other part ENGINE START Check engine start for readiness WARNING Before performing the following check be sure to have enough room around the vehicle Then firmly apply both the parking brake and the regular brakes Do not use the accelerator pedal If the engine starts be ready to turn off the ignition promptly Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage On automatic transmission vehicles try to start the engine in each select lever position The starting motor should crank only in P Park or N Neutral On manual transmission vehicles place the shift lever in Neutral depress clutch pedal fully any try to start EXHAUST SYSTEM CHECK Check for leakage cracks or loose supports CLUTCH FOR MANUAL TRANSMISSION Check for the following e Clutch is completely released when depressing clutch pedal e No slipping clutch occurs when releasing pedal and accelerating e Clutch itself is free from any abnormal condition MAINTENANCE AND LUBRICATION 0B 21 GEARSHIFT OR SELECTOR LEVER TRANSMISSION Check gear shift or selector lever for smooth shifting to all positions and for good performance of transmission in any position With automatic transmission equipped vehicle also check that shift indicator indicates pr
67. Also fuel tank may drop and cause personal injury 1 Relieve fuel pressure in fuel feed line referring to Fuel Pres sure Relief Procedure in Section 6 2 Disconnect negative cable at battery 3 Remove fuel filler cap ENGINE FUEL 6C 5 4 Insert hose of a hand operated pump into fuel filler hose 1 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 2 5 Hoist vehicle 6 Remove exhaust center pipe referring to Components in Section 6K and rear propeller shaft referring to Propeller Shafts in Section 4B lt N Disconnect coupler 1 for fuel pump assembly The coupler is close by left rear suspension coil spring 3 2 2 Fueltank 8 Remove fuel tank filler hose protector Disconnect filler hose and breather hose from fuel filler neck Disconnect fuel vapor hose from pipe With fuel tank supported on a jack remove fuel tank bolts Ko 10 lt 11 Lower fuel tank a little and hold it Unclamp fuel hoses and disconnect them from fuel pump assembly 1 When disconnecting joints of fuel feed line and return line from pipe unlock joint by inserting special tool between pipe 3 and joint lock first Special tool A 09919 47020 2 Quick joint 5 Disconnect joint 4 Inse
68. CMP sensor 11 Sensed information MAP sensor ECT sensor IAT sensor TP sensor Knock sensor VSS Park Neutral position signal Electric load signal Engine start signal Test switch terminal 6 CKP sensor Diagnosis Condition Possible Cause Correction Engine cranks but will not start or hard to start No spark Blown fuse for ignition coil Replace Loose connection or disconnection of or high tension cord s lead wire Connect securely Faulty high tension cord s Replace Faulty spark plug s Adjust clean or replace Faulty ignition coil Replace ignition coil assembly Faulty CKP sensor or CKP sensor plate Clean tighten or replace Faulty ECM Replace Poor fuel economy or engine performance Incorrect ignition timing Check related sensors and CKP sensor plate Faulty spark plug s or high tension cord s Adjust clean or replace Faulty ignition coil assembly Replace Faulty CKP sensor or CKP sensor plate Clean tighten or replace Faulty ECM Replace 6F 4 IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM IGNITION SYSTEM DIAGNOSTIC FLOW TABLE Step Action Yes No Was Engine Diagnostic Flow Table in Section 6 per Go to Step 2 Go to Engine Diag 1 formed Flow Table in Section 6 Ignition Spark Test Go to Step 11 Go to Step 3 1 Check all spark pl
69. Cam height a of camshaft Standard Limit Intake cam 44 919 45 079 mm 44 80 mm 1 768 1 775 in 1 764 in Exhaust cam 44 399 44 559 mm 44 28 mm 1 748 1 754 in 1 743 in Camshaft Runout Set camshaft between two V blocks and measure its runout by using a dial gauge If measured runout exceeds below limit replace camshaft Camshaft runout limit 0 10 mm 0 0039 in Camshaft Journal Wear Check camshaft journals and camshaft housings for pitting scratches wear or damage If any malcondition is found replace camshaft or cylinder head with housing Never replace cylinder head without replacing housings 6A1 44 ENGINE MECHANICAL M13 ENGINE Check clearance by using gauging plastic Checking procedure is as follows 1 Clean housings and camshaft journals Remove all tappets with shims Install camshafts to cylinder head Place a piece of gauging plastic to full width of journal of camshaft parallel to camshaft 5 Install camshaft housing AUN 6 Tighten camshaft housing bolts in such order as indicated in figure a little at a time till they are tightened to specified a 5 torque zi FLOC AR TRSA ooo B FD aal NOTE HO Cle Do not rotate camshaft while gauging plastic is installed Tightening torque Camshaft housing bolts a 11 N m 1 1 kg m 8 0 Ib ft OUR RM EEE 7 Remove housing and using scale 2 on gauging plastic 1
70. Check and repair according to Engine Basic Inspec repair malfunc tion and Engine Diagnosis Table section tion part s Are check and repair complete Go to Step 11 9 Trouble shooting for DTC 1 Check and repair according to applicable DTC diag flow table Are check and repair complete 10 Check for Intermittent Problems Repair or replace mal Go to Step 11 1 Check for intermittent problems referring to the follow function part s ings Go to Step 11 Is 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 the follow ings Is there any problem symptom DTC or abnormal condi tion 6 12 ENGINE GENERAL INFORMATION AND DIAGNOSIS 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 2 DIAGNOSTIC TROUBLE CODE DTC FREEZE FRAME DATA CHECK RECORD AND CLEAR ANCE First check DTC including pending DTC referring to DTC check section If DTC is indicated print it and freeze frame data or write them down and then clear them by referring to DTC clearance section DTC indi cates malfunction that occurred in the system but does not indicate whether it exists now or it occurr
71. Disposal ace iow mee erie BGG PAMALE eters PE XR Drive Air Bag Inflator Module For Vehicle Tightening Torque Specifications 3C 19 with Air Bag System 3C 4 Required Service Materrial ssssss0 3C 19 Steering WhEEl eee eeeeeeeeneeeeeeteeeeeeeaees 3C 5 Special TOOL cccseseccsseceeeseeeeesseeeeeseeeeeeeeees 3C 19 3C 2 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 e The column is energy absorbing designed to compress in a front end collision e The ignition switch and lock are mounted conveniently on this column e 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 recommended 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 col umn 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
72. Drive in reservoir pin 2 till both of its ends at the right and left of reservoir 1 become the same length 3 Connect reservoir lead wire 4 Fill reservoir 1 with specified fluid 5 Upon completion of installation check for fluid leakage 2 Cap Master Cylinder Assembly REMOVAL 1 Disconnect reservoir lead wire at coupler 2 Clean around reservoir cap 1 and take out fluid with syringe or such 3 Disconnect brake pipes 4 from master cylinder 3 CAUTION Brake fluid is extremely damaging to paint Do not allow brake fluid to get on painted surfaces 4 Remove master cylinder attaching nuts 5 5 Remove master cylinder 3 For vehicle equipped with P amp B valve 6 remove master cylinder 3 with P amp B valve 6 and its bracket then sepa rate P amp B valve 6 from master cylinder 3 2 Reservoir 5 38 BRAKES INSTALLATION NOTE e See NOTE at the beginning of this section e Check clearance between booster piston rod and pri mary 1 Install master cylinder as shown and torque attaching nuts to specification Tightening torque Master cylinder nuts a 13 N m 1 3 kg m 9 5 Ib ft 2 Attach hydraulic lines and torque flare nuts to specification Tightening torque Brake pipe flare nuts b 16 N m 1 6 kg m 12 0 Ib ft 3 Connect reservoir lead wire 4 Fill reservoir with specified brake fluid
73. E18 18 to E19 2 A C condenser fan control relay 70 1109 E18 10 to E18 7 Main relay 70 1109 E19 1 to Body ground Ground Continuity E19 2 to Body ground Ground Continuity E19 3 to Body ground Ground Continuity NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model Component Location NOTE 6 42 ENGINE GENERAL INFORMATION AND DIAGNOSIS The figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the other side 1 IAT sensor a Immobilizer indicator lamp if equipped A ECM 2 TP sensor b A C condenser fan motor relay if equipped B A T control module 3 Monitor connector c Main relay C EVAP canister 4 CO adjusting resistor if equipped d Fuel pump relay D DLC 5 CKP sensor e IAC valve E ABS control module if equipped 6 MAP sensor f EVAP canister purge valve 7 CMP sensor g EGR valve if equipped 8 Transmission range switch h Fuel injector 9 VSS i Ignition coil assemblies 10 HO2S 1 if equipped j MIL 11 HO2S 2 if equipped 12 ECT sensor ae v Knock sensor ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 43 Table A 1 Malfunction Indicator Lamp Circuit Check Lamp Does Not Come ON at Ignition Switch ON But Engine at Stop CIRCUIT DESCRIPTION 5 8 B W VY B BI B W 4 Or BI 2 Or BI B i W G Or
74. F 3 Connect connector 1 to injector securely 6E 26 ENGINE AND EMISSION CONTROL SYSTEM C REMOVAL 1 Relieve fuel pressure according to procedure described in Fuel Pressure Relief Procedure in Section 6 2 Disconnect battery negative cable at battery 3 Disconnect fuel injector couplers and release wire harness from clamps 4 Remove clamp bolt for fuel feed pipe and return pipe 5 Remove fuel delivery pipe bolts 2 6 Remove fuel injector s 3 CAUTION A small amount of fuel may come out after removal of fuel injectors cover them with shop cloth 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 1 Install injector 3 and fuel pressure regulator 4 to special tool injector checking tool Special tool A 09912 58421 2 Connect special tools hose and attachment to fuel feed hose 1 of vehicle Special tool B 09912 58432 3 Connect special tool test lead to injector Special tool C 09930 88530 2 Fuel return line 4 Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting ENGINE AND EMISSION CONTROL SYSTEM 6E 27 5 Put graduated cylinder under injector as shown
75. F fev 1 G E19 26 5 BI G 4 50 Gr B ee Gr BI RIB GR 7 Gr EA G B ew 20 i CRP LgB BvOr B BI 31 w WG aa Ors mT 33 HEATER R P B a E oo eji P B O hs 3g Sty VY amp 37 IG RIG O T 39 4 SO e e ry 5 B BI Br Ww EH E01 Br B ay 7 Br 3 Gt 12 Y EPS AT ETC B Or z 18 BIY 19 52 G W 20 54 25956 47 EERE P A 5 4 W BAW METER yo es F a1 Bl ra DOME B B 57948 Sic EA ji 15 l z 2 LAM we B R or B Y i BATT B B R 1 B R G 54 55 ql NOTE See NOTE in ECM INPUT OUTPUT CIRCUIT DIAGRAM for applicable model 6E 12 ENGINE AND EMISSION CONTROL SYSTEM 1 CKP sensor 20 Power steering pressure switch 39 Ignition coil assembly for No 1 and No 4 spark plugs if equipped 2 CMP sensor 21 A C switch 40 Ignition coil assembly for No 2 and No 3 spark plugs 3 VSS 22 A C refrigerant pressure switch 41 Stop lamp switch if equipped 4 MAP sensor 23 Immobilizer control module if equipped 42 Stop lamp 5 Knock sensor 24 Data link connector 43 Lighting switch 6 TP sensor 25 Injector No 1 44 Position lamp 7 ECT sensor 26 Injector No 2 45 Rear defogger switch if equipped 8 IAT sensor 27 Injector No 3 46 Rear defogger if equipped 9 Heated oxygen sensor 1 i
76. For 2WD model a Using lock plate 1 lock bearing lock nut If lock screw hole is not aligned with screw hole in lock nut turn lock nut in tightening direction till they align Tightening torque Wheel bearing lock washer screw a 1 5 N m 0 15 kg m 1 0 Ib ft b Remove grease old sealant and dusts from mating sur faces of hub cap 1 and wheel hub 2 to clean apply water tight sealant to hub cap mating surface evenly and install hub cap 1 to wheel hub 2 NOTE e When installing hub cap 1 hammer lightly several locations on the collar of cap until collar comes closely into contact with wheel hub 2 e If fitting part of cap is deformed or damaged or if it is fitted loosely replace with new one A Sealant 99000 31090 For 4WD model a Caulk front wheel bearing lock nut at groove of spindle b Apply lithium grease thinly to both surface all around of front spindle thrust washer 1 A Grease 99000 25010 FRONT SUSPENSION 3D 27 c Install front axle shaft circlip 1 and apply thin coat of grease to spline part of axle shaft NOTE When installing circlip 1 to front axle shaft utilize screw hole in axle shaft to pull it out and bring large diameter 2 of circlip at right as shown A Grease 99000 25010 d Clean mating surface of air locking hub and wheel hub Install air locking hub assembly to whe
77. IAC valve screws x lt Do not reuse ON VEHICLE INSPECTION e Check that throttle valve lever 1 moves smoothly REMOVAL 1 Disconnect negative cable at battery 2 Drain cooling system 3 Disconnect accelerator cable 1 from throttle valve lever ENGINE AND EMISSION CONTROL SYSTEM 6E 19 4 Disconnect air cleaner outlet NO 2 hose 1 from throttle body 5 Disconnect electric connector from TP sensor 1 and IAC valve 2 6 Remove throttle body from intake manifold 7 Disconnect engine coolant hoses from throttle body DISASSEMBLY NOTE While disassembling and assembling throttle body use special care not to deform levers on throttle valve shaft or cause damage to any other parts 1 Remove TP sensor and IAC valve from throttle body CLEANING Clean throttle body bore 1 and idle air passage 2 by blowing compressed air NOTE TP sensor idle air control valve or other components containing rubber must not be placed in a solvent or cleaner bath A chemical reaction will cause these parts to swell harden or get distorted REASSEMBLY 1 Install IAC valve to throttle body referring to Idle Air Control Valve in this section 2 Install TP sensor to throttle body referring to Throttle Posi tion Sensor in this section for installation 6E 20 ENGINE AND EMISSION CONTROL SYSTEM INSTALLA
78. It will affect its original performance 1 Parking brake lever assembly 3 Bolt INSPECTION Connect positive cable of 12 volt battery to A terminal of sensor and ground cable to C terminal Then using voltmeter check voltage between B terminal and C terminal If measured voltage is not as specified replace sensor with bracket G sensor specification When placed horizontally 2 3V When placed upright with arrow upward 3 4V When placed upright with arrow downward 1 2V A A Horizontal B Upright with arrow upward C Upright with arrow downward B C INSTALLATION 1 Connect connector to sensor securely 2 Install sensor onto floor so that arrow mark directs vehicle forward Tightening torque G sensor bolts a 23 N m 2 3 Kg m 17 0 Ib ft 3 Install rear console box 5E 40 ANTILOCK BRAKE SYSTEM ABS Tightening Torque Specification Tightening torque Fastening part Nem kam b fit Brake pipe flare nuts 16 1 6 11 6 ABS hydraulic unit control module assembly bracket bolts 11 1 1 8 0 ABS hydraulic unit control module assembly bolts 9 0 9 6 5 Front wheel speed sensor bolt 10 1 0 7 2 Front wheel speed sensor harness clamp bolts 10 1 0 7 2 Rear wheel speed sensor bolt 10 1 0 7 2 Rear wheel speed sensor harness clamp bolts 10 1 0 7 2 G sensor bolts 23
79. No 16 Flow Table in Section 6 If malfunction is found replace Fuel level sensor GAUGE INSPECTION Refer to Fuel Meter Fuel Gauge Unit in Section 8 REMOVAL INSTALLATION Refer to Fuel Pump Assembly in Section 6C Knock sensor INSPECTION Check knock sensor referring to DTC P0325 No 17 Flow Table in Section 6 If malfunction is found replace REMOVAL INSTALLATION Refer to Knock Sensor in Section 6A1 Main relay fuel pump relay and A C condenser fan control relay INSPECTION 1 Disconnect negative cable at battery 2 Remove main relay 1 fuel pump relay 2 and A C con denser fan control relay 3 from vehicle 3 Check that there is no continuity between terminal A and B If there is continuity replace relay 4 Connect battery positive terminal to terminal C of relay Connect battery negative terminal D of relay Check continuity between terminal A and B If there is no continuity when relay is connected to the bat tery replace relay ENGINE AND EMISSION CONTROL SYSTEM 6E 37 Fuel cut operation INSPECTION NOTE Before inspection check to make sure that gear shift lever is in neutral position with A T model selector lever in P range A C is OFF 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 1 by using sound s
80. Oversize 0 50 ENGINE MECHANICAL M13 ENGINE 6A1 89 3 Using micrometer measure piston diameter Measurement position for piston diameter a 19 5 mm 0 77 in 4 Calculate cylinder bore diameter to be rebored as follows D A B C D Cylinder bore diameter to be rebored A Piston diameter as measured B Piston clearance 0 02 0 04 mm 0 0008 0 0016 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 6A1 90 ENGINE MECHANICAL M13 ENGINE INSTALLATION NOTE e All parts to be installed must be perfectly clean e Be sure to oil crankshaft journals journal bearings thrust bearings crankpins connecting rod bearings pistons piston rings and cylinder bores e Journal bearings bearings caps connecting rods rod bearings rod bearing caps pistons and piston rings are in combination sets Do not disturb such combina tion and make sure that each part goes back to where it came from when installing 1 Install sensor plate 1 to crankshaft 2 and tighten bolts to specified torque NOTE When installing sensor plate align spring pin 3 on crankshaft and hole of sensor plate Tightening torque Sensor plate bolts a 11 N m 1 1 kg m 8 0 lb
81. Oversize 78 453 78 468 mm 0 50 mm 0 0196 in 3 0887 3 0893 in Standard size a 19 5 mm 0 77 in ENGINE MECHANICAL M13 ENGINE 6A1 65 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 Standard 0 032 0 061 mm 0 0013 0 0024 in Limit 0 161 mm 0 0063 in NOTE Cylinder bore diameters used here are measured in thrust direction at two positions a 19 5 mm 0 77 in e Ring groove clearance Before checking piston grooves must be clean dry and free of carbon deposits 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 limit replace piston Ring groove clearance Top ring Standard 0 03 0 07 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring Standard 0 02 0 06 mm 0 0008 0 0024 in Limit 0 10 mm 0 0039 in Oil ring Standard 0 03 0 17 mm 0 0012 0 0067 in Piston Pin e Check piston pin connecting rod small end bore and piston bore for wear or damage paying particular attention to con dition of small end bore bush If pin connecting rod
82. REMOVAL 1 Remove rear axle shaft For details refer to Rear Axle Shaft and Wheel Bearing in this section 2 Remove rear axle shaft inner oil seal by using special tools Special tool A 09942 15510 B 09944 96010 remover C 09921 26010 collar INSTALLATION 1 Using special tools drive in oil seal 1 until it contacts oil seal protector 2 in axle housing NOTE e Make sure that oil seal 1 is free from inclination as it is installed e Refer to figure so that oil seal 1 is installed in proper direction Special tool A 09913 75520 A Grease 99000 25010 2 For procedure hereafter refer to Rear Axle Shaft and Wheel Bearing in this section 3 Differential side 3E 18 REAR SUSPENSION Rear Axle Housing REMOVAL 1 Hoist vehicle and remove wheels 2 Remove rear axle shaft refer to Rear Axle Shaft and Wheel Bearing in this section 3 Disconnect brake pipe 3 from flexible hose 1 and remove E ring 2 4 Remove brake pipe clamps and pipes from axle housing 5 For jobs hereafter support rear axle housing 2 by using floor jack 1 under axle housing 2 6 Remove LSPV stay from axle housing if equipped with LSPV 7 Before removing propeller shaft 2 give match marks 1 on joint flange and propeller shaft 2 as shown Remove propeller shaft 2 8 Remove differential carrier assembly 3 9 Remove later
83. although it takes a longer time A Tire out of round 1 Smooth road B Tire stiffness variation 2 Suspension movement loaded runout C Rim bent or out of round 3 8 STEERING SUSPENSION WHEELS AND TIRES FRONT WHEEL ALIGNMENT 3A 1 SECTION 3A FRONT WHEEL ALIGNMENT CONTENTS General Description ccccseseecceeeeeeeeeeeees 3A 2 Toe AGjUStMeNt 0 ccecceececeeeeeeeeeeeeeeeeeeeteeees 3A 3 TOG SONI Gy sete oes ctecctetes teen Fee ner cease 3A 2 Camber And Caster Check And CAST eee ee E 3A 2 AdjUStMEnt eeceeeeeseseereeseereneseeceneseseeneneees 3A 4 Alignment Service Data Reference 3A 2 Steering Angle Check And Adjustment 3A 4 DiagnosiS a zesc6cccteceetets seletcauetccecacttenntacsseccicicien 3A 3 Side Slip Reference seceececeeeceee 3A 4 Diagnosis Table eeeeeeeeeirrrerrrrrrrereerna 3A 3 Preliminary Checks Prior To Adjusting Front Wheel Alignment cceecesseeceeeeeeeneeeees 3A 3 3A 2 FRONT WHEEL ALIGNMENT A A of General Description Front alignment refers to the angular relationship between the front wheels the front suspension attaching parts and the ground Generally the only adjustment required for front wheel alignment is toe setting Camber and caster can t be adjusted Therefore should camber or caster be out of specification due to the damage caused by hazardous road c
84. and nuts 2 to specified torque Tightening torque Intake manifold bolts and nuts a 25 N m 2 5 kg m 18 0 Ib ft Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled Adjust accelerator cable play referring to Accelerator Cable Adjustment in Section 6E Refill cooling system referring to Cooling System Flush and Refill in Section 6B Upon completion of installation turn ignition switch ON but engine OFF and check for fuel leaks Finally start engine and check for engine coolant leaks Exhaust Manifold ENGINE MECHANICAL M13 ENGINE 6A1 21 6 U 55 N m 5 5 kg m 1 Exhaust manifold 4 Exhaust manifold cover m Tightening torque 2 Exhaust manifold gasket 5 Engine hook x Do not reuse 3 Heated oxygen sensor if equipped 6 Exhaust manifold mounting nut WARNING To avoid danger of being burned do not service exhaust system while it is still hot Service should be performed after system cools down REMOVAL 1 Disconnect negative cable at battery 2 Disconnect heated oxygen sensor coupler 1 if equipped and detach it from its stay 3 Remove exhaust manifold cover 2 4 Remove exhaust manifold stiffener 1 6A1 22 ENGINE MECHANICAL M13 ENGINE 5 Disconnect exhaust pipe 1 from exha
85. and propeller shaft 2 as shown 4 Remove propeller shaft s INSPECTION Inspect propeller shaft and flange yoke for damage and propeller shaft for runout If damage is found or shaft runout exceeds its limit replace Propeller shaft runout limit 0 8 mm 0 031 in 4B 4 PROPELLER SHAFTS INSTALLATION Install propeller shaft s reversing removal procedure noting fol lowing points e When installing propeller shaft align the match marks Otherwise vibration may occur during driving e Use following specification to torque universal joint flange Tightening torque Propeller shaft bolt propeller shaft No 1 No 2 and No 3 rear differential side a 50 N m 5 0 kg m 36 5 Ib ft Propeller shaft bolt propeller shaft No 3 transfer case side b 33 N m 3 3 kg m 24 Ib ft NOTE If transmission oil was drained for front propeller shaft removal pour specified gear oil into transmission case to specified level e Grease splines of propeller shaft No 2 and No 3 A Chassis Grease 99000 25030 e Match marks 1 are provided on slip on spline connections of propeller shaft No 2 and No 3 Inserting splined end into splined bore without regard to match marks can be a possi ble cause of noise or vibration of propeller shaft Be sure to index marks PROPELLER SHAFTS 4B 5 Universal Joint DISASSEMBLY 1 Using specia
86. good ECM and recheck Is 119 C 246 F indicated A Fig 1 for Step 2 B Fig 2 for Step 5 C Fig 3 for Step 6 A B ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 55 DTC P0120 DTC No 13 Throttle Position Circuit Malfunction CIRCUIT DESCRIPTION ECM a DTC DETECTING CONDITION POSSIBLE CAUSE e Signal voltage high e Signal voltage low B BI circuit open Lg circuit open or shorted to ground B BI circuit open or shorted to power or ground TP sensor malfunction ECM malfunction NOTE e When DTC P0105 No 11 P0110 No 18 P0115 No 19 P0120 No 13 and or P0460 are indicated together it is possible that B BI or Lg R circuit is open e When this DTC and P1700 are stored together also clear DTC stored in TCM after completion of repair DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC 6 56 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag 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 inter
87. in the position as shown in figure and install oil pump strainer 2 Tighten strainer bolt 3 first and then bracket bolt 4 to specified torque Tightening torque Oil pump strainer bolt a 11 N m 1 1 kg m 8 0 Ib ft Oil pump strainer bracket bolt b 11 N m 1 1 kg m 8 0 Ib ft 3 After fitting oil pan to cylinder block run in securing bolts and start tightening at the center move wrench outward tightening one bolt at a time Tighten bolts and nuts to specified torque Tightening torque Oil pan bolts and nuts a 11 N m 1 1 kg m 8 0 lb ft 4 Install new gasket and drain plug to oil pan Tighten drain plug to specified torque Tightening torque Oil pan drain plug b 50 N m 5 0 kg m 36 5 Ib ft 5 Install clutch housing torque converter housing for A T vehi cle lower plate 1 ENGINE MECHANICAL M13 ENGINE 6A1 27 6 Lower engine and tighten engine mounting bracket bolts to specified torque Tightening torque Engine mounting bracket bolts a 50 N m 5 0 kg m 36 5 Ib ft 7 Install oil level gauge 8 Refill engine with engine oil referring to Engine Oil and Filter Change in Section OB 9 Verify that there is no engine oil leakage at each connection 6A1 28 ENGINE MECHANICAL M13 ENGINE Timing Chain Cover 7 E 23 N m 2 3 kg m 1 E 150 N m 15 0 kg m REMOVAL A Sealant application
88. leakage A T fluid level leakage Air cleaner element dirt clogging Battery fluid level corrosion of terminal Water pump belt tension damage Throttle cable play installation Vacuum hoses of air intake system disconnection looseness deterioration bend Connectors of electric wire harness disconnection friction Fuses burning Parts installation bolt looseness Parts deformation 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 Fuel level meter operation Tachometer if equipped operation Abnormal air being inhaled from air intake system Exhaust system leakage of exhaust gas noise Other parts that can be checked visually Section 0B Section 0B Section 0B Section 0B Section 0B Section 0B Section 6E Section 8 Section 6 Section 6H Section 8 Section 6 for pressure check Section 8 Section 8 Engine basic inspection ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 21 This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in visual inspection Follow the flow table carefully lows if equipped 1 Check immobilizer indicator lamp or MIL m
89. module assembly See B power 3 Check for proper connection to ABS hydraulic unit con trol module assembly at each sensor terminal 4 If OK then turn ignition switch ON and measure voltage between sensor positive terminal of module connector and body ground Is it OV 3 1 Ignition switch OFF Go to step 4 Circuit open or 2 Connect connector to sensor shorted to ground 3 Measure resistance between sensor terminals at mod ule connector 4 Measure resistance between sensor positive terminal and negative terminal of module connector between positive terminal and body ground Are measured resistance values within each specified range described in above step 1 4 1 Remove wheel speed sensor Go to step 5 Clean or replace 2 Check sensor for damage or foreign material being sensor attached Is it in good condition See C 5 Check visually through wheel speed sensor installation hole Go to step 6 Clean repair or for following replace e Ring serration teeth neither missing or damaged e No foreign material being attached e Ring not being eccentric e Wheel bearing free from excessive play Are they in good condition See D 6 1 Install sensor to knuckle or axle housing Substitute a known Replace sensor and 2 Tighten sensor bolt to specified torque and check that good ABS hydraulic recheck there is not any clearance between sensor and knuckle unit control module or axle housing See E assembly
90. performed Go to Step 2 Go to Engine Diag Flow Table 2 Check EVAP canister purge valve operation B G circuit open or Replace EVAP canister 1 With ignition switch OFF disconnect coupler from short purge valve canister purge valve See Fig 1 EVAP canister purge valve resistance Between terminal and body 1M Q or higher Is it as specified 2 Check resistance of EVAP canister purge valve Between two terminals 30 34 Q at 20 C 68 F Fig 1 for Step 2 6 92 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0481 A C Condenser Fan Control Circuit Malfunction CIRCUIT DESCRIPTION ECM 1 CY pI Y B BI i IG COIL mle HEATER 31G B R T AN 2 METER 4 Lg E19 3 g t 2 Lg 2 1 R BI E17 17P E19 31P im CESS oes E18 B E18 18 1 Ignition switch 3 A C condenser fan relay 5 A C condenser fan 7 Fuse box DTC DETECTING CONDITION POSSIBLE CAUSE e Low voltage at terminal E18 18 when ECM doesn t out e P B or Lg circuit open or short put A C ON signal to A C amplifier or when engine cool Condenser fan motor relay malfunction ant temp is not 110 C 230 F or more e ECM malfunction 2 driving cycle detection logic continuous monitoring D
91. push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely or fuel leak may occur 2 Quick joint 5 Install fuel tank to vehicle and connect wire harness coupler 6 Connect fuel filler hose and breather hose to fuel filler neck Connect fuel vapor hose to pipe Clamp them securely 7 Install fuel filler hose protector Fuel Pump Assembly WARNING Before starting the following procedure be sure to observe Precaution on Fuel System Service in Section 6 REMOVAL 1 Remove fuel tank from vehicle Refer to Fuel Tank in this section 2 Disconnect wire harness coupler and fuel vapor hose from fuel pump assembly 3 Remove fuel pump assembly from fuel tank by removing bolts 6C 8 ENGINE FUEL INSPECTION Check fuel pump assembly for damage Check fuel suction filter 1 for evidence of dirt and contamination If present replace or clean and check for presence of dirt in fuel tank For inspection of fuel pump itself refer to Table B 3 Fuel Pres sure Check in Section 6 For inspection of fuel level gauge refer to Fuel Meter Fuel Gauge Unit in Section 8 2 Fuel filter amp bracket assembly 3 Fuel pump motor amp level gauge assembly DISASSEMBLY REASSEMBLY 2 A 2 A 4 v ke A Apply oil 4 Housing 8 Cushion 1 Bra
92. tap ping it by a copper hammer 1 PROPELLER SHAFTS 4B 7 3 Insert bearing race into opposite side of shaft yoke until it is flush with side face of shaft yoke tapping it by a copper hammer 4 In the same way as Step 2 to Step 3 insert bearing races into flange yoke 5 Using round bar of 22 24 mm 0 87 in 0 94 in in diame ter and hammer tap bearing races into shaft or flange yoke until circlips can be installed in its groove on yoke bores 6 Install 4 circlips in each groove on shaft and flange yoke bores NOTE e After reassembly ensure that both shaft yoke and flange yoke move smoothly e Make sure that each circlip is fitted in groove securely Tightening Torque Specification Tightening torque Fastening portion Nem Kg m Ib ft Propeller shaft bolt propeller shaft No 1 No 2 and No 3 rear dif 50 5 0 36 5 ferential side Propeller shaft bolt propeller shaft No 3 transfer case side 33 3 3 24 Required Service Material Material Recommended SUZUKI product Part Number Use Lithium grease SUPER GREASE C 99000 25030 e To apply to spider bearing race and propel ler shaft No 2 and No 3 splines 4B 8 PROPELLER SHAFTS Special Tool 09900 06108 09926 48010 Snap ring pliers Closing Universal joint disassem type bling tool set BRAKES 5 1 SECTION 5 BRAKES WARNING For lifting point
93. there is also the possibility or causing a serious fire A At air bleed 3 From reservoir B At valves closed 4 To reservoir C At pressure relief 5 Pressure in radiator D At vacuum relief Coolant Reservoir A see through plastic reservoir 1 is connected to the radiator by a hose Coolant level should be between FULL level mark 2 and LOW level mark 3 on the reservoir Coolant should be added only to the reservoir as necessary NOTE When installing reservoir cap set arrow marks 4 on the reservoir and cap as the figure 6B 4 ENGINE COOLING Water Pump The centrifugal type water pump is used in the cooling system The pump impeller is supported by a totally sealed bearing The water pump can not be disassembled Thermostat A wax pellet type thermostat is used in the cooling system The temperature at which the valve begins to open is stamped on thermostat In the top portion of the thermostat an air bleed valve 1 is pro vided this valve is for venting out the gas or air if any that is accumulated in the circuit Cooling Fan Clutch Fluid is enclosed in the cooling fan clutch 2 and at its center front there is a bimetal 3 whose thermal reaction and the engine speed control the cooling fan speed NOTE Do not disassemble clutch assembly WARNING Keep hands tool
94. tion P0720 Output Shaft Speed Sensor Circuit Malfunc tion P0725 Engine Speed Input Circuit Malfunction Refer to Section 7B P0730 Incorrect Gear Ratio i These DTCs can not be read on vehicle without P0743 Torque Converter Clutch Circuit Electrical Pees raat f Immobilizer indicator lamp by ECM application of P0753 Shift Solenoid A Electrical SUZUKI scan tool P0758 Shift Solenoid B Electrical l P0763 Shift Solenoid C Electrical P0768 Shift Solenoid D Electrical P1700 Throttle Position Signal Input Malfunction P1702 Internal Control Module Memory Check Some Error P1709 Engine Coolant Temperature Signal Input Malfunction P1887 Transfer Signal P1620 No 84 ECU code not registered P1621 No ECU code transmitted from Immobilizer No 83 Control Module Refer to Section 8G F102 Faulty in ECM No 82 y P1623 No 81 ECU code not matched NOTE e For marked No in DTC column it is used for vehicle without Immobilizer indicator lamp e DTC No 12 appears when none of the other codes is identified vehicle without Immobilizer indica tor lamp Fail safe table When any of the following DTCs is detected ECM enters fail safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 19 DTC NO DETECTED ITEM FAIL SAFE OPERATION SYMPTOM P0105 Manifold absolute p
95. warmed up 7 Heater of HO2S 1 10 14V Ignition switch ON 8 Fuel injector NO 4 10 14V__ Ignition switch ON 9 Fuel injector NO 1 10 14V Ignition switch ON 10 Sensor ground 11 Camshaft position sensor 9 Fu i Ignition switch ON 12 13 Heater oxygen sensor 1 Refer to DTC P0130 diag flow table CO adjusting resistor w o HO2S 0 5V Ignition switch ON position 14 Ignition switch ON E19 Engine coolant temp sensor 0 55 0 95 V Engine coolant temp 80 C 176 F 15 Ignition switch ON Intake air temp sensor 2 0 2 7 V Intake air temp 20 C 68 F 02 10V Ignition Switch ON position and throttle 16 Throttle opening signal Valve alee postion Ignition switch ON position and throttle 2 8 4 8 V valve fully open EGR valve stepper motor coil 3 if Ignition switch ON position leaving engine 17 i 10 14V equipped OFF EGR valve stepper motor coil 1 if Ignition switch ON position leaving engine 18 10 14V equipped OFF 19 Ignition coil 2 20 Ignition coil 1 21 Fuel injector NO 2 10 14V_ Ignition switch ON 22 Power source for sensors 4 75 5 25 V Ignition switch ON 23 Crankshaft position sensor pei Ignition switch ON position 24 25 Knock sensor About 2 5 V At specified idle speed after engine warmed up ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 35 TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE Ignition switch ON 26 Manifold absolute pressure sensor 3
96. when installing rear wheel speed sensor 1 Sensor bolt 2 Clamp bolt 3 Check that there is no clearance between sensor and rear axle housing 5E 38 ANTILOCK BRAKE SYSTEM ABS Rear Wheel Sensor Ring REMOVAL 1 Remove rear axle shaft Refer to Rear Axle Shaft and Wheel Bearing in Section 3E 2 In order to remove sensor ring 3 from retainer ring 2 grind with a grinder one part of the sensor ring 8 as illus trated till it becomes thin CAUTION e Cover vinyl sheet 4 or the like over wheel bearing so that fine grains from grinding will not enter there e Be careful not to go so far as to grind the retainer ring 2 1 Rear axle A Grind with grinder 3 Break with a chisel the thin ground sensor ring and it can be removed INSTALLATION 1 Press fit sensor ring 1 as shown NOTE Use care not to cause any damage to outside of retainer ring 2 Install rear axle shaft referring to Rear Axle Shaft and Wheel Bearing in Section 3E 3 Install brake drum and wheel Refer to Brake Drum in Section 5 ANTILOCK BRAKE SYSTEM ABS 5E 39 G Sensor REMOVAL 1 Turn ignition switch OFF and disconnect battery negative cable 2 Remove rear center console box 3 Disconnect connector from G sensor 2 4 Remove G sensor 2 from floor CAUTION Sensor must not be dropped or shocked
97. 000 1524 85 5 001 1525 Under 634 85 2 7 3 7 l l over 567 l 8 000 2 438 76 8 001 2 439 Under 567 76 2 5 3 3 l l over 526 l 10 000 3 048 70 4 Install MAP sensor 1 securely 5 Connect MAP sensor 1 connector securely ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 51 DTC P0110 DTC No 18 Intake Air Temp IAT Circuit Malfunction CIRCUIT DESCRIPTION ECM Lg B B BI DTC DETECTING CONDITION POSSIBLE CAUSE e Low intake air temperature High voltage High resistance Lg R circuit open or shorted to power e High intake air temperature Low voltage Low resistance B BI circuit open e IAT sensor malfunction ECM malfunction NOTE e When DTC P0105 No 11 P0110 No 18 P046 P0115 No 19 and P0120 No 13 are indicated together it is possible that B BI circuit is open e Before inspecting be sure to check that ambient temperature is higher than 40 C 40 F DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode no scan tool and check DTC INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check IAT Sensor and Its Circuit Go to Step 3 Intermittent trouble 1 Connect scan tool to DLC with ignition Che
98. 12 Power supply 6 124 ENGINE GENERAL INFORMATION AND DIAGNOSIS ENGINE MECHANICAL M13 ENGINE 6A1 1 SECTION 6A1 ENGINE MECHANICAL M13 ENGINE WARNING conditions may result in severe injury For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under 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 e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CONTENTS General Description cccccssssseeceeeeeeeeeees 6A1 2 Oil Pan and Oil Pump Strainer 6A1 24 PAGING Ate Goce E E A cle 6A1 2 Timing Chain Cover scene 6A1 28 Engine Lubrication
99. 14V ee ON and shift select switch E17 2 R ignal A T range signal Ignition switch ON and shift select switch 0 1 3V in other than R range 3 Blank ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 39 TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 4 Blank 0 1 0V ee switch ON and ECT less than t signal Ta SAOR NA Ignition switch ON and ECT more than 10 14V 60 C Ignition switch ON and shift select switch 10 14V 6 D range idle up signal A T in other than P and N range g nae Ignition switch ON and shift select switch O0 16V in P and N range ov Ignition switch ON Stop lamp switch OFF 7 Stop lamp switch 7 10 14V Ignition switch ON Stop lamp switch ON 8 9 Ignition switch 10 14V_ Ignition switch ON E17 10 deflect 44 Wehiclacapead sensor between Ignition switch ON and rear right wheel P 0 1 6 and turned slowly with rear left wheel locked 4 14V 12 ABS signal if equipped 10 14V__ Ignition switch ON 13 Engine start signal 6 14V While engine cranking 14 15 10 14V_ Ignition switch ON and rear defogger switch ON Ue ear cored ger Sw Ne Nhe aa 0 1 3V_ Ignition switch ON and rear defogger switch OFF 17 A T failure signal with immobilizer _ gt indicator lamp A T For TYPE B See NOTE NOTE See NOTE in ECM TERMINAL VOLTAGE VALUES TABLE for applicable model
100. 2 ccccecccccccceccceccececeuceceees 6A1 3 Oil Pump 5555 Ri wm i nna cre Se a TT oi ow 6A1 33 Diagnosis eieren asasan asne enannana toanen in aoieanna 6A1 4 Timing Chain and Chain Tensioner 6A1 37 f i Camshaft Tappet and Shim 05 6A1 42 aoe acs Ene See eta SA nee Valves and Cylinder Head sscssseeeeee 6A1 48 Bane oe a E EEEE p Pistons Piston Rings Connecting Gil Pressure Check gat 7 Rods and Gylder 6A1 62 Valve Lash Clearance cccccccccseeceeeeens 6A1 9 7 PEN ae i e E SAA eae On Vehicle Service scscsssssssessscseeseesees 6A1 13 E A tek AU sirarni araeir iets ge g ngine Assembly cccceseceeeeesteeeseees Ae E EESTE E T eo Main Bearings Crankshaft and Cylinder Knock Sensor Pins eet geek 6A1 14 Block PEOR oa nae ane 6A1 79 Cylinder Head Cover ccccccsccscesssesesescseees 6A1 15 Required Service Material s 1 6A1 93 Throttle Body and Intake Manifold 6A1 18 Tightening Torque Specification 6A1 93 Exhaust Manifold ccccccccccccceeeceeeeeeeeees 6A1 21 Special ToOl i iiri saiia ccsstssersivedsdesssncecced 6A1 94 6A1 2 ENGINE MECHANICAL M13 ENGINE General Description Engine The engine is water cooled in line 4 cylinders 4 stroke cycle gasoline unit with its DOHC Double overhead camshaft valve mechanism arranged for V type valve configuration and 16 valves 4 valves one cylinder The double overhead camshaft is mounted o
101. 24 BRAKES ASSEMBLY CAUTION e Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir e Never use other fluid or thinner e Before installing piston and piston seal to cylinder apply fluid to them After reassembling brake lines bleed air from them 1 Check that slide bushes and boots for wear corrosion dam age movement or deterioration If it is found faulty correct or replace Apply rubber grease to bush outer surface And then make sure that each bush slides easily through each caliper bolt hole NOTE Where temperature gets as low as 30 C 22 F in cold weather use rubber grease whose viscosity varies very little even at 40 C 40 F 2 Tighten bleeder plug to specified torque and install cap Tightening torque Front caliper bleeder plug a 11 N m 1 1 g m 8 0 Ib ft 1 Apply rubber grease 3 Piston seal is used to seal piston and cylinder and to adjust clearance between pad and disc Replace with a new one at every overhaul Fit piston seal into groove in cylinder taking care not to twist it 4 Before inserting piston 2 into cylinder install new boot 1 onto piston 2 as shown A 2 grooved side directed inside B 3 grooved side directed outside BRAKES 5 25 5 Fit boot as it is in figure into boot groove in cylinder with fin gers 6 Insert
102. 3 Is fuel pump relay in good condition CAUTION Check to make sure that connection is made between correct terminals Wrong connection can cause damage to ECM wire harness etc A Fig 1 for Step 2 B Fig 2 for Step 3 C Fig 3 for Step 4 6 112 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table B 3 Fuel Pressure Check 1 Injector 3 Fuel pump B Hose 2 Delivery pipe A Fuel pressure gauge C Attachment INSPECTION Step Action Yes No 1 Check Fuel Pressure Refer to Section 6E for Go to Step 2 Go to Step 4 details 1 Release fuel pressure from fuel feed line 2 Install fuel pressure gauge See Fig 1 3 Check fuel pressure by repeating ignition switch ON and OFF Is fuel pressure then 270 310 kPa 2 7 3 1 kg cm 38 4 44 0 psi 2 Is 250 kPa 2 5 kg cm 35 6 psi or higher fuel Normal fuel pressure Go to Step 3 pressure retained for 1 minute after fuel pump is stopped at Step 1 3 Is there fuel leakage from fuel feed line hose Fuel leakage from hose __ Faulty fuel pressure regu pipe or their joint pipe or joint lator 4 Was fuel pressure higher than spec in Step 1 Faulty fuel pressure regu Clogged fuel filter lator Restricted fuel feed hose or pipe Faulty fuel pump or Fuel leakage from hose connection in fuel tank ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 113 Fig 1 for
103. 3 4 0 V Barometric pressure 100 kPa 760 mmHg Ignition switch ON A C evaporation temp 27 A C evaporator temp sensor 2 0 2 3 V sensor at 25 C 77 F E19 EGR valve stepper motor coil 4 if Ignition switch ON position leaving engine 28 10 14V equipped OFF EGR valve stepper motor coil 2 if Ignition switch ON position leaving engine 29 10 14V equipped OFF 30 31 Fuel injector NO 3 10 14V_ Ignition switch ON For TYPE B See NOTE NOTE See NOTE in ECM TERMINAL VOLTAGE VALUES TABLE for applicable model TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 1 Ground 7 2 Ground 3 Ground 4 EVAP canister purge valve 10 14V__ Ignition switch ON While engine running at idle speed turn 5 Power steering pressure switch 0 1 3V_ steering wheel to right or left as far as it if equipped stops 10 14V_ Ignition switch ON liacair controlas 0 13V At specified idle speed after engine warmed up 7 Heater of HO2S 1 10 14V_ Ignition switch ON 8 Fuel injector NO 4 10 14V_ Ignition switch ON 9 Fuel injector NO 1 10 14V_ Ignition switch ON 10 Sensor ground A 11 Camshaft position sensor 9 Pa a Ignition switch ON 12 13 Heater oxygen sensor 1 Refer to DTC P0130 diag flow table CO adjusting resistor w o HO2S 0 5V Ignition switch ON position Ignition switch ON 14 Engine coolant temp sensor 0 55 0 95
104. 41 Resistance Check 1 Disconnect ECM couplers 1 from ECM with ignition switch OFF CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter 2 2 Check resistance between each terminal of couplers discon nected CAUTION e Be sure to connect ohmmeter probe from wire harness side of coupler e Be sure to turn OFF ignition switch for this check e Resistance in table below represents that when parts temperature is 20 C 68 F 1 ECM coupler disconnected 2 Ohmmeter TERMINALS CIRCUIT STANDARD RESISTANCE E19 7 to E17 9 HO2S 1 heater 5 6 4Q For TYPE A See NOTE E19 7 to E18 11 For TYPE B See NOTE E18 4 to E17 9 HO2S 2 heater 11 7 14 3 0 For TYPE A See NOTE E19 9 to E19 2 No 1 injector 12 0 13 0 Q E19 21 to E19 2 No 2 injector 12 0 13 0 Q E19 31 to E19 2 No 3 injector 12 0 13 0 Q E19 8 to E19 2 No 4 injector 12 0 13 0 Q E19 28 to E19 2 EGR valve stepper motor coil 4 20 240 E19 17 to E19 2 EGR valve stepper motor coil 3 20 240 E19 29 to E19 2 EGR valve stepper motor coil 2 20 240 E19 18 to E19 2 EGR valve stepper motor coil 1 20 240 E19 4 to E19 2 EVAP canister purge valve 30 34 Q E18 19 to E17 9 For Fuel pump relay 70 1109 TYPE A See NOTE E18 19 to E18 11 For TYPE B See NOTE E18 1 to Body ground A C compressor clutch 3 459
105. 5 After installing bleed air from system refer to Air Bleeding of Brake System in this section and check brake pedal height and play 6 Perform brake test and check each installed part for fluid leakage Master Cylinder Apply brake fluid confirm installing direction 1 A 2 A B a gt 59 7 Le 3 we 5 O Ss IAQ vo D o ae 8 12 te as 5 feo FLD 11 8 10 N m 1 0 kg m A For vehicle without ABS 7 Piston cup Apply brake fluid confirm installing direction B For vehicle with ABS 8 Secondary piston 1 Piston stopper circlip 9 Sealing Apply brake fluid confirm installing direction 2 Piston stopper 10 Secondary piston return spring 3 Cylinder cup and plate 11 Secondary piston stopper bolt Apply brake fluid confirm installing direction 4 Primary piston 12 Master cylinder body 5 Piston cu Q Tightening Torque 6 Secondary piston pressure cup Apply brake fluid confirm installing direction x lt Do not reuse A p9 Si B BRAKES 5 39 DISASSEMBLY 1 Remove circlip 1 2 Remove primary piston 2 Master cylinder 3 For vehicle with ABS Pull out primary piston assembly straight so as not to cause any damage to inside o cylinder wall Pull out secondary piston assembly straight so as not to cause any damage to inside of cylinder wall and by tapping fla
106. 6 Operate fuel pump and apply fuel pressure to injector as fol lows a When using SUZUKI scan tool i Connect SUZUKI scan tool to DLC with ignition switch OFF ii Turn ignition switch ON clear DTC and select MISC TEST mode on SUZUKI scan tool iii Turn fuel pump ON by using SUZUKI scan tool A SUZUKI scan tool b Without using SUZUKI scan tool i Remove fuel pump relay from connector ii Connect two terminals of relay connector using service wire 1 as shown in figure CAUTION Check to make sure that connection is made between correct terminals Wrong connection can cause damage to ECM wire harness etc iii Turn ignition switch ON 7 Apply battery voltage 3 to injector 2 for 15 seconds and measure injected fuel volume with graduated cylinder Test each injector two or three times If not within specification replace injector Injected fuel volume 43 47 cc 15 sec 1 45 1 51 1 58 1 65 US Imp 02 15 sec 4 Keep as far apart as possible A When using SUZUKI scan tool B Without using SUZUKI scan tool 8 Check fuel leakage from injector nozzle Do not operate injector for this check but fuel pump should be at work If fuel leaks 1 more than following specifications replace Fuel leakage 1 Less than 1 drop min 6E 28 ENGINE AND EMISSION CONTROL SYSTEM INSTALLATION For installation reverse removal procedure and
107. 6F 1 SECTION 6F IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CONTENTS General Description ccccseseeeeeeeeeeseneees 6F 2 Ignition Coil Assembly Including Ignitor 6F 7 Diagnosis oiccdyzid istaitsapaanid atiwtdacadeueactucnab heres 6F 3 Crankshaft Position Sensor CKP Sensor 6F 8 On Vehicle Service csscscssssesecseeseeseneeees 6F
108. 8000 ft or less 560 mmHg 75 kPa or more Drive vehicle under usual driving condition for 5 min and check HO2S 2 output voltage and short term fuel 5 Increase vehicle speed to higher than 20 mph 32 km h and then stop vehicle ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 65 O Repeat above steps 5 4 times Increase vehicle speed to about 50 mph 80 km h in 3rd gear or 2 range Release accelerator pedal and with engine brake applied keep vehicle coasting fuel cut condition for 10sec or more Stop vehicle don t turn ignition switch OFF and run engine at idle for 2 min After this step 9 if Oxygen Sensor Monitoring TEST COMPLETED is displayed in READINESS TESTS mode and DTC is not dis played in DTC mode confirmation test is completed If TEST NOT COMPLTD is still being displayed proceed to next step 10 Drive vehicle under usual driving condition for 10 min or vehicle is at a stop and run engine at idle for 10 min or longer CN lt x lt 10 11 Stop vehicle don t turn ignition switch OFF Confirm test results according to Test Result Confirmation Flow Table in DTC CONFIRMATION PROCEDURE of DTC P0420 50 mph 4 eee eee ee ee 80 km h Usual driving 4 edi ee te A eee Above 20 mph 32 km h o io A Ioi 1 c i 1 1 I l 1 2 3 4 5 and 6 7 8 9 10 11
109. Any defects should be fixed at once Ignition System Spark Plugs REPLACEMENT Replace spark plugs with new ones referring to Spark Plug in Section 6F Fuel System Air Cleaner Filter INSPECTION 1 Remove air cleaner case clamps 1 2 Take cleaner filter out of air cleaner case 3 Check air cleaner filter for dirt Replace excessively dirty fil ter 4 Blow off dust by compressed air from air outlet side of filter 5 Install air cleaner filter into case 6 Install air cleaner case cap and clamp it securely 0B 10 MAINTENANCE AND LUBRICATION REPLACEMENT Replace air cleaner filter with new one according to steps 1 2 and 5 6 of inspection procedure Fuel Lines and Connections INSPECTION 1 Visually inspect fuel lines and connections for evidence of fuel leakage hose cracking and damage Make sure all clamps are secure Repair leaky joints if any Replace hoses that are suspected of being cracked Fuel Filter REPLACEMENT WARNING This work must be performed in a well ventilated area and away from any open flames such as gas hot water heaters Fuel filter 1 is a part of fuel pump assembly 2 which is installed in fuel tank Replace fuel filter with new one periodically referring to Fuel Pump Assembly with Fuel Filter Fuel Level Gauge and Fuel Cut Valve in Section 6C for proper procedure Fuel Tank INSPECTION Check fuel tank for damag
110. Attempt to pull it out partially may cause it to be deformed 3 Vise 4 Lever INSPECTION ee e Check ring teeth for being missing damaged or deformed haan Sa e Check sensor ring 1 for being deformed os 2X e Check that no foreign material is attached If any malcondition is found repair or replace INSTALLATION 1 Install sensor ring 3 as shown NOTE e Pipe 2 used here should have inner diameter of 90 mm 3 55 in 96 mm 3 77 in and its outside should not contact teeth of sensor ring e Use care not to insert wheel hub diagonally 1 Steel plate 4 Wheel hub 5 Hydraulic press 2 Install wheel hub brake disc brake caliper locking hub and wheel Refer to Wheel Hub Bearing Oil Seal in Section 3D 5E 36 ANTILOCK BRAKE SYSTEM ABS Rear Wheel Speed Sensor 4 U 10 N m 1 0 kg m U 10 N m 1 0 kg m 1 Left rear wheel sensor 3 Sensor ring Q Tightening torque 2 Trailing arm 4 Clamp bolt OUTPUT VOLTAGE INSPECTION Check in the same procedure as that used of front wheel speed sensor check Output AC voltage at 1 to 1 1 3 rotation per second 100 mV or more at 38 49 Hz Reference When using oscilloscope peak to peak voltage at 1 to 1 1 3 rotation per second 280 mV or more at 38 49 Hz REMOVAL 1 2 3 4 Disconnect negative cab
111. B BTDC Before Top Dead Center eid BBDC Before Bottom Dead Center IN VAPA aver MISSION EVAP Canister Evaporative Emission Canister Charcoal Canister CKT Circuit F 4WD 4 Wheel Drive CMP Sensor Camshaft Position Sensor GEN Generator Crank Angle Sensor CAS GND Ground CO Carbon Monoxide C CPP Switch Clutch Pedal Position Switch Clutch Switch Clutch Start HC Hydrocarbons Switch HO2S Heated Oxygen Sensor CPU Central Processing Unit CRS Child Restraint System DC Direct Current IAC Valve Idle Air Control Valve Idle Speed DLC Data Link Connector Control Solenoid Valve ISC Assembly Line Diag Link ALDL Solenoid Valve Serial Data Link SDL IAT Sensor Intake Air Temperature Sensor D DOHC Double Over Head Camshaft Air temperature Sensor ATS DOJ Double Offset Joint ICM Immobilizer Control Module DRL Daytime Running Light IG Ignition DTC Diagnostic Trouble Code ISC Actuator Idle Speed Control Actuator Diagnostic Code Motor 0A 22 GENERAL INFORMATION L LH Left Hand TBI Throttle Body Fuel Injection LSPV Load Sensing Proportioning Valve Single Point Fuel Injection SPI MAF Sensor Mass Air Flow Sensor TCC Torque Converter Clutch Air Flow Sensor AFS Air Flow TCM Transmission Control Module Meter AFM A T Controller A T Control Mod MAP Sensor Manifold Absolute Pressure ule Sensor Pressure Sensor PS TP Sensor Throttle Position Sensor M Max Maximum TVV Thermal Vacu
112. BCD Drive belt V rib belt Every 45 000 km 27 000 miles or 36 months A CDEF H Engine oil and oil filter Every 5 000 km 3 000 miles or 4 months r Every 15 000 km B Exhaust pipe mountings 9 000 miles or 12 months Every 2 500 km 1 500 miles C Air cleaner filter 1 R Every 30 000 km 18 000 miles or 24 months Nickel spark plug R Every 10 000 km 6 000 miles or 8 months ABC EF H_ Spark plugs Iridium spark plug R Every 30 000 km 18 000 miles or 24 months Every 15 000 km Se esas Ane parng 9 000 miles or 12 months Every 15 000 km B Suspension bolts and nuts T 9 000 miles or 12 months Every 15 000 km B DE H_ Propeller shafts 9 000 miles or 12 months First time only AEE eet oe 15 000 km 9 000 miles or 12 months B E H nerad differential oil R Second time and after Every 30 000 km 18 000 miles or 24 months reckoning from O km 0 mile or O month a i Every 30 000 km B E H_ Automatic transmission fluid R 18 000 miles or 24 months A Every 15 000 km BCD Steering knuckle seal 9 000 miles or 12 months NOTE e P Inspect and correct replace or lubricate if necessary e R Replace or change e T Tighten to the specified torque e 1 Inspect or replace more frequently if necessary MAINTENANCE AND LUBRICATION OB 5 Maintenance Service Engine Drive Belt WARNING All inspection and replacement are to be performed with ENGINE NOT RUNNING
113. Check continuity between two terminal as shown figure If check results are continuity proceed to next operation check If not replace Connect battery to blower motor as shown then check that the blower motor operates smoothly INSTALLATION 1 Reverse removal procedure for installation 2 Enable air bag system if equipped Refer to Enabling Air Bag System in Section 10B HEATER AND VENTILATION 1A 5 Heater Blower Resistor REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to Disabling Air Bag System in Section 10B 3 Disconnect resistor coupler 4 Remove blower motor resistor 3 as shown figure 1 Heater unit 2 Blower motor INSPECTION Measure each terminal to terminal resistance on resistor If measured resistance is incorrect replace heater blower motor resistor Heater blower resistor resistance Me Lo approx 2 4 Q Me Hi approx 1 2 Q INSTALLATION 1 Reverse removal procedure for installation 2 Enable air bag system if equipped Refer to Enabling Air Bag System in Section 10B Heater Control Lever Assembly REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to Disabling Air Bag System in Section 10B 3 Remove meter cluster hood ashtray center garnish instru ment glove box and radio or access
114. DIAGNOSIS Step Action Yes No 2 ECM Power and Ground Circuit Check Does engine start Go to Step 3 Go to Table A 5 ECM Power and Ground Circuit Check If engine is not cranked go to Diagnosis in Sec tion 8G MIL Circuit Check 1 Turn ignition switch OFF and disconnect connectors from ECM 2 Check for proper connection to ECM at ter minal E18 2 Case of TYPE A See NOTE or E17 9 Case of TYPE B See NOTE 3 If OK then using service wire ground termi nal E18 2 Case of TYPE A See NOTE or E17 9 Case of TYPE B See NOTE in connector disconnected Does MIL turn on at ignition switch ON Substitute a known good ECM and recheck Bulb burned out V Y wire circuit open or P wire shorted to ground Table A 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 Diagnostic Trouble Code DTC check 1 Check DTC referring to DTC CHECK sec tion Is there any DTC s DTC check 1 Start engine and recheck DTC while engine running Is there any DTC s Go to Step 2 of Engine Diag Flow Table Go to Step 2 Go to Step 3 MIL Circuit check 1 Turn OFF ignition switch 2 Disconnect connectors from ECM Does MIL turn ON at ignition switch ON V Y wire circui
115. DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Start engine and run it at idle for 1 min 4 Check DTC and pending DTC INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 ls SUZUKI scan tool available Go to Step 3 Go to Step 4 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 97 Step Action Yes No 3 Check Idle Air Control System Intermittent trouble or Go to Step 5 1 Connect SUZUKI scan tool to DLC with igni faulty ECM tion switch OFF set parking brake and block Check for intermittent drive wheels See Fig 1 referring to Intermittent 2 Warm up engine to normal operating tem and Poor Connection in perature Section OA 3 Clear DTC and select MISC TEST mode on SUZUKI scan tool Is it possible to control increase and reduce engine idle speed by using SUZUKI scan tool 4 Check Idle Air Control System Intermittent trouble or Go to Step 5 1 Remove IAC valve from throttle boy refer faulty ECM ring to IAC Valve in Section 6E Check for intermittent 2 Check IAC valve for operation referring to referring to Intermittent IAC Valve in Section 6E See Fig 2 and Poor Connection in Is check result satisfactory Section OA 5 Check Wire Harness for Open and Short Replace IAC valve and Repair or replace
116. FAILURE A battery is not designed to last indefinitely however with proper care it will provide many years of service If the battery performs satisfactorily during test but fails to operate properly for no appar ent reason the followings are some factors that may point to the cause of trouble e Accessories left on overnight or for an extended period with out the generator operating Slow average driving speeds for short periods Electrical load exceeding generator output particularly with addition of after market equipment Defects in charging system such as high resistance slipping drive belt loose generator output terminal faulty generator or voltage regulator Refer to Generator in this Diagnosis section Battery abuse including failure to keep battery cable termi nals clean and tight or loose battery hold down Mechanical problems in electrical system such as shorted or pinched wires VISUAL INSPECTION Check for obvious damage such as cracked or broken case or cover that could permit loss of electrolyte If obvious damage is noted replace battery Determine cause of damage and correct as needed HYDROMETER TEST The direct method of checking the battery for state of charge is to carry out a high rate discharge test which involves a special pre cise voltmeter and an expensive instrument used in the service shops but not recommendable to the user of the vehicle At 20 C of battery temperature electrol
117. FLOW DUTY IDLE AIR SPEED CONTROL DUTY This parameter indicates current flow time rate within a certain set cycle of IAC valve valve opening rate which controls the amount of bypass air idle speed 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 BATTERY VOLTAGE V This parameter indicates battery positive voltage inputted from main relay to ECM CANIST PURGE DUTY EVAP CANISTER PURGE FLOW DUTY This parameter indicates valve ON valve open time rate within a certain set cycle of EVAP purge solenoid valve which controls the amount of EVAP purge 0 means that the purge valve is completely closed while 100 is a fully open valve CLOSED THROTTLE POSITION ON OFF This parameter will read ON when throttle valve is fully closed or OFF when the throttle is not fully closed FUEL CUT ON OFF ON Fuel being cut output signal to injector is stopped OFF Fuel not being cut A C CONDENSER FAN A C CONDENSER FAN RELAY ON OFF ON Command for condenser fan relay operation being output OFF Command for relay operation not being output ELECTRIC LOAD ON OFF ON Headlight small light heater fan or rear window defogger ON signal inputted OFF Above electric loads all turned OFF A C SWITCH ON OFF ON Command f
118. LINKAGE WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They 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
119. MAP sen sor in Section 6E Faulty injector Diagnostic Flow Table B 1 Faulty ECM Inspection of ECM and its circuit in this section Malfunctioning EGR valve if equipped EGR system in Section 6E High idle speed Refer to item Improper Engine Idle Speed previously outlined Low compression Previously outlined Poor valve seating Valves and cylinder head in Section 6A1 Dragging brakes Diagnosis Table in Section 5 Slipping clutch Diagnosis Table in Section 7C Thermostat out of order Thermostat in Section 6B Improper tire pressure Refer to Section 3F 6 26 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Excessive engine oil consumption Sticky piston ring Pistons piston rings connecting rods and cylinders in Section 6A1 Worn piston and cylinder Pistons piston rings connecting rods and cylinders in Section 6A1 Worn piston ring groove and ring Pistons piston rings connecting rods and cylinders in Section 6A1 Improper location of piston ring gap Pistons piston rings connecting rods and cylinders in Section 6A1 Worn or damaged valve stem seal Valves and cylinder head in Section 6A1 Worn valve stem Valves and cylinder head in Section 6A1 Low oil pressure Improper oil viscosity ITEM1 3 Engine oil and oil filter change in Section OB
120. N m 2 5 kg m 18 0 Ib ft 6 Apply grease to all around of knuckle seal lip A Grease 99000 25010 7 Install knuckle seal retainer 1 knuckle seal 2 and knuckle seal cover 3 tighten bolts to specified torque NOTE Install knuckle seal cover 3 and knuckle seal retainer 1 so that their split section comes at the top as shown in figure Tightening torque Knuckle seal cover bolts a 10 N m 1 0 kg m 7 5 Ib ft 4 Steering knuckle 5 Split part FRONT SUSPENSION 3D 31 8 Press fit spindle bushing 2 to wheel spindle 1 by using special tool Set cut part 4 of spindle bushing 2 as shown in figure opposite side of the groove 3 of wheel spindle Special tool A 09922 55131 9 Press fit spindle oil seal 1 until it becomes flush with wheel spindle 2 surface by using special tool and then apply grease to its lip Special tool A 09944 66020 10 Apply grease to spindle oil seal lip A Grease 99000 25010 11 Apply grease to spindle bushing inside surface and flange 2 A Grease 99000 25010 CAUTION As this hole is a part of the passage of the vacuum that activates the air locking hub if it is clogged with grease the air locking hub cannot be locked or unlocked Therefore be careful not to apply too much grease to avoid clogging the vacuum passage 12 Install wheel spindle to knuckle coat their mati
121. P S system 5 Check steering column lower seal 1 for breakage or defor mation If found defective replace STEERING WHEEL AND COLUMN 3C 19 6 Check steering shaft joints and shaft for any damages such as crack breakage malfunction or excessive play If anything is found faulty replace as lower joint assembly or column assembly 7 Check steering shaft for smooth rotation If found defective replace as column assembly 8 Check steering shaft and column for bend cracks or defor mation If found defective replace Tightening Torque Specifications Tightening torque Fastening part Nem kam b fit Driver air bag inflator module bolts 9 0 9 6 5 Steering shaft nut 33 3 3 23 5 Steering column mounting bolts and nuts 14 1 4 10 5 Steering shaft joint bolts 25 2 5 18 0 Required Service Material Material Recommended SUZUKI product Use Water tight sealant SEALING COMPOUND 366E e To apply to steering column seal 99000 31090 Lithium grease SUZUKI GREASE CE T e Contact plate 99000 25290 Special Tool 09944 36011 Steering wheel remover 3C 20 STEERING WHEEL AND COLUMN FRONT SUSPENSION 3D 1 SECTION 3D FRONT SUSPENSION WARNING When hoisting vehicle be sure to select the lifting point suitable for the service work referring to Sec tion 0A NOTE e All front suspension fasteners are an importa
122. REMOVAL 1 Remove steering lower shaft joint bolt 2 2 Remove drag rod end nut from pitman arm 1 3 Disconnect drag rod end 2 from pitman arm 1 using spe cial tool Special tool A 09913 65210 4 Remove radiator support member 5 Remove steering gear box bolts and remove steering gear box 1 6 Remove pitman arm mounting nut 4 7 Make match marks 3 on pitman arm 1 and sector shaft 2 for a guide during reinstallation 8 Remove pitman arm 1 by using puller STEERING GEAR BOX MANUAL TYPE AND LINKAGE 3B 7 INSTALLATION Reverse removal procedure to install steering gear box 1 Install pitman arm 1 to sector shaft 2 of steering gear box with match marks 3 aligned as shown in figure and torque to specification Tightening torque Pitman arm mounting nut a 135 N m 13 5 kg m 98 0 Ib ft 2 Install sector shaft 2 to steering lower shaft joint 1 Tighten joint bolt to specified torque NOTE Align flat part 3 of sector shaft with bolt hole of lower shaft joint as shown Then insert sector shaft into lower shaft joint Tightening torque Steering lower shaft joint bolt a 25 N m 2 5 kg m 18 0 Ib ft 3 Install steering gear box mounting bolts 2 3 with short bolt 3 positioned as shown in figure Tighten nuts and bolt to specified torque Tightening torque Steering gear box mounting
123. Red and Green Red and Black Undersize bearing to be installed Rear Oil Seal Special tool A 09911 97820 Carefully inspect oil seal 1 for wear or damage If its lip is worn or damaged replace it For oil seal installation press fit rear oil seal 1 to oil seal hous ing 2 by using special tool as shown in the figure Crank rear oil seal installing position a 3 mm 0 12 in 6A1 88 ENGINE MECHANICAL M13 ENGINE Flywheel e If ring gear is damaged cracked or worn replace flywheel e If the surface contacting clutch disc is damaged or exces sively worn replace flywheel e Check flywheel for face runout with a dial gauge If runout exceeds its limit replace flywheel Flywheel runout Limit 0 2 mm 0 0079 in Sensor Plate e Check sensor plate for crack or damage If malcondition is found replace it Cylinder Block Distortion of gasketed surface e Using straightedge and thickness gauge check gasketed surface for distortion and if flatness exceeds its limit correct it Cylinder block flatness Limit 0 05 mm 0 0020 in 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 diameter Size Piston diameter 78 453 78 468 mm 3 0887 3 0893 in
124. See Fig 1 Is voltage within 10 14 V 6 1 Measure voltage from terminal c of VSS Go to Step 7 Y or Y G wire open or connector to ground See Fig 2 short Is voltage more than 4 V Poor connection of ECM connector terminal If OK substitute a known good ECM and recheck 7 1 Remove VSS Faulty VSS signal rotor Poor connection of VSS 2 Visually inspect VSS sensor signal rotor for damage Was any damage found connector terminal If OK substitute a known good VSS and recheck A Fig 1 for Step 5 B Fig 2 for Step 4 and Step 6 6 96 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION Bl ECM Gly E19 6 r BI B E18 6 B f e0 E18 5 E18 10 2 ja BI B E18 24P L Ei dT 1 IAC valve 3 Ignition switch 5 FIP fuse 2 Main relay 4 IG COIL METER fuse DTC DETECTING CONDITION POSSIBLE CAUSE e No closed signal to IAC valve is detected after engine start 2 driving cycle detection logic continuous monitoring e BI B G Y or B R circuit open or short e AC valve malfunction e ECM malfunction
125. Step 1 Special tool A 09912 58441 B 09912 58431 C 09912 58490 6 114 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table B 4 Idle Air Control System Check Or BI B Or a sae a BIB eas BiB BIB l E19 31P E17 17 EA FREE 1 Main fuse 2 Fuse box 3 Main relay 4 IAC valve INSPECTION Step Action Yes No 1 Check engine idle speed and IAC duty referring to Go to Step 2 Go to Step 4 Idle Speed IAC Duty Inspection in Section 6E Is idle speed within specification 2 Is IAC duty within specification in Step 1 Go to Step 3 Check for followings e Vacuum leak e EVAP canister purge control system e Clog of IAC air pas sage e Accessory engine load e Closed throttle posi tion TP sensor e Stuck of PCV valve ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 115 Step Action Yes No 3 ls engine idle speed kept specified speed even System is in good condi Check IAC system for with headlight ON tion operation referring to Step 3 or Step 4 of DTC P0505 Diag Flow Table 4 Was idle speed higher than specification in Step Go to Step 5 Go to Step 8 1 5 Check A C input signal circuit referring to Step 1 Go to
126. Table B 3 Maintenance in Section 6K Check oxygen sensor output voltage Refer to DTC P0130 No 14 Table in this section Diagnostic Flow Table B 1 Inspection of ECM and its circuit in this section EGR system in Section 6E 6 28 ENGINE GENERAL INFORMATION AND DIAGNOSIS 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 detected by ECM and output from ECM as commands and there may be cases where the engine or actuator is not operating in the condi tion as indicated by the scan tool Be sure to use the timing light to check the ignition timing NOTE e With the generic scan tool only star marked data in the table below can be read e The triangle A marked data in the table below can not be read for vehicle without immobilizer indi cator lamp at combination meter e 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
127. Torque values must be used as specified dur ing reassembly to assure proper retention of these parts CONTENTS General Description 20 cccscsssseeeeeeeeeseeeeees 3B 2 On Vehicle Service 2 ccccceseeeeeeeeeeeeeneeee 3B 6 Diagnosis ccceseeeeeeeseeeeeeeeeeeseeeeeensenerenseeeeenees 3B 3 Steering Gear BOX ecer 3B 6 Diagnosis Table s c 3B 3 Tie Rod And Drag Rod eee 3B 8 Steering Wheel Play Check ceee 3B 3 Tightening Torque Specifications 3B 10 Tie Rod And Drag Rod Check 3B 3 Required Service Material s0e00 3B 10 Steering Gear Box Oil Level Check 3B 4 Special TOONS vessssescicscsstiatancsnnsetoolettacsecauanaies 3B 10 Adjustment of Worm Shaft Starting Torque 3B 4 3B 2 STEERING GEAR BOX MANUAL TYPE AND LINKAGE General Description 1 Steering gear box 5 Tie rod 9 Worm shaft 13 Sector shaft 2 Pitman arm 6 Steering lower shaft 10 Ball 14 Rack gear 3 Drag rod 7 Steering wheel 11 Ball nut 4 Knuckle arm 8 Steering upper shaft 12 Gear case STEERING GEAR BOX MANUAL TYPE AND LINKAGE 3B 3 Diagnosis Diagnosis Table Refer to Diagnosis Table in Section 3 Steering Wheel Play Check Check steering wheel for play and rattle holding vehicle in straight forward condition on ground Steering wheel play a 10 30 mm 0 4 1 2 in I
128. Usual driving Driving at 30 40 mph 50 60 km h including short stop according to traffic signal under driving condition other than high load high engine speed rapid accelerating and decelerating INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check exhaust system for leakage loose con Go to Step 3 Repair or replace nection and damage Is it good condition 3 Check HO2S 2 and Its Circuit Go to Step 4 B BI or W circuit open Was HO2S 2 output voltage indicated on scan or HO2S 2 malfunction tool in step 3 of DTC confirmation test less than 1 275 V 4 Check Short Term Fuel Trim Check W and B BI wire Check fuel system Go to Did short term fuel trim very within 20 20 for open and short and DTC P0171 P0172 Diag range in step 3 of DTC confirmation test connection for poor con __ Flow Table nection If wire and con nection are OK replace HO2S 2 6 66 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0141 Heated Oxygen Sensor HO2S Heater Circuit Malfunction Sen sor 2 CIRCUIT DESCRIPTION ECM IG1 B W J R BI DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition it met e HO2S 2 heater circuit open
129. V Engine coolant temp 80 C 176 F 15 Intake air temp sensor 2 0 2 7 V enon STETA Intake air temp 20 C 68 F 02 10V Ignition switch oN position and throttle 16 Throttle opening signal VANS ANAS POSMON Ignition switch ON position and throttle 2 8 4 8 V valve fully open EGR valve stepper motor coil 3 if Ignition switch ON position leaving engine 17 i 10 14V equipped OFF 6 36 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE EGR valve stepper motor coil 1 if Ignition switch ON position leaving engine 18 10 14V equipped OFF 19 Ignition coil 2 20 Ignition coil 1 21 Fuel injector NO 2 10 14V Ignition switch ON 22 Power source for sensors 4 75 5 25 V Ignition switch ON 23 Crankshaft position sensor pas Ignition switch ON position 24 ae kiok sencor About 2 5 V At specified idle speed after engine E19 warmed up Ignition switch ON 26 Manifold absolute pressure sensor 3 3 4 0 V Barometric pressure 100 kPa 760 mmHg 27 EGR valve stepper motor coil 4 if Ignition switch ON position leaving engine 28 10 14V equipped OFF EGR valve stepper motor coil 2 if Ignition switch ON position leaving engine 29 10 14V equipped OFF 30 31 Fuel injector NO 3 10 14V Ignition switch ON For TYPE A See NOTE NOTE See NOTE in ECM TERMINAL VOLTAGE VALUES TAB
130. a Tighten 5 0 kg m a Tighten 36 5 lb ft b Turn 60 b Turn 60 b Turn 60 Rear oil seal housing bolts 11 0 1 1 8 0 Flywheel or drive plate bolts 70 0 7 0 51 0 Torque converter bolts 20 0 2 0 14 5 Timing chain tensioner bolt 22 0 2 2 16 0 Knock sensor 23 0 2 3 16 5 Cylinder block and transmission fasten ing bolts and nuts vehicle with M T oa aa ene Cylinder block and transmission fasten 80 0 8 0 58 0 ing bolts and nuts vehicle with A T Special Tool 09911 97720 Oil seal guide 09911 97820 Oil seal installer 09913 75520 Bearing installer 09915 47330 Oil filter wrench 2 09915 64510 001 Compression gauge Connector g 09915 64510 002 Hose 09915 64530 09915 67010 Attachment 4 ENGINE MECHANICAL M13 ENGINE 6A1 95 09915 67310 Vacuum gauge 09915 77310 Oil pressure gauge Ne 09915 78211 Oil pressure gauge attachment 09916 14510 Valve lifter 09916 14521 Valve lifter attachment 09916 34542 Reamer handle 09916 34550 Reamer 5 5 mm 09916 37320 Reamer 10 5 mm 09916 44910 Valve guide remover O 09916 56011 Valve guide installer attachment 09916 58210 Valve guide installer han dle 09916 67020 Tappet holder 09916 77310 Piston ring compressor 09916 84511 Forceps 09917 68221 Camshaft lock holder w 09917 98221 Valve stem seal installer 6A1 96 ENGIN
131. aas 1B 21 Abnormal noise from A C evaporator 1B 8 FOCOVEIY nti oescce ca cccagtaraces i tecsted actcanatazete 1B 22 Abnormal noise from blower fan motor 1B 8 Replenishing Compressor Oil 008 1B 22 Quick Checking of Refrigerant Charge 1B 9 1B 2 AIR CONDITIONING OPTIONAL EVACUATING ssnreccecessescszeptverrteeseccndeeeoenizenteens 1B 23 Evacuating procedure seere 1B 23 Charging sei iced tes heeereteeieis E 1B 25 Charging procedure sesse 1B 25 Removing Manifold Gauge Set 1B 28 beak TeSt ra eeaeee Ee aaia 1B 28 On Vehicle Service s ssssenssssnnsernnnnnnnnnnennnna 1B 29 Service Precaution 1B 29 Refrigerant line 1B 29 Handling refrigerant HFC 134a R4348 irinin ekanna eee 1B 30 Condenser Assembly eeren 1B 31 Receiver Dryer cccccceeeceeeeeeeeseeeeeeeees 1B 32 Condenser Cooling Fan Assembly 1B 33 Cooling Unit Evaporator 00 cceee 1B 34 A C Evaporator Thermistor A C Evaporator Temperature Sensor cccceceeeeeeeeeees 1B 37 Expansion Valve eeren 1B 37 Dual Pressure Switch eeeeeeeeeeees 1B 38 AIC Switch wi ce cseseciegedese ee ceeceeetvneneieneeenee 1B 39 Condenser Cooling Fan Motor Relay 1B 39 COMPIeSSOM 2 s0 33 ceceeeesenteceeen dele th cvneeeees 1B 39 Magnet ClUtch cceeesseeeesseeeeeeseeereeees 1B 41 Lip Type Seal eececeeeceeeeeseseeeeeeeseeeeaees 1B 45 Tightening Tor
132. 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 e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CONTENTS General Description cccsssseeeeeeeeeseeeseenees 6H 2 GONELratOl ccceececeeeeeeceeeeeeeeeeeeeeeeeetetenaees Battery siete tcita tein iem tse tite eaten 6H 2 Generator belt n Generatot aaisen ekrane ari eee 6H 4 Unit Repair Overhaul DIAGNOSIS isisao iinei etnias aoronat aiies aauina 6H 6 GONELratOl eeeeceeeeeeeeeeeeeeeeeeseeneeeeeetetenaees BANE tana eerie ota tie ee oa 6H 6 DISMOUNTING cesses ees eeteteteteeenneees GSMOT ARO Mo
133. alignment out of adjustment Adjust front wheel alignment Steering wheel installed improperly twisted Install steering wheel correctly Hydraulic pressure failing to rise See NOTE A Replace P S pump Slow hydraulic pressure rise See NOTE A Steering wheel feels heavy momentarily when turning it to the left or right Air drawn in due to insufficient amount of fluid Add fluid and bleed air Slipping belt Adjust belt tension or replace belt as necessary No idle up See NOTE B Defective pressure switch Replace pressure switch terminal set NOTE e A Be sure to warm up engine fully before performing this check Pump vanes are sometimes hard to come out where temperature is low e B Acceptable if idling speed does not drop Condition Possible Cause Correction Steering wheel returns slowly from turns See NOTE C Dust or foreign object mixed in fluid Change fluid Deformed pipes or hoses Correct or replace Steering column installed improperly Install correctly Wheel alignment maladjusted Adjust Linkage or joints not operating smoothly Correct Vehicle pulls to one side during straight driving Low or uneven tire inflation pressure Inflate tire s as necessary Wheel alignment maladjusted Adjust Defective spool valve Replace gear box assembly
134. and Replace sensor if any recheck Referring to Front Wheel Speed Sensor in this section check output voltage or waveform of sensor Is proper out put voltage or waveform obtained ANTILOCK BRAKE SYSTEM ABS 5E 23 A c 1 ABS hydraulic unit control module connector 2 Lock position 3 Unlock position D E OK NG 5E 24 ANTILOCK BRAKE SYSTEM ABS DTC C1041 DTC 41 DTC C1042 DTC 42 Right Front Solenoid Circuit DTC C1045 DTC 45 DTC C1046 DTC 46 Left Front Solenoid Circuit DTC C1055 DTC 55 DTC C1056 DTC 56 Rear Solenoid Circuit W BI A25 A23 ea co Cl ea Ca Ca ca od i i oa Ca jes ca Ca jet ca cI 1 ABS hydraulic unit control module assembly 2 1 Lock position 2 ABS hydraulic unit control module connector of harness 2 2 Unlock position DESCRIPTION The ABS control module monitors the voltage of the terminal of the solenoid circuit constantly with the ignition switch turned ON It sets this DTC when the terminal voltage does not become low high for the ON OFF com mand to the solenoid or the voltage difference between solenoid circuit terminals exceeds the specified value with the solenoid turned OFF INSPECTION Step Action Yes No 1 1 Check solenoid referring to ABS Hydraulic Unit Check terminals A25 and Go to step 2 Op
135. and electric lead wires securely 10 Install air cleaner outlet hoses 11 Install radiator with cooling fan and connect A T fluid hoses vehicle with A T radiator inlet and outlet hoses referring to Water Pump Belt and Cooling Fan and Radiator in Sec tion 6B 12 Adjust generator belt tension referring to Water Pump Belt Tension in Section 6B 13 Adjust A C compressor and or P S pump belt tension if equipped referring to Compressor Drive Belt in Section 1B or Power Steering Belt in Section 3B1 14 Adjust accelerator cable play referring to Accelerator Cable Adjustment in Section 6E 15 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled 16 Refill cooling system with coolant engine with engine oil and A T with specified A T fluid vehicle with A T 17 Connect negative cable at battery 18 Verify that there is no fuel leakage coolant leakage oil leak age A T fluid leakage vehicle with A T and exhaust gas leakage at each connection 6A1 62 ENGINE MECHANICAL M13 ENGINE Pistons Piston Rings Connecting Rods and Cylinders N 10 Top ring 8 Piston pin 2nd ring 9 Piston pin circlip Oil ring 10 Bearing cap nut 5 1 Tighten all nuts to 15 N m 1 5 kg m 2 Turn all nuts to 45 3 Then turn all nuts to 45 once again Piston Tightening torque Connecting rod Apply en
136. and then pull SS NO them apart by holding connectors themselves GENERAL INFORMATION 0A 11 e When connecting connectors also hold connectors and push them together until they lock securely a click is heard e When installing the wiring harness fix it with clamps so that no slack is left e When installing vehicle parts be careful so that the wir ing harness is not interfered with or caught by any other part e To avoid damage to the harness protect its part which may contact against a part forming a sharp angle by winding tape or the like around it e Be careful not to touch the electrical terminals of parts which use microcomputers e g electronic control unit like as ECM PCM P S controller etc The static elec tricity from your body can damage these parts 0A 12 GENERAL INFORMATION Never connect any tester voltmeter ohmmeter or what ever to electronic control unit when its coupler is dis connected Attempt to do it may cause damage to it Never connect an ohmmeter to electronic control unit with its coupler connected to it Attempt to do it may cause damage to electronic control unit and sensors Be sure to use a specified voltmeter ohmmeter Other wise accurate measurements may not be obtained or personal injury may result When taking measurements at electrical connectors using a tester probe 2 be sure to insert
137. and tighten switch to specified torque NOTE If sealing tape edge is bulged out from screw threads of switch cut it off Tightening torque Oil pressure switch a 14 N m 1 4 kg m 10 5 Ib ft 7 Start engine and check oil pressure switch for oil leakage If oil leakage is found repair it 8 Connect oil pressure switch coupler 1 ENGINE MECHANICAL M13 ENGINE 6A1 9 Valve Lash Clearance 1 Remove negative cable at battery 2 Remove cylinder head cover referring to Cylinder Head Cover in this section 3 Using 17 mm wrench turn crankshaft pulley 1 clockwise until cam lobes 2 become perpendicular to shim faces 3 at valves 1 and 7 as shown in figure 4 Check valve lashes with thickness gauge 4 according to the following procedure If valve lash is out of specification record valve lash and adjust it to specification by replacing shim a Check valve lashes at valves 1 and 7 b Turn camshafts by 90 by turning crankshaft with wrench c Make sure that cam lobes are perpendicular to shim faces at valves to be checked in this case 3 and 8 if not adjust it by turning crankshaft Check valve lashes d In the same manner as b c check valve lashes at valves 4 and 6 e In the same manner as b c again check valve lashes at valves 2 and 5 Valve clearance specification
138. and wheel spindle thrust washer c Uncaulk front wheel bearing lock nut 1 Wheel hub FRONT SUSPENSION 3D 23 6 Remove front wheel bearing lock nut by using special tool Special tool A 09944 77020 For 4WD A 09951 16050 For 2WD 7 Remove front wheel bearing washer 8 Remove wheel hub complete 1 with bearings 2 and oil seal 4 3 Circlip NOTE If wheel hub can not be removed by hand use special tools as shown Special tool A 09943 35511 or 09943 35512 B 09942 15510 9 Remove sensor rotor from wheel hub as shown if equipped with ABS CAUTION Pull out sensor rotor from wheel hub gradually and evenly Attempt to pull it out partially may cause it to be deformed Sensor rotor Wheel hub Vise Flat end rod AJJ N 10 Remove wheel bearing oil seal and circlip 3D 24 FRONT SUSPENSION 11 Using hydraulic press 1 and special tool remove wheel bearing 2 Special tool A 09913 75520 12 Remove hub bolts from hub INSTALLATION 1 Insert new stud in hub hole Rotate stud slowly to assure ser rations are aligned with those made by original bolt 1 Oil hydraulic press 2 Hub bolt CAUTION Press fit wheel bearing 3 vertically to hub 4 2 Using special tool press fit wheel bearing 8 un
139. are operating accurately LIGHTS Check that all lights operate properly WINDSHIELD DEFROSTER Periodically check that air comes out from defroster outlet when operating heater or air conditioning Set mode control lever to defroster position and fan switch lever to HI position for this check 0B 22 MAINTENANCE AND LUBRICATION Recommended Fluids and Lubricants Engine oil SE SF SG SH SJ or SL Refer to Engine Oil and Oil Filter in this section for engine oil viscos ity Engine coolant Ethylene glycol base coolant Antifreeze Anticorrosion coolant Brake fluid DOT 3 Manual transmission oil Refer to Maintenance Service in Section 7A Transfer oil Refer to Oil Change in Section 7D Differential oil front amp rear Refer to Oil Change in Section 7E and 7F Automatic transmission fluid An equivalent of DEXRON IIE or DEXRON III Power steering fluid An equivalent of DEXRON II DEXRON IIE or DEXRON III Clutch linkage pivot points Steering knuckle seal Water resistance chassis grease SUZUKI SUPER GREASE A 99000 25010 Door hinges Hood latch assembly Engine oil or water resistance chassis grease Key lock cylinder Spray lubricant HEATER AND VENTILATION 1A 1 SECTION 1A HEATER AND VENTILATION WARNING For vehicles equipped with Supplement Restraint Air Bag System e Servic
140. arm nut Front differential carrier bolt 23 2 3 17 0 Front propeller shaft flange bolt 50 5 0 36 5 Wheel nut 95 9 5 69 0 Vacuum pipe clamp bolt 5 5 0 55 4 0 Required Service Material Material Recommended SUZUKI product Use Part Number Lithium grease SUZUKI SUPER GREASE A 99000 25010 e Knuckle seal axle shaft oil seal e Recess of wheel spindles e Wheel hub oil seal e Wheel bearing e Spindle thrust washer e Spindle bush inside and flange part e Spindle oil seal SUZUKI SUPER GREASE C 99000 25030 e Kingpin bearing e Axle shaft joint for 4WD Sealant SUZUKI BOND NO 1215 99000 31110 e Mating surfaces of wheel spindle and knuckle e Mating surface of differential carrier and axle housing Sealing compound SUZUKI SEALING COMPOUND 366E 99000 31090 e Mating surface of wheel spindle and knuckle e Kingpin e Mating surfaces of hub cap and wheel hub Special Tool FRONT SUSPENSION 3D 45 09917 47910 Vacuum pump gauge 09913 50121 Oil seal remover 09913 65210 Tie rod end remover 09913 75520 Bearing installer 09951 76010 Bearing installer 09924 74510 Bearing installer handle 09942 15510 Sliding hammer 09943 35511 or 09943 35512 Brake drum remover 09944 66010 Wheel hub knuckle oil seal installer 09944 68510 Bearing installer attach ment 09951 16050 Wheel bearing tightening tool O 09944 77020 Ring nut wren
141. as shown in left figure is equal distribution of weight on each side of wheel centerline so that when the tire spins there is no tendency for the assembly to move from side to side Wheels that are dynamically unbalanced may cause shimmy 1 Heavy spot wheel shimmy C Before correction 2 Balance weights addition point D Corrective weights 3 C L of spindle General Balance Procedure Deposits of mud etc must be cleaned from inside of rim WARNING Stones should be removed from tread in order to avoid operator injury during spin balancing and to obtain good balance Tire should be inspected for any damage then balanced according to equipment manufacturers recommenda tion Off vehicle balancing Most electronic off vehicle balancers are more accurate than on vehicle spin balancers They are easy to use and give a dynamic two plane balance Although they do not correct for drum or disc unbalance as does on vehicle spin balancing this is overcome by their accuracy usually to within 1 8 ounce On vehicle balancing On vehicle balancing methods vary with equipment and tool manufacturers Be sure to follow each manufac turer s instructions during balancing operation WHEELS AND TIRES 3F 5 WARNING Wheel spin should be limited to 35 mph 55 km h as indicated on speedometer This limit is necessary because speedometer only indicates one half of actual wheel speed when
142. bag inflator module mounting bolts 1 to specified torque Tightening torque Driver air bag inflator module mounting bolts a 9 N m 0 9 kg m 6 5 Ib ft 6 Install steering wheel side cap 2 7 Connect negative battery cable 8 Enable air bag system Refer to Enabling Air Bag System under Service Precautions in Section 10B Steering Wheel CAUTION For vehicle with air bag system Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil on the combi nation switch more than allowable number of turns about two and a half turns from the center position clockwise or counterclockwise respectively or coil will break 3C 6 STEERING WHEEL AND COLUMN REMOVAL 1 Disconnect negative battery cable at battery terminal 2 Remove steering wheel pad for vehicle without air bag sys tem or driver air bag inflator module for vehicle with air bag system as follows e Vehicle without air bag system for TYPE A a Remove steering wheel pad b Disconnect horn connector e Vehicle without air bag system for TYPE B a As shown in the figure while pushing the set spring 1 with a screwdriver or the like inserted in the hole of the steering wheel pull the lower part of the pad forward and remove the steering wheel pad A For TYPEA B For TYPE B e Vehicle with air bag system a Remove driver air b
143. be started at least 90 seconds after the ignition switch is turned to the LOCK position and negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They 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 dur ing reassembly to assure proper retention of these parts CONTENTS General Description cccsseeesseeeeeeseeees 3B1 2 Air Bleeding Procedure ceecee 3B1 8 Diago sisaan aaaea NA 3B1 3 Hydraulic Pressure In P S Circuit Check 3B1 10 Diagnosis Table c 2 0cc ena cena 3B1 3 On Vehicle Service eecececeeeeeeeeeees 3B1 12 Steering Wheel Play Check cece 3B1 5 Power Steering Belt nce 3B1 12 Steering Force Check cccceseeeeeeeeeees 3B1 5 Power Steering P S Pump 00 3B1 12 Power Steering Belt Check n s 3B1 6 Power Steering P S Gear Box 4 3B1 18 Power Steering Belt Tension Adjustment 3B1 6 Tightening Torque Specifications 3B1 21 Power Steering Fluid Level Check 3B1 6 Required Service Materials
144. block in Section 6A1 NOTE Before checking the mechanical noise make sure that e Ignition timing is properly adjusted e Specified spark plug is used e Specified fuel is used ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 27 Condition Possible Cause Reference Item Excessive hydrocar bon HC emission or Excessive carbon mon oxide CO emission Faulty ignition coil Fuel pressure out of specification Lead contamination of three way catalytic converter Malfunctioning PCV system Faulty EVAP control system Closed loop system A F feed back com pensation fails Faulty TP sensor Faulty ECT sensor or MAP sensor Faulty oxygen sensor Faulty injector Faulty ECM Low compression Ignition coil assembly in Section 6F Diagnostic Flow Table B 3 Maintenance in Section 6K PCV system in Section 6E EVAP control system in Section 6E Check oxygen sensor output voltage Refer to DTC P0130 No 14 Table in this section Diagnostic Flow Table B 1 Inspection of ECM and its circuit in this section Previously outlined Excessive nitrogen oxides NOx emission Fuel pressure out of specification Lead contamination of three way catalytic converter Closed loop system A F feed back com pensation fails Faulty TP sensor Faulty ECT sensor or MAP sensor Faulty oxygen sensor Faulty injector Faulty ECM Faulty EGR system if equipped Diagnostic Flow
145. board 1 or the like This prevents damage to radiator fins when removing and installing radiator 11 Remove radiator with cooling fan referring to Section 6B Then remove water pump pulley 12 With hose connected detach P S pump from its bracket if equipped referring to Power Steering Pump in Section 3B1 NOTE Suspend removed P S pump at a place where no damage will be caused during removal and installation of engine assembly 13 If vehicle equipped with A C compressor work of right hand steering vehicle differs from its of left hand steering vehicle Each work is as follows 6A1 74 ENGINE MECHANICAL M13 ENGINE a For right hand steering vehicle With hose connected detach A C compressor from its bracket NOTE Suspend removed A C compressor at a place where no damage will be caused during removal and installation of engine assembly b For left hand steering vehicle i Recover refrigerant from refrigeration system using recov ery and recycling equipment ii Disconnect magnet clutch lead wire iii Remove suction pipe and disconnect discharge pipe from A C compressor v Remove A C compressor from its bracket When servicing above steps refer to Compressor in Section 1B 14 15 lt 17 Remove air cleaner outlet No 1 and No 2 hoses Disconnect the following electric lead wires TP sensor 1 MAP sensor 2 CKP sensor if equip
146. bodies and each diode lead 2 Check both directions by reversing probes of ohmmeter and there should be only one way continuity in each case If check result is not satisfactory replace rectifier 1 6H 16 CHARGING SYSTEM Drive End Bearing Check that the bearing is not rough or worn End Housing Bearing Check that the bearing is not rough or worn When removal is necessary use bearing puller to remove end housing bearing 1 CAUTION Be careful not to distort cooling fan blade while applying puller Replace Brush 1 Unsolder and remove the brush and spring 2 Run the wire of a new brush through the spring and the hole in the brush holder and insert the spring and brush into the brush holder 3 Solder the brush wire to the brush holder at specified exposed length Exposed brush length a 10 5 mm 0 413 in 4 Check that the brush moves smoothly in the brush holder 5 Cut off the excess wire 6 Apply insulation paint to the soldered area CHARGING SYSTEM 6H 17 Specifications Battery 55B24R TYPE Rated capacity 36 AH 5HR 12 Volts Electrolyte 3 1 L 6 55 5 46 US Imp pt Electrolyte S G 1 28 when fully charged at 20 C 68 F 38B20R TYPE Rated capacity 28 AH 5HR 12 Volts Electrolyte 2 1 L 4 44 3 70 US Imp pt Electrolyt
147. boiling and e Do not remove radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pres sure if either cap is taken off too soon To check level look at see through reservoir It is not necessary to remove radiator cap to check coolant level When engine is cool check coolant level in reservoir 1 A normal coolant level should be between FULL 2 and LOW 3 marks on reservoir 1 If coolant level is below LOW mark remove reservoir cap and add proper coolant to reservoir to bring coolant level up to FULL mark Then reinstall cap NOTE e If proper quality antifreeze is used there is no need to add extra inhibitors or additives that claim to improve system They may be harmful to proper operation of system e When installing reservoir cap set arrow marks 4 on the reservoir and cap as the figure Cooling System Service WARNING To help avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pres sure if cap is taken off too soon Cooling system should be serviced as follows 1 Check cooling system for leakage or damage 2 Wash radiator cap and filler neck with clean water by remov ing radiator cap when engine is cold 3 Check coolant for proper level and freeze protection 4 Using a pressure tester check system a
148. bolt Retighten bolt Abnormal noise from tension pulley Condition Possible Cause Correction Clattering noise is heard from pulley Worn or damaged bearing Replace tension pulley Pulley cranks upon contact Cracked or loose bracket Replace or retighten bracket Abnormal noise from A C evaporator Condition Possible Cause Correction Whistling sound is heard from A C evapo rator Depending on the combination of the interior exterior temperatures engine rpm and refriger ant pressure the refrigerant flowing out of the expansion valve may under certain conditions make a whistling sound At times slightly decreasing refrig erant volume may stop this noise Inspect expansion valve and replace if faulty Abnormal noise from blower fan motor Condition Possible Cause Correction Blower fan motor emits a chirping sound in proportion to its speed of rotation Worn or damaged motor brushes or commuta tor Repair or replace blower fan motor Fluttering noise or large droning noise is heard from blower fan motor Leaves or other debris introduced from fresh air inlet to blower fan motor Remove debris and make sure that the screen at fresh air inlet is intact AIR CONDITIONING OPTIONAL 1B 9 Quick Checking of Refrigerant Charge The following procedure can be used for quic
149. bolt and nuts a 80 N m 8 0 kg m 58 0 Ib ft 2 Steering gear box 4 Install radiator support member 5 Connect drag rod 2 to pitman arm 1 Tighten new drag rod end nut to specified torque NOTE To prevent ball stud from being rotated while tightening tie rod end nut tighten Nut M12 x 1 25 to about 20 N m 2 0 kg m 14 5 lb ft and remove it Then tighten new nut to specified torque Tightening torque Drag rod end nut pitman arm side a 50 N m 5 0 kg m 36 5 Ib ft 3B 8 STEERING GEAR BOX MANUAL TYPE AND LINKAGE Tie Rod And Drag Rod REMOVAL 1 Hoist vehicle and remove wheel s 2 Remove tie rod end nut from steering knuckle 3 Mark 3 one end of tie rod before removing the rod as shown in figure to distinguish the correct installing direction easy 4 Disconnect tie rod end 2 from knuckle 1 using special tool Special tool A 09913 65210 5 For ease of adjustment after installation make marking 3 of tie rod end lock nut position on tie rod thread Then loosen lock nut 2 and remove tie rod end 1 from tie rod INSTALLATION 1 Install tie rod end lock nut 2 and tie rod end 1 to tie rod and or drag rod Align lock nut with mark 3 on tie rod thread STEERING GEAR BOX MANUAL TYPE AND LINKAGE 3B 9 2 Adjust tie rod and or drag rod length to the measurement shown in figure then tighten tie ro
150. cc 1 83 cu in Receiver dryer 20 cm 20 cc 1 22 cu in Hoses 10 cm 10 cc 0 61 cu in each Pipes 10 cm 10 cc 0 61 cu in each Evacuating Evacuating procedure Whenever opened exposed to atmospheric air A C system must be evacuated by using a vacuum pump NOTE Do not evacuate before recovering refrigerant and replen ishing compressor oil 1B 24 AIR CONDITIONING OPTIONAL 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 hose Attach center charging hose 6 of manifold gauge set 3 to vacuum pump 7 Operate vacuum pump 7 and then open discharge side valve Hi 8 of manifold gauge set 3 If there is no blockage in the system there will be an indica tion on high pressure gauge 9 In this case open the other side valve Lo 10 of the set and repair the system Approximately 10 minutes later low pressure gauge 11 should show a vacuum lower than 760 mmHg providing no leakage exists NOTE ol lt 7 If the system does not show a vacuum below 760 mmHg 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
151. charge the air conditioning system with refrigerant from the refrigerant service con tainer When charging refrigerant recovered by using the refrig erant and recycling equipment when recycling refriger ant follow the procedure described in the equipment manufacturer s instruction manual Charging procedure 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 from the low pressure side with the engine running 1 Check to make sure that hoses are routed properly after evacuating the system 1B 26 AIR CONDITIONING OPTIONAL 2 Connect Low charging hose 1 and High charging hose 2 of the manifold gauge set 3 in position Thus open refriger ant container valve 4 to purge the charging line 3 Open the high pressure side valve 5 and charge refrigerant to system 4 After a while open the low pressure side valve 6 and close the high pressure side valve 5 5 Start engine and keep engine speed at 1500 r min Then operate air conditioning 6 Charge A C system with refrigerant in vapor state At this time refrigerant container should be held upright WARNING Make sure that high pressure side valve is closed securely 7 When refrigerant container 3 is emptied use the following procedure to replace refrigerant container with a new refrig erant conta
152. circuit ter minals changes to High Low High If anything faulty is found in the initial check and when the voltage at all solenoid circuit terminals is low with the ignition switch turned ON and ABS not operated 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 Under charged Battery in Sec tion 6H 2 Check ABS main fuse and connection Go to step 3 Repair and or replace Is it in good condition fuse 3 1 2 lt mo oo lt Is it 10 14 V Ignition switch OFF Disconnect ABS hydraulic unit control module connector Check proper connection to ABS hydraulic unit control module at terminal A25 4 If OK then measure voltage between con nector terminal A25 and body ground Substitute a known good ABS hydraulic unit con trol module assembly and recheck W BI circuit open or short to ground 5E 28 ANTILOCK BRAKE SYSTEM ABS DTC C1071 DTC 71 ABS Control Module DESCRIPTION This DTC will be set when an internal fault is detected in the ABS control module INSPECTION Step Action Yes No 1 1 Ignition switch OFF Substitute a known good Repair or replace 2 Disconnect connectors from ABS control ABS control module and module recheck 3 Check for proper connection to ABS control module at all terminals Are they
153. components are enclosed into a solid mold This unit along with the brush holder assembly is attached to the rear housing The IC regulator uses integrated circuits and controls the voltage produced by the generator and the volt age setting cannot be adjusted The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication Two brushes carry current through the two slip rings to the field coil mounted on the rotor and under normal con ditions will provide long period of attention free service The stator windings are assembled on the inside of a laminated core that forms part of the generator frame A condenser mounted in the rear housing suppresses radio noise CHARGING SYSTEM 6H 5 B IG O O L 7 C 6 4 L 8 fo 7 A t D 1 i paum C ee ee G E 1 Generator with regulator assembly 3 Stator coil 5 Field coil rotor coil 7 Main switch 2 I C regulator 4 Diode 6 Charge indicator light 8 Battery 1 Pulley 5 Stator core 9 Front housing IG Ignition terminal 2 Pulley nut 6 Field coil 10 Rear housing L Lamp terminal 3 Rotor fan 7 Regulator B Generator output Battery terminal 4 Stator coil 8 Brush E Ground 6H 6 CHARGING SYSTEM Specific gravity 16 15 5 0 5 10 15 20 25 30 35 40 45 C Temperature Diagnosis Battery COMMON CAUSES OF
154. condition ON Be oe Other than fuel cut condition OFF Ignition switch A C not operating OFF A C CONDENSER FAN ON AIC operating ON Ignition switch ON Headlight small light heater fan and rear window defogger all OFF turned OFF PEE GIBRIG ESAD Ignition switch ON Headlight small light heater fan or rear window defogger turned ON ON Engine running after warming up A C not OFF A C SWITCH pparaing l Engine running after warming up A C oper ON ating PNP SIGNAL PARK NEU tion swi P O REEI ROEN P N Range TRAL POSITION SIGNAL gnition switch position a AIT only ON Selector lever in R D D Range 2 or L position EGR VALVE At specified idle speed after warming up 0 FUEL TANK LEVEL 0 100 BAROMETRIC PRESS B Display the E pres Within 3 seconds after ignition switch ON or ON FUEL PUMP engine running Engine stop at ignition switch ON OFF 6 30 ENGINE GENERAL INFORMATION AND DIAGNOSIS SCAN TOOL DATA CONDITION REFERENCE VALUES Brak li i N BRAKE SW a releasing OFF iti i f itch ON N BLOWERFAN on Ce loner tar eek oF oF 7 ti N womaccLuTcH ignition switch JAC operating OFF Scan tool data definitions FUEL SYSTEM FUEL SYSTEM STATUS Air fuel ratio feedback loop status displayed as either open or closed loop Open indicates that ECM ignores feedback from the exhaust oxygen sensor Closed indicates final injection duration is corrected for oxygen sen
155. diag switch ter ABS hydraulic unit con to ground minal and ground trol module assembly and Is it10 14 V recheck 3 1 Ignition switch ON Go to step 7 of ABS diag Substitute a known good ABS hydraulic unit con trol module assembly and recheck ANTILOCK BRAKE SYSTEM ABS 5E 17 Table D Code DTC is Not Outputted Even With Diag Switch Terminal Con nected to Ground 1 ABS warning lamp in combination meter 3 1 Diag switch terminal 4 1 Lock position 2 ABS hydraulic unit control module assembly 3 2 Diag ground terminal 4 2 Unlock position 3 Monitor connector 4 ABS hydraulic unit control module connector of harness CIRCUIT DESCRIPTION When the diag switch terminal is connected to the ground with the ignition switch turned ON the ABS control module outputs a diagnostic trouble code by flashing ABS warning lamp INSPECTION Step Action Yes No 1 Is it shorted diag switch terminal and ground __ Go to step 2 Connect service wire terminal by service wire properly securely 2 1 Disconnect service wire P B circuit open Go to step 3 2 Disconnect ABS hydraulic unit control module connector 3 Measure resistance between diag switch terminal and connector terminal A12 Is it infinite cc 3 1 Measure resistance between ground termi Go to step 4 B circuit open or poor nal of monitor connector and body ground
156. eee 1A 7 On Vehicle ServiCe ccsssscsseseessseeeseeeeeaes 1A 4 Heater Unit Boost Ventilation ey 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 of front passengers and the defroster air outlets at places right and left along the windshield glass The heater and ventilation consist of following parts 1 Side ventilator outlet 6 Ventilator duct 11 Heater core 2 Side defroster outlet 7 Control lever 12 Damper 3 Center ventilator outlet 8 Blower motor 13 Air inlet box without air conditioning without n other parts marked cooling unit if equipped 4 Heater unit 9 Blower resistor with air conditioning 5 Defroster duct 10 Blower fan switch Blower fan and A C switch if equipped with air conditioning Diagnosis Table Diagnosis HEATER AND VENTILATION 1A 3 Condition Possible Cause Correction Heater blower won t work even when its switch is ON Blower fuse blown Replace fuse to check for short Blower resistor faulty Check resistor Blower fan switch faulty Check blower fan switch Blower motor faulty Repla
157. enter its installation hole 5 Disconnect brake pipe s 2 from wheel cylinder and put wheel cylinder bleeder plug cap 1 onto pipe to prevent fluid from spilling 6 Remove brake back plate nuts 3 from axle housing 7 Using special tools indicated draw out axle shaft with brake back plate Special tool A 09942 15510 B 09943 35511 or 09943 35512 8 If equipped with ABS in order to remove sensor rotor from retainer ring grind with a grinder one part of the sensor rotor as illustrated till it becomes thin 9 Break with a chisel the thin ground sensor rotor and it can be removed if equipped with ABS 3E 14 REAR SUSPENSION 10 In order to remove the retainer ring 1 from the shaft 3 grind with a grinder 2 two parts of the bearing retainer ring 1 as illustrated till it becomes thin CAUTION Be careful not to go so far as to grind the shaft 3 11 Break with a chisel the thin ground retainer ring and it can be removed 12 Using special tools remove bearing 1 from shaft and then remove brake back plate 2 Special tool A 09927 18411 B 09921 57810 13 Remove stud bolt s 1 by using hydraulic press 2 B REAR SUSPENSION 3E 15 INSTALLATION Install removed parts in reverse order of removal procedure not ing the following 1 Aligning serrations between new stud bolt s 1 and
158. envelop measure gauging plastic width at its widest point Camshaft journal clearance Standard Limit 0 045 0 087 mm 0 12 mm 0 0018 0 0034 in 0 0047 in If measured camshaft journal clearance exceeds limit measure A journal housing bore and outside diameter of camshaft journal Replace camshaft or cylinder head assembly whichever the dif ference from specification is greater Camshaft journal outside diameter A ltem Standard 26 934 26 955 mm 1 0604 1 0612 in Other 22 934 22 955 mm B CESEN z 0 9029 0 9037 in AS No 1 y Camshaft journal bore diameter B J A Item Standard alee pe ang 27 000 27 021 mm VA 1 0630 1 0638 in iil Q OM 23 000 23 021 mm omer 0 9055 0 9063 in A B Beeline ENGINE MECHANICAL M13 ENGINE 6A1 45 Wear of Tappet and Shim Check tappet and shim for pitting scratches or damage If any malcondition is found replace Measure cylinder head bore and tappet outside diameter to deter mine cylinder head to tappet clearance If clearance exceeds limit replace tappet or cylinder head Cylinder head to tappet clearance Standard 0 025 0 066 mm 0 0010 0 0026 in Limit 0 15 mm 0 0059 in Tappet outside diameter A Standard 30 959 30 975 mm 1 2189 1 2195 in Cylinder head tappet bore B Standa
159. 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 cccccssssseereeeeeeeseeeees 5 3 Fluid Pressure Test Diagnosi Sannaa anara Ni 5 4 If Equipped with LSPV 0 eee 5 15 Road Testing Brake ccccccececccccececccececceuueusens 5 4 On Vehicle Service ccccccccecceeeseeeseeennees 5 17 Brake Fluid Leaks sanese 5 4 Air Bleeding of Brake System eee 5 17 Substandard or Contaminated Brake Fluid 5 4 Brake Hose and Pipe Inspection 5 18 Diagnosis Table eere 5 5 Front Disc Brake 00 00 eeeeceeeeeeesneeeeeeeees 5 19 Brake Pedal Free Height Adjustment 5 8 Brak pad wa An aniiniinns anaes 5 20 Brake Pedal Play Check nsss 5 8 Caliper aSSEMDI ccceceeeeeeteeeeeeeeees 5 22 Stop Light Switch Adjustment 68 5 8 Brake DISC sisson hae Heth 5 26 Excessive Pedal Travel Check 5 9 Rear Brake ccecceceeccsecsseeeeaeeeeeeeeeeeeeeeeeees 5 29 Front Brake Disc Check n se 5 9 Brake drU sinen anae 5 29 Front Brake Pad Check s seeeeeeeeeeeteees 5 9 Brake Sh0e s sssssssssssssressssssseessrrrerersnens 5 32 Rear Brake Shoe Check seese 5 10 Wheel Cylinder
160. flange install new stud bolt s 1 by tightening nut 2 as shown 3 Washer 4 Flange of axle shaft 2 Press fit wheel bearing 1 and retainer ring 2 as shown NOTE e Use care not to cause any damage to outside of retainer ring 2 e Refer to figure so that wheel bearing 1 is installed in proper direction 3 For vehicle with ABS press fit new sensor rotor as shown NOTE Use care not to cause any damage to outside of retainer ring 2 A Vehicle without ABS B Vehicle with ABS 4 Inspect axle shaft length Rear axle shaft length a 775 5 mm 30 5 in left side 559 5 mm 22 0 in right side 5 Apply grease to axle shaft oil seal lip 1 as shown A Grease 99000 25010 6 Apply sealant to mating surface of axle housing 2 with brake back plate NOTE Make sure to remove old sealant before applying it anew B Sealant 99000 31110 3E 16 REAR SUSPENSION 7 Install rear axle shaft to rear axle housing 2 and tighten brake back plate nuts 4 to specified torque NOTE When installing rear axle shaft be careful not to cause damage to oil seal lip in axle housing 2 Tightening torque Brake back plate nuts a 23 N m 2 3 kg m 17 0 lb ft 8 Connect brake pipe 3 to wheel cylinder and tighten brake pipe flare nut to specified torque Tightening torque Brake pipe flare nut b
161. flows out of level plug hole or if oil level is found up to hole when level plug is removed oil is properly filled If oil is found insufficient pour specified amount of specified oil Q N lt x A Transfer B Front differential C Rear differential 1 Oil filler evel plug Apply sealant for transfer 2 Drain plug Apply sealant CAUTION Hypoid gear oil must be used for differential 4 Tighten level plug to specified torque Refer to Oil Change in Section 7D 7E or 7F for tightening torque CHANGE Change transfer oil and differentials oil with new specified oil referring to Oil Change in Section 7D 7E or 7F 0B 18 MAINTENANCE AND LUBRICATION Steering System INSPECTION 1 Check steering wheel for play and rattle holding vehicle in straight forward condition on the ground Steering wheel play a 0 30 mm 0 1 2 in 2 Check universal joints of steering lower shaft 1 for rattle and damage If rattle or damage is found replace defective part with a new one 3 Check steering linkage including kingpin for looseness and damage Repair or replace defective part if any 4 Check bolts and nuts for tightness and retighten them as necessary Repair or replace defective parts if any Refer to table of Tightening Torque Specifications in Sec tion 3B or 3B1 and 3C for particular check points 5 Inspect steering
162. ft 2 Install main bearings to cylinder block Upper half of bearing 1 has an oil groove 2 Install it to cylinder block 3 and the other half without oil groove to bearing cap Make sure that two halves are painted in the same color 3 Install thrust bearings 1 to cylinder block between No 2 and No 3 cylinders Face oil groove 2 sides to crank webs 4 Confirm that dowel pins 3 are installed to intake side of each journal ENGINE MECHANICAL M13 ENGINE 6A1 91 5 Install crankshaft to cylinder block 6 Install bearing cap to cylinder block making sure to point arrow mark on each cap to crankshaft pulley side Fit them sequentially in ascending order 1 2 3 4 and 5 starting from pulley side After applying engine oil to bearing cap No 1 bolts 1 10 and bearing cap No 2 bolts 11 20 tighten them gradually as follows NOTE e If bearing cap No 1 bolts are reused check thread diameters of them for deformation according to previ ous mentioned Main Bearing Cap No 1 Bolt and T replace them with new ones if thread diameter exceeds a 08 4 04 2 026 1900 Feo limit a Tighten bolts 1 10 to 30 N m 3 0 kg m 22 0 lb ft according to numerical order as shown by using a 12 cor ner socket wrenches b In the same manner as in Step a tighten them to 50 N m 5 z 5 0 kg m 36 5 lb ft BO 09 c Inthe same manner as in Step a retighte
163. gear box 2 for evidence of oil leakage If leakage is found check oil level in gear box 6 Check boots of steering linkage for damage leaks detach ment tear dent etc If damage is found replace defective boot with new one 7 Check wheel alignment Refer to Preliminary Checks Prior to Adjusting Front Alignment in Section 3A Steering Knuckle Seal INSPECTION 1 Remove knuckle seal cover 1 2 Check knuckle seal 2 for wear damage and deterioration If defective replace 3 Apply grease to seal lip and install seal and seal cover a Grease 99000 25010 MAINTENANCE AND LUBRICATION 0B 19 Power Steering P S System if equipped INSPECTION 1 Visually check power steering system for fluid leakage and hose for damage and deterioration Repair or replace defective parts if any 2 With engine stopped check fluid level indicated on fluid tank or level gauge of tank cap which should be between MAX and MIN marks If it is lower than MIN fill fluid up to MAX mark NOTE e Be sure to use an equivalent of DEXRON II DEXRON IIE or DEXRON III for P S fluid e Fluid level should be checked when fluid is cool 3 Visually check pump drive belt for cracks and wear 4 Check belt for tension referring to Drive Belt in this section If necessary have belt adjusted or replaced All Hinges Latches and Locks DOORS INSPECTION Check that each door of front and back do
164. guide bolts to specified torque Tightening torque Timing chain No 1 guide bolts a 9 N m 0 9 kg m 6 5 Ib ft 6A1 40 ENGINE MECHANICAL M13 ENGINE 6 Apply engine oil to sliding surface of chain tensioner 1 and install chain tensioner and spacer Tighten tensioner bolt to specified torque Tightening torque Timing chain tensioner bolt a 22 N m 2 2 kg m 16 0 Ib ft 7 Check that match marks 1 on intake and exhaust camshaft timing sprockets are in match with dark blue plates 2 of tim ing chain and match mark 8 on crankshaft timing sprocket is in match with gold plate 4 of timing chain 8 Screw in plunger 1 by turning timing chain tensioner adjuster 2 in arrow direction and install a retainer 3 wire to hold plunger in place 9 Install timing chain tensioner adjuster assembly 1 with a retainer 2 Tighten adjuster bolts to specified torque and then remove a retainer from chain tensioner adjuster assembly Tightening torque Timing chain tensioner adjuster bolts a 11 N m 1 1 kg m 8 0 Ib ft ENGINE MECHANICAL M13 ENGINE 6A1 41 10 Apply engine oil to timing chain and then turn crankshaft clockwise by 2 revolutions and check that match marks 1 on intake and exhaust camshaft timing sprockets are in match with notches 2 on cylinder head and key 3 is on upside of crankshaft as shown in figure If each mark of timing chain and each ma
165. ie istne ea eed 3E 6 Rear Shock Absorber Check cccccececeeeece 3E 3 Bump Stopper AEE ATE EEEE asm ne heh nina adie 3E 9 Trailing Arm Lateral Rod Axle Housing Lateral ROG eiin rrenaren eearri 3E 9 and Coil Spring Check c cccscssecseeseceeeeeees 3E 3 Trailing Arm BUSHING eee eee 3E 10 Trailing Arm and Lateral Rod Bush Check 3E 3 Rear Axle Shaft and Wheel Bearing 3E 12 Rear Suspension Fasteners 3E 4 Rear Axle Shaft Inner Oil Seal 3E 17 Bearing Retainer and Axle Shaft Oil Seal Rear Axle Housing 56 SH OH E RRR EEN 3E 18 CHECK E EE E EER 3E 4 Tightening Torque Specifications 3E 22 Bump Stopper and Spring Rubber Seat Required Service Materials 3E 22 CHECK iiss Sosceteen tis an a Aa dats 3E 4 Special TOO AEE E 3E 23 Wheel Disc Nut and Bearing Check 3E 4 3E 2 REAR SUSPENSION General Description Rear axle housing 4 Bearing oil seal 7 Brake drum 10 Bump stopper i Rear wheel bearing 5 Oil seal protector 8 Rear axle shaft 11 Coil spring wo Bearing retainer ring 6 Lateral rod 9 Shock absorber 12 Trailing arm REAR SUSPENSION 3E 3 Diagnosis Diagnosis Table Refer to Diagnosis Table in Section 3 Rear Shock Absorber Check e Inspect for deformation or damage e Inspect bushings for wear or damage e Insp
166. in Section 10B Failure to follow proper procedures could result in possible air bag sys tem activation personal injury damage to parts or air bag system being unable to activate when necessary e 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 e 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 e 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 bag wire harness in instrument panel 5 Contact coil wire harness and floor wire harness 2 Passenger air bag inflator module 6 Driver air bag inflator module 3 SDM 7 Seat belt pretensioner if equipped 4 DLC Diagnosis e When troubleshooting air bag system be sure to follow Air Bag Diagnostic System Check in Section 10B Bypassing these procedures may result in extended diagnostic time incorrect diagnosis and incorrect parts replacement e 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 a
167. in good condition ANTILOCK BRAKE SYSTEM ABS 5E 29 On Vehicle Service Ignition sw Motor Solenoid R F L F Rear Precaution When connectors are connected to ABS hydraulic unit control module assembly do not disconnect connectors of sensors fuse etc and turn ignition switch ON Then DTC will be set in ABS con trol module ABS Hydraulic Unit Operation Check 1 Check that basic brake system other than ABS is in good condition 2 Check that battery voltage is 11 V 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 Turn each wheel gradually by hand to check if brake drag ging occurs If it does correct 7 With diag switch terminal 3 of monitor connector 1 con nected to ground terminal 2 by using service wire 4 turn ignition switch ON and check if ABS warning lamp indicates DTC 12 When other DTC s appear on display refer to ABS Diagnos tic Flow Table in this section 8 Turn ignition switch OFF 9 Perform following checks with help of another person Brake pedal 1 should be depressed and then ignition switch 2 turned ON by one person and wheel 3 should be turned by another person s hand At this time check that Operation sound of solenoid
168. in the Sensing and Diagnostic Module SDM CONTENTS Maintenance Schedule cccsssseseeneeees OB 2 Fuel Evaporative Emission Control Maintenance Schedule Under Normal System Aad A E TA OB 11 Driving Conditions ccicc2 a sesame tates 0B 2 Chassis and Body v ieidninnsanciiteclaimuien 0B 11 Maintenance Recommended Under Severe GUC EAEE TEE ETE EAE EE OB 11 Driving Conditions vtec ta c2s ccecdtntede 0B 4 Brake Discs and PadS s ss1 11s11 111 OB 11 Maintenance Service sssssssssesesssessseseees OB 5 Brake Drums and ShOeS seeeee 0B 12 Brake Hoses and Pipes OB 12 ee ee ee enna te ae Brake Fluide i ni creer ene 0B 12 Vale AASB tee aiana es G Paring Brake Leven ale CAD Eragi e Engine Oil and Filter cc 0B 6 Tires Wheels E EEATT OB 13 Engine Coolant cccccscssssseeeeseseseee 0B 8 SUSPENSION SYSTEM sis teratai tidnin pea Exhaust System OB 8 Propeller Shafts ieee eseeseeneenseneaeeasenss OB 15 Ignition SYStOM eececcccccccssssssscseeseeeereeen 0B 9 Manual Transmission Oil seteeeeeeeneeees OB 16 Be a E T Automatic Transmission Fluid i 0B 16 RO yE esae OBO ers er ANA MIN ETEMA M es sipa RE Air Cleaner Filter csccccccscssssseeeeeeesnesee 0B 9 ali oe Ey pare H Fuel Lines and Connections OB 10 g P aN Na de AA OONAN E O Crise daca 0B 10 F ower Steering PISI System Fuel TAAK ea ra ra i 0B 10 U a a E E pene Emission Control System n OB 10 PAGES TENS and Logkssrc
169. 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 at brake pedal 10 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 11 Turn ignition switch OFF 12 Remove service wire from monitor connector 5E 30 ANTILOCK BRAKE SYSTEM ABS ABS Hydraulic Unit Control Module Assembly CAUTION Do not 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 1 F 16 Nm 1 6 kg m ee 1 F 16 N m 1 6 kg m Qo 9 5 U 11 N m 1 1 kg m FOAR 7S Yj CH a ss 7 w De U 2 N m 0 9 kg m 1 Brake pipe 3 Bracket Q Tightening torque 2 ABS hydraulic unit control 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 Using special tool disconnect brake pipes from ABS hydrau lic unit control module assembly 1 Special tool A 09950 78220 NOTE Put bleeder plug cap onto pipe to prevent fluid from spill ing Do not allow brake fluid to get on painte
170. lip A Grease 99000 25010 3 Install oil seal retainer 1 oil seal 2 and oil seal cover 3 to steering knuckle 4 Tighten bolts to specified Torque NOTE Install the seal 2 in oil seal retainer 1 bringing the split part 5 to top side and locating it about 30 off the matching face of oil seal retainer 1 Tightening torque Knuckle seal cover bolts a 10 N m 1 0 kg m 7 5 Ib ft Lateral Rod REMOVAL 1 Hoist vehicle 2 Remove mounting bolts of lateral rod 1 3 Remove lateral rod 1 INSTALLATION 1 Install lateral rod 1 to vehicle body and front axle housing referring to figure for proper installing direction of bolts Bolt and nut should not be tightened NOTE For left hand steering vehicle install lateral rod with its bending point 2 placed to right side of vehicle 2 Lower hoist and with vehicle in non loaded condition tighten bolt and nut of lateral rod to specified torque Tightening torque Lateral rod bolt and nut a 90 N m 9 0 kg m 65 0 Ib ft A Right hand steering vehicle B Left hand steering vehicle 3D 36 FRONT SUSPENSION Leading Arm Bushing REMOVAL 1 Hoist vehicle 2 Remove air locking hub vacuum pipe clamp bolts 2 for 4WD 1 Leading arm right side 3 Support front axle housing by using floor jack 4 Remove shock absorber lower mounting bolt refer to Front Shock Absorber in this
171. magnetic clutch Compressor faulty Check compressor Air in A C system Replace receiver dryer and perform evacuation and charging Air leaking from cooling unit or air duct Repair as necessary Heater and ventilation system faulty Check air inlet box cooling unit heater control lever assembly and heater unit referring to Section 1A Blower fan motor faulty Check blower fan motor referring to Sec tion 1A Excessive compressor oil existing in A C system Pull out compressor oil in A C system cir cuit and replace compressor Cool air won t come out only intermittently Wiring connection faulty Repair as necessary Expansion valve faulty Check expansion valve Excessive moisture in A C system Replace receiver dryer and perform evacuation and charging Magnetic clutch faulty Check magnetic clutch Excessive charge of refrigerant Check charge of refrigerant Thermal switch faulty Check thermal switch Cool air comes out only at high speed Condenser clogged Check A C condenser Insufficient charge of refrigerant Check charge of refrigerant Air in A C system Replace receiver dryer and perform evacuation and charging Compressor drive belt loosen or broken Adjust or replace drive belt Compressor faulty Check compressor Cool air won t come out only at high speed Excessive charge of refrige
172. new valve stem seal 1 to valve guide After applying engine oil to seal and spindle of special tool Valve guide installer handle fit oil seal to spindle and then install seal to valve guide by pushing special tool by hand After installing check to be sure that seal is properly fixed to valve guide Special tool A 09917 98221 B 09916 58210 NOTE e Do not reuse once disassembled seal Be sure to install new seal e When installing do not tap or hit special tool with a hammer or else Install seal to guide only by pushing special tool by hand Tapping or hitting special tool may cause damage to seal ENGINE MECHANICAL M13 ENGINE 6A1 59 6 Install valve to valve guide Before installing valve to valve guide apply engine oil to stem seal valve guide bore and valve stem 7 Install valve spring and spring retainer Each valve spring has top end large pitch end 1 and bot tom end small pitch end 2 Be sure to position spring in place with its bottom end small pitch end facing the bottom valve spring seat side A Valve spring retainer side B Valve spring seat side 8 Using special tools Valve lifter compress valve spring and fit two valve cotters 1 into groove in valve stem Special tool A 09916 14510 B 09916 14521 C 09916 84511 NOTE When compressing the valve spring do not damage inside face of tappet installing h
173. of vehicle refer to Section 0A WARNING For vehicles equipped with Supplement Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE e When inspecting and servicing vehicle equipped with ABS be sure to refer to section 5E first e 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
174. one drive wheel is spinning and the other drive wheel is stopped Unless care is taken in limiting drive wheel spin spinning wheel can reach excessive speeds This can result in possible tire disintegration or differential failure which could cause serious personal injury or extensive vehicle damage CAUTION For vehicle equipped with ABS using on vehicle balancing method with ignition switch ON may set malfunction diagnostic trouble code DTC of ABS even when system is in good condition Never turn ignition switch ON while spinning wheel 3F 6 WHEELS AND TIRES Maintenance and Minor Adjustments Wheel and Tire Wheel repairs that use welding heating or peening are not approved All damaged wheels should be replaced Studs If a broken stud is found see Section 3E rear or Section 3D front for Note and Replacement procedure Matched tires and wheels For vehicle equipped with steel wheels Tires and wheels are matchmounted at the assembly plant This means that the radially stiffest part of the tire or high spot is matched to the smallest radius or low spot of the wheel This is done to provide the smoothest possible ride The high spot of the tire is originally marked by paint dot 1 on the outboard sidewall This paint dot will eventually wash off the tire The low spot of the wheel is originally marked by paint dot 2 on the wheel rim flange Properly assembled the wheel rim
175. or CFC 12 R 12 is indicated on compressor label 1 Also it can be checked by the shape of the service charge valve 2 Diagnosis General Diagnosis Table AIR CONDITIONING OPTIONAL 1B 5 Condition Possible Cause Correction Cool air won t come out A C system won t operative No refrigerant Perform recover evacuation and charging Fuse blown Check fuses in main and circuit fuse boxes and check short circuit to ground A C switch faulty Check A C switch Blower fan switch faulty Check blower fan switch referring to Sec tion 1A A C evaporator thermistor faulty Check A C evaporator thermistor Dual pressure switch faulty Check dual pressure switch Wiring or grounding faulty Repair as necessary ECT sensor faulty Check ECT sensor referring to Section 6E ECM and its circuit faulty Check ECM and its circuit referring to Sec tion 6E 4WD controller faulty Check 4WD controller referring to Section 3D Cool air won t come out A C compressor won t operative ECM faulty Check ECM and its circuit referring to Sec tion 6E Magnet clutch faulty Check magnet clutch Compressor drive belt loosen or broken Adjust or replace drive belt Compressor faulty Check compressor Cool air won t come out A C condenser cooling fan motor won t operative Fuse blown Check A C fuse in main fuse b
176. or disc mounting surface by scraping and wire brushing Install ing wheels without good metal to metal contact at mounting surfaces can cause wheel nuts to loosen which can later allow wheel to come off while vehicle is moving Tightening order A B C D E Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft WHEELS AND TIRES 3F 9 Tire Mounting and demounting Use tire changing machine to mount or demount tires Follow equipment manufacturer s instructions Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim Rim bead seats should be cleaned with wire brush or coarse steel wool to remove lubricants old rubber and light rust Before mounting or demounting tire bead area should be well lubricated with approved tire lubricant After mounting inflate to 240 kPa 35 psi so that beads are completely seated Then adjust pressure to speci fied shown on tire placard WARNING Do not stand over tire when inflating Bead may break when bead snaps over rim s safety hump and cause serious personal injury Do not exceed 240 kPa 35 psi pressure when inflating If 240 kPa 35 psi pressure will not seat beads deflate re lubricate and reinflate Over inflation may cause bead to break and cause serious personal injury Install valve core and inflate to proper pressure Repair There are many different mater
177. or the rubber components in the hydraulic system to deteriorate If primary piston cups are swollen then rubber parts have deteriorated This deterioration may also be evi denced by swollen wheel cylinder piston cups on the drum brake wheels If deterioration of rubber is evident disassemble all hydraulic parts and wash with alcohol Dry these parts with compressed air before assembly to keep alcohol out of the system Replace all rubber parts in the system including hoses Also when working on the brake mechanisms check for fluid on the linings If excessive fluid is found replace the linings If master cylinder piston seals are satisfactory check for leakage or excessive heat conditions If condition is not found drain fluid flush with brake fluid refill and bleed the system The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contained parts that have been subjected to contaminated fluid Diagnosis Table BRAKES 5 5 Condition Possible Cause Correction Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair Brake disc or pads stained with oil Clean or replace Overheated brakes Determine cause and repair Poor contact of shoes on brake drum Repair for proper contact Brake shoes linings stained with oil or wet with Replace water Badly worn brake shoe linings Replace
178. outer rotor 1 and case 2 using thickness gauge 3 If clearance exceeds its limit replace outer rotor or case Limit on radial clearance between outer rotor and case for oil pump 0 310 mm 0 0122 in Side clearance Using straight edge 1 and thickness gauge 2 measure side clearance Limit on side clearance for oil pump inner rotor 0 15 mm 0 0059 in 6A1 36 ENGINE MECHANICAL M13 ENGINE ASSEMBLY 1 Wash clean and then dry all disassembled parts 2 Apply thin coat of engine oil to inner and outer rotors oil seal lip portion and inside surfaces of oil pump case and plate 3 Install outer 1 and inner rotors 2 to oil pump case 4 Install relief valve component 1 to rotor plate 2 5 Install rotor plate and tighten all bolts to specified torque After installing plate check to be sure that rotors turn smoothly by hand 0 3 N m 0 03 kg m 0 25 Ib ft torque or below Tightening torque Oil pump rotor plate bolts a 11 N m 1 1 kg m 8 0 Ib ft INSTALLATION For installation referring to Timing Chain Cover in this section ENGINE MECHANICAL M13 ENGINE 6A1 37 Timing Chain and Chain Tensioner 8 U o N m 0 9 kg m 1 Crankshaft timing sprocket 5 Timing chain tensioner adjuster assembly Q Tightening torque 2 Timing chain 6 Chain tensioner adjuster mounting bolt Apply engine oil to sliding surface 3 Timing chain No 1 guide
179. parts i e stabi lizer etc or vehicle floor or it may get deformed In raising front or rear vehicle end off the floor by jacking be sure to put the jack against the center portion of the front axle housing 1 or rear axle housing 2 To perform service with either front or rear vehicle end jacked up be sure to place safety stands 1 under chassis frame so that body is securely supported And then check to ensure that chas sis frame does not slide on safety stands 1 and the vehicle is held stable for safety s sake A Front IB Rear Abbreviations GENERAL INFORMATION 0A 21 Abbreviations May Be Used In This Manual ABC Anti lock Brake System EBCM Electronic Brake Control Module ATDC After Top Dead Center ABS Control Module API American Petroleum Institute ECM Engine Control Module ATF Automatic Transmission Fluid ECT Sensor Engine Coolant Temperature ALR Automatic Locking Retractor Sensor Water Temp Sensor A AC Alternating Current WTS A T Automatic Transmission EGR Exhaust Gas Recirculation A C Air Conditioning EGRT Sensor EGR Temperature Sensor ABDC After Bottom Dead Center Recirculated Exhaust Gas Temp A F Air Fuel Mixture Ratio Sensor REGTS A ELR Automatic Emergency EFE Heater Early Fuel Evaporation Locking Retractor Heater Positive Temperature Coefficient PTC Heater B Battery Positive Voltage ae emergency eg Paa EPS Electronic Power Steering
180. performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e 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 e 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 e 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 that is air bag or inflator modules SDM and or seat belt with pretensioner beforehand to avoid component damage or unintended activation FOREWORD This manual contains procedures for diagnosis maintenance adjustments minor service operations replace ment of components Service and for disassembly and assembly of major components Unit Repair Overhaul Applicable model JIMNY SN413 of and after the vehicle identification numbers below XJSAFJA43V00140001 X XJSAFJB43V00140001 X XJSAFJB43V20140001 X XJSAFJB43V24140001X XJSAFJB43V34140001 X JS3JB43V1241 40001 JS3JB43V1341 40001 The contents are classified into sections each
181. position straight position NOTE As input shaft makes 4 full turns from lock to lock neu tral position is obtained by turning it till it locks and turn ing it back by 2 full turns 2 Vinyl tube See through tube 8 Remove special tools and install steering gear box to vehi cle and P S pipe hose to steering gear box referring to Power Steering P S Gear Box in this section NOTE e Don t install pitman arm and steering lower shaft to steering gear box Installation of these parts will cause input shaft and or sector shaft to turn allowing air to enter gear box e Plug up opening after pipe or hose disconnection 9 Bleed air in P S system referring to Air Bleeding Procedure in this section 10 Install pitman arm and steering lower shaft to steering gear box 3B1 10 POWER STEERING P S SYSTEM If equipped 60 C 50 C Hydraulic Pressure In P S Circuit Check 1 Clean where pipe is connected thoroughly then disconnect high pressure hose from high pressure pipe connector and connect oil pressure gauge special tool as shown Special tool A 09915 77410 B 09915 77420 1 To gear box 4 Union bolt 2 Attachment 5 Pressure hose 3 Washer 2 Bleed air 3 With engine running at idling speed keep turning steering wheel to the right and left till fluid in P S fluid reservoir is warmed to 50 to 60 C 122 140 F
182. refrigerant from system the amount of removed compressor oil must be measured for replen ishing compressor oil e When handling recovery and recycling equipment be sure to follow the instruction manual for the equip ment Replenishing Compressor Oil It is necessary to replenishing specified amount of compressor oil to compressor 1 from compressor suction side hole 2 before evacuating and charging refrigerant Compressor oil 99000 99088 00D0 WHEN CHARGING REFRIGERANT ONLY When charging refrigerant without replacing any component part replenish the same amount of measured oil when recover refrig erant if not measure replenish 30 cc oil AIR CONDITIONING OPTIONAL 1B 23 WHEN REPLACING COMPRESSOR Compressor oil is sealed in each new compressor by the amount required for A C system Therefore when using a new compres sor for replacement drain oil from new compressor by the amount calculated as follows Cc A B C Amount of oil to be drained A Amount of oil sealed in a new compressor B Amount of oil remaining in removed compressor 1 New compressor 2 Removed compressor WHEN REPLACING OTHER PART Replenish the following amount of oil to compressor Amount of compressor oil to be replenished Replaced part Amount of compressor oil to be replenished Evaporator 30 cm 30 cc 1 83 cu in Condenser 30 cm 30
183. section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE Starting motor varies depending on specifications etc Therefore be sure to check model and speci fication of vehicle being serviced before replacing parts CONTENTS General Description cccsssseeeeeeeeeeesseeees 6G 2 Performance Test ccceeeeeetesteeeeeeeeeeeee 6G 4 Cranking Circuit 6G 2 On Vehicle Service ccccsseeesseeneseseeeeeeeees 6G 5 Di AQNOSIS wescceicescteniesasdceescseascasdedatTesadacseuanctzence 6G 2 Starting Motor ce eeeeeeeseeeeeenneeeeeeneeeeeeaeees 6G 5 Diagnosis Table wccssccieesserecoecseucetiesepenren 6G 2 SPeCifiCATIONS eeccsseeeeeseeeeeeeseeeeeneeeeeeeeeeeees 6G 7 6G 2 CRANKING SYSTEM General Description Cranking Circuit 10 a O N N 1 Pinion drive lever 5 Plunger 9 A T Transmission range switch shift lever switch 2 Pinion amp Over running clutch 6 Magnetic switc
184. sensor 26 Injector No 2 45 Rear defogger switch if equipped 8 IAT sensor 27 Injector No 3 46 Rear defogger if equipped 9 Heated oxygen sensor 1 if equipped 28 Injector No 4 47 A C compressor clutch if equipped 10 Heated oxygen sensor 2 if equipped 29 IAC valve 48 Ignition switch 11 A C evaporator temp sensor if equipped 30 EVAP canister purge valve 49 Main relay 12 Speedometer 31 Fuel pump relay 50 CO adjusting register if equipped 13 Fuel level sensor 32 Fuel pump 51 Starting motor 14 TCM A T 33 A C condenser fan relay if equipped 52 4WD controller 4WD 15 Transmission range switch A T 34 A C condenser fan motor if equipped 53 ABS control module if equipped 16 Shift lock solenoid A T if equipped 35 EGR valve if equipped 54 Engine ground 17 Backup lamp 36 Malfunction indicator lamp 55 Body ground 18 Heater fan motor 37 Immobilizer indicator lamp if equipped 19 Heater fan switch 38 Monitor connector vehicle without immo bilizer indicator lamp ENGINE AND EMISSION CONTROL SYSTEM 6E 11 For TYPE B See NOTE B 2 Se 25 Taa W 36 Tis k RIG 27 o E a EE a WB eal y 6 29 LgR GY Ea 1 L 7 g E19 16 Bie
185. shift lever in Neutral shift selector lever to P range for A T model and set parking brake and block drive wheels 3 Disconnect accelerator cable 1 from clamp 2 For left hand steering vehicle only 4 Remove cylinder head upper cover 3 5 Disconnect ignition coil couplers 1 6 Remove ignition coil assemblies 2 with high tension cord 3 7 Remove all spark plugs 8 Disconnect fuel injector wires 4 at the coupler 9 Install special tools Compression gauge into spark plug hole Special tool A 09915 64510 001 B 09915 64510 002 C 09915 64530 D 09915 67010 CA lt z N ba 4 OF ENGINE MECHANICAL M13 ENGINE 6A1 5 10 Disengage clutch 1 to lighten starting load on engine for M T vehicle and depress accelerator pedal 2 all the way to make throttle fully open 11 Crank engine with fully charged battery and read the highest pressure on compression gauge NOTE e For measuring compression pressure crank engine at least 250 rpm by using fully charged battery e If check results are below the limit valve check instal lation condition for special tool Compression pressure specification 1400 kPa Standard 2 14 0 kg cm 199 0 psi oon 1100 kPa Limit 2 11 0 kg cm 156 0 psi Max difference between 100 kPa any two cylinders 1 0 kg cm 14 2 psi 12 Carry out Steps 9 thro
186. silicon carbide abrasive paper place abrasive paper on and over surface plate and rub gasketed surface against paper to grind off high spots Should this fail to reduce thickness gauge readings to within limit replace cylinder head Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface such leakage results in reduced power output Limit of distortion for surface of cylinder head piston side 0 03 mm 0 001 in Distortion of manifold seating faces Check seating faces of cylinder head for manifolds using a straightedge and thickness gauge in order to determine whether these faces should be corrected or cylinder head replaced Limit of distortion for surface of cylinder head intake and exhaust manifolds sides 0 05 mm 0 002 in ENGINE MECHANICAL M13 ENGINE 6A1 57 Valve Springs e Referring to data given below check to be sure that each spring is in sound condition free of any evidence of break age or weakening Remember weakened valve springs can cause chatter not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure Valve spring free length Standard 36 83 mm 1 450 in Limit 35 83 mm 1 410 in Valve spring preload Standard 107 125 N 10 7 12 5 kg for 31 5 mm 23 6 27 6 Ib 1 240 in Limit 102 N 10 2 kg for 31 5 mm 22 9 Ib 1 240 in e Spring skewness Use a squar
187. small end bore or piston bore is badly worn or damaged replace pin connecting rod and or piston 6A1 66 ENGINE MECHANICAL M13 ENGINE Piston pin clearance Check piston pin clearance in small end and piston Replace connecting rod and or piston if its small end is badly worn or damaged or if measured clearance exceeds limit Piston pin clearance in connecting rod small end 0 003 0 014 mm 0 0001 0 0006 in Piston pin clearance in piston 0 006 0 017 mm 0 00024 0 00067 in Small end bore for connecting rod 20 003 20 011 mm 0 7875 0 7878 in Piston pin diameter 19 997 20 000 mm 0 7873 0 7874 in Piston bore 20 006 20 014 mm 0 7876 0 7880 in Piston Rings To measure end gap insert piston ring 1 into cylinder bore and then measure the gap by using thickness gauge 2 If measured gap is out of specification replace ring NOTE Decarbon and clean top of cylinder bore before inserting piston ring Piston ring end gap Item Standard Limit Top ring 0 20 0 35 a 0 7 mm 0 0079 0 0138 in 0 0276 in 2nd ring 0 30 0 45 mm 1 0mm 0 0118 0 0177 in 0 0039 in Oil ring 0 20 0 70 mm 1 5mm 0 0079 0 0276 in 0 059 in a 120 mm 4 72 in Connecting Rod e Big end side clearance Check big end of connecting rod for side clearance with rod fitted and connected
188. speed sensor Left front 5E 4 ANTILOCK BRAKE SYSTEM ABS ABS Component Parts Location A Y ay 9 2 a A Q a m 1 Wheel speed sensor Right front 6 ABS hydraulic unit control module assembly 11 Proportioning valve 2 Stop lamp switch 7 Monitor connector A For LH steering vehicle 3 ABS warning lamp 8 Wheel speed sensor Left front B For RH steering vehicle 4 Wheel speed sensor Right rear 9 Wheel speed sensor ring 5 Wheel speed sensor Left rear 10 G sensor ANTILOCK BRAKE SYSTEM ABS 5E 5 ABS Control Module 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 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 warn ing lamp lights and the area where that abnormality lies is stored in the memory in ABS control module 4 When Diag switch terminal of monitor connector is grounded the abnormal area is output as DTC
189. 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 with care to prevent accidental deployment When servicing be sure to observe all WARNINGS and CAUTIONS in this section and Service Precautions in Section 10B Steering wheel nut Steering lock assembly ignition switch Combination switch or contact coil and com 10 bination switch assembly 1 Driver air bag inflator module 6 Steering column upper cover 11 Steering lower shaft 2 Steering wheel 7 Steering column lower cover A For vehicle with air bag system 3 Steering wheel side cap 8 Steering column assembly B For vehicle without air bag system 4 9 5 0 Steering column hole cover STEERING WHEEL AND COLUMN 3C 3 Diagnosis For maintenance service of the steering wheel and column refer to Steering System Inspection in Section OB For diagnosis of the steering wheel and column refer to Diagnosis Table in Section 3 For diagnosis of the air bag system refer to Air Bag Diagnosis System Check Flow Table in Section 10B Inspection and Repair Required After Accident e For vehicle without air bag system After an accident be sure to perform checks inspections and repairs described under Checking Steering Column for Accident Damage i
190. then refill to specified level CAUTION Do not use shock absorber fluid or any other fluid which contains mineral oil Do not use a container which has been used for mineral oil or a container which is wet from water Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake system and water mixed into brake fluid will lower fluid boiling point Keep all fluid containers capped to prevent contamination Rear Drum Brake Shoe Adjustment Rear brake has self adjusting mechanism but it does require adjustment for proper drum to shoe clearance when brake shoe has been replaced or brake drum has been removed for some other service Adjustment is automatically accomplished by depressing brake pedal about 30 times with approximately 30 kg 66 Ibs load after all parts are installed Then check brake drum for dragging and brake system for proper performance After lowering vehicle from hoist brake test should be performed Parking Brake Inspection and Adjustment INSPECTION Hold center of parking brake lever grip and pull it up with 20 kg 44 Ibs force With parking brake lever pulled up as above count ratchet notches There should be 6 to 8 notches Also check if both right and left rear wheels are locked firmly To count number of notches easily listen to click sounds that ratchet makes while pulling parking brake lever without pressing its but ton One click sound corresponds t
191. this adjustment right and left tie rod should become equal in length A After adjustment tighten lock nuts to specified torque Tightening torque Tie rod end lock nuts a 65 N m 6 5 kg m 47 0 Ib ft 3A 4 FRONT WHEEL ALIGNMENT Camber And Caster Check And Adjustment Should camber or caster be found out of specifications upon inspection locate its cause first If it is in damaged loose bent dented or worn suspension parts and axle housing they should be replaced If it is in vehicle body repair it so as to attain specifi cations NOTE To prevent possible incorrect reading of camber or caster vehicle front end must be moved up and down a few times before inspection Steering Angle Check And Adjustment When tie rod 2 or tie rod end 3 was replaced check toe and then also steering angle with turning radius gauge 1 If steering angle is not correct check if right and left tie rods are equal in length A NOTE If tie rod lengths were changed to adjust steering angle reinspect toe in Steering angle Inside 35 3 Outside 32 3 Side Slip Reference For inspecting front wheel side slip with side slip tester If side slip exceeds limit toe or front wheel alignment may out not be correct Side slip limit Less than 3 mm m Less than 0 118 in 3 ft STEERING GEAR BOX MANUAL TYPE AND LINKAGE 3B 1 SECTION 3B STEERING GEAR BOX MANUAL TYPE AND
192. to its crank pin in the normal manner If measured clearance is found to exceed its limit replace con necting rod Side clearance for connecting rod big end Standard 0 25 0 40 mm 0 0098 0 0157 in Limit 0 55 mm 0 0217 in ENGINE MECHANICAL M13 ENGINE 6A1 67 e Connecting rod alignment Mount connecting rod on aligner to check it for bow and twist If limit is exceeded replace it Connecting rod alignment Limit on bow 0 05 mm 0 0020 in Limit on twist 0 10 mm 0 0039 in Connecting rod bolt diameter Plastic deformation tightening bolt Measure connecting rod 1 bolt 2 for diameter A on 32 mm 1 25 in from bolt mounting surface and diameter B on 40 mm 1 57 in from bolt mounting surface by using a micrometer 3 Calculate difference in diameters A B If it exceeds limit replace connecting rod Connecting rod bolt measurement points a 32 mm 1 25 in b 40 mm 1 57 in Connecting rod bolt diameter difference Limit A B 0 1 mm 0 004 in Crank Pin and Connecting Rod Bearings e Inspect crank pin for uneven wear or damage Measure crank pin for out of round or taper with a micrometer If crank pin is damaged or out of round or taper is out of limit replace crankshaft or regrind crank pin to undersize and use undersize bearing Crank pin diameter wonnernng ee Crank pin dia
193. torque 4 Valve stem seal 9 Cylinder head bolt Do not reuse 1 Tighten all bolts at 40 N m 4 0 kg m x 2 Turn all bolts to 60 3 Then turn all bolts to 60 once again 5 Valve spring seat 10 Cylinder head Apply engine oil to sliding surface of each part ENGINE MECHANICAL M13 ENGINE 6A1 49 REMOVAL 1 2 3 4 Relieve fuel pressure referring to Fuel Pressure Relief Pro cedure in Section 6 Disconnect negative cable at battery Drain engine oil Drain coolant by loosening drain plug 1 WARNING To help avoid danger of being burned do not remove drain plug 1 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 5 6 7 oe Remove air cleaner outlet No 1 and No 2 hoses and breather hose Remove intake manifold bracket 1 with main harness from intake manifold Disconnect the following electric lead wires EGR valve if equipped IAC valve 2 TP sensor 3 MAP sensor 4 CMP sensor ECT sensor EVAP canister purge valve 5 Injectors 6 Ignition coils Heated oxygen sensor Ground terminal 7 from intake manifold Each wire harness clamps Remove heated oxygen sensor bracket from cylinder head and detach heated oxygen sensor coupler from its bracket 6A1 50 ENGINE MECHANICAL M13 ENGINE
194. was detected by checking the freeze frame data Also ECM 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 A An Example of Freeze Frame Data B 1st 2nd or 3rd in parentheses here represents which position in the order the malfunction is detected Priority of freeze frame data ECM has 4 frames where the freeze frame data can be stored The first frame stores the freeze frame data of the malfunction which was detected first However the freeze frame data stored in this frame is updated according 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 mal function among misfire detected P0300 P0304 fuel system too lean P0171 and fuel system too rich P0172 Freeze frame data when a malfunction other than those in 1 above is detected 6 8 ENGINE GENERAL INFORMATION AND DIAGNOSIS In the 2nd through the 4th frames the freeze frame data of each malfunction is stored i
195. 0 in 1 Paint 6A1 86 ENGINE MECHANICAL M13 ENGINE 4 From number stamped on crank web No 2 and alphabets stamped on cylinder block determine new standard bearing to be installed to journal by referring to table shown below For example if number stamped on crank web No 2 is 1 and alphabet stamped on cylinder block is B install a new standard bearing painted in Purple to its journal Specification of standard crankshaft main bearing Number stamped on crank web No 2 Journal diameter 1 2 3 Alphabet A Pink Purple Brown stamped on B Purple Brown Green cylinder block Cap bore dia Brown Green Black lt New standard bearing to be installed 5 Using scale 1 on gauging plastic 2 check bearing clear ance with newly selected standard bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance When replacing crankshaft or cylinder block due to any rea son select new standard bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new cylinder block UNDERSIZE BEARING 0 25 mm e 0 25 mm undersize bearing is available in five kinds varying in thickness To distinguish them each bearing is painted in the following colors at the center of bearing Each color represents the following thickness Undersize of crank
196. 1 as specified torque Tightening torque Clutch plate bolt a 14 N m 1 4 kg m 10 5 Ib ft Special tool A 09991 06020 AIR CONDITIONING OPTIONAL 1B 45 Lip Type Seal REMOVAL 1 Remove magnet clutch referring to Magnet Clutch in this section 2 Remove front head mounting bolts 10 pcs 1 Front head 3 Remove front head 1 by pushing compressor shaft 2 NOTE Be careful not to remove cylinder 3 from compressor body assembly 4 4 Remove O ring 5 5 Remove lip type seal from front head 1 using bearing remover 2 INSTALLATION 1 Press fit lip type seal 1 into front head 2 using special tool Special tool A 09991 06050 CAUTION Do not reuse lip seal 1 once removed from compressor 1B 46 AIR CONDITIONING OPTIONAL A 2 Coat special tool surface with compressor oil and place it on compressor shaft 1 Special tool A 09991 06040 3 Install O ring 1 to compressor body assembly 2 4 Apply compressor oil to lip type seal and O ring 1 5 Install front head 3 to compressor body assembly 2 Special tool A 09991 06040 6 Tighten new front head bolts to specified toque Tightening torque Front heat bolts a 14 N m 1 4 kg m 10 5 Ib ft b 23 N m 2 3 kg m 17 0 Ib ft NOTE Tighten bolt a first and next b Tightening Torque
197. 1 B Ground for ECM 7 w Backup power source A Rater Immobilizer indicator lamp 2 B R Ground for drive circuit i oe if equipped er Duty output terminal vehicle without 3 B R Ground for drive circuit immobilizer indicator lamp 4 BIG Canister purge valve 9 Power steering pressure switch 5 BI Or if equipped 10 BI Main relay 6 G Y IAC valve 11 Br Tachometer T P B Heater of HO2S 1 if equipped 12 Y B Data link connector 5 V mi Heated oxygen sensor 2 8 W B No 4 fuel injector 13 w if equipped Diagnosis switch terminal 9 R W No 1 fuel injector 14 W BI vehicle without immobilizer indicator lamp Test switch terminal 10 B BI Ground for sensor circuit E18 15 P vehicle without immobilizer indicator lamp 11 WwW CMP sensor 16 G W A C SW signal if equipped 12 17 R Y Lighting switch R Heated oxygen sensor 1 13 if equipped 18 P B A C condenser fan relay if equipped R BI CO adjusting resistor w o HO2S 14 G B ECT sensor 19 W G Fuel pump relay E19 15 Lg B IAT sensor 20 B BI Ground for sensor 16 Lg TP sensor 21 B R ame opening signal output for A T EGR valve stepper motor coil 3 if Fuel level gauge vehicle with immo 7 Gr B equipped 2a WR bilizer indicator lamp EGR valve stepper motor coil 1 if x 2 18 Gr equipped 23 19 Br B Sie assembly for No 2 and 3 spark 24 BUY Heater blower switch 20 Br W A assembly for No 1 and 4 spark 21 R G No 2 fuel injector 1 22 Lg R Power supply for sensor 2 R R range signal A T 23 G R CKP
198. 1280 psi failure in steering gear Relief pressure 6 400 8 400 kPa 65 85 kg cm 925 1208 psi 1 P S fluid reservoir 4 Oil pressure gauge 2 P S pump 5 High pressure side 3 Steering gear box 3B1 12 POWER STEERING P S SYSTEM If equipped On Vehicle Service Power Steering Belt REMOVAL 1 Disconnect negative cable at battery 2 Loosen tension pulley bolts 2 3 Remove power steering belt 1 INSPECTION e Check power steering belt for wear and cracks and replace as required INSTLLATION 1 Install belt to power steering pump pulley 1 crankshaft pul ley 2 A C pulley if equipped 3 and tension pulley 4 2 Adjust belt tension referring to Power Steering Belt Check in this section Power Steering P S Pump REMOVAL 1 Take out fluid in P S fluid reservoir with syringe or such 2 Remove P S belt 3 Disconnect high pressure hose and low pressure hose 4 Disconnect pressure switch lead harness POWER STEERING P S SYSTEM If equipped 3B1 13 5 Remove P S pump 1 removing 3 mounting bolts 3 CAUTION e Clean couplers at intake and discharge ports com pletely before disconnection e Plug ports of removed pump to prevent dust and any foreign object from entering 2 P S pump bracket DISASSEMBLY 1 Clean its exterior thoroughly 2 With al
199. 2 tion cycles applicable ae Terminal voltage is lower than specification TA P0141 Pe e EE mal at heater OFF or it is higher at heater ON pis ane or heater circuit or short Short term fuel trim or total fuel trim short P0171 Fuel system too lean and long terms added is larger than spec 2 driving Not ification for specified time or longer cycles applicable fuel trim toward rich side is large Short term fuel trim or total fuel trim short P0172 Fuel system too rich and long term added is smaller than spec 2 driving Not ification for specified time or longer cycles applicable fuel trim toward lean side is large MIL flashing P0300 Random misfire detected Misfire of such level as to cause damage during mis Not P0301 Cylinder 1 misfire detected to three way catalyst fire detec applicable P0302 Cylinder 2 misfire detected tion P0303 Cylinder 3 misfire detected Misfire of such level as to deteriorate emis 2 driving Not P0304 Cylinder 4 misfire detected sion but not to cause damage to three way cycles applicable catalyst P0325 Knock sensor circuit mal Knock sensor circuit low input 1 driving 1 driving No 17 function Knock sensor circuit high input cycle cycle ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 17 DTC DETECTING ITEM DETECTING CONDITION MIL MIL NO DTC will set when detecting vehicle vehicle with immo without b
200. 2 3 17 0 Special Tool 09950 78220 Flare nut wrench 10 mm 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE A below Mass storage cartridge for Tech 1A 09931 76030 16 14 pin DLC cable for Tech 1A Tech 2 kit SUZUKI scan tool See NOTE B below NOTE e A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor e B This kit includes the following items and substitutes for the Tech 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 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 1 SECTION 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice P
201. 25 2 750 0 1083 275 2 275 0 0896 228 2 775 0 1093 278 2 300 0 0906 230 2 800 0 1102 280 2 325 0 0915 233 2 825 0 1112 283 2 350 0 0925 235 2 850 0 1122 285 2 375 0 0935 238 2 875 0 1132 288 2 400 0 0945 240 2 900 0 1142 290 2 425 0 0955 243 2 925 0 1152 293 2 450 0 0965 245 2 950 0 1161 295 2 475 0 0974 248 2 975 0 1171 298 2 500 0 0984 250 3 000 0 1181 300 2 525 0 0994 253 2 550 0 1004 255 2 575 0 1014 258 2 600 0 1024 260 2 625 0 1033 263 2 650 0 1043 265 7 Install new shim facing shim No side with tappet 6A1 12 ENGINE MECHANICAL M13 ENGINE 8 Lift valve by turning crankshaft counterclockwise in opposite direction against above Step 4 and remove special tool Special tool A 09916 67020 1 Tappet 2 Camshaft 9 Install camshaft housing 1 and tighten them to specified torque Tightening torque Camshaft housing bolts a 11 N m 1 1 kg m 8 0 Ib ft 10 Check valve clearance again 11 Install cylinder head cover referring to Cylinder Head Cover in this section ENGINE MECHANICAL M13 ENGINE 6A1 13 On Vehicle Service Air Cleaner Element REMOVAL 1 Open air cleaner case by unhooking its clamps 2 Remove air cleaner element from case INSPECTION Check air cleaner element for dirt Replace excessively dirty ele ment CLEANING Blow off dust by compressed air from a
202. 4 Back pressure check With engine running at idling speed and hands off from steering wheel check hydraulic pressure If back pressure exceeds 980 kPa 10 kg em 142 psi check control valve and pipes for obstruction Back pressure 980 kPa 10 kg cm2 142 psi 1 P S fluid reservoir 5 Low pressure side 2 P S pump 6 High pressure side 3 Steering gear box 7 Valve open 4 Oil pump pressure gauge POWER STEERING P S SYSTEM If equipped 3B1 11 5 Relief pressure check CAUTION e Be sure not to keep gauge valve closed for longer than 10 seconds e Never keep steering wheel turned fully for longer than 10 seconds a Increase engine speed to about 1 500 to 1 600 rpm Close valve 6 gradually while watching pressure increase indicated on gauge 4 and take reading of relief pressure maximum hydraulic pressure If higher than 8 400 kPa 85 kg cm 1208 psi malfunction of relief valve If lower than 6 400 kPa 65 kg cm 925 psi failure of P S pump or settling of relief valve spring Relief pressure 6 400 8 400 kPa 65 85 kg cm 925 1208 psi 1 P S fluid reservoir 3 Steering gear box 2 P S pump 5 High pressure side b Next open gauge valve 6 fully and increase engine speed to about 1 500 to 1 600 r min Then turn steering wheel to the left or right fully and take reading of relief pressure If lower than 6 400 kPa 65 kg cm
203. 5 No 11 Flow Table of Section 6 If malfunction is found replace 6E 30 ENGINE AND EMISSION CONTROL SYSTEM Throttle position sensor TP sensor INSPECTION 1 Disconnect negative cable at battery and connector from TP sensor 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 resistance TERMINALS RESISTANCE Between 1 and 4 0 6 0 kQ 3 terminals Between 2 and 20 0 Q 6 0 KQ varying according to 3 terminals throttle valve opening NOTE There should be more than 2 kQ resistance difference between when throttle valve is at idle position and when it is fully open 1 Reference voltage terminal 2 Output voltage terminal 3 Ground terminal 3 Connect TP sensor connector securely 4 Connect negative cable to battery REMOVAL 1 Remove throttle body from intake manifold referring to Throttle Body in this section for removal 2 Remove TP sensor from throttle body INSTALLATION 1 Install TP sensor 1 to throttle body Fit TP sensor to throttle body in such way that its holes 3 are a little away from TP sensor screw holes 2 and turn TP sensor clockwise so that those holes align Tightening torque TP sensor screws a 2 5 N m 0 25 kg m 1 8 lb ft 2 Connect connector to TP sensor securely 3 Connect battery negativ
204. 5 Ignition TIMING esse eeseessees testes neenteenteeaneeniee 6F 8 Ignition Spark Test ccccsscsesseecsseesseeseseesseeeee 6F 5 Special TOOlS ssssnnnnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnn 6F 10 High tension Cords c ccsccccscssesssetesesesceeees 6F 5 Tightening Torque Specification 6F 10 Spark PlUGS iaie a ee tteenss 6F 6 6F 2 IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM General Description The ignition system is an electronic distributorless ignition system It consists of the parts as described below and has an electronic ignition control system ECM It detects the engine and vehicle conditions through the signals from the sensors determines the most suit able ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor power unit in the ignition coil assembly Ignition coil assembly including an ignitor The ignition coil assembly has a built in ignitor which turns ON and OFF the current flow to the primary coil according to the signal from ECM When the current flow to the primary coil is turned OFF a high voltage is induced in the secondary coil High tension cords and spark plugs CMP sensor Camshaft position sensor and CKP sensor Crankshaft position sensor Using signals from these sensors ECM identifies the specific cylinder whose piston is in the compression stroke detects the crank angle and adjust initial ignition timing automatically TP senso
205. 5 N m 13 5 kg m 98 0 Ib ft e Install lower shaft by the following steps 1 Align flat part of steering gear box worm shaft 1 with bolt hole in lower joint as shown Then insert lower joint 2 onto worm shaft 2 Be sure that front wheels and steering wheel are in straight forward state and insert upper joint onto steering shaft 3 Torque lower shaft joint bolt to specification Tightening torque Steering shaft lower joint bolt a 25 N m 2 5 kg m 18 0 Ib ft e Fill engine coolant to radiator e Bleed air in P S circuit referring to Air Bleeding Procedure in this section POWER STEERING P S SYSTEM If equipped 3B1 21 Tightening Torque Specifications 7 Tightening torque Fastening part Nem kam bft Tension pulley bolt 25 2 5 18 0 Oil pump mounting bolt 25 2 5 18 5 Oil pump high pressure union bolt 60 6 0 43 5 Oil pump cover bolts 28 2 8 20 0 Pressure switch 28 2 8 20 0 Suction connector bolt 12 1 2 8 5 Power steering gear box mounting bolt 80 8 0 58 0 and nuts Gear box high pressure union bolt 35 3 5 25 5 Pitman arm mounting nut 135 13 5 98 0 Steering shaft joint bolt 25 2 5 18 5 Plug 60 6 0 43 5 Required Service Materials Recommended SUZUKI product Part Number nee Material Power steering fluid An equivalent of DEXRON II DEXRON IIE or DEXRON III e To fill P S fluid reservoir e Parts lubrication when installing
206. 61 in Limit 0 9 mm 0 035 in e Inspect valve stem end face for pitting and wear If pitting or wear is found there valve stem end may be resurfaced but not too much to grind off its chamber When it is worn out too much that its chamber is gone replace valve e Check each valve for radial runout with a dial gauge and V block To check runout rotate valve slowly If runout exceeds its limit replace valve Limit on valve head radial runout 0 08 mm 0 003 in e Seating contact width Create contact pattern on each valve in the usual manner i e by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head Valve lapper tool used in valve lapping must be used Pattern produced on seating face of valve must be a continu ous ring without any break and the width of pattern must be within specified range Standard seating width a revealed by contact pattern on valve face In and Ex 1 1 1 3 mm 0 0433 0 0512 in ENGINE MECHANICAL M13 ENGINE 6A1 55 e Valve seat repair A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping EXHAUST VALVE SEAT Use valve seat cutters 1 to make two cuts as illustrated in figure Two cutters must be used the first for making 15 angle and
207. 6A1 85 2 Next check bearing cap bore diameter without bearing On mating surface of cylinder block five alphabets are stamped as shown in figure Three kinds of alphabets A B and C represent the fol lowing cap bore diameters JP Stamped alphabets on cylinder block represent bearing cap Coma a e bore diameter marked with an arrow in figure respectively pi For example stamped A indicates that corresponding o RO 16 J 6 O bearing cap bore diameter is 49 000 49 006 mm 1 9291 wE EE E EEDU E 1 9294 in ee pae a ANA j Crankshaft bearing cap bore aa Stamped alphabet Bearing cap bore diameter without bearing 49 000 49 006 mm 1 9291 1 9294 in B 49 006 49 012 mm 1 9294 1 9296 in c 49 012 49 018 mm 1 9296 1 9298 in 3 There are five kinds of standard bearings differing in thick ness To distinguish them they are painted in the following colors at the center of bearings Each color indicates the following thickness Standard size of crankshaft main bearing Color painted Bearing thickness Pink 1 990 1 994 mm 0 0783 0 0785 in Purple 1 993 1 997 mm 0 0785 0 0786 in Broan 1 996 2 000 mm 0 0786 0 0787 in eae 1 999 2 003 mm 0 0787 0 0789 in Black 2 002 2 006 mm 0 0788 0 079
208. 7 14 15 6 1 Front housing 6 Over running clutch 11 Magnetic switch 16 Packing 21 Rear bracket 2 Bush 7 Lever 12 Ball 17 Yoke 22 Rear bush 3 Snap ring 8 Plunger 13 Internal gear 18 Armature 23 Brush spring 4 Pinion stop ring 9 Plate 14 Planetary carrier shaft 19 Brush E Apply grease 99000 25010 5 Pinion gear 10 Seal rubber 15 Planetary gear 20 Brush holder x lt Do not reuse CRANKING SYSTEM 6G 7 Specifications Voltage 12 volts Output 0 9 kW 1 2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length 12 3 mm 0 48 in 12 3 mm 0 48 in Number of pinion teeth 8 Performance Condition Guarantee A 90 A maximum 90 A maximum No load ch terist 11 0 V Ry SA es 9 2 800 rpm minimum 2 500 rpm minimum 8 0 V 4 8 Nm 0 48 kg m 3 5 lb ft minimum 200 A Pe cot 1 260 rpm minimum Load characteristic 75V 10 5 N m 1 05 kg m Mogae 300 A 7 6 lb ft minimum 20 C 68 F 880 rom minimum Locked rotor current 550 A maximum 3 5 V 12 2 N m 1 22 kg m 8 8 lb ft minimum 4 0 V 760 A maximum 19 5 N m 1 95 kg m 14 1 lb ft minimum Magnetic switch operating voltage 8 volts maximum 6G 8 CRANKING SYSTEM CHARGING SYSTEM 6H 1 SECTION 6H CHARGING SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the
209. 7P LI Ee H E17 17 The serial data line is pulled up to about 12 V by ECM and TCM transmits information to ECM through it by con trolling its grounding TCM constantly sends information while ignition switch is ON as to whether judgement was made or not with respect to all detectable DTCs as well as whether or not abnormality exists after judgement DTC DETECTING CONDITION POSSIBLE CAUSE No signal inputted from TCM to ECM or check sum e G R circuit open or short error while engine running e TCM power or ground circuit open TCM malfunction e ECM malfunction DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Start engine and run it at idle for 1 min 4 Select DTC mode on scan tool and check DTC INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check signal voltage Intermittent trouble or Go to Step 3 Check voltage between terminal E17 17 and faulty ECM or TCM body ground with ignition switch ON See Fig 1 Check for intermittent Does it change between 0 12 V trouble referring to Inter mittent and Poor Connec tion in Section OA 6 106 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Yes No 3 Is it about 12 V at Step 2 B R wire open poor Go to Step 4 E21 11 c
210. 8 Intake Air Temp IAT Circuit Malfunction seee 6 51 DTC P0115 DTC No 19 Engine Coolant Temperature ECT Circuit Malfunction 6 53 DTC P0120 DTC No 13 Throttle Position Circuit Malfunction oo cece ceeceeeeeeeeeeeeeees 6 55 DTC P0121 Throttle Position Circuit Range Performance Problem cccccceeeceeeeeeeeeeees 6 57 DTC P0130 DTC No 14 Heated Oxygen Sensor HO2S Circuit Malfunction SENSO 1 os cescieevevecececceddacacssubvenceecusiactenecedeses 6 59 DTC P0133 Heated Oxygen Sensor HO2S Circuit Slow Response Sensor 1 6 61 DTC P0135 DTC No 14 Heated Oxygen Sensor HO2S Heater Circuit Malfunction S NSOP 1 ceceeeceeeeeeeceeeeeeeeeeceeeeeeeeeseneeeeeetees 6 62 DTC P0136 Heated Oxygen Sensor HO2S Circuit Malfunction Sensor 2 ee 6 64 DTC P0141 Heated Oxygen Sensor HO2S Heater Circuit Malfunction Sensor 2 6 66 DTC P0171 Fuel System Too Lean 6 68 DTC P0172 Fuel System Too Rich 6 68 DTC P0300 Random Misfire Detected Misfire Detected at 2 or More Cylinders 6 72 DTC P0301 Cylinder 1 Misfire Detected 6 72 DTC P0302 Cylinder 2 Misfire Detected 6 72 DTC P0303 Cylinder 3 Misfire Detected 6 72 DTC P0304 Cylinder 4 Misfire Detected 6 72 DTC P0325 DTC No 17 Knock Sensor Circuit Malfunction ccceeceeeeeeeseeseesseeaseeeeeeeeeeeeees 6 77 DTC P0335 DTC No 23 Crankshaft Position
211. 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower Engine coolant temp 70 110 C 158 230 F 2 Start engine and drive vehicle at 35 45 mph 55 65 km h for 8 min or longer While this driving if Catalyst Monitoring TEST COMPLETED is displayed in READINESS TESTS mode and DTC is not displayed in DTC mode confirmation test is completed lf TEST NOT COMPLTD is still being displayed continue test driving 3 Decrease vehicle speed at 30 40 mph 50 60 km h and hold throttle valve at that opening position for 2 min and confirm that short term fuel trim vary within 20 20 range 4 Stop vehicle do not turn ignition switch OFF and confirm test results according to following Test Result Confirmation Flow Table 35 45 mph 55 65 km h 30 40 mph 50 60 km h 6 90 ENGINE GENERAL INFORMATION AND DIAGNOSIS Test Result Confirmation Flow Table Step Action Yes No 1 Check DTC in DTC mode and pending DTC in Proceed to applicable Go to Step 2 ON BOARD TEST or PENDING DTC mode DTC Diag Flow Table Is DTC or pending DTC displayed 2 Set scan tool to READINESS TESTS mode No DTC is detected con Repeat DTC confirmation and check if testing has been completed firmation test is com procedure Is tes
212. AND LUBRICATION Brake Drums and Shoes INSPECTION 1 Remove wheel and brake drum 2 Check rear brake drums and brake linings for excessive wear and damage while wheels and drums are removed At the same time check wheel cylinders for leaks Replace these parts as necessary For details refer to Brake Drum in Section 5 Brake Hoses and Pipes INSPECTION Check brake hoses and pipes for proper hookup leaks cracks chafing and other damage Replace any of these parts as necessary CAUTION After replacing any brake pipe or hose be sure to carry out air purge operation Brake Fluid CHANGE CAUTION Since brake system of this vehicle is factory filled with glycol base brake fluid do not use or mix different type of fluid when refilling system otherwise serious damage will occur Do not use old or used brake fluid or one taken from unsealed container Change brake fluid as follows Drain existing fluid from brake system completely fill system with above recommended fluid and carry out air purge operation For air purging procedure refer to Air Bleeding of Brake System in Section 5 MAINTENANCE AND LUBRICATION 0B 13 Parking Brake Lever and Cable INSPECTION 1 Inspect brake cable for damage and smooth movement Replace cable if it is in deteriorated condition ED JanS i ee 2 Check tooth tip of each notch for damage or wear
213. AP canister and warm up engine to normal operating temperature Turn ignition switch OFF Restart engine and run it at 2000 r min for 2 min or more Disconnect purge hose from EVAP canister Also check that vacuum is felt when engine is running at 3000 r min 4 5 6 7 YS re rr wa NOTE ECM detects a change in the purge fuel vapor concentra tion and sometimes stops purging for several seconds but this is nothing abnormal 8 If vacuum is not felt in Step 7 run engine at idle for 8 min or more and then repeat check in Step 7 If check result is not satisfactory in Steps 2 and 8 check vac uum passage hoses EVAP canister purge valve wire harness and ECM VACUUM PASSAGE INSPECTION Start engine and run it at idle speed Disconnect vacuum hose 1 from EVAP canister purge valve 2 With finger placed against hose disconnected check that vacuum is applied If it is not applied clean vacuum passage by blowing compressed air VACUUM HOSE INSPECTION Check hoses for connection leakage clog and deterioration Replace as necessary EVAP CANISTER PURGE VALVE INSPECTION Check EVAP canister purge valve referring to step 2 of DTC P0443 Flow Table in Section 6 If found malfunction replace ENGINE AND EMISSION CONTROL SYSTEM 6E 41 EVAP CANISTER INSPECTION WARNING DO NOT SUCK nozzles on EVAP canister Fuel vapor inside EVAP canister is harmful 1 Check outside of EVAP canister visu
214. Adjustment 1 Loosen tension pulley bolts 3 and set hexagon wrench to hexagon hole 5 2 Turn tension pulley counterclockwise by hexagon wrench in order to obtain above specification 3 Tighten tension pulley bolts to specified torque Tightening torque Tension pulley bolts a 25 N m 2 5 kg m 18 0 Ib ft 1 P S pump pulley 4 A C compressor pulley if equipped 2 Crank pulley Power Steering Fluid Level Check CAUTION e Make sure to use an equivalent of DEXRON II DEXRON IIE or DEXRON III for P S fluid e Fluid level should be checked when fluid is cool before starting engine With engine stopped check fluid level indicated on P S fluid reser voir 1 or level gauge 3 which should be between MAX and MIN marks If it is lower than lower limit MIN replenish fluid up to upper limit MAX mark 2 Cap POWER STEERING P S SYSTEM If equipped 3B1 7 Idle Up System Check 1 Warm up engine to normal operating temperature 2 Turn A C switch OFF if equipped 3 Turn steering wheel fully and check idle speed Engine idle speed drops a little momentarily when steering wheel is turned fully but returns to its specified level immediately If power steering pressure switch connector is connected check the same with that con nector disconnected Momentary drop of engine idle speed should be less when it is connected than when disconnected Power Steering Fluid Lea
215. Air Bag System in Section 10B If necessary remove steering wheel and combination switch assembly referring to Steering Wheel and Combination switch Contact Coil and Combination Switch Assembly in this section If not removing steering wheel and or combination switch assembly perform the following procedure a Turn steering wheel so that vehicle s front tires are at straight ahead position b Turn ignition switch to LOCK position and remove key oo 4 Remove steering column hole cover 1 5 Disconnect all connectors of the following parts Combination switch contact coil and combination switch assembly Ignition switch Immobilizer control system parts if equipped 6 Remove joint bolt steering column side 3 and loosen joint bolt steering gear box side 7 Remove steering column mounting nuts 2 and bolts 1 STEERING WHEEL AND COLUMN 3C 13 8 If equipped with shift key interlock cable 1 remove shift key interlock cable screw 2 and then disconnect its cable from ignition switch in order a c as shown in the figure 9 Remove steering column from vehicle 10 Remove steering column seal 1 from steering column lower bracket CAUTION Don t separate double tube type steering column assem bly into steering column and shaft If column or shaft is defective replace as and assembly
216. BLY 1 Before disassembly clean all around caliper with brake fluid 2 Remove piston set ring 1 and boot from caliper pry off with a flat bladed tool Be careful not to damage boot 3 Blow compressed air into cylinder through bolt hole where flexible hose was fitted With this air pressure piston can be pushed out of cylinder WARNING Do not apply too highly compressed air which will cause piston to jump out of cylinder Place a cloth 1 to prevent piston from damage It should be taken out gradually with moderately compressed air Do not place your fin gers in front of piston when using compressed air 4 Remove piston seal using a thin blade like a thickness gauge etc NOTE Be careful not to damage inside bore side of cylinder 5 Remove bleeder plug and cap from caliper BRAKES 5 23 INSPECTION Cylinder Slide Bush Check slide bush for smooth movement as shown If it is found faulty correct or replace Apply rubber grease to bush outer surface Rubber grease should be the one whose viscosity is less affected by such low temperature as 40 C 40 F 1 Apply rubber grease Bush Dust Boot and Cylinder Boot Check boots for breakage crack and damage If defective replace Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth return of the piston In such a case replace rubber seal 5
217. COLUMN AND SHAFT 00 02 cee eee eee eee Section 3C 1 FRONT SUSPENSION 0 00 e eee eee eee Section 3D 1 REAR SUSPENSION se sscee 0ie cfccnt cape ie o oSaca fle ein ein la ethno on eel bce wai ielde th ate wale lef le ettiateseiecalece Section 3E 1 WHEELS AND TIRES errre cle ietee ain eis eo eee EEES EE RERA T TES Section 3F 1 CONTENTS General DiaQnOSis cccsesesseeceeeeeeesneeteneees 3 2 Wear Indicators e eenen 3 5 Diagnosis Table s ssnsssssisiisesisirrirriereereene 3 2 Radial Tire Waddle snnnssnsn1ssiitrrtrtestnnennne 3 5 Tire Diagnosis ccccssssscssseseseseseessseesseeseers 3 5 Radial Tire Lad seein 3 7 Irregular and or Premature Wear sssseesse 3 5 Vibration Diagnosis ccccceeceeeeeeeeeeeeees 3 7 3 2 STEERING SUSPENSION WHEELS AND TIRES General Diagnosis Since the problems in steering suspension wheels and tires involve several systems they must all be consid ered when diagnosing a complaint To avoid using the wrong symptom always road test the vehicle first Proceed with the following preliminary inspections and correct any defects which are found 1 Inspect tires for proper pressure and uneven wear 2 Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged parts 3 Spin front wheel Inspect for out of round tires out of balance tires bent rims loose and or rough wheel bearings Dia
218. Check AIR LOCKING HUB 1 Start engine and shift transfer shift control lever to 2H posi tion 2 Connect vacuum pump gauge special tool to the spindle hose 2 which is disconnected from upper side pipe as shown Apply vacuum and check operating sound from air locking hub 1 If there is not operating sound replace air locking hub assembly Vacuum specification More than 40 kPa 0 40 kg cm 5 70 Psi Special tool A 09917 47910 3 Connect hose then start engine and shift transfer shift con trol lever to 4H or 4L position 4 Connect vacuum pump gauge to the spindle hose 2 dis connected from lower side pipe Apply vacuum and check operating sound from air locking hub 1 If there is no operating sound replace air locking hub assembly Vacuum specification More than 40 kPa 0 40 kg cm 5 70 Psi Special tool A 09917 47910 VSV1 AND VSV2 1 Disconnect coupler from VSV1 1 VSV2 2 and check resistance between two terminals of VSV1 1 VSV2 2 If resistance is out of specification replace Resistance of VSV1 and VSV2 33 399 3D 12 FRONT SUSPENSION 2 Blow air from B and check that air comes out of C If found faulty replace 3 Connect 12 V battery to VSV1 VSV2 terminals and check continuity between A and B Blow air from B and check that air comes out of A If found faulty replace
219. Check shoe 1 for wear or damage ENGINE MECHANICAL M13 ENGINE 6A1 39 INSTALLATION CAUTION After timing chain is removed never turn crankshaft and camshafts independently more than such an extent a b as shown in figure If turned interference may occur between piston and valves and valves themselves and parts related to piston and valves may be damaged 1 Check that match marks 1 on intake and exhaust camshaft timing sprockets are in match with notches 2 on cylinder head as shown in figure 2 Set key 3 and turn crankshaft to position key on upside of crankshaft a 90 5 Crankshaft allowable turning range By key on crankshaft within 90 from top on both right and left ps 15 4 Camshaft IN and EX allowable turning range By marks on camshaft timing sprocket within 15 from notches on cylinder head on both right and left 3 Install timing chain by aligning dark blue plate 1 of timing chain and mark 2 on camshaft timing sprocket and then aligning dark blue plate 3 and triangle mark 4 as shown in figure 4 Fit crankshaft timing sprocket to timing chain by aligning gold plate 5 of timing chain and mark 6 on crankshaft timing sprocket Then install crankshaft timing sprocket fitted with chain to crankshaft 5 Apply engine oil to sliding surface of timing chain No 1 guide 1 and install it as shown in figure Tighten
220. Condenser cooling fan motor 12 ECT sensor 17 ECM 3 Blower fan motor switch and A C switch 8 Compressor 13 Lighting switch AIR CONDITIONING OPTIONAL 1B 17 A C System Inspection of ECM and ITS Cir cuits ECM and its circuits can be checked at ECM wiring couplers by measuring voltage CAUTION ECM cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from ECM Voltage Check 1 Remove ECM from vehicle by referring to Engine Control Module in Section 6E 2 Connect ECM couplers 1 to ECM 2 3 Check voltage at each terminal of couplers connected NOTE Because each terminal voltage is affected by the battery voltage confirm that the battery voltage is 11 V or more when ignition switch is ON A Fig A B Fig B 3 E19 3 1B 18 AIR CONDITIONING OPTIONAL A B D ASS 2 N i i 3 2 eee ete e a 12 O p 1 M 6 p Q a O O 1 Blower fan motor 8 Compressor A To A C fuse 25A in main fuse box 2 Dual pressure switch 9 Thermal switch B To HEATER fuse 20A in circuit fuse box 3 A C switch 10 Main relay C To FI fuse 15A in main fuse box 4 A C evaporator thermistor 11 Engine earth D 4WD model 5 ECT sensor 12 Blower fan motor switch E 2WD model 6 Condenser cooling fan motor relay 13 4W
221. D controller 7 Condenser cooling fan motor 14 ECM Terminal arrangement of ECM coupler Viewed from harness side E19 E18 E17 LIe Is Ias BEELEN Fels lahs pe u poe 8 eelere AIR CONDITIONING OPTIONAL 1B 19 ECM VOLTAGE VALUES TABLE FOR RELATION OF A C CONTROL M t Terminal Wire Circuit SEa Normal value Condition ground Blower fan motor switch and A C Compressor 10 14 volt i Ground to switch ON with engine running E18 1 P magnet clutch z engine Fig B Except the above mentioned condi output 0 1 volts tion with engine running Main power sup Ground to Ignition switch ON with engine E18 BI B 29 ply for ECM engine Fig B ne WOE stopped Main power sup Ground to Ignition switch ON with engine E18 BI B ae ply for ECM engine Fig B ONS stopped Ground to 0 5 1 2 volt Ignition switch ON with engine E18 10 BI Main relay drive engine Fig B stopped g g 0 volts Ignition switch OFF Blower fan motor switch or A C switch 12 15 volts OFF with engine running Grounato Avon Blower fan motor switch and A C E18 16 G W A C switch input engine Fig B switch ON with engine running g g Within several seconds after operate 12 15 volts transfer lever between 2WD and 4WD with above condition Blower fan motor switch and A C Campinssct Oro switch ON or engine coolant tempera P Ground to ture at more than 110 C 230
222. DTE Oooo rallodie 5E 27 Pa E to lie NE 5E 14 OTET OCR TC Abo Conn Table B ABS Warning Lamp Circuit Module RENE paren an ge cae 5E 28 Check Lamp Comes ON Steady 5E 15 On Vehicle Service cccccssssssesessesseeeeees 5E 29 Table C ABS Warning Lamp Circuit Precaution ia 5E 29 Check Lamp Flashes Continuously ABS Hydraulic Unit Operation Check 5E 29 While Ignition Switch is ON c cccccseeeee 5E 16 ABS Hydraulic Unit Control Module Table D Code DTC is Not Outputted Assembly LaRPu De eewwecn cedar bere vkan ednaaeeneesceneeeeeeey 5E 30 Even With Diag Switch Terminal Front Wheel Speed Sensor 5E 32 Connected to Ground cccececeseeceeeeeeees 5E 17 Front Wheel Sensor Ring sseeeeeeees 5E 35 DTC C1015 DTC 15 G Sensor Rear Wheel Speed Sensor eee 5E 36 erat ae oe Aa A 5E 18 Rear Wheel Sensor Ring csss 5E 38 DTC C1016 DTC 16 Stop Lamp GSONSOM ssvevegeecccecaceneadectateasyedtsescaahdenlacaas 5E 39 ilro l EEE alone eB elders doe 5E 20 Tightening Torque Specification 5E 40 DTC C1021 DTC 21 DTC C1022 Special Tool iyisine 5E 40 DTC 22 Right Front Wheel Speed Sensor CirCuit cccccsessessseesseeeeeeeeeeeees 5E 21 DTC C1025 DTC 25 DTC C1026 DTC 26 Left Front Wheel Speed Sensor Circuiti ateiciai inene 5E 21 5E 2 ANTILOCK BRAKE SYSTEM ABS General Description The ABS Antilock Brake
223. Diag Flow Table 2 Check ECT Sensor and Its Circuit Go to Step 3 Intermittent trouble 1 Connect scan tool with ignition switch OFF Check for intermittent See Fig 1 referring to Intermittent 2 Turn ignition switch ON and Poor Connection in 3 Check engine coolant temp displayed on Section OA scan tool Is 40 C 40 F or 119 C 246 F indicated 3 Check Wire Harness Replace ECT sensor G B wire shorted to 1 Disconnect ECT sensor connector ground 2 Check engine coolant temp displayed on If wire is OK substitute a scan tool known good ECM and Is 40 C 40 F indicated recheck 4 Does scan tool indicate 40 C 40 F at Step Go to Step 6 Go to Step 5 2 5 Check Wire Harness Go to Step 4 G B wire open or 1 Disconnect ECT sensor connector with igni shorted to power or poor tion switch OFF E19 14 connection 2 Check for proper connection to ECT sensor If wire and connection are at B BI and G B wire terminals OK substitute a known See Fig 2 good ECM and recheck 3 If OK then with ignition switch ON Is voltage applied to B B wire terminal about 4 6V 6 Check Wire Harness Replace ECT sensor B BI wire open or poor 1 Using service wire connect ECT sensor E19 10 connection connector terminals See Fig 3 If wire and connection are 2 Turn ignition switch ON and check engine OK substitute a known coolant temp displayed on scan tool
224. Disconnect TCM connectors sor connector connec If wire and connection are 3 Check for proper connection to TCM at ter tion select cable OK substitute a known minal E21 5 maladjusted transmis good ECM and recheck 4 If OK then check voltage at terminal E21 8 sion range sensor malad in TCM connector disconnected with igni justed or transmission tion switch ON See Fig 3 range sensor malfunction Is it10 14 V If all above are OK sub stitute a known good TCM and recheck A Fig 1 for Step 3 B Fig 2 for Step 4 C Fig 3 for Step 6 B C E17 6 21 26P E22 16P JL Ei P E18 24P E17 117P i q H o AE E peulo a Teselli fs Tes CEL CT CI TNI L 4 26425 Ft 23 22 ah 20419 18 hte 15 14 pens 14 13 12 11 i 9 Er Ti y Tir ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 109 D Table 1 for Step 3 and 4 Scan tool voltmeter SUZUKI SCAN TOOL VOLTAGE AT E17 6 DISPLAY Selector lever P and N range P N range 10 14V position R D 2 and L range D range 0 1V Table B 1 Fuel Injector Circuit Check ECM R W R G BI B W G W B B R B R E199 198 E19 31P TL I E17 24P l LJ E18 17P
225. E AIR TEMP C F It is detected by intake air temp sensor and used to determine the amount of air passing into the intake manifold as air density varies with temperature MAF MASS AIR FLOW RATE gm s Ib min It represents total mass of air entering intake manifold which is computed based on signals from MAP sensor IAT sensor TP sensor etc ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 31 THROTTLE POS ABSOLUTE THROTTLE POSITION When throttle position sensor is fully closed position throttle opening is indicated as 0 and 100 full open position OXYGEN SENSOR B1 S1 HEATED OXYGEN SENSOR 1 V It indicates output voltage of HO2S 1 installed on exhaust manifold pre catalyst OXYGEN SENSOR B1 S2 HEATED OXYGEN SENSOR 2 V It indicates output voltage of HO2S 2 installed on exhaust pipe post catalyst It is used to detect catalyst dete rioration DESIRED IDLE DESIRED IDLE SPEED rpm The Desired Idle Speed is an ECM internal parameter which indicates the ECM requested idle If the engine is not running this number is not valid TP SENSOR VOLT THROTTLE POSITION SENSOR OUTPUT VOLTAGE V The Throttle Position Sensor reading provides throttle valve opening information in the form of voltage INJ PULSE WIDTH FUEL INJECTION PULSE WIDTH msec This parameter indicates time of the injector drive valve opening pulse which is output from ECM but injector drive time of NO 1 cylinder for multiport fuel injection IAC
226. E MECHANICAL M13 ENGINE 09924 17810 09926 58010 09944 36011 Flywheel holder Bearing puller attachment Steering wheel remover ENGINE COOLING 6B 1 SECTION 6B ENGINE COOLING CONTENTS General Description cccccssseecceeeeseeseeeees 6B 2 Cooling System Flush and Refill 6B 8 Cooling System Circulation ccccceeeeee 6B 2 Water Pump Belt Tension ee 6B 9 Radiator Cap ccccccsccccccccceccsceeseeeeeeseeseeeess 6B 3 On Vehicle Service ccccccceeceessseessesenes 6B 10 Coolant Reservoir cceceeeeeeeeeteeteeeeeeteee 6B 3 Cooling System Component c00000 6B 10 Water PUMP iiisicctcrettsseestreteceesesicescretesinetiecens 6B 4 Coolant Draining soactsecccscitetencceecetsvuseetiness 6B 11 Thermostat moreeni niies aeiia 6B 4 Cooling Water Pipes or Hoses 06 6B 11 Cooling Fan CltCh os sites aee nna 6B 4 Thermostat 6B 11 Coolant Water Temperature Gauge 6B 4 Water Pump Belt and Cooling Fan 6B 13 DIAGNOSIS i 222 cccsccscteetecsecccsstenececeecieesticceccd cesses 6B 5 Radiator mie a seat Maintenance ccscessesesesessssssseerseseeseseesseneeees 6B 6 Water PUMP a tictetecicnereie tv teats Coolant cies suet eke a Ae ee 6B 6 Required Service Material ssssesee Coolant Level cccccecceseeeeeeeseeeeneeeeeetee 6B 7 Tightening Torque Specification 6B 2 ENGINE COOLING Gene
227. F with E18 18 P B cooling fan relay f f aunit engine Fig B engine running P Except the above mentioned condi 12 15 volts tion with engine running Sensor ground Ground E18 20 B BI o A C evapora body Fig A 0 5 0 volt Engine running Blower fan motor switch 2nd or 3rd 0 1 volt i with engine running E18 24 BI Y Blower fan Ground to Pee Blower fan motor switch 1st with speed input engine Fig B engine running 42 15 volts Blower fan motor switch and A C switch OFF with engine running Main ground for Ground to l E19 1 B 0 5 1 volt 9 ECM engine Fig A 0 5 vo Engine running E19 2 B R eee eroune for ragna ie 0 5 1 volt Engine running power circuit engine Fig A E19 3 B R EGM goung ior rouna i 0 5 1 volt Engine running power circuit engine Fig A Sensor ground Ground to E19 10 B BI 0 5 1 volt Engine running for ECT sensor body Fig A 1B 20 AIR CONDITIONING OPTIONAL Terminal Wire Circuit Measurement ground Normal value Condition E19 14 G B ECT sensor input Ground to engine Fig B 0 73 0 83 volts 315 355 Q Engine coolant temperature at approximately 80 C 176 F with engine running 0 35 0 45 volts 145 165 Q Engine coolant temperature at approximately 110 C 230 F with engine running If the temperature is more than 113 C 235 F compressor should
228. Front B Rear 3D 38 FRONT SUSPENSION Front Axle Housing REMOVAL 1 Hoist vehicle 2 Remove front wheels 3 Drain front differential gear oil for 4WD 4 Remove caliper carrier bolts R amp L and suspend caliper CAUTION During removal be careful not to damage brake flexible hose and not to depress brake pedal 5 Remove right and left brake disc NOTE If brake disc can not be removed by hand use 8mm bolts 1 6 Remove wheel speed sensor if equipped with ABS 7 Disconnect spindle vacuum hoses from wheel spindle for 4WD CAUTION Give match mark to spindle vacuum hose and wheel spindle before removal 1 Vacuum hose to lock 2 Vacuum hose to unlock 8 Remove tie rod and drag rod end nuts and disconnect tie rod and drag rod ends 2 from knuckle arm 1 R amp L with special tool Special tool A 09913 65210 FRONT SUSPENSION 3D 39 9 Remove knuckle seal cover bolts take off knuckle seal cover 1 knuckle seal and knuckle seal retainer 10 Remove upper and lower kingpins 2 from steering knuckle NOTE The removed upper and lower kingpins 2 must be kept separated so as to prevent an error when putting them back in their place in reassembly 11 Remove knuckle with hub assembly from axle housing for 2WD model or draw out right
229. GINE GENERAL INFORMATION AND DIAGNOSIS DTC P0500 DTC No 16 Vehicle Speed Sensor VSS Malfunction CIRCUIT DESCRIPTION c LL A T B b rs 31P l J i 24P E17 017P LI LITI Lo E18 22 et 1 VSS 3 VSS connector B Case of TYPE B is shown See NOTE 2 Combination meter A Case of TYPE A is shown See NOTE NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model DTC DETECTING CONDITION POSSIBLE CAUSE e VSS signal not inputted while vehicle running in D e B Or circuit open range or during fuel cut at deceleration e Y or BI B circuit open or short 2 driving cycle detection logic continuous monitoring VSS malfunction e ECM malfunction e Speedometer malfunction DTC CONFIRMATION PROCEDURE WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester 1 Clear DTC and warm up engine to normal operating temperature 2 Increase vehicle speed to 50 mph 80 km h in 3rd
230. 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 or Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before
231. INLET TEMPERATURE Condition Possible Cause Correction Crossing point is higher than accept able range E 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 door in Repair or replace cooling heater unit Compressor malfunction Check compressor Crossing point is lower than acceptable range F area Insufficient air volume from center duct Heater blower malfunction Check blower motor and fan Compressor malfunction Check compressor Detail diagnosis table Ambient temperature at 30 C 86 F Condition MPa MAMEOLD kg cm Possible Cause Correction GAUGE rat Detail Lo Hi 0 23 0 35 1 4 1 75 2 3 3 5 14 17 5 Normal condition 33 50 200 249 The low pressure side Dust particles or water Clean expansion valve reads a negative pres droplets are either stuck Replace it if it cannot be sure and the high pres or frozen inside expan _ cleaned 0 5 0 6 sure side reads an sion valve preventing the Replace receiver dryer Negative r sir 5 6 extremely low pressure refrigerant from flowing Evacuate the A C sys P 71 2 85 3 Presence of frost tem and recharge with around tubin
232. If any damage or wear is found replace parking lever 3 Check parking brake lever for proper operation and stroke f and adjust it if necessary For checking and adjusting procedures refer to Parking Brake Inspection and Adjustment in Section 5 Parking brake lever stroke a 6 8 notches with 200 N 20 kg 44 Ibs of pull pres sure Tires Wheels TIRE INSPECTION AND ROTATION 1 Check tires for uneven or excessive wear or damage If defective replace Refer to Irregular and or Premature Wear and Wear Indi cators in Section 3 for details 1 Wear indicator 2 Check inflating pressure of each tire and adjust pressure to specification as necessary Refer to Inflation of Tires in Section 3F for details NOTE e Tire inflation pressure should be checked when tires are cool e Specified tire inflation pressure should be found on tire placard or in owner s manual which came with the vehicle 0B 14 MAINTENANCE AND LUBRICATION 3 Rotate tires For details refer to Tire Rotation in Section 3F WHEEL DISCS INSPECTION Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced WHEEL BEARING INSPECTION 1 Check front wheel bearing for wear damage abnormal noise or rattles For details refer to Wheel Disc Nut and Bearing Check in Section 3D 2 Check rea
233. LE for applicable model TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 1 A C compressor clutch OV Ignition switch ON eee 10 14V_ Engine running e a AA 0 1 0V_ Ignition switch ON leaving engine OFF 3 Data link connector 10 14V_ Ignition switch ON 4 Heater of HO2S 2 if equipped 10 14V__ Ignition switch ON 5 Power source 10 14V_ Ignition switch ON 6 Power source 10 14V_ Ignition switch ON 7 Power source for buck up 10 14V__ Ignition switch ON and OFF E18 Immobilizer indicator lamp 10 14V Engine running 8 with immobilizer indicator lamp 0 1 0 V Ignition switch ON leaving engine OFF ne oe termina winot 0 1 0 V Ignition switch ON immobilizer indicator lamp 9 10 14V_ Ignition switch OFF a ARAN 0 4 1 5V Ignition switch ON 11 Tachometer 12 Data link connector 4 5V Ignition switch ON 13 Heated oxygen sensor 2 Refer to DTC P0130 diag flow table ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 37 TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE Gs Peg Sune terminat without 4 5V ignition switch ON immobilizer indicator lamp 15 Test switch terminal without immo 4 5V ignition switch ON bilizer indicator lamp 10 14V Ignition switch ON A C switch OFF 16 A C input signal 0 2V Ignition switch ON A C switch ON sacl 10 14V Lighting switch ON ie e
234. LOCK 1322 99000 25030 99000 32110 Apply SUZUKI SUPER GREASE E Apply THREAD LOCK 1333B 99000 25050 my1333B 99000 32020 Apply SUZUKI SUPER GREASE H Apply THREAD LOCK 1342 99000 25120 m1342 99000 32050 Apply SUZUKI SUPER GREASE 99000 25210 215 JAJAA Peo s Apply SUZUKI BOND NO 1215 99000 31110 99000 31150 BS amp Do not reuse Apply SUZUKI BOND NO 1207C Note on reassembly WIRE COLOR SYMBOLS Symbol Wire Color Symbol Wire Color B BLK Black O Or ORN Orange BI BLU Blue R RED Red Br BRN Brown W WHT White G GRN Green Y YEL Yellow Gr GRY Gray P PNK Pink Lbl LT BLU Light blue V PPL Violet Lg LT GRN Light green GRN Base Color GRN Base Color YEL Stripe Color gt ORN YEL 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 GRN in the figure and the second symbol represents the color of the stripe YEL in the figure 0A 24 GENERAL INFORMATION Fasteners Information Metric Fasteners Most of the fasteners used for this vehicle are metric fasteners When replacing any fasteners it is most impor tant that replacement fast
235. LT TENSION INSPECTION 1 Check belt tension It should be within specification Refer to Water Pump Belt Tension in this section 2 If tension is out of specification adjust it For its adjustment refer to Water Pump Belt Tension in this section After adjustment be sure to tighten bolts COOLING FAN CLUTCH INSPECTION Inspect fluid coupling for oil leakage If necessary replace fan clutch assembly Do not disassemble clutch assembly 6B 14 ENGINE COOLING Radiator REMOVAL 1 Drain cooling system Remove radiator shroud Disconnect water hoses from radiator With automatic transmission A T vehicle disconnect addi tional two fluid hoses from radiator Place some container under radiator to receive A T fluid which will flow out when hose is disconnected Install radiator protection board to between radiator and cooling fan RW ND o1 lt 6 Remove radiator after removing two bolts 1 INSPECTION If the water side of the radiator is found excessively rusted or cov ered with scales clean it by flushing with the radiator cleaner compound This flushing should be carried out at regular intervals for scale or rust formation advances with time even where a recommended type of coolant is used Periodical flushing will prove more eco nomical Inspect the radiator cores and straight
236. M If equipped 3B1 5 Steering Wheel Play Check With engine ON check steering wheel play as follows Move steering wheel to the right and left from its straight position and measure along its circumference how much it must be turned before tires start to move It should be as specified below Steering wheel play a 30 mm 1 18 in or less e Also check steering wheel for looseness or rattle by trying to move it in its column direction and forward direction Steering Force Check 1 Place vehicle on level concreted road and set steering wheel at straight position 2 Check that tire inflation pressure is as specified Refer to tire placard 3 Start engine and keep it running till power steering fluid is warmed to 50 to 60 C 122 140 F 4 With engine running at idling speed measure steering force by pulling spring balancer hooked on steering wheel in tan gential direction Steering force Less than 6 0 kg 13 2 Ib 3B1 6 POWER STEERING P S SYSTEM If equipped Power Steering Belt Check INSPECTION e Check that belt is free from any damage and properly fitted in pulley groove e Check belt tension by measuring how much it deflects when pushed at mid point between pulley with about 10 kg 22 Ib force Deflection of oil pump belt a 6 9 mm 0 25 0 35 in Power Steering Belt Tension
237. Main Relay Operating Sound Check Go to Step 5 Go to Step 2 Is operating sound of main relay heard at ignition switch ON 2 Main Relay Check Go to Step 3 Replace main 1 Turn OFF ignition switch and remove main relay 1 relay 2 Check for proper connection to main relay 1 at terminal 3 and 4 3 Check resistance between each two terminals See Fig 1 and 2 Main relay resistance Between terminals A and B Infinity Between terminals C and D 70 110 Q at 20 C 68 F 4 Check that there is continuity between terminals 1 and 2 when bat tery is connected to terminals 3 and 4 See Fig 3 Is main relay in good condition ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 47 Is main relay in good condition Step Action Yes No 3 Fuse Check Go to Step 4 Check for Is main Fl fuse in good condition See Fig 1 short in cir cuits con nected to this fuse 4 ECM Power Circuit Check Go to Step 5 B W Or or 1 Turn OFF ignition switch disconnect connectors from ECM and BI B circuit install main relay open 2 Check for proper connection to ECM at terminals E17 9 Case of TYPE A See NOTE or E18 11 Case of TYPE B See NOTE E18 10 E18 5 and E18 6 3 If OK then measure voltage between terminal E18 10 and ground E17 9 Case of TYPE A See NOTE or E18 11 Case of TYPE B See NOTE and ground with ignition switch ON Is each voltage 10 14 V
238. ND EMISSION CONTROL SYSTEM cccccccccesceeeeeeeseesseeesesseseesseseesscesseeeeeeseeeeeeeseeeeseeeennas 6E 1 IGNITION SYSTEM E AE et eceecce tack tags dvedi A A E 6F 1 GRANKING SYSTEM ississscdsccccte ec cine cesta decid catteve cccecducedeseducedesecscesdconcusactuaddessssvecsucksesessvcdssccevsonnusesestesvaces 6G 1 CHARGING SYSTEM Wrsssccssesscesdeesscsseataceaed cect scccteesenssssieadadtvscssscastoaceadedenssecesdcedecstsisscesessvdssdasvssdassbescecsece 6H 1 EXHAUST SYSTEM eaaa ccs cceccecutteccedeececsichts sede seacbencedsveGacadseccadesteatvedesiesesenssseasssuswsalcacienedescccceceeveveess 6K 1 CONTENTS General Information cccccesceeseeeeeeseeessseeesees 6 3 On Board Diagnostic System Vehicle without Statement on Cleanliness and Care 6 3 Immobilizer Indicator Lamp cccccceeeeees 6 9 General Information on Engine Service 6 3 Precaution in Diagnosing Trouble 6 10 Precaution on fuel system SEIVICE ccceceeee 6 4 Engine Diagnostic Flow Table 000008 6 11 Fuel pressure relief procedure 0 00 6 5 Customer problem inspection form Fuel leakage check procedure eee OAAR EN 6 5 example AREA EEE TTILE 6 13 Engine Diagnosis sscssssescssssesssseesseeeees 6 6 Malfunction indicator lamp MIL check 6 14 Diagnostic trouble code DTC check 6 14 Diagnostic trouble code DTC clearance cececeeeeeeeceeeeeeceeeeesaaeaaeseeeeeess 6 15
239. NFORMATION AND DIAGNOSIS 6 77 DTC P0325 DTC No 17 Knock Sensor Circuit Malfunction CIRCUIT DESCRIPTION 31P J J 24P E19 25 DTC DETECTING CONDITION POSSIBLE CAUSE e Knock sensor voltage is 3 91 V or more e Knock sensor voltage is 1 23 V or less ECM malfunction e W circuit open or shorted to ground e Knock sensor malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 With ignition switch at OFF position discon nect knock sensor connector 3 With ignition switch at ON position check voltage from W to body ground terminal of knock sensor connector See Fig 2 Is it4 5 V Substitute a known good knock sensor and recheck 2 1 With engine running check voltage from Knock sensor and its cir Go to Step 3 E19 25 terminal of ECM connector to cuit are in good condition body ground See Fig 1 Intermittent trouble or 2 Is voltage about 1 25 3 75 V faulty ECM Recheck referring to Intermittent Trouble in Section OA 3 1 Stop engine Faulty knock sensor
240. NG Decarbon piston head and ring grooves using a suitable tool INSPECTION Cylinder e 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 6A1 64 ENGINE MECHANICAL M13 ENGINE e Using a cylinder gauge 1 measure cylinder bore in thrust and axial directions at two positions a and b as shown in figure If any of the following conditions is noted rebore cylinder 1 Cylinder bore dia exceeds limit 2 Difference of measurements at two positions exceeds taper limit 3 Difference between thrust and axial measurements exceeds out of round limit Limit on cylinder bore diameter 78 114 mm 3 073 in Limit on taper and out of round for cylinder 0 10 mm 0 004 in NOTE If any one of four cylinders has to be rebored rebore all four to the same next oversize This is necessary for the sake of uniformity and balance a 50 mm 1 96 in b 95 mm 3 74 in Pistons e Inspect piston for faults cracks or other damaged Damaged or faulty piston should be replaced e Piston diameter As indicated in figure piston diameter should be measured at a position 19 5 mm 0 77 in from piston skirt end in the direction perpendicular to piston pin Piston diameter specification 77 953 77 968 mm 3 0690 3 0696 in
241. NG FROM GEAR BOX NOTE Bleed air from gear box e When steering gear box has been replaced with a new one e When entry of air into hydraulic circuit of steering gear box is suspected 1 Remove steering gear box from vehicle referring to Power Steering P S Gear Box in this section 2 Install special tool as shown Special tool A 09945 35010 1 Steering gear box 3 High pressure hose pipe 2 Low pressure hose pipe A B POWER STEERING P S SYSTEM If equipped 3B1 9 3 After running engine at idling speed for 3 to 5 seconds stop it and add fluid up to specified level Repeat this step a few times NOTE Don t operate steering system for this step 4 Set steering gear box 1 to state A as shown 5 With engine running at idling speed turn input shaft by using special tool in both directions as far as it locks till all foams are gone NOTE e Add fluid into P S fluid reservoir whenever its level lowers while servicing e Turn input shaft till it locks return it a little and turn it again in the same direction till it locks Repeat this some times Special tool B 09944 18211 6 Perform Step 5 but with steering gear box in state B this time and then in state C NOTE To change of state of gear box from A to B and from B to C turn gear box in arrow direction in figures A and B 7 Set input shaft at neutral
242. ON AND DIAGNOSIS 6 103 DTC P1510 ECM Back up Power Supply Malfunction CIRCUIT DESCRIPTION 2 sti erp w w E18 7 ECM 1 I LAMP DOME a E18 7 31P mn M ap 1 Tap LI 1 Main fuse 2 Fuse box Battery voltage is supplied so that diagnostic trouble code memory values for engine control learned by ECM etc are kept in ECM even when the ignition switch is turned OFF DTC DETECTING CONDITION POSSIBLE CAUSE e Low voltage at terminal E18 7 after starting engine W circuit open e ECM malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and run it at idle for 1 min 2 Select DTC mode on scan tool and check DTC INSPECTION Step Action Yes No 1 Check for voltage at terminal E18 7 of ECM Poor E18 7 connection or W circuit open connector connected under each condition intermittent trouble ignition switch OFF and engine running Check for intermittent Is it 10 14 V at each condition referring to Intermittent and Poor Connection in Section OA If wire and connections are OK substitute a known good ECM and recheck 6 104 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P1570 DTC No 21 ABS Signal Circuit Malfunction CIRCUIT DESCRIPTION ECM 4 G
243. Other O Other O Poor Idling O Engine Stall when O Poor fast idle O Immediately after start C Abnormal idling speed O Accel pedal is depressed High OLow r min O Accel pedal is released O Unstable C Load is applied O Hunting r min to r min C A C CElectric load FIP S O Other O Other Other C OTHERS VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather OFair Cloudy Rain Snow OAlways Other Temperature JHot LJWarm Cool Cold F C OAlways Frequency OAlways Sometimes times day month LJOnly once Under certain condition Road Urban OSuburb JHighway CiMountainous Uphill JDownhill TTarmacadam Gravel Other Vehicle Condition Engine Cold OWarming up phase Warmed up LJAlways JOther at starting Olmmediately after start JRacing without load Engine speed r min Vehicle During driving LJConstant speed Accelerating JDecelerating condition Right hand corner CLeft hand corner OWhen shifting Lever position Vehicle speed when problem occurs kmh Mile h JOther Malfunction indicator 7 lamp condition OAlways ON Sometimes ON OAlways OFF Good condition Diagnostic trouble First check No code JMalfunction code code Second check No code JMalfunction code NOTE The above form is a standard sample It should be modifie
244. Performance Problem WIRING DIAGRAM Refer to DTC P0120 section CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE e After engine warmed up e TP sensor malfunction e Difference between actual throttle opening detected from TP sensor High resistance in the circuit and opening calculated by ECM Obtained on the basis of engine e ECM malfunction speed and intake manifold pressure in larger than specified value 2 driving cycle detection logic continuous monitoring DTC CONFIRMATION PROCEDURE WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester on a level road _ Turn ignition switch OFF Clear DTC with ignition switch ON check vehicle and environmental condition for Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower Engine coolant temp 70 C 158 F or higher Warm up engine to normal operating temperature Increase vehicle speed to 30 40 mph 50 60 km h in 3rd gear or D range and hold throttle valve at that opening position for 1 min 4 Stop vehicle 5 Check DTC in DTC mode and pending DTC in ON BOARD TEST or
245. R R BI or B circuit Replace A C 1 Turn ignition switch OFF condenser fan A Fig 1 for Step 1 B Fig 2 for Step 3 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 123 Special Tool Usk 09912 58441 09912 58431 09912 58490 09912 58421 Pressure gauge Pressure hose 3 way joint amp hose Checking tool set See NOTE A D 09912 57610 09917 47010 09930 88530 09931 76011 Checking tool plate Vacuum pump gauge Injector test lead SUZUKI scan tool Tech 1A kit See NOTE B 09931 76030 Mass storage cartridge 16 14 pin DLC cable Tech 2 kit SUZUKI scan tool See NOTE C NOTE e A This kit includes the following items 1 Tool body amp washer 2 Body plug 3 Body attachment 4 Holder 5 Return hose amp clamp 6 Body attachment 2 amp washer 7 Hose attachment 1 8 Hose attachment 2 e 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 e C This kit includes the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector 11 Storage case
246. R 3 a i Q Manual transmission oil leakage level l 1st 15 000 km only R Automatic transmission Fluid level Fluid change Replace every 165 000 km 99 000 miles Fluid hose R Transfer oil leakage level Differential oil leakage level R 1st 15 000 km only R orl Steering system tightness damage breakage rattle Power steering if equipped All latches hinges and locks NOTE R Replace or change I Inspect and correct replace or lubricate if necessary 0B 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 shown in the fol lowing table Severe condition code A Repeated short trips B Driving on rough and or muddy roads C Driving on dusty roads D Driving in extremely cold weather and or salted roads E Repeated short trips in extremely cold weather F Leaded fuel use Geecuc H Trailer towing if admitted Severe Maintenance Malntenance Maintenance Interval Condition Code Operation Every 15 000 km f 9 000 miles or 12 months
247. R INSPECTION e Check sensor for damage e Check sensor for resistance If any malfunction is found replace Resistance between terminals of sensor 1 2 1 6 KQ at 20 C 68 F Resistance between terminal and sensor body 1 MQ or more 1 Right wheel sensor terminals 2 Left wheel sensor terminals 5E 34 ANTILOCK BRAKE SYSTEM ABS SENSOR RING INSPECTION e Check ring teeth for being missing damaged or deformed e Turn drive shaft and check if ring rotation is free from eccen tricity and looseness e Check that no foreign material is attached If any faulty is found repair or replace INSTALLATION 1 Check that no foreign material is attached to sensor 1 and ring 2 Install it by reversing removal procedure Tightening torque Front wheel speed sensor bolt and front wheel speed sen sor harness clamp bolts a 10 N m 1 0 kg m 7 2 Ib ft 3 Check that there is no clearance between sensor and knuckle CAUTION Do not pull wire harness or twist more than necessary when installing front wheel speed sensor 2 Bolt ANTILOCK BRAKE SYSTEM ABS 5E 35 Front Wheel Sensor Ring REMOVAL 1 Remove wheel hub with sensor ring Refer to Wheel Hub Bearing Oil Seal in Section 3D 2 Remove sensor ring 1 from wheel hub 2 as shown CAUTION Pull out sensor ring 1 from wheel hub 2 gradually and evenly
248. RING SUSPENSION WHEELS AND TIRES 1 Ride vehicle to determine whether the front or rear waddles 2 Install tires and wheels that are known to be good on similar vehicle in place of those on wadding end of vehicle If wadding end cannot be identified substitute rear ones 3 Road test again If improvement is noted reinstall originals one at a time till waddle causal tire is found If no improvement is noted install known good tires in place of all four Then reinstall originals in the same man ner as above EQUIPMENT MANUFACTURE S RECOMMENDATIONS INFLATE TIRES TO RECOMMENDED PRESSURE ROAD TEST VEHICLE LEVEL UNCROWNED ROAD IN BOTH DIRECTIONS SWITCH FRONT TIRES SIDE TO SIDE AND ROAD TEST AGAIN LEAD CORRECTED IF LEAD IN SAME ee et ae LEAD REVERSES DIRECTION REPLACE TIRES DIRECTION PUT TIRES BACK IN INSTALL A KNOWN GOOD TIRE ORIGINAL POSITION ON ONE FRONT SIDE AND CHECK ALIGNMENT LEAD CORRECTED LEAD REMAING REPLACE TIRE INSTALL A KNOWN GOOD TIRE IN PLACE OF OTHER FRONT TIRE LEAD CORRECTED LEAD REMAING REPLACE TIRE KNOWN GOOD TIRES ARE NOT GOOD STEERING SUSPENSION WHEELS AND TIRES 3 7 Radial Tire Lead Lead is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering wheel Lead is usually ca
249. Section 5 Then perform final confirmation test after clearing diagnostic trouble code Is trouble recur Go to Step 7 End Check for intermittent problems referring to Intermittent and Poor Connection in Section OA and related circuit of trouble code recorded in Step 3 Then perform final confirmation test after clearing diagnostic trouble code Is trouble recur Go to Step 7 End Perform diagnostic trouble code check record and clearance Is there any trouble code Go to Step 4 Go to Step 5 ANTILOCK BRAKE SYSTEM ABS 5E 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 Date of issue Date of Reg Date of problem Mileage e 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 e Wheel is locked at braking e Pump motor does not stop running e Braking does not work Other Frequency of occurrence daca times a day a month Vehicle at stop amp ignition switch ON When starting at initial start only at every start O
250. Specification Tightening torque Fastening part Nem kam b fit Tension pulley bolt for vehicle with P S 25 2 5 18 0 Refrigerant 8 mm pipe 0 31 in 13 1 3 9 5 Refrigerant 12 mm pipe 0 47 in 23 2 3 16 6 Refrigerant 14 5 mm pipe 0 57 in 33 3 3 23 8 Dual pressure switch 10 1 0 7 0 Clutch plate bolt 14 1 4 10 5 Front head bolt 5 mm 14 1 4 10 5 Front head bolt 8 mm 23 2 3 16 6 AIR CONDITIONING OPTIONAL 1B 47 Required Service Materials Material Recommended SUZUKI product Part Number Use Compressor oil Refrigerant oil COMPRESSOR OIL RS20 150 cc 99000 99088 00D0 e O ring e Each component Special Tools 09900 06107 Snap ring pliers Open type 09991 06010 Magnet clutch pulley installer ep 09991 06020 Armature plate spanner 09991 06030 Armature plate remover 09991 06040 Lip type seal protector 09991 06050 Lip type seal installer 1B 48 AIR CONDITIONING OPTIONAL STEERING SUSPENSION WHEELS AND TIRES 3 1 SECTION 3 STEERING SUSPENSION WHEELS AND TIRES DIAGNOSIS aa aa E a E a ster cde ican ce A wal due eluate Da tetera culesdiaus AD a a i 3 1 FRONT END ALIGNMENT 200 ce eee eee ees Section 3A 1 STEERING GEAR BOX AND LINKAGE 0 22 00 e eee eee Section 3B 1 POWER STEERING SYSTEM IF EQUIPPED 0 00 eee eee eee eee eee Section 3B1 1 STEERING WHEEL
251. Step 2 to check ABS control mod ule for proper self diagnosis function If the malfunction DTC which was once displayed and then cleared can be detected indicated again when ignition switch is turned ON proceed to Step 3 O lt 5E 8 ANTILOCK BRAKE SYSTEM ABS 2 ol 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 lamp 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 DIAGNOSTIC TROUBLE CODE CHECK Recheck diagnostic trouble code referring to DTC Check in this section DIAGNOSTIC TROUBLE CODE FLOW TABLE According to Diagnostic Flow Table for the diagnostic trouble code confirmed in Step 3 locate the cause of the trouble namely in a sensor switch wire harness connector actuator ABS control module or other part and repair or replace faulty parts DIAGNOSIS TABLE IN SECTION 5 Check the parts or system suspected as a possible cause referring to Diagnosis Table in Section 5 and based on symptoms appearing on the vehicle symptoms obtained through Step 1 a 1 b and 2 and repair or replace faulty parts if any 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 Section OA and related circ
252. Step 6 Repair or replace A C of Table B 5 A C Signal Circuit Check if signal circuit or A C sys equipped A C signal can be also checked by tem using SUZUKI scan tool Is it in good condition 6 Check IAC system referring to Step 2 to Step 4 of Go to Step 7 Go to Step 5 of DTC DTC P0505 Diag Flow Table P0505 Diag Flow Table Is check result satisfactory 7 Was IAC duty less than about 3 or more than Check abnormal air Check TP sensor about 97 for OFF duty meter in Step 1 of this inhaling from air intake closed throttle position table system PCV valve and and ECT sensor for per EVAP canister purge formance control system If sensors are OK sub stitute a known good ECM 8 ls SUZUKI scan tool available Go to Step 9 Go to Step 10 9 Check PNP signal D range signal Go to Step 11 Repair or replace 1 Connect SUZUKI scan tool to DLC with igni tion switch OFF 2 Turn ignition switch ON and check PNP signal P N and D range on display when shifting selector lever to each range See Table 1 Is check result satisfactory 10 Check PNP signal D range signal Go to Step 11 Repair or replace 1 Turn ignition switch ON 2 Check voltage at terminal E17 6 of ECM con nector connected See Fig 1 and Table 1 Is check result satisfactory 11 Check IAC system referring to Step 2 to Step 4 of Go to Step 12 Go to Step 5 of DTC DTC P0505 Diag Flow Table P0505 Diag Flow Table Is check resu
253. System is a system to prevent each wheel to lock during hard braking or braking ona slippery road by controlling the fluid pressure from master cylinder to each brake either brake caliper or wheel cylinder The ABS of this vehicle monitors all four wheels four sensors and controls all four wheels when the system is active The component parts of this ABS includes following parts in addition to those of the conventional brake system Wheel speed sensor senses revolution speed of each wheel and sends outputs to ABS control module In this ABS ABS hydraulic unit actuator assembly ABS control module pump motor transistor and fail safe transistor are combined as one component ABS control module 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 operates according to signal from ABS control module and controls fluid pressure applied to wheel cylinder of each of 4 wheels Fail safe transistor which supplies power to solenoid valve in ABS hydraulic unit Pump motor transistor supplies power to pump motor in ABS hydraulic unit ABS warning lamp lights to inform abnormality when system fails to operate properly G sensor which detects body deceleration speed A 1 Front disc brake 5 Brake master cylinder booster 2 Proportioning valve A For LH steerin
254. TC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Start engine and then turn both A C switch and heater blower switch ON for 2 sec or more 4 Run engine at idle for 5 sec or more which A C switch and heater blower switch OFF 5 Check DTC and pending DTC ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 93 INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check A C Condenser Fan Control Relay and its Intermittent trouble or Go to Step 3 Circuit faulty ECM 1 Turn ignition switch ON Check for intermittent 2 Check for voltage at terminal E18 18 of ECM referring to Intermittent connector connected under following condition and Poor Connection in When A C switch turns OFF 10 14 V Section OA Is voltage as specified 3 Check A C Condenser Fan Control Relay Lg or P B circuit open Replace A C con 1 Turn ignition switch OFF and remove A C con denser fan control relay 1 See Fig 1 2 Check for proper connection to the relay at P B and Lg wire terminals 3 If OK then measure resistance between termi nals C and D See Fig 2 Is it 70 1109 or short If wires and connections are OK substitute a known good ECM and recheck denser fan control relay A Fig 1 for Step 3 B Fig 2 for Step 3 B 6 94 EN
255. TION 1 Clean mating surfaces and install throttle body gasket to intake manifold Use new gasket 2 Connect engine coolant hoses 3 Install throttle body 1 to intake manifold 4 Connect connectors to TP sensor 2 and IAC valve 3 securely 5 Install air cleaner outlet No 2 hose 1 and pipe 6 Connect accelerator cable and adjust cable play to specifica tion 7 Refill cooling system 8 Connect negative cable at battery ENGINE AND EMISSION CONTROL SYSTEM 6E 21 Idle air control valve IAC valve REMOVAL 1 Remove throttle body from intake manifold referring to Throttle Body in this section for removal 2 Remove IAC valve from throttle body INSPECTION 1 Connect each connector to IAC valve 1 TP sensor and IAT sensor 2 Check that rotary valve 2 of IAC valve opens and closes once and then stops in about 60 ms as soon as ignition switch is turned ON NOTE e This check should be performed by two people one person turns on ignition switch while the other checks valve operation e As valve operation is momentary it may be over looked To prevent this perform this operation check 3 times or more continuously If rotary valve of IAC valve does not operate at all check wire harness for open and short If wire harness is in good condition replace IAC valve and recheck INSTALLATION 1 Install new O ring 2 to IAC valve 1 2 Install IAC valve 1 to throttle bo
256. TIONING OPTIONAL Performance Diagnosis 1 Confirm that vehicle and environmental conditions are as fol lows e Vehicle is not exposed to direct sun e 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 set 3 are firmly closed 3 Connect high pressure charging hose 4 to high pressure service valve 5 and connect low pressure charging hose 6 to low pressure service valve 7 4 Bleed the air in charging hoses 4 6 by loosening their respective nuts on manifold gauge set 3 utilizing the refrig erant pressure When a hissing sound is heard immediately tighten nut 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 Radiator cooling fan should not be working when checking pressure and temperature 6 Turn A C switch ON and set blower switch at HI 3rd posi tion temperature knob at COOL air outlet control knob at FACE and fresh circulation control knob at CIRCULA TION Confirm that A C compressor and radiator con denser cooling fan are working Keep all windows doors and engine food open Performance diagnosis condition Ambient temperature 15 35 C 59
257. Tech 1A 09931 76030 16 14 pin DLC adapter for Tech 1A Tech 2 kit SUZUKI scan tool See NOTE B NOTE e A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor e B This kit includes the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 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 Tightening Torque Specification Fastening part Tightening torque Nem kg m lb ft Spark plug 25 2 5 18 0 CRANKING SYSTEM 6G 1 SECTION 6G CRANKING SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system
258. Tightening torque mod 1 Oil pan 6 Strainer bolt Do not reuse Apply sealant 99000 31150 to mating surface x 2 Strainer 7 Bracket bolt REMOVAL 1 Remove oil level gauge 2 Remove air cleaner outlet No 1 1 and No 2 2 hoses and breather hose 3 3 To facilitate and ensure removal of oil pan increase clear ance between engine and vehicle body according to the fol lowing procedure a Install support device 1 b Loosen engine mounting bracket bolts 2 but do not remove them c Hoist engine 10 15 mm 0 4 0 6 in CAUTION Do not hoist engine more than instructed above That may cause trouble to engine or transmission ENGINE MECHANICAL M13 ENGINE 6A1 25 4 Drain engine oil by removing drain plug 5 Remove clutch housing torque converter housing for A T vehicle lower plate 1 6 Remove oil pan and then oil pump strainer 1 from cylinder block CLEAN e Inside of oil pan and oil pump strainer screen e Clean sealing surface on oil pan and cylinder block Remove oil old sealant and dust from sealing surface 6A1 26 ENGINE MECHANICAL M13 ENGINE INSTALLATION 1 Apply sealant continuously to oil pan mating surface as shown in figure A sealant 99000 31150 Sealant amount for oil pan Width a 3 mm 0 12 in Height b 2 mm 0 08 in 2 Install new O rings 1
259. V good ECM and recheck 2 Test switch terminal circuit check Substitute a known good P wire test switch termi 1 With the ignition switch ON position check ECM and recheck nal shorted to ground cir voltage between E18 15 terminal of ECM cuit connector and ground If OK substitute a known Is voltage 4 5 V good ECM and recheck 6 46 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table A 5 ECM Power and Ground Circuit Check MIL Doesn t Light at Ignition Switch ON and Engine Doesn t Start Though It Is Cranked Up CIRCUIT DESCRIPTION B BI W G FE Or 6 1 E18 5 E18 2 W BI N 31P Peay 17P IT m L i nae E17 9 1 Main fuse 4 Main relay 7 IG fuse A Case of TYPE A is shown See NOTE 2 Ignition switch 5 Malfunction indicator lamp in 8 IG COIL METER fuse B Case of TYPE B is shown See combination meter NOTE 3 Fuse box 6 FI fuse NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model When the ignition switch tuned ON the main relay turns ON the contact point closes and the main power is supplied to ECM INSPECTION Step Action Yes No 1
260. Valve REMOVAL CAUTION Do not allow brake fluid to get on painted surfaces 1 Clean around reservoir cap and take out fluid with syringe or such 2 Disconnect brake pipes from P valve 3 Remove P valve WARNING Never disassemble P valve assembly If it is found faulty replace it with new assembly INSTALLATION 1 Install P valve 2 Tightening torque P valve bolts a 25 N m 2 5 kg m 18 0 Ib ft 2 Tighten flare nuts to specified torque Tightening torque Brake pipe flare nuts b 16 N m 1 6 kg m 12 0 Ib ft 3 Fill reservoir with specified brake fluid 4 Bleed air from system 1 Flare nuts BRAKES 5 45 Brake Booster 5 U 25 N m 2 5 kg m D pa 5 N oP 8 F 13 N m 1 3 kg m U 13 N m 1 3 kg m Brake master cylinder assembly 5 Nut 9 Brake vacuum hose Brake booster assembly 6 Clevis pin m Tightening torque Gasket 7 Clip Push rod clevis 8 Nut CAUTION Never disassemble brake booster Disassembly will spoil its original function If faulty condition is found replace it with new one REMOVAL 1 Remove master cylinder assembly referring to Maser Cylin der in the section 2 Disconnect brake vacuum hose 2 from booster 1 3 Remove brake pipes 3 5 46 BRAKES 4 Disconnect push rod clevis pin 4 from brake pedal arm 3 5 Remov
261. Valve for Closing Check EVAP control Go to Step 8 1 Disconnect purge hose 1 from EVAP canister system 2 Place finger against the end of disconnected hose See Section 6E 3 Check that vacuum is not felt there when engine is cool and running at idle See Fig 7 Is vacuum felt 8 Check manifold absolute pressure sensor for perfor Go to Step 9 Repair or replace mance See step 4 DTC P0105 Diag Flow Table Is it in good condition 9 Check engine coolant temp sensor for performance Go to Step 10 Replace engine See Section 6E coolant temp sen Is itin good condition sor 10 Check parts or system which can cause engine rough Check wire harness Repair or replace idle or poor performance and connection of e Engine compression See Section 6A1 ECM ground ignition e Valve lash See Section 6A1 system and fuel injec e Valve timing Timing belt installation See Section tor for intermittent 6A1 open and short Are they in good condition CAUTION For iridium spark plugs do not adjust air gap or clean A Fig 1 for Step 3 B Fig 2 for Step 3 C Fig 3 for Step 4 D Fig 4 for Step 5 E Fig 5 for Step 4 C D 3 Fuel delivery pipe 4 Fuel feed hose 3 Fuel pressure gauge amp 3 way joint 6 76 ENGINE GENERAL INFORMATION AND DIAGNOSIS F Fig 6 for Step 5 G Fig 7 for Step 7 ENGINE GENERAL I
262. a List mode on scan tool to check IAC duty A SUZUKI scan tool b When using duty meter 3 Vehicle without immobilizer indicator lamp NOTE IAC duty can be checked using monitor connector only for vehicle not equipped with immobilizer indicator lamp B i Set tachometer ii Using service wire 2 ground Diag switch terminal in monitor connector 1 and connect duty meter between Duty output terminal 4 and Ground terminal 5 of monitor connector 1 A When using SUZUKI scan tool B When using duty meter Vehicle without immobilizer indicator lamp 4 If duty and or idle speed is out of specifications inspect idle air control system referring to Diagnostic Flow Table B 4 Idle Air Control System Check in Section 6 Engine idle speed and IAC duty A C OFF A C ON 700 50 r min rpm 900 50 r min M T vehicle 5 25 rpm A T vehicle 750 50 r min rpm 900 50 r min at P N range 5 25 rpm NOTE Above duty values are ON duty low voltage rate meter indications 5 Remove service wire from monitor connector 6 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 signal circuit and idle air control sys tem Fr me ENGINE AND EMISSION CONTROL SYSTEM 6E 17 Idle mixture inspection adjustment vehicle without heated oxyg
263. a service performed on the system LIQUID LEAK DETECTOR There are a number of fittings and places throughout the air con ditioning system where a liquid leak detector solution may be used to pinpoint refrigerant leaks By merely applying the solution to the area in question with a swab such as attached to the cap of a vial bubbles will form within seconds if there is a leak j For confined areas such as sections of the evaporator and con denser an electronic refrigerant leak detector 1 is more practi cal for determining leaks AIR CONDITIONING OPTIONAL 1B 29 On Vehicle Service Service Precaution When servicing air conditioning system note the following instructions Refrigerant line JCE fe Hee eS WA g R gt 4 f 1 Suction hose 4 Condenser outlet pipe ig Apply compressor oil to O ring 2 Apply compressor oil to O ring 2 Discharge hose 5 Expansion valve 2 Apply compressor oil to O ring 2 Apply compressor oil to O ring 3 Receiver dryer outlet pipe 6 Dual pressure switch R Apply compressor oil to O ring 2 Apply compressor oil to O ring e Never use heat for bending pipes When bending a pipe try to make its bending radius as slight as possible e 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 e When connecting ho
264. ae straight pipe fit hose till pipe is about 20 to 30 mm 0 79 1 18 in into the ose B Hose Pipe Clamp Clamp securely at a position 3 to 7 mm 0 1 2 0 27 in from hose end 20 to 30 mm 0 79 1 18 in i a a E e When installing injector or fuel delivery pipe lubricate its O ring with spindle oil or gasoline ZAZA e When connecting fuel pipe flare nut first tighten flare nut by hand and then tighten it to specified torque ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 5 Fuel pressure relief procedure CAUTION This work must not be done when engine is hot If done so it may cause adverse effect to catalyst After making sure that engine is cold release fuel pressure as fol lows 1 Place transmission gear shift lever in Neutral Shift selector lever to P range for A T model set parking brake and block drive wheels Remove relay box cover oO N Disconnect fuel pump relay 1 from its connector 4 Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it 5 Start engine and run it till it stops for lack of fuel Repeat cranking engine 2 3 times for about 3 seconds each time to dissipate fuel pressure in lines Fuel connections are now safe for servicing Upon completion of servicing connect fuel pump relay 1 to its connector O Fuel leakage check procedure After perfor
265. aft bolt Differential case side 50 5 0 36 5 Rear propeller shaft bolt Shaft No 3 transfer case side 33 3 3 24 0 Wheel nut 95 9 5 69 0 Wheel speed sensor bolt and harness clamp bolt 10 1 0 7 5 Required Service Materials Material Recommended SUZUKI product Use Part Number Lithium grease PVEVR SUP PR OREA SEA Oil seal lip 99000 25010 Sealant SUZUKI BOND NO 1215 e Joint seam of differential carrier and 99000 31110 axle housing SEALING COMPOUND 366E e To apply to mating surfaces of brake Water tight sealant 99000 31090 back plate and 4 axle ekardi For gear oil information refer to Mainte Differential gear nance Service in Section 7E of this manual Rear axle housing Special Tools REAR SUSPENSION 3E 23 09913 75520 Bearing installer 09913 85210 Oil seal installer 09924 74510 Bearing installer handle Rs 1 09927 18411 Universal puller 2 09921 57810 Bearing remover P 09941 66010 Bump stopper wrench 09942 15510 Sliding hammer 09943 35511 or 09943 35512 Brake drum remover 09944 96010 Bearing outer race remover 09921 26010 Bearing outer race remover collar 09951 16030 Bush remover 09951 26010 Bush remover plate 3E 24 REAR SUSPENSION WHEELS AND TIRES 3F 1 SECTION 3F WHEELS AND TIRES NOTE All wheel fasteners are important attaching parts in that they could affect the performanc
266. aft housing bolts 8 0 0 8 6 0 for replacement of shim Camshaft housing bolts 11 0 1 1 8 0 Cylinder head cover bolts 8 0 0 8 6 0 Intake manifold bolts and nuts 25 0 2 5 18 0 Exhaust manifold bolts and nuts 55 0 5 5 40 0 Exhaust pipe bolts 50 0 5 0 36 5 Exhaust manifold stiffener bolts 50 0 5 0 36 5 Oil pump strainer bolt 11 0 1 1 8 0 Oil pump strainer bracket bolt 11 0 1 1 8 0 Oil pan bolts and nuts 11 0 1 1 8 0 Oil pan drain plug 50 0 5 0 36 5 Timing chain cover bolts and nut 23 0 2 3 17 0 Crankshaft pulley bolt 150 0 15 0 108 5 Oil pump rotor plate bolts 11 0 1 1 8 0 Timing chain No 1 guide bolts 9 0 0 9 6 5 Timing chain tensioner adjuster bolts 11 0 1 1 8 0 Venturi plug 5 0 0 5 3 5 Cylinder head bolt for M8 22 0 2 2 16 0 Cylinder head bolts for M10 a Tighten 40 N m a Tighten 4 0 kg m a Tighten 29 0 lb ft b Turn 60 b Turn 60 b Turn 60 c Turn 60 c Turn 60 c Turn 60 Connecting rod bearing cap nuts a Tighten 15 N m a Tighten 1 5 kg m a Tighten 11 0 lb ft b Turn 45 b Turn 45 b Turn 45 c Turn 45 c Turn 45 c Turn 45 Engine mounting bolts 50 0 5 0 36 5 6A1 94 ENGINE MECHANICAL M13 ENGINE Fastening part Tightening torque Nem kg m lb ft Crankshaft bearing cap No 1 bolts for inspection of crankshaft thrust play IN oe ee Crankshaft bearing cap No 2 bolts 22 0 2 2 16 0 Sensor plate bolts 11 0 1 1 8 0 Crankshaft bearing cap No 1 bolts a Tighten 50 N m
267. ag inflator module from steering wheel referring to Driver Air Bag Inflator Module in this section 3 Remove steering shaft nut 4 Make alignment marks 1 on steering wheel and shaft for a guide during reinstallation A STEERING WHEEL AND COLUMN 3C 7 5 Remove steering wheel 1 with special tool Special tool A 09944 36011 CAUTION Do not hammer the end of the shaft Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column INSTALLATION 1 Check that vehicle s front tires are at straight ahead position If equipped with air bag system align contact coil to original position referring to Centering Contact Coil in this section CAUTION For vehicle with air bag system These two conditions are prerequisite for installation of steering wheel If steering wheel has been installed with out these conditions contact coil will break when steer ing wheel is turned 2 Install steering wheel as follows e For vehicle without air bag system a Apply grease to contact plate 1 A Grease 99000 25290 b Install steering wheel onto shaft aligning them by match marks e For vehicle with air bag system Install steering wheel to steering shaft with 2 lugs 2 on con tact coil fitted in two grooves 3 in the back of steering wheel and also aligning marks 4 on ste
268. age between A2 terminal and Check in this section ground Y R and Gr R circuits Is it 10 14 V when transfer lever is in 2H range of VSV2 and about 0 V for 5 seconds after it is shifted to If OK substitute a known 4H or 4L range good 4WD controller and recheck 6 Check vacuum switch circuit Go to Step 7 Check vacuum switch 1 Turn ignition switch ON stating engine refer to 4WD Control 2 Check voltage between A6 terminal and System Check in this ground section Gr and B cir Is it 10 14 V when transfer lever is in 2H range cuits of vacuum switch and about 0 V for 5 seconds after it is shifted to If OK substitute a known 4H or 4L range good 4WD controller and recheck 7 Check 4WD indicator light circuit Substitute a known good Check BI circuit includ 1 Turn ignition switch ON 2 Check voltage between A3 terminal and ground Is it 10 14 V when transfer lever is in 2H range and about 0 V within 15 seconds after it is shifted to 4H or 4L range 4WD controller and recheck ing indicator light and combination meter refer to Combination Meter in Section 8 If OK substitute a known good 4WD controller and recheck 3D 10 FRONT SUSPENSION ee AWD Controller and ITS Circuit Check laidag A8 A7 A6 A5 A4 A3 A2 A1 VOLTAGE CHECK Check for
269. al rod 1 REAR SUSPENSION 3E 19 10 Loosen rear mounting nuts of trailing arm 2 but don t remove bolt 11 Remove shock absorber 1 lower mounting bolt 12 Lower floor jack until tension of suspension coil spring becomes a little loose and remove rear mount bolts of trailing arm 13 Lower rear axle housing gradually 14 Remove axle housing INSTALLATION Install removed parts in reverse order of removal noting the fol lowing 1 Place rear axle housing 1 on floor jack Then install trailing arm 2 rear mounting bolts right amp left in proper direction as shown At this time mount nuts but don t tighten them 3 Out side 4 Body center 2 Install coil spring 2 right amp left on spring seat 1 of axle housing and raise axle housing NOTE e Upper and lower diameters of coil spring 2 are differ ent Bring larger diameter end at bottom and set its open end in place on spring seat 1 e When seating coil spring 2 mate spring end with stepped part 3 of rear axle spring seat 1 as shown A Upper side small dia B Lower side large dia 3E 20 REAR SUSPENSION 3 Install lower part of shock absorber 1 to right and left sides of axle housing and tighten bolts 2 temporarily by hand 4 Install lateral rod 1 and install bolts in proper direction as shown At
270. al to enrich and enlean A F mixture See Fig 2 Does HO2S 1 output voltage deflect between 0 3 V and over 0 6 V repeatedly Check for intermittent referring to Intermittent and Poor Connection in Section OA wires for open and short and connections for poor connection If wires and connections are OK replace HO2S 1 A Fig 1 for Step 3 B Fig 2 for Step 3 A B NG NG NG ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 61 DTC P0133 Heated Oxygen Sensor HO2S Circuit Slow Response Sensor 1 WIRING DIAGRAM Refer to DTC P0130 section CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE e When running at specified idle speed after engine warmed up and e Heated oxygen sensor 1 malfunction running at specified vehicle speed response time time to change from lean to rich or from rich to lean of HO2S 1 output voltage is about 1 sec at minimum or average time of 1 cycle is 5 sec at minimum See Fig 1 2 driving cycle detection logic Monitoring once 1 driving Fig 1 1 cycle time HO2s 1 Output voltage Response time DTC CONFIRMATION PROCEDURE Refer to DTC P0130 section INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 ls there DTC s other than HO2S 1 DTC Go to applicable DTC Replace HO2S 1 P0133 Diag Flow Table
271. al tool 12 IN2 13 14 15 IN345 E2 EX2 E3 E4 E5 EX345 A Intake side or E Exhaust side B Position from timing chain side C Pointing to timing chain side 4 Turn camshaft by approximately 90 clockwise and remove shim 3 WARNING Never put in the hand between camshaft and tappet 1 Special tool 2 Magnet ENGINE MECHANICAL M13 ENGINE 6A1 11 5 Using a micrometer 2 measure the thickness of the removed shim 1 and determine replacement shim by cal culating the thickness of new shim with the following formula and table Intake side A B C 0 20 mm 0 008 in Exhaust side A B C 0 30 mm 0 012 in A Thickness of new shim B Thickness of removed shim C Measured valve clearance Example of intake side When thickness of removed shim is 2 40 mm 0 094 in and measured valve clearance is 0 45 mm 0 018 in A 2 40 mm 0 094 in 0 45 mm 0 018 in 0 20 mm 0 008 in 2 65 mm 0 104 in Calculated thickness of new shim 2 65 mm 0 104 in 6 Select new shim No 1 with a thickness as close as possi ble to calculated value Available new shims No Thickness Shim Thickness Shim mm in No mm in No WA 2 175 0 0856 218 2 675 0 1053 268 2 200 0 0866 220 2 700 0 1063 270 2 225 0 0876 223 2 725 0 1073 273 2 250 0 0886 2
272. alfunction indicator lamp for flashing Is it flashing when ignition switch is turned to ON position Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check battery voltage Go to Step 3 Charge or replace battery Is it 11 V or more 3 Is engine cranked Go to Step 4 Go to Diagnosis in Sec tion 6G 4 Does engine start Go to Step 5 Go to Step 9 5 Check idle speed as follows Go to Step 6 Go to Engine Diagnosis 1 Warm up engine to normal operating temp Table 2 Shift transmission to neutral position for M T P position for A T 3 All of electrical loads are switched off 4 Check engine idle speed with scan tool See Fig 1 Is it 650 750 r min 700 800 r min for A T vehicle 6 ls SUZUKI scan tool available Go to Step 8 Go to Step 7 7 Check ignition timing as follows Go to Engine Diagnosis Check ignition control 1 Connect test switch terminal 2 of monitor Table related parts referring to coupler 1 to ground See Fig 2 Section 6F 2 Remove air cleaner bolt and crips and shift air cleaner position to observe ignition tim ing 3 Using timing light 1 check initial ignition timing See Fig 4 Is it 5 3 BTDC at specified idle speed 8 Check ignition timing as follows Go to Engine Diagnosis Check ignition control 1 Select MISC mode on SUZUKI scan tool Table related parts re
273. all the following parts to engine as previously outlined Piston and connecting rod Cylinder head assembly Camshaft tappet and shim Timing chain guide chain tensioner adjuster chain ten sioner timing chain and crankshaft timing sprocket Timing chain cover Cylinder head cover Intake manifold and exhaust manifold Oil pan and oil pump strainer Install clutch to flywheel vehicle with M T referring to Clutch Cover Clutch Disc Flywheel and Release Bearing in Section 7C 12 Install engine assembly to vehicle referring to Engine Assembly in this section ENGINE MECHANICAL M13 ENGINE 6A1 93 Required Service Material Material Recommended SUZUKI product Part Number Use Sealant 99000 31150 SUZUKI BOND NO 1207C e To apply to mating surface of cylinder block and oil pan e To apply to mating surface of cylinder block and timing chain cover e To apply to sealing surface of cylinder head cover e To apply to mating surface to rear oil seal housing 99000 31140 SUZUKI BOND NO 1207B e To apply to mating surface of cylinder block cylin der head and timing chain cover 99000 31110 SUZUKI BOND NO 1215 e To flywheel M T or drive plate A T bolts Tightening Torque Specification Tightening torque Fastening part Nem kgm Ib tt Oil pressure switch 14 0 1 4 10 5 Camsh
274. ally 2 Disconnect vacuum hoses from EVAP canister 3 Check that there should be no restriction of flow through 4 fer baie purge pipe 1 and air pipe 2 when air is blown 4 into tank 7 pipe 3 If any faulty condition is found in above inspection replace PCV system NOTE Be sure to check that there is no obstruction in PCV valve or its hoses before checking IAC duty for obstructed PCV valve or hose hampers its accurate adjustment PCV HOSE INSPECTION Check hoses for connection leakage clog and deterioration Replace as necessary PCV VALVE INSPECTION 1 Disconnect PCV valve 1 from cylinder head cover and install plug to 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 6E 42 ENGINE AND EMISSION CONTROL SYSTEM Special Tools 4 After checking vacuum stop engine and remove PCV valve 1 Shake valve and listen for the rattle of check needle inside the valve If valve does not the rattle replace valve 5 After checking remove plug and install PCV valve 1 D 09912 57610 Checking tool plate Sati 09912 58421 Checking tool set See NOTE A 09912 58432 Pressure hose 09912 58442 Pressure gauge 09912 58490 3 way joint amp hose 09930 88530 Injector test lead 09931 76011 SUZUKI sca
275. als Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal If contact tension is not enough reform it to increase contact tension or replace 1 Check contact tension by inserting and removing just once 2 Check each terminal for bend and proper alignment 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 repair or replace Wire insulation which is rubbed through causing an intermit tent short as the bare area touches other wiring or parts of the vehicle Wiring 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 Precaution For Installing Mobile Communica tion Equipment When installing mobile communication equipment such as CB Citizens Band radio or cellular telephone be sure to observe the following precautions Failure to follow cautions may adversely affect electronic control system Keep the antenna as far away as possible from the vehicle s electronic control unit Keep the antenna feeder more than 20 cm 7 9 in away from electronic control unit and its wire harnesses Do not run the antenna feeder parallel
276. amaged wheel bearings Replace wheel bearing Broken suspension springs Replace spring Wander or Poor Steering Stability Mismatched or uneven tires Replace tire or inflate tires to proper pressure Loose king pin bearings and tie rod ends Replace king pin bearing or tie rod end Faulty shock absorbers or mounting Replace absorber or repair mount ing Loose stabilizer bar Tighten or replace stabilizer bar or bushes Broken or sagging springs Replace spring Steering gear box not properly adjusted Check or adjust steering gear box torque Front wheel alignment Check and adjust front wheel align ment Erratic Steering when Braking Worn wheel bearings Replace wheel bearing Broken or sagging springs Replace spring Leaking wheel cylinder or caliper Repair or replace wheel cylinder or caliper Warped discs Replace brake disc Badly worn brake linings Replace brake shoe lining Drum is out of round in some brakes Replace brake drum Wheel tires are inflated unequally Inflate tires to proper pressure Defective wheel cylinders Replace or repair wheel cylinder Disturbed front wheel alignment Check front wheel alignment Ride Too Soft Faulty shock absorber Replace shock absorber Suspension bottoms Overloaded Check loading Faulty shocks absorber Replace shock absorber Incorr
277. and left axle shafts with knuckle and hub assembly for 4WD model NOTE At this time lower kingpin bearing sometimes falls off So remove bearing while pulling off knuckle gradually 12 Before removing front propeller shaft 1 give match marks 3 on joint flange 2 and front propeller shaft as shown for 4WD 13 Remove front differential from front axle housing for 4WD 14 Remove air locking hub vacuum pipe from axle housing 1 for 4WD 15 Support front axle housing by using floor jack 16 Remove lateral rod refer to Lateral Rod in this section 17 Remove stabilizer bar refer to Stabilizer Bar Bushings in this section 18 Loosen mounting nuts of leading arm 1 but don t remove bolts 3D 40 FRONT SUSPENSION 19 Lower floor jack until tension of suspension coil spring becomes a little loose and remove right and left sides lower mounting bolt of shock absorber 1 20 Remove front mounting bolts of leading arm 21 Lower front axle housing gradually 22 Remove axle housing INSTALLATION 1 Place rear axle housing on floor jack Then install leading arm front mounting bolts right amp left in proper direction as shown At this time mount nuts but don t tighten them A Body outside 2 Install lower part of shock absorber 1 to right and left sides of axle housing and install bolts 2 in proper direction a
278. ar on the edges of the tread 4 Tire rim bruises and rupture 5 Tire cord breakage 6 High tire temperatures 7 Reduced handling 8 High fuel consumption Tire placard The tire placard is located on the driver s side door lock pillar and should be referred to for tire information The placard lists the maximum load tire size and cold tire pressure where applicable NOTE Whether rim size and or maximum load are listed or not depends on regulations of each country Tire rotation F To equalize wear rotate tires according to left figure Radial tires t should be rotated periodically Set tire pressure NOTE Due to their design radial tires tend to wear faster in the shoulder area particularly in front positions This makes regular rotation especially necessary i A RH steering vehicle B LH steering vehicle F Front A 3F 8 WHEELS AND TIRES On Vehicle Service Wheel REMOVAL 1 Loosen wheel nuts by approximately 180 half a rotation 2 Hoist vehicle 3 Remove wheel CAUTION Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel bearings INSTALLATION Wheel nuts must be tightened in sequence and to proper torque to avoid bending wheel or brake drum or disc as shown NOTE Before installing wheels remove any build up of corro sion on wheel mounting surface and brake drum
279. asing the fuel pressure or fuel can be sprayed out under pressure e When performing a work that produces a heat exceeding 80 C 176 F in the vicinity of the electrical parts remove the heat sensitive electrical part s beforehand e Use care not to expose connectors and electrical parts to water which will be a cause of a trouble e Always be careful not to handle electrical parts com puter relay etc in a rough manner or drop them 0A 10 GENERAL INFORMATION Precautions For Catalytic Converter For vehicles equipped with a catalytic converter use only unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged e Conduct a spark jump test only when necessary make it as short as possible and do not open the throttle e Conduct engine compression checks within the shortest possible time e Avoid situations which can result in engine misfire e g starting the engine when the fuel tank is nearly empty Precautions For Electrical Circuit Service e When replacing a fuse make sure to use a fuse of the Jy specified capacity Use of a fuse with a larger capacity NO Q ILa will cause a damage to the electrical parts and a fire e When disconnecting and connecting coupler make sure to turn ignition switch OFF or electronic parts may get damaged e When disconnecting connectors never pull the wiring harnesses Unlock the connector lock first
280. ator Thermistor A C Evaporator Temperature Sensor INSPECTION Check resistance between terminals for A C evaporator ther mistor 1 If check results are as not specified replace thermistor A C evaporator temperature sensor resistance Sensor Temperature C F Resistance kQ 0 32 6 4 7 0 25 77 1 8 2 2 NOTE When A C evaporator thermistor 1 removed its should be reinstalled in original position Expansion Valve INSPECTION Refer to Performance Diagnosis in this section REMOVAL 1 Disconnect negative cable at battery 2 Recover refrigerant from A C system by referring to Recover in this section NOTE The amount of removed compressor oil must be mea sured for replenishing compressor oil 3 Remove attaching bolt 1 4 Remove suction hose 2 and receiver dryer outlet pipe 3 from expansion valve 4 5 Remove expansion valve 4 1B 38 AIR CONDITIONING OPTIONAL B Pressure Continuity No continuity f A INSTALLATION Reverse removal procedure for installation and then note the fol lowing instructions e Replenish specified amount of compressor oil to compressor suction side by referring to Replenishing Compressor Oil in this section e Evacuate and charge refrigerant by referring to Evacuation and Charging in this section Dual Pressure Switch INSPECTION 1 Check dual press
281. aust system of this vehicle consists of the exhaust manifold exhaust center pipe muffler seals etc The catalytic converter is an emission control device added to the exhaust system to lower the level of Hydro carbon HC Carbon Monoxide CO and Oxides of Nitrogen NOx pollutants in the exhaust gas The catalyst ek in the catalytic converter is of Three way type 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 Maintenance WARNING To avoid danger of being burned do not touch exhaust system when system is hot Any service on exhaust system should be performed when system is cool At every interval of periodic maintenance service and when vehicle is raised for other service check exhaust system as follows Check rubber mountings for damage deterioration and out of position Check exhaust system for leakage loose connection dent and damage If bolts or nuts are loosened tighten them to specified torque Refer to Components in this section Check nearby body areas for damaged missing or mispositioned part open seam hole loose connection or any other defect which could permit exhaust fumes to seep into vehicle Make sure that exhaust system components have enough clearance from underbody to avoid overheating and possible damage to passenger compartment car
282. ay Crankshaft thrust play Standard 0 11 0 31 mm 0 0043 0 0122 in Limit 0 35 mm 0 0138 in NOTE After checking the thrust play check for thread deforma tion of each bearing cap No 1 bolt according to previous mentioned Main Bearing Cap No 1 Bolt once again Out of round and taper of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length or both This dif ference if any is determined by taking micrometer readings If any one of journals is badly damaged or if amount of uneven wear in the sense explained above exceeds its limit regrind or replace crankshaft Crankshaft out of round and taper Limit 0 01 mm 0 0004 in Out of round A B Taper a b Main Bearings General information e Service main bearings are available in standard size and 0 25 mm 0 0098 in undersize and each of them has 5 kinds of bearings differing in tolerance 12 6 16 10 ros 16 10 EIX TERE a Ta p jar r SS peg oG o4 nance QOO 20 ENGINE MECHANICAL M13 ENGINE 6A1 83 e Upper half of bearing 1 has an oil groove 2 as shown in figure Install this half with oil groove to cylinder block e Lower half of bearing does not have an oil groove Visual inspection Check bearings for
283. be stop come back at less than 111 C 232 F E19 27 W R A C evaporator thermistor tem perature input Ground to engine Fig B 2 0 2 3 volts 1800 2200 Q Evaporator thermistor temperature at approximately 25 C 77 F with engine running 3 5 3 6 volts 6300 7000 Q Evaporator thermistor temperature at approximately 0 C 32 F with engine running If the temperature is less than approximately 2 5 C 36 5 F com pressor cooling fan should be stop come back at less than approxi mately 4 C 39 2 F AIR CONDITIONING OPTIONAL 1B 21 Refrigerant Recovery Evacuating and Charging WARNING e Your eyes should not be exposed to refrigerant liquid Any liquid HFC 134a R 134a escaping by accident shows a temperature as low as approximately 6 C 21 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 to always wear gog gles Should it occur that HFC 134a R 134a strikes your eyes 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 e Should the HFC 134a R 134a liq
284. ble between two types of A C one using refrigerant HFC 134a R 134a and the other using refrigerant CFC 12 R 12 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 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 service Use of incorrect one will result in leakage of refrigerant damage in parts or other faulty condition e Always wear goggles to protect your eyes e Avoid you direct contact to liquid refrigerant e Do not heat refrigerant container higher than 40 C 104 F e Do not discharge refrigerant into atmosphere e Do not allow liquid refrigerant to touch bright metals Refrigerant combined with moisture is corrosive and will tarnish surfaces of bright metals including chrome AIR CONDITIONING OPTIONAL 1B 31 Condenser Assembly CAUTION Be careful not to damage condenser fins If condenser fin is bent straighten it by using flat head screwdriver or pair of pliers INSPECTION Check the following e Check clog of condenser fins If any clogs are found condenser fins should be washed with water and should be dried with compressed air e Check condenser fins for leakage and breakage If an
285. bolts 4 Remove condenser cooling fan assembly 2 from con denser 3 Remove front bumper INSTALLATION Reverse removal procedure for installation 1B 34 AIR CONDITIONING OPTIONAL Cooling Unit Evaporator CAUTION Be careful not to damage A C evaporator fins If A C evaporator fin is bent straighten A C evaporator fin by using flat head screwdriver or pair of pliers 1 A C evaporator 3 Expansion valve 5 Packing 7 O ring 2 A C evaporator thermistor 4 Evaporator case 6 Air inlet door 8 Door link A C evaporator temperature sensor REMOVAL 1 Disconnect negative cable at battery 2 Recover refrigerant from A C system by referring to Recov ery in this section NOTE The amount of removed compressor oil must be mea sured for replenishing compressor oil AIR CONDITIONING OPTIONAL 1B 35 3 Drain engine coolant and disconnect heater hoses 1 from heater unit 4 Disable air bag system referring to Disabling Air Bag Sys tem in Section 10B if equipped 5 Remove attaching bolt 1 6 Disconnect suction hose 2 and receiver dryer outlet pipe 3 from expansion valve 4 7 Remove instrument panel referring to Instrument Panel in Section 9 8 Remove cooling unit 1 with heater unit 2 from vehicle body 9 Remove cooling unit 1 from heater unit 2 INSPECTION Check the followi
286. bushings so that either face of bushing are aligned with housing edge of leading arm also the length between the aligned side end of bushing and trailing arm 1 are within specification below Specification for trailing arm bushing protrusion a 8 5 10 5 mm 0 33 0 41 in b 6 0 9 0 mm 0 24 0 35 in 2 Install trailing arm 1 to vehicle body and rear axle housing referring to figure for proper installing direction of bolts 3 Remove floor jack 4 Connect wheel speed sensor harness clamps to trailing arm if equipped with ABS 5 Connect parking brake cable clamp to trailing arm 6 Lower hoist and with vehicle in non loaded condition tighten trailing arm nuts to specified torque Tightening torque Trailing arm nuts a 90 N m 9 0 kg m 65 0 Ib ft Rear Axle Shaft and Wheel Bearing REMOVAL 1 Hoist vehicle and remove wheel 2 Remove rear brake drum and disconnect parking brake cable from brake back plate For details refer to Brake back plate in Section 5 3 Drain gear oil from rear axle housing by loosening drain plug REAR SUSPENSION 3E 13 4 Remove wheel speed sensor 4 from rear axle housing if equipped with ABS CAUTION e Do not pull wire harness or twist more than necessary when removing rear wheel speed sensor 4 e Do not cause damage to surface of rear wheel speed sensor 4 or pole piece and do not allow dust etc to
287. cations ee Be sure to bear this in mind when performing service work e EGR valve e Heated oxygen sensor s or CO adjusting resistor e Three way catalytic converter TWC and warm up three way catalytic converter WU TWC Fuel iNj CtOr eee eeecececeeeceeeeeeeeeeeeeeeeeeees 6E 25 Electronic Control System eeeee 6E 29 CONTENTS General Description cccsssseeeeeeeeeeesseeeees 6E 3 Engine control module ECM 6E 29 Air Intake System ccccccccecsesseeceeeeeeeeeeeees 6E 5 Manifold absolute pressure sensor MAP Fuel Delivery System ssec 6E 6 SONSON wish edi reenen aeaaaee evened 6E 29 Fuel PUMpic Midwse es ee eee 6E 6 Throttle position sensor TP sensor 6E 30 Electronic Control SysteM ccccceeceeee 6E 7 Intake air temperature sensor Engine amp emission control input output IAT sensor ETET 6E 31 ele e R E chee ae E ane 6E 8 Engine coolant temperature sensor On Vehicle Service sssseceesesesseeeeeeees 6E 15 a a ais Bectes rosea ange eee 6E 32 eated oxygen sensor Accelerator cable adjustment 6E 15 Idle speed idle air control IAC duty Salone and sensor 2 KEEN 6E 33 INSPECTION ssesssesssssssesssessseerrererernnernnens 6E 15 amona Poe See ree ee eet Idle mixture inspection adjustment Cranksha t position SENSO ee 6E 35 Vehicle speed sensor VSS 06 6E 36 vehicle without heated oxygen sensor 6E 17 Fuel level sen
288. ce motor Wiring or grounding faulty Repair as necessary Incorrect temperature output Control cables broken or binding Check cables Temperature control lever faulty Check control lever Control cable clamp position is faulty Check and adjustment Air damper broken Repair damper Air ducts clogged Repair air ducts Heater radiator leaking or clogged Replace radiator Heater hoses leaking or clogged Replace hoses When mode control lever is changed air outlet port is not changed Control cable broken or binding Check cable Mode control lever faulty Check control lever Control cable clamp position is faulty Check and adjustment Air damper broken Repair damper Air ducts leaking on clogged Repair air ducts Wiring Circuit HEATER WIPER WASHER 1 Heater motor 3 Heater blower motor switch 5 ToECM 7 To 4WD controller or A C controller 2 Fuse box 4 Heater resister 6 To combination switch if equipped 1A 4 HEATER AND VENTILATION On Vehicle Service Heater Blower Motor REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to Disabling Air Bag System in Section 10B 3 Remove column hole cover 4 Disconnect blower motor couplers 5 Remove blower motor 1 INSPECTION
289. ch 09944 78210 Bearing installer support 09917 88210 Valve guide installer attachment 09916 58210 Valve guide installer han dle 09922 55131 Bearing installer 3D 46 FRONT SUSPENSION 09944 66020 Bearing installer 09913 85210 Oil seal installer 09951 16030 Bush remover 09951 26010 Bush remover plate REAR SUSPENSION 3E 1 SECTION 3E REAR SUSPENSION WARNING When hoisting vehicle be sure to select the lifting point suitable for the service work referring to Sec tion OA NOTE e 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 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 e Never attempt to heat quench or straighten any suspension part Replace it with a new part or damage to the part may result CONTENTS General Description 0 cccssseeeeeeeeeeeesseenees 3E 2 On Vehicle Service cccccseseeeeeeeeeeeeeeneees 3E 5 DiaGnoOSiS nia eaaa aea heii ans 3E 3 Rear Shock Absorbet ccecseeeeeeeeees 3E 5 Diagnosis Table ccccceseseeseseeseseeeeen 3E 3 Coll Spring
290. circuits including an electronic control unit such as ECM TCM ABS control module etc it is important to perform careful check starting with items which are easier to check 1 Disconnect negative cable from battery 2 Check each connector at both ends of the circuit being checked for loose connection Also check lock condition of connector if equipped with connector lock oo Using a test male terminal check both terminals of the circuit being checked for contact tension of its female terminal Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is locked in the connector fully 1 Check contact tension by inserting and removing just for once 4 Using the following continuity check or voltage check proce dure check the wire harness for open circuit and poor con nection with its terminals Locate abnormality if any 1 Looseness of crimping 2 Open 3 Thin wire single strand of wire 0A 14 GENERAL INFORMATION ECM Q N Cn CONTINUITY CHECK 1 Measure resistance between connector terminals at both ends of the circuit being checked between A 1 and C 1 in the figure If no continuity is indicated infinity or over limit that means that the circuit is open between terminals A 1 and C 1 2 Disconnect the connector included i
291. ck ccccccccccccccccccccccccececececcccecees 3D 14 Lateral Rod rrera cies hanna cnbanneee eee eteta 3D 35 Leading Arm Bushing Lateral Rod Leading Arm Bushing E E 3D 36 Bushing Check ci ood eo aed 3D 15 Front Axle HOUSING eset 3D 38 Kingpin Kingpin Bearing Check 3D 15 Tightening Torque Specifications 3D 44 Barfield Joint Check cceceeeeeeeeeeeeees 3D 15 Required Service Material csssssse 3D 44 Steering Knuckle Seal Check 0 0 3D 15 Special TOOI sccssssssscssscsssssssssserassssssessensees 3D 45 Wheel Disc Nut and Bearing Check 3D 16 3D 2 FRONT SUSPENSION General Description 1 Front axle housing 3 Steering knuckle 5 Wheel spindle 7 Wheel bearing 2 Shock absorber 4 Kingpin 6 Wheel hub 8 Front axle shaft 4WD 4WD Control System The 4WD control system consists of a 4WD switch a vacuum switch a vacuum tank two vacuum switching valves VSV1 and VSV2 and air locking hub assemblies The 4WD controller controls locking or unlocking of the air locking hub according to operation of the transfer shift control lever Vacuum generated in the intake manifold passes through the check valve and stored in the vacuum tank According to signals from the 4WD switch the 4WD controller activates VSV1 for unlocking or VSV2 for lock ing to apply vacuum from the vacuum tank so that the front axle and the w
292. ck for intermittent switch OFF See Fig 1 referring to Intermittent 2 Turn ignition switch ON and Poor Connection in 3 Check intake air temp displayed on scan Section OA tool Is 40 C 40 F or 119 C 246 F indicated 6 52 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1 Using service wire connect IAT sensor con nector terminals 2 Check intake air temp displayed on scan tool with ignition switch ON See Fig 3 Is 119 C 246 F indicated Step Action Yes No 3 Check Wire Harness Go to Step 5 Lg B wire open or 1 Disconnect IAT sensor connector with igni shorted to power or poor tion switch OFF E19 15 connection 2 Check for proper connection to IAT sensor If wire and connection are at Lg B and B B wire terminals OK substitute a known See Fig 2 good ECM and recheck 3 If OK then with ignition switch ON Is voltage applied to Lg B wire terminal about 4 6V 4 Does scan tool indicate 40 C 40 F at Step Go to Step 6 Go to Step 5 2 5 Check Wire Harness Replace IAT sensor Lg B wire shorted to 1 Check intake air temp displayed on scan ground tool with ignition switch ON If wire is OK substitute a Is 40 C 40 F indicated known good ECM and recheck 6 Check Wire Harness Replace IAT sensor Lg B wire open or poor E19 10 connection If wire and connection are OK substitute a known go
293. cket sub assembly including fuel filter 5 Lead wire 9 Bracket 2 Grommet 6 Fuel level gauge 10 Spacer 3 Tube 7 Fuel pump A B ENGINE FUEL 6C 9 CAUTION e While removing fuel level gauge do not contact resis tor plate 2 or deform arm 3 It may cause fuel level gauge to fail e When removing grommet from fuel tube or bracket sub assembly be very careful not to cause damage to grommet installed section sealed section in bore Should it be damaged replace it with new one or fuel will leak from that part NOTE e When removing fuel level gauge press snap fit part 1 and slide it in the arrow direction as shown in figure e When installing fuel level gauge to housing fit protru sion 4 of fuel level gauge in groove 5 in housing and slide it up till lug 6 fits in window 7 securely Refer to figure shown A Removal B Installation INSTALLATION 1 Clean mating surfaces of fuel pump assembly and fuel tank 2 Install new gasket 2 and plate 3 to fuel pump assembly 1 then install fuel pump assembly to fuel tank Tightening torque Fuel pump assembly bolts a 10 N m 1 0 kg m 7 5 Ib ft 3 Connect wire harness coupler 2 and fuel vapor hose 3 to fuel pump assembly 1 4 Install fuel tank to vehicle Refer to Fuel Tank in this sec tion 6C 10 ENGINE FUEL Tightening Torque Specification Tighteni
294. confirm that MAP sensor is normal and then substitute a known good ECM and recheck 4 Check MAP sensor according to MAP Sensor Lg R wire shorted to QG Replace MAP sensor Individual Check below wire B BI wire open Is it in good condition poor E19 10 connection If wire and connection are OK substitute a known good ECM and recheck NOTE When battery voltage is applied to Lg R wire it is possible that MAP sensor is also faulty A Fig 1 for Step 2 B Fig 2 for Step 3 A B 6 50 ENGINE GENERAL INFORMATION AND DIAGNOSIS MAP Sensor Individual Check 1 Disconnect connector from MAP sensor 1 2 Remove MAP sensor 1 3 Arrange 3 new 1 5 V batteries 2 in series check that total voltage is 4 5 5 0 V and connect its positive terminal to Vin terminal of sensor and negative terminal to Ground terminal Then check voltage between Vout and Ground Also check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump 3 If check result is not satisfactory replace MAP sensor 1 Output voltage When input voltage is 4 5 5 5 V ambient temp 20 30 C 68 86 F ALTITUDE BAROMETRIC OUTPUT Reference PRESSURE VOLTAGE ft m mmHg kPa V 0 0 760 100 3 3 4 3 l l l l 2 000 610 707 94 2 001 611 Under 707 94 3 0 4 1 l l over 634 l 5
295. connection Is continuity indicated 4 1 Check for proper connection to ABS hydrau Substitute a known good Repair ABS warning lic unit control module at terminal A12 ABS hydraulic unit con lamp circuit and A24 trol module assembly and 2 If OK then check ABS warning lamp cir recheck cuit referring to TABLE A B and C Is it in good condition 5E 18 ANTILOCK BRAKE SYSTEM ABS DTC C1015 DTC 15 G Sensor Circuit B W Jt 1 Ignition switch 3 ABS hydraulic unit control module assembly 2 G sensor 4 ABS hydraulic unit control module connector of harness DESCRIPTION While a vehicle is at stop or running if the potential difference between the sensor signal terminal A11 and the sensor ground terminal A13 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 INSPECTION ANTILOCK BRAKE SYSTEM ABS 5E 19 Step Action Yes No 1 Is G sensor installed floor securely Go to step 2 Tighten sensor or bracket screw securely If not use new screw 1 2 3 4 Ignition switch OFF Remove G sensor with bracket Check for proper connection to G sensor If OK then check G sensor
296. converter by HO2S 2 When the catalyst is functioning properly the variation cycle of HO2S 2 output voltage oxygen concentration is slower than that of HO2S 1 output voltage because of the amount of oxygen in the exhaust gas which has been stored in the catalyst REFERENCE A 0 5 V Div 2 sec Div i it 1 I 1 i 3 lt 2 gt 1 1 3 1 Engine running at closed loop 2 Fuel cut 3 Idle after fuel cut A Oscilloscope waveforms condition ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 89 DTC DETECTING CONDITION POSSIBLE CAUSE e While vehicle running at constant speed under other than e Exhaust gas leak high load e Three way catalytic converter malfunction e Time from rich or lean switching command is output till HO2S e Fuel system malfunction 2 output voltage crosses 0 45 V less than specified value e HO2S 2 malfunction 2 driving cycle detection logic monitoring once 1 driving e HO2S 1 malfunction DTC CONFIRMATION PROCEDURE WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester on a level road 1 Turn ignition switch OFF Clear DTC with ignition switch ON check vehicle and environmental condition for Altitude barometric pressure 2400 m
297. coolant temperature has risen by at least 22 C 40 F from engine starting and reaches a minimum temperature of 70 C 160 F A 1 Trouble Code 2 Engine Speed 3 Eng Cool Tmp 4 Vehicle Spd 5 MAP Sensor 6 St Term FT1 7 Ug Term FT1 8 Fuel 1 Stat 9 Fuel 2 Stat 10 Load value P0102 1st 782 RPM 80 C 0 km h 39kPa 0 8 Lean 1 6 Lean Closed Loop Not used 25 5 B ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 7 DRIVING CYCLE A Driving Cycle consists of engine startup and engine shutoff 2 DRIVING CYCLES DETECTION LOGIC The malfunction detected in the first driving cycle is stored in ECM memory in the form of pending DTC and freeze frame data but the malfunction 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 stores the engine and driving conditions in the from of data as shown in the figure at the moment of the detection of a mal function 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
298. cope 2 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 A C condenser fan control system SYSTEM INSPECTION WARNING Keep hands tools and clothing away from A C con denser 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 posi tion Check system for operation referring to Flow Table B 7 in Sec tion 6 If A C condenser fan fails to operate properly check relay A C condenser fan and electrical circuit A C condenser fan INSPECTION 1 Check continuity between each two terminals If there is no continuity replace A C condenser fan motor MISSION CONTROL SYSTEM 6E 38 ENGINE AND E H C HT TEMP lr F EGR 2 Connect battery 3 to A C condenser fan motor coupler 2 as shown in figure then check that the A C condenser fan motor 1 operates smoothly If A C condenser fan motor does not operate smoothly replace motor Reference current data of A C condenser fan motor Approx 6 7 8 3 A at 12 V Output signals of throttle valve opening and engine coolant temp Vehicle w
299. ction e Malfunctioning EGR valve if equipped EGR system in Section 6E e Maladjusted accelerator cable play Accelerator cable adjustment in Sec tion 6E Low compression Previously outlined e Dragging brakes Diagnosis table in Section 5 e Slipping clutch Diagnosis table in Section 7C Improper engine idling or engine fails to idle e Faulty ignition coil Ignition coil assembly in Section 6F Engine overheating Refer to Overheating of this table e Fuel pressure out of specification Diagnostic Flow Table B 3 e Faulty idle air control system Diagnostic Flow Table B 4 e Faulty evaporative emission control sys tem EVAP control system in Section 6E e Faulty injector Diagnostic Flow Table B 1 e Faulty ECT sensor TP sensor or MAP sensor ECT sensor TP sensor or MAP sen sor in Section 6E e Malfunctioning PCV system PCV system in Section 6F e Faulty ECM Inspection of ECM and its circuit in this section e Faulty EGR system if equipped EGR system in Section 6E Low compression Previously outlined Engine hesitates Momentary lack of response as the accel erator is depressed Can occur at all vehicle speeds Usually most severe when first trying to make the vehicle move as from a stop sign e Faulty ignition coil Ignition coil assembly in Section 6F Engine overheating Refer to Over
300. ction Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 1 Disconnect HO2S 1 coupler with ignition switch OFF 2 Check for proper connection to HO2S 1 at B W and P B wire terminals 3 If OK then check heater resistance See Fig 2 Is it5 6 4 Q at 20 C 68 F shorted to ground or poor connection at E19 7 If wire and connection are OK substitute a known good ECM and recheck 2 _ Check Heater for Operation Intermittent trouble Check Go to Step 3 1 Check voltage at terminal E19 7 See Fig 1 for intermittent referring to 2 Warm up engine to normal operating tem __ Intermittent and Poor perature Connection in Section 3 Stop engine OA 4 Turn ignition switch ON and Check voltage at terminal E19 7 See Fig 1 Voltage should be over 10 V 5 Start engine run it at idle and check voltage at the same terminal Voltage should be below 1 9 V Are check results are specified 3 Check Heater of Sensor 1 P B wire open or Replace HO2S 1 A Fig 1 for Step 2 B Fig 2 for Step 3 A B 6 64 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0136 Heated Oxygen Sensor HO2S Circuit Malfunction Sensor 2 CIRCUIT DESCRIPTION B BI E18 13 ECM 831P 1 __ 4P LI
301. d according to conditions characteristic of each market 6 14 ENGINE GENERAL INFORMATION AND DIAGNOSIS Malfunction indicator lamp MIL check 1 Turn ON ignition switch but the engine at stop and check that MIL lights If MIL does not light up or MIL dims go to Diagnostic Flow Table A 1 for troubleshooting If MIL flushes go to Diagnostic Flow Table A 3 for trouble shooting vehicle without immobilizer indicator lamp 2 Start engine and check that MIL turns OFF If MIL remains ON and no DTC is stored in ECM go to Diagnostic Flow Table A 2 for troubleshooting Diagnostic trouble code DTC check Using SUZUKI Scan Tool 1 Prepare SUZUKI scan tool ane 2 With ignition switch OFF connect it to data link connector mae f 7 o o DLC 1 located on underside of instrument panel at drivers seat side Special tool A SUZUKI scan tool 3 Turn ignition switch ON and confirm that MIL lights 4 Read DTC pending DTC and freeze frame data according to instructions displayed on scan tool and print it or write it down Refer to scan tool operators manual for further details If communication between scan tool and ECM is not possi ble check if scan tool is communicable by connecting it to ECM in another vehicle If communication is possible in this case scan tool is in good condition Then check data link connector and serial data line circuit in the vehicle w
302. d by slow cranking or indicator clear with red dot can be caused by one or more of the following condi tions even though indicator lamp may be operating normal Following procedure also applies to cars with voltmeter and ammeter 1 Make sure that undercharged condition has not been caused by accessories left on for extended period of time 2 Check drive belt for proper tension 3 If battery defect is suspected refer to BATTERY section 4 Inspect wiring for defects Check all connections for tight ness and cleanliness battery cable connections at battery starting motor and ignition ground cable lt 5 Connect voltmeter and ammeter as shown in the figure NOTE Use fully charged battery Generator Ammeter between generator B terminal and battery terminal Voltmeter between generator B terminal and ground Battery Load Switch ojala rm a 6 Measure current and voltage No load Check 1 Run engine from idling up to 2 000 rpm and read meters NOTE Turn off switches of all accessories wiper heater etc Standard current 10 A maximum Standard voltage 14 4 15 0 V at 20 C 68 F NOTE Consideration should be taken that voltage will differ somewhat with regulator case temperature as shown in the graph Higher Voltage If voltage is higher than standard value check ground of brushes If brushes are not grounded replace IC regulator Lower V
303. d end lock nuts temporarily by finger Tie rod and drag rod length Tie rod length a 1132 mm 44 6 in Drag rod length a 864 5 mm 34 0 in NOTE Make the length b of right and left tie rod end the same 3 Align lock nut 3 with mark on tie rod thread and connect tie rod end to knuckle and or pitman arm Tighten new nut 1 to specified torque NOTE To prevent ball stud from being rotated while tightening tie rod end nut 1 tighten Nut M12 x 1 25 to about 20 N m 2 0 kg m 14 5 Ib ft and remove it Then tighten new nut 1 to specified torque Tightening torque Tie rod end nut a 43 N m 4 3 kg m 31 5 Ib ft 4 Inspect for proper toe and steering angle inside amp outside Refer to Preliminary Checks Prior To Adjusting Front Align ment in Section 3A Adjust tie rod 2 and drag rod length as required if neces sary 5 After confirming proper toe tighten tie rod end lock nut 3 to specified torque Tightening torque Tie rod end lock nut b 65 N m 6 5 kg m 47 0 Ib ft 6 Tighten wheel nuts to specified torque and lower hoist 3B 10 STEERING GEAR BOX MANUAL TYPE AND LINKAGE Tightening Torque Specifications Tightening torque Fastening part Nem kamm b fit Steering gear box oil plug 4 0 4 3 0 Steering gear box adjusting bolt lock nut 30 3 0 22 0 Pitman arm mounting nut 135 13 5 98 0 Steering shaft j
304. d surfaces ANTILOCK BRAKE SYSTEM ABS 5E 31 3 Disconnect ABS hydraulic unit control module assembly connector 1 by pulling up lock 4 Remove ABS hydraulic unit control module assembly with its bracket 2 Lock position 3 Unlock position 5 Remove three bolts 3 and take out ABS hydraulic unit control module assembly 1 from bracket 2 CAUTION e Do not give an impact to hydraulic unit e Use care not to allow dust to enter hydraulic unit e 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 by reversing removal procedure Tightening torque Brake pipe flare nuts a 16 N m 1 6 kg m 12 0 Ib ft ABS hydraulic unit control module assembly bracket bolts b 11 N m 1 1 kg m 8 0 Ib ft ABS hydraulic unit control module assembly bolts c 9 N m 0 9 kg m 6 5 Ib ft 2 Bleed air from brake system referring to Air Bleeding of Brake System in Section 5 3 Check each installed part for fluid leakage and perform hydraulic unit operation check To left front To right front To rear AJ oj N From proportioning valve 5E 32 ANTILOCK BRAKE SYSTEM ABS Front Wheel Speed Sensor 1 Front wheel speed sensor 3 Knuckle 2 Sensor ring
305. der disassembled parts for wear cracks cor rosion or damage NOTE Clean wheel cylinder components with brake fluid 5 34 BRAKES INSTALLATION 1 Apply sealant to wheel cylinder Then take off bleeder plug cap from brake pipe and connect pipe for pipes 3 to wheel cylinder just enough to prevent fluid from leaking A Sealant 99000 31090 2 Tighten wheel cylinder to brake back plate 1 to specified torque 3 Torque flare nut or nuts 2 of brake pipe which was con nected in step 1 to specification Tightening torque Wheel cylinder mounting bolts a 9 N m 0 9 kg m 6 5 Ib ft Brake pipe flare nut b 16 N m 1 6 kg m 11 5 Ib ft 4 Wheel cylinder bolts 4 Install breather plug cap taken off from pipe back to breather plug 5 For procedure hereafter refer to Brake Shoe in this sec tion NOTE Be sure to bleed brake system Brake back plate REMOVAL 1 Remove brake drum referring to Brake Drum in this sec tion 2 Remove brake shoe referring to Brake Shoe in this section 3 Remove wheel cylinder referring to Wheel Cylinder in this section 4 Drain rear differential gear oil 5 Remove cable from brake back plate 2 by squeezing park ing brake cable stopper ring 1 6 Remove brake back plate nuts 3 from rear axle housing BRAKES 5 35 7 Using special tools draw out rear axle shaft with brake back pla
306. disconnect special tool Vacuum gauge from intake manifold 7 Install cap to intake manifold ENGINE MECHANICAL M13 ENGINE 6A1 7 Oil Pressure Check NOTE Prior to checking oil pressure check the following items e Oil level in oil pan If oil level is low add oil up to Full level mark hole 1 on oil level gauge 2 Low level mark hole Oil quality If oil is discolored or deteriorated change it For particular oil to be used refer to the table in Section OB e Oil leaks If leak is found repair it 1 Disconnect oil pressure switch coupler 1 and remove oil pressure switch 2 from cylinder block 2 Install special tools Oil pressure gauge to vacated threaded hole Special tool A 09915 77310 B 09915 78211 3 Start engine and warm it up to normal operating tempera ture NOTE Be sure to place transmission gear shift lever in Neu tral shift selector lever to P range for A T model and set parking brake and block drive wheels 4 After warming up raise engine speed to 4 000 rom and mea sure oil pressure Oil pressure specification 280 430 kPa 2 8 4 3 kg cm 39 8 61 1 psi at 4 000 rpm 5 Stop engine and remove oil pressure gauge and attachment 6A1 8 ENGINE MECHANICAL M13 ENGINE 6 Before reinstalling oil pressure switch 2 be sure to wrap its screw threads with sealing tape 1
307. dy 3 Tighten IAC valve screws to specified torque Tightening torque IAC valve screws a 3 5 N m 0 35 kg m 2 5 Ib ft 3 Install throttle body to intake manifold referring to Throttle Body in this section for installation 6E 22 ENGINE AND EMISSION CONTROL SYSTEM Fuel Delivery System Fuel pressure inspection WARNING Be sure to perform work in a well ventilated area and away from any open flames or there is a risk of a fire breaking out 1 Relieve fuel pressure in fuel feed line referring to Fuel Pres sure Relief Procedure in Section 6 2 Disconnect fuel feed hose from fuel delivery pipe CAUTION A small amount of fuel may be released when fuel hose is disconnected Place container under the joint with a shop cloth so that released fuel is caught in container or absorbed in cloth Place that cloth in an approved con tainer 3 Connect special tools and hose between fuel delivery pipe 1 and fuel feed hose 2 as shown in figure and clamp hoses securely to ensure no leaks occur during checking Special tool A 09912 58442 B 09912 58432 C 09912 58490 3 Fuel return pipe 4 Check that battery voltage is above 11 V 5 Turn ignition switch ON to operate fuel pump and after 2 sec onds turn it OFF Repeat this 3 or 4 times and then check fuel pressure Fuel pressure specification CONDITION FUEL PRESSURE Wi
308. e Clean or replace Condenser cooling fan malfunction Insufficient cooling of condenser Check condenser cooling fan Dirty or bent condenser fins Insufficient cooling of condenser Clean or repair Compressor malfunction Insufficient oil etc Check compressor Engine overheat Check engine cooling system refer ring to Section 6B Pressure is lower than acceptable range B area Insufficient refrigerant Insufficient charge or leakage Check for leakage repair if neces sary and recharge Expansion valve malfunction valve opens too wide Check expansion valve Compressor malfunction Insufficient compres sion Check compressor LOW PRESSURE GAUGE Condition Possible Cause Correction Pressure is higher than acceptable range C area Expansion valve malfunction valve opens too wide Check expansion valve Compressor malfunction Insufficient compres sion Check compressor Pressure is lower than acceptable range D area Insufficient refrigerant Insufficient charge or leakage Check for leakage repair if neces sary and recharge Expansion valve malfunction valve opens too narrow Check expansion valve Clogged refrigerant passage crashed pipe Repair or replace AIR CONDITIONING OPTIONAL 1B 13 CROSSING POINT OF CENTER VENTILATION LOUVER TEMPERATURE AND RECIRCULATION AIR
309. e cracks fuel leakage corrosion and tank bolts looseness If a problem is found repair or replace Emission Control System Crankcase Ventilation Hoses and Connections INSPECTION Refer to PCV Positive Crankcase Ventilation Valve in this sec tion MAINTENANCE AND LUBRICATION OB 11 PCV Positive Crankcase Ventilation Valve INSPECTION Check crankcase ventilation hose and PCV hose for leaks cracks or clog and PCV valve for stick or clog Refer to PCV System of Section 6E for PCV valve checking procedure Fuel Evaporative Emission Control System INSPECTION 1 Visually inspect hoses for cracks damage or excessive bends Inspect all clamps for damage and proper position 2 Check EVAP canister for operation and clog referring to Evaporative Emission EVAP Control System in Section 6E If a malfunction is found repair or replace Chassis and Body Clutch INSPECTION Check clutch pedal for height and free travel 1 referring to Main tenance Service in Section 7C Adjust or correct if necessary Brake Discs and Pads INSPECTION 1 Remove wheel and caliper but don t disconnect brake hose from caliper 2 Check front disc brake pads and discs for excessive wear damage and deflection Replace parts as necessary For details refer to Brake Pad and Brake Disc in Section 5 Be sure to torque caliper pin bolts to specification 0B 12 MAINTENANCE
310. e personal injury may result e 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 disposal e 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 e After an air bag inflator module has been deployed the surface of the air bag may contain a powdery resi due This powder consists primarily of cornstarch used to lubricate the bag as it inflates and by prod ucts of the chemical reaction As with many service procedures gloves and safety glasses should be worn A Always Carry Air Bag Inflator Module With Trim Cover Air Bag Opening Away from Body B Always Place Air Bag Inflator Module On Workbench With Trim Cover Air Bag Opening Up Away From Loose Objects GENERAL INFORMATION 0A 5 WARNING SDM e During service procedures be very careful when handling a Sensing and Diagnostic Module SDM Never strike or jar the 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 attac
311. e vehicle with A T and exhaust gas leakage at each connection ENGINE MECHANICAL M13 ENGINE 6A1 79 Main Bearings Crankshaft and Cylinder Block sc 15 8 70 N m 7 0 kg m CB 11 N m 1 1 kg m 17 W 22 N m 2 2 kg m WU Q Tightening torque 4 Venturi plug 12 Input shaft bearing x lt Do not reuse 5 Main bearing 13 Flywheel Apply engine oil to inside sliding 6 Sensor plate 14 Main bearing cap 2 surface a 3mm 0 12 in 7 Crankshaft timing sprocket key 15 Flywheel mounting bolt Apply sealant 99000 31110 to thread part b 2mm 0 08 in 8 Crankshaft 16 Rear oil seal housing mounting bolt 1 CKP sensor if equipped 9 Thrust bearing 17 Main bearing cap No 2 bolt 2 Knock sensor 10 Rear oil seal housing 18 Main bearing cap No 1 bolt Apply specified amount A of seal 1 Tighten all bolts to 50 N m 5 0 kg m ant 99000 31150 to mating surface 2 Then turn all bolts to 60 3 Cylinder block 11 Rear oil seal 6A1 80 ENGINE MECHANICAL M13 ENGINE 3 13 14 4 17 7 19 9 15 5 Sees 0 to lt N 1 he FANN o yp oe 18 8 20 10 6 16 eyageteues 1 11 12 2 REMOVAL 1 2 Remove engine assembly from vehicle as previously out lin
312. e 17 Magnet 24 Spindle 4 4WD switch 11 Vacuum tank 18 Housing 25 Front axle shaft 5 A C switch if equipped 12 VSV1 19 Spring 26 To opposite side 6 Vacuum switch 13 VSV2 20 Diaphragm 27 A C controller 7 A C cut signal if equipped 14 Outer gear 21 Sleeve A Vacuum circuit 4WD 2WD FRONT SUSPENSION 3D 7 When the transfer shift control lever is shifted from the 4WD 4H or 4L to the 2WD 2H position the 4WD con troller activates VSV1 and the intake manifold vacuum is applied to the chamber A in the hub housing As the slide gear is shifted to the wheel side by the vacuum force and disengaged from the outer gear rotation of the front wheel hub is not transmitted to the front axle shaft 1 EPI amp A C controller 8 Engine speed signal 15 Chamber A 22 Slide gear 2 4WD controller 9 Intake manifold 16 Piston A 23 Wheel hub 3 4WD indicator lamp 10 Check valve 17 Magnet 24 Spindle 4 4WD switch 11 Vacuum tank 18 Housing 25 Front axle shaft 5 A C switch if equipped 12 VSV1 19 Spring 26 To opposite side 6 Vacuum switch 13 VSV2 20 Diaphragm 27 A C controller 7 A C cut signal if equipped 14 Outer gear 21 Sleeve A Vacuum circuit 3D 8 FRONT SUSPENSION Diagnosis Table Diagnosis For description not found in the table below refer to Diagnosis Table in Section 3 4WD CONTROL SYSTEM Condition Possible Cause
313. e 2 Flexible hose 9 P valve V ViewV 3 Hose washer 10 Hose bracket W ViewW 4 Hose bolt 11 To front right brake caliper BRAKES 5 49 For right hand steering vehicle V F i6 N m 1 6 kg m W F 23 Nm x 4 F 23 Nm 2 3 kg m y Lf gt 4 eae B16 N m 2 1 6 kg m lt RA oa H T i6 N m 1 6 kg Ura DA EO 8 25 N m 2 5 kg m II LP a b c d Zz A For vehicle without ABS X View X 5 Brake caliper 12 To front left brake caliper B For vehicle with ABS Y View Y 6 4 way joint 13 To rear brake F Frontside Z ViewZ 7 5 way joint 14 Front brake master cylinder R Right side 1 E ring 8 ABS hydraulic unit a f Clamp T Top side 2 Flexible hose 9 P valve m Tightening torque V ViewV 3 Hose washer 10 Hose bracket W ViewW 4 Hose bolt 11 To front right brake caliper 5 50 BRAKES REMOVAL 1 Raise suitably support vehicle Remove wheel if necessary 2 Clean dirt and foreign material from both hose end or pipe end fittings Remove brake hose and pipe INSTALLATION 1 Install brake hose and pipe by reversing removal procedure noting the following points 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 a
314. e NOTE in ECM Terminal Voltage Values Table for applicable model INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check Fuel Pump Control System for Opera Fuel pump circuit is in Go to Step 3 tion See Fig 1 good condition Is fuel pump heard to operate for 2 sec after ignition switch ON 3 Check Fuel Pump for Operation Go to Step 4 P B or BI B circuit 1 Remove fuel pump relay from relay box with open or fuel pump mal ignition switch OFF function 2 Check for proper connection to relay at each terminals 3 If OK using service wire connect terminals A and B of relay connector See Fig 2 and CAUTION Is fuel pump heard to operate at ignition switch ON ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 111 Step Action Yes No 4 Check Fuel Pump Relay for Operation W G circuit open or poor Replace fuel pump 1 Check resistance between each two termi E18 19 connection relay nals of fuel pump relay See Fig 3 If wire and connection are Fuel pump relay resistance OK substitute a known Between terminals A and B Infinity good ECM and recheck Between terminals C and D 100 150 Q 2 Check that there is continuity between ter minals A and B when battery is con nected to terminals C and D See Fig
315. e S G 1 28 when fully charged at 20 C 68 F Generator Type 70 A type Rated voltage 12 V Nominal output 70A Permissible max speed 18 000 r min No load speed 1 300 r min rpm Setting voltage 14 4 to 15 0 V Permissible ambient temperature 30 to 90 C 22 to 194 F Polarity Negative ground Rotation Clockwise viewed from pulley side Tightening Torque Specification Tightening torque Fastening part Nem komi b t Body ground bolt 8 0 8 6 0 Generator mounting bolts 23 2 3 16 5 B terminal inner nut 4 2 0 42 3 0 B terminal outer nut 8 0 8 6 0 Pulley nut 118 11 8 85 5 Rear end frame nuts 45 0 45 35 Rear end cover nuts Rectifier B bolt 3 9 0 39 3 0 Stator stud bolts 8 8 0 88 6 5 Drive end bearing plate screws 2 6 0 26 2 0 Rectifier screws 2 2 1 Regulator and brush holder screws 2 Qay Terminal plate bolt 3 8 0 38 3 0 6H 18 CHARGING SYSTEM EXHAUST SYSTEM 6K 1 SECTION 6K EXHAUST SYSTEM CONTENTS General Description cccccssseecceeeeeseeseeeees 6K 1 On Vehicle Service s eccccceeeeeeeeeeeeeeeeeeeee 6K 2 Maintenance i iu sieniin iania 6K 1 Exhaust Manifold cccccceceeeeeteeeeeeeees 6K 2 EXMAUSE PIPE t ngeret e nies 6K 2 NOTE Whether following parts are used in the particular vehicle or not depends on specification Be sure to bear this in mind when performing service work e Three Way Catalytic Converter TWC General Description The exh
316. e air bag system component parts directly to hot air drying or baking the vehicle after painting or flames e WARNING CAUTION labels are attached on each part of air bag system components Be sure to follow the instructions e After vehicle is completely repaired perform Air Bag Diagnostic System Check in Section 10B GENERAL INFORMATION 0A 7 General Precautions The WARNING and CAUTION below describe some general precautions that you should observe when servic ing a vehicle These general precautions apply to many of the service procedures described in this manual and they will not necessarily be repeated with each procedure to which they apply WARNING e Whenever raising a vehicle for service be sure to follow the instructions under Vehicle Lifting Points in this section e When it is necessary to do service work with the engine running make sure that the parking brake is set fully and the transmission is in Neutral for manual transmission vehicles or Park for auto matic transmission vehicles Keep hands hair clothing tools etc away from the fan and belts when the engine is running e When it is necessary to run the engine indoors make sure that the exhaust gas is forced outdoors e Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system When working with toxic or flammable materials such as gasoline and refriger ant make sure that the a
317. e and surface plate to check each spring for skewness in terms of clearance between end of valve spring and square Valve springs found to exhibit a larger clearance than limit given below must be replaced Valve spring skewness Limit 1 6 mm 0 063 in ASSEMBLY 1 Before installing valve guide into cylinder head ream guide hole with special tool 10 5 mm reamer so as to remove burrs and make it truly round Special tool A 09916 34542 B 09916 37320 6A1 58 ENGINE MECHANICAL M13 ENGINE 2 Install valve guide to cylinder head Heat cylinder head uniformly to a temperature of 80 to 100 C 176 to 212 F so that head will not be distorted and drive new valve guide into hole with special tools Drive in new valve guide until special tool Valve guide installer con tacts cylinder head After installing make sure that valve guide protrudes by specified dimension a from cylinder head Special tool A 09916 58210 B 09916 56011 NOTE e Do not reuse once disassembled valve guide Make sure to install new valve guide e Intake and exhaust valve guides are identical Specification for valve guide protrusion a Intake and exhaust sides 11 3 mm 0 44 in 3 Ream valve guide bore with special tool 5 5 mm reamer After reaming clean bore Special tool A 09916 34542 B 09916 34550 4 Install valve spring seat to cylinder head 5 Install
318. e attaching nuts 6 and then booster as shown Steering column 2 Push rod clevis 5 Clip 2 INSTALLATION NOTE See NOTE at the beginning of this section Check length of push rod clevis and adjust clearance between booster piston rod and master cylinder pis ton Refer to Brake Booster Inspection and Adjust ment in this section Apply silicone grease to master cylinder piston Install booster to dash panel as shown Then connect booster push rod clevis 2 to pedal arm 3 with clevis pin 4 and clip 5 Tighter booster attaching nuts to the specified torque Tightening torque Booster nuts a 13 N m 1 3 kg m 9 5 Ib ft 3 Connect brake vacuum hose to brake booster 4 Install master cylinder referring to Master Cylinder in this section 1 Steering column Inspection and adjustment INSTALLATION POSITION OF PUSH ROD Install push rod clevis 1 so that measurement a is obtained and torque nut 2 to specification Tightening torque Booster clevis nut a 25 N m 2 5 kg m 18 0 Ib ft Distance a between center of booster clevis pin hole and booster surface Standard 126 1 127 1 mm 4 96 5 00 in BRAKES 5 47 CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON The length of booster piston rod 1 is adjusted to provide speci fied clearance a betwe
319. e battery volt age confirm that it is 11 V or more when ignition switch is ON 1 E E19 31P E18 24P E17 17P olelz7 e sl4fa eli ile s 4 s 214 ilels 4 3 2 1 21 20 ji 18 17 16 Jis 14 13 pie Ju pio he his 1413 12 41 10 9 8 i 12 11 10 9 8 7 31 30 29 2s 27 26 25 24 2s 22 24 2 22 21 20 19 18 17 whel 1s 44 13 1 ECM 2 ECM connectors Viewed from harness side 6 34 ENGINE GENERAL INFORMATION AND DIAGNOSIS ECM TERMINAL VOLTAGE VALUES TABLE For TYPE A See NOTE NOTE e Type A is other than follows e Type B is left hand steering vehicle equipped with fasten seat belt light and EGR valve or right hand steering vehicle equipped with fasten seat belt light and immobilizer control system TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 1 Ground 7 2 Ground T 3 Ground 4 EVAP canister purge valve 10 14V_ Ignition switch ON While engine running at idle speed turn 5 Power steering pressure switch 0 1 3V_ steering wheel to right or left as far as it if equipped stops 10 14V Ignition switch ON b nalawieecreiaive 0 13V At specified idle speed after engine
320. e cable to battery RESISTANCE 2 21 2 69 for reference 0 322 32 20 40 60 80 C 68 104 140 176 F TEMPERATURE ENGINE AND EMISSION CONTROL SYSTEM 6E 31 Intake air temperature sensor IAT sensor REMOVAL 1 Disconnect battery negative cable at battery 2 Disconnect connector from IAT sensor 1 3 Remove IAT sensor 1 from air cleaner case 2 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 left figure replace IAT sensor INSTALLATION Reverse removal procedure noting the following e Clean mating surfaces of IAT sensor and air cleaner case e Connect IAT sensor connector 1 securely 6E 32 ENGINE AND EMISSION CONTROL SYSTEM Engine coolant temperature sensor ECT sensor REMOVAL 1 Disconnect battery negative cable at battery 2 Drain coolant referring to Step 6 of Cooling System Flush and Refill in Section 6B WARNING To help avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pres sure if cap is taken off too soon 3 Disconnect connector from ECT sensor 4 Remove ECT sensor 1 from water outlet cap INSPECTION
321. e 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 filter properly it is important to accurately identify the position at which filter O ring first contacts the mounting surface 5 Tighten the filter 1 3 4 turn from the point of contact with the mounting surface using an oil filter wrench 2 Tightening torque b 14 N m 1 4 kg m 10 5 Ib ft for reference 0B 8 MAINTENANCE AND LUBRICATION A eC F 4 30 20 22 10W 40 10W 50 4 10 10W 30 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 SJ or SL grade Select the appropriate oil viscosity according to the proper engine oil viscosity chart A Engine oil specification Oil pan capacity About 3 8 liters 8 0 6 7 US Imp pt Oil filter capacity About 0 2 liters 0 4 0 3 US Imp pt Others About 0 3 liters Total 0 6 0 5 US Imp pt 9 1 7 6 US Imp pt a About 4 3 liters NOTE Engine oil capacity is specified However note that the amount of oil required when actually changing oil may somewhat differ
322. e 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 replace ment part of lesser quality or substitute design Torque values must be used as specified during reas sembly 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 scccscssseeseessseeesseeeeees 3F 2 Wheel and Tire cccccceecceeeeeeeeeeeeeeeeetauees 3F 6 MS E ec ct Sat state cae E A 3F 2 Studs Renn enone ne oar Ponte a a 3F 6 WHE6lSexctccnctes eset eee Coes eae 3F 2 Matched tires and wheels Replacement Tires s ni 3F 2 For vehicle equipped with steel Replacement Wheels c cccccceeeeees 3F 3 WhOGIS essaveti steeds E EE 3F 6 How To Measure Wheel Runout 3F 3 Inflation Of Tires wo cceeeccccsseeeeeeeeeeeeeeeeeeees 3F 6 Metric Lug Nuts and Wheel Studs 3F 3 Tire platar sis ccvcuss tates ssseesateiactetessenenties snore 3F 7 DI AGMOSIS wiseiscasdsasnciissdanavsinnlshssseatacstnactunetadieeies 3F 4 Tire rotation es eeeeee ees tees teste eeseeseseeneseenens 3F 7 Diagnosis Table sccsssssesssssessssseessseeesseees 3F 4 On Vehicle Service ssssssssesesseessseeesneesnsee 3F 8 Balancing Wheels ccccccccesecsecseeeeeeneens 3F 4 Whee lori aa aeaa eeens 3F 8 Gene
323. e 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 e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE The link mechanism of the heater varies depending on the specifications CONTENTS General Description 0 cccsssseeeeeeeeseeseeeeees 1A 2 Heater Blower Motor c ccscccecceeeeeeeeeeees 1A 4 DIAGMOSIS henares riaa iniiis 1A 3 Heater Blower Resistor 0 eee 1A 5 Diagnosis Table o c cccccsesseesseesssesseeeses 1A 3 Heater Control Lever Assembly 1 1A 5 Wiring Circuit sess uses den akacte Ace 1A 3 Heater Blower Fan Switch
324. e to check oil seal during disassembly check its lip for wear If oil leakage or worn lip is found replace defective oil seal Bump Stopper and Spring Rubber Seat Check Inspect for wear and breakage If found defective replace Wheel Disc Nut and Bearing Check e Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced e Check wheel hub nuts for tightness and as necessary retighten to specification Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft REAR SUSPENSION 3E 5 Check wheel bearings for wear When measuring thrust play apply a dial gauge to axle shaft center after removing wheel center cap from wheel disc When measurement exceeds limit replace bearing Rear wheel bearing thrust play limit 0 8 mm 0 03 in e By rotating wheel actually check wheel bearing for noise and smooth rotation If it is defective replace bearing On Vehicle Service Rear Shock Absorber WARNING When discarding shock absorber be sure to refer to instructions in Rear Shock Absorber Check in this section for proper procedure as it is gas sealed type The shock absorber is non adjustable non refillable and cannot be disassembled The only service the shock absorber requires is replacement when it has lost its resistance is damaged or leaking fluid REMOVAL 1 Hoist vehicle 2 Support rear axle housing 1 by using floor
325. each step Step Action Yes No 1 Customer Complaint Analysis Go to Step 2 Perform cus 1 Perform customer complaint analysis referring to the tomer complaint followings analysis Was customer complaint analysis performed 2 Diagnostic Trouble Code DTC and Freeze Frame Data Print DTC and freeze Go to Step 4 Check Record and Clearance frame data or write them 1 Check for DTC including pending DTC referring to the down and clear them by followings referring to DTC Clear Is there any DTC s ance section Go to Step 3 3 Visual Inspection Repair or replace mal Go to Step 5 1 Perform visual inspection referring to the followings function part Is there any faulty condition Go to Step 11 4 Visual Inspection Go to Step 8 1 Perform visual inspection referring to the followings Is there any faulty condition 5 Trouble Symptom Confirmation Go to Step 6 Go to Step 7 1 Confirm trouble symptom referring to the followings Is trouble symptom identified 6 Rechecking and Record of DTC Freeze Frame Data Go to Step 9 Go to Step 8 1 Recheck for DTC and freeze frame data referring to DTC Check section Is there any DTC s 7 Rechecking and Record of DTC Freeze Frame Data Go to Step 10 1 Recheck for DTC and freeze frame data referring to DTC Check section Is there any DTC s 8 Engine Basic Inspection and Engine Diagnosis Table Go to Step 11 Check and 1
326. eater Unit Boost Ventilation REMOVAL 1 Disconnect negative cable at battery 2 If equipped with air bag system disable air bag system Refer to Disabling Air Bag System in Section 10B 3 Drain engine coolant and disconnect water hoses 1 from heater unit 4 Remove instrument panel 5 Remove bolts nuts and screws as shown figure 6 Remove heater unit 1 INSTALLATION Install heater unit by reversing removal procedure noting the fol lowing items When installing each part be careful not to catch any cable or wiring harness Adjust control cable refer to heater control lever assembly in this section Fill engine coolant to radiator If equipped with air bag system enable air bag system Refer to Enabling Air Bag System in Section 10B 1A 8 HEATER AND VENTILATION CAUTION When the heater unit is disassembled and reassembled locking force of the heater case lock may reduce In such a case tighten the heater case with a tapping screw of M4xL16 1 as shown in the figure or air may leak from its joint section AIR CONDITIONING OPTIONAL 1B 1 SECTION 1B AIR CONDITIONING OPTIONAL WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General De
327. ecaution on fuel system service e Work must be done with no smoking in a well ventilated area and away from any open flames e As fuel feed line between fuel pump and fuel delivery pipe 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 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 e Never run engine with fuel pump relay disconnected when engine and exhaust system are hot e Fuel or fuel vapor hose connection varies with each type of pipe When reconnecting fuel or fuel vapor hose be sure to connect and clamp each hose correctly referring to the figure i Hose Connection After connecting make sure that it has no twist or kink pe COL apg 2 A With short pipe fit hose as far as it reaches pipe joint as shown B With following type pipe fit hose as far as its peripheral projection as shown C With bent pipe fit hose as its bent part as shown or till pipe is about 20 to 30 mm 0 79 1 18 in into the hose D
328. ecification FRONT SUSPENSION 3D 21 5 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft 6 Lower hoist 7 Confirm front end wheel alignment referring to Prelimi nary Checks Prior to Adjusting Front Alignment in Section 3A Bump Stopper and Spring Upper Seat REMOVAL 1 Remove coil spring refer to Coil Spring in this section 2 Remove bump stopper and spring upper seat INSTALLATION 1 Install bump stopper 1 and spring upper seat 2 NOTE Before installing bump stopper 1 apply soap water on it 2 Install coil spring refer to Coil Spring in this section Wheel Hub Bearing Oil Seal REMOVAL 1 Hoist vehicle and remove wheel 2 Remove brake caliper carrier bolts and suspend caliper 1 CAUTION During removal be careful not to damage brake flexible hose and not to depress brake pedal 3 Remove ABS wheel sensor if equipped with ABS 3D 22 FRONT SUSPENSION 4 Remove brake disc NOTE If brake disc can not be removed by hand using 8 mm bolts 5 Remove front wheel bearing lock nut as follows For 2WD model a Remove hub cap b Remove front wheel bearing lock plate 1 by loosening 4 screws 2 For 4WD model a Remove air locking hub assembly 1 b Remove front axle shaft circlip
329. eck injector circuit wire or coupler or injector Turn ignition switch OFF and disconnect a fuel injector connector Check for proper connection to fuel injector at each terminal If OK then check injector resistance See Fig 4 Injector resistance 11 3 13 8 ohm at 20 C 68 F 5 Carry out steps 1 and 3 on each injector 6 Check each injector for injected fuel volume referring to Section 6E See Fig 5 Injected fuel volume 43 47 cc 15 sec 1 45 1 51 1 58 1 65 US Imp oz 15 sec 7 Check each injector for fuel leakage after injec tor closed Fuel leakage Less than 1 drop min 1 Is check result in step 1 and 3 to 7 satisfactory Go to Step 6 Check injector circuit or replace fuel injector s Check EVAP Canister Purge Valve 1 Disconnect purge hose 2 from EVAP canister 2 Place finger against the end of disconnected hose 3 Check that vacuum is not felt there when engine is cool and running at idle See Fig 6 Is vacuum felt Check EVAP control system See Section 6E Go to Step 7 Check intake manifold absolute pressure sensor for performance See step 4 of DTC P0105 No 11 Diag Flow Table Is it in good condition Go to Step 8 Repair or replace Check engine coolant temp sensor for perfor mance See Section 6E Is it in good condition Go to Step 9 Replace engine coolant temp sensor Check intake air temp sensor for perfo
330. ect broken or sagging springs Replace spring Body Leans or Sways in Corners Loose stabilizer bar Tighten stabilizer bar bolts or replace bushes Faulty shocks absorbers or mounting Replace shock absorber or tighten mounting Broken or sagging springs Replace spring Overloaded Check loading Cupped Tires Worn wheel bearings Replace wheel bearing Excessive tire or wheel run out Replace tire or wheel disc Tire out of balance Adjust tire balance STEERING SUSPENSION WHEELS AND TIRES 3 5 Tire Diagnosis Irregular and or Premature Wear Al Irregular and premature wear has many possible causes Some of them are incorrect inflation pressures lack of tire rotation driv ing habits improper alignment If the following conditions are noted rotation is in order e Front tire wear is different from rear e Uneven wear exists across the tread of any tire e Left front and right front tire wear is unequal e Left rear and right rear tire wear is unequal e There is cupping flat spotting etc A wheel alignment check is in order if the following conditions are noted e Left front and right front tire wear is unequal e Wear is uneven across the tread of any front tire e Front tire treads have scuffed appearance with feather edges on one side of tread ribs or blocks A Hard cornering under inflation or lack of tire rotation B Inco
331. ect for evidence of oil leakage Replace any defective part WARNING When handling rear shock absorber in which high pres sure gas is sealed make sure to observe the following precautions e Don t disassemble it e Don t put it into the fire Don t store it where it gets hot e Before disposing it be sure to drill a hole in it where shown by an arrow in the figure and let gas and oil out Lay it down sideways for this work e The gas itself is harmless but it may issue out of the hole together with chips generated by the drill There fore be sure to wear goggle A Drill hole with approximately 3 mm 0 12 in diameter Trailing Arm Lateral Rod Axle Housing and Coil Spring Check Inspect for cracks deformation or damage Replace any defective part Trailing Arm and Lateral Rod Bush Check Inspect for wear and breakage If found defective replace 3E 4 REAR SUSPENSION Rear Suspension Fasteners Check each bolt and nut fastening suspension parts for tightness Tighten loose one if any to specified torque referring to Tighten ing Torque Specifications of this section Bearing Retainer and Axle Shaft Oil Seal Check e When brake drum has been removed check inside of brake drum for gear oil leakage e Also check backside of brake back plate for oil leakage If oil leakage is found replace defective oil seal e Whenever it is possibl
332. ected to terminal c and d If there is no continuity replace relay Compressor REMOVAL 1 Run engine at idle speed with air conditioning ON for 10 min utes After that stop the engine 2 Disconnect negative cable at battery 3 Recover refrigerant from refrigeration system by referring to Recovery in this section NOTE The amount of removed compressor oil must be mea sured for replenishing compressor oil 1B 40 AIR CONDITIONING OPTIONAL 4 Remove compressor drive belt 1 as follows For vehicle with P S Loosen tension pulley bolts 2 For vehicle without P S Loosen tension pulley tightening nut 3 and adjusting bolt 4 A Vehicle with P S B Vehicle without P S A B 5 Disconnect thermal switch connector 6 Disconnect suction and discharge hoses from compressor NOTE Cap open fittings immediately to keep moisture out of system 7 Remove compressor 1 from its bracket 2 NOTE If compressor is replaced drain oil from removed com pressor And then measure its amount INSTALLATION Reverse removal procedure for installation and then noting the following instructions e Replenish specified amount of compressor oil to compressor suction side by referring to Replenishing Compressor Oil in this section e Evacuate and charge system by referring to Recovery in this section e Adjust drive belt
333. ector termi nal A24 to body ground Is continuity indicated Substitute a known good ABS hydraulic unit con trol module assembly and recheck B circuit open 5E 16 ANTILOCK BRAKE SYSTEM ABS Table C ABS Warning Lamp Circuit Check Lamp Flashes Continuously While Ignition Switch is ON 1 ABS warning lamp in combination meter 3 1 Diag switch terminal 5 Pedal bracket 2 ABS hydraulic unit control module assembly 3 Monitor connector 4 Service wire 3 2 Diag ground terminal CIRCUIT DESCRIPTION When the diag switch terminal is shorted or connected to the ground with the ignition switch ON the diag trou ble code DTC is indicated by flashing of the ABS warning lamp only in following cases e Normal DTC 12 is indicated if no malfunction DTC is detected in the ABS e A history malfunction DTC is 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 diag switch terminal connected to ground via Go to step 3 Go to step 2 service wire 2 Does flashing of ABS warning lamp indicate DTC DTC 12 or history DTC nostic flow table in this section 2 1 Ignition switch ON Substitute a known good P B wire circuit shorted 2 Measure voltage between
334. ed 4 Remove pads 3 INSPECTION Check pad lining for wear When wear exceeds limit replace with new one CAUTION Never polish pad lining with sandpaper If lining is pol ished with sandpaper hard particles of sandpaper will be deposited in lining and may damage disc When pad lin ing requires correction replace it with a new one Brake pad thickness lining pad rim Standard 15 mm 0 59 in Limit 7 mm 0 28 in NOTE When pads are removed visually inspect caliper for brake fluid leak Correct leaky point if any BRAKES 5 21 INSTALLATION NOTE See NOTE at the beginning of this section 1 Install pad shim 1 to outside pad and pads 2 to caliper carrier 3 2 Install caliper and torque caliper pin bolts 1 to specification NOTE Make sure that boots are fit into groove securely Tightening torque Brake caliper pin bolts a 22 N m 2 2 kg m 16 0 Ib ft 3 Install wheel and torque front wheel nuts to specification Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft 4 Upon completion of installation perform brake test 5 22 BRAKES Caliper assembly REMOVAL 1 Hoist vehicle and remove wheel 2 Remove brake flexible hose mounting bolt from caliper As this will allow fluid to flow out of hose have a container ready beforehand 3 Remove caliper pin bolts 4 Remove caliper from carrier DISASSEM
335. ed Remove clutch cover clutch disc and flywheel drive plate for A T by using special tool Special tool A 09924 17810 5 6 Remove the following parts from engine as previously out lined Oil pan and oil pump strainer Intake manifold and exhaust manifold Cylinder head cover Timing chain cover Timing chain guide chain tensioner adjuster chain ten sioner timing chain and crankshaft timing sprocket Camshaft tappet and shim Cylinder head assembly Piston and connecting rod Remove rear oil seal housing 1 Loosen bearing cap No 1 and No 2 bolts in such order as indicated in figure and remove them Remove crankshaft from cylinder block ENGINE MECHANICAL M13 ENGINE 6A1 81 INSPECTION Main bearing cap No 1 bolt Measure each thread diameter of bearing cap No 1 bolts 1 at A on 60 mm 2 36 in from seat side of flange bolt and B on 90 mm 3 54 in from seat side of flange bolt by using a micrometer 2 Calculate difference in diameters A B If it exceeds limit replace with new one Bearing cap No 1 bolt diameter measurement points a 60 mm 2 36 in b 90 mm 3 54 in Bearing cap No 1 bolt diameter difference Limit A B 0 2 mm 0 008 in Crankshaft Crankshaft runout Using a dial gauge measure runout at center journal Rotate crankshaft slowly If runout exceeds its limit replace cranks
336. ed in the past and the normal condition has been restored now To check which case applies check the symptom in ques tion according to Step 4 and recheck DTC according to Step 5 Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead to incorrect diagnosis trouble diagnosis of a normal circuit or difficulty in troubleshooting NOTE If only Automatic transmission DTCs P0702 P1717 or Immobilizer DTCs P1620 P1623 are indicated in this step perform trouble diagnosis according to Diagnosis in Section 7B or Section 8G 3 AND 4 VISUAL INSPECTION As a preliminary step be sure to perform visual check of the items that support proper function of the engine referring to Visual Inspection section 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 Diagnosis section 6 AND 7 RECHECKING AND RECORD OF DTC FREEZE FRAME DATA Refer to DTC Check section for checking procedure 8 ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE Perform basic engine check according to the Engine Basic Inspection 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
337. eering wheel side cap 1 of left side 4 Loosen 2 bolts 2 mounting driver air bag inflator module till it turns freely pull them out and fix them to bolt clamps 3 5 Remove driver air bag inflator module 1 from steering wheel 6 Disconnect yellow connector 2 in order a b as shown INSPECTION WARNING Never disassemble driver air bag inflator module or measure its resistance Otherwise personal injury may result CAUTION If air bag inflator module was dropped from a height of 90 cm 3 ft or more it should be replaced STEERING WHEEL AND COLUMN 3C 5 Check air bag inflator module visually and if any of the following is found replace it with a new one e Airbag being deployed e Trim cover 1 pad surface being cracked e Wire harness 3 or connector being damaged e Air bag inflator module being damaged or having been exposed to strong impact dropped 2 Inflator case INSTALLATION 1 Check that horn wire is connected to horn terminal securely 2 Connect yellow connector 1 of driver air bag inflator mod ule 3 pushing connector till it is locked 3 Install driver air bag inflator module to steering wheel tak ing care so that no part of wire harness is caught between them 4 Make sure that clearance between module and steering wheel is uniform all the way 5 Tighten driver air
338. ehicle 2 Remove lateral rod mounting bolt 2 and nut 3 3 Remove lateral rod 1 3E 10 REAR SUSPENSION INSTALLATION 1 Install lateral rod to vehicle body and rear axle housing Tighten bolt and nut temporarily by hand 2 Lower hoist and with vehicle in non loaded condition tighten lateral rod bolt and nut to specified torque Tightening torque Lateral rod bolt and nut a 90 N m 9 0 kg m 65 0 Ib ft Trailing Arm Bushing REMOVAL 1 Hoist vehicle 2 Support rear axle housing 1 by using floor jack 2 3 Disconnect parking brake cable clamp 1 from trailing arm 4 Disconnect wheel speed sensor harness clamps 2 from trailing arm if equipped with ABS 5 Remove trailing arm mounting bolts 6 Remove trailing arm 1 REAR SUSPENSION 3E 11 7 Remove bushings 1 by using hydraulic press and special tools Special tool A 09924 74510 B 09951 16030 C 09951 26010 INSTALLATION 1 Install bushings 1 by using hydraulic press and special tools noting the following points Special tool A 09913 85210 B 09951 26010 e For axle side bushings 1 install them so that center line and slit lines of them are parallel as shown figure 2 Slit 3 Center line of bushings 4 Slit line of bushings 3E 12 REAR SUSPENSION e Install
339. el hub and tighten bolts to specified torque Tightening torque Air locking hub bolts a 48 N m 4 8 kg m 35 0 Ib ft 12 Install ABS wheel sensor if equipped with ABS 13 Install brake disc and caliper assembly Tighten carrier bolts to specified torque Tightening torque Brake caliper carrier bolts a 85 N m 8 5 kg m 61 5 Ib ft 14 Install wheel and tighten wheel nuts specified torque Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft 15 Lower hoist 16 For 4WD model Check air locking hub for air leakage refer to 4WD System Check in this section 3D 28 FRONT SUSPENSION Steering Knuckle Wheel Spindle REMOVAL 1 Hoist vehicle and remove wheel 2 Remove wheel hub assembly refer to Wheel Hub Bearing Oil Seal in this section 3 Disconnect spindle vacuum hoses 1 from wheel spindle for 4WD CAUTION Give match mark to each spindle vacuum hoses before removing hose 4 Remove disc dust cover 1 and wheel spindle 2 5 Remove tie rod end and drag rod end nut s and discon nect tie rod end and drag rod end 2 from steering knuckle 1 with special tool Special tool A 09913 65210 6 Remove knuckle seal cover bolts Then remove knuckle seal cover 1 knuckle seal and knuckle seal retainer from knuckle FRONT SUSPENSION 3D 29 7 Remove lower and uppe
340. el pump assembly with fuel filter and fuel level gauge and fuel cut valve fuel feed line fuel return line and fuel vapor line For the details of fuel flow and fuel vapor flow refer to Fuel Delivery System and Emission Control System in Section 6E 4 2 10 8 1 5 N m 0 15 kg m 5 R 3 NS 2 oo mm 8 X ARA oO tf t B Y 1 i A My 10 9 1 5 N m 0 15 kg m N EX Cc DETAIL C DETAIL A DETAIL B 1 Fuel tank 4 Fuel filler cap 7 Fuel vapor line 10 Fuel filler hose clamp 2 Fuel pump assembly 5 Fuel feed line 8 Fuel filler neck m Tightening torque 3 Breather hose 6 Fuel return line 9 Fuel tank mounting bolt Fuel Tank The fuel tank is located under the rear section of the vehicle The fuel pump assembly is installed in fuel tank Whenever servicing the fuel pump assembly the fuel tank must be removed from the vehicle a a ENGINE FUEL 6C 3 Fuel Pump Assembly The fuel pump assembly 1 consists of fuel pump 6 fuel filter 2 fuel level gauge 5 and fuel cut valve 4 3 Suction filter FUEL PUMP For structure and operation of the fuel pump refer to Fuel Deliv ery System in Section 6E FUEL CUT VALVE The fuel cut valve consists of a float and a spring It allows only the fuel vapor to flow into the canister and prevents the fuel from flowing into the canister Fuel Filler Cap The fuel tank fill
341. emoving the battery be sure to disconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover When removing parts that are to be reused be sure to keep them arranged in an orderly manner so that they may be reinstalled in the proper order and position Whenever you use oil seals gaskets packing O rings locking washers split pins self locking nuts and cer tain other parts as specified be sure to use new ones Also before installing new gaskets packing etc be sure to remove any residual material from the mating surfaces e Make sure that all parts used in reassembly are perfectly clean e When use of a certain type of lubricant bond or sealant is specified be sure to use the specified type A Sealant 99000 31150 e Be sure to use special tools when instructed Special tool A 09917 98221 B 09916 58210 A NOL EY GENERAL INFORMATION 0A 9 e When disconnecting vacuum hoses attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly e After servicing fuel oil coolant vacuum exhaust or brake systems check all lines related to the system for leaks For vehicles equipped with fuel injection systems never disconnect the fuel line between the fuel pump and injector without first rele
342. en 0 1 3V Lighting switch OFF 18 A C condenser fan motor relay 0 1 0V_ A Cis operating if equipped 10 14V_ A Cis not operating 46 eae Guess 0 1V For 2 seconds after ignition switch ON mea tid 10 14V _ After the above time E18 20 Sensor ground Indication Throttle opening signal for Aeren 21 TCM AN i repeated Ignition switch ON O V and 10 14V 0 2V Ignition switch ON Fuel level sensor gauge Fuel tank fully filled 22 ete Paes 7 f with immobilizer indicator lamp Ignition switch ON 45 7 5V Fuel tank emptied 23 0 20V Ignition switch ON and heater blower switch ON 24 Heater blower switch 7 z Ignition switch ON and heater blower 10 14V switch OFF For TYPE B See NOTE NOTE See NOTE in ECM TERMINAL VOLTAGE VALUES TABLE for applicable model TERMINAL CIRCUIT NORMAL CONDITION NO VOLTAGE 1 A C compressor clutch OV Ignition switch ON 2 3 4 5 Power source 10 14V_ Ignition switch ON E18 6 Power source 10 14V__ Ignition switch ON 7 Power source for buck up 10 14V__ Ignition switch ON and OFF Immobilizer indicator lamp 10 14V_ Engine running 8 with immobilizer indicator lamp 0 1 0 V Ignition switch ON leaving engine OFF PUY Papu nee nes 0 1 0V Ignition switch ON immobilizer indicator lamp 6 38 ENGINE GENERAL INFORMATION AND DIAGNOSIS
343. en piston rod end and master cylinder piston 2 Before measuring clearance push piston rod several times so as to make sure reaction disc is in place Keep inside of booster at atmospheric pressure for measure ment Remove piston push rod seal from booster if equipped x Set special tool E on master cylinder 1 and push pin 3 until contacts piston 2 Special tool E 09950 96010 2 Turn special tool upside down and place it on booster 1 Adjust booster piston rod 2 length until rod end contacts pin head 3 Special tool E 09950 96010 Clearance b between special tool and piston rod 0 mm 0 in NOTE Take measurement with booster set vertically or piston rod supported with screw driver or such so as to set rod at the center 3 Adjust clearance by turning adjusting screw of piston rod Special tool F 09952 16010 5 48 BRAKES Brake Hose Pipe Front brake hose pipe For left hand steering vehicle 8 11 Nem 1 1 kg m 23 N m 2 3 kg m 16 N m 1 6 kg m MISS PY A For vehicle without ABS X View X 5 Brake caliper 12 To front left brake caliper B For vehicle with ABS Y View Y 6 4 way joint 13 To rear brake F Front side Z ViewZ 7 5 way joint a d Clamp R Right side 1 E ring 8 ABS hydraulic unit control mod Q Tightening torque ule assembly T Top sid
344. en sensor All vehicles not equipped with heated oxygen sensor are shipped with their CO factory adjusted as follows Engine idle mixture CO 0 5 1 5 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 IAC 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 NOTE CO adjusting resistor knob to A increases CO A F mixture becomes rich and turning it to B decreases CO A F mixture becomes lean 1 CO adjusting resistor 3 If idle mixture has been adjusted confirm that idle speed is within specification 6E 18 ENGINE AND EMISSION CONTROL SYSTEM Air Intake System Throttle body 7 8 2 5 N m 0 25 kg m 6 U 3 5 n m 0 35 kg m 1 Throttle body 4 Gasket 7 TP sensor screws 2 Throttle body gasket 5 Idle air control valve m Tightening torque 3 TP sensor 6
345. en the flattened or bent fins if any Clean the cores removing road grimes and trashes Excessive rust or scale formation on the wet side of the radiator lowers the cooling efficiency Flattened or bent fins obstruct the flow of air through the core to impede heat dissipation Radiator flushing interval recommended Two years INSTALLATION Reverse removal procedures NOTE e Refill cooling system with proper coolant referring to Coolant and Cooling System Flush and Refill in this section e With automatic transmission vehicle fill A T fluid up to specified level For procedure to check A T fluid and its level refer to Changing Fluid in Section 7B e After installation check each joint for leakage ENGINE COOLING 6B 15 Water Pump COMPONENTS 5 U 23 N m 2 3 kg m 6 U 11 N m 1 1 kg m 7 8 11 N m 1 1 kg m 1 Water pump 4 Radiator cooling fan 7 Radiator cooling fan mounting bolt 2 Water pump pulley 3 Radiator cooling fan clutch 5 Water pump mounting bolts Q Tightening Torque 6 Water pump pulley and fan clutch mounting nuts REMOVAL 1 Drain cooling system Refer to Step 6 of Cooling System Flush and Refill in this section Drain plug XS Teo B a 2 Remove the radiator shroud 3 Remove radiator referring to Radiator in this section 4 Loosen water pump drive belt tension Then remo
346. eners be the correct diameter thread pitch and strength Fastener Strength Identification Most commonly used metric fastener strength property classes are 4T 6 8 7T 8 8 and radial line with the class identification embossed on the head of each bolt Some metric nuts will be marked with punch 6 or 8 mark strength identification on the nut face Figure shows the different strength markings When replacing metric fasteners be careful to use bolts and nuts of the same strength or greater than the origi nal fasteners the same number marking or higher It is likewise important to select replacement fasteners of the correct diameter and thread pitch Correct replacement bolts and nuts are available through the parts divi sion Metric bolts Identification class numbers or marks correspond to bolt strength increasing numbers represent increasing strength 1 Nuts strength identification Standard Tightening Torque Each fastener should be tightened to the torque specified in each section of this manual If no description or specification is provided refer to the following tightening torque chart for the applicable torque for each fastener When a fastener of greater strength than the original one is used however use the torque specified for the orig inal fastener NOTE e For the flanged bolt flanged nut and self lock nut of 4T and 7T strength add 10 to the tightening torque given in the chart below e The c
347. ent of 8 8 strength Nm 3 2 65 12 29 59 113 175 270 395 fastener without flange kg m 0 32 0 65 1 2 29 5 9 11 3 17 5 27 39 5 lb ft 2 5 5 0 9 0 21 0 43 0 82 0 126 5 195 5 286 0 Self lock nut 0A 26 GENERAL INFORMATION MAINTENANCE AND LUBRICATION OB 1 SECTION 0B MAINTENANCE AND LUBRICATION WARNING conditions may result in severe injury For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under 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 e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy
348. ep Action Yes No 1 Check Fan Control System A C condenser fan con Go to Step 2 1 Connect scan tool to DLC with ignition switch OFF See trol system is in good Fig 1 condition 2 Start engine and select DATA LIST mode on scan tool 3 Warm up engine until coolant temp is 110 C 230 F or higher and A C switch turn OFF If engine coolant temp does not rise check engine cooling system or ECT sen sor Is A C condenser fan started when engine coolant temp reached above temp 2 Check A C Condenser Fan Relay and Its Circuit Go to DTC P0481 Diag Go to Step 3 1 Check DTC and pending DTC with scan tool Flow Table Is DTC P0481 displayed 3 Check A C Condenser Fan Relay 1 Go to Step 4 Replace A C 1 Turn ignition switch OFF and remove A C condenser fan condenser fan relay relay 2 Check for proper connection to relay at terminals A and B 3 If OK check that there is continuity between A and B when battery is connected to terminals C and D See Fig 2 Is check result satisfactory 6 122 ENGINE GENERAL INFORMATION AND DIAGNOSIS 2 Disconnect fan motor connector 2 3 Check for proper connection to motor at R BI and B terminals See Fig 3 Is it in good condition 4 If OK connect battery to motor and check for operation open motor Step Action Yes No 4 Check A C Condenser Fan 1
349. er Shaft CAUTION For vehicle with air bag system Never turn steering wheel while steering shaft lower joint 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 Turn steering wheel so that vehicle s front tires are at straight ahead position 2 Turn ignition switch to LOCK position and remove key STEERING WHEEL AND COLUMN 3C 17 3 Make alignment marks 3 on lower shaft 2 and shaft col umn side 1 and lower shaft 2 and gear box shaft gear box side 4 for a guide during reinstallation 4 Remove lower shaft joint bolts 5 Remove steering lower shaft INSTALLATION 1 Be sure that front wheels and steering wheel are in straight forward state 2 Insert lower shaft joint into shaft of steering column with matching marks 3 3 Align flat part A of steering gear box shaft 4 with bolt hole B of lower shaft joint as shown Then insert lower shaft joint into steering gear box shaft 4 with matching marks 3 4 Tighten shaft joint bolt column side to specified torque first and then shaft joint bolt gear box shaft side to specified torque Tightening torque Steering shaft joint bolts a 25 N m 2 5 kg m 18 0 Ib ft 1 Steering column assembly
350. er and lower diameters of coil spring 2 are differ ent A Bring larger diameter end at bottom and set its open x end in place on spring seat 1 e When seating coil spring 2 mate spring end with stepped part 3 of rear axle spring seat 1 as shown A Upper side small dia B Lower side large dia 3 Install shock absorber lower mounting bolt Tighten bolt temporarily by hand 4 Install brake flexible hose E ring 5 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft 6 Lower hoist and tighten absorber lower bolt 2 to specified torque Tightening torque Shock absorber lower bolt a 85 N m 8 5 kg m 61 5 Ib ft NOTE For tightening of lower bolt 2 refer to NOTE given under Shock Absorber in this section REAR SUSPENSION 3E 9 Bump Stopper REMOVAL 1 Hoist vehicle 2 Remove wheel 3 Remove bump stopper 1 by using special tool Special tool A 09941 66010 INSTALLATION 1 Tighten bump stopper 1 to specified torque by using spe cial tool Special tool A 09941 66010 Tightening torque Bump stopper a 50 N m 5 0 kg m 36 5 Ib ft 2 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft 3 Lower hoist Lateral Rod REMOVAL 1 Hoist v
351. er neck has a vacuum cap A ratchet tightening device on the threaded fuel filler cap reduces the chances of incorrect installation which would prevent sealing fuel vapors After the gasket 2 on fuel filler cap and the filler neck flange con tact the ratchet produces a loud clicking noise indicating the seal has been set This cap has a vacuum relief valve 1 inside The vacuum relief valve opens to relieve the vacuum created in the fuel tank 6C 4 ENGINE FUEL On Vehicle Service Before work refer to Precaution on Fuel System Service in Sec tion 6 Fuel Lines Due to the fact that fuel feed line is under high pressure use spe cial care when servicing it INSPECTION Visually inspect fuel lines for evidence of fuel leakage hose crack and deterioration or damage Make sure all clamps are secure Replace parts as needed Fuel Filler Cap Remove cap 1 and check gasket 2 for even filler neck imprint and deterioration or any damage If gasket is in malcondition replace cap NOTE If cap requires replacement only a cap with the same fea tures should be used Failure to use correct cap can result in critical malfunction of system Fuel Tank REMOVAL WARNING e Before starting the following procedure be sure to observe Precaution on Fuel System Service in Sec tion 6 e Keep fuel tank horizontally and stably when removing it Fuel may come out if tank is tilted
352. er than fuel system Go to applicable DTC Go to Step 3 DTC P0171 P0172 Diag Flow Table 3 Check HO2S 1 Output Voltage Go to Step 4 Go to DTC P0130 Diag 1 Connect scan tool to DLC with ignition switch Flow Table HO2S 1 cir OFF See Fig 1 cuit check 2 Warm up engine to normal operating tempera ture and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from pedal to enrich and enlean A F mixture Does HO2S 1 output voltage deflect between below 0 3 V and over 0 6 V repeatedly 4 Check Fuel Pressure Refer to Section 6E for Go to Step 5 Go to Diag Flow Table details B 3 Fuel Pressure 1 Release fuel pressure from fuel feed line Check 2 Install fuel pressure gauge See Fig 2 3 Check fuel pressure Fuel pressure specification With fuel pump operating and engine at stop 270 310 kPa 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 Is measured value as specified 6 70 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Yes No 5 Check Fuel Injectors and Circuit 1 Using sound scope 4 or such check operating sound of each injector 5 when engine is run ning Cycle of operating sound should vary according to engine speed See Fig 3 If no sound or an unusual sound is heard ch
353. eration Check in this section A23 connection Is it in good condition If connections OK substitute a known good ABS hydraulic unit control module assem bly and recheck 2 1 Ignition switch OFF Substitute a known good W BI circuit 2 Disconnect ABS hydraulic unit control module connector 3 Check for proper connection to ABS hydraulic unit control module connector at terminal A25 4 If OK then measure voltage between terminal A25 of module connector and body ground Is it10 14 V ABS hydraulic unit control module assembly and recheck open ANTILOCK BRAKE SYSTEM ABS 5E 25 DTC C1057 DTC 57 Power Source Circuit C3 o ae aa ial a Sa aS 1 1 D a B A24 1 Ignition switch 3 ABS hydraulic unit control module assembly 5 ABS hydraulic unit control module connector 2 Main fuse 4 Circuit fuse DESCRIPTION The ABS control module monitors the power source voltage at terminal A18 When the power source voltage becomes extremely low this DTC will be set As soon as the voltage rises to the specified level the set DTC will be cleared 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 Under charged Battery in Sec tion 6H 2 Check ABS main fuse circuit fuse and connec Go to step 3 Repair and o
354. ering wheel and steering shaft A For vehicle without air bag system B For vehicle with air bag system 3C 8 STEERING WHEEL AND COLUMN 3 Tighten steering shaft nut to specified torque Tightening torque Steering shaft nut a 33 N m 3 3 kg m 23 5 Ib ft NOTE After installing the steering wheel turn the steering wheel about 1 full rotation so that the cancel cam pin fits into the pin hole in the steering wheel and then check the turn signal lever for proper function 4 Install steering wheel pad for vehicle without air bag system or driver air bag inflator module for vehicle with air bag system as follows e For vehicle without air bag system For TYPE A a Connect horn connector b Install steering wheel pad For TYPE B a To install the pad hook 1 the upper part of the pad to the pawl of the steering wheel and push in the lower part of the pad until it fits to the set spring securely e For vehicle with air bag system a Install driver air bag inflator module to steering wheel Refer to Driver Air Bag Inflator Module in this section Centering contact coil for vehicle with air bag sys tem 1 Check that vehicle s wheels front tires are set at straight ahead position 2 Check that ignition switch is at LOCK position 3 Turn contact coil counterclockwise slowly with a light force till contact coil will not turn any f
355. ering wheel referring to Steering Wheel in this section 12 If the vehicle equipped with air bag system enable air bag system referring to Enabling Air Bag System in Section 10B 13 Connect negative battery cable Steering Lock Assembly Ignition Switch REMOVAL 1 Remove steering column 1 referring to Steering Column in this section 2 Steering lock 3C 16 STEERING WHEEL AND COLUMN 2 Loosen and remove steering lock mounting bolts 2 using center punch 1 as shown NOTE Use care not to damage aluminum part of steering lock body with center punch 3 Turn ignition key to ACC or ON position and remove steering lock assembly from steering column INSTALLATION 1 Position oblong hole 1 of steering shaft in the center of hole 3 in column 4 2 Turn ignition key to ACC or ON position and install steer ing lock assembly 5 onto column 4 3 Now turn ignition key to LOCK position and pull it out 4 Align hub on lock with oblong hole 1 of steering shaft and rotate shaft to assure that steering shaft 2 is locked 5 Tighten new bolts until head of each bolt is broken off 6 Turn ignition key to ACC or ON position and check to be sure that steering shaft rotates smoothly Also check for lock operation 7 Install steering column referring to Steering Column in this section Steering Low
356. es 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 In 0 020 0 047 mm 0 07 mm 0 0008 0 0019 in 0 0028 in Ex 0 045 0 072 mm 0 09 mm 0 0018 0 0028 in 0 0035 in Valve stem diameter A Standard in 5 465 5 480 mm 0 2152 0 2157 in 5 440 5 455 mm Ex 0 2142 0 2148 in Valve guide bore B Standard 5 485 5 510 mm 0 2159 0 2169 in In and Ex If bore gauge is not available check end deflection of valve stem with a dial gauge instead Move stem end in directions 1 and 2 to measure end deflec tion If deflection exceeds its limit replace valve stem and valve guide Valve stem end deflection limit In 0 14 mm 0 006 in Ex 0 18 mm 0 007 in 6A1 54 ENGINE MECHANICAL M13 ENGINE ae Valves e Remove all carbon from valves e Inspect each valve for wear burn or distortion at its face and stem end as necessary replace it e Measure thickness a of valve head If measured thickness exceeds limit replace valve Valve head thickness a In and Ex Standard 1 22 1 55 mm 0 048 0 0
357. es 3 Front Wheel Alignment 3A Steering Gear Box Manual Type and Linkage 3B STEERING SUSPENSION WHEELS AND Power Steering P S System if equipped 3B1 TIRES Steering Wheel and Column 3C Front Suspension 3D Rear Suspension 3E Wheels and Tires 3F DRIVE SHAFT AND PROPELLER SHAFT Propeller Shafts 4B Brakes 5 PARARE SATEN Antilock Brake System ABS 5E Engine General Information and Diagnosis 6 Engine Mechanical M13 Engine 6A1 Engine Cooling 6B Engine Fuel 6C ENGINE Engine and Emission Control System 6E Ignition System Electronic Ignition System 6F Cranking System 6G Charging System 6H Exhaust System 6K Manual Transmission 7A Automatic Transmission 4 A T 7B TRANSMISSION CLUTCH AND Clutch 7C DIFFERENTIAL Transfer 7D Front Differential 7E Rear Differential 7F Body Electrical System 8 Sonne ee Immobilizer Control System if equipped 8G BODY SERVICE 9 Restraint System 10 RESTRAINT SYSTEM Air Bag System 10B N N N N N N D wo geo a aaa RS SSRs ss Ro SSR SS ess as as GENERAL INFORMATION 0A 1 SECTION 0A GENERAL INFORMATION CONTENTS How to Use This Manual cccsssseeeeeeeees 0A 2 Identification Information csssesee 0A 17 PreCaUtionS iciicicctscctesesteccececticaceectenteseeentetctecces 0A 3 Body Number 0 cccseeecceeeeeeeeeeeeeeeees OA 17 Precaution for Vehicles Equipped with a Engine Identification Numbet 0 OA 17 Supplemental Restraint Air Bag Sy
358. essure Fuel pressure specification With fuel pump operating and engine at stop 270 310 kPa 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 Is measured value as specified 5 Check Fuel Injectors and Circuit Go to Step 6 Check injector cir 1 sing sound scope 1 or such check operating sound cuit or replace fuel of each injector 2 when engine is running Cycle of injector s operating sound should very according to engine speed See Fig 4 If no sound or an unusual sound is heard check injector circuit wire or coupler or injector 2 Turn ignition switch OFF and disconnect a fuel injec tor connector 3 Check for proper connection to fuel injector at each terminal 4 If OK then check injector resistance See Fig 5 Injector resistance 11 3 13 8 ohm at 20 C 68 F 5 Carry out steps 1 and 3 on each injector 6 Check each injector for injected fuel volume referring to Section 6E See Fig 6 Injected fuel volume 43 47 cc 15 sec 1 45 1 51 1 58 1 65 US Imp oz 15 sec 7 Check each injector for fuel leakage after injector closed Fuel leakage Less than 1 drop min Is check result in step 1 and 3 to 7 satisfactory 6 Check PCV valve for clogging See Section 6E Go to Step 7 Replace PCV Is it in good condition valve ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 75 Step Action Yes No 7 Check EVAP Canister Purge
359. f balance Balance wheels or replace tire Vibration and or wheel Loose wheel bearings Replace wheel bearing Loose wheel hub nuts Retighten Worn tie rod ends Replace tie rod end Worn king pin bearings or king pins Replace king pin bearing and or king pin Excessive wheel runout Repair or replace wheel and or tire Blister or bump on tire Replace tire Excessively loaded radial runout of tire wheel Replace tire or wheel assembly Disturbed front wheel alignment Check and adjust front wheel align ment Loose or worn steering linkage Tighten or replace steering linkage Loose steering gear box bolts Tighten box bolts Worn steering knuckle oil seal Replace Hard Steering Bind in tie rod end ball studs or king pin bear Replace tie rod end or king pin ings bearing Disturbed front wheel alignment Check and adjust front wheel align ment Steering gear box adjustment Check and adjust steering gear box Tire not adequately inflated Inflate tires to proper pressure Bind in steering column Repair or replace Low fluid level loose drive belt or malfunction of Check and correct power steering system if equipped with P S Too Much Play in Wheel bearings worn Replace wheel bearing Steering Steering gear box attachments loose Tighten or repair Steering gear box adjustments Check and adjust steering gear box Worn steering shaft joints Replace joint Worn tie rod ends drug rod ball joi
360. f equipped 28 Injector No 4 47 A C compressor clutch if equipped 10 Heated oxygen sensor 2 if equipped 29 IAC valve 48 Ignition switch 11 A C evaporator temp sensor if equipped 30 EVAP canister purge valve 49 Main relay 12 Speedometer 31 Fuel pump relay 50 CO adjusting register if equipped 13 Fuel level sensor 32 Fuel pump 51 Starting motor 14 TCM A T 33 A C condenser fan relay if equipped 52 4WD controller 4WD 15 Transmission range switch A T 34 A C condenser fan motor if equipped 53 ABS control module if equipped 16 Shift lock solenoid A T if equipped 35 EGR valve if equipped 54 Engine ground 17 Backup lamp 36 Malfunction indicator lamp 55 Body ground 18 Heater fan motor 37 Immobilizer indicator lamp if equipped 19 Heater fan switch 38 Monitor connector vehicle without immo bilizer indicator lamp ENGINE AND EMISSION CONTROL SYSTEM 6E 13 ECM TERMINAL ARRANGEMENT TABLE For TYPE A See NOTE CONNEC TERMINAL WIRE COLOR CIRCUIT CONNEC TERMINAL WIRE COLOR CIRCUIT
361. f parking brake switch at coupler NOTE Don t disassemble parking brake lever switch It must be removed and installed as a complete switch assembly 5 Remove adjusting nut 6 Loosen bracket nut 3 and disconnect parking brake cables 2 from equalizer 4 7 Remove parking brake lever bolts and then remove parking brake lever assembly 1 INSTALLATION 1 Install in reverse order of REMOVAL procedure Equalizer angle a within 15 degrees Tightening torque Parking brake lever bolts a 23 N m 2 3 kg m 17 0 lb ft 2 After all parts are installed parking brake lever needs to be adjusted Refer to Parking Brake Inspection and Adjust ment in this section 3 Check brake drum for dragging and brake system for proper performance 1 Parking brake lever 2 Parking brake cable 3 Adjusting nut 4 Equalizer BRAKES 5 53 Parking Brake Cable REMOVAL 1 Raise suitably support vehicle and remove wheel if necessary 2 Remove parking brake cable INSTALLATION 1 Install it by reversing removal procedure noting the following points e Install clamps properly referring to figure below e Tighten bolts and nuts to specified torque 2 Upon completion of installation adjust cable Refer to Parking Brake Inspection and Adjustment in this section Then check brake drum for dragging and brake system for proper performance After removing vehicle fr
362. f play is not within specification inspect for the following If found defective replace e Wear of tie rod end ball stud e Wear of king pin bearing e Wear of steering shaft joint e Loosely install or joined parts e Wear of steering rack sector gear Tie Rod And Drag Rod Check Inspect deformation or damage Replace any defective part INSPECTION 1 Inspect for play in tie rod end ball joint 1 If found defective replace 2 Inspect boot 2 for tear If even a small tear is noted replace with new one 3B 4 STEERING GEAR BOX MANUAL TYPE AND LINKAGE Steering Gear Box Oil Level Check Oil surface should be up to the level as shown in figure If not add prescribed gear oil SAE 90 Steering gear box oil level a 23 mm 0 91 in Apply sealant to thread parts of breathing plug and tighten breath ing plug to specified torque A Sealant 99000 31110 Tightening torque Breathing plug a 4 N m 0 4 kg m 3 0 Ib ft Adjustment of Worm Shaft Starting Torque Steering gear box has adjusting bolt 1 which gives preload to sector shaft Special tool A 09944 18211 MAKE ADJUSTMENT ACCORDING TO FOLLOWING PRO CEDURE 1 Check worm shaft 1 to ensure that it is free from thrust play 2 Position pitman arm 2 in nearly parallel with worm shaft 1 as shown With pitman arm 2 in this position front wheels are in straightforward state
363. f removed compressor oil must be mea sured for replenishing compressor oil 2 Remove front bumper referring to Front Bumper in Section 8 3 Disconnect receiver dryer outlet hose 1 and condenser outlet pipe 2 from receiver dryer 3 4 Remove receiver dryer 3 with its bracket 4 INSTALLATION Reverse removal procedure to install receiver dryer and then noting the following instructions e Replenish specified amount of compressor oil to compressor suction side by referring to Replenishing Compressor Oil in this section e Evacuate and charge refrigerant by referring to Evacuating and Charging in this section AIR CONDITIONING OPTIONAL 1B 33 Condenser Cooling Fan Assembly ASSEMBLY CAUTION Be careful not to damage condenser fins If condenser fin is bent straighten condenser fin by using flat head screwdriver or pair of pliers INSPECTION 1 Check continuity between each two terminals about the con denser cooling fan motor 1 If check results are no continuity replace condenser cooling fan motor 2 Connect battery to condenser cooling fan motor as shown in figure then check that the condenser cooling fan motor operates smoothly Reference current of condenser cooling fan motor approximately 7 5 A at 12 V REMOVAL 1 2 Disconnect condenser cooling fan motor connector 1 3 Remove radiator mounting
364. f too soon ENGINE MECHANICAL M13 ENGINE 6A1 19 4 Remove air cleaner outlet No 1 1 and No 2 2 hoses and breather hose 3 5 Remove intake manifold bracket 1 with main harness from intake manifold 6 Disconnect the following electric lead wires e IAC valve 2 e TP sensor 3 e EVAP canister purge valve 4 e MAP sensor 5 e Fuel injector wire harness at couplers 6 e Ground terminal 7 from intake manifold 7 Disconnect accelerator cable 1 from throttle body 8 Disconnect the following hoses e Brake booster hose 2 from intake manifold e PCV hose 3 from PCV valve e Fuel pressure regulator vacuum hose 4 from intake mani fold Canister purge hose from EVAP canister purge valve e Water hoses from throttle body e Vacuum hose 5 to check valve from throttle body e Fuel feed hose and return hose from each pipe 9 Remove fuel delivery pipe with fuel injectors from cylinder head and intake manifold 10 Remove canister purge hose bracket 11 Disconnect EGR pipe from EGR valve 12 Remove intake manifold stiffener 1 6A1 20 ENGINE MECHANICAL M13 ENGINE 13 Remove intake manifold 1 with throttle body 2 and EGR pipe 3 from cylinder head 4 and then its gasket INSTALLATION Reverse removal procedure for installation noting the followings e Use new intake manifold gasket and EGR pipe gasket e Tighten long bolt 1 short bolt 3
365. ferring to and fix ignition timing to initial one See Fig Section 6F 3 2 Remove air cleaner bolt and crips and shift air cleaner position to observe ignition tim ing 3 Using timing light 1 check initial ignition timing See Fig 4 Is it 5 3 BTDC at specified idle speed 9 Check immobilizer system malfunction as fol Go to Diagnosis in Sec Go to Step 10 tion 8G 6 22 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Yes No 10 Check fuel supply as follows 1 Check to make sure that enough fuel is filled in fuel tank 2 Turn ON ignition switch for 2 seconds and then OFF See Fig 5 Is fuel return pressure returning sounds felt from fuel feed hose 1 when ignition switch is turned ON Go to Step 12 Go to Step 11 11 Check fuel pump for operating 1 Was fuel pump operating sound heard from fuel filler for about 2 seconds after ignition switch ON and stop Go to Diag Flow Table B 3 Go to Diag Flow Table B 2 12 Check ignition spark as follows 1 Disconnect injector couplers 2 Remove spark plugs and connect them to high tension cords 3 Ground spark plugs 4 Crank engine and check if each spark plug sparks Is it in good condition Go to Step 13 Go to Ignition Spark Test in Section 6F 13 Check fuel injector for operation as follows 1 Install spark plugs and connect injector con
366. fied torque For vehicle without ABS Tightening torque Piston stopper bolt a 10 N m 1 0 kg m 7 5 Ib ft Fill Reservoir CAUTION Do not use shock absorber fluid or any other fluid which contains mineral oil Do not use container which has been used for mineral oil or which is wet from water Min eral oil will cause swelling and distortion of rubber parts in hydraulic brake system and water will mix with brake fluid lowering fluid boiling point Keep all fluid contain ers capped to prevent contamination BRAKES 5 41 Fluid to fill reservoir with is indicated on reservoir cap of that vehi cle with embossed letters or in owner s manual supplied with it Add fluid up to MAX line 5 42 BRAKES LSPV Load Sensing Proportioning Valve Assembly If Equipped CAUTION Brake fluid is extremely damaging to paint Do not allow brake fluid to get on painted surface LSPV assembly must not be disassembled Replace with new one if defective REMOVAL 1 Clean around reservoir cap and take out fluid with syringe or such 2 Hoist vehicle 3 Disconnect brake pipes from LSPV 4 Remove LSPV assembly from vehicle NOTE As shown in figure LSPV assembly should be removed together with its spring and stay installed as they are 5 Remove spring and stay from LSPV INSTALLATION Install by reversing removal procedure noting the following 1 Torque each bol
367. fluid vehicle with A T 12 Connect negative cable at battery 13 Verify that there is no fuel leakage coolant leakage oil leak age A T fluid leakage vehicle with A T and exhaust gas leakage at each connection 6A1 72 ENGINE MECHANICAL M13 ENGINE Engine Mountings F 50 N m 5 0 kg m F 55 N m 5 5 kg m F 50 N m 5 0 kg m F 45 N m 4 5 kg m w NA S F 45 N m 4 5 kg m E 45 N mi4 5 kg m m Tightening torque ENGINE MECHANICAL M13 ENGINE 6A1 73 Unit Repair Overhaul Engine Assembly REMOVAL 1 Relieve fuel pressure referring to Fuel Pressure Relief Pro cedure in Section 6 2 Disconnect negative cable at battery 3 Remove engine hood after disconnecting windshield washer hose 4 Remove A C compressor and or P S pump belt if equipped 5 Remove generator belt 6 Drain engine oil 7 Drain coolant WARNING To help avoid danger of being burned do not remove drain plug 1 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 8 Disconnect radiator inlet and outlet hoses from each pipe 9 Disconnect A T fluid hoses 2 vehicle with A T and release its clamps Place some container under radiator to receive A T fluid which will flow out when hose is disconnected 10 Remove fan shroud upper bolts and install
368. from the data in the table depending on various conditions temperature viscosity etc 7 Check oil filter and drain plug for oil leakage 8 Start engine and run it for three minutes Stop it and wait five minutes before checking oil level Add oil as necessary to bring oil level to FULL level mark on dipstick 1 Full level mark hole 2 Low level mark hole Engine Coolant CHANGE Change engine coolant referring to Cooling System Flush and Refill in Section 6B Exhaust System INSPECTION WARNING To avoid danger of being burned do not touch exhaust system when it is still hot Any service on exhaust sys tem should be performed when it is cool v Se MAINTENANCE AND LUBRICATION OB 9 When carrying out periodic maintenance or the vehicle is raised for other service check exhaust system as follows Check rubber mountings for damage deterioration and out of position Check exhaust system for leakage loose connections dents and damages If bolts or nuts are loose tighten them to specification Check nearby body areas for damaged missing or misposi tioned parts open seams holes loose connections or other defects which could permit exhaust fumes to seep into the vehicle Make sure that exhaust system components have enough clearance from the underbody to avoid overheating and pos sible damage to the floor carpet
369. g 2 Front housing 6 Stator 10 Brush 3 Bearing 7 1C regulator 4 Retainer 8 Rectifier 6H 14 CHARGING SYSTEM Inspection Rotor 1 Using ohmmeter check for continuity between slip rings of rotor 1 If there is no continuity replace rotor Standard resistance between slip rings of rotor 1 8 2 10 2 Using ohmmeter check that there is no continuity between slip ring and rotor core If there is continuity replace rotor 3 Check slip rings for roughness or scoring If rough or scored replace rotor 1 4 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 Slip ring diameter Standard 14 4 mm 0 567 in Limit 14 0 mm 0 551 in Stator 1 Using ohmmeter check all leads for continuity If there is no continuity replace stator 1 CHARGING SYSTEM 6H 15 2 Using ohmmeter check that there is no continuity between coil leads 2 and stator core If there is continuity replace stator 1 Brush and Brush Holder Check each brush for wear by measuring its length If brush is found worn down to service limit replace brush Brush length a Standard 16 mm 0 63 in Service limit 2 mm 0 08 in Rectifier 1 Using ohmmeter check continuity between each of upper and lower rectifier
370. g clutch Poor sliding of over running clutch Repair Over running clutch slipping Replace over running clutch Worn teeth of ring gear Replace flywheel M T or drive plate A T Noise Abnormally worn bush Replace bush Worn pinion or worn teeth of ring gear Replace pinion or flywheel M T or drive plate A T Poor sliding of pinion failure in return movement Repair or replace Worn internal or planetary gear teeth Replace Lack of oil in each part Lubricate 6G 4 CRANKING SYSTEM Condition Possible Cause Correction Starting motor does not stop running Fused contact points of magnetic switch Replace magnetic switch Short circuit between turns of magnetic switch coil layer short circuit Replace magnetic switch Failure of returning action in ignition switch Replace Performance Test CAUTION Each test must be performed within 3 5 seconds to avoid coil from burning PULL IN TEST Connect battery to magnetic switch as shown Check that plunger and pinion move outward If plunger and pinion don t move replace magnetic switch NOTE Before testing disconnect lead wire from terminal M 1 Terminal S 2 Terminal M 3 Lead wire switch to motor HOLD IN TEST While connected as above with plunger out di
371. g to and fresh refrigerant from receiver dryer and expansion valve Normats During A C operation Expansion valve is frozen Replace expansion valve Normal 14 1 75 the low pressure side due to moisture in the Replace receiver dryer 0 23 0 35 1 4 47 5 sometimes indicates system and temporarily Evacuate A C system 2 3 3 5 200 249 negative pressure and shuts off the refrigeration and recharge with fresh 33 50 T sometimes normal cycle refrigerant TL _ pressure Also high Abnormal Abnormal pressure side reading i 0 69 0 98 Negative 7 10 fluctuates between the pressure 100 142 abnormal and normal pressure 1B 14 AIR CONDITIONING OPTIONAL Condition MPa piieis P kg cm Detail Possible Cause Correction psi Lo Hi Both low and high pres Insufficient refrigerant in Using leak detector sure sides indicate low system check for leaks and repair readings Refrigerant leaking as necessary Continuous air bub Recharge refrigerant to a 0 05 0 15 bles are visible through specified amount 0 5 1 5 sight glass If the pressure reading is 4 2 21 3 Output air is slightly almost 0 when the mani 0 69 0 98 cold fold gauges are attached 7 10 check for any leaks repair them and evacu 100 142 ate the system Pressure on low pres Internal leak in compres Inspect compressor and su
372. g vehicle 3 Rear drum brake B For RH steering vehicle 4 ABS hydraulic unit control module assembly System Schematic ANTILOCK BRAKE SYSTEM ABS 5E 3 cro 2 a a E 7 jsesens OUTPUT Pump motor P transistor HIP Meter INPUT Fail safe a transistor Wheel speed sensor RF 4 Wheel speed sensor RR gt LF hold solenoid Wheel speed sensor LR gt Wheel speed sensor LF gt ABS control A Stop lamp switch Hl moade LF release solenoid G sensor gt Diag switch terminal RF hold solenoid Battery voltage AWD switch for 4WD model only RF release solenoid Rear hold solenoid Rear release solenoid J gt ABS warning lamp Idle up ABS hydraulic unit control ECM module assembly m Data link connector 1 Wheel speed sensor Right front 7 Wheel speed sensor Left rear 13 ABS hydraulic unit 2 Stop lamp switch 8 ABS warning lamp 14 G sensor 3 ABS control module 9 ABS pump motor transistor 15 Data link connector 4 Wheel speed sensor Right rear 10 ABS solenoid valve transistor 16 ABS hydraulic unit control module assembly 5 Monitor connector 11 Proportioning valve 17 4WD switch for 4WD model only 6 ABS lamp driver module 12 Wheel
373. gear or 2 range while observing vehicle speed displayed on scan tool 3 Release accelerator pedal and with engine brake applied keep vehicle coasting fuel cut condition for 4 sec or more 4 Check pending DTC and DTC ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 95 INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Does speedometer indicate vehicle speed Go to Step 3 Go to Step 5 3 Check Vehicle Speed Signal Intermittent trouble or Go to Step 4 Is vehicle speed displayed on scan tool in step faulty ECM 2 and 3 of DTC confirmation procedure Check for intermittent referring to Intermittent and Poor Connection in Section OA 4 1 Turn ignition switch to OFF position Faulty speedometer Y or Y G wire open or 2 Disconnect combination meter connec short tors Refer to Section 8 Poor connection of ECM 3 Turn ignition switch to ON position without connector terminal running engine If OK substitute a known 4 Measure voltage from terminal c of VSS good ECM and recheck connector to ground See Fig 2 Is voltage within 4 5 V 5 1 With ignition switch at OFF position discon Go to Step 6 BI B or B Or wire open nect VSS connector or short 2 Turn ignition switch to ON position without running engine 3 Measure voltage from terminal a to b of VSS connector
374. gine oil to sliding surface except inner surface of big end and rod bolts Make sure rod bolt diameter when reuse it due to plastic deformation tightening Refer to Inspection of Connecting Rod 10 Apply engine oil to sliding surface of each parts N Connecting rod bearing cap Point arrow mark on cap to crankshaft pulley side Do not reuse Connecting rod bearing REMOVAL 1 Relieve fuel pressure referring to Fuel Pressure Relief Pro cedure in Section 6 Drain coolant Head in this section 6 Mark cylinder number on all pistons connecting rods and connecting rod caps using silver pencil or quick drying paint 7 Remove rod bearing caps Disconnect negative cable at battery 3 Drain engine oil Remove cylinder head referring to Valves and Cylinder ENGINE MECHANICAL M13 ENGINE 6A1 63 8 Install guide hose 1 over threads of rod bolts This prevents damage to bearing journal and rod bolt threads when removing connecting rod 9 Decarbon top of cylinder bore before removing piston from cylinder 10 Push piston and connecting rod assembly out through the top of cylinder bore DISASSEMBLY 1 Using piston ring expander remove two compression rings Top and 2nd and oil ring from piston 2 Remove piston pin from connecting rod e Ease out piston pin circlips 1 as shown e Force piston pin out CLEANI
375. gnition switch 3 TCM DTC DETECTING CONDITION POSSIBLE CAUSE e D range signal not inputted Park Neutral position e G Y circuit open signal inputted to ECM while vehicle running e Transmission range switch malfunction 2 driving cycle detection logic Continuous monitoring R D 2 or L range signal circuit open e TCM power or ground circuit open e TCM malfunction e ECM malfunction DTC CONFIRMATION PROCEDURE WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Start engine and shift selector lever to D range 4 Increase vehicle speed to higher than 20 mph 32 km h and then stop vehicle 5 Repeat above step 4 9 times 6 Shift selector lever to 2 range and repeat above step 4 and 5 7 Shift selector lever to L range and repeat above step 4 and 5 8 Check DTC in DTC mode and pending DTC in ON BOARD TEST or PENDING DTC mode 6 108 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Is SUZUKI scan
376. gnosis Table Condition Possible Cause Correction Vehicle Pulls Leads Mismatched or uneven tires Replace tire Tires not adequately inflated Adjust tire pressure Broken or sagging springs Replace spring Radial tire lateral force Replace tire Disturbed front wheel alignment Check and adjust wheel alignment Disturbed rear wheel alignment Check and adjust wheel alignment Brake dragging in one road wheel Repair front brake Loose bent or broken front or rear suspension parts Tighten or replace suspension part Abnormal or Excessive Tire Wear Sagging or broken springs Replace spring Tire out of balance Adjust balance or replace tire Disturbed front wheel alignment Check wheel alignment Faulty shock absorber Replace shock absorber Hard driving Replace tire Overloaded vehicle Replace tire Not rotating tire Replace or rotate tire Worn or loose road wheel bearings Replace wheel bearing Wobbly wheel or tires Replace wheel or tire Tires not adequately inflated Adjust the pressure Wheel Tramp Blister or bump on tire Replace tire Improper shock absorber action Replace shock absorber STEERING SUSPENSION WHEELS AND TIRES 3 3 Condition Possible Cause Correction Shimmy Shake or Tire or wheel out o
377. gp g 21 Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary 22 Remove cylinder head with intake manifold and exhaust manifold Use lifting device if necessary 6A1 52 ENGINE MECHANICAL M13 ENGINE DISASSEMBLY 1 For ease in servicing cylinder head remove intake manifold injectors and exhaust manifold from cylinder head 2 Using special tools Valve lifter compress valve spring and then remove valve cotters 1 by using special tool For ceps Special tool A 09916 14510 B 09916 14521 C 09916 84511 3 Release special tools and remove spring retainer and valve spring 4 Remove valve from combustion chamber side 5 Remove valve stem seal 1 from valve guide and then valve spring seat 2 NOTE Do not reuse seal once disassembled Be sure to use new seal when assembling 6 Using special tool valve guide remover drive valve guide out from combustion chamber side to valve spring side Special tool A 09916 44910 NOTE Do not reuse valve guide once disassembled Be sure to use new valve guide Oversize when assembling 7 Place disassembled parts except valve stem seal and valve guide in order so that they can be installed in their original position A B ENGINE MECHANICAL M13 ENGINE 6A1 53 INSPECTION Valve Guid
378. h contacts 10 Ignition amp Starter switch 3 Magnetic switch 7 Pull in coil 11 Battery 4 Hold in coil 8 Starting motor Diagnosis Diagnosis Table Possible symptoms due to starting system trouble would be as follows e Starting motor does not run or runs slowly e Starting motor runs but fails to crank engine e Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery wiring harness including starting motor switch starting motor or engine Do not remove motor just because starting motor does not run Check following items and narrow down scope of possible causes 1 Condition of trouble 2 Tightness of battery terminals including ground cable connection on engine side and starting motor termi nals 3 Discharge of battery 4 Mounting of starting motor CRANKING SYSTEM 6G 3 Condition Possible Cause Correction Motor not running No operating sound of magnetic switch Shift lever switch is not in P or N or not adjusted A T Shift in P or N or adjust switch Battery run down Recharge battery Battery voltage too low due to battery deteriora tion Replace battery Poor contact in battery terminal connection Retighten or replace Loose grounding cable connection Retighten Fuse set loose or blown off Tighten or replace Poor contacting action of ignition switch and mag Replace
379. haft Crankshaft runout Limit 0 04 mm 0 0016 in Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the nor mal manner that is with thrust bearing 1 and journal bearing caps installed Thickness of crankshaft thrust bearing Standard 2 500 mm 0 0984 in Oversize 0 125 mm 0 0049 in 2 563 mm 0 1009 in 6A1 82 ENGINE MECHANICAL M13 ENGINE e 08A 14 e ae 16 10 11 5 15 DQ to D ji 9 19 Tighten bearing cap No 1 bolts 1 10 and No 2 bolts 11 20 gradually as follows 1 Tighten bolts 1 10 to 30 N m 3 0 kg m 22 0 lb ft according to numerical order in figure 2 In the same manner as in Step 1 tighten them to 50 N m 5 0 kg m 36 5 Ib ft 3 In the same manner as in step 1 retighten them to 60 4 Tighten bolts 11 20 to 22 N m 2 2 kg m 16 0 lb ft according to numerical order in figure Tightening torque Crankshaft bearing cap No 1 bolts 1 10 50 N m 5 0 kg m 36 5 Ib ft and extra tightening 60 Crankshaft bearing cap No 2 bolts 11 20 22 N m 2 2 kg m 16 0 Ib ft Use a dial gauge to read displacement in axial thrust direction of crankshaft If its limit is exceeded replace thrust bearing with new standard one or oversize one to obtain standard thrust pl
380. hart below is applicable only where the fastened parts are made of steel light alloy GENERAL INFORMATION 0A 25 Tightening torque chart Thread Diameter Nominal Diameter mm 4 5 6 8 10 12 14 16 18 An gquValentoraATstengih iiis o e al ag ases 408 eieo fastener aor kg m 0 15 0 30 0 55 1 3 2 9 45 65 10 5 16 R4 SS a ae ae lb ft 1 0 2 5 4 0 9 5 21 0 32 5 47 0 76 0 116 0 L An equivalent of 6 8 strength fastener without flange S ASD KF An equivalent of 6 8 strength fastener without flange Nem 2 4 4 7 84 20 42 80 125 193 280 kg m 0 24 0 47 0 84 2 0 4 2 80 12 5 19 3 28 lb ft 2 0 3 5 6 0 14 5 30 5 58 0 90 5 139 5 202 5 Nem 2 4 4 9 88 21 44 84 133 203 298 kg m 0 24 0 49 0 88 2 1 4 4 84 13 3 20 3 29 8 lb ft 2 0 3 5 6 5 15 5 32 0 61 0 96 5 147 0 215 5 sirengin An equivalent of 7T strength Nm 2 3 4 5 10 23 50 85 135 210 240 fastener kg m 0 23 0 45 1 0 2 3 5 0 85 13 5 21 24 LOQ Gy lb ft 2 0 3 5 7 5 17 0 36 5 61 5 98 0 152 0 174 0 An equivalent of 8 8 strength Nem 3 1 6 3 11 27 56 105 168 258 373 fastener without flange kg m 0 31 0 63 1 1 2 7 5 6 10 5 16 8 25 8 37 3 lb ft 2 5 4 5 8 0 19 5 40 5 76 0 121 5 187 0 270 0 An equival
381. heating of this table e Fuel pressure out of specification Diagnostic Flow Table B 3 e Faulty injector Diagnostic Flow Table B 1 e Faulty TP sensor ECT sensor or MAP sensor TP sensor ECT sensor or MAP sen sor in Section 6E e Faulty ECM Inspection of ECM and its circuit in this section e Malfunctioning EGR valve if equipped EGR system in Section 6E Low compression Previously outlined Surges Engine power variation under steady throttle or cruise Feels like the vehicle speeds up and down with no change in the accelerator pedal e Faulty ignition coil or high tension cord Ignition coil assembly or high tension cords in Section 6F e Variable fuel pressure Diagnostic Flow Table B 3 e Faulty MAP sensor MAP sensor in Section 6E e Faulty injector Diagnostic Flow Table B 1 e Faulty ECM Inspection of ECM and its circuit in this section e Malfunctioning EGR valve if equipped EGR system in Section 6E ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 25 Condition Possible Cause Reference Item Excessive detonation The engine makes sharp metallic knocks that change with throt tle opening Sounds like pop corn popping Engine overheating Refer to Overheating of this table Faulty spark plug Spark plugs in Section 6F Clogged fuel filter and fuel lines Diagnostic Flow Table B 3
382. heck 2 Turn ignition switch ON 3 Erase DTC and pending DTC according to instructions dis played on scan tool 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 memory are also cleared in following cases Be careful not to clear them before keeping their record e When power to ECM is cut off by disconnecting bat tery cable removing fuse or disconnecting ECM con nectors e When the same malfunction DTC is not detected again during 40 engine warm up cycles Without Using SUZUKI 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 temperature Time to cut power to ECM Over 0 C 32 F 30 sec or longer Not specifiable Under 0 C 32 F Select a place with higher than 0 C 32 F temperature 6 16 ENGINE GENERAL INFORMATION AND DIAGNOSIS Diagnostic trouble code DTC table DTC DETECTING ITEM DETECTING CONDITION MIL MIL NO DTC will set when detecting vehicle vehicle with immo without bilizer indi immobi cator lamp lizer indica tor lamp Low pressure high vacuum low vol
383. hed to the vehicle which could cause deployment and result in personal injury WARNING Driver and Passenger Seat Belt Pretensioners lf equipped e For handling and storage of a live seat belt preten sioner select a place where the ambient temperature below 65 C 150 F without high humidity and away from electric noise e Never carry seat belt pretensioner by wire or connector of pretensioner When placing a live seat belt preten sioner 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 1 or to put a seat belt pretensioner on top of another Otherwise personal injury may result e Never dispose of live inactivated seat belt pretension ers driver and passenger If disposal is necessary be sure to activate them according to activation proce dures described in Section 10B before disposal e 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 e With many service procedures gloves and safety glasses should be worn to prevent any possible irrita tion of the skin or eyes 0A 6 GENERAL INFORMATION CAUTION e 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 instruction
384. heel hub are disengaged or engaged FRONT SUSPENSION 3D 3 1 Air locking hub assembly 4 VSV2 7 4WD controller 10 4WD indicator light 13 ABS controller 2 VSV1 5 Vacuum accumulation tank 8 Intake manifold 11 4WD switch 14 Transfer 3 Check valve 6 Vacuum switch 9 Wheel spindle 12 Combination meter 3D 4 FRONT SUSPENSION SYSTEM CIRCUIT VSV1 VSV2 Vacuum I 1 l I I switch QEFE _ ON OFF I I I I 5 13 IGP VS 1 Br GriB an Y R 2 6 iO 7 ou ACS vsv2 eal 8 GIB Gr R pe YR 3 IND Bi aa O ACCT B 9 B B G W ysc B Gr GND B 10 12 1G2 7 Gi G ig YR en ST To leer A10 A9 A8 A7 A6 AS A4 A3 A2 Al Operation 2WD 4WD l 4WD 2WD ON AWD switch OFF i OFF 1 OPEN l l l wl os I 4WD indicator I l ON light OEE i l OFF I l ON ON _ I A C cut OFF l OFF When A C switch ON I and Blower fan switch ON l 1 4WD controller 4 4WD indicator lamp 7 Blower fan switch 10 Vacuum switch 13 IG fuse 2 VSV1 5 ECM 8 A C switch if equipped 11 Main fuse 14 A C controller if equipped 3 VSV2 6 Blower fan motor 9 4WD switch 12 IG switch 15 Coupler of 4WD controller FRONT SUSPENSION 3D 5 Components and Functions Component Function 4WD switch When the transfer shift leve
385. her 1 driving Not sor circuit malfunction than specification or sensor malfunction cycle applicable Difference between manifold absolute Barometric pressure sen Janets IE ee ner value anana 2 driving Not P1451 metric pressure barometric pressure sen f sor performance problem d Pee cycles applicable sor value is larger than specification during cranking Starter signal circuit mal Paner pane eT Pee vom engine 2 driving Not P1500 cranking till its start and after or it is always function cycles applicable inputted P1510 BEM Pep iia No backup power after starting engine ening bak malfunction cycle applicable Serial communication prob F P1600 lem between ECM and No signal or check sum error while engine 1 driving Not running cycle applicable TCM P1717 AT D range signal circuit No D range park neutral position sig 2 driving Not malfunction nal is inputted while vehicle running cycles applicable P1570 ABS signal circuit malfunc ABS signal ON low voltage when engine Not 1 driving tion start applicable cycle 6 18 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC NO DETECTING ITEM DETECTING CONDITION MIL DTC will set when detecting P0702 Transmission Control System Electrical P0705 Temperature Sensor Circuit Malfunction P0710 Transmission Temperature Sensor Circuit Mal function P0715 Input Turbine Speed Sensor Circuit Malfunc
386. hicle with Immobilizer Indicator Lamp ECM in this vehicle has following functions When the ignition switch is turned ON with the engine at a stop malfunction indicator lamp MIL 1 turns ON to check the bulb of the malfunction indicator lamp 1 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 turn ON or flash flashing only when detecting a misfire which can cause damage to the catalyst 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 and turning ON the malfunction indicator lamp 1 due to that malfunction 2 driv ing cycle detection logic is adopted to prevent erroneous detection When a malfunction is detected engine and driving condi tions then are stored in ECM memory as freeze frame data For the details refer to description on Freeze frame data It is possible to communicate by using not only SUZUKI scan tool 2 but also generic scan tool Diagnostic information can be accessed by using a scan tool WARM UP CYCLE A warm up cycle means sufficient vehicle operation such that the
387. htening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft 3 Check wheel bearing for wear After retightening lock nut to specified torque apply dial gauge to wheel hub center and measure thrust play Wheel bearing thrust play limit 0 05 mm 0 002 in When measurement exceeds limit replace bearing 4 By rotating wheel actually check wheel bearing for noise and smooth rotation If defective replace bearing FRONT SUSPENSION 3D 17 On Vehicle Service Stabilizer Bar Bushings REMOVAL 1 Hoist vehicle 2 Remove front bumper 3 Disconnect stabilizer ball joints right amp left 1 from front axle housing 2 1 3 4 Remove stabilizer bar mount bush bracket bolts 1 i 5 Remove stabilizer bar with its ball joint 6 Disconnect stabilizer ball joints right amp left from its bar INSTALLATION 1 Connect stabilizer ball joints right amp left to its bar 3D 18 FRONT SUSPENSION 2 a 4 2 a NOTE For correct installation of stabilizer bar side to side be sure that color paint 1 on stabilizer bar aligns with mount bush both right and left as shown 2 When installing stabilizer loosely assemble all components while insuring that stabilizer is centered side to side 3 Tighten stabilizer bracket bolts 2 and stabilizer ball joint nuts to specified torque NOTE Tighten stabilizer mount bracket bolts 2 with vehicle hoisted a little in non load c
388. ials and techniques on the market to repair tires As not all of these work on all types of tires tire manufacturers have published detailed instructions on how and when to repair tires These instructions can be obtained from the tire manufacturer 3F 10 WHEELS AND TIRES PROPELLER SHAFTS 4B 1 SECTION 4B PROPELLER SHAFTS NOTE e All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems and or could result in major repair expense They 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 e Never attempt to heat quench or straighten any propeller shaft part Replace it with a new part or damage to the part may result CONTENTS General Description cccsssseeeeeeeeeeesseeeees 4B 2 Propeller Shafts ccscccceseseseeeeeeeeeteees 4B 3 COMpONEN S a cccteaien ket aichatddectdatniiin 4B 2 Universal JOIN okere EAE 4B 5 DIAGNOSIS cvives E E 4B 2 Tightening Torque Specification 4B 7 Diagnosis Table c ccsccscsesesesesescseseeeteees 4B 2 Required Service Material 4B 7 Propeller Shaft Joint Check 4B 2 Special TOO c ccciscctecsectcesetecscces seeeteseceecteeteuceccs 4B 8 On Vehicle ServiCe
389. iate point between compressor pulley 1 and crankshaft pulley 2 with about 100 N 10 kg 22 Ib force If belt tension is out of above specification adjust belt ten sion according to the following procedures Deflection of compressor drive belt a 6 9 mm 0 24 0 35 in ADJUSTMENT For Vehicle With P S 1 Loosen tension pulley bolts 3 and set hexagon wrench 4 to hexagon hole 2 Turn tension pulley 5 counterclockwise by hexagon wrench in order to obtain above specified tension 3 Tighten tension pulley bolts 3 to specified torque Tightening torque Tension pulley bolts a 25N m 2 5 kg m 18 0 Ib ft For Vehicle Without P S 1 Loosen tension pulley tightening nut 6 2 Adjust belt tension by tighten or loosen tension pulley adjust ing bolt 7 in order to obtain above specified tension 3 Tighten tension pulley tightening nut 6 A Vehicle with P S B Vehicle without P S 1B 16 AIR CONDITIONING OPTIONAL Wiring Diagram Electronical Diagnosis ee 20A IG COIL amp METER 15A R BI B BI P A 4WD model 4 Dual pressure switch 9 Thermal switch 14 Circuit fuse box B 2WD model 5 4WD controller 10 Ignition switch 15 Main fuse box 1 Blower fan motor 6 Condenser cooling fan motor relay 11 A C evaporator thermistor 16 Generator 2 Blower fan motor resistor 7
390. ic scan tool Before using scan tool read its Operator s Instruction Manual carefully to have good understanding as to what functions are available and how to use it Priorities for diagnosing troubles Vehicle with Immobilizer indicator lamp If multiple diagnostic trouble codes DTCs are stored proceed to the flow table of the DTC which has 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 Fuel system too lean too rich DTC P0300 P0301 P0302 P0303 P0304 Misfire detected and DTC P0400 EGR flow malfunction DTC P0171 P0172 Fuel system too lean too rich and DTC P0400 EGR flow malfunction DTC P0300 P0301 P0302 P0303 P0304 Misfire detected Be sure to read Precautions for Electrical Circuit Service in Section OA before inspection and observe what is written there ECM Replacement When substituting a known good ECM check for following conditions Neglecting this check may cause damage to a known good ECM Resistance value of all relays actuators is as specified respectively MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted to ground ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 11 Engine Diagnostic Flow Table Refer to the following pages for the details of
391. icle being serviced Use of incorrect one will result in leakage of refrigerant damage in parts or other faulty condition NOTE For basic servicing method of the air conditioning system that is not described in this section refer to AIR CONDITIONING BASIC MANUAL Part number 99520 02130 CONTENTS General Description cecccsseeeeeesseeeeesseees 1B 3 Performance Diagnosis 1B 10 Major Components and Location 06 1B 3 Performance diagnosis table 1B 12 Refrigerant Circulation c ccccccccseseecteeee 1B 4 Detail diagnosis table Ambient Refrigerant Type cccccsscssssssesesssssseesesees 1B 4 temperature at 30 C 86 F 0 1B 13 Diagnosis dinn aa n aa 1B 5 Compressor Drive Belt csseeesen 1B 15 General Diagnosis Table scscssssssseesseeee 1B 5 Electronical Diagnosis 0cceesesseeeees 1B 16 Abnormal Noise Diagnosis 00ccce 1B 7 Wiring Diagram eeens 1B 16 Abnormal noise from compressor 1B 7 A C System Inspection of ECM and ITS Abnormal noise from magnetic clutch 1B 7 AN e cd eee tise eee ek oa As 1B 17 Abnormal noise from tubing 0 1B 7 Refrigerant Recovery Evacuating and Abnormal noise from condenser 1B 7 CH ArG ing A AAE a ocd feats ceetetedunstavesdececs 1B 21 Abnormal noise from crankshaft pulley 1B 8 Operation Procedure for Refrigerant Abnormal noise from tension pulley 1B 8 Charging aisa snena e
392. ight and left off the ground e Shift transfer shift lever to 2H rear wheel position if equipped and start engine for a few seconds then stop e Side figure shows outer periphery of tire e Be careful not to depress brake pedal when checking tire for rotation If tire rotation is heavy check the following e Piston piston seal and cylinder slide bush of caliper for installation e Wheel bearings for breakage e Disc for flatness Improper flatness brings disc into contact with lining during rotation and makes rotation heavy To check this measure disc deflection 1 String 2 Spring measure BRAKES 5 29 Rear Brake Q 8 Nm 0 8 een P Q 9 N m 0 9 kg m 1 Brake back plate 5 Shoe return spring lower 9 Shoe hold down pin 2 Brake shoe 6 Adjuster lever 10 Wheel cylinder Apply brake fluid to piston cap 3 Spring and rod assembly 7 Adjuster spring w Tightening torque 4 Parking brake shoe lever 8 Shoe hold down spring Brake drum REMOVAL 1 Hoist vehicle and pull up parking brake lever 2 3 4 Remove wheel Release parking brake lever lt x wa Loosen parking brake cable adjusting nut 1 5 30 BRAKES 5 To increase clearance between brake shoe and brake drum remove rubber plug from brake back plate and turn adjuster downward with flat head screw driver 6 Remove brake drum 1 off by using 8 mm bolts 2
393. ile 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 DTC s 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 DIAG FLOW TABLE in this section check whether or not any abnormality exists e The vehicle was driven with parking brake pulled e The vehicle was driven with brake dragging e Wheel spin occurred while driving e Wheel s was turned while the vehicle was jacked up e The vehicle was stuck 5E 22 ANTILOCK BRAKE SYSTEM ABS INSPECTION Step Action Yes No 1 1 Disconnect the applicable sensor connector with ignition Go to step 2 Replace sensor switch OFF 2 Measure resistance between sensor terminals Resistance of wheel speed sensor 1 4 1 8 KQ at 20 C 68 F 3 Measure resistance between each terminal and body ground Insulation resistance 1MQ or higher Were measured resistance values in step 2 and 3 as spec ified See A 2 1 Ignition switch OFF Go to step 3 Sensor positive cir 2 Disconnect connector from ABS hydraulic unit control cuit shorted to
394. ilizer indi immobi cator lamp lizer indica tor lamp P0335 Crankshaft position sensor No signal for 2 sec During engine crank 1 driving 1 driving No 23 circuit malfunction ing cycle cycle P0340 Camshaft position sensor Aerator PE E 1 driving 1 driving No 15 circuit malfunction g T g cycle cycle Exhaust gas recirculation f i TA 2 driving Not P0400 Excessive or insufficient EGR flow flow malfunction detected cycles applicable Output waveforms of HO2S 1 and HO2S 2 are similar talyst t ffici 2 drivi Not P0420 eshte it Sees Time from output voltage change of ae 4 ii HO2S 1 to that of HO2S 2 is shorter than y PP specification Purge control valve circuit Purge control valve circuit is open or 2 driving Not P0443 f malfunction shorted to ground cycles applicable P0481 A C condenser fan control A C condenser fan relay terminal voltage is 2 driving Not circuit malfunction low when fan command is not outputted cycles applicable P0500 Vehicle speed sensor mal No signal while running in D range or 2 driving 1 driving No 16 function during fuel cut at decelerating cycles cycle P0505 Idle control system malfunc No closed signal to IAC valve is detected 2 driving Not tion cycles applicable P0601 Internal control module Data write error or check sum error when 2 driving Not No 71 memory check sum error written into ECM cycles applicable P1450 Barometric pressure sen _ Barometric pressure is lower or hig
395. inal B 10 14 V Terminal Vout 4 5 V Terminal GND 0 V Is check result satisfactory 4 Was terminal Vout voltage out of specification in W wire open short or BI B or B R wire Step 3 check poor connection open short or poor If wire and connection connection are OK substitute a known good ECM and recheck 5 Check Ground Circuit for Open Go to Step 6 B R wire open or 1 Turn ignition switch OFF poor ground connec 2 Check for continuity between GND terminal of tion CMP sensor connector and engine ground Is continuity indicated 6 Check CMP Sensor for Operation Go to Step 7 Replace CMP sen 1 Remove CMP sensor from sensor case sor 2 Remove metal particles on end face of CMP sen sor if any 3 Connect each connector to ECM and CMP sensor 4 Turn ignition switch ON 5 Check for voltage at terminal E19 11 of connector connected to ECM by passing magnetic sub stance iron 1 while keeping approximately 1 mm 0 03 in gap with respect to end face of CMP sensor See Fig 2 and 3 Does voltage vary from low 0 1 V to high 4 5 V or from high to low 7 Check signal rotor for the following Intermittent trouble or Clean rotor teeth or See Fig 4 e Damage e No foreign material attached Is it in good condition faulty ECM Check for intermittent referring to Intermittent and Poor Connection in Section OA replace CMP sensor
396. iner 3 a 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 the following proce dure 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 c Purge any air existing in center charging hose When using refrigerant container tap valve use the follow ing procedure to purge air i Once fully tighten refrigerant container tap valve 1 and then loosen open plate nut 2 slightly ii Open low pressure side valve 3 of manifold gauge set 4 a little iii AS soon as refrigerant comes out with a hiss through a clearance between refrigerant container and tap valve tighten plate nut 2 as well as low pressure side valve 3 iv Turn handle of tap valve 1 clockwise so that its needle is screwed into the new container to make a hole for refriger ant flow AIR CONDITIONING OPTIONAL 1B 27 4 8 After the system has been charged with specified amount 500 600 g of refrigerant or when low pressure gauge 1 and high pressure gauge 2 have indicated the following specified amount close low pressure side valve 3 on mani fold gauge set 4 At this time look into the sight glass 5 of receiver dryer 6 and check that
397. ing REMOVAL 1 Hoist vehicle and remove wheel 2 Disconnect stabilizer ball joint from axle housing 3 Remove brake caliper carrier bolts and suspend caliper CAUTION During removal be careful not to damage brake flexible hose and wheel speed sensor harness vehicle with ABS and not to depress brake pedal 3D 20 FRONT SUSPENSION 4 Support front axle housing by using floor jack NOTE When supporting axle housing it should be in non load condition 5 Remove shock absorber lower mounting bolt 1 6 Lower front axle housing 2 gradually as far down as where coil spring 1 can be removed 7 Remove coil spring 1 INSTALLATION Install removed parts in reverse order of removal procedures not ing the followings 1 Install coil spring 3 NOTE e Make sure that coil spring direction as shown e When seating coil spring mate spring end with stepped part 4 of lower spring seat 2 1 Front axle housing U Upper side A Small B Large 2 Install absorber lower mounting bolt refer to Front Shock Absorber in this section 3 Install caliper assembly and tighten caliper bolts to specified torque Tightening torque Brake caliper carrier bolts a 85 N m 8 5 kg m 61 5 Ib ft 4 Connect stabilizer ball joint to axle housing and tighten nut referring to Stabilizer Bar in this section for tightening torque sp
398. ing its evacuation If the gauge shows a stable reading suggesting no leakage continue evacuation Evacuation should be carried out for a total of at least 15 minutes Continue evacuation until low pressure gauge 9 indicates a vacuum less than 760 mmHg and then close both valves 8 10 Stop vacuum pump 7 Disconnect center charging hose 6 from pump inlet Now the system is ready for charging refrig erant AIR CONDITIONING OPTIONAL 1B 25 Charging CAUTION e Always charge through low pressure side of A C sys tem at after the initial charging is performed from the high pressure side with the engine stopped e Never charge to high pressure side of A C system with engine running Do not charge while compressor is hot e When installing tap valve to refrigerant container to make a hole there through carefully follow directions given by manufacturer e A pressure gauge should always be used before and during charging e The refrigerant container should be emptied of refrig erant when discarding it e The refrigerant container should not be heated up to 40 C 104 F or over e Refrigerant container should not be reversed in direc tion during charging Reversing in direction causes liq uid 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
399. ing the follow ing points e Tighten torque converter bolts to specified torque vehicle with A T Tightening torque Torque converter bolts a 20 N m 2 0 kg m 14 5 Ib ft 6A1 78 ENGINE MECHANICAL M13 ENGINE e Install seal ring and exhaust pipe to exhaust manifold Tighten pipe fasteners to specified torque Tightening torque Exhaust pipe bolts a 50 N m 5 0 kg m 36 5 Ib ft 6 Reverse disconnected hoses cables and electric wires for connection 7 Install air cleaner outlet hoses 8 Install radiator with cooling fan and connect A T fluid hoses vehicle with A T radiator inlet and outlet hoses referring to Water Pump Belt and Cooling Fan and Radiator in Sec tion 6B 9 Adjust generator belt tension referring to Water Pump Belt Tension in Section 6B 10 Adjust A C compressor and or P S pump belt tension if equipped referring to Compressor Drive Belt in Section 1B or Power Steering Belt in Section 3B1 11 Adjust accelerator cable play referring to Accelerator Cable Adjustment in Section 6E 12 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled 13 Refill cooling system with coolant engine with engine oil and A T with specified A T fluid vehicle with A T 14 Connect negative cable at battery 15 Verify that there is no fuel leakage coolant leakage oil leak age A T fluid leakag
400. ing vehicle 7 Remove steering lower shaft joint bolt 2 1 Steering lower shaft POWER STEERING P S SYSTEM If equipped 3B1 19 8 Disconnect high pressure hose 2 and return hose 3 from gear box 1 NOTE Plug up the section where hose disconnection 9 Remove gear box assy from vehicle CAUTION Never turn gear box input shaft Otherwise air goes into gear box which needs air bleeding for gear box NOTE e Don t disassemble P S gear box e For adjustment of worm shaft starting torque refer to item Adjustment of Worm Shaft Starting Torque in Section 3B INSTALLATION Reverse removal procedure to install P S gear box noting the fol lowing points e Tightening torque specification Tightening torque Power steering gear box mounting bolt and nuts a 80 N m 8 0 kg m 58 0 Ib ft Gear box high pressure union bolt b 35 N m 3 5 kg m 25 5 Ib ft e Before servicing set steering wheel and wheel tire at straight position 1 Steering gear box 4 High pressure hose 2 Bolt long 5 Return hose 3 Bolt short 3B1 20 POWER STEERING P S SYSTEM If equipped e Install pitman arm 1 to sector shaft 2 of P S gear box 3 with match marks A and B aligned as shown in figure and torque to specification Tightening torque Pitman arm mounting nut a 13
401. input or output voltage of 4WD controller 1 voltage between each circuit and body ground with 4WD controller con nector connected and ignition switch turned START engine run CAUTION e Disable air bag system if equipped with Air Bag refer to Disabling Air Bag System in Section 10B e This check must be carried out in a well ventilated place Terminal Circuit Wire Color Normal Voltage Condition about 0 V 10 seconds after transfer shift con A1 VSV1 Gr B trol lever 4WD gt 2WD 10 14V Transfer shift control lever 4WD about 0 V 5 seconds after transfer shift control A2 vsv2 Gr R lever 2WD gt 4WD 10 14V Transfer shift control lever 2WD A3 4WD indicator BI about 0 V Transfer shift control lever 4WD lamp 10 14V Transfer shift control lever 2WD k 5 10 seconds after engine starts or eee transfer shift control lever switches A4 A C controller G W about 0 V A C switch and blower fan switch ON A5 Ground B about 0 V any time sabourOY 5 seconds after transfer shift control A6 Vacuum switch Gr lever 2WD gt 4WD 10 14V Other than above about 0 V Transfer shift control lever 4WD a He SWIER BUR 10 14V Transfer shift control lever 2WD about 0 V A C switch ON and blower fan switch A8 A C switch G B ON 10 14V Other than above AQ Ignition coil Br ae L Voltage varies according to engine speed A10 Ignition switch Y R 10 14V IG ON With engine running FRONT SUSPENSION 3D 11 4WD Control System
402. ir WIG 1 a WB a 6 xs 29 Lg R E19 22 5 GIY 4 Lg E19 16 B R Ve 4 amp 30 t EE 1 G E19 26 A x BI G fa 50 Gr B Ba m ET Gr BI t GR a 7 R BI au a t G B A 20 i ERD Lop BVOr B BI 34 _ w Wa 32 ss FOARE TE 33 HEATER R P B z E oo fae P B u Ka 3e G1 VY D fe w 37 IG R BI RIG 39 11 eD WR ig B BI Br at T2 i gt t o o meen 2 oe aw E e BI OT ONO ay at SOME BVB t STO 48 al isk le Lane e B R or BIY t BATT fa ee B a B R t T B R J 4 54 7 gt 55 NOTE Type A is other than follows Type B is left hand steering vehicle equipped with fasten seat belt light and EGR valve or right hand steering vehicle equipped with fasten seat belt light and immobilizer control system 6E 10 ENGINE AND EMISSION CONTROL SYSTEM 1 CKP sensor 20 Power steering pressure switch 39 Ignition coil assembly for No 1 and No 4 spark plugs if equipped 2 CMP sensor 21 A C switch 40 Ignition coil assembly for No 2 and No 3 spark plugs 3 VSS 22 A C refrigerant pressure switch 41 Stop lamp switch if equipped 4 MAP sensor 23 Immobilizer control module if equipped 42 Stop lamp 5 Knock sensor 24 Data link connector 43 Lighting switch 6 TP sensor 25 Injector No 1 44 Position lamp 7 ECT
403. ir outlet side of element INSTALLATION Reverse removal procedure for installation 6A1 14 ENGINE MECHANICAL M13 ENGINE Air Cleaner Assembly REMOVAL 1 Disconnect negative cable at battery 2 Disconnect IAT sensor coupler 1 3 Disconnect breather hose from air cleaner outlet No 2 hose 2 4 Remove air cleaner outlet No 2 hose fastening bolt 3 5 Loosen air cleaner outlet No 2 hose clamp bolt 4 6 Remove air cleaner case fastening bolts 5 7 Remove air cleaner assembly with outlet hoses INSTALLATION Reverse removal procedure for installation Knock Sensor REMOVAL 1 Disconnect negative cable at battery 2 Remove intake manifold referring to Throttle Body and Intake Manifold in this section 3 Disconnect knock sensor connector 1 4 Remove knock sensor 2 from cylinder block INSPECTION Check sensor for damage If any faulty is found replace INSTALLATION Reverse removal procedure for installation Tightening torque Knock sensor a 23 N m 2 3 kg m 16 5 Ib ft ery 2 WS a Saleh a avid oT _ ENGINE MECHANICAL M13 ENGINE 6A1 15 Cylinder Head Cover REMOVAL 1 Disconnect negative cable at battery 2 Disconnect accelerator cable 1 from clamp 2 For left hand steering vehicle only 3 Remove cylinder head upper cover 3 4 Disconnect ignition coil couplers 1 5 Remo
404. ircuit Check 6 109 Table B 2 Fuel Pump and Its Circuit GHO CK EE E EE EE A 6 110 Table B 3 Fuel Pressure Check 6 112 Table B 5 A C Signal Circuits Check Vehicle with A C cccccceseseeeeeeeeseeteeees 6 117 Table B 6 Electric Load Signal Circuit CHECK a ra eee 6 119 TAble B 7 A C Condenser Fan Control System Che ck ccccccccceeeeeseesssseessssesseeeaes 6 121 Special Tool iinan nine etenae 6 123 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 3 General Information Statement on Cleanliness and Care An automobile engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter ten thousands of an inch 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 e A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation e 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
405. ire tools jack and jack han dle 1 Stop vehicle on level floor and place approximately about 140 kg 309 Ibs weight on rear housing so that rear axle weights 600 kg 1323 Ib Rear axle weight L 600 kg 1323 Ib 2 Install special tool to front and rear brake NOTE Special tool should be connected to bleeder plug hole of front driver s side brake and rear brakes Special tool Front brake A 09956 02310 B 55473 82030 Use the air bleeder plug supplied as a spare part Rear brake A 09956 02310 B 55473 82030 Use the air bleeder plug supplied as a spare part 1 Air bleeder plug 2 Weight 3 Attachment 3 Depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pressure of rear brake It should be within specification given below Front brake Rear brake 5000 kPa 3800 5100 kPa 50 kg cm 38 51 kg cm 711 psi 540 725 psi As done above apply 100 kg cm pressure to front brake and check that rear brake pressure is within specification as given below Front brake Rear brake 10000 kPa 5100 6500 kPa 100 kg cm 51 65 kg cm 1422 psi 725 924 psi 5 16 BRAKES 4 If rear brake pressure is not within specification adjust it by changing stay position as follows If rear brake pressure is higher than specification move sta
406. ires Lead is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel Section 3 of this man ual contains a procedure for determining the presence of a tire lead problem Before making any adjustment affecting toe setting the following checks and inspections should be made to ensure correctness of alignment readings and alignment adjustments 1 Check all tires for proper inflation pressures and approximately the same tread wear 2 Check for loose of king pin bearings Check tie rod ends if excessive looseness is noted it must be cor rected before adjusting 3 Check for run out of wheels and tires 4 Check vehicle trim heights if out of limits and a correction is to be made it must be made before adjusting toe 5 Check for loose of suspension arms 6 Check for loose or missing stabilizer bar attachments 7 Consideration must be given to excess loads such as tool boxes If this excess load is normally carried in vehicle it should remain in vehicle during alignment checks 8 Consider condition of equipment being used to check alignment and follow manufacturer s instructions 9 Regardless of equipment used to check alignment vehicle must be on a level surface both fore and aft and transversely Toe Adjustment Toe is adjusted by changing tie rod length Loosen right and left tie rod end lock nuts first and then rotate tie rod to align toe in to specification In
407. iridium platinum spark plugs replace them with new plugs Spark plug air gap a 1 0 1 1 mm 0 040 0 043 in Spark plug type NGK BKR6E 11 IFR5E11 DENSO K20PR U11 SK16PR A11 b NOTE NGK IFR5E11 or DENSO SK16PR A11 is highly recom mended for better engine starting performance under 25 C 13 F 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 5 Install spark plugs and torque them to specification Tightening torque Spark plug 25 N m 2 5 kg m 18 0 Ib ft 6 Install ignition coil assemblies referring to Ignition Coil Assembly in this section 7 Install high tension cords securely by gripping their caps Ignition Coil Assembly Including Ignitor 1 Disconnect negative cable at battery 2 Remove cylinder head upper cover 3 Disconnect ignition coil connector 4 Disconnect high tension cord 3 from ignition coil assembly 2 5 Remove ignition coil bolts 1 and then pull out ignition coil assembly 6F 8 IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM 6 Measure resistance between terminals as follows by using analog type ohmmeter If check result is not satisfactory replace ignition c
408. is section Charging and electrical sys tems should also be checked at this time Clear or Light Yellow This means that fluid level is below the bottom of hydrome ter Its possible cause is excessive or prolonged charging a broken case excessive tipping or normal battery deteriora tion When the battery is found in such condition it is possible that high charging voltage is caused by the faulty charging system and therefore charging and electrical systems need to be checked If there is a trouble in cranking and its cause lies in the battery it should be replaced CARE OF BATTERY WARNING Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive Do not allow battery fluid to contact eyes skin fabrics or painted surfaces as fluid is a corrosive acid Flush any contacted area with water immediately and thor oughly Batteries should always be kept out of reach of chil dren The battery is a very reliable component but needs periodi cal attentions Keep the battery carrier clean Prevent rust formation on the terminal posts Keep the electrolyte up to the upper level uniformly in all cells 6H 4 CHARGING SYSTEM Generator The generator is a small and high performance type with an IC regulator incorporated The internal components are connected electrically as shown below figure The generator features are as follows When kee
409. isassembled Water tight sealant SEALING COMPOUND 366E 99000 31090 To apply to mating surfaces of brake back plate and rear wheel cylinder Sealant SUZUKI BOND NO 1215 99000 31110 To apply to mating surfaces of brake back plate and rear axle housing To apply to mating surfaces of brake back plate and rear wheel bearing retainer Special Tool BRAKES 5 55 09900 20205 Micrometer 0 25 mm 09900 20602 Dial gauge 1 1000 mm 09900 20701 Magnetic stand Cam 09956 02210 Brake circuit plug 09922 85811 Connector pin remover 09942 15510 Sliding hammer Q SAS AN 09943 35511 Brake drum remover Front wheel hub remover oe 09950 78220 Flare nut wrench 10 mm 09950 96010 Booster piston rod gauge 09952 16010 Booster piston rod adjuster 09956 02310 Fluid pressure gauge 5 56 BRAKES ANTILOCK BRAKE SYSTEM ABS 5E 1 SECTION 5E ANTILOCK BRAKE SYSTEM ABS NOTE 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 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 e
410. ise cs ce ndiccseedecectten icc c deccccdnardateatiads 6H 7 REMOUNUNG siccrintesinimnrigiertteee On Vehicle Service ssscsccsssesesesssseseeeees 6H 9 Disassembly and reassembly 6H 13 Bate sce A eae Ae oy 6H 9 HISSCHON iiaeaa iieii PEENI Jump starting in case of emergency 6H 9 Specifications c cccccscceeeeesseeseeeesees 6H 17 Dismounting el ssaiastiteatsa teaescteadsceaxt ates 6H 11 aeit a AET AAE AE TE 6H 17 Handling Cape eee ones eee ee mR EEE 6H 11 Generate tence eek eed hae 6H 17 REMOUNTING eeeeeeee eenen 6H 11 Tightening Torque Specification 6H 17 6H 2 CHARGING SYSTEM General Description Battery The battery has three major functions in the electrical system e It is a source of electrical energy for cranking the engine e It acts as a voltage stabilizer for the electrical system e It can for a limited time provide energy when the electrical load exceeds the output of the generator CARRIER AND HOLD DOWN The battery carrier should be in good condition so that it will sup port the battery securely and keep it level Before installing the battery the battery carrier and hold down clamp should be clean and free from corrosion and make certain there are no parts in carrier To prevent the battery from shaking in its carrier the hold down bolts should be tight enough but not over tightened ELECTROLYTE FREEZING The freezing point of electro
411. itch contact coil and combination switch assembly 1 from steering column INSPECTION e For vehicle with air bag system Check contact coil and combination switch wire harness for any signs of scorching melting or other damage If it is dam aged replace Contact coil and combination switch assembly To horn Connector to driver air bag inflator module AJ oj N Connector to air bag wire harness INSTALLATION 1 Check to make sure that vehicle s front tires are set at straight ahead position and then ignition switch is at LOCK position 2 Install combination switch contact coil and combination switch assembly to steering column NOTE For vehicle with air bag system New contact coil and combination switch assembly is supplied with contact coil set and held at its center posi tion with a lock pin 2 and seal 1 Remove this lock pin after installing contact coil and combination switch assembly to steering column 3 Connect all connectors that have been disconnected in REMOVAL 4 Install steering column upper 3 and lower cover 4 and then tighten steering column cover standard screw 1 and tapping screws 2 CAUTION When installing lower cover 3 and upper cover 2 be careful so that combination switch contact coil and com bination switch lead wirer is not caught between covers STEERING WHEEL AND COLUMN 3C 11 5 Tigh
412. ith which communication was not possible After completing the check turn ignition switch off and dis connect scan tool from data link connector Without Using SUZUKI Scan Tool Vehicle Without Immobilizer Indicator Lamp 1 Check malfunction indicator lamp referring to Malfunction Indicator Lamp Check in this section o1 lt 2 With the ignition switch OFF position connect diagnosis switch terminal 3 and ground terminal 2 in monitor con nector 1 with service wire 4 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 does not flash or remains ON or OFF go to Diag nostic Flow Table A 4 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 15 NOTE e If abnormality or malfunction lies in two or more areas malfunction indicator lamp indicates applicable codes three times each And flashing of these codes is repeated as long as diagnosis terminal is grounded and ignition switch is held at ON position e Take a note of diagnostic trouble code indicated first 4 After completing the check turn the ignition switch OFF posi tion and disconnect service wire from monitor coupler Diagnostic trouble code DTC clearance Using SUZUKI Scan Tool 1 Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC c
413. ith A T only THROTTLE VALVE OPENING SIGNAL INSPECTION Check throttle valve opening throttle position signal referring to step 1 of DTC P1700 No 32 or 33 Flow Table in Section 7B If check result is not satisfactory check each wire harness circuit connections and TP sensor ENGINE COOLANT TEMP SIGNAL INSPECTION Check engine coolant temp signal referring to step 1 of DTC P1709 No 51 Flow Table in Section 7B If check result is not satisfactory check each wire harness circuit connection and ECT sensor Emission Control System EGR system If equipped SYSTEM INSPECTION USING SUZUKI SCAN TOOL 1 Connect SUZUKI scan tool to DLC with ignition switch OFF 2 Turn ignition switch ON and then select DATA LIST mode on scan tool 3 Make sure that vehicle condition is as following e Vehicle speed 0 km h 0 KPH e Engine speed lt 3000 rpm 4 Clear DTC by using CLEAR INFO mode 5 With engine idling without depressing accelerator pedal open EGR valve by using STEP EGR mode in MISC TEST menu In this state according as EGR valve opening increases engine idle speed drops If not possible cause is clogged EGR gas passage stuck or faulty EGR valve poor perfor mance of ECT sensor or TP sensor or DTC and or pending DTC is are stored in ECM memory 1 SUZUKI scan tool display 2 EGR valve opening 0 Close 100 Full Open ENGINE AND EMISSION CONTROL SYSTEM 6E 39
414. its circuit in this section e Malfunctioning PCV system Low compression PCV system in Section 6E Compression check in Section 6A1 e Improper valve lash Valve lash in Section 6A1 e Improper valve timing Timing chain and chain tensioner in Section 6A1 e Compression leak from valve seat Valves and cylinder head in Section 6A1 e Sticky valve stem Valves and cylinder head in Section 6A1 e Weak or damaged valve springs Valves and cylinder head in Section 6A1 e Compression leak at cylinder head gasket Valves and cylinder head in Section 6A1 e Sticking or damaged piston ring Pistons piston rings connecting rods and cylinders in Section 6A1 e Worn piston ring or cylinder Pistons piston rings connecting rods and cylinders in Section 6A1 6 24 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Engine has no power Engine overheating Refer to Overheating of this table e Faulty ignition coil Ignition coil assembly in Section 6F e Faulty knock sensor Knock sensor malfunction in this sec tion e Fuel pressure out of specification Diagnostic Flow Table B 3 e Faulty injector Diagnostic Flow Table B 1 e Faulty TP sensor ECT sensor or MAP sensor TP sensor ECT sensor or MAP sen sor in Section 6E e Faulty ECM Inspection of ECM and its circuit in this se
415. jack 2 to pre vent it from lowering 3E 6 REAR SUSPENSION 3 Remove upper mounting bolt 2 4 Remove lower mounting bolt 3 5 Remove shock absorber 1 INSTALLATION 1 Install shock absorber 1 refer to figure for proper installing direction of bush and washer 2 Tighten bolts 3 temporarily by hand 2 Remove floor jack 3 Lower hoist 4 Tighten shock absorber bolts 3 to specified torque NOTE Tighten lower bolt with vehicle off hoist and in non loaded condition Tightening torque Shock absorber upper and lower bolts a 85 N m 8 5 kg m 61 5 Ib ft Coil Spring REMOVAL 1 Hoist vehicle and remove wheel 2 Support rear axle housing 1 by using floor jack 2 3 Remove brake flexible hose E ring 2 1 Brake flexible hose REAR SUSPENSION 3E 7 4 Remove shock absorber lower mounting bolt 2 1 Shock absorber 5 Lower rear axle housing 2 gradually as far down as where coil spring 1 can be removed 6 Remove coil spring 1 pA y 7 Remove spring rubber seat 1 3E 8 REAR SUSPENSION INSTALLATION f 1 Install spring rubber seat 1 ra l NOTE Before installing spring rubber seat 1 apply soap water on it 2 Install coil spring 2 on spring seat 1 of axle housing and then raise axle housing gt g NOTE e Upp
416. kage Check Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is applied to system Then visually check gear box P S pump and P S fluid reservoir respectively and each joint of hydraulic pressure piping for leakage During this check however never keep steering wheel turned fully for longer than 10 seconds C7 l f fo amp 3 ss as eas 7 3B1 8 POWER STEERING P S SYSTEM If equipped Air Bleeding Procedure AIR BLEEDING FROM SYSTEM CAUTION When air bleeding is not complete it is indicated by foaming fluid on level gauge or humming noise from P S pump NOTE Bleed air from system when P S system has been ser viced in any way other than replacement of steering gear box e g disconnection of piping replacement of P S pump Never operate steering system while servicing Or Air Bleeding from gear box must be performed 1 Jack up the front end of vehicle and apply rigid rack 2 Fill P S fluid reservoir with fluid up to specified level 3 With engine running at idling speed add fluid up to specified level 4 When fluid stops reducing stop engine and leave P S sys tem as it is for about 10 minutes 5 After running engine at idling speed for 1 minute stop it 6 As a final step check to make sure that fluid is up to speci fied level 7 Check steering condition and P S system for fluid leakage AIR BLEEDI
417. kly checking whether the A C system has a proper charge of refrigerant or not Run engine at fast idle and operate A C at its maximum cooling capacity for a few minutes Then look at the sight glass 1 on receiver dryer 2 and compare what is observed with the symp toms listed in below 3 Bubbles CHECKING REFRIGERANT CHARGE Symptom Charge of refrigerant condition Correction Bubbles observed in sight glass Insufficient charge of refrigerant in system Check system for leaks with a leak tester No bubbles observed in sight glass No or insufficient charge of refrig erant in system Refer to the items 3 and 4 No temperature difference between compressor inlet and outlet Empty or nearly empty system Evacuate and charge system and then check it for leaks with a leak tester Noticeable temperature difference between compressor inlet and outlet Proper or too much charge of refrigerant in system Refer to the items 5 and 6 When A C is turned OFF refrigerant in sight glass clears immediately and remains clear Too much charge of refrigerant in system Discharge excess refrigerant in order to obtain a specified charge When A C is turned OFF refrigerant in sight glass once produces bubbles and then clears Proper charge of refrigerant in system No correction needed because charge of refrigerant is normal 1B 10 AIR CONDI
418. l by terminal Tightening torque Body ground bolt a 8 0 N m 0 8 kg m 6 0 Ib ft Generator Generator belt Refer to Water Pump Belt and Cooling Fan in Section 6B 6H 12 CHARGING SYSTEM Unit Repair Overhaul Generator Dismounting 1 Disconnect negative cable 2 at battery 1 i i 2 Remove bolts 2 and then canister 1 together with its bracket 3 Disconnect B terminal wire 3 and coupler 2 from gener ator 1 4 Remove generator belt Refer to Water Pump Belt and Cooling Fan in Section 6B 5 Remove generator 1 Generator adjusting bolt 2 Generator pivot bolt 3 B terminal Disassembly and reassembly CHARGING SYSTEM 6H 13 Remounting 1 Mount generator on the generator bracket 2 Tighten generator bolts Tightening torque Generator pivot bolt a 23 N m 2 3 kg m 16 5 Ib ft b 50 N m 5 0 kg m 36 0 Ib ft 3 Install generator cooling fan belt Refer to Water Pump Belt and Cooling Fan in Section 6B 4 Connect B terminal wire 3 and coupler to generator Tightening torque B terminal outer nut of generator b 8 0 N m 0 8 kg m 6 0 Ib ft 1 Upper generator bolt Short 2 Lower generator bolt Long 5 Install canister 6 Connect negative cable at battery 1 Pulley 5 Rotor 9 Rear housin
419. l noise from magnetic clutch Condition Possible Cause Correction A rumbling noise is heard when compres sor is not operating Worn or damaged bearings Replace magnet clutch assembly A chattering noise is heard when compres sor is engaged Faulty clutch clearance excessive Adjust clutch clearance Worn clutch friction surface Replace magnet clutch assembly Compressor oil leaked from lip type seal Replace lip type seal Contaminating the friction surface Replace compressor body assem bly Abnormal noise from tubing Condition Possible Cause Correction A droning noise is heard inside vehicle but not particularly noticeable in engine compartment Faulty tubing clamps Reposition clamps or increase the number of clamps Resonance caused by pulsation from variations in refrigerant pressure Attach a silencer to tubing or mod ify its position and length Abnormal noise from condenser Condition Possible Cause Correction Considerable vibra tion in condenser Resonance from condenser bracket and body Firmly insert a silencer between condenser bracket and body 1B 8 AIR CONDITIONING OPTIONAL Abnormal noise from crankshaft pulley Condition Possible Cause Correction A large rattling noise is heard at idle or sud den acceleration Loosen crankshaft pulley
420. l side 3 Connect sensor connector securely 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 6E 34 ENGINE AND EMISSION CONTROL SYSTEM 1 Disconnect negative cable at battery 2 For sensor 1 remove exhaust manifold cover 1 and dis connect connector of heated oxygen sensor and release its wire harness from clamps 3 For sensor 2 disconnect connector of heated oxygen sensor and release its wire harness from clamp Hoist vehicle and then remove exhaust No 1 pipe covers 3 4 Remove heated oxygen sensor 2 from exhaust manifold or exhaust No 1 pipe A HO2S 1 B HO2S 2 INSTALLATION Reverse removal procedure noting the following e Tighten heated oxygen sensor 2 to specified torque Tightening torque Heated oxygen sensor a 45 N m 4 5 kg m 32 5 Ib ft e Connect connector of heated oxygen sensor 2 and clamp wire harness securely e After installing heated oxygen sensor 2 start engine and check that no exhaust gas leakage exists Camshaft position sensor INSPECTION Check camshaft position sensor referring to DTC P0340 No 15 Diag Flow Table in Section 6 If malfunction is found replace REMOVAL 1 Disconnect negative cable at battery 2 Disconnect connector from camshaft position sensor 3 Remove camshaft posi
421. l tool remove 4 circlips 1 Special tool A 09900 06108 2 Apply penetrate lubricant between bearing race outer diame ter and shaft yoke bore 3 Using a set of special tool push spider bearing race 1 out 3 4mm 0 12 0 16 in from shaft yoke side face 2 Special tool B 09926 48010 Pushed out value of bearing race from shaft yoke side face a 3 4 mm 0 12 0 16 in 4 Tapping shaft yoke 2 with a hammer remove bearing race 1 from shaft yoke 2 completely 5 Take out bearing race 1 on the opposite side of shaft yoke 2 in the same way as shown 4B 6 PROPELLER SHAFTS 6 Push out bearing race 2 on flange yoke 1 in the same way as Step 2 7 Holding bearing race 2 by a vise 3 tap flange yoke 1 and take out race 8 Take out bearing race 2 on the opposite side of flange yoke 1 in the same way as Step 5 to Step 6 REASSEMBLY CAUTION Do not reuse spider 1 bearings 2 and circlips Other wise it may damage propeller shaft or cause abnormal vibration or noise 1 Apply grease to rollers 1 in bearing races 2 A Grease 99000 25030 NOTE Make sure that rollers 1 in bearing race 2 are all in place 2 With spider 4 inserted into bearing race 2 to prevent roll ers in race from coming out insert bearing race 2 into shaft yoke 3 until it is flush with side face of shaft yoke 3
422. lace Kingpin Kingpin Bearing Check 1 Inspect for wear or deterioration 2 Inspect for crack damage or deformation of kingpin If defective replace Barfield Joint Check To be checked on this joint is its axial play which shows up when a push and pull motion is given to live axle shaft and wheel spin dle held in both hands as shown in figure There should be no play at all but a play of up to 1 5 mm 0 06 in is permissible If play exceeds service limit replace it Axial play in barfield joint Standard Service Limit O mm no play 1 5 mm 0 06 in Steering Knuckle Seal Check The knuckle seal used at the spherical sliding joint between the knuckle and the inner case accomplishes the additional purposes of keeping out road dust and of acting as the damper for the steering handwheel As the wear of this seal advances its damp ing effect decreases and thus make the front wheel develop a ten dency to shimmy not only that road dust begins to creep into the sliding clearance to promote the wear of the spherical sliding sur faces Check the knuckle seal for wear or damage If defective replace with new one 3D 16 FRONT SUSPENSION Wheel Disc Nut and Bearing Check 1 Inspect each wheel disc for dents distortion and cracks Disc in badly damaged condition must be replaced 2 Check wheel nuts for tightness and as necessary retighten them to specification Tig
423. lace 9 1 Check ignition trigger signal wire for open short and poor connection Is circuit in good condition A Known good Ignition Coil Assembly Substitution Go to Step 11 Substitute a known 10 1 Substitute a known good ignition coil assembly good ECM and then and then repeat Step 2 repeat Step 2 Is check result of Step 2 satisfactory Ignition Timing Check System is in good con Check CKP sensor 11 1 Check initial ignition timing and ignition timing dition CKP sensor plate and advance referring to Ignition Timing section input signals related to Is check result satisfactory this system IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM 6F 5 On Vehicle Service Ignition Spark Test 1 Disconnect all injector connectors 1 from injectors WARNING Without disconnection of injector couplers combustible gas may come out from spark plug holes during this test and may get ignited in engine room 2 Remove cylinder head upper cover 3 Remove spark plug and check it for condition and type refer ring to Spark Plugs in this section 4 If OK connect ignition coil connector to ignition coil assem bly and connect spark plug to ignition coil assembly or high tension cord Ground spark plug 5 Crank engine and check if each spark plug sparks 6 If no spark is emitted inspect the related parts as described under Diagnosis earlier in this section High tension Cords 1 Remo
424. lant 99000 31090 14 Apply grease to axle shaft oil seals lip 1 right amp left as shown A Grease 99000 25010 15 Install rear axle shafts brake shoes brake drums and wheels For details refer to Rear Axle Shaft and Wheel Bearing in this section 16 Lower hoist 17 Tighten right and left trailing arm nuts and shock absorber lower bolts to specified torque Tighten lateral rod bolt and nut to specified torque NOTE When tightening these bolts and nuts be sure that vehi cle is off hoist and in non loaded condition Tightening torque Trailing arm nuts and lateral rod bolt and nut a 90 N m 9 0 kg m 65 0 Ib ft Shock absorber lower bolts b 85 N m 8 5 kg m 61 5 Ib ft 18 Check to ensure that brake drum is free from dragging and proper braking is obtained 19 Perform brake test foot brake and parking brake For brake test see Section 5 20 Check each installed part for oil leakage 1 Shock absorber 2 Trailing arm 3 Lateral rod 3E 22 REAR SUSPENSION Tightening Torque Specifications Tightening torque Fastening portion Nem kg m bt Shock absorber upper and lower bolt 85 8 5 61 5 Bump stopper 50 5 0 36 5 Lateral rod bolt and nut 90 9 0 65 0 Trailing arm nut Front and Rear Brake back plate nut 23 2 3 17 0 Brake pipe flare nut 16 1 6 11 5 Rear differential carrier bolt 23 2 3 17 0 Rear propeller sh
425. le from battery Hoist vehicle Disconnect rear wheel speed sensor coupler 1 Detach ABS wheel sensor wire harness from suspension frame xw rere wa 2 Rear wheel sensor OK ANTILOCK BRAKE SYSTEM ABS 5E 37 5 Remove rear wheel speed sensor 1 from rear axle housing CAUTION e Do not pull wire harness when removing rear wheel speed sensor 1 e Do not cause damage to surface of rear wheel speed sensor and do not allow dust etc to enter its installa tion hole 2 Rear wheel sensor ring SENSOR INSPECTION e Check sensor for damage e Check sensor for resistance Resistance between terminals of sensor 1 4 1 8 KQ at 20 C 68 F Resistance between sensor terminal and sensor body 1 MQ or more If any malcondition is found replace SENSOR RING INSPECTION e Check ring teeth for being missing damaged or deformed e Turn wheel and check if ring rotation is free from eccentricity and looseness e Check that no foreign material is attached If any faulty is found repair or replace INSTALLATION 1 Check that no foreign material is attached to sensor and ring 2 Install it by reversing removal procedure Tightening torque Rear wheel speed sensor bolt and rear wheel speed sen sor harness clamp bolts a 10 N m 1 0 kg m 7 2 Ib ft CAUTION Do not pull wire harness or twist more than necessary
426. le without immobi lizer indicator lamp Disconnect scan tool from DLC and connect D and E ter minals of monitor connector 1 or E to body ground by using service wire so that ignition timing is fixed on initial one oO lt 6 Using timing light 1 check that ignition timing is within specification Initial ignition timing test switch terminal grounded or fixed with SUZUKI scan tool 5 3 BTDC at idle speed Ignition order 1 3 4 2 7 If ignition timing is out of specification check the followings e CKP sensor CKP sensor plate TP sensor Test switch signal circuit e VSS Timing chain cover installation After checking Initial Ignition Timing release ignition timing fixation by using SUZUKI scan tool or disconnect service wire from monitor connector 9 With engine idling test switch terminal ungrounded throttle opening at closed position and car stopped check that igni tion timing is about 7 17 BTDC Constant variation within a few degrees from 7 17 indicates no abnormality but proves operation of electronic timing control system Also check that increasing engine speed advances ignition timing If above check results are not satisfactory check CKP sen sor test switch terminal circuit and ECM 6F 10 IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM Special Tools 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE A Mass storage cartridge for
427. liquid is nearly colorless Drain system and then close radiator drain plug tightly 5 lt 6 lt N Disconnect hose from water reservoir 1 Remove reservoir and pour out any fluid Scrub and clean inside of reservoir with soap and water Flush it well with clean water and drain Reinstall reservoir and hose 8 Add 50 50 mixture of good quality ethylene glycol antifreeze and water to radiator and reservoir Fill radiator to the base of radiator filler neck and reservoir to FULL level mark 2 Reinstall reservoir cap setting the arrow marks 4 on the reservoir and cap as the figure 3 LOW level mark ENGINE COOLING 6B 9 9 Run engine with radiator cap removed until radiator upper hose is hot 10 With engine idling add coolant to radiator until level reaches the bottom of filler neck Install radiator cap making sure that the ear of cap lines up with reservoir hose Water Pump Belt Tension WARNING Disconnect negative cable at battery before checking and adjusting belt tension 1 Inspect belt for cracks cuts deformation wear and cleanli ness If it is necessary to replace belt refer to Water Pump Belt and Cooling Fan in this section 2 Check belt for tension Belt is in proper tension when it deflects 4 5 to 5 5 mm 0 18 0 22 in under thumb pres sure about 10 kg or 22 Ib Water pump belt tension a 4 5 5 5 mm
428. lt satisfactory 12 Was IAC duty more than about 30 or 40 or Check parts or system Substitute a known good less than 70 or 60 for OFF duty meter in which can cause engine ECM and recheck Step 1 of this table See NOTE low idle e Accessory engine load e Clog of air passage e Etc NOTE Duty value with are applicable to vehicle used at high altitude higher than 2000 m or 6560 ft 6 116 ENGINE GENERAL INFORMATION AND DIAGNOSIS Fig 1 for Step 10 E17 6 Soneaennes ce mnaeen ccocey ICD EEE CO EM Table 1 for Step 9 and 10 Scan tool or voltmeter SUZUKI SCAN TOOL VOLTAGE AT E17 6 DISPLAY Selector lever P and N range P N range 10 14V position R D 2 and L range D range 0 1V ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 117 Table B 5 A C Signal Circuits Check Vehicle with A C E18 20 A E17 14 B 19 27 A E19 31P E18 24P E17 17P LI LI Ooo E OoN ONO E18 16 1 A C compressor magnet clutch 4 A C condenser fan 7 Evaporator temp sensor 2 A C switch 5 Refrigerant pressure switch A Case of TYPE A is show
429. lyte depends on its specific gravity Since freezing may ruin a battery it should be protected against freezing by keeping it in a fully charged condition If a battery is frozen accidentally it should not be charged until it is warmed SULFATION If the battery is allowed to stand for a long period in discharged condition the lead sulfate becomes converted into a hard crystal line substance which will not easily turn back to the active mate rial again during the subsequent recharging Sulfation means the result as well as the process of that reaction Such a battery can be revived by very slow charging and may be restored to usable condition but its capacity is lower than before LOW LEVEL CHARGING ELECTROLYTE NECESSARY REPLACE Green dot Dark DOAPO V2Z2 HN HNOZOFP O crp lt H lt PwH CHARGING SYSTEM 6H 3 BUILT IN INDICATOR IF EQUIPPED The battery has a built in temperature compensated indicator in the top of the battery This indicator is to be used with the follow ing diagnostic procedure When checking the indicator make sure that the battery has a clean top A light may be needed in some poorly lit areas Three types of indication which is available under normal opera tion are as follows Green Dot Battery is sufficiently charged for testing Dark Battery must be charged before testing If there is a cranking complaint battery should be tested as described in Diagnos
430. mentarily 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 what is written there ABS control module during inspection ABS Diagnostic Flow Table Refer to the following for the details of each step Be sure to read Precautions for Electronic Circuit Service in Section OA before inspection and observe Be sure to use the trouble diagnosis procedure as described in the flow table Failure to follow the flow table may result in incorrect diagnosis Some other diag trouble code may be stored by mistake in the memory of Step Action Yes No F Perform customer complaint analysis problem symptom confir mation and diagnostic trouble code check record and clear ance Is there any trouble code Go to Step 2 Go to Step 5 Perform driving test Is trouble symptom identified Go to Step 3 Go to Step 6 Check diagnostic trouble code Is it malfunction code Go to Step 4 Go to Step 5 Inspect and repair referring to applicable diagnostic trouble code table in this section Then perform final confirmation test after clearing diagnostic trouble code Is trouble recur Go to Step 7 End Inspect and repair referring to Diagnosis Table in
431. meter bearing size 41 982 42 000 mm pea 1 6528 1 6535 in 0 25 mm 0 0098 in 41 732 41 750 mm undersize 1 6430 1 6437 in Out of round A B Taper a b Crank pin taper and out of round Limit 0 01 mm 0 0004 in 6A1 68 ENGINE MECHANICAL M13 ENGINE e Rod bearing Inspect bearing shells for signs of fusion pitting burn or flak ing and observe contact pattern Bearing shells found in defective condition must be replaced Two kinds of rod bearing are available standard size bear ing and 0 25 mm 0 0098 in undersize bearing For identifi cation of undersize bearing it is painted red at the position as indicated in figure undersize bearing thickness is 1 605 1 615 mm 0 0632 0 0635 in at the center of it 1 Red paint e Rod bearing clearance 1 Before checking bearing clearance clean bearing and crank pin 2 Install bearing in connecting rod and bearing cap 3 Place a piece of gauging plastic 1 to full width of crank pin as contacted by bearing parallel to crankshaft avoiding oil hole 4 Install rod bearing cap 1 to connecting rod When installing cap be sure to point arrow mark 2 on cap to crankshaft pulley side as shown in figure After applying engine oil to rod bolts and tighten cap nuts 3 gradually as follows a Tighten all cap nuts to 15 N m 1 5 kg m 11 0 Ib ft b Retighten them to 45 c Repeat step b
432. ming any service on fuel system check to make sure that there are no fuel leakages as follows 1 Turn ON ignition switch for 3 seconds to operate fuel pump and then turn 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 feed hose 2 In this state check to see that there are no fuel leakages from any part of fuel system 6 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS Engine Diagnosis General Description This vehicle is equipped with an engine and emission control system which are under control of ECM The engine and emission control system in this vehicle are controlled by ECM ECM has an On Board Diagnos tic system which detects a malfunction in this system and abnormality of those parts that influence 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 accord ing to ENGINE DIAGNOSTIC FLOW TABLE 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 turn ON it should be diagnosed according to this flow table On Board Diagnostic System Ve
433. mission Fluid INSPECTION 1 Inspect transmission case for evidence of fluid leakage Repair leaky point if any 2 Make sure that vehicle is placed level for fluid level check 3 Check fluid level For fluid level checking procedure refer to Fluid Level Check in Section 7B and be sure to perform it under speci fied conditions If fluid level is low replenish specified fluid 1 Dipstick 2 FULL HOT mark 3 LOW HOT mark CHANGE 1 Inspect transmission case for evidence of fluid leakage Repair leaky point if any 2 Make sure that vehicle is placed level for fluid level check 3 Change fluid For its procedure refer to Changing Fluid in Section 7B CAUTION Use of specified fluid is absolutely necessary 1 Drain plug A MAINTENANCE AND LUBRICATION 0B 17 FLUID COOLER HOSE CHANGE Replace inlet and outlet hoses of cooler hose and their clamps For replacement procedure refer to Oil Cooler Hoses in Section 7B Transfer and Differential Oil INSPECTION 1 Check transfer case and differential for evidence of oil leak age Repair leaky point if any Make sure that vehicle is placed level for oil level check Remove level plug of transfer and differentials front and rear and check oil level Oil level can be checked roughly by means of level plug hole That is if oil
434. mit 2 0 mm 0 08 in 1 Pad rim 2 Disc 5 10 BRAKES Rear Brake Shoe Check Inspection should be carried out on following points after brake pedal travel pedal to wall clearance check even when pedal travel is normal Amount of brake shoe wear can be checked as follows 1 Hoist vehicle 2 Remove rubber plug 1 from brake back plate 3 Through hole of back plate visually check for thickness of brake shoe lining 2 If lining thickness a is found less than limit replace all shoes with new ones at the same time Rear brake shoe thickness a lining thickness Limit 1 0 mm 0 04 in 3 Brake shoe rim Master Cylinder and Brake Fluid Level Check 1 Check master cylinder and reservoir for crack damage and brake fluid leakage If any faulty condition exists correct or replace 2 Check that brake fluid level is between MAX and MIN marks on reservoir BRAKES 5 11 NOTE Be sure to use particular brake fluid either as indicated on reservoir cap of that vehicle or recommended in owner s manual which comes along with that vehicle Use of any other fluid is strictly prohibited Fluid level should be between MIN and MAX lines marked on reservoir When brake warning lamp lights sometimes during driv ing replenish fluid to MAX level When fluid decreases quickly inspect brake system for leakage Correct leaky points and
435. mittent switch OFF and then turn ignition switch ON referring to Intermittent See Fig 1 and Poor Connection in 2 Check throttle valve opening percentage dis Section OA played on scan tool Is it displayed 0 or 100 3 Check Wire Harness Go to Step 4 Lg R wire open Lg R 1 Disconnect connector from TP sensor with wire shorted to ground cir ignition switch OFF cuit or power circuit or 2 Check for proper connection to TP sensor at B BI wire Lg wire open Lg R Lg and B BI wire terminal or shorted to ground cir 3 If OK then with ignition switch ON check cuit or poor E19 22 or voltage at each of Lg R and Lg wire ter E19 16 connection minals and body ground See Fig 2 If wire and connection are Is voltage about 4 6 V at each terminal OK substitute a known good ECM and recheck 4 Check TP Sensor B BI wire open or poor Replace TP sensor 1 Check resistance between terminals of TP E19 10 connection sensor See Fig 3 If wire and connection are TP sensor resistance OK substitute a known Between 1 and 3 4 0 6 0 KQ good ECM and recheck Between 2 and 3 Varying according to throttle valve opening 0 02 6 0 KQ Are measured values within specifications A Fig 1 for Step 2 B Fig 2 for Step 3 C Fig 3 for Step 4 A ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 57 DTC P0121 Throttle Position Circuit Range
436. mshaft pulley 3 A C compressor pulley if equipped 4 Belt tension pulley 5 Connect negative cable to battery REPLACEMENT Replace belt with new one referring to Compressor Drive Belt in Section 1B or Power Steering Belt Check in Section 3B1 Valve Lash INSPECTION 1 Inspect intake and exhaust valve lash and adjust as neces sary Refer to Valve Lash Clearance in Section 6A1 for valve lash inspection and adjustment procedure 1 Camshaft 2 Thickness gauge Engine Oil and Filter CHANGE WARNING e 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 e 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 3 4 turn MAINTENANCE AND LUBRICATION OB 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 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 47330 NOTE Befor
437. n Cooling Water Pipes or Hoses REMOVAL 1 Drain cooling system 2 To remove water pipes or hoses loosen screw on each pipe or hose clip and pull hose end off INSTALLATION Install removed parts in reverse order of removal procedure not ing the following e Tighten each clamp bolt securely e Refill cooling system with proper coolant referring to description on Coolant and Cooling System Flush and Refill in this section Thermostat REMOVAL 1 Drain cooling system and tighten drain plug 2 Remove intake manifold referring to Throttle Body and Intake Manifold in Section 6A1 3 Disconnect thermostat cap 1 from thermostat case 2 4 Remove thermostat 3 6B 12 ENGINE COOLING INSPECTION 1 Make sure that air bleed valve 1 of thermostat is clear Should this valve be clogged engine would tend to overheat 2 Check valve seat for some foreign matters being stuck which prevent valve from seating tight 3 Check thermostatic movement of wax pellet as follows a Immerse thermostat 1 in water and heat water gradually b Check that valve starts to open at specification temp c If valve starts to open at a temperature substantially below or above thermostat unit should be replaced with a new one Such a unit if re used will bring about overcooling or over heating tendency Thermostat functional specification Temp at which valve begins
438. n See NOTE 3 Blower fan 6 ECT sensor B Case of TYPE B is shown See NOTE NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model 6 118 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Yes No 1 Check evaporator temp sensor Go to Step 2 Faulty A C evaporator 1 Disconnect ECM connectors with ignition thermistor or its circuit switch at OFF position 2 Check resistance between E19 14 terminal and E19 10 terminal Reference value Refer to characteristic curve below ECT sensor resistance At 0 C 6 3 6 9 KQ At 25 C 1 8 2 2 KQ Is it within specification 2 Check A C switch circuit Go to Step 3 G W wire open or short 1 Check voltage at E18 16 terminal under Poor E18 16 terminal con each condition given below nection A C switch signal specification If wire and connection are Ignition switch ON A C switch OFF OK substitute a known 10 14V good ECM and recheck Ignition switch ON A C switch ON Go to Step 3 0 1V Is check result satisfactory 3 Check A C compressor signal A C control system cir P wire open or short 1 Check voltage at E18 1 terminal under each cuits are in good condi Poor E18 1 terminal con condition given below See NOTE tion nection A C compressor signal specification If wire and connection are While engine running A C switch OFF OK substitute a known 0V good ECM and
439. n all Be sure to bleed air of brake system according to following proce dure when its oil hydraulic circuit has been disconnected 1 Fill master cylinder reservoir with brake fluid and keep at least one half full of fluid during bleeding operation 2 Remove bleeder plug cap 1 Attach a vinyl tube 2 to bleeder plug and insert the other end into container 3 3 Depress brake pedal several times and then while holding it depressed loosen bleeder plug about one third to one half turn 5 18 BRAKES 4 When fluid pressure in the cylinder is almost depleted retighten bleeder plug 5 Repeat this operation until there are no more air bubbles in hydraulic line 6 When bubbles stop depress and hold brake pedal and tighten bleeder plug Tightening torque Front caliper bleeder plug b 11 N m 1 1 kg m 8 0 Ib ft Rear wheel cylinder and LSPV bleeder plug c 8 N m 0 8 kg m 6 0 Ib ft 7 Then attach bleeder plug cap 8 After completing bleeding operation apply fluid pressure to pipe line and check for leakage 9 Replenish fluid into reservoir up to specified level 10 Check brake pedal for sponginess If found spongy repeat entire procedure of bleeding Brake Hose and Pipe Inspection HOSE The brake hose assembly should be checked for road hazard damage for cracks and chafing of the outer cover for leaks and blisters A light and mirro
440. n the circuit connector B in the figure and measure resistance between terminals A 1 and B 1 If no continuity is indicated that means that the circuit is open between terminals A 1 and B 1 If continuity is indi cated there is an open circuit between terminals B 1 and C 1 or an abnormality in connector B VOLTAGE CHECK If voltage is supplied to the circuit being checked voltage check can be used as circuit check 1 With all connectors connected and voltage applied to the cir cuit being checked measure voltage between each terminal and body ground a If measurements were taken as shown in the figure at the left and results were as listed below it means that the cir cuit is open between terminals B 1 and A 1 Voltage Between C 1 and body ground Approx 5V B 1 and body ground Approx 5V A 1 and body ground 0V b Also if measured values were as listed below it means that there is a resistance abnormality of such level that corre sponds to the voltage drop in the circuit between terminals A 1 and B 1 Voltage Between C 1 and body ground Approx 5V B 1 and body ground Approx 5V A 1 and body ground Approx 3V 2V voltage drop GENERAL INFORMATION 0A 15 Short circuit check wire harness to ground 1 Disconnect negative cable from battery 2 Disconnect connectors at both ends of the circuit to be checked NOTE If the circuit to be checked is connected to other parts 1 disconnect all connect
441. n the order as the malfunction is detected These data are not updated Shown in the table below are examples of how freeze frame data are stored when two or more malfunctions are detected FRAME FRAME 1 FRAME 2 FRAME 3 FRAME4 FREEZE FRAME ist FREEZE 2nd FREEZE 3rd FREEZE DATA to be updated FRAME DATA FRAME DATA FRAME DATA MALFUNCTION No malfunction No freeze frame data DETECTED P0400 EGR Data at P0400 Data at P0400 ORDER detected detection detection P0171 Fuel sys Data at P0171 Data at P0400 Data at P0171 tem detected detection detection detection P0300 Misfire Data at P0171 Data at P0400 Data at P0171 Data at P0300 detected detection detection detection detection P0301 Misfire Data at P0171 Data at P0400 Data at P0171 Data at P0300 detected detection detection detection detection Freeze Frame Data Clearance The freeze frame data is cleared at the same time as clearance of diagnostic trouble code DTC DATA LINK CONNECTOR DLC DLC 1 is in compliance with SAEJ1962 in its installation posi tion the shape of connector and pin assignment Serial data line K line of ISO 9141 3 is used for SUZUKI scan tool or generic scan tool to communicate with ECM TCM Air Bag SDM and ABS control module SUZUKI serial data line 6 is used for SUZUKI scan tool to com municate with immobilizer control module 2 B 4 ECM ground 5 Body grou
442. n them to 60 d Tighten bolts 11 20 to 22 N m 2 2 kg m 16 0 lb ft according to numerical order as shown 7 11 8 5 Tightening torque Crankshaft bearing cap No 1 bolts 1 10 50 N m 5 0 kg m 36 5 lb ft and extra tightening 60 Crankshaft bearing cap No 2 bolts 11 20 22 N m 2 2 kg m 16 0 Ib ft NOTE After tightening cap bolts check to be sure that crank shaft rotates smoothly when turning it by 12 N m 1 2 kg m 9 0 Ib ft torque or below 7 Apply sealant to mating surface of rear oil seal housing 1 A Sealant 99000 31150 Sealant amount for rear oil seal housing Width a 3 mm 0 12 in Height b 2 mm 0 08 in 6A1 92 ENGINE MECHANICAL M13 ENGINE 8 Install rear oil seal housing 1 and tighten bolts to specified torque by using special tool Special tool A 09911 97720 Tightening torque Rear oil seal housing bolts 11 N m 1 1 kg m 8 0 Ib ft A Crankshaft side 9 Install flywheel drive plate for A T 10 11 Using special tool lock flywheel or drive plate and tighten flywheel or drive plate bolts applied with sealant to specifica tion A Sealant 1215 99000 31110 Special tool A 09924 17810 Tightening torque Flywheel or drive plate bolts a 70 N m 7 0 kg m 51 0 Ib ft lt Inst
443. n this section e For vehicle with air bag system 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 under Diagnosis in Section 10B On Vehicle Service Service Precautions For Vehicle with Air Bag System Refer to Service Precautions in Section 10B Diagnosis and servicing Refer to Diagnosis and Servicing in Section 10B Disabling air bag system Refer to Disabling Air Bag System in Section 10B Enabling air bag system Refer to Enabling Air Bag System in Section 10B Handling and storage Refer to Handling and Storage in Section 10B Disposal Refer to Disposal in Section 10B 3C 4 STEERING WHEEL AND COLUMN Drive Air Bag Inflator Module For Vehicle with Air Bag System WARNING When handling an air bag inflator module be sure to read Service Precautions given earlier in this section and observe each instruction Failure to follow them could cause a damage to the air bag inflator module or result in personal injury REMOVAL 1 Disconnect negative battery cable at battery terminal 2 Disable air bag system Refer to Disabling Air Bag System in Section 10B 3 Remove st
444. n tool Tech 1A kit See NOTE B Mass storage cartridge ENGINE AND EMISSION CONTROL SYSTEM 6E 43 09931 76030 16 14 pin DLC cable Tech 2 kit SUZUKI scan tool See NOTE C NOTE e 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 e 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 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor e C This kit includes the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector 11 Storage case 12 Power supply Tightening Torque Specifications Tightening torque Fastening part Nem kg m bf TP sensor mounting screw 2 5 0 25 1 8 IAC valve screw 3 5 0 35 2 5 ECT sensor 15 1 5 11 5 Heated oxygen sensor 1 and 2 45 4 5 32 5 Camshaft position sensor 10 1 0 7 5 Fuel pressure regulator bolt 10 1 0 7 5 6E 44 ENGINE AND EMISSION CONTROL SYSTEM IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM
445. nal from 4WD switch vacuum is applied through its circuit to the vacuum switch The vacuum switch turns on when it detects vacuum exceeding 260 mmHg AWD indicator lamp It lights up when 4WD control system is in the 4WD mode It flashes to warn that locking hub operation has not completed 4WD control system fails to shift 4WD 3D 6 FRONT SUSPENSION OPERATION 2WD 4WD When the transfer shift control lever is shifted from the 2WD 2H position to the 4WD 4H or 4L position a 4WD ON signal is transmitted to the 4WD controller which then activates VSV2 to apply vacuum in the intake mani fold to the chamber B in the hub housing When vacuum is applied the slide gear is separated from the magnet moves toward the center of the vehicle body and gets engaged with the outer gear In this way the front axle shaft and the front wheel hub rotate as one unit If vacuum in the circuit fails to reach 260 mmHg within 15 seconds after operation of VSV2 due to such trouble as a hole in the vacuum pipe the slide gear does not operate and the 4WD indicator light flashes to warn that the hub is unlocked 1 ECM 8 Engine speed signal 15 Chamber B 22 Slide gear 2 4WD controller 9 Intake manifold 16 PistonA 23 Wheel hub 3 4WD indicator lamp 10 Check valv
446. nd ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 9 On Board Diagnostic System Vehicle without Immobilizer Indicator Lamp 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 indicates the result by turning on or flashing mal function indicator lamp 1 Heated oxygen sensor if equipped ECT sensor TP sensor IAT sensor MAP sensor CMP sensor CKP sensor Knock sensor VSS CPU Central Processing Unit of ECM ECM and malfunction indicator lamp 1 operate as follows Malfunction indicator lamp 1 lights when the ignition switch is turned 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 turns 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 immedia
447. nd extreme left turn 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 BRAKES 5 51 Rear Brake Hose Pipe REMOVAL 1 Raise suitably support vehicle Remove wheel if necessary 2 Clean dirt and foreign material from both hose end or pipe end fittings Remove brake hose and pipe INSTALLATION 1 Install brake hose and pipe by reversing removal procedure noting the following points Fill and maintain brake fluid level in reservoir Bleed brake system 2 Perform brake test and check each installed part for fluid leakage CAUTION e Position clamps to white marks on two brake pipes e Be sure to obtain more than 3 mm 0 118 in clearance between axle housing and brake pipe e Install clamps properly referring to figure below and tighten bolts e When installing hose make sure that it has no twist or kink T Top side 2 Rear axle housing 5 Fuel tank 8 Brake pipe vehicle with LSPV R Right side 3 Rear wheel cylinder 6 Chassis frame a b Clamp 1 Clamp 4 LSPV if equipped 7 Fuel pipe Q Tightening torque 5 52 BRAKES Parking Brake Lever Cable Parking brake lever REMOVAL 1 Hoist vehicle and release parking brake lever 2 Disconnect negative cable at battery 3 Remove parking brake lever cover 4 Disconnect lead wire o
448. nd in non loaded condition Tightening torque Lateral rod bolt and nut a 90 N m 9 0 kg m 65 0 Ib ft 18 Tighten right and left shock absorber lower mounting nuts and leading arm mounting nuts to specified torque NOTE When tightening these nuts be sure that vehicle is off hoist and in non loaded condition Tightening torque Shock absorber lower nuts and leading arm nuts a 90 N m 9 0 kg m 65 0 Ib ft 1 Shock absorber 2 Leading arm 19 Refill front axle differential housing with new specified gear oil Refer to Maintenance Service in Section 7E for refill 20 Confirm front end wheel alignment referring to Preliminary Checks Prior to Adjusting Front Alignment in Section 3A 3D 44 FRONT SUSPENSION Tightening Torque Specifications Tightening torque Fastening part Nem kg m lb ft Stabilizer mount bracket bolt 20 2 0 14 5 Stabilizer ball joint nut 50 5 0 36 5 Shock absorber lock nut 29 2 9 21 0 Shock absorber lower nut 90 9 0 65 0 Brake caliper carrier bolt 85 8 5 61 5 Wheel bearing lock nut 220 22 0 160 0 Wheel bearing lock washer screw 1 5 0 15 1 0 Air locking hub bolt 48 4 8 35 0 Wheel spindle bolt 50 5 0 36 5 Kingpin bolt 25 2 5 18 0 Knuckle seal cover bolt 10 1 0 7 5 Tie rod end nut Drag rod end nut Knuckle side ae ne aye Parera rod bolt and nut 90 9 0 65 0 Leading
449. nd 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 pretensioner 0A 4 GENERAL INFORMATION A Servicing and handling WARNING Many of service procedures require disconnection of Air Bag fuse and all air bag inflator module s from initia tor circuit to avoid an accidental deployment Driver and Passenger Air Bag Inflator Modules e 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 e When carrying a live air bag inflator module make sure the bag opening is pointed away from you In case of an accidental deployment the bag will then deploy with minimal chance of injury Never carry the air bag inflator module by the wires or connector on the underside of the module 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 pas senger 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 This is nec essary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment Otherwis
450. nd radiator cap for proper pressure holding capacity 1 1 kg cm 15 6 psi 110 kPa If replacement of cap is required use proper cap spec ified for this vehicle 6B 8 ENGINE COOLING NOTE After installing radiator cap 1 to radiator make sure that its ear 2 is aligned with reservoir hose 3 as shown in figure If not turn cap more to align its ear with hose 5 Tighten hose clamps and inspect all hoses Replace hoses whenever cracked swollen or otherwise deteriorated 6 Clean frontal area of radiator core Cooling System Flush and Refill WARNING To help avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Scald ing fluid and steam can be blown out under pressure if cap is taken off too soon 1 Remove radiator cap when engine is cool Turn cap slowly to the left until it reaches a stop Do not press down while turning it Wait until pressure is relieved indicated by a hissing sound then press down on cap and continue to turn it to the left 2 With radiator cap removed run engine until upper radiator hose is hot this shows that thermostat is open and coolant is flowing through system 3 Stop engine and open radiator drain plug 1 to drain cool ant 4 Close drain plug Add water until system is filled and run engine until upper radiator hose is hot again Repeat steps 3 and 4 several times until drained
451. nected when throttle valve is If OK substitute a known at idle position and fully opened See Fig 2 good ECM and recheck and 3 Dose voltage vary within specified value linearly as shown in figure 5 Check TP Sensor High resistance in Lg R Replace TP sensor A Fig 1 for Step 3 B Fig 2 for Step 4 C Fig 3 for Step 3 and 4 B C En 4 1 4 8 V I a TP sensor output voltage Ey Ve j 7E 0 2 0 8 V A When using SUZUKI scan tool B When not using SUZUKI scan tool Fig 4 for Step 5 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 59 DTC P0130 DTC No 14 Heated Oxygen Sensor HO2S Circuit Malfunction Sensor 1 CIRCUIT DESCRIPTION ECM B BI E19 13 1 Heated oxygen sensor 1 HO2S 1 DTC DETECTING CONDITION POSSIBLE CAUSE e When running at idle speed after engine warmed up and Heated oxygen sensor 1 malfunction running at specified vehicle speed HO2S 1 output volt e B BI or R circuit open poor connection or age does not go below 0 3 V or over 0 6 V short 2 driving cycle detection logic Monitoring once 1 driving DTC CONFIRMATION PROCEDURE WARNING
452. nectors 2 Using sound scope 2 check operating sound of each injector 3 when cranking engine See Fig 6 Was injector operating sound heard from all injectors Go to Engine Diagnosis Table Go to Diag Flow Table B 1 A Fig 1 for Step 5 B Fig 2 for Step 7 C Fig 3 for Step 8 Select DATA LIST mode B When not using SUZUKI scan tool C When using SUZUKI scan tool ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 23 D Fig 4 for Step 7 or 8 E Fig 5 for Step 10 F Fig 6 for Step 13 Engine diagnosis table Perform troubleshooting referring to following table when ECM has no DTC and no abnormality found in visual inspection and engine basic inspection previously Condition Possible Cause Reference Item Hard Starting Engine cranks OK e Faulty ignition coil Ignition coil assembly in Section 6F e Faulty CMP sensing rotor or CKP sensing rotor CMP sensing rotor or CKP sensing rotor inspection in Section 6E e Faulty idle air control system Diagnostic Flow Table B 4 e Faulty ECT sensor TP sensor CKP sen sor CMP sensor or MAP sensor e Fuel pressure out of specification ECT sensor TP sensor CKP sensor CMP sensor or MAP sensor in Sec tion 6E Diagnostic Flow Table B 3 e Faulty fuel injector Diagnostic Flow Table B 1 e Faulty ECM Inspection of ECM and
453. ner 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 General Description cccsssseeeeeeeeeeeeseeeees 3C 2 Centering contact coil for vehicle with DIA GTI OSIS sacasacesech dacitucsestsndadence Oasedvecessevntncietse 3C 3 air bag SYSLEM s iiicenassdvieiedisloatakeba daca 3C 8 Inspection and Repair Required Combination Switch For Vehicle without After ACCICONt c ccccccccccsesscsessessssesseeess 3C 3 Air Bag System Contact Coil and P Combination Switch Assembly For Vehicle On Vehicle SOMVICO ss sssssrrccvsssssoreernnne sobwecswante 3C 3 with Air Bag SyStem qccccccsssccssssescssssssssseon 30 9 Service Precautions For Vehicle with Steering Column Assembly ccccee 3C 11 Air Bag System iiaei etetesetireeetineeerennennten 3C 3 Steering Lock Assembly Diagnosis and Servicing eee 3C 3 Ignition Switch sccssseesssseesssessseeeeeeeeeeees 3C 15 Disabling air bag System s s 30 3 Steering Lower Shaft cccceeeeeees 3C 16 Handing and storage 36 3 Checking Steering Column for Accident
454. ness 3 Tail stop fuse 6 Stop lamp DESCRIPTION The ABS control module monitors the voltage at the stop lamp while the ignition switch is ON When the voltage is without the specified range at terminal A2 a DTC will be set INSPECTION Step Action Yes No 1 1 Turn IG switch OFF Check for proper connection to G W circuit open 2 Disconnect connectors from ABS hydraulic ABS control module at terminal unit control module assembly 3 Depress the brake pedal 4 Measure the voltage between the stop lamp recheck terminal A2 and body ground Is it 10 14 V A2 If OK substitute a known good ABS control module and ANTILOCK BRAKE SYSTEM ABS 5E 21 DTC C1021 DTC 21 DTC C1022 DTC 22 Right Front Wheel Speed Sensor Circuit DTC C1025 DTC 25 DTC C1026 DTC 26 Left Front Wheel Speed Sensor Circuit DTC C1031 DTC 31 DTC C1032 DTC 32 Right Rear Wheel Speed Sensor Circuit DTC C1035 DTC 35 DTC C1036 DTC 36 Left Rear Wheel Speed Sensor Circuit W G 4 4 1 Ignition switch 4 Right front wheel speed sensor 7 ABS hydraulic unit control module connector of harness 2 ABS hydraulic unit control module assembly 5 Left rear wheel speed sensor 3 Left front wheel speed sensor 6 Right rear wheel speed sensor DESCRIPTION The ABS control module monitors the voltage at the positive terminal of each sensor wh
455. ng e Check clog of A C evaporator fins If any clogs are found A C evaporator fins should be washed with water and should be dried with compressed air e Check A C evaporator fins for leakage and breakage If any defects are found repair or replace A C evaporator e Check A C evaporator fittings for leakage If any defects are found repair or replace A C evaporator 1B 36 AIR CONDITIONING OPTIONAL INSTALLATION Reverse removal procedure to install cooling unit and then noting the following instructions If A C evaporator thermistor removed its should be rein stalled in original position Install uniformly the packing 1 to installation hole Replenish specified amount of compressor oil to compressor suction side by referring to Replenishing Compressor Oil in this section Evacuate and charge refrigerant by referring to Evacuating and Charging in this section Adjust mode control cable temperature control cable and fresh air control cable by referring to Heater Control Lever Assembly in Section 1A Enable air bag system referring to Enable Air Bag System in Section 10B if equipped Fill engine coolant to radiator referring to Cooling System Flush and Refill in Section 6B Resistance kQ 7 6 65 6 5 4 3 2 1 Cee 0 65 23 30 40 10 15 20 25 C 50 60 70 77 F AIR CONDITIONING OPTIONAL 1B 37 A C Evapor
456. ng Brakes Brakes should be tested on dry clean smooth and reasonably level roadway which is not crowned Road test brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if the vehicle stops evenly and effectively Also drive vehicle to see if it leads to one side or the other without brake application If it does check the tire pressure front end alignment and front suspension attachments for looseness See diagnosis table for other causes Brake Fluid Leaks Check the master cylinder fluid levels While a slight drop in reservoir level does result from normal lining wear an abnormally low level indicates a leak in the system In such a case check the entire brake system for leak age If even a slight evidence of leakage is noted the cause should be corrected or defective parts should be replaced If fluid level is lower than the minimum level of reservoir refilling is necessary Fill reservoir with specified brake fluid Brake fluid Refer to reservoir tank cap CAUTION Since brake system of this vehicle is factory filled with brake fluid indicated on reservoir tank cap do not use or mix different type of fluid when refilling otherwise serious damage will occur Do not use old or used brake fluid or any fluid from a unsealed container Substandard or Contaminated Brake Fluid Improper brake fluid mineral oil or water in the fluid may cause the brake fluid to boil
457. ng a hammer handle tap piston head to install piston into bore Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore Special tool A 09916 77310 ENGINE MECHANICAL M13 ENGINE 6A1 71 5 Install bearing cap 1 Point arrow mark 2 on cap to crankshaft pulley side After applying oil to rod bolts and tighten cap nuts 3 gradu ally as follows NOTE Before installing bearing cap make sure to check con necting rod bolt diameter Refer to Inspection of Connecting Rod in this sec tion a Tighten all cap nuts to 15 N m 1 5 kg m 11 0 lb ft b Retighten them to 45 c Repeat Step b Tightening torque Connecting rod bearing cap nuts a 15 N m 1 5 kg m 11 0 lb ft and extra tightening 45 twice 6 Reverse removal procedure for installation as previously out lined 7 Adjust generator belt tension referring to Water Pump Belt Tension in Section 6B 8 Adjust A C compressor and or P S pump belt tension if equipped referring to Compressor Drive Belt in Section 1B or Power Steering Belt in Section 3B1 9 Adjust accelerator cable play referring to Accelerator Cable Adjustment in Section 6E 10 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled 11 Refill cooling system with coolant engine with engine oil and A T with specified A T
458. ng chain cover cylinder block and cylinder head Remove oil old sealant and dust from sealing surface ENGINE MECHANICAL M13 ENGINE 6A1 31 INSPECTION e Check oil seal 1 lip for fault or other damage Replace as necessary NOTE When installing new oil seal tap it in until its surface is flash with edge of timing chain cover 2 To install oil seal use special tool Bearing installer Special tool A 09913 75520 INSTALLATION Reverse removal procedure to install timing chain cover noting the following points 1 Apply sealant A to mating surface of cylinder and cylinder head and B to mating surface of timing chain cover as shown in figure A Sealant 99000 31140 B Sealant 99000 31150 Sealant amount for timing chain cover Width a 3 mm 0 12 in Height b 2 mm 0 08 in 2 Apply engine oil to oil seal lip then install timing chain cover 1 and water outlet pipe 2 Tighten bolts and nut to specified torque NOTE Before installing timing chain cover check that pin is securely fitted Tightening torque Timing chain cover bolts and nut a 23 N m 2 3 kg m 17 0 lb ft 6A1 32 ENGINE MECHANICAL M13 ENGINE 3 Install crankshaft pulley 1 Tighten bolt 2 to specified torque To lock crankshaft pulley use special tool with it as shown in figure Special tool A 09917 68221 Tighteni
459. ng surface with sealant B Sealant 99000 31110 or 99000 31090 13 Install wheel spindle 1 and disc dust cover 2 to steering knuckle Tighten wheel spindle bolts to specified torque Tightening torque Wheel spindle bolts a 50 N m 5 0 kg m 36 5 Ib ft 3D 32 FRONT SUSPENSION 14 Blow air into pipes at the top and the front of wheel spindle and check that it comes out of the hole as shown in figure for 4WD CAUTION As this hole is a part of the passage of the vacuum that activates the air locking hub if it is clogged with grease the air locking hub cannot be locked or unlocked Therefore be careful not to apply too much grease to avoid clogging the vacuum passage 15 Connect spindle vacuum hoses to wheel spindle for 4WD 16 Connect tie rod and drag rod to steering knuckle refer to Tie rod and Drag Rod in Section 3B 17 Install wheel hub assembly refer to Wheel Hub Bearing Oil Seal in this section 18 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nuts 95 N m 9 5 kg m 69 0 Ib ft 19 Lower hoist Front Axle Shaft Oil Seal Kingpin Bearing Outer Race REMOVAL 1 Hoist vehicle 2 Drain differential gear oil from front axle housing by loosing drain plug for 4WD 3 Remove steering knuckle For details refer to Steering Knuckle Wheel Spindle in this section 4 Draw out axle shaft 2
460. ng surface of timing chain cover referring to the figure of Step 1 in Timing Chain Cover Installation a 3 mm 0 12 in 5 Pin 11 Oil pump mounting bolt b 2 mm 0 08 in 6 Oil seal 12 Timing chain cover mounting bolts 1 Rotor plate 7 Relief valve Q Tightening torque 2 Outer rotor 8 Spring x lt Do not reuse 3 Inner rotor 9 Retainer m Apply thin coat of engine oil to sliding surface of each parts REMOVAL 1 Disconnect negative cable at battery 2 Remove timing chain cover referring to Timing Chain Cover in this section DISASSEMBLY 1 Remove rotor plate 1 by removing its mounting bolts 6A1 34 ENGINE MECHANICAL M13 ENGINE 2 Remove outer rotor 1 and inner rotor 2 3 Remove relief valve 1 spring 2 and retainer 3 by remov ing circlip 4 INSPECTION e Check oil seal lip for fault or other damage Replace as nec essary NOTE When installing new oil seal 1 press fit it till its end face is flush with oil pump case 2 end face Special tool A 09913 75520 ENGINE MECHANICAL M13 ENGINE 6A1 35 e Check outer 1 and inner rotors 2 rotor plate and oil pump case for excessive wear or damage e Check relief valve 1 for excessive wear or damage and operates smoothly MEASUREMENT Radial clearance Check radial clearance between
461. ng torque Fasteni t astening par Nem kg m lb ft Fuel pump assembly bolt 10 1 0 7 5 Special Tool 09919 47020 Quick joint remover ENGINE AND EMISSION CONTROL SYSTEM 6E 1 SECTION 6E ENGINE AND EMISSION CONTROL SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE Whether following systems parts are used in the particular vehicle or not depends on specifi
462. ng torque Crankshaft pulley bolt a 150 N m 15 0 kg m 108 5 Ib ft 4 Install P S pump bracket 1 P S pump 2 and A C com pressor and or P S pump belt tension pulley 3 if equipped referring to Power Steering Pump in Section 3B1 5 Install cylinder head cover referring to Cylinder Head Cover in this section 6 Install oil pan referring to Oil Pan and Oil Pump Strainer in this section 7 Install radiator with cooling fan and connect A T fluid hoses vehicle with A T radiator inlet and outlet hoses referring to Water Pump Belt and Cooling Fan and Radiator in Sec tion 6B 8 Adjust generator belt tension referring to Water Pump Belt Tension in Section 6B for adjusting procedure 9 Adjust A C compressor and or P S pump belt tension if equipped referring to Compressor Drive Belt in Section 1B or Power Steering Belt in Section 3B1 for adjusting proce dure 10 Refill cooling system with coolant engine with engine oil and A T with specified A T fluid vehicle with A T 11 Verify that there is no coolant leakage oil leakage and A T fluid leakage vehicle with A T at each connection ENGINE MECHANICAL M13 ENGINE 6A1 33 Oil Pump 12 U 23 N m 2 3 kg m A Sealant application 4 Timing chain cover 10 Circlip amount Apply sealant 99000 31140 to the mating surface of cylinder and cylinder head Apply sealant 99000 31150 to mati
463. nge in the crankshaft revolution speed and from how many times such change occurred in every 200 or 1000 engine revolutions it detects occurrence of misfire When ECM detects a misfire misfire rate per 200 revolutions which can cause overheat and damage to the three way catalytic converter it makes the malfunction indicator lamp MIL flash as long as misfire occurs at that rate After that however when the misfire rate drops MIL remains ON until it has been judged as normal 3 times under the same driving conditions Also when ECM detects a misfire misfire rate per 1000 revolutions which will not cause damage to three way catalytic converter but can cause exhaust emission to be deteriorated it makes MIL light according to the 2 driv ing cycle detection logic ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 73 DTC DETECTING CONDITION POSSIBLE CAUSE e Engine under other than high revolution condition e Engine overheating e Not on rough road e Vacuum leaks air inhaling from air intake system e Engine speed changing rate below specified value Ignition system malfunction spark plug s high e Manifold absolute pressure changing rate below tension cord s ignition coil assembly specified value e Fuel pressure out of specification e Throttle opening changing rate below specified e Fuel injector malfunction clogged or leakage value e Engine compression out of specification e Misfire rate per 200 or 1000 engine revolutions how
464. nge with a piece of wood or something soft 4 For vehicle without ABS Remove piston stopper bolt 1 Then remove secondary pis ton by blowing compressed air 2 into hole from which pis ton stopper bolt was removed Be cautions during removal as secondary piston jumps out INSPECTION e Inspect all disassembled parts for wear or damage and replace parts if necessary NOTE e Wash disassembled parts with brake fluid Do not reuse piston cups e Inspect master cylinder bore for scoring or corrosion It is best to replace corroded cylinder Corrosion can be identified as pits or excessive roughness NOTE Polishing bore of master cylinder with cast aluminum body with anything abrasive is prohibited as damage to cylinder bore may occur A Vehicle equipped with ABS B Vehicle not equipped with ABS 5 40 BRAKES e Rinse cylinder in clean brake fluid Shake excess rinsing fluid from cylinder Do not use a cloth to dry cylinder as lint from cloth cannot be kept from cylinder bore surfaces ASSEMBLY NOTE e See NOTE at the beginning of this section e Before assembling wash each part in fluid recom mended to use for that vehicle 1 Install secondary piston assembly into cylinder 2 Install primary piston in cylinder 3 Depress and install circlip 2 1 Rod 4 Install piston stopper bolt with pistons pushed in all the way and tighten it to speci
465. nger air bag inflator module 3 Air bag warning label on steering column 6 Seat belt pretensioner label on retractor GENERAL INFORMATION 0A 19 Vehicle Lifting Points WARNING Before applying hoist to underbody always take vehicle balance throughout service into consider ation Vehicle balance on hoist may change depending on what part to be removed Before lifting up the vehicle check to be sure that end of hoist arm is not in contact with brake pipe fuel pipe bracket or any other part When using frame contact hoist apply hoist as shown right and left at the same position Lift up the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by try ing to move vehicle body in both ways Work can be started only after this confirmation Make absolutely sure to lock hoist after vehicle is hoisted up When Using Frame Contact Hoist 1 Front lifting point 2 Rear lifting point 3 Front 0A 20 GENERAL INFORMATION A B When Using Floor Jack WARNING If the vehicle to be jacked up only at the front or rear end be sure to block the wheels on ground in order to ensure safety After the vehicle is jacked up be sure to support it on stands It is extremely dangerous to do any work on the vehicle raised on jack alone CAUTION Never apply jack against suspension
466. note following precautions e Replace injector O ring 1 with new one using care not to damage it e Check if cushion 2 is scored or damaged If it is replace with new one e Apply thin coat of fuel to O rings 1 and then install injectors 3 into delivery pipe 4 and intake manifold Make sure that injectors 3 rotate smoothly 6 If not proba ble cause is incorrect installation of O ring 1 Replace O ring 1 with new one Tighten delivery pipe bolts 5 and make sure that injectors 3 rotate smoothly 6 After installation with engine OFF and ignition switch ON check for fuel leaks around fuel line connection ENGINE AND EMISSION CONTROL SYSTEM 6E 29 Electronic Control System Engine control module ECM CAUTION As ECM consists of precision parts be careful not to expose it to excessive shock REMOVAL 1 Disconnect battery negative cable at battery 2 Disable air bag system refer to Disabling Air Bag System in Section 10B if equipped 3 Remove glove box 4 Disconnect ECM 1 and TCM 3 if equipped connectors 5 Loosen 2 nuts 2 and remove ECM and TCM if equipped INSTALLATION 1 Reverse removal procedure noting the following e Connect connectors to ECM and TCM if equipped securely Manifold absolute pressure sensor MAP sensor INSPECTION Check MAP sensor referring to MAP Sensor Individual Check in DTC P010
467. nsor circuit open or short rect during 8 revolution of crankshaft e Signal rotor teeth damaged e CMP sensor malfunction foreign material being attached or improper installation e ECM malfunction e CMP sensor phase lag REFERENCE Connect oscilloscope between terminals E19 11 of ECM connector connected to ECM and body ground and check CMP sensor signal A 2V DIV 2V DIV eee re ee 1 HC p D 10ms DIV 20ms DIV B 1 No 1 cylinder 3 No 3 cylinder A Oscilloscope Waveforms C CKP sensor waveform 2 No 2 cylinder 4 No 4 cylinder B Waveforms at specified idle speed D CMP sensor waveform DTC CONFIRMATION PROCEDURE 1 Clear DTC 2 Start engine and keep it at idle for 1 min 3 Select DTC mode on scan tool and check DTC ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 83 INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check CMP Sensor and connector for proper installa Go to Step 3 Correct tion Is CMP sensor installed properly and connector con nected securely 3 Check Wire Harness and Connection Go to Step 5 Go to Step 4 1 Disconnect connector from CMP sensor 2 Check for proper connection to CMP sensor at each terminal 3 If OK turn ignition switch ON and check for volt age at each terminal of sensor connector discon nected See Fig 1 Term
468. nstalling these piston rings to piston direct marked side of each ring toward top of piston b 1st ring 1 differs from 2nd ring 2 in thickness shape and color of surface contacting cylinder wall Distinguish 1st ring from 2nd ring by referring to figure c When installing oil ring 3 install spacer first and then two rails 3 After installing three rings 1st 2nd and oil rings distribute their end gaps as shown in figure Arrow mark 1st ring end gap 2nd ring end gap and oil ring spacer gap Oil ring upper rail gap Oil ring lower rail gap oaj AJ oO nm 6A1 70 ENGINE MECHANICAL M13 ENGINE INSTALLATION 1 Apply engine oil to pistons rings cylinder walls connecting rod bearings and crankpins NOTE Do not apply oil between connecting rod and bearing or between bearing cap and bearing 2 Install guide hoses 1 over connecting rod bolts These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly When installing piston and connecting rod assembly into cyl inder bore point front mark on piston head to crankshaft pul ley side A Crankshaft pulley side B Flywheel side Install piston and connecting rod assembly into cylinder bore Use special tool Piston ring compressor to compress rings Guide connecting rod into place on crankshaft Usi
469. nt 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 damage to the part may result Never attempt to heat quench or straighten any front suspension part Replace it with a new part or CONTENTS General Description ccscseseeeceeeeeesseeeees 3D 2 On Vehicle Service 2 ccceeseseeeeeeeeeeeeeee 3D 17 AWD Control System 3D 2 Stabilizer Bar Bushings 3D 17 DiaQnois s ecssssssesessseseseseseseestsnenseseeeteess 3D 8 Front Shock Absorber w cccse se iteielesien 3D 19 Diagnosis Table PAE E T AEE 3D 8 Coil Spring TETERE E E O E seeee rete 3D 19 4WD Controller and ITS Circuit Check 3D 10 Bump Stopper and Spring Upper Seat 3D 21 4WD Control System Check 0 cceceeee 3D 11 Wheel Hub Bearing Oil Seal 4 3D 21 Stabilizer bar bushing check 3D 13 Steering Knuckle Wheel Spindle 3D 28 Shock Absorber and or Coil Spring Front Axle Shaft Oil Seal Kingpin CHEE ects Sue me corte 3D 14 Bearing Outer Race sess 3D 32 Leading Arm Lateral Rod Steering Steering Knuckle Seal 3D 34 Knuckle Che
470. nts Replace tie rod end Worn king pin bearings or king pin Replace king pin bearing and or king pin Poor Returnability Bind in tie rod end ball studs Replace tie rod end Bind in king pin bearings Replace king pin bearing Bind in steering column Repair or replace Steering gear box needing lubricant Check repair or lubricate steering gear box Disturbed front wheel alignment Check and adjust front wheel align ment Steering gear box not properly adjusted Check and adjust steering gear box torque Tires not adequately inflated Adjust pressure Steering Noise Loose bolts and nuts Retighten Rattle or Chuckle Broken or otherwise damaged wheel bearings Replace wheel bearing Worn or sticky tie rod ends Replace tire rod end Linkage joints needing grease Lubricate or replace 3 4 STEERING SUSPENSION WHEELS AND TIRES Condition Possible Cause Correction Abnormal Noise Worn sticky or loose tie rod ends drug rod ball Replace tie rod end king pin bear Front End joints king pin bearings or axle shaft joints ing or axle shaft joint Damaged shock absorbers or mountings Replace or repair Worn leading arm bushings Replace Worn stabilizer bar bushings Replace Worn lateral rod bushings Replace Loose stabilizer bar Tighten bolts or replace bushes Loose wheel nuts Tighten wheel nuts Loose suspension bolts or nuts Tighten suspension bolts or nuts Broken or otherwise d
471. o individual inspection of it is impossi ble 1 Remove filler cap and turn ON ignition switch 2 Then fuel pump operating sound should be heard from fuel filler 1 for about 2 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 2 in Section 6 2 Turn OFF ignition switch and leave over 10 minutes as it is 6E 24 ENGINE AND EMISSION CONTROL SYSTEM 3 Fuel pressure should be felt at fuel feed hose 1 for 2 sec onds after ignition switch ON If fuel pressure is not felt advance to Diagnostic Flow Table B 3 in Section 6 REMOVAL Remove fuel tank from body according to procedure described in Fuel Tank of 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 1 Install fuel pump to its bracket 2 Install fuel pump to fuel tank and then install fuel tank to body according to procedure described in Fuel Tank of Section 6C Fuel pressure regulator ON VEHICLE INSPECTION Perform fuel pressure inspection according to procedure described in Fuel Pressure Inspection of this section REMOVAL 1 Relieve fuel pressure according to procedure described on Fuel Pressure Relief Procedure in Section 6 2 Disc
472. o one notch 5 12 BRAKES If number of notches is out of specification adjust cable by refer ring to adjustment procedure described on the following so as to obtain specified parking brake stroke NOTE Check tooth tip of each notch for damage or wear If any damage or wear is found replace parking brake lever ADJUSTMENT NOTE Make sure for following conditions before cable adjust ment e No air is trapped in brake system e Brake pedal travel is proper e Brake pedal has been depressed a few times with about 30 kg 66 Ibs load e Parking brake lever 1 has been pulled up a few times with about 20 kg force e Rear brake shoes are not worn beyond limit and self adjusting mechanism operates properly After confirming that above 5 conditions are all satisfied adjust parking brake lever stroke by loosening or tightening adjusting nut 3 indicated in figure NOTE Check brake drum for dragging after adjustment Parking brake stroke when lever is pulled up at 200 N 20 kg 44 Ibs 6 8 notches 2 Brake cable Booster Operation Check There are two ways to perform this inspection with and without a tester Ordinarily it is possible to roughly determine its condition without using a tester NOTE For this check make sure that no air is in hydraulic line BRAKES 5 13 CHECK AIR TIGHTNESS 1 Start engine 2 Stop engine after running for 1 to 2 minutes 3 Depress b
473. od ECM and recheck A Fig 1 for Step 2 B Fig 2 for Step 3 C Fig 3 for Step 6 A B C ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 53 DTC P0115 DTC No 19 Engine Coolant Temperature ECT Circuit Malfunc tion CIRCUIT DESCRIPTION ECM G B B BI DTC DETECTING CONDITION POSSIBLE CAUSE e Low engine coolant temperature High voltage High resis e G B circuit open or shorted to power tance e B BI circuit open e High engine coolant temperature Low voltage Low resis e ECT sensor malfunction tance e ECM malfunction NOTE e When DTC P0105 No 11 P0110 No 18 P0115 No 19 P0120 No 13 and P0460 are indicated together it is possible that B BI circuit is open e Before inspecting be sure to check that coolant temp meter in combination meter indicates normal operating temperature Engine is not overheating e When this DTC and P1709 are stored together also clear DTC stored in TCM after completion of repair DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC 6 54 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine
474. of which is given a section number as indicated in the Table of Contents on following page And on the first page of each individual section is an index of that section This manual should be kept in a handy place for ready reference of the service work Strict observance of the so specified items will enable one to obtain the full performance of the vehicle When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricant 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 JIMNY SN413 WIRING DIAGRAM MANUAL 99512 81A20 015 SUZUKI MOTOR CORPORATION COPYRIGHT SUZUKI MOTOR CORPORATION 2002 TABLE OF CONTENTS General Information 0A ene ooo Maintenance and Lubrication 0B Heater and Ventilation 1A HEATING AND AIR CONDITIONING Air Conditioning Optional 1B Steering Suspension Wheels and Tir
475. oil assem bly Secondary coil resistance a b 7 5 14 KQ at 20 C 68 F 7 Install ignition coil assembly 8 Tighten ignition coil bolts and then connect ignition coil cou pler 9 Install high tension cord to ignition coil assembly while grip ping its cap 10 Install cylinder head upper cover Crankshaft Position Sensor CKP Sensor Refer to Crankshaft Position Sensor in Section 6E for removal inspection and installation Ignition Timing NOTE e Ignition timing is not adjustable If ignition timing is out of specification check system related parts e Before starting engine place transmission gear shift lever in Neutral shift selector lever to P range for A T model and set parking brake INSPECTION 1 When using SUZUKI scan tool 1 connect SUZUKI scan tool to DLC 2 with ignition switch OFF Special tool A SUZUKI scan tool 2 Start engine and warm it up to normal operating tempera ture 3 Make sure that all of electrical loads except ignition are switched off 4 Check to be sure that idle speed is within specification Refer to Idle Speed Idle Air Control Duty Inspection in Section 6E IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM 6F 9 5 Fix ignition timing to initial one as follows a When using SUZUKI scan tool Select MISC mode on SUZUKI scan tool and fix ignition timing to initial one Without using SUZUKI scan tool vehic
476. oint bolt 25 2 5 18 0 Steering gear box nuts and bolt 80 8 0 58 0 Tie rod end nut and drag rod end nut 43 4 3 315 knuckle side Wheel nut 95 9 5 69 0 Tie rod end lock nut 65 6 5 47 0 Drag rod end nut pitman arm side 50 5 0 36 5 Required Service Material Recommended SUZUKI product Material Part Number P Use Sealant SUZUKI BOND NO 1215 e Thread of oil breathing plug 99000 31110 Special Tools 09913 65210 Tie rod end remover 09944 18211 Pinion torque checking socket POWER STEERING P S SYSTEM If equipped 3B1 1 SECTION 3B1 POWER STEERING P S SYSTEM If equipped WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must
477. ole 9 Install intake manifold injectors and exhaust manifold to cyl inder head INSTALLATION 1 Clean mating surface of cylinder head and cylinder block Remove oil old gasket and dust from mating surface 2 Install knock pins 1 to cylinder block 3 Install new cylinder head gasket 2 to cylinder block TOP mark provided on gasket comes to crankshaft pulley side facing up toward cylinder head side 6A1 60 ENGINE MECHANICAL M13 ENGINE te O iG Ni ne Oey fais A aloa ae o o 40 Qe ams see b BN a BETO 4 o o Be OSRIR LAA Hen eee oe 240 OO O oo l 4 Make sure that oil jet venturi plug 1 is installed and if it is that it is not clogged When installing it be sure to tighten to specified torque Tightening torque Venturi plug a 5 N m 0 5 kg m 3 5 Ib ft 5 Install cylinder head to cylinder block Apply engine oil to cylinder head bolts and tighten them gradually as follows NOTE If cylinder head bolts are reused check thread diameters of them for deformation according to the following and replace them with new ones if thread diameter difference exceeds limit Measure each thread diameter of cylinder head bolt 1 at A on 83 5 mm 2 81 in from seat side of flange bolt and B on 115 mm 4 53 in from seat side of flange bolt by using a micrometer 2 Then calculate difference in diameters
478. oltage If voltage is below or in standard value increase engine speed up to 2 000 2 500 rpm soon after starting engine and read maxi mum value on ammeter immediately If current is less than 49 A repair or replace generator CHARGING SYSTEM 6H 9 2 Ground F terminal and start engine then measure voltage at B terminal as shown in left figure e Voltage is higher than standard value It is considered that generator itself is good but IC regulator has been damaged replace IC regulator e Voltage is lower than standard value Generator itself has problem check the generator Load Check 1 Run engine at 2 000 rpm and turn on head light and heater motor 2 Measure current and if it is less than 20 A repair or replace generator OVERCHARGED BATTERY 30 C 20 C 22 F 68 F Temperature 1 To determine battery condition refer to Battery section 2 If obvious overcharged condition exists as evidenced by excessive spewing of electrolyte measure generator B ter minal voltage at engine 2 000 rpm 3 If measured voltage is higher than upper limit value proceed to disassembly section of generator service 4 Check ground of brushes If brushes are not grounded replace IC regulator Then check field coil for grounds and shorts referring to INSPECTION section On Vehicle Service Battery Jump starting in case of emergency WITH AUXILIARY BOOSTER BATTERY CAUTION If
479. olts and install board 1 or the like This prevents damage to radiator fins when removing and installing radiator 9 Remove radiator with cooling fan Then remove water pump pulley Refer to Radiator and Water Pump Belt and Cool ing Fan in Section 6B 10 Remove A C compressor and or P S pump belt tension pul ley 1 if equipped 11 With hose connected detach P S pump from its bracket and then remove P S pump bracket 2 if equipped referring to Power Steering Pump in Section 3B1 NOTE Suspend removed P S pump at a place where no damage will be caused during removal and installation of timing chain cover 6A1 30 ENGINE MECHANICAL M13 ENGINE 12 Remove crankshaft pulley bolt To lock crankshaft pulley 1 use special tool with it as shown in figure Special tool A 09917 68221 13 Remove crankshaft pulley 1 If itis hard to remove use special tools as shown in figure If bolts of special tool are too long replace them with those of suitable length Special tool A 09944 36011 B 09926 58010 14 Remove oil pan referring to Oil Pan and Oil Pump Strainer in this section 15 Remove cylinder head cover referring to Cylinder Head Cover in this section 16 Disconnect CMP sensor coupler 1 and release its harness clamps 17 Remove water outlet pipe 2 18 Remove timing chain cover 3 CLEANING e Clean sealing surface on timi
480. om hoist brake test should be performed U 23 N m 2 3 kg m E 23 N m 2 3 kg m E 20 N m 2 0 kg m a SG lt I O E ViewE J ViewJ 2 Floor m Tightening torque G ViewG K View K 3 Cross member H ViewH 1 Bracket 4 Clamp 5 54 BRAKES Tightening Torque Specifications described in owner s manual of vehi cle f Tightening torque Fastening part Nem kg m bt Brake caliper carrier bolt 85 8 5 61 5 Brake caliper pin bolt 22 2 2 16 0 Front brake flexible hose bolt 23 2 3 17 0 Rear brake back plate nut 23 2 3 17 0 Master cylinder nut 13 1 3 9 5 Booster nut 13 1 3 9 5 Brake pipe 5 way 4 way joint bolt 11 1 1 8 0 Brake pipe flare nut 16 1 6 12 0 LSPV bolt P valve bolt 25 2 5 18 0 Front caliper 11 1 1 8 0 lane VOOSE ung Rear wheel cylinder LSPV 8 0 8 6 0 Wheel nut 95 9 5 69 0 Hose bracket bolt 11 1 1 8 0 Booster clevis nut 25 2 5 18 0 Stop light switch lock nut 6 5 0 65 4 7 Parking brake lever bolt 23 2 3 17 0 Wheel cylinder mounting bolt 9 0 9 6 5 Piston stopper bolt 10 1 0 7 5 LSPV adjust bolt 25 2 5 18 0 Required Service Material Material Recommended SUZUKI products Use Brake fluid Indicated on reservoir tank cap or e To fill master cylinder reservoir To clean and apply to inner parts of master cylinder caliper and wheel cylinder when they are d
481. on symptoms appearing on the vehicle symptoms obtained through steps of customer com plaint analysis trouble symptom confirmation and or basic engine check and repair or replace faulty parts if any 9 TROUBLESHOOTING FOR DTC SEE EACH DTC DIAG FLOW TABLE Based on the DTC indicated in Step 5 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 or other part and repair or replace faulty parts 10 CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur e g wire harness connector etc referring to Intermittent and Poor Connection in Section OA and related circuit of DTC recorded in Step 2 11 FINAL CONFIRMATION TEST Confirm that the problem symptom has gone and the engine is free from any abnormal conditions If what has been repaired is related to the DTC clear the DTC once perform DTC confirmation procedure and confirm that no DTC is indicated ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 13 Customer problem inspection form example ViN Date of problem PROBLEM SYMPTOMS O Difficult Starting L Poor Driveability No cranking O Hesitation on acceleration O No initial combustion O Back fire L_JAtter fire O No combustion O Lack of power O Poor starting at O Surging cold warm always O abnormal knocking O
482. ondition Tightening torque Stabilizer mount bracket bolts a 20 N m 2 0 kg m 14 5 Ib ft Stabilizer ball joint nuts b 50 N m 5 0 kg m 36 5 Ib ft 4 Install front bumper 5 Lower hoist 3 Stabilizer ball joint 4 Front axle housing FRONT SUSPENSION 3D 19 Front Shock Absorber REMOVAL 1 Hoist vehicle 2 Support front axle housing by using floor jack to prevent it from lowering refer to When Using Floor Jack under Vehi cle Lifting Points in Section OA 3 Remove shock absorber lower mounting bolt 6 4 Remove shock absorber upper mounting lock nut 2 and absorber nut 3 Then remove shock absorber 1 INSTALLATION Install removed parts in reverse order of removal proceeded not ing the followings e As shown in figure install washer 4 and bush 5 first and after tightening absorber nut 3 tighten lock nut 2 to speci fied torque Tightening torque Shock absorber lock nut a 29 N m 2 9 kg m 21 0 Ib ft e Install absorber lower mounting bolt 6 in proper direction as shown in the figure and tighten it with no load applied to axle housing Tightening torque Shock absorber lower nut b 90 N m 9 0 kg m 65 0 Ib ft e Confirm front end wheel alignment referring to Preliminary Checks Prior to Adjusting Front Alignment in Section 3A W Wheel side 7 Lower mounting nut Coil Spr
483. onditions or collision whether the damage is in body or in suspension should be determined If the body is dam aged it should be repaired and if suspension is damaged it should be replaced Toe Setting Toe is the turning in or out of the front wheels The purpose of a toe specification is to ensure parallel rolling of the front wheels Excessive toe in or toe out may increase tire wear Toe in B A 2 6 mm 0 08 0 24 in NOTE Toe in value was measured by using a toe in gauge For adjusting toe setting refer to Toe Adjustment in this section A Wheel top view 1 Forward Camber Camber is the tilting of the front wheels from the vertical as viewed from the front of the vehicle When the wheels tilt outward at the top the camber is positive When the wheels tilt inward at the top the camber is negative The amount of tilt is measured in degrees Camber C 0 30 1 Alignment Service Data Reference Caster 1 55 1 1 Body center A Front view 2 Center line of wheel FRONT WHEEL ALIGNMENT 3A 3 Diagnosis Diagnosis Table For the details refer to Diagnosis Table in Section 3 Preliminary Checks Prior To Adjusting Front Wheel Alignment Steering and vibration complaints are not always the result of improper alignment An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured t
484. onnect battery negative cable from battery 3 Disconnect vacuum hose 1 from fuel pressure regulator 2 4 Remove fuel pressure regulator from fuel delivery pipe 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 3 from fuel pressure regulator ENGINE AND EMISSION CONTROL SYSTEM 6E 25 INSTALLATION For installation reverse removal procedure and note following precautions e Use new O ring 1 e Apply thin coat of gasoline to O ring to facilitate installation e Tighten fuel pressure regulator bolts to specified torque Tightening torque Fuel pressure regulator bolts a 10 N m 1 0 kg m 7 5 Ib ft e With engine OFF and the ignition switch ON position 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 2 when engine is running or cranking Cycle of operating sound should vary according to engine speed If no sound or an unusual sound is heard check injector cir cuit wire or connector or injector 2 2 Disconnect connector 1 from injector connect ohmmeter between terminals of injector and check resistance If resistance is out of specification replace Resistance of injector 11 3 13 8 Q at 20 C 68
485. onnection or TCM power or ground cir cuit open If wires and connections are OK substitute a known good TCM and recheck 4 Check signal circuit Check TCM power and B R wire shorted to 1 Disconnect TCM coupler with ignition switch ground circuit for open ground or poor E17 17 OFF If OK substitute a known terminal connection 2 Check voltage between E21 20 terminal good TCM and recheck If wire and connection are and body ground with ignition switch ON OK substitute a known See Fig 2 good ECM and recheck Is it about 12 V A Fig 1 for Step 2 B Fig 2 for Step 4 A B E21 26P E22 16P q q F COE 13 12 1110 9 8 7jelsjaja3j2 ij ajz e s 4 3 2 1 16 15 14 13 12 11 10 9 26 25 24 23 22 21 20 19 18 17 16 15 14 ui CME y ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 107 DTC P1717 A T Drive Range Park Neutral Position Signal Circuit Malfunc tion CIRCUIT DESCRIPTION er ee E17 6 E19 31P E18 24P E17 17P _ El E 1 Transmission range switch 2 From i
486. operly according to which position selector lever is shifted to With automatic transmission equipped vehicle make sure that vehicle is at complete stop when shifting selector lever to P range position and release all brakes BRAKE Foot Brake Check the following e that brake pedal has proper travel e that brake works properly e that it is free from noise e that braking force is applied equally on all wheels e and that brake do not drag Parking Brake Check that lever has proper travel WARNING With vehicle parked on a fairly steep slope make sure nothing is in the way downhill to avoid any per sonal injury or property damage Be prepared to apply regular brake quickly even if vehicle should start to move Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake lever is pulled all the way STEERING e Check to ensure that steering wheel is free from instability or abnormally heavy feeling e Check that the vehicle does not wander or pull to one side ENGINE e Check that engine responds readily at all speeds e Check that engine is free from abnormal noise and abnormal vibration BODY WHEELS AND POWER TRANSMITTING SYSTEM Check that body wheels and power transmitting system are free from abnormal noise and abnormal vibration or any other abnormal condition METERS AND GAUGE Check that speedometer odometer fuel meter temperature gauge etc
487. or no load is indicated turn OFF A C all electric loads P S and all the other necessary switches SCAN TOOL DATA CONDITION REFERENCE VALUES FUEL SYSTEM B1 FUEL SYSTEM STATUS At specified idle speed after warming up CLOSED closed loop CALC LOAD At specified idle speed with no load after CALCULATED LOAD warming up ee VALUE At 2500 r min with no load after warming up 12 17 COOLANT TEMP ENGINE COOLANT At specified idle speed after warming up 80 100 C 176 212 F TEMP SHORT FT B1 SHORT TERM FUEL TRIM At specified idle speed after warming up 20 20 LONG FT B1 LONG TERM are gt FUEL TRIM At specified idle speed after warming up 15 15 MAP INTAKE MANIFOLD 30 37 kPa ABSOLUTE PRESSURE At specified idle speed with no load after 220 340 mmHg ENGINE SPEED At idling with no load after warming up Desired idle speed 50 r min VEHICLE SPEED At stop 0 km h 0 MPH IGNITION ADVANCE IGNITION TIMING At specified idle speed with no load after 5 16 BTDC ADVANCE FOR NO 1 CYL INDER warming up INTAKE AIR TEMP At specified idle speed after warming up Ambient temp 15 C 59 F 5 C 23 F MAF MASS AIR FLOW At specified idle speed with no load after 1 4 gm sec RATE warming up THROTTLE POS Sy Throttle valve fully closed 7 18 THROTTLE POSITION g Throttle valve f
488. or A C operation being output from ECM to A C amplifier OFF Command for A C operation not being output 6 32 ENGINE GENERAL INFORMATION AND DIAGNOSIS 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 PNP SIGNAL PARK NEUTRAL POSITION SIGNAL P N RANGE or D RANGE It is detected by signal from TCM D range A T is in R D 2 or L range P N range A T is in P or N range or the above signal is not inputted from TCM EGR VALVE This parameter indicates opening rate of EGR valve which controls the amount of EGR flow PSP SW The Power Steering Pressure switch parameter displays ON when steering wheel is turned all the way to the right or left ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 33 Inspection of ECM and Its Circuits ECM and its circuits can be checked at ECM wiring connectors by measuring voltage and resistance CAUTION ECM cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to ECM with connector disconnected from it VOLTAGE CHECK 1 Remove ECM from body referring to Section 6E 2 Check voltage at each terminal of connectors connected NOTE As each terminal voltage is affected by th
489. or short tion switch OFF 2 Check voltage between BI B wire terminal 2 of EGR valve connector 1 and body ground with ignition switch ON See Fig 1 3 Are they about 10 14 V 8 Check EGR valve referring to EGR System in EGR valve harness Faulty EGR valve Section 6E Gr B Gr BI Gr R or Is it good condition Gr wire open or short or poor connector connec tion EGR valve connec tor E19 28 17 29 18 If wire harness and connec tion are OK substitute a known good ECM and recheck A Fig 1 for Step 7 B Fig 2 for Step 3 and 4 A B E19 18 E19 17 6 88 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0420 Catalyst System Efficiency below Threshold CIRCUIT DESCRIPTION ZW E19 10 E18 13 18 20 E17 14 1 Heated oxygen sensor 1 3 Three way catalytic converter 5 To the sensor B Case of TYPE Bis shown See NOTE 2 Warm up three way catalytic 4 Heated oxygen sensor 2 A Case of TYPE A is shown converter See NOTE NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic
490. or shorted to ground 1 Low voltage at terminal E18 4 for specified time after ECM malfunction engine start or while engine running at high load 2 High voltage at terminal E18 4 while engine running under other than above condition 2 driving cycle detection logic continuous monitoring DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF once and then ON 2 Clear DTC start engine and warm up engine to normal operating temperature 3 Keep it at 2000 r min for 2 min 4 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode INSPECTION ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 67 Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check HO2S 2 Heater and Its Circuit Intermittent trouble Go to Step 3 1 Warm up engine to normal operating tem Check for intermittent perature referring to Intermittent 2 Stop engine and Poor Connection in 3 Turn ignition switch ON and check voltage at Section OA terminal E18 4 See Fig 1 Voltage should be over 10 V 4 Start engine run it at idle and check voltage at the same terminal after 1 min from engine start Voltage should be below 1 9 V Are check result as specified 3 Check Heater or Sensor 2 R BI wire open or Replace HO2S 2 1 Disconnect HO2S 2 coupler with ignition switch OFF 2 Check for
491. or temp sensor 22 Lg R Power supply for sensor 2 R R range signal A T 23 G R CKP sensor 3 24 4 25 WwW Knock sensor 5 B Or Overdrive cut signal A T 26 G MAP sensor 6 GIY D range idle up signal A T 27 7 Y B Data link connector EGR valve stepper motor coil 4 if _ 28 Gr B equipped 8 29 Gr R Say stepper motor coil 2 if Ele 9 VY Malfunction indicator lamp 30 10 31 W G No 3 fuel injector 11 P G Data link connector 12 V 12 G ABS signal if equipped 1 P A C compressor clutch if equipped 13 BI Y Heater blower switch 2 14 B BI Ground for sensor E18 3 15 B R Throttle opening sensor 4 R BI Heater of HO2S 2 if equipped 16 Br Tachometer 5 BI B Power source 17 6 BI B Power source E19 E18 E17 Pira Lo slaf fel slah EOI bua 16hsjiajishe nho pens panpe mpo e Hinepare rs 27 f 26 28 24 23 22 24723 22 21720119118 17 ma es NOTE See NOTE in ECM INPUT OUTPUT CIRCUIT DIAGRAM for applicable model ENGINE AND EMISSION CONTROL SYSTEM 6E 15 On Vehicle Service Accelerator cable adjustment 1 2 With throttle valve closed check accelerator pedal play which should be within following specification If measured value is out of specification adjust it to specifi cation with cable adjusting nut 1 Accelerator pedal play a 2 7 mm 0 08 0 27 in With accelerator pedal depressed fully check clearance between throttle lever 2 and le
492. ors of those parts Otherwise diagnosis will be misled 3 Measure resistance between terminal at one end of circuit A 1 terminal in figure and body ground If continuity is indi cated it means that there is a short to ground between ter minals A 1 and C 1 of the circuit 4 Disconnect the connector included in circuit connector B and measure resistance between A 1 and body ground If continuity is indicated it means that the circuit is shorted to the ground between terminals A 1 and B 1 1 To other parts Intermittent and Poor Connection Most intermittent are caused by faulty electrical connections or wiring although a sticking relay or solenoid can occasionally be at fault When checking it for proper connection perform careful check of suspect circuits for e Poor mating of connector halves or terminals not fully seated in the connector body backed out e 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 RZ a sand paper or the like is prohibited e 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 0A 16 GENERAL INFORMATION N G N Nn y N be Mi Improperly formed or damaged termin
493. ors opens and closes smoothly and locks securely when closed If any malfunction is found lubricate hinge and latch or repair door lock system ENGINE HOOD INSPECTION Check that secondary latch operates properly check that sec ondary latch keeps hood from opening all the way even when pull ing hood release handle inside vehicle Also check that hood opens and closes smoothly and properly and hood locks securely when closed If any malfunction is found lubricate hinge and latch or repair hood lock system Check hood latch bolt for tightness Tightening torque Hood latch bolts 10 N m 1 0 kg m 7 5 Ib ft 0B 20 MAINTENANCE AND LUBRICATION Final Inspection WARNING When carrying out road tests select a safe place where no man or no running vehicle is seen so as to prevent any accident SEATS Check that seat slides smoothly and locks securely at any position Also check that reclining mechanism of front seat back allows it to be locked at any angle SEAT BELT Inspect belt system including webbing buckles latch plates retractors and anchors for damage or wear If REPLACE BELT label on front seat belt is visible replace belt Check that seat belt is securely locked BATTERY ELECTROLYTE LEVEL CHECK Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case If bat tery is equipped with built in indicator check battery condition by the indicator
494. ory case if equipped Then remove mounting screws 2 from heater control lever assembly 1 1A 6 HEATER AND VENTILATION 4 Disconnect blower fan switch coupler and A C switch coupler if equipped 5 Disconnect each heater control cables 6 Remove heater control lever assembly 1 7 Remove blower fan switch screw 3 8 Remove blower fan switch 2 as shown figure 1 Heater control lever assembly INSTALLATION 1 Install in reverse order of removal procedure adjustment the following items e Move control lever fully in arrow direction e Push heater lever and air inlet box lever fully in arrow direc tion and fix cable with clamp in position as shown figure NOTE After installing control cables be sure that control levers move smoothly and stop at proper position Heater unit Air inlet box Mode control cable Temperature control cable Fresh air control cable oaj A wj N 2 If equipped with air bag enable air bag system Refer to Enabling Air Bag System in Section 10B HEATER AND VENTILATION 1A 7 Heater Blower Fan Switch INSPECTION Check blower fan switch for each terminal to terminal continuity For the detail refer to Wiring Circuit earlier in this section B E l L M H O O QO Oo O oO 0O O O oO O O O H
495. osm PRN Crankcase Ventilation Hoses and Final INSPOCtION cccccceeceeseeeeeeeeeeeeseeeneeeeeees 0B 20 CONNECHONS ssijccterastssvoivececctmmercrtiasstuts 0B 10 Recommended Fluids and Lubricants 0B 22 PCV Positive Crankcase Ventilation 0B 2 MAINTENANCE AND LUBRICATION Maintenance Schedule Maintenance Schedule Under Normal Driving Conditions NOTE e This interval should be judged by odometer reading or months whichever comes first e 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 60 75 90 Interval Miles x 1 000 9 18 27 36 45 54 Months 12 24 36 48 60 72 ENGINE Drive belt V belt R R R V rib belt Flat type R Valve lash clearance Engine oil and oil filter R R R R R R Engine coolant R R Exhaust system IGNITION SYSTEM Spark plugs When Vehicle without Nickel spark B R 7 R _ R unleaded HO2S plug fuel j uel is used Iridium spark p R B _ R plug Vehicle with Nickel spark R _ 7 R HO2S plug Iridium spark R plug When leaded fuel is used refer to Maintenance Recommended Under Severe Driving Condi tions in this section FUEL SYSTEM Air cleaner filter R R Fuel lines and connections
496. ous sensors and controlled devices TWNOIS dWv1dOLS daddIno3 JI HOLSISAY SSA gaLAW balan ONILSNV OO aaadS OHOVL due soyeoiput JBZIIIGOUNUU NOYIM BIO1YeA daddINDA J HOLIMS SYNSSSUd ONINSSLS YIMOd aadainos 41 daddinoa 41 AVTaY NYA JINON 1OdLNOO YASNSONOO JY YAZINIEOWNI d3ddIND3 41 WOL HOLIMS J NYY NOISSINSNYHL d3daInoa 41 TWNOIS aadainoa 41 HOLIMS 9 Y HOLNTO HOSNS GAL qWNDIS SONVU YOSSSYdNOD O v DAYATAN UN TYNDIS IND SAIC 4340 TWNOIS STLLOYHL TWNOIS d Gi due soyeapur SONVY 12 d Jeziiqouluu YIM apiya viva SHMTI4 Liv HOLOANNOS YOLINOW aaadinoa sl INGON 10YLNO0 Sav HOSN3S SYNSS3Yd OlIWLAWOHVE TOHLNOO 43J1Y3H BOLONII JANA INYA une Been TS eal 4 Ea q N EEDI gt HaLLSINYO gt 394d OIHO dvAa HAISINYD PZE YOSNSS L ADONJA 5 YOSNIS Avi HOSNAS NL JATA AVA owl MN L Tan4 NOO iaIaanoa 41 el 1 S OH adld fvivo AVM IOJINY 4 4 1SNYHX3 334H1 LSNVHXS ANIONS jana 4 sv snvhxa 4m HOdWA lt a uly amp 6E 4 ENGINE AND EMISSION CONTROL SYSTEM sed Fk 0 ZE 6c 8z L6 ENGINE AND EMISSION CONTROL SYSTEM 6E 5 1 Air Cleaner 17 Knock sensor 31 2 Test switch terminal
497. ox and check short circuit to ground Wiring or grounding faulty Repair as necessary Condenser cooling fan motor relay faulty Check condenser cooling fan motor relay Condenser cooling fan motor faulty Check condenser cooling fan motor Cool air won t come out Blower fan motor won t operative Fuse blown Check fuses in main and circuit fuse boxes and check short circuit to ground Blower fan motor resistor faulty Check blower fan motor resistor referring to Section 1A Blower fan switch faulty Check blower fan switch referring to Sec tion 1A Wiring or grounding faulty Repair as necessary Blower fan motor faulty Check blower fan motor referring to Sec tion 1A 1B 6 AIR CONDITIONING OPTIONAL Condition Possible Cause Correction Cool air won t come out or insufficient cooling A C system normal operative Insufficient or excessive charge of refrigerant Check charge of refrigerant and system for leaks Condenser clogged Check condenser A C evaporator clogged or frosted Check A C evaporator and A C evaporator thermistor A C evaporator thermistor faulty Check A C evaporator thermistor Expansion valve faulty Check expansion valve Receiver dryer clogged Check receiver dryer Compressor drive belt loosen or broken Adjust or replace drive belt Magnetic clutch faulty Check
498. p body as shown in fig ure Tighten suction connector bolt 3 to specified torque Tightening torque Suction connector bolt a 12 N m 1 2 kg m 8 5 Ib ft 1 P S pump 3B1 18 POWER STEERING P S SYSTEM If equipped INSTALLATION CAUTION After installation fill A T fluid an equivalent to DEXRON II DEXRON IIE or DEXRON III and be sure to bleed air referring to Air Bleeding Procedure in this section Install components in reverse order of removal procedure noting the following points e Tighten each bolt as specified below Tightening torque Oil pump mounting bolts a 25 N m 2 5 kg m 18 5 Ib ft Oil pump high pressure union bolt b 60 N m 6 0 kg m 43 5 Ib ft 1 Union bolt e Adjust P S belt referring to Power Steering Belt Check in this section e Connect pressure switch terminal Power Steering P S Gear Box REMOVAL 1 Take out fluid in P S fluid reservoir with syringe or such 2 Turn steering wheel fully counterclockwise and loosen sector shaft nut of P S gear box 3 Return steering wheel to straightforward state and remove pitman arm from P S gear box by using puller 4 Remove radiator for left steering vehicle referring to Radi ator in Section 6B 5 Remove radiator support member 6 Disconnect suction hose and return hose from P S fluid res ervoir and remove P S fluid reservoir assembly for left steer
499. p it at idle for 2 min or more 5 Check DTC in DTC mode and pending DTC in ON BOARD TEST or PENDING DTC mode 6 If DTC is not detected at idle consult usual driving based on information obtained in Customer complaint analysis and Freeze frame data check INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Is there DTC other than Fuel system DTC P0171 Go to applicable DTC Go to Step 3 P0172 and misfire DTC P0300 P0304 Diag Flow Table 6 74 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Yes No 3 Check Ignition System Go to Step 4 Check ignition sys 1 Remove spark plugs and check them for tem parts Refer to e Air gap 1 0 1 1 mm 0 040 0 043 in See Fig 1 Section 6F e Carbon deposits Insulator damage Plug type If abnormality is found adjust clean or replace by referring to Section 6F See CAUTION 2 Disconnect all injector connectors See Fig 2 3 Connect spark plugs to high tension cords and then ground spark plugs 4 Crank engine and check that each spark plug sparks Are above check results satisfactory 4 Check Fuel Pressure Refer to Section 6E for details Go to Step 5 Go to Diag Flow 1 Release fuel pressure from fuel feed line Table B 3 fuel pres 2 Install fuel pressure gauge See Fig 3 sure check 3 Check fuel pr
500. ped 3 CMP sensor ECT sensor Heated oxygen sensor EGR valve if equipped IAC valve 4 EVAP canister purge valve 5 Injectors 6 Ignition coils Generator Starting motor Oil pressure switch Ground terminal from intake manifold and cylinder block Each wire harness clamps Remove intake manifold bracket 7 with main harness from intake manifold Remove starting motor referring to Dismounting in Section 6G ENGINE MECHANICAL M13 ENGINE 6A1 75 18 Remove heated oxygen sensor bracket from cylinder head and detach No 1 heated oxygen sensor coupler from its bracket 19 Release accelerator cable 1 from clamp 2 for left hand steering vehicle only and disconnect accelerator cable from throttle body 20 Remove canister purge hose bracket from intake manifold 21 Disconnect the following hoses e Brake booster hose 3 from intake manifold e Canister purge hose 4 from EVAP canister purge valve e Fuel feed and return hoses 5 from each pipe e Heater inlet and outlet hoses from each pipe e Vacuum hose 6 to check valve 22 Disconnect exhaust pipe 1 from exhaust manifold 23 Remove clutch housing torque converter housing for A T lower plate 1 24 With drive plate locked by using a proper size rod 1 or the like remove torque converter bolts 2 vehicle with A T 25 Support transmission For A T vehicle do not jack under A T oil pan to support tran
501. pet Any defect should be fixed at once 6K 2 EXHAUST SYSTEM On Vehicle Service COMPONENTS 10 50 N m 5 0 kg m ape 10 50 N m 5 0 kg m 1 Exhaust pipe Vehicle without TWC 6 Gasket 11 Mounting nuts 2 Exhaust pipe Vehicle with TWC 7 Spring Q Tightening torque 3 Exhaust center pipe 8 Mounting x lt Do not reuse 4 Muffler 9 Oxygen sensor 5 Seal ring 10 Mounting bolts Exhaust Manifold REMOVAL AND INSTALLATION Refer to Exhaust Manifold in Section 6A1 for removal and installation procedures of exhaust manifold INSPECTION Check seals for deterioration or damage Exhaust Pipe REMOVAL AND INSTALLATION For replacement of exhaust pipe exhaust center pipe muffler or any parts used to mount or connect them be sure to hoist vehicle and observe WARNING under Maintenance and the following CAUTION Exhaust pipe with three way catalytic converter should not be exposed to any impulse Do not drop it or hit it against something
502. ping battery on vehicle over a long period of time follow instructions given below Weekly start the engine and run it until it reaches normal operating temperature with engine speed of 2 000 to 3 000 rpm Make sure all electric switches are off before storing the vehicle Recharge the battery twice a month to prevent it from dis charging excessively This is especially important when ambient temperature is low The battery discharges even when it is not used while vehi cles are being stored Battery electrolyte can freeze and bat tery case can crack at cold ambient condition if battery is not properly charged Keep the battery cable connections clean The cable connections particularly at the positive termi nal post tend to become corroded The product of corrosion or rust on the mating faces of conductors resists the flow of current Clean the terminals and fittings periodically to ensure good metal to metal contact and grease the connections after each cleaning to protect them against rusting Be always in the know as to the state of charge of the bat tery The simplest way to tell the state of charge is to carry out a hydrometer test The hydrometer is an instrument for measuring the specific gravity S G of the battery electro lyte The S G of the electrolyte is indicative of the state of charge Refer to HYDROMETER TEST in this section Solid state regulator is mounted inside the generator All regulator
503. piston into cylinder by hand and fit boot in boot groove in piston 7 To confirm that boot is fitted in its groove in cylinder properly pull piston out of cylinder a little but do not take it all out NOTE Boot s face B should be at the same level from cylin der s face A all around 8 Insert piston into cylinder by hand 9 Install piston set ring INSTALLATION 1 Install caliper to caliper carrier 2 Torque caliper pin bolts 1 to specification NOTE Make sure that boots are fit into groove securely Tightening torque Brake caliper pin bolts a 22 N m 2 2 kg m 16 0 Ib ft 5 26 BRAKES 3 Install brake flexible hose 4 as shown and torque hose mounting bolt 3 to specification Tightening torque Front brake flexible hose bolt a 23 N m 2 3 kg m 17 0 lb ft 4 Install wheel and torque wheel nuts to specification 5 After completing installation fill reservoir with brake fluid and bleed brake system Perform brake test and check each installed part for oil leakage 1 Brake caliper 2 Washer Brake Disc REMOVAL 1 Hoist vehicle and remove wheel 2 Remove caliper assembly by loosening carrier bolts 2 pcs CAUTION During removal be careful not to damage brake flexible hose and not to depress brake pedal 3 Pull brake disc off by using 8 mm bolts 1 2 pcs
504. pitting scratches wear or damage If any malcondition is found replace both upper and lower halves Do not replace either half without replacing the other half Main bearing clearance Check clearance by using gauging plastic according to the follow ing procedure 1 Remove bearing caps 2 Clean bearings and main journals 3 Place a piece of gauging plastic 1 the full width of bearing parallel to crankshaft on journal avoiding oil hole 4 Tighten bearing cap No 1 bolts 1 10 and No 2 bolts 11 20 gradually as follows a Tighten bolts 1 10 to 30 N m 3 0 kg m 22 0 lb ft according to numerical order in figure b In the same manner as in Step a tighten them to 50 N m 5 0 kg m 36 5 lb ft c Inthe same manner as in step a retighten them to 60 d Tighten bolts 11 20 to 22 N m 2 2 kg m 16 0 Ib ft according to numerical order in figure Tightening torque Crankshaft bearing No 1 bolts 1 10 50 N m 5 0 kg m 36 5 Ib ft and extra tightening 60 Crankshaft bearing No 2 bolts 11 20 22 N m 2 2 kg m 16 0 Ib ft NOTE Do not rotate crankshaft while gauging plastic is installed 6A1 84 ENGINE MECHANICAL M13 ENGINE 5 Remove bearing caps and using scale 1 on gauging plastic 2 envelop measure gauging plastic width at its widest point If clearance exceeds its limit replace bearing Always replace both uppe
505. place it as an assembly unit because it can not be disassembled 2 Shock absorber function check Check and adjust tire pressures as specified Bounce body three or four times continuously by pushing front end on the side with shock absorber to be checked Apply the same amount of force at each push and note shock absorber resistance both when pushed and rebound ing Also note how many times vehicle body rebounds before coming to stop after hands are off Do the same for shock absorber on the other side Compare shock absorber resistance and number of rebound on the right with those on the left And they must be equal in both With proper shock absorber body should come to stop the moment hands are off or after only one or two small rebounds If shock absorbers are sus pected compare them with known good vehicle or shock absorber RW lt x rer n Inspect for damage or deformation Inspect for cracks or deformation in spring seat Inspect for deterioration of bump stopper Inspect shock absorber mount for wear cracks or deforma tion Replace any parts found defective in steps 2 6 OT ax O P Leading Arm Lateral Rod Steering Knuckle Check Inspect for cracks deformation or damage FRONT SUSPENSION 3D 15 Leading Arm Bushing Lateral Rod Bushing Check Inspect for damage wear or deterioration If defective rep
506. proper connection to HO2S 2 at B W and R BI wire terminals 3 If OK then check heater for resistance Is it 11 7 14 3 Q at 20 C 68 F shorted to ground or poor connection at E18 4 If wire and connection are OK substitute a known good ECM and recheck Fig 1 for Step 2 6 68 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0171 Fuel System Too Lean DTC P0172 Fuel System Too Rich CIRCUIT DESCRIPTION e f ECM Oxygen concentration increases a Signal to decrease amount of fuel injection d A F mixture becomes richer 1 Injector Oxygen concentration decreases b Signal to increase amount of fuel injection e High voltage 2 Heated oxygen sensor 1 HO2S 1 c A F mixture becomes leaner f Low voltage DTC DETECTING CONDITION POSSIBLE CAUSE under closed loop condition Air fuel ratio too lean than 30 or Air fuel ratio too rich Total fuel trim is less than 30 e When following condition occurs while engine running Total fuel trim short and long terms added is more 2 driving cycle detection logic continuous monitoring Vacuum leaks air drawn in Exhaust gas leakage Heated oxygen sensor 1 circuit malfunction Fuel pressure out of specification Fuel injector malfunction clogged or leakage MAP sen
507. que Specification 1B 46 Required Service Materials s 1B 47 Special Tools c0c csescccctecesscsetetccteaseneenevvene 1B 47 AIR CONDITIONING OPTIONAL 1B 3 General Description Major Components and Location TOC ee 6 LE ae s SS si 2 8 NANN ee os fi TY A EAN OY z A WEIS JS 7 RN F CA 4 rey NS Gz E 3 us 3 O 1 Cooling unit 6 Suction hose 11 Foot air 16 Heater unit 2 Compressor 7 Receiver dryer outlet pipe 12 Defroster air 17 A C evaporator 3 Condenser assembly 8 Condenser outlet pipe 13 Demister air 18 Dual pressure switch 4 Receiver dryer 9 Expansion valve 14 Fresh air 19 Low pressure service charge valve 5 Discharge hose 10 Ventilation air 15 Recirculation air 20 High pressure service charge valve 1B 4 AIR CONDITIONING OPTIONAL Refrigerant Circulation M m 2 4 Si Coke i i S i A Liquid 1 Compressor 4 Receiver dryer 7 Evaporator B Vapor 2 Magnet clutch 5 Dual pressure switch C Superheated vapor 3 Condenser assembly 6 Expansion valve HFC 134a 2 CFC 12 Refrigerant Type Whether the A C in the vehicle being serviced uses HFC 134a R 134a
508. r ECT sensor MAP sensor and other sensors switches Refer to Electronic Control System in Section 6E for details Although this ignition system does not have a distributor it has two ignition coil assemblies one is for No 1 and No 4 spark plugs and the other is for No 2 and No 3 spark plugs When an ignition signal is sent from ECM to the ignitor in the ignition coil assembly for No 1 and No 4 spark plugs a high voltage is induced in the secondary coil and that passes through the high tension cords and causes No 1 and No 4 spark plugs to spark simulta neously Likewise when an ignition signal is sent to the ignitor in the other ignition coil assembly No 2 and No 3 spark plugs spark simultaneously SYSTEM COMPONENTS 1 ECM 7 ECT sensor 13 Monitor connector 2 Ignition coil assembly for No 1 and No 4 spark plugs 8 IAT sensor 14 Knock sensor 3 Ignition coil assembly for No 2 and No 3 spark plugs 9 TP sensor 15 DLC 4 CMP sensor 10 VSS 16 Spark plugs 5 CKP sensor 11 Transmission range switch A T 6 MAP sensor 12 High tension cords SYSTEM WIRING DIAGRAM Br W Br B IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM 6F 3 1 Ignition switch 7 No 1 spark plug 2 Main relay 8 No 2 spark plug 3 Ignition coil assembly for No 1 and No 4 spark plugs 9 No 3 spark plug 4 Ignition coil assembly for No 2 and No 3 spark plugs 10 No 4 spark plug 5
509. r 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 of 0 25 mm undersize bearing After selecting new bearing recheck clearance Main bearing clearance Standard 0 025 0 045 mm 0 0010 0 0018 in Limit 0 065 mm 0 0026 in NOTE After checking the bearing clearance check for thread deformation of each bearing cap No 1 bolt according to previous mentioned Step 4 once again Selection of main bearings STANDARD BEARING If bearing is in malcondition or bearing clearance is out of specifi cation select a new standard bearing according to the following procedure and install it 1 First check journal diameter As shown in figure crank web No 2 has stamped numbers Three kinds of numbers 1 2 and 3 represent the fol lowing journal diameters Stamped numbers on crank web No 2 represent journal diameters marked with an arrow in figure respectively For example stamped number 1 indicates that correspond ing journal diameter is 44 994 45 000 mm 1 7714 1 7717 in Crankshaft journal diameter Stamped numbers Journal diameter 4 44 994 45 000 mm 1 7714 1 7717 in 2 44 988 44 994 mm 1 7712 1 7714 in 3 44 982 44 988 mm 1 7709 1 7712 in ENGINE MECHANICAL M13 ENGINE
510. r cleaner outlet hose 2 throttle body 3 idle air control valve 4 and intake manifold 5 The air by the amount corresponding to the throttle valve 6 opening and engine speed is filtered by the air cleaner 1 passes through the throttle body 3 is distributed by the intake manifold 5 and finally drawn into each combustion chamber When the idle air control valve 4 is opened according to the signal from ECM the air 7 bypasses the throttle valve 6 through bypass passage and is finally drawn into the intake manifold 5 2 a 6E 6 ENGINE AND EMISSION CONTROL SYSTEM Fuel Delivery System The fuel delivery system consists of the fuel tank 1 fuel pump 2 fuel filter 3 fuel pressure regulator 11 delivery pipe 9 and fuel injectors 10 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 open according to the injection signal from ECM The fuel relieved by the fuel pressure regulator returns through the fuel return line 8 to the fuel tank
511. r connection to 4WD con 3 If OK check continuity between A5 terminal and body ground Is there continuity between A5 terminal and Go to Step 2 nals B wire is open 2 Check power circuit ground Is it 10 14 V 1 Disconnect coupler from 4WD controller 2 Turn ignition switch ON 3 Check voltage between A10 terminal and Go to Step 3 Y R circuit is open or short FRONT SUSPENSION 3D 9 Step Action Yes No 3 Check 4WD switch circuit Go to Step 4 Check 4WD switch refer 1 Connect coupler to 4WD controller to AWD Switch in Sec 2 Turn ignition switch ON and check voltage tion 7D BI B and B between A7 terminal and ground circuits of 4WD switch Transfer lever is in 2H about 10 14 V If OK substitute a known Transfer lever is in 4L or 4H about 0 V good 4WD controller and Is check result satisfactory recheck 4 Check VSV1 circuit Go to Step 5 Check VSV1 refer to 1 Turn ignition switch ON AWD Control System 2 Check voltage between A1 terminal and Check in this section ground Y R and Gr B circuits Is it 10 14 V when transfer lever is in 4H or 4L of VSV1 range and about 0 V for 10 seconds after it is If OK substitute a known shifted to 2H range good 4WD controller and recheck 5 Check VSV2 circuit Go to Step 6 Check VSV2 refer to 1 Turn ignition switch ON AWD Control System 2 Check volt
512. r is shifted to 4L or 4H position from 2H this switch turns ON and cause the 4WD control system to turn ON 4WD controller When the 4WD switch turns on the 4WD controller activates VSV2 to lock the air locking hubs and when it receives an ON signal from the vacuum switch it makes VSV2 to complete operation within 5 seconds and causes the 4WD indi cator light to light up If vacuum in the vacuum circuit fails to reach the specified level due to a leakage in the vacuum circuit when no ON signal is inputted from the vacuum switch the 4WD controller stops operation of VSV2 in 15 seconds and makes the 4WD indicator light to flash to warn occurrence of a trouble When the 4WD switch turns off the 4WD controller activates VSV1 for 10 sec onds to unlock the hubs and at the same time makes the 4WD indicator light turn off VSV1 VSV1 operates according to the signal from the 4WD controller When it is acti vated the port opens and vacuum in the intake manifold is applied through the vacuum circuit to unlock to the slide gear in the air locking hub As a result the air locking hubs are unlocked VSV2 VSV2 operates according to the signal from the 4WD controller When it is acti vated the port opens and vacuum in the intake manifold is applied through the vacuum circuit to lock to the slide gear in the air locking hub As a result the air locking hubs are locked Vacuum switch When VSV2 receives the ON sig
513. r kingpins 1 NOTE Upper and lower kingpins 1 when removed must be marked off one from the other 8 Remove steering knuckle 1 NOTE e When steering knuckle 1 is pulled lower kingpin bearing sometimes falls off So remove bearing while pulling off the knuckle gradually e Upper and lower kingpin bearings must be also marked off one from the other 9 Remove knuckle seal cover 1 knuckle seal 2 and knuckle seal retainer 3 from front axle housing 4 10 Remove spindle oil seal by using special tool Special tool A 09913 50121 1 Wheel spindle 11 Remove spindle bushing by using special tools Special tool A 09917 88210 B 09916 58210 3D 30 FRONT SUSPENSION INSTALLATION 1 Set knuckle seal cover 2 knuckle seal 4 and knuckle seal retainer 5 on front axle housing 6 2 Apply grease within the knuckle 1 Amount of grease to be applied within the knuckle 1 is approximately 100 g for 4WD A Grease 99000 25030 3 Apply grease to kingpin bearings 3 and install them to front axle housing 6 NOTE When reusing bearing 3 install bearing 3 with sealing at the top A Grease 99000 25030 4 Apply sealant to indicated part of kingpin 1 A Sealant 99000 31090 5 Install steering knuckle 1 and king pins 2 and tighten king pin bolts to specified torque Tightening torque Kingpin bolts a 25
514. r may be needed for an adequate inspec tion If any of the above conditions are observed on the brake hose it is necessary to replace it Front Disc Brake BRAKES 5 19 PIPE Inspect the tube for damage cracks dents and corrosion If any defect is found replace it 5 B 11 Nm 1 1 kg m Pele Ss 1 5 22 N m 2 2 kg m 3 ACH 2 10 F 85 N m 6 5 kg m E 50 N m 5 0 kg m P 20 FLD S3 PR Go 14 1 Caliper pin bolt 10 Carrier bolt 2 Boot 11 Brake caliper carrier 3 Cylinder slide bush Apply rubber grease to mating surface of caliper 12 Pad clip 4 Bleeder plug cap 13 Disc brake caliper 5 Bleeder plug 14 Disc brake pad 6 Anti noise shim 15 Piston seal Apply brake fluid to all around part of piston seal 7 Disc brake piston Apply brake fluid to contact surface of cylinder m Tightening torque 8 Cylinder boot x lt Do not reuse 9 Seat ring boot ring 5 20 BRAKES Brake pad REMOVAL 1 Hoist vehicle and remove wheel 2 Remove caliper pin bolts 2 1 Caliper 3 Disc 3 Remove caliper 1 from caliper carrier NOTE Hang removed caliper 1 with a wire hook 2 or the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal with pads 3 remov
515. r missing parts also for parts showing signs of wear or lack of lubrica tion Replace any parts found defective in steps 1 to 5 3 Spring seat Propeller Shafts INSPECTION 1 Check universal joint and spline of propeller shaft for rattle If rattle is found replace defective part with a new one 2 Check propeller shaft front amp rear flange yoke bolts for tightness and retighten them as necessary Refer to Components in Section 4B for tightening torque LUBRICATION Grease splines of propeller shaft No 2 1 and No 3 2 A Chassis Grease 3 Nipple 0B 16 MAINTENANCE AND LUBRICATION Ma nual Transmission Oil INSPECTION 1 CH Au Inspect transmission case for evidence of oil leakage Repair leaky point if any Make sure that vehicle is placed level for oil level check Remove level plug 2 of transmission Check oil level Oil level can be checked roughly by means of level plug hole That is if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed oil is properly filled If oil is found insufficient pour specified amount of specified oil 5 Tighten level plug to specified torque Refer to Maintenance Service in Section 7A for installation and tightening torque ANGE Change transmission oil with new specified oil referring to Main tenance Service in Section 7A tomatic Trans
516. r replace tion Is it in good condition fuse 3 1 Ignition switch OFF Substitute a known good B W circuit open 2 Disconnect ABS hydraulic unit control ABS hydraulic unit con module connector trol module assembly and 3 Check proper connection to ABS hydraulic recheck unit control module connector at terminal A18 4 If OK then measure voltage between con nector terminal A18 and body ground Is it 10 14 V 5E 26 ANTILOCK BRAKE SYSTEM ABS DTC C1061 DTC 61 ABS Pump Motor Circuit Se dala ca Ca Ca fa Ca ca Ca 5 i i si oo mo sabes re sl D 1 ABS hydraulic unit control module assembly 1 3 ABS fail safe transistor 2 2 Unlock position 1 1 ABS pump motor transistor 2 ABS hydraulic unit control module connector of harness 1 2 ABS pump motor 2 1 Lock position DESCRIPTION The ABS control module monitors the voltage at the terminal A23 of the pump motor circuit constantly with the ignition switch turned ON It sets this DTC when the voltage at the terminal A23 does not become high low according to ON OFF commands to the motor transistor of the module INSPECTION Step Action Yes No 1 1 Check pump motor referring to ABS Check terminal A23 con Go to step 2 Hydraulic Unit Operation Check in this sec tion Is it in good condition nection If connections OK sub
517. r wheel bearing for wear damage abnormal noise or rattles For details refer to Wheel Disc Nut and Bearing Check in Section 3E Suspension System INSPECTION Check suspension bolts and nuts for tightness and retighten them as necessary Repair or replace defective parts if any NOTE For details of check points refer to tables of Tightening Torque Specification in Section 3D and 3E FRONT 1 Check stabilizer bar 6 for damage or deformation 2 Check bushing 8 for damage wear or deterioration 3 Check coil spring 1 lateral rod 5 and leading arm 3 for deformation and damage 4 Check lateral rod 5 and leading arm bushings for wear damage and deterioration 5 Inspect absorbers 2 for evidence of oil leakage dents or any other damage on sleeves and inspect anchor ends for deterioration 6 Inspect for cracks or deformation in spring seat 7 Inspect for deterioration of bump stopper 4 Front axle housing 7 Ball joint MAINTENANCE AND LUBRICATION 0B 15 REAR 1 Check shock absorber 1 for damage deformation oil leak age and operation 2 Check bushings for wear and damage 3 Check coil spring 4 trailing arm 6 and lateral rod 5 for deformation and damage 4 Check trailing arm 6 and lateral rod bushings and bump stopper 2 for wear damage and deterioration 5 Check other suspension parts for damage loose o
518. rake pedal several times with the same load as in ordinary braking and observe pedal travel If pedal goes down deep the first time but its travel decreases as it is depressed the second and more times air tightness is obtained 1 1st 2 2nd 3 3rd 4 If pedal travel doesn t change air tightness isn t obtained NOTE If defective inspect vacuum lines and sealing parts and replace any faulty part When this has been done repeat the entire test 1 1st 2nd 3rd CHECK OPERATION 1 With engine stopped depress brake pedal several times with the same load and make sure that pedal travel doesn t change 2 Start engine while depressing brake pedal If pedal travel increases a little operation is satisfactory But no change in pedal travel indicates malfunction 5 14 BRAKES CHECK AIR TIGHTNESS UNDER LOAD 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed H Hold 2 Hold brake pedal depressed for 30 seconds If pedal height does not change condition is good But it isn t if pedal rises H Hold T 30 seconds BRAKES 5 15 Fluid Pressure Test If Equipped with LSPV Test procedure for LSPV assembly is as follows Before testing confirm the following e Fuel tank is filled with fuel fully e Vehicle is equipped with spare t
519. ral Balance Procedure aa anann 3F 4 il ame me a ae pie AE EA AEE E a OP a 3F 9 Off vehicle balancing sccseeeee 3F 4 Mounting and demounting e 3F 9 On vehicle balancing ccccccccseeceeeeeees 3F 4 PCP Alsi Severe eeaeee era eee rN ceeded 3F 9 Maintenance and Minor Adjustments 3F 6 3F 2 WHEELS AND TIRES General Description Tires This vehicle is equipped with following tire Tire size 205 70 R15 or 175 80 R15 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 15 x 5 1 2 JJ Replacement Tires When replacement is necessary the original equipment type tire should be used Refer to the Tire Placard Replacement tires should be of the same size load range and construction as those originally on the vehicle Use of any other size or type tire may affect ride handling speedometer odometer calibration vehicle ground clearance and tire or snow chain clearance to the body and chassis WARNING Do not mix different types of tires on the same vehicle such as radial bias and bias belted tires except in emergencies beca
520. ral Description The cooling system consists of the radiator cap radiator reservoir hoses water pump cooling fan amp clutch thermostat The radiator is of tube and fin type Cooling System Circulation 1 Radiator inlet hose 5 Water pump 9 Heater outlet hose 2 Radiator outlet hose 6 Fast idle control plunger of throttle body 10 Radiator 3 Water inlet pipe 7 Cylinder block cylinder head 4 Thermostat 8 Heater inlet hose ENGINE COOLING 6B 3 Radiator Cap A pressure vent cap is used on the radiator The cap contains a pressure valve 1 and ventilation valve 2 The cap has its face marked 1 1 which means that its pressure valve opens at 1 1 kg cm 15 6 psi 110 kPa NOTE Do not remove radiator cap to check engine coolant level check coolant visually at the see through coolant reservoir Coolant should be added only to reservoir as necessary WARNING As long as there is pressure in the cooling system the temperature can be considerably higher than the boiling temperature of the solution in the radiator without caus ing the solution to boil Removal of the radiator cap while engine is hot and pressure is high will cause the solution to boil instantaneously and possibly with explosive force spewing the solution over engine fenders and person removing cap If the solution contains flammable anti freeze such as alcohol not recommended for use at any time
521. rant Check charge refrigerant A C evaporator frosted Check A C evaporator and A C evaporator thermistor Insufficient velocity of cooled air A C evaporator clogged or frosted Check A C evaporator and A C evaporator thermistor Air leaking from cooling unit or air duct Repair as necessary Blower fan motor faulty Check blower fan motor referring to Sec tion 1A Wiring or grounding faulty Repair as necessary Abnormal Noise Diagnosis There are various types of noise ranging from those produced in the engine compartment to those from the passenger compartment also from rumbling noises to whistling noises Abnormal noise from compressor AIR CONDITIONING OPTIONAL 1B 7 Condition Possible Cause Correction During compressor operation a rumbling noise is heard propor tional to engine revo lutions Inadequate clearance in piston area piston or swash plate Repair or replace compressor as necessary A loud noise is heard at a certain rpm dis proportionately to engine revolution Loose or faulty compressor drive belt Adjust drive belt tension or replace belt Loose compressor mounting bolts Retighten mounting bolts A loud rattle is heard at low engine rpm Loose compressor clutch plate bolt Retighten clutch plate bolt Replace compressor if it was oper ated in this condition for a long time Abnorma
522. rcuit malfunction 3 Check electric load signal under following each condition See Table 1 Is check result satisfactory 3 Check Electric Load Signal Circuit Electric load signal circuit R W R Y and or BI Y 1 Turn ignition switch ON 2 Check voltage at each terminals E17 16 E18 17 and E18 24 Case of TYPE A or E18 12 E18 17 and E17 13 Case of TYPE B See NOTE of ECM connector con nected under above each condition See Fig 2 and Table 1 Is each voltage as specified is in good condition circuit open or short Elec tric load diodes malfunc tion or Each electric load circuit malfunction 6 120 ENGINE GENERAL INFORMATION AND DIAGNOSIS A Fig 1 for Step 2 B Fig 2 for Step 3 IA B E1624 E17 16 ME ai L T Eis 24P L E17 7 i HFH Tl VA C sS oVe E18 17 E17 13 Table 1 for Step 2 and 3 Scan tool or voltmeter SUZUKI VOLTAGE VOLTAGE SCAN TOOL AT E18 17 AT E18 24 or E17 16 or E17 13 E18 12 Ignition switch ON Small OFF OFF OV 10 14V light heater blower fan and ON ON 10 14V ov rear defogger all turned ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 121 TAble B 7 A C Condenser Fan Control System Check INSPECTION St
523. rd 31 000 31 025 mm 1 2205 1 2215 in 6A1 46 ENGINE MECHANICAL M13 ENGINE INSTALLATION 1 Install tappets and shims to cylinder head Apply engine oil around tappet and then install it to cylinder head NOTE When installing shim make sure to direct shim No side toward tappet 2 Install camshafts 1 Apply engine oil to sliding surface of each camshaft and camshaft journal then install them as shown in figure NOTE Before installing camshafts turn crankshaft until key position faces upward Refer to Timing Chain and Chain Tensioner 3 Install camshaft housing pins 1 as shown in figure 4 Check position of camshaft housings Embossed marks are provided on each camshaft housing indicating position and direction for installation Install hous ings as indicated by these marks A Intake side or E Exhaust side B Position from timing chain side C Pointing to timing chain side HUNS PER RED i z i ENGINE MECHANICAL M13 ENGINE 6A1 47 5 After applying engine oil to housing bolts tighten them tem porarily first Then tighten them by the following numerical order in figure Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque Tightening torque Camshaft housing bolts a 11 N m 1 1 kg m 8 0 Ib ft 6 In
524. re 4 at ground ter minal 2 at least 5 times within 10 seconds NOTE Service wire ON time must be for 0 1 second and more 5 Turn ignition switch OFF and disconnect service wire 4 from monitor connector 1 6 Perform DRIVING TEST Step 2 of ABS Diagnostic Flow Table and DTC CHECK and confirm that normal DTC DTC 12 is displayed 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 ANTILOCK BRAKE SYSTEM ABS 5E 11 DTC DTC displayed on indicated by ABS warning light flashing SUZUKI scan ABS warn pattern PRONSSIN IEMS tool ing lamp 1 2 12 Iil Normal 1 5 C1015 15 LLL G sensor circuit for 4WD model only 1 6 C1016 16 LL Stop lamp switch circuit 2 1 C1021 21 Hl RF 2 5 C1025 25 iil Iiii LF 3 1 C1031 31 iiil RR 3 5 C1035 35 HT UL LR Wheel speed sensor circuit and or sen 2 2 sor ring C1022 22 iil Iil RF 2 6 C1026 26 iil UUT LF 3 2 C1032 32 UL I RR 3 6 C1036 36 HT LL LR 4 1 C1041 41 HTL Hold solenoid valve circuit RF 4 2 C1042 42 LL Hil Release solenoid valve circuit 4 5 C1045 45 HTT UU Hold solenoid valve circuit LF 4 6 C1046 46 UL ULL Release solenoid valve circuit 5 5 C1055 55 UL UL Hold solenoid valve circuit Rear 5 6 C1056 56 Release solenoid valve circuit
525. re side is high sor repair or replace as nec 0 4 0 6 Pressure on high pres essary 4 6 sure side is low 56 9 85 3 Both pressure becom ing equal right after A C is turned OFF 0 35 0 45 Pressure on both low Overcharged A C sys Adjust refrigerant to 3 5 4 5 and high pressure tem specified amount 50 64 sides is high Faulty condenser cooling Clean condenser Air bubbles are not visi operation ble even when engine Faulty condenser cooling Inspect and repair con rpm is lowered fan operation denser cooling fan Pressure on both low Presence of air in A C Replace receiver dryer and high pressure system Inspect quantity of com 1 96 2 45 sides is high Improperly evacuated pressor oil and presence 20 25 Low pressure side tub of contaminants in oil ing is not cold when Evacuate system and 285 355 touched recharge with fresh Air bubbles are visible refrigerant through sight glass 0 45 0 55 Pressure on both low _ Faulty expansion valve Replace expansion valve 4 5 5 5 and high pressure Refrigerant flow is not 64 78 sides is high regulated properly Large amount of frost or dew on the low pres sure side tubing A B AIR CONDITIONING OPTIONAL 1B 15 Compressor Drive Belt INSPECTION e Check belt for wear and cracks and replace as required e Check belt tension by measuring how much it deflects when pushed at intermed
526. re the wheel runout it is necessary to use accurate dial indicator The tire may be on or off the wheel The wheel should be installed to the wheel balancer of the like for proper measure ment Take measurements of both lateral runout 1 and radial runout 2 at both inside and outside of the rim flange With dial indicator set in place securely turn the wheel one full revolution slowly and record every reading of the indicator When the measured runout exceeds the specification and correc tion by the balancer adjustment is impossible replace the wheel If the reading is affected by welding paint or scratch it should be ignored Lateral runout limit a 1 20 mm 0 047 in Radial runout limit b 1 20 mm 0 047 in Metric Lug Nuts and Wheel Studs All models use metric lug nuts and wheel studs Metric lug nuts and wheel studs size M12 x 1 25 3F 4 WHEELS AND TIRES Diagnosis Diagnosis Table Refer to Diagnosis Table in Section 3 Balancing Wheels There are two types of wheel and tire balance static and A B 2 dynamic Static balance as shown in figure is equal distribution of weight around wheel Wheels that are statically unbalanced cause bouncing action called tramp This condition will eventually cause uneven tire wear 1 Heavy spot wheel tramp A Before correction 2 Balance weights addition point B Corrective weights 3 C L of spindle Dynamic balance
527. rea you work in is well ventilated e To avoid getting burned keep away from hot metal parts such as the radiator exhaust manifold tailpipe muffler etc e New and used engine oil can be hazardous Children and pets may be harmed by swallowing new or used oil Keep new and used oil and used engine oil filters away from children and pets Continuous contact with used engine oil has been found to cause skin cancer in laboratory ani mals Brief contact with used oil may irritate skin To minimize your exposure to used engine oil wear a long sleeve shirt and moisture proof gloves such as dish washing gloves when changing engine oil If engine oil contacts your skin wash thoroughly with soap and water Launder any clothing or rags if wet with oil recycle or properly dispose of used oil and filters e Make sure the bonnet is fully closed and latched before driving If it is not it can fly up unexpectedly during driving obstructing your view and resulting in an accident e Before starting any service work cover fenders seats and any other parts that are likely to get scratched or stained during servicing Also be aware that what you wear e g buttons may cause damage to the vehicle s finish e When performing service to electrical parts that does not require use of battery power disconnect the nega tive cable of the battery 0A 8 GENERAL INFORMATION e When r
528. recautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE Whether the following systems parts are used in the particular vehicle or not depends on vehicle specifications Be sure to bear this in mind when performing service work e EGR valve e Heated oxygen sensor s or CO adjusting resistor e Three way catalytic converter TWC and warm up three way catalytic converter WU TWC GENERAL INFORMATION AND ENGINE DIAGNOSIS 1 0 0 cececseeeeeeeeeeeeeeeeeeesesneesnsesnsesessesesseessseesseeesoees 6 1 ENGINE MECHANICAL i wcsssccescicccctatads sieve coddteccciesssdassatdewesscscencedceadsceceucasvisiasdeueseuenedelacuvseuacsusedecnancecteteeves 6A1 1 ENGINE COOLIN e a E E E tate snus ceancdeaaccaccesdeusteccucesdasdacsdsecedsnandesduased eacescdeccase 6B 1 ENGINE FUEL E A diccdcetescnccdestasshussdecccaadelesdadecscaceicedoaes catannsdeladesbssduedacaasaaldacecactuuedeaade 6C 1 ENGINE A
529. recheck Go to Step 3 6 100 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Yes No 3 Check MAP Sensor Check air intake system Replace MAP sensor 1 Remove MAP sensor from intake manifold for air being drawn in and and connect vacuum pump gauge to MAP engine compression sensor See Fig 2 If OK then substitute a 2 Connect scan tool to DLC and turn ignition known good ECM and switch ON recheck 3 Check intake manifold absolute pressure displayed on scan tool for specified value See Table 1 Is check result satisfactory A Fig 1 for Step 2 B Fig 2 for Step 3 A Table 1 Applying Vacuum Displayed Value on Scan Tool 0 Barometric pressure Approx 100 kPa 760 mmHg 027 kPa Barometric pressure 27 kPa 200 mmHg Approx 73 kPa 560 mmHg 67 kPa Barometric pressure 67 kPa 500 mmHg Approx 33 kPa 260 mmHg ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 101 DTC P1500 Engine Starter Signal Circuit Malfunction CIRCUIT DESCRIPTION C 1 Starter 3 Ignition switch starter switch A Case of TYPE A is shown See NOTE C M T vehicle 2 Transmission range sensor switch 4 Main fuse B Case of TYPE B is shown See NOTE D A T vehicle NOTE For TYPE A and TYPE B refer to
530. recheck While engine running A C switch ON 10 14V Is check result satisfactory NOTE When A C evaporator thermistor temp is below 2 5 C 36 5 F A C remain OFF E18 1 terminal volt age become 0 1 V This condition is not abnormal Fig 1 for Step 1 Resistance 20 30 40 50 60 70 80 F Temperature ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 119 Table B 6 Electric Load Signal Circuit Check ECM IG1 i Be R E17 16 A EE 5 z mmt wy ae mea A BESAR eters E IG2 BI Y E18 24 A R HEATER ae E19 31P E18 24P 17 13 B _ E17 16 E17 17P E18 24 T ae E17 13 E18 17 1 Rear defogger switch 3 Blower fan switch B Case of TYPE B is shown See NOTE 2 Light switch A Case of TYPE A is shown See NOTE NOTE For TYPE A and TYPE B refer to the NOTE in ECM Terminal Voltage Values Table for applicable model INSPECTION Step Action Yes No 1 Is SUZUKI scan tool available Go to Step 2 Go to Step 3 2 Check Electric Load Signal Circuit Electric load signal circuit R W R Y and or BI Y 1 Connect SUZUKI scan tool to DLC with igni is in good condition circuit open or short Elec tion switch OFF See Fig 1 tric load diodes malfunc 2 Start engine and select DATA LIST mode tion or Each electric load on scan tool ci
531. referring to G Sensor in this section Is it in good condition YS re rr wa Go to step 3 Replace G sensor 1 Disconnect connectors from ABS hydraulic unit control module assembly See A and G sensor 2 Check for proper connection to ABS control module at terminals A11 and A13 3 If OK then turn ignition switch ON and mea sure voltage between B W terminal of sen sor connector and body ground Is it 10 14 V Go to step 4 B W circuit open Measure voltage between R W terminal of sensor connector and body ground Is it 0 V Go to step 5 R W circuit shorted to power circuit 1 Ignition switch OFF 2 Check that R W circuit is free from open or short to ground and Or B circuit See B Is it in good condition Or B circuit open If circuit is OK substitute a known good ABS hydraulic unit control module assembly R W circuit open or shorted to ground or Or B circuit A B 1 ABS hydraulic unit control module connector 2 Lock position 3 Unlock position 5E 20 ANTILOCK BRAKE SYSTEM ABS DTC C1016 DTC 16 Stop Lamp Circuit A18 1 Main fuse 4 IG fuse 7 ABS hydraulic unit control module assembly 2 Ignition switch 5 Stop lamp switch 8 ABS hydraulic unit control module connector of har
532. ressure sensor circuit ECM uses value determined by throttle opening and No 11 malfunction engine speed P0110 Reke Air eM OC sensorar AAHINEHOn ECM controls actuators assuming that intake air tem No 18 P perature is 20 C 68 F P0115 Engine coolant temp sensor circuit mal ECM controls actuators assuming that engine coolant No 19 function temperature is 80 C 176 F P0120 Throttle position sensor circuit malfunc ECM controls actuators assuming that throttle opening No 13 ition is 20 High idle speed P0335 Crankshaft position sensor circuit mal EN Canos MIEAION ee pedueniia ieonta f synchronous injection Cranking for a few seconds to No 23 function start engine P0340 Camshaft position sensor circuit malfunc FOM conto Meson oon Sequentiar INACHE TO i synchronous injection Cranking for a few seconds to No 15 tion j start engine P0500 No 16 Vehicle speed sensor malfunction ECM stops idle air control P1450 Barometric pressure sensor low high ECM controls actuators assuming that barometric input pressure is 100 kPa 760 mmHg P1570 hoa i ECM controls actuators assuming that ABS signal is No 21 ABS signal circuit malfunction OFF 6 20 ENGINE GENERAL INFORMATION AND DIAGNOSIS Visual inspection Visually check following parts and systems INSPECTION ITEM REFERRING SECTION Engine oil level leakage Engine coolant level leakage Fuel level
533. rmance See Section 6E Is it in good condition Go to Step 10 Replace intake air temp sensor 10 Check throttle position sensor for performance See step 5 of DTC P0121 Diag Flow Table Is it in good condition Go to Step 11 Replace throttle position sensor 11 Check PCV valve for valve clogging See Section 6E Is it good condition Substitute a known good ECM and recheck Replace PCV valve ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 71 A Fig 1 for Step 3 B Fig 2 for Step 4 C Fig 3 for Step 5 C 1 Fuel delivery pipe 2 Fuel feed hose 3 Fuel pressure gauge amp 3 way joint D Fig 4 for Step 5 E Fig 5 for Step 5 F Fig 6 for Step 6 6 72 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0300 Random Misfire Detected Misfire Detected at 2 or More Cylinders DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected ECM Ignition coil assembly for No 1 and No 4 cylinder Ignition coil assembly for No 2 and No 3 cylinder Fuel injector CKP sensor CMP sensor aj AJ vjl N CIRCUIT DESCRIPTION ECM monitors crankshaft revolution speed and engine speed via the crankshaft position sensor and cylinder No via the camshaft position sensor Then it calculates the cha
534. rometric pressure sensor voltage is 4 7 V or higher or tion DTC P1451 e Vehicle stopped e Engine cranking kPa 10 mmHg e Difference between barometric pressure and intake mani fold absolute pressure is 26 kPa 200 mmHg or more e Difference between intake manifold absolute pressure at engine start and pressure after engine start is less than 1 3 2 driving cycle detection logic monitoring once 1 driving tion e ECM barometric pressure sensor malfunc DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Turn ignition switch ON for 2 sec crank engine for 2 sec and run it at idle for 1 min 4 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode INSPECTION DTC P1450 Substitute a known good ECM and recheck DTC P1451 NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when performing these check Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table switch OFF See Fig 1 LIST mode on scan tool 3 Check manifold absolute pressure mmHg at sea level 2 1 Connect scan tool to DLC with ignition 2 Turn ignition switch ON and select DATA Is it barometric pressure approx 100 kPa 760 Substitute a known good ECM and
535. rotor 1 11 Apply power steering fluid to O ring 1 and fit it to pump body 12 Install O ring 1 to pump body 13 Apply power steering fluid to sliding surface of pump cover 1 and rotor 14 Match the dowel pins 2 to the holes of the cover plate as shown and install pump cover to pump body 15 Tighten pump cover bolts to specified torque NOTE After installing pump cover 1 check to make sure that shaft can be turned by hand Tightening torque Oil pump cover bolts a 28 N m 2 8 kg m 20 0 Ib ft 3 a POWER STEERING P S SYSTEM If equipped 3B1 17 16 Apply power steering fluid to relief valve flow control valve 1 17 Install relief valve flow control valve 1 to pump body NOTE Check that relief valve flow control valve slides smoothly 18 Apply power steering fluid to O ring of plug 3 19 Install O ring to plug 3 20 Tighten plug to specified torque Tightening torque Plug a 60 N m 6 0 kg m 43 5 Ib ft 2 Flow control valve spring 21 Apply power steering fluid to O rings of pressure switch 1 22 Install O rings to pressure switch 1 23 Install pressure switch 1 to pump body Tightening torque Pressure switch a 28 N m 2 8 kg m 20 0 Ib ft 24 Apply power steering fluid to O ring 2 of suction connector 1 25 Install O ring 2 to suction connector 1 26 Install suction connector 2 to pum
536. rrect wheel alignment tire construction not uniform or wheel heavy acceleration Wear Indicators The original equipment tires have built in tread wear indicators to show when tires need replacement These indicators will appear as 12 mm 0 47 inch wide bands when the tire tread depth becomes 1 6 mm 0 063 inch When the indicators appear in 3 or more grooves at 6 locations tire replacement is recommended Radial Tire Waddle Waddle is side to side movement at the front and or rear of the vehicle It is caused by the steel belt not being straight within the tire It is most noticeable at low speed 5 to 30 mph It is possible to road test a vehicle and tell on which end of the vehicle the faulty tire is located If the waddle tire is on the rear the rear end of the vehicle will shake from side to side or waddle From the driver s seat it feels as though someone is pushing on the side of the vehicle If the faulty tire is on the front the waddle is more visual The front sheet metal appears to be moving back and forth and the driver feels as though he is at the pivot point in the vehi cle Waddle can be quickly diagnosed by using a Tire Problem Detector TPD and following the equipment manufacturer s rec ommendations Ifa TPD is not available the more time consuming method of sub stituting known good tire wheel assemblies on the problem vehi cle can be used as follows 3 6 STEE
537. rt special tool 6C 6 ENGINE FUEL 12 Remove fuel tank 1 from vehicle Remove fuel tank protec tor 3 and inlet valve 2 as necessary FUEL TANK PURGING PROCEDURE CAUTION This purging procedure will not remove all fuel vapor Do not attempt any repair on tank where heat or flame is required as an explosion resulting in personal injury could occur The following procedure is used for purging the fuel tank 1 After removing fuel tank remove all hoses and fuel pump assembly from fuel tank 2 Drain all remaining fuel from tank 3 Move tank to flushing area 4 Fill tank with warm water or tap water and agitate vigorously and drain Repeat this washing until inside of tank is clean Replace tank if its inside is rusty 5 Completely flush out remaining water after washing ENGINE FUEL 6C 7 INSTALLATION 1 Install fuel pump 1 assembly to fuel tank Refer to Fuel Pump Assembly in this section Install protector to fuel tank 2 Install inlet valve to fuel tank If deformed or damaged in any other way replace with a new one 3 Connect fuel filler and breather hoses to fuel tank and vapor hose to fuel pump assembly Clamp them securely 4 Lift up fuel tank on jack Connect fuel feed hose 4 and return hose 3 to pipes as shown in figure and clamp them securely CAUTION When connecting joint clean outside surfaces of pipe where joint is to be inserted
538. s and clothing away from engine cool ing fan 1 to help prevent personal injury Coolant Water Temperature Gauge A water temp gauge is located at intake manifold This gauge activates a temp meter in the instrument cluster When installing wind sealing tape on gauge thread and tighten it Diagnosis ENGINE COOLING 6B 5 Condition Possible Cause Correction Engine overheats Loose or broken water pump belt Not enough coolant Faulty thermostat Faulty water pump Dirty or bent radiator fins Coolant leakage on cooling system Defective cooling fan clutch Plugged radiator Faulty radiator cap Maladjusted ignition timing Dragging brakes Slipping clutch Adjust or replace Check coolant level and add as necessary Replace Replace Clean or remedy Repair Check and replace as necessary Check and replace radiator as necessary Replace Check system related parts Adjust brake Adjust or replace 6B 6 ENGINE COOLING Maintenance Coolant The coolant recovery system is standard The coolant in the radiator expands with heat and the overflow is col lected in the reservoir When the system cools down the coolant is drawn back into the radiator The cooling system has been filled at the factory with a quality coolant that is either 50 50 mixture of water and anti freeze anti corrosion coolant ethylene glycol antifreeze The 50 50 mixture coolant solution provide
539. s shown in figure At this time mount nuts 3 but don t tighten them FRONT SUSPENSION 3D 41 3 Install air locking hub vacuum pipe and tighten clamp bolts to specified torque for 4WD Tightening torque Vacuum pipe clamp bolts a 5 5 N m 0 55 kg m 4 0 Ib ft 4 Install stabilizer bar refer to Stabilizer Bar Bushings in this section 5 Install lateral rod 1 to vehicle body and axle housing Install bolts in proper direction as shown in figure At this time mount bolt and nut but don t tighten them NOTE For left hand steering vehicle install lateral rod with its bending point 2 placed to right side of vehicle A Right hand steering vehicle B Left hand steering vehicle 6 Clean mating surfaces of axle housing 1 and differential carrier and apply sealant to housing side for 4WD A Sealant 99000 31110 7 Install differential carrier assembly 2 to axle housing and tighten carrier bolts to specified torque for 4WD Tightening torque Front differential carrier bolts a 23 N m 2 3 kg m 17 0 Ib ft 8 Install front propeller shaft 1 to joint flange aligning match marks 3 and torque flange bolts to specification for 4WD Tightening torque Front propeller shaft flange bolts b 50 N m 5 0 kg m 36 5 Ib ft 3D 42 FRONT SUSPENSION 9 Install right and left axle shafts to axle hou
540. s depressed hydraulic pressure is developed in the master cylinder to actuate pis tons two in front and four in rear The master cylinder is a tandem master cylinder Three or two brake pipes are connected to the master cylin der and they make two independent circuits One connects front brakes right and left and the other connects rear brakes right and left The load sensing proportioning valve LSPV the proportioning and bypass P amp B valve or proportioning P valve is included in these circuits between the master cylinder and the rear brake In this brake system the disc brake type is used for the front wheel brake and a drum brake type leading trailing shoes for the rear wheel brake The parking brake system is mechanical It applies brake force to only rear wheels by means of the cable and mechanical linkage system The same brake shoes are used for both parking and foot brakes NOTE The figures shows left hand steering vehicle WARNING If any hydraulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlubricated fasteners A B C A Vehicle without ABS LSPV 1 Master cylinder 4 P amp B valve F Forward B Vehicle with LSPV 2 5 way joint 4 way joint 5 P Proportioning valve C Vehicle with ABS 3 LSPV Load Sensing Proportion 6 Hydraulic Unit ing valve 5 4 BRAKES Diagnosis Road Testi
541. s freezing protection to 36 C 33 F e Maintain cooling system freeze protection at 36 C 33 F to ensure protection against corrosion and loss of coolant from boiling This should be done even if freezing temperatures are not expected e Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added protection against freezing at temperature lower than 36 C 33 F Anti freeze proportioning table Freezing temperature I ae F 3 33 Anti freeze Amticorogion 30 50 coolant concentration Ratio of compound ltr 1 35 3 15 2 25 2 25 to cooling water US pt 2 85 6 65 4 75 4 75 Imp pt 2 37 5 53 3 95 3 95 Coolant capacity Engine radiator and heater 5 2 liters 11 0 9 2 US Imp pt Reservoir 0 7 liters 1 5 1 2 US Imp pt Total 5 9 liters 12 5 10 5 US Imp pt NOTE e 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 e 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 ENGINE COOLING 6B 7 Coolant Level WARNING To help avoid danger of being burned Do not remove reservoir cap while coolant is
542. s in that section are listed 2 Each section of this manual has its own pagination It is indicated at the top of each page along with the Sec tion name 3 The special tool usage and torque specification are given as shown in figure 6 Install oil pump Refer to Oil pump in this section 7 Install flywheel for M T vehicle or drive plate for A T vehicle Using special tool lock flywheel or drive plate and tighten flywheel or drive plate bolts 1 to specified torque Special Tool A 09924 17810 Tightening Torque c 78 Nem 7 8 kg m 56 0 Ib ft 4 Anumber of abbreviations are used in the text For their full explanations refer to Abbreviations May be Used in This Manual in this section 5 The SI metric and foot pound systems are used as units in this manual 6 Diagnosis are included in each section as necessary 7 At the end of each section there are descriptions of Special Tool Required Service Material and Tight ening Torque Specifications that should be used for the servicing work described in that section GENERAL INFORMATION 0A 3 Precautions Precaution for Vehicles Equipped with a Sup plemental Restraint Air Bag System WARNING e 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
543. s under Repair and Inspection Required after an Accident in Section 10B e When servicing parts other than air bag system if shocks may be applied to air bag system compo nent parts remove those parts beforehand e When handling the air bag inflator modules driver and passenger seat belt pretensioners driver and passenger or SDM be careful not to drop it or apply an impact to it If an excessive impact was applied e g dropped from a height of 90 cm 3 feet or more never attempt disassembly or repair but replace it with a new one e When grease cleaning agent oil water etc has got onto air bag inflator modules driver and pas senger or seat belt pretensioners drive and passenger wipe off immediately with a dry cloth e Air bag wire harness can be identified easily as it is covered with a yellow protection tube Be very careful when handling it e When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly e 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 e Never use air bag system component parts from another vehicle e When using electric welding be sure to disconnect air bag inflator module connectors driver and passenger and seat belt pretensioner connectors driver and passenger respectively e Never expos
544. same mating surfaces as when removed e Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts e Throughout this manual the four cylinders of the engine are identified by numbers No 1 1 No 2 2 No 3 3 and No 4 4 counted from crankshaft pulley side to flywheel side General Information on Engine Service THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY AS IT IS IMPORTANT IN PREVENTING DAMAGE AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE e 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 can be grounded ground cable of the battery should be disconnected at battery Any time the air cleaner throttle body or intake manifold is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow intake passage into cylin der and cause extensive damage when engine is started 6 4 ENGINE GENERAL INFORMATION AND DIAGNOSIS Pr
545. sconnect negative lead from terminal M Check that plunger and pinion remain out If plunger and pinion return inward replace magnetic switch PLUNGER AND PINION RETURN TEST Disconnect negative lead from starting motor body Check that plunger and pinion return inward If plunger and pinion don t return replace magnetic switch CRANKING SYSTEM 6G 5 NO LOAD PERFORMANCE TEST Connect battery and ammeter to starter as shown Check that starter rotates smoothly and steadily with pinion mov ing out Check that ammeter indicates specified current Specified current No load performance test 90 A MAX at 11 V On Vehicle Service Starting Motor 3 1 Starting motor 3 Transmission case 5 Starting motor mounting nut 7 Battery cable 2 Clutch housing upper plate 4 Starting motor mounting bolt 6 Magnetic switch lead wire Q Tightening Torque DISMOUNTING 1 Disconnect negative battery lead at battery 2 Disconnect magnetic switch lead wire 6 and battery cable 7 from starting motor terminals 3 Remove starting motor mount bolts 4 and nut 5 4 Remove starting motor 1 REMOUNTING Reverse the dismounting procedure 6G 6 CRANKING SYSTEM DISASSEMBLY AND REASSEMBLY NOTE e Make sure to apply grease before assembly where are indicated A in the figure below e Spare parts have been lubricated is all 21 A 20 48 1
546. scription in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CAUTION The air conditioning system of this vehicle uses refrigerant HFC 134a R 134a None of refrigerant compressor oil and component parts is interchangeable between two types of A C one using refrigerant HFC 134a R 134a and the other using refrigerant CFC 12 R 12 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 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 veh
547. section 5 Remove mounting bolts and leading arm 1 6 Remove bushings by using hydraulic press and special tools Special tool A 09924 74510 B 09951 16030 C 09951 26010 FRONT SUSPENSION 3D 37 INSTALLATION 1 Install bushings 1 by using hydraulic press and special tools noting the following point e Install bushings 1 so that either face of bushing are aligned with housing edge of leading arm 2 also the length between the aligned side end of bushing and leading arm 2 are within specification below Special tool A 09913 85210 B 09951 26010 Specification for leading arm bushing protrusion a 8 5 10 5 mm 0 33 0 41 in b 6 0 9 0 mm 0 24 0 35 in 2 Install leading arm 1 to vehicle body and axle housing referring to figure for proper installing direction of bolts Nuts should not be tightened 3 Install shock absorber lower mounting bolt refer to Front Shock Absorber in this section 4 Install air locking hub vacuum pipe clamp bolts and tighten them to specified torque for 4WD Tightening torque Vacuum pipe clamp bolts b 5 5 N m 0 55 kg m 4 0 Ib ft 5 Lower hoist and with vehicle in non loaded condition tighten nuts of leading arm to specified torque Tightening torque Leading arm nuts a 90 N m 9 0 kg m 65 0 Ib ft 2 Vacuum hose 3 Body outside A
548. sensor if any 3 Connect each connector to ECM and CKP sensor 4 Turn ignition switch ON 5 Check for voltage at terminal E19 23 of con nector connected to ECM by passing magnetic substance iron 1 while keeping approxi mately 1 mm 0 03 in gap with respect to end face of CKP sensor See Fig 2 and 3 Does voltage vary from low 0 1 V to high 4 5 V or from high to low Go to Step 7 Replace CKP sensor Check signal rotor for the following See Fig 4 e Damage e No foreign material attached Is it in good condition Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection in Section OA Clean rotor teeth or replace CKP sensor ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 81 A Fig 1 for Step 3 B Fig 2 for Step 6 C Fig 3 for Step 6 A B C Vout G R B B R Fig 4 for Step 7 P 9 6 82 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0340 DTC No 15 Camshaft Position CMP Sensor Circuit Malfunction CIRCUIT DESCRIPTION E18 24P E17 17P DTC DETECTING CONDITION POSSIBLE CAUSE e The number of CMP sensor signal pulses is incor CMP se
549. sensor 3 24 4 25 Ww Knock sensor 5 B Or Overdrive cut signal A T 26 G MAP sensor 6 G Y D range idle up signal A T 27 W R A C evaporator temp sensor t G W Stop lamp switch EGR valve stepper motor coil 4 if 28 Gr B equipped 8 TE EGR valve stepper motor coil 2 if i 29 Gr R equipped E17 9 B W Ignition switch 30 10 31 W G No 3 fuel injector 11 Y Vehicle speed sensor 12 G ABS signal if equipped 1 P A C compressor clutch if equipped 13 an A Engine start signal 2 VY Malfunction indicator lamp 14 E18 3 P G Data link connector 12 V 15 4 R BI Heater of HO2S 2 if equipped 16 R W Rear defogger switch if equipped A T failure signal A T vehicle with 5 BIB Power source 1 GIR immobilizer indicator lamp 6 BI B Power source E19 E18 Eiz selslal 3 CETEL a zji snaa 21 20 19 18 17 16 15 14 13 J12 1110 1116 15 14773 12 11 10 9 8 12 11 10 91 817 29 Ean 26 25124 23122 r 2312A 2i 20 19 18 17 0718 AEE NOTE See NOTE in ECM INPUT OUTPUT CIRCUIT DIAGRAM for applicable model 6E 14 ENGINE AND EMISSION CONTROL SYSTEM For TYPE B See NOTE
550. ses and pipes apply a few drops of compressor oil to seats of coupling nuts and O ring e When tightening or loosening a fitting use two wrenches one for turning and the other for support e Tighten flared nuts by the following specified torque Tightening torque Flared Nut Used for 8 mm pipe 13 N m 1 3 kg m 9 5 Ib ft 12 mm pipe 23 N m 2 3 kg m 16 6 lb ft 14 5 mm pipe 33 N m 3 3 kg m 23 8 Ib ft e Route drain hose so that drained water does not make any contact to vehicle components e Before evacuating and charging refrigerant replenish specified amount of compressor oil to compressor suction side by referring to Replenishing Compressor Oil in this section 1B 30 AIR CONDITIONING OPTIONAL Handling refrigerant HFC 134a R 134a WARNING Should refrigerant HFC 134a R 134a strike your eye s consult a doctor immediately e 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 e 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 The air conditioning system of this vehicle uses refrigerant HFC 134a R 134a None of refrigerant compressor oil and component parts is interchangea
551. shaft main bearing Color painted Bearing thickness Red and Pink 2 115 2 119 mm 0 0833 0 0834 in Red and Purple 2 118 2 122 mm 0 0834 0 0835 in Red and Brown 2 121 2 125 mm 0 0835 0 0837 in Red and Green 2 124 2 128 mm 0 0836 0 0838 in Red and Black 2 127 2 131 mm 0 0837 0 0839 in 1 Paint ENGINE MECHANICAL M13 ENGINE 6A1 87 e If necessary regrind crankshaft journal and select undersize bearing to use with it as follows a Regrind journal to the following finished diameter Finished diameter 44 732 44 750 mm 1 7611 1 7618 in 1 Using micrometer measure reground journal diameter Measurement should be taken in two directions perpendicu lar to each other in order to check for out of round 2 Using journal diameter measured above and alphabets stamped on cylinder block select an undersize bearing by referring to table given below Check bearing clearance with newly selected undersize bearing Specification of undersize crankshaft main bearing Measured journal diameter 44 744 44 750 mm 1 7616 1 7618 in 44 738 44 744 mm 1 7613 1 7616 in 44 732 44 738 mm 1 7611 1 7613 in Alphabets stamped on cylinder block A Red and Pink Red and Purple Red and Brown B Red and Purple Red and Brown Red and Green Cc Red and Brown
552. sing for 4WD Install knuckle to axle housing for 2WD NOTE Place knuckle seal and retainer in axle housing before installing axle shaft knuckle using care for installation direction of knuckle seal 10 Install kingpins 2 and knuckle seal cover 1 to steering knuckle R amp L refer to Steering Knuckle Wheel Spindle in this section 11 Install right and left brake disc and caliper assembly Tighten carrier bolts to specified torque Tightening torque Brake caliper carrier bolts a 85 N m 8 5 kg m 61 5 Ib ft 12 Connect spindle vacuum hoses to wheel spindle for 4WD while aligning the match mark 13 Install ABS wheel sensor to steering knuckle if equipped with ABS 14 Install tie rod ends and drag rod end to knuckle arm 1 R amp L Tighten new nuts to specified torque NOTE To prevent ball stud from being rotated while tightening tie rod end nut tighten Nut M12 x 1 25 to about 20 N m 2 0 kg m 14 5 lb ft and remove it Then tighten new nut to specified torque Tightening torque Tie rod end nuts and drag rod end nut Knuckle side a 43 N m 4 3 kg m 31 5 Ib ft 15 Install wheels and tighten wheel nuts to specified torque Tightening torque Wheel nuts 95 N m 9 5 kg m 69 0 Ib ft 16 Lower hoist FRONT SUSPENSION 3D 43 17 Tighten lateral rod 1 mounting bolt and nut to specified torque NOTE When tightening bolt and nut be sure that vehicle is off hoist a
553. smission 6A1 76 ENGINE MECHANICAL M13 ENGINE 26 Remove bolts and nuts fastening cylinder block and trans mission 27 Install board 1 or the like on A C condenser This prevents damage to condenser fins when lifting and lowering engine assembly 28 Install lifting device 29 Remove right and left engine mounting bracket bolts 1 30 Before lifting engine check to ensure all hoses electric wires and cables are disconnected from engine 31 Remove engine assembly from chassis and transmission by lifting a little sliding toward front side and then carefully hoist engine assembly ENGINE MECHANICAL M13 ENGINE 6A1 77 INSTALLATION 1 Lower engine assembly into engine compartment Connect engine to transmission Hard tighten bolts and nuts fastening cylinder block and transmission 2 Tighten right and left engine mounting bracket bolts to speci fied torque Tightening torque Engine mounting bracket bolts a 50 N m 5 0 kg m 36 5 Ib ft 3 Tighten bolts and nuts fastening cylinder block and transmis sion to specified torque Tightening torque Vehicle with M T Cylinder block and transmission fastening bolts and nuts a 94 N m 9 4 kg m 68 0 Ib ft Vehicle with A T Cylinder block and transmission fastening bolts and nuts a 80 N m 8 0 kg m 58 0 Ib ft 4 Remove lifting device 5 Reverse removal procedure for installation not
554. sor GAUGE 6E 36 Air Intake System cccccsceecsseseeeecseeteeeees 6E 18 NOEK ae Pe eee eee Bere Throttle Dody cecsecssesssessssesseessseesseeeteeees 6E 18 Maly Tela y i uel purp relay Anda Idle air control valve IAC valve 6E 21 a sales a ee A Fuel Delivery System n 6E 22 P fan control system a Fuel pressure inspection scce 6E 22 A C condenser TAN CONO SYSTEM sizz E Fiel bum 6E 23 A C condenser fan n se 6E 37 Fliel pressure regulator a cuocsx BEA Spur SONAS Or MONE valve opening and engine coolant temp Vehicle with A T only eereeee 6E 38 Emission Control System 6E 38 6E 2 ENGINE AND EMISSION CONTROL SYSTEM EGR system If equipped 08 Evaporative emission EVAP control SYSUOM r EE EES EEE PCV SySteM wivsececteteiesstensteisbavaieenetabecvens Special TOONS visscssiessscccsaissnacesscceceeevesecescersess Tightening Torque Specifications ENGINE AND EMISSION CONTROL SYSTEM 6E 3 delivery pipe fuel pressure regulator etc Electronic control system General Description The engine and emission control system is divided into 4 major sub systems air intake system fuel delivery system electronic control system and emission control system Air intake system includes air cleaner throttle body IAC valve and intake manifold Fuel delivery system includes fuel pump Emission control system includes EGR EVAP and PCV system includes ECM vari
555. sor feedback 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 COOLANT TEMP ENGINE COOLANT TEMPERATURE C F It is detected by engine coolant temp sensor SHORT FT B1 SHORT TERM FUEL TRIM Short term fuel trim value represents short term corrections to the air fuel mixture computation A value of 0 indicates 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 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 MAP INTAKE MANIFOLD ABSOLUTE PRESSURE kPa inHg It is detected by manifold absolute pressure sensor and used among other things to compute engine load ENGINE SPEED rpm It is computed by reference pulses from crankshaft position sensor VEHICLE SPEED km h MPH It is computed based on pulse signals from vehicle speed sensor IGNITION ADVANCE IGNITION TIMING ADVANCE FOR NO 1 CYLINDER Ignition timing of NO 1 cylinder is commanded by ECM The actual ignition timing should be checked by using the timing light INTAK
556. sor poor performance ECT sensor poor performance IAT sensor poor performance TP sensor poor performance EVAP control system malfunction PCV valve malfunction ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 69 DTC CONFIRMATION PROCEDURE WARNING e 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 e Road test should be carried out with 2 persons a driver and a tester on a level road 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Check vehicle and environmental condition for Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower 4 Start engine and drive vehicle under usual driving condition described in DTC confirmation procedure of DTC P0136 for 5 min or longer and until engine is warmed up to normal operating temperature 5 Keep vehicle speed at 30 40 mph 50 60 km h in 5th gear or D range for 5 min or more 6 Stop vehicle do not turn ignition switch OFF 7 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Is there DTC s oth
557. st to correct specifi cations Weakened or broken return springs in the brake Replace Sluggish parking brake cables or linkage Repair or replace Wheel cylinder or caliper piston sticking Repair as necessary Malfunctioning ABS if equipped with ABS Check system and replace as nec essary Pedal pulsation Pedal pulsates when depressed for brak ing Damaged or loose wheel bearings Replace wheel bearings Distorted steering knuckle or rear axle shafts Replace knuckle or rear axle shaft Excessive disc lateral runout Check per instructions If not within specifications replace or machine the disc Parallelism not within specifications Check per instructions If not with specifications replace or machine the disc Rear drums out of round Check runout Repair or replace drum as neces sary Braking noise Glazed shoe linings or foreign matters stuck to linings Repair or replace brake shoe Worn or distorted shoe linings Replace brake shoe or pad Loose front wheel bearings Replace wheel bearing Distorted backing plates or loose mounting bolts Replace or retighten securing bolts Brake warning light turns on after engine start Parking brake applied Release parking brake and check that brake warning light turns off Insufficient amount of brake fluid Add brake fluid Brake fluid leaking from brake line
558. stall timing chain with crankshaft sprocket referring to Timing Chain and Chain Tensioner in this section 7 Install timing chain cover referring to Timing Chain Cover in this section 8 Check valve lashes referring to Valve Lash in this section 9 Install cylinder head cover and oil pan referring to Cylinder Head Cover and Oil Pan and Oil Pump Strainer in this sec tion 10 Install radiator with cooling fan and connect A T fluid hoses vehicle with A T radiator inlet and outlet hoses referring to Water Pump Belt and Cooling Fan and Radiator in Sec tion 6B 11 Adjust generator belt tension referring to Water Pump Belt Tension in Section 6B 12 Adjust A C compressor and or P S pump belt tension if equipped referring to Compressor Drive Belt in Section 1B or Power Steering Belt in Section 3B1 13 Refill cooling system with coolant engine with engine oil and A T with specified A T fluid vehicle with A T 14 Verify that there is no coolant leakage oil leakage and A T fluid leakage vehicle with A T at each connection 6A1 48 ENGINE MECHANICAL M13 ENGINE Valves and Cylinder Head XEN E 1 Valve cotters 6 Intake valve 11 Cylinder head gasket 5 TOP mark provided on gasket comes to crankshaft pulley side facing up 2 Valve spring retainer 7 Exhaust valve 12 Knock pin g 3 Valve spring 8 Valve guide m Tightening
559. stem 0A 3 Transmission Identification Number OA 17 DIAGNOSIS seinri indeed 0A 3 Warning Caution and Information Servicing and handling cceeeeeeee 0A 4 kabels anrea areena ana s 0A 18 General Precautions s str OA 7 Vehicle Lifting Points sssseeeeees 0A 19 Precautions For Catalytic Converter 0A 10 When Using Frame Contact Hoist OA 19 Precautions For Electrical Circuit Service 0A 10 When Using Floor Jack cccccccccscseeeceeeeees 0A 20 Electrical Circuit Inspection Procedure 0A 13 og Open circuit ChECK sscscssscsssssssssssseeeseeee 0A 13 ODE ations May Pe veed Inns PENI CIMGUIt G IGOK i Wai Wallis Asche ecseuneatii ce Scio adie ara OA 21 Short circuit check wire harness to a GOLA Pasnssrnictch ected iat daonseg nine ata 0A 15 Abbreviations iniiaiee 0A 21 Intermittent and Poor Connection 0A 15 Fasteners Information ccsssecssesecseeeees 0A 24 Precaution For Installing Mobile Metric Fasteners eeen 0A 24 Communication Equipment 0 0A 16 Fastener Strength Identification 0A 24 Standard Tightening Torque eee OA 24 0A 2 GENERAL INFORMATION How to Use This Manual 1 There is a Table of Contents on the third page of this manual whereby you can easily find the section that offers the information you need Also there is a CONTENTS on the first page of each section where the main item
560. stered on gauge varies with ambient tem perature Therefore use graph when determining if pres sures are normal or not Low side and high side pressure example Gauges should read as follows when ambient tempera ture is 30 C 86 F 1400 1750 kPa Pressure on high pres 2 14 0 17 5 kg cm sure gauge 3 199 1 248 9 psi 230 350 kPa Pressure on low pressure 2 2 3 3 5 kg cm gauge 32 7 49 8 psi 9 Check inlet port temperature to outlet port temperature rela tionship using graph For example if evaporator inlet port temperature is 25 C 77 F and center duct air outlet temperature is 8 C 46 4 F their crossing point is within acceptable range as shown in the graph If crossing point is out of acceptable range diagnose trouble referring to Performance Diagnosis Table in this section 1B 12 AIR CONDITIONING OPTIONAL Performance diagnosis table NOTE If ambient temperature is approximately 30 C 86 F it is possible to diagnose A C system in detail referring to Detail Diagnosis Table Ambient Temperature At 30 C 86 F under Performance Diagnosis in this section HIGH PRESSURE GAUGE Condition Possible Cause Correction Pressure in higher than acceptable range A area Refrigerant overcharged Recharge Expansion valve frozen or clogged Check expansion valve Clogged refrigerant passage of high sid
561. sti tute a known good ABS hydraulic unit control module assembly and recheck 1 Ignition switch OFF 2 Disconnect ABS hydraulic unit control module connector 3 Check for proper connection to ABS hydrau lic unit control module connector at termi nal A23 4 If OK then measure voltage between termi nal A23 of module connector and body ground Is it 10 14V Go to step 3 W BI circuit open Measure resistance between connector termi nal A22 of ABS hydraulic unit control module assembly and body ground Is it infinite co B circuit open Substitute a known good ABS hydraulic unit con trol module assembly and recheck ANTILOCK BRAKE SYSTEM ABS 5E 27 DTC C1063 DTC 63 ABS Fail Safe Circuit B W 1 n W BI i I A18 A25 S an Arq tes bea oe i q 0 1 Ignition switch 3 1 Lock position 2 ABS hydraulic unit control module assembly 3 2 Unlock position DESCRIPTION 3 ABS hydraulic unit control module connector of harness The ABS control module monitors the voltage at the terminal of the solenoid circuit constantly with the ignition switch turned ON Also immediately after the ignition switch is turned ON perform an initial check as follows Switch the fail safe transistor in the order of ON gt OFF ON and check if the voltage at 6 solenoid
562. t and nut to specification as indicated respectively Tightening torque LSPV bolts a 25 N m 2 5 kg m 18 0 Ib ft Brake pipe flare nuts b 16 N m 1 6 kg m 12 0 Ib ft 2 Upon completion of installation fill reservoir tank with speci fied fluid and bleed air from brake system NOTE Make sure to bleed air from LSPV bleeder without fail Tightening torque LSPV bleeder plug a 8 N m 8 0 kg m 6 0 Ib ft 3 After bleeding air check that LSPV is installed properly referring to following INSPECTION amp ADJUSTMENT BRAKES 5 43 LSPV Assembly INSPECTION AND ADJUSTMENT 1 x Confirm the following before inspection and adjustment e Fuel tank is filled with fuel fully Vehicle is equipped with spare tire tools jack and jack han dle Vehicle is free from any other load Place it on level floor Push up LSPV lever with finger till it stops and measure length of coil spring a in figure N 3 Spring length a should be as specified Spring length a 147 mm 5 79 in 4 If it isn t adjust it to specification by changing stay position as shown in figure After adjustment tighten bolt to specified torque Tightening torque LSPV adjust bolt a 25 N m 2 5 kg m 18 0 Ib ft NOTE Check to make sure that LSPV body and brake pipe joints are free from fluid leakage Replace defective parts if any 5 44 BRAKES P Proportioning
563. t completed pleted INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check Short Term Fuel Trim Go to Step 3 Check fuel system Did short term fuel trim vary within 20 Go to DTC P0171 P0172 20 range in step 3 of DTC confirmation Diag Flow Table test 3 Check HO2S 2 for Output Voltage Replace three way cata Check W and B BI Perform steps 1 through 9 of DTC confirma tion procedure for DTC P0136 HO2S 2 mal function and check output voltage of HO2S 2 then Is over 0 6 V and below 0 3 V indicated lytic converter wires for open and short and connections for poor connection If wires and connections are OK replace HO2S 2 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 91 DTC P0443 Purge Control Valve Circuit Malfunction CIRCUIT DESCRIPTION 1 B Q BI B ah ECM BIG E19 4 Y4 B R E19 2 4 B R F19 3 1 EVAP canister purge vale DTC DETECTING CONDITION POSSIBLE CAUSE Canister Purge control valve circuit is opened or shorted e BI G circuit open or short e BI B circuit open or short e Canister purge valve malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC with ignition switch ON 2 Select DTC mode on scan tool and check DTC INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table
564. t is open e When DTC P0105 No 11 P0110 No 18 P0115 No 19 P0120 No 13 and P0460 are indicated together it is possible that B BI circuit is open DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check MAP Sensor and Its Circuit Go to Step 3 Intermittent trouble 1 Connect scan tool to DLC with ignition Check for intermittent switch OFF See Fig 1 referring to Intermittent 2 Turn ignition switch ON and Poor Connection in 3 Check intake manifold pressure Section OA Is it 126 kPa 37 2 inHg or 0 kPa 0 inHg ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 49 Step Action Yes No 3 Check Wire Harness Go to Step 4 Lg R wire open or 1 Disconnect MAP sensor connector with shorted to ground circuit ignition switch OFF or shorted to power circuit 2 Check for proper connection of MAP sensor See NOTE Q wire at G and B BI wire terminals open or shorted to 3 If OK then with ignition switch ON check ground poor E19 26 con voltage at each of Lg R and G wire termi nection or E19 22 con nals and body ground See Fig 2 nection Is voltage about 4 6 V at each terminal If wire and connection are OK
565. t lining replace it with a new one INSTALLATION NOTE See NOTE at the beginning of this section 1 Before installing brake drum check outer diameter of brake shoes If it is not within value as specified below adjust it to specification by turning adjuster 1 Outer diameter of brake shoes a 219 4 219 7 mm 8 638 8 650 in 2 Spring and rod assembly 3 Brake shoes 2 Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil 3 Upon completion of all jobs depress brake pedal with about 30 kg 66 Ibs load about 30 times so as to obtain proper drum to shoe clearance Adjust parking brake cable 4 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nuts a 95 N m 9 5 kg m 69 0 Ib ft 5 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 5 32 BRAKES Brake shoe REMOVAL 1 Remove brake drum referring to Brake Drum in this sec tion 2 Remove shoe return spring lower 3 spring and rod assem bly 4 and shoe hold down springs 2 by turning shoe hold down pins 1 WARNING Use special care when installing brake shoe return spring Failure in its proper installation may allow it to spring back and cause personal injury
566. t shorted to ground Substitute a known good ECM and recheck ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 45 Table A 3 Malfunction Indicator Lamp Circuit Check Mil Flashes at Ignition Switch ON WIRING DIAGRAM CIRCUIT DESCRIPTION Refer to table A 1 INSPECTION Step Action Yes No 1 MIL flashing pattern check Go to Step 2 Go to Diagnosis in Sec 1 With the ignition switch ON position check tion 8G MIL flashing pattern Does MIL flashing pattern indicate DTC diag nostic trouble code 2 Diagnosis switch terminal check Substitute a known good W BI wire diagnosis 1 With the ignition switch ON position check ECM and recheck switch terminal shorted voltage between E18 14 terminal of ECM to ground circuit coupler and ground If OK substitute a known Is voltage 4 5 V good ECM and recheck Table A 4 Malfunction Indicator Lamp Circuit Check MIL Does Not Flash Just Remains ON or Just Remains OFF Even with Grounding Diagnosis Switch Terminal WIRING DIAGRAM CIRCUIT DESCRIPTION Refer to table A 1 INSPECTION Step Action Yes No 1 MIL flashing pattern check Go to Step 2 W BI wire diagnosis 1 With grounding diagnosis switch terminal switch terminal B wire and turn the ignition switch ON position of monitor connector check voltage between E18 14 terminal of open ECM connector and ground If OK substitute a known Is voltage 0 1
567. tage P0105 Manifold absolute pressure or MAP sensor circuit shorted to ground 1 driving 1 driving No 11 circuit malfunction High pressure low vacuum high voltage cycle cycle or MAP sensor circuit open P0110 Intake air temp circuit mal Intake air temp circuit low input 1 driving 1 driving No 18 function Intake air temp circuit high input cycle cycle P0115 Engine coolant temp cir Engine coolant temp circuit low input 1 driving 1 driving No 19 cuit malfunction Engine coolant temp circuit high input cycle cycle P0120 Throttle position circuit mal Throttle position circuit low input 1 driving 1 driving No 13 function Throttle position circuit high input cycle cycle P0121 Throttle position circuit per Poor performance of TP sensor 2 driving Not formance problem cycles applicable Min output voltage of HO2S higher than P0130 HO2S circuit malfunction specification 2 driving 1 driving No 14 Sensor 1 Max output voltage of HO2S lower than cycles cycle specification HO2S circuit slow response BesHolee uneon Hoea output vorago 2 driving Not P0133 between rich and lean is longer than spec Sensor 1 ee cycles applicable ification P0135 HO2S heater circuit mal Terminal voltage is lower than specification 2 driving 1 driving No 14 function Sensor 1 at heater OFF or it is higher at heater ON cycles cycle HO2S circuit malfunction HO28 2 voltage is higher than specifica 2 driving Not P0136 f i Sensor
568. tch mark are no matches adjust each sprocket and timing chain 11 Install timing chain cover referring to Timing Chain Cover in this section 12 Perform Steps 3 to 8 of INSTALLATION of Timing Chain Cover in this section 6A1 42 ENGINE MECHANICAL M13 ENGINE Camshaft Tappet and Shim 1 Intake camshaft 4 Tappet Q Tightening torque 2 Exhaust camshaft 5 Camshaft housing Apply engine oil to sliding surface of each part P 3 Shim 6 Camshaft housing bolt 5 Shim No on it faces tappet side REMOVAL 1 Remove cylinder head cover and oil pan referring to Cylin der Head Cover and Oil Pan and Oil Pump Strainer in this section 2 Remove timing chain cover referring to Timing Chain Cover in this section 3 Remove timing chain referring to Timing Chain and Chain Tensioner in this section Ney ci eek tee Ne eaten 4 ale 4 Loosen camshaft housing bolts in such order as indicated in 12 13 20 21 416 17 8 9 g figure and remove them 5 Remove camshaft housings 6 Remove intake and exhaust camshafts HINES BUN EL a ENGINE MECHANICAL M13 ENGINE 6A1 43 7 Remove tappets 1 with shims 2 INSPECTION Cam Wear Using a micrometer measure cam height a If measured height is below its limit replace camshaft
569. te Special tool A 09943 35511 B 09942 15510 8 Remove wheel bearing retainer and wheel sensor ring if equipped with ABS refer to Rear Axle Shaft and Wheel Bearing in Section 3E 9 Remove brake back plate from axle shaft INSTALLATION 1 Install wheel cylinder and tighten wheel cylinder bolts to specified torque Refer to Wheel Cylinder in this section 2 Install brake back plate 2 to axle shaft 1 3 For installation procedure here after perform Rear Axle Shaft and Wheel Bearing in Section 3E 3 Wheel bearing 4 Retainer ring 5 36 BRAKES 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 connector pin 2 by using special tool Special tool A 09922 85811 Remove reservoir 1 Cad CAUTION Brake fluid is extremely damaging to paint Do not allow brake fluid to get on painted surfaces 2 Connector pin 3 Grommets BRAKES 5 37 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 with Then press fit grommets to master cylinder Grommets must be seated in place 2 Install reservoir 1 and drive in reservoir pin 2 NOTE
570. tely And it is not erased unless the power to ECM is shut off for specified time below ECM also indicates trouble area in memory by means of flashing of malfunction indicator lamp 1 at the time of inspection i e when connecting diagnosis switch terminal 2 and ground terminal 4 of monitor connector 3 with a service wire 5 and ignition switch is turned ON NOTE When a trouble occurs in the above areas and disap pears soon while the diagnosis switch terminal is ungrounded and the engine is running malfunction indicator lamp 1 lights and remains ON as long as the trouble exists but it turns OFF when the normal condi tion is restored Time required to erase diagnostic trouble code mem ory thoroughly varies depending on ambient tempera ture as follows 6 10 ENGINE GENERAL INFORMATION AND DIAGNOSIS AMBIENT TEMPERATURE TIME TO CUT POWER TO ECM Over 0 C 82 F 60 sec or longer Not specifiable Under 0 C 32 F Select a place with higher than 0 C 32 F temperature Precaution in Diagnosing Trouble Don t disconnect couplers from ECM battery cable at battery ECM ground wire harness from engine or main fuse before confirming diagnostic information DTC freeze frame data etc stored in ECM memory Such disconnection will erase memorized information in ECM memory Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool or gener
571. ten steering column mounting nuts and bolts by hand and then tighten mounting nuts 1 first and then tighten mounting bolts 2 Tightening torque Steering column mounting bolts and nuts a 14 N m 1 4 kg m 10 5 Ib ft 6 Install steering column hole cover 1 7 Install steering wheel to steering column referring to Steer ing Wheel in this section Steering Column Assembly CAUTION Once the steering column is removed from the vehicle the column is extremely susceptible to damage e Dropping the column assembly on its end could col lapse the steering shaft or loosen the plastic shear pins which maintain column length e Leaning on the column assembly could cause it to bend or deform Any of the above damage could impair the column s col lapsible design 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 components leave steering wheel installed on steering column 3C 12 STEERING WHEEL AND COLUMN REMOVAL WARNING For vehicle with air bag system Never rest a steering column assembly on the steering wheel with the air bag inflator module face down and column vertical Otherwise personal injury may result 1 Disconnect negative battery cable at battery terminal 2 For vehicle equipped with air bag system disable air bag system referring to Disabling
572. tension by referring to Compressor Drive Belt in this section Magnet Clutch AIR CONDITIONING OPTIONAL 1B 41 1 Thermal switch Magnet clutch coil a Front head bolt Tighten bolt a first and next b 2 Compressor body assembly Compressor pulley b Front head bolt Tighten bolt a first and next b 3 O ring 8 Circlip c Clutch plate bolt 4 Lip seal 9 Shim m Tightening torque 5 Front head 10 Clutch plate x Do not reuse 1B 42 AIR CONDITIONING OPTIONAL INSPECTION e Check clutch plate and clutch pulley for leaks of compressor oil e Check clutch bearing of compressor pulley for noise wear and grease leakage e Measure resistance of magnet clutch coil 1 between mag net clutch lead wire 2 and compressor body assembly If measured resistance is not within tolerance replace mag net clutch coil Magnet Clutch coil resistance 3 4 4 1 Q at 20 C 68 F e Check thermal switch 1 for continuity using ohmmeter If it is no continuity replace thermal switch REMOVAL 1 Remove compressor from vehicle referring to Compressor in this section 2 Fix clutch plate 1 with special tool and remove clutch plate bolt 2 and washer 3 Special tool A 09991 06020 3 Remove clutch plate 1 using special tool Special tool A 09991 06030
573. th fuel pump operating and 270 310 kPa engine stopped 2 7 3 1 kg em 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 over 200 kPa pump stop Pressure 2 reduces as time passes 2 0 kolom 28 4 psi ENGINE AND EMISSION CONTROL SYSTEM 6E 23 6 Start engine and warm it up to normal operating tempera ture 7 Measure fuel pressure at idling If measured pressure doesn t satisfy specification refer to Diagnostic Flow Table B 3 in Section 6 and check each possibly defective part Replace if found defective 8 After checking fuel pressure remove fuel pressure gauge CAUTION As fuel feed line is still under high fuel pressure make sure to release fuel pressure according to following pro cedures e Place fuel container under joint e Cover joint with rag and loosen joint nut slowly to release fuel pressure gradually 9 Remove special tools from fuel delivery pipe 10 Connect fuel feed hose to fuel delivery pipe and clamp it 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 NOTE The fuel pressure regulator is the one body with the fuel pump assembly s
574. the NOTE in ECM Terminal Voltage Values Table for applicable model DTC DETECTING CONDITION POSSIBLE CAUSE engine or engine 2 driving cycle detection logic continuous monitoring e Low voltage at terminal E17 13 or E18 20 when cranking e High voltage at terminal E17 13 or E18 20 after starting e B Y circuit open e ECM malfunction DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON crank engine and run it at idle for 3 min 3 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode 6 102 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check for voltage at terminal E17 13 Case of Poor E17 13 Case of B Y or B R circuit TYPE A See NOTE or E18 20 Case of TYPE TYPE A See NOTE or open B See NOTE of ECM connector connected E18 20 Case of TYPE B under following condition See NOTE connection Engine starter signal specification or intermittent trouble While engine cranking 6 10 V Check for intermittent After starting engine 0 V referring to Intermittent Is voltage as specified and Poor Connection in Section OA If wire and connections are OK substitute a known good ECM and recheck ENGINE GENERAL INFORMATI
575. the probe from the wire harness side backside of the connector 1 When connecting meter probe 2 from terminal side of coupler 1 because it can t be connected from harness side use extra care not to bend male terminal of coupler of force its female terminal open for connection In case of such coupler as shown connect probe as shown to avoid opening female terminal Never connect probe where male terminal is supposed to fit When checking connection of terminals check its male half for bend and female half for excessive opening and both for locking looseness corrosion dust etc Before measuring voltage to check for electrical system check to make sure that battery voltage is 11V or higher Such terminal voltage check at low battery voltage will lead to erroneous diagnosis Se GENERAL INFORMATION 0A 13 Electrical Circuit Inspection Procedure While there are various electrical circuit inspection methods described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter Open circuit check Possible causes for the open circuit are as follows As the cause is in the connector or terminal in many cases they need to be checked particularly carefully e Loose connection of connector e Poor contact of terminal due to dirt corrosion or rust on it poor contact tension entry of foreign object etc e Wire harness being open When checking system
576. the second for making 45 angle The second cut must be made to produce desired seat width Seat width for exhaust valve seat 2 a 1 1 1 3 mm 0 0433 0 0512 in INTAKE VALVE SEAT Use valve seat cutters to make three cuts as illustrated in figure Three cutters must be used the 1st for making 15 angle the 2nd for making 60 angle and 3rd for making 45 angle The 3rd cut 45 must be made to produce desired seat width Seat width for intake valve seat b 1 1 1 3 mm 0 0433 0 0512 in 3 VALVE LAPPING Lap valve on seat in two steps first with coarse size lapping compound applied to face and the sec ond with fine size compound each time using valve lapper according to usual lapping method Cylinder Head Remove all carbon deposits from combustion chambers NOTE Do not use any sharp edged tool to scrape off carbon deposits Be careful not to scuff or nick metal surfaces when decarboning The same applies to valves and valve seats too 6A1 56 ENGINE MECHANICAL M13 ENGINE Check cylinder head for cracks on intake and exhaust ports combustion chambers and head surface Using a straightedge and thickness gauge check flatness of gasketed surface at a total of 2 locations If distortion limit given below is exceeded correct gasketed surface with a surface plate and abrasive paper of about 400 Waterproof
577. ther e Vehicle speed while accelerating while decelerating at stop while turning while running at constant speed other ______ e Road surface condition Paved road rough road snow covered road other Conditions for Occurrence of Problem Chain equipment Environmental Condition e Weather fair cloudy rain snow other _ e Temperature OFF C f First check Normal code malfunction code Diagnostic Trouble Code Second check after test drive Normal code malfunction code b Problem Symptom Confirmation Check if what the customer claimed in Customer Questionnaire is actually found in the vehicle and if the symptom is found determine whether it is identified as a failure This step should be shared with the cus tomer if possible When ABS warning lamp is not operating correctly proceed to Diagnostic Flow Table A B or C in this section 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 turned ON attempt to diagnose the trouble based on the DTC recorded in this step may mislead the diagnosis or make diagnosing difficult Proceed to
578. there are no bubbles 7 in the sight glass which means that the system is fully charged LE e SA R A e ap Gauges should read as follows when ambient tempera les SSSA es A a ture is 30 C 86 F 1400 1750 kPa 14 0 17 5 kg cm 199 1 248 9 psi 230 350 kPa 2 3 3 5 kg cm 32 7 49 8 psi Pressure on high pressure gauge Pressure on low pressure gauge 1B 28 AIR CONDITIONING OPTIONAL Removing Manifold Gauge Set When A C system has been charged with a specified amount of refrigerant remove manifold gauge set as follows 1 Close low pressure side valve of manifold gauge set The high pressure side valve is closed continuously during the process of charging 2 Close refrigerant container valve 3 Stop engine 4 Using shop rag remove charging hoses from service valves This operation must be performed rapidly WARNING High pressure side is naturally under high pressure So care must be used to protect your eyes and skin 5 Put caps on service valves Leak Test Whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result in dis turbing lines or connections it is advisable to test for leaks Common sense should be used in performing any refrigerant leak test since the need and extent of any such test will in general depend upon the nature of a complaint and the type of
579. these terminals through a lamp e Do not connect any load between L and E e When connecting a charger or a booster battery to vehicle battery refer to this section describing battery charging B Generator output Battery terminal E Ground IG Ignition terminal L Lamp terminal Trouble in charging system will show up as one or more of follow ing conditions 1 Faulty indicator lamp operation 2 An undercharged battery as evidenced by slow cranking or indicator dark 3 An overcharged battery as evidenced by excessive spewing of electrolyte from vents Noise from generator may be caused by a loose drive pulley loose mounting bolts worn or dirty bearings defective diode or defective stator and engine off Condition Possible Cause Correction Charge light does not Fuse blown Check fuse light with ignition ON Light burned out Replace light Wiring connection loose Tighten loose connection IC regulator or field coil faulty Check generator Charge light does not go out with engine running battery requires fre quent recharging Drive belt loose or worn Adjust or replace drive belt IC regulator or generator faulty Check charging system Wiring faulty Repair wiring 6H 8 CHARGING SYSTEM 30 C 20 C 120 C 22 F 68 F 248 F Temperature UNDERCHARGED BATTERY This condition as evidence
580. this time mount bolt and nut but don t tighten them 5 Clean mating surfaces of axle housing 1 and differential carrier and apply sealant to housing side A Sealant 99000 31110 6 Install differential carrier assembly 3 to axle housing and tighten carrier bolts to specified torque Tightening torque Rear differential carrier bolts a 23 N m 2 3 kg m 17 0 Ib ft 7 Install propeller shaft 2 to joint flange aligning match marks 1 and tighten flange bolts to specified torque Tightening torque Rear propeller shaft bolts b 50 N m 5 0 kg m 36 5 Ib ft 8 Install LSPV stay to axle housing and adjust LSPV stay posi tion referring to LSPV Assembly Inspection and Adjust ment in Section 5 if equipped with LSPV 9 Remove floor jack from axle housing 10 Connect brake pipes and parking brake cable onto axle housing and clamp them securely For clamping positions refer to Rear Brake Hose Pipe and Parking Brake Cable in Section 5 REAR SUSPENSION 3E 21 11 Connect brake flexible hose 2 to bracket on axle housing and secure it with E ring 1 12 Connect brake pipe to brake flexible hose and tighten brake pipe flare nut to specified torque Tightening torque Brake pipe flare nut a 16 N m 1 6 kg m 11 5 Ib ft 13 Clean mating surface of axle housing 2 right amp left with brake back plate and apply sealant as shown B Sea
581. til its end contacts stepped surface of wheel hub 4 Special tool A 09944 78210 3 Install bearing circlip 1 Oil hydraulic press 2 Steel plate 4 Drive in wheel bearing oil seal 1 by using special tools Special tool B 09944 66010 C 09924 74510 FRONT SUSPENSION 3D 25 5 Apply lithium grease to lip portion and hollow of oil seal 1 NOTE Amount of grease applied to hollow in oil seal 1 should be more than 60 of its vacant space A Grease 99000 25010 2 Wheel hub 6 Install sensor rotor 3 as shown if equipped with ABS NOTE e Pipe 2 used here should have inner diameter of 90 mm 3 55 in 96 mm 3 77 in and its outside should not contact teeth of sensor rotor 3 e Use care not to insert wheel hub 4 diagonally 1 Steel plate 5 Hydraulic press 7 Apply lithium grease inside wheel bearing thin A Grease 99000 25010 8 Install wheel hub complete with bearings and oil seal onto front wheel spindle 9 Install bearing washer 10 Tighten wheel bearing lock nut to specified torque while turn ing wheel hub by hand Special tool A 09944 77020 For 4WD A 09951 16050 For 2WD Tightening torque Wheel bearing lock nut a 220 N m 22 0 kg m 160 Ib ft 11 Install hub cap for 2WD model or air locking hub assembly for 4WD model as follows 3D 26 FRONT SUSPENSION
582. tion control system Also with A T model ECM sends throttle valve opening signal and over drive cut signal to transmission control module to control A T NOTE The figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the other side j LP ZS _ Sy 1 IAT sensor a Immobilizer indicator lamp if equipped A ECM 2 TP sensor b A C condenser fan motor relay if equipped B A T control module 3 Monitor connector c Main relay C EVAP canister 4 CO adjusting resistor if equipped d Fuel pump relay D DLC 5 CKP sensor e IAC valve E ABS control module if equipped 6 MAP sensor f EVAP canister purge valve 7 CMP sensor g EGR valve if equipped 8 Transmission range switch h Fuel injector 9 VSS i Ignition coil assemblies 10 HO2S 1 if equipped J MIL 11 HO2S 2 if equipped 12 ECT sensor 13 Knock sensor 6E 8 ENGINE AND EMISSION CONTROL SYSTEM Engine amp emission control input output table ELECTRIC CONTROL DEVICE Ww w OUTPUT ha 2 gt W xt aL lt x E Aal gt OCld a zoll oe eS Q G a a 2 2 a o 2 t 5 lt gt El 2laqglajse Q S Z 9l Z D iam no W a O a alu WUJA O l ATT ol jpuj
583. tion sensor from cylinder head INSTALLATION 1 Check that O ring is free from damage 2 Check that camshaft position sensor and signal rotor tooth are free from any metal particles and damage 3 Install camshaft position sensor to sensor case Tightening torque Camshaft position sensor bolt a 10 N m 1 0 kg m 7 5 Ib ft 4 Connect connector to it securely 5 Connect negative cable to battery ENGINE AND EMISSION CONTROL SYSTEM 6E 35 Crankshaft position sensor INSPECTION Check crankshaft position sensor referring to step 2 and 6 of DTC P0335 No 23 Flow Table in Section 6 If malfunction is found replace REMOVAL 1 Disconnect negative cable at battery 2 Remove generator drive belt loosen pivot bolt and move generator outward 3 Disconnect connector from crankshaft position sensor 4 Remove crankshaft position sensor 1 from cylinder block INSTALLATION 1 Check to make sure that crankshaft position sensor and pul ley tooth is free from any metal particles and damage 2 Install crankshaft position sensor to cylinder block 3 Connect connector to it securely 4 Adjust generator belt tension refer to Water Pump Belt Ten sion in Section 6B 5 Connect negative cable to battery 6E 36 ENGINE AND EMISSION CONTROL SYSTEM Vehicle speed sensor VSS INSPECTION Check vehicle speed sensor referring to step 7 of DTC P0500
584. to open Temp at which valve becomes fully open 80 84 C 176 183 F 93 97 C 199 207 F More than 8 mm at 95 C Valve lift 203 F 2 Thermometer 3 Heater INSTALLATION 1 When positioning the thermostat 2 on the thermostat case 1 be sure to align its air breather valve 3 with mark 4 2 Install thermostat cap 5 to thermostat case with align air bleed valve and mark Then tighten mounting bolts to specified torque Tightening torque Thermostat cap bolts a 11 N m 1 1 kg m 8 0 Ib ft Thermostat case bolts b 25 N m 2 5 kg m 18 0 Ib ft 3 Install intake manifold by referring to Throttle Body and Intake Manifold in Section 6A1 4 Fill the cooling system ENGINE COOLING 6B 13 Water Pump Belt and Cooling Fan REMOVAL 1 Remove radiator shroud securing bolts 1 2 Remove radiator by referring to Radiator in this section 3 Loosen water pump drive belt tension 4 Remove cooling fan by removing securing nuts Remove power steering and or compressor drive belt before removing water pump belt 5 Remove pump belt INSTALLATION Once cooling fan or water pump belt has been removed make sure to tighten bolts and nuts securely in reinstallation and adjust pump belt tension to specification For specified tension refer to Water Pump Belt Tension in this section WATER PUMP BE
585. tool available Go to Step 3 Go to Step 4 3 Check PNP signal D range signal Intermittent trouble or Go to Step 5 1 Connect SUZUKI scan tool to DLC with igni faulty ECM Check for tion switch OFF See Fig 1 intermittent referring to 2 Turn ignition switch ON and check PNP sig Intermittent and Poor nal P N or D range on display when Connection in Section shifting selector lever to each range OA Is D range on display Is 0 1 V indicated no matter which of R D 2 and L range posi tions selector lever may be at See Table 1 4 Check PNP Signal D range signal Intermittent trouble or Go to Step 5 1 Turn ignition switch ON faulty ECM Check for 2 Check voltage at terminal E17 6 of ECM intermittent referring to connector connected See Fig 2 Intermittent and Poor Is D range on display Is 0 1 V indicated no Connection in Section matter which of R D 2 and L range posi OA tions selector lever may be at See Table 1 5 ls P N range on display Is 10 14 V indi Check transmission range Go to Step 6 cated when selector lever is at one of R D switch and circuits refer 2 and L range positions only ring to Section 7B 6 Check PNP signal circuit Y B circuit open poor G Y circuit open or poor 1 Turn ignition switch OFF transmission range sen E17 6 connection 2
586. torque Cylinder head cover bolts a 8 N m 0 8 kg m 6 0 Ib ft 5 Connect breather hose 1 and PCV hose 2 6 Install oil level gauge 3 7 Install ignition coil assemblies with high tension cord 8 Connect ignition coil couplers 9 Install cylinder head upper cover 10 Connect accelerator cable to clamp For left hand steering vehicle only 11 Connect negative cable at battery 6A1 18 ENGINE MECHANICAL M13 ENGINE Throttle Body and Intake Manifold 16 amp oy Eas N m 2 5 kg m 1 Intake manifold 7 EVAP canister purge valve 13 Intake manifold mounting nut 19 Injector assembly 2 Intake manifold gasket 8 TP sensor 14 Intake manifold mounting bolt short 20 Cushion 3 Throttle body 9 IAC valve 15 Intake manifold mounting bolt long m Tightening torque 4 Gasket 10 Fuel delivery pipe 16 EGR pipe gasket x lt Do not reuse 5 EGR pipe 11 Engine hook 17 O ring 6 MAP sensor 12 Intake manifold stiffener 18 Grommet REMOVAL 1 Relieve fuel pressure referring to Fuel Pressure Relief Pro cedure in Section 6 2 Disconnect negative cable at battery 3 Drain coolant by loosening drain plug 1 WARNING To help avoid danger of being burned do not remove drain plug 1 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 of
587. ts and nuts shaft joint bolts should be tightened 1 2 3 Be sure that front wheels and steering wheel are in straight forward state If equipped install shift key interlock cable to ignition switch Apply sealant to the steering column lower bracket shaded section in the figure and fit the steering column seal 1 to the stepped part of the steering column lower bracket securely A Sealant 99000 31090 STEERING WHEEL AND COLUMN 3C 15 S Insert steering lower shaft 1 to steering shaft Put the steering column upper cover 3 on top of the steer ing column 2 if necessary and then tighten steering col umn mounting nuts 5 and bolts 4 by hand 6 Tighten mounting nuts 5 first and then mounting bolts 4 to specified torque ol Tightening torque Steering column mounting bolts and nuts a 14 N m 1 4 kg m 10 5 Ib ft 7 Tighten steering column side joint bolt 1 first and then tighten steering gear box side joint bolt 2 Tightening torque Steering shaft joint bolts b 25 N m 2 5 kg m 18 0 Ib ft 8 If combination switch is removed install combination switch referring to Combination Switch Contact Coil and Combina tion Switch Assembly in this section 9 Connect all connectors that have been removed in removal 10 Install steering column hole cover 1 11 If steering wheel is removed install ste
588. ttery and the other end to a solid engine ground such as exhaust manifold at least 45 cm 18 in away from battery of vehicle being started WARNING Do not connect negative cable directly to negative termi nal of dead battery 5 Start engine of vehicle with booster battery and turn off elec trical accessories Then start engine of the vehicle with dis charged battery 6 Disconnect jumper cables in the exact reverse order WITH CHARGING EQUIPMENT CAUTION When jump starting engine with charging equipment be sure equipment used is 12 volt and negative ground Do not use 24 volt charging equipment Using such equip ment can cause serious damage to electrical system or electronic parts CHARGING SYSTEM 6H 11 Dismounting Disconnect negative cable 3 2 Disconnect positive cable 2 Remove retainer 5 Remove battery 1 4 Body ground bolt Handling When handling battery following safety precautions should be followed e Hydrogen gas is produced by battery A flame or spark near battery may cause the gas to ignite e Battery fluid is highly acidic Avoid spilling on clothing or other fabric Any spilled electrolyte should be flushed with large quantity of water and cleaned immediately Remounting 1 Reverse removal procedure 2 Torque battery cables to specification NOTE Check to be sure that ground cable has enough clear ance to hood pane
589. ugh 11 on each cylinder to obtain 4 readings 13 After checking install spark plugs and ignition coil assem blies 1 with high tension cord 2 14 Connect ignition coil couplers 3 15 Connect fuel injector wires 4 at the coupler 16 Check cylinder head upper cover gasket for deterioration and then install it into groove of cylinder head upper cover 1 securely 17 Install cylinder head upper cover with gasket on to cylinder head cover 18 Connect accelerator cable 2 to clamp 3 For left hand steering vehicle only 6A1 6 ENGINE MECHANICAL M13 ENGINE Engine Vacuum Check The engine vacuum that develops in the intake line is a good indi cator of the condition of the engine The vacuum checking proce dure is as follows 1 Warm up engine to normal operating temperature NOTE After warming up engine be sure to place transmission gear shift lever in Neutral shift selector lever to P range for A T model and set parking brake and block drive wheels 2 Stop engine and turn off the all electric switches 3 Remove cap 1 from intake manifold 4 Connect special tool Vacuum gauge to intake manifold Special tool A 09915 67310 5 Run engine at specified idle speed and read vacuum gauge Vacuum should be within specification Vacuum specification at sea level 59 73 kPa 45 55 cm Hg 17 7 21 6 in Hg at specified idle speed 6 After checking
590. ugs for condition and type refer 2 ring to Spark Plugs section 2 If OK perform ignition spark test referring to Igni tion Spark Test section Is spark emitted from all spark plugs Diagnostic Trouble Code DTC Check Go to applicable DTC Go to Step 4 3 Ils DTC stored in ECM Diag Flow Table in Section 6 Electrical Connection Check Go to Step 5 Connect securely 4 1 Check ignition coil assemblies and high tension cords for electrical connection Are they connected securely High tension Cords Check Go to Step 6 Replace high tension 1 Check high tension cord for resistance referring to cord s 5 5 High Tension Cords section Is check result satisfactory Ignition Coil Assembly Power Supply and Ground Cir Go to Step 7 Repair or replace cuit Check 6 1 Check ignition coil assembly power supply and ground circuits for open and short Are circuits in good condition Ignition Coil Assembly Check Go to Step 8 Replace ignition coil 7 1 Check ignition coil for resistance referring to Igni assembly tion Coil Assembly section Is check result satisfactory Crankshaft Position CKP Sensor Check Go to Step 9 Tighten CKP sensor 1 Check crankshaft position sensor referring to Step bolt replace CKP sen 8 2 and 6 of DTC P0335 No 23 CKP Sensor Cir sor or CKP sensor cuit Malfunction in Section 6 plate Is check result satisfactory Ignition Trigger Signal Circuit Check Go to Step 10 Repair or rep
591. uid come into contact with your skin the affected area should be treated in the same manner as when skin is frostbitten or frozen e Refrigerant must not be handled near where welding or steam cleaning is performed e 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 e Avoid breathing fumes produced when HFC 134a R 134a is burned Such fumes may be hazardous to health Operation Procedure for Refrigerant Charging Replenish compressor oil a gt Start evacuating e 15 minutes 760 mmHg m gt Stop evacuating Inspect and repair connections J Wait 10 mintues A la x If gauge shows Check system for abnormal conditions pressure tightness a J 4 gt Check A C system Mg ie ee Charge 550 50 g of With refrigerant refrigerant in gas form Check system for refrigerant leaks and refrigerant charging quantity Performance test 1B 22 AIR CONDITIONING OPTIONAL Recovery REFRIGERANT RECOVERY When evacuating A C system always recover refrigerant by using equipment 1 for refrigerant recovery and recycling Discharging refrigerant HFC 134a R 134a into atmosphere would cause adverse effect to environments NOTE e After recover
592. uit of trouble code recorded in Step 1 c FINAL CONFIRMATION TEST Confirm that the problem symptom has 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 a normal code is indicated ANTILOCK BRAKE SYSTEM ABS 5E 9 ABS Warning Lamp Check Turn ignition switch ON and check that ABS warning lamp comes ON for about 2 seconds and then goes OFF If any faulty condition is found advance to Diagnostic Flow Table A B or C Diagnostic Trouble Code DTC Check 1 Test drive vehicle at 40 km h for more than a minute 2 Stop vehicle and while IG switch OFF connect diagnosis switch terminal 3 and ground terminal 2 of monitor con nector 1 with service wire 4 3 Turn IG switch ON read the flashing ABS warning lamp which represents DTC as shown in example below and write it down When more than 2 DTC s are stored in memory flashing for each DTC is repeated three times starting with the smallest DTC number in increasing order For details of DTC refer to DTC Table Example When right front wheel speed sensor circuit opens DTC 21 DTC 21 DTC 21 DTC 21 2 1 2 1 2 OFF TLL LLL e a 1 0 I 3 0 3 0 Time sec 3 0 3 y ON 0 NOTE ABS warning lamp indicates only following DTCs DTC 12
593. ully open 70 90 stopped HEATED OXY Resets a At specified idle speed after warming up 0 01 0 95 V GEN SENSOR 1 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 29 SCAN TOOL DATA CONDITION REFERENCE VALUES O2S B1 S2 HEATED OXY When engine is running at 2000 r min for 0 01 0 95 V GEN SENSOR 2 3 min or longer after warming up PSP SW No load to power steering OFF DESIRED IDLE At idling with no load after warming up M T M T 700 r min DESIRED IDLE SPEED jat neutral A T at P range A T 750 r min TP SENSOR VOLT THROTTLE POSITION SENSOR OUTPUT VOLT AGE Throttle valve fully closed More than 0 2 V Ignition switch ON engine stopped Throttle valve fully open Less than 4 8 V INJ PULSE WIDTH FUEL At specified idle speed with no load after INJECTION PULSE warming up Sir BO SAE WIDTH At 2500 r min with no load after warming up 2 0 3 6 msec IAC FLOW DUTY IDLE AIR CONTROL FLOW At idling with no load after warming up 5 25 DUTY TOTAL FT B1 At specified idle speed after warming up 35 435 BATTERY VOLTAGE Ignition switch ON engine stop 12 15V CANIST PRG DUTY EVAP CANISTER PURGE 0 100 FLOW DUTY CLOSED THROT POS Throttle valve at idle position ON CLOSED THROTTLE Throttle valve opens larger than idle posi OFF POSITION tion When engine is at fuel cut
594. um Valve MFI Multiport Fuel Injection Thermal Vacuum Switching Valve Multipoint Fuel Injection TVSV Bimetal Vacuum Switching Min Minimum Valve BVSV MIL Malfunction Indicator Lamp TWC Three Way Catalytic Converter CHECK ENGINE Light Three Way Catalyst M T Manual Transmission 2WD 2 Wheel Drive VIN Vehicle Identification Number el Deas Nitrogen Dxidgs VSS Vehicle Speed Sensor OBD On Board Diagnostic System WU OC Warm Up Oxidation Catalytic o Self Diagnosis Function Converter O D Overdrive WU TWC Warm Up Three Way Catalytic OHC Over Head Camshaft Converter PNP Park Neutral Position P S Power Steering P PSP Switch Power Steering Pressure Switch P S Pressure Switch PCM Powertrain Control Module PCV Positive Crankcase Ventilation R RH Right Hand SAE Society of Automotive Engineers SDM Sensing and Diagnostic Module S Air bag controller Air bag control module SFI Sequential Multiport Fuel Injection SOHC Single Over Head Camshaft SYMBOLS GENERAL INFORMATION 0A 23 DEFINITION DEFINITION Tightening torque 1216 Apply SUZUKI BOND NO 1216 99000 31160 Apply oil engine transmission trans fer differential Apply SILICONE SEALANT 99000 31120 Apply fluid brake power steering or automatic transmission fluid 99000 25010 on wo Q 2 w A 2 BE Apply SEALING COMPOUND 366E 99000 31090 Apply SUZUKI SUPER GREASE A Apply SUZUKI SUPER GREASE C Apply THREAD
595. uminum plates placed on vise first grip pump case with it 3 Remove suction connector 10 and O ring from pump body 1 4 Remove power steering pressure switch 3 from pump body 1 5 Remove relief valve flow control valve 2 and spring from pump body 1 6 Remove pump cover 11 O ring and cam ring 6 from pump body 1 7 Remove vanes 9 from rotor 5 8 Remove snap ring 8 from pump shaft 4 and pull out rotor 5 and pulley shaft 4 9 Remove side plate 7 and O ring from pump body 1 10 Remove oil seal from pump body 1 INSPECTION Pump body cover and shaft Check sliding surfaces of each part for wear and damage If any defect is found replace pump assembly 1 Pulley 3 Pump cover 2 Pump body 3B1 14 POWER STEERING P S SYSTEM If equipped CAM RING AND SIDE PLATE Check vane sliding surface of cam ring 2 for wear and damage If any defect is found replace pump assembly 2 Side plate ROTOR AND VANE e Check sliding surfaces of rotor and vane for wear and dam age e Check clearance between rotor and vane Replace pump assembly if any defect is found Clearance between rotor and vane Standard 0 01 mm 0 0004 in Limit 0 06 mm 0 0023 in 1 Thickness gauge RELIEF VALVE FLOW CONTROL VALVE AND ITS SPRING e Check fluid passage of relief valve and orifice of connector for obstruction clogged
596. ure switch 1 for continuity at normal tem perature approximately 25 C 77 F when A C system has a proper charge of refrigerant and A C system compressor is under operation In each of these cases switch should show proper continuity 2 Check switch for continuity at specified pressure as shown Approximately 195 kPa 1 95 kg cm 27 5 psi Approximately 3140 kPa 31 4 kg cm 446 5 psi Approximately 225 kPa 2 25 kg cm 32 0 psi Approximately 2550 kPa 25 5 kg cm2 362 5 psi 00 W D gt Tightening torque Dual pressure switch a 10 N m 1 0 kg m 7 0 Ib ft AIR CONDITIONING OPTIONAL 1B 39 A C Switch REMOVAL AND INSTALLATION Refer to Heater Control Lever Assembly in Section 1A INSPECTION e Press A C switch button and check if there is continuity between terminals A and B e With battery voltage connected to terminal C and to terminal A press A C Switch button and blower fan switch to Hi 3rd position Check if indicator lamp lights 1 Blower fan and A C switch Condenser Cooling Fan Motor Relay INSPECTION 1 Disconnect negative cable at battery 2 Remove condenser cooling fan motor relay 1 from vehicle 3 Check that there is no continuity between terminal a and b If there is continuity replace relay 4 Check that there is continuity between terminals a and b when battery is conn
597. uring testing to avoid occurrence of an accident e Road test should be carried out with 2 persons a driver and a tester on a level road 1 Turn ignition switch OFF Clear DTC with ignition switch ON check vehicle and environmental condition for Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 122 F or lower 6 86 ENGINE GENERAL INFORMATION AND DIAGNOSIS 2 Start engine and warm it up to normal operating temperature 70 110 C 158 230 F and run it at idle for 5 min 3 Increase vehicle speed to 50 55 mph 80 88 km h in 5th gear or in D range 4 Hold throttle valve at that opening position for 2 min or longer 5 Increase engine speed to 4000 r min in 3rd gear or in 2 range 6 Release accelerator pedal and with engine brake applied keep vehicle coasting fuel cut condition till engine speed reaches 1500 r min 7 Stop vehicle don t turn ignition switch OFF and confirm test results according to following Test Result Con firmation Flow Table Vehicle speed Engine speed 4000 r min 50 55 mph 80 88 km h Keep throttle valve opening constantly o 0 1 2 3 4 5 6 7 Test Result Confirmation Flow Table Step Action Yes No 1 Check DTC in DTC mode and pending DTC in Proceed to applicable Go to Step 2
598. urther NOTE Contact coil can turn about 5 turns at maximum that is if it is at the center position can turn about two and a half turns both clockwise and counterclockwise STEERING WHEEL AND COLUMN 3C 9 4 From the position where contact coil became unable to turn any further it stopped turn it back clockwise about two and a half rotations and align center mark with alignment mark 1 Combination Switch For Vehicle without Air Bag System Contact Coil and Combination Switch Assembly For Vehicle with Air Bag System CAUTION For vehicle with air bag system Do not turn contact coil on combination switch more than allowable number of turns about two and a half turns from the center position clockwise or counter clockwise respectively or coil will break REMOVAL 1 Remove steering wheel from steering column referring to Steering Wheel in this section 2 Remove steering column hole cover 1 3 Remove steering column cover standard screw 1 and tap ping screws 2 4 Loosen steering column mounting bolts and nuts referring to Steering Column in this section 5 Separate upper cover 3 and lower cover 4 then remove them 6 Disconnect all connectors for combination switch contact coil and combination switch assembly 3C 10 STEERING WHEEL AND COLUMN 7 Remove combination sw
599. use vehicle handling may be seriously affected and may result in loss of control It is recommended that new tires be installed in pairs on the same axle If necessary to replace only one tire it should be paired with the tire having the most tread to equalize braking traction The metric term for tire inflation pressure is the kilopascal kPa Tire pressures will usually be printed in both kPa and psi on the Tire Placard Metric tire gauges are available from tool suppliers The following chart converts commonly used inflation pressures from kPa to psi kPa kgf cm psi 160 1 6 23 180 1 8 26 200 2 0 29 220 2 2 32 240 2 4 35 260 2 6 38 280 2 8 41 300 3 0 44 320 3 2 47 340 3 4 50 WHEELS AND TIRES 3F 3 Replacement Wheels Wheels must be replaced if they are bent dented have excessive lateral or radial runout leak air through welds have elongated bolt holes if lug nuts won t stay tight or if they are heavily rusted Wheels with greater runout than shown in How to Measure Wheel Runout may cause objectional vibrations Wheels for replacement must be equivalent to the originally equipped wheels in load capacity diameter rim width off set and mounting configuration A wheel of improper size or type may affect wheel and bearing life brake cooling speedometer odom eter calibration ground clearance to the body and chassis How To Measure Wheel Runout To measu
600. used by 1 Incorrect alignment 2 Uneven brake adjustment 3 Tire construction The way in which a tire is built can produce lead in a vehicle An example of this is placement of the belt Off center belts on radial tires can cause the tire to develop a side force while rolling straight down the road If one side of the tire has a little larger diameter than the other the tire will tend to roll to one side This will develop a side force which can produce vehicle lead The procedure in above figure Lead Diagnosis should be used to make sure that front alignment is not mis taken for tire lead 1 Part of the lead diagnosis procedure is different from the proper tire rotation pattern currently in the owner and service manuals If a medium to high mileage tire is moved to the other side of the vehicle be sure to check that ride roughness has not developed 2 Rear tires will not cause lead Vibration Diagnosis Wheel unbalance causes most of the highway speed vibration problems If a vibration remains after dynamic balancing its possible causes are as follows 1 Tire runout 2 Wheel runout 3 Tire stiffness variation Measuring tire and or wheel free runout will uncover only part of the problem All three causes known as loaded radial runout must be checked by using a Tire Problem Detector TPD If TPD is not available alternative method of substituting known good tire and wheel assemblies on the problem vehicle can be used
601. ust manifold 6 Remove exhaust manifold 1 and its gasket from cylinder head INSTALLATION 1 Install new gasket to cylinder head Then install exhaust manifold Tighten manifold nuts to specified torque Tightening torque Exhaust manifold nuts a 55 N m 5 5 kg m 40 0 Ib ft 2 Install seal ring and install exhaust pipe 1 to exhaust mani fold Before installing seal ring check it for deterioration or dam age and replace as necessary Tighten pipe fasteners to specified torque Tightening torque Exhaust pipe bolts a 50 N m 5 0 kg m 36 5 Ib ft ENGINE MECHANICAL M13 ENGINE 6A1 23 3 Install exhaust manifold stiffener 1 Tighten exhaust manifold stiffener bolts to specified torque Tightening torque Exhaust manifold stiffener bolts a 50 N m 5 0 kg m 36 5 Ib ft 4 Install exhaust manifold cover 1 5 Connect heated oxygen sensor coupler 2 and fit coupler to bracket securely if equipped 6 Connect negative cable at battery 7 Check exhaust system for exhaust gas leakage 6A1 24 ENGINE MECHANICAL M13 ENGINE Oil Pan and Oil Pump Strainer 6 8 11 N m 1 1 kg m i 9 3 7 B14 N m 1 1 kg m amp 8 811 N m 1 1 kg m 9 8 11 N m 1 1 kg m ge 8 50 N m 5 0 kg m A Sealant application amount 3 O ring 8 Oil pan nut a 3mm 0 12 in 4 Gasket 9 Oil pan bolt b 2mm 0 08 in 5 Drain plug m
602. ve cylinder head upper cover and disconnect high ten sion cords 2 from ignition coil assemblies 1 while gripping each cap 2 Pull out high tension cords from spark plugs while gripping each cap CAUTION e Removal of high tension cords together with clamps will be recommended so as not to damage their inside wire resistive conductor e For the same reason pull out each connection by grip ping cap portion 3 Measure resistance of high tension cord 1 by using ohm meter High tension cord resistance 4 10 kQ m 1 2 3 0 kQ ft 4 If resistance exceeds specification replace high tension cord s 6F 6 IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM 5 Install high tension cords 2 to spark plugs and ignition coil assemblies 1 while gripping each cap CAUTION e Never attempt to use metal conductor high tension cords as replacing parts e Insert each cap portion fully when installing high ten sion cords Spark Plugs 1 Pull out high tension cords by gripping their caps and then remove ignition coil assemblies referring to Ignition Coil Assembly in this section 2 Remove spark plugs 3 Inspect them for e Electrode wear e Carbon deposits e Insulator damage IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM 6F 7 4 If any abnormality is found adjust air gap clean with spark plug cleaner or replace them with specified new plugs For
603. ve ignition coil assemblies 2 with high tension cord 3 6 Remove oil level gauge 1 7 Disconnect breather hose 2 from cylinder head cover 3 and PCV hose 4 from PCV valve 5 8 Remove cylinder head cover mounting bolts in such order as indicated in figure 9 Remove cylinder head cover 1 with cylinder head cover gasket 2 and spark plug hole gasket 3 6A1 16 ENGINE MECHANICAL M13 ENGINE INSTALLATION 1 Install new spark plug hole gaskets 1 and new cylinder head cover gasket 2 to cylinder head cover 3 as shown in figure NOTE Be sure to check each of these parts for deterioration or any damage before installation and replace if found defective 2 Remove oil old sealant and dust from sealing surface on cylinder head and cover After cleaning apply sealant A to the following point e Cylinder head gasket 1 sealing surface area 2 as shown A Sealant 99000 31150 e Timing chain cover 1 and cylinder head 2 matching sur face as shown A Sealant 99000 31150 ENGINE MECHANICAL M13 ENGINE 6A1 17 3 Install cylinder head cover to cylinder head NOTE When installing cylinder head cover use care so that cyl inder head cover gasket or spark plug hole gaskets will not get out of place or fall off 4 Tighten bolts in such order as indicated in figure a little at a time till they are tightened to specified torque Tightening
604. ve water pump pulley 2 with fan clutch 3 and pump drive belt 5 Remove water pump assembly 1 6B 16 ENGINE COOLING INSPECTION NOTE Do not disassemble water pump If any repair is required on pump replace it as assembly e Rotate water pump by hand to check for smooth operation If pump does not rotate smoothly or makes an abnormal noise replace it INSTALLATION 1 Apply sealant to water pump 1 A Sealant 99000 31150 Sealant quantity for mating surface of water pump Width a 3mm 0 12 in Height b 2mm 0 08 in 2 Install water pump 1 to cylinder block Tightening torque Water pump bolts a 23 N m 2 3 kg m 17 0 Ib ft 3 Install water pump pulley 2 with fan clutch 3 Tightening torque Water pump pulley nuts b 11 N m 1 1 kg m 8 0 Ib ft Fan clutch bolts c 11 N m 1 1 kg m 8 0 Ib ft 4 Install water pump drive belt cooling fan and radiator shroud 5 Adjust water pump belt tension Refer to Water Pump Belt Tension in this section 6 Connect negative cable at battery 7 Fill the cooling system Required Service Material ENGINE COOLING 6B 17 Recommended SUZUKI product Material Part Number Use Ethylene glycol base coolant Anti freeze Anti corrosion coolant Additive to engine cooling system for improving cooling efficiency and for protection against rusting Sealant SUZUKI BOND NO 1207C
605. vehicle is manual transmission model and has a cata lytic converter do not push or tow it to start Damage to its emission system and or to other parts may result Both booster and discharged battery should be treated carefully when using jumper cables Follow procedure outlined below being careful not to cause sparks 6H 10 CHARGING SYSTEM WARNING e Departure from these conditions or procedure described below could result in Serious personal injury particularly to eyes or property damage from such causes as battery explo sion battery acid or electrical burns Damage to electronic components of either vehicle e Remove rings watches and other jewelry Wear approved eye protection Be careful so that metal tools or jumper cables do not contact positive battery terminal or metal in contact with it and any other metal on vehicle because a short circuit could occur 1 Set parking brake and place automatic transmission in PARK NEUTRAL on manual transmission Turn off ignition turn off lights and all other electrical loads 2 Check electrolyte level If it is below low level line add dis tilled water 3 Attach end of one jumper cable to positive terminal of booster battery and the other end of the same cable to posi tive terminal of discharged battery Use 12 volt battery only to jump start engine 4 Attach one end of the remaining negative cable to negative terminal of booster ba
606. vehicle w o immobilizer indicator lamp 2 EVAP canister purge valve 18 ECT sensor 31 3 Duty output terminal vehicle w o immobilizer indicator lamp 3 IAT sensor 19 CMP sensor 32 Immobilizer indicator lamp if equipped 4 TP sensor 20 CKP sensor 33 Stop lamp switch 5 IAC valve 21 VSS 34 ECM 6 MAP sensor 22 A C condenser fan if equipped 35 Barometric pressure sensor vehicle with immobilizer indicator lamp 7 EGR valve if equipped 23 Malfunction indicator lamp in combination meter 36 Battery 8 EVAP canister 24 Park Neutral position switch in TR switch A T 37 Immobilizer control module if equipped 9 Tank pressure control valve built in fuel pump 25 Ignition switch 38 ABS control module if equipped 10 Fuel pump 26 Starter magnetic switch 39 CO adjusting resistor if equipped 11 Fuel level sensor 27 TCM A T 40 Power steering pressure switch if equipped 12 Ignition coil assembly 28 Transmission range switch A T 41 A C compressor clutch if equipped 13 Fuel injector 29 DLC 42 A C EVAP TEMP sensor if equipped 14 Heated Oxygen Sensor HO2S 1 if equipped 30 Electric load 43 A C switch if equipped 15 Heated Oxygen Sensor HO2S 2 if equipped 31 Monitor connector if equipped 16 Three way catalytic convertor if equipped 31 1 Diagnosis switch terminal vehicle w o immobilizer indicator lamp Air Intake System The main components of the air intake system are air cleaner 1 ai
607. ver stopper 3 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 1 Accelerator cable adjustment clearance With pedal depressed fully a 0 5 2 0 mm 0 02 0 07 in Idle speed idle air control IAC duty inspection Before idle speed IAC duty check make sure of the following Lead wires and hoses of Electronic Fuel Injection and engine emission control systems are connected securely Accelerator cable has some play that is it is not tight Valve lash is checked and adjusted according to mainte nance schedule 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 No abnormal air inhaling from air intake system 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 6E 16 ENGINE AND EMISSION CONTROL SYSTEM 1 Connect SUZUKI scan tool to DLC with ignition switch OFF if it is available 2 Warm up engine to normal operating temperature 3 Check engine idle speed and IAC duty as follows a When using SUZUKI scan tool i Select Dat
608. ver the cylinder head it is driven from crankshaft through timing chain and no push rods are provided in the valve train system aid Ss aS ENGINE MECHANICAL M13 ENGINE 6A1 3 Engine Lubrication The oil pump is of a trochoid type and mounted under the crankshaft Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter The filtered oil flows into 2 paths in cylinder block In one path oil reaches the crankshaft journal bearings Oil from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersecting passages drilled in the crankshaft and then injected from the big end of connecting rod to lubricate piston rings and cylinder wall In other path oil goes up to the cylinder head and lubricates valves and camshafts etc after passing through the internal oilway of camshafts An oil relief valve is provided on the oil pump This valve starts relieving oil pressure when the pressure exceeds about 400 kPa 4 0 kg cm 56 9 psi i am im E bad 6A1 4 ENGINE MECHANICAL M13 ENGINE Diagnosis Diagnosis Table Refer to Engine Diagnosis Table in Section 6 Compression Check Check compression pressure on all 4 cylinders as follows 1 Warm up engine 2 Stop engine after warming up NOTE After warming up engine place transmission gear
609. which means that no malfunction DTC is stored and history DTC which indicates history trouble area When there is current trouble ABS warning lamp remains ON and therefore DTC is not indicated 4 After completing the check turn ignition switch off discon nect service wire from monitor connector 5E 10 ANTILOCK BRAKE SYSTEM ABS DTC Check Using SUZUKI Scan Tool 1 Connect SUZUKI scan tool to data link connector after set ting cartridge for ABS to it Special tool A SUZUKI scan tool 2 Turn 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 preforming 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 DTC s by pre forming the following procedure 1 Turn ignition switch OFF 2 Using service wire 4 connect diag switch terminal 3 of monitor connector 1 to ground terminal 2 3 With connection described in above step 2 maintained turn ignition switch ON 4 Repeat ON OFF operation of service wi
610. with other wire har nesses Confirm that the antenna and feeder are correctly adjusted GENERAL INFORMATION 0A 17 Identification Information Body Number The vehicle body number is punched on the chassis inside the tire housing on the right rear side 1 Right rear tire Engine Identification Number The number is punched on the cylinder block M 13 Serial number Engine displacement 13 1 3 L Engine type M Transmission Identification Number The automatic transmission identification number is located on the transmission case 0A 18 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 NOTE Air bag CAUTION WARNING labels are attached on the vehicle equipped with air bag system only 1 Emission control label Australia only 3 Air bag label on sun visor 5 Engine cooling fan label 2 Airbag label on engine hood 4 Radiator cap label 1 Air bag warning label on driver air bag inflator module 4 Air bag label on SDM 2 Air bag warning label on contact coil and combination switch assembly 5 Air bag label on passe
611. xtensive damage and weakening of the metal CONTENTS General Description c ccsssssssesesseesseeesees 5E 2 DTC C1031 DTC 31 DTC C1032 System Schematic s 5E 3 DTC 32 Right Rear Wheel Speed ABS Component Parts Location ccccceee 5E 4 Sensor Circuit a an rreren 5E 21 ABS Control MOdUIe c ccsccceceseseseseeesens 5E 5 DTC C1035 DTC 35 DTC C1036 Self diagnosis function cccecsceceeseeeees 5E 5 DTC 36 Left Rear Wheel Speed Fail Safe FUNCTION cccccccccccccccccccccecceceecee 5E 5 Sensor Circuit eeeeeeeeeeeeeeeeeeeeeeeseeeees 5E 21 DI AQnOSIS ics E TTE 5E 6 DTC C1041 DTC 41 DTC C1042 Precaution in Diagnosing Troubles 5E 6 DTG 47 Right Front Solenoid Circuit SE 24 DTC C1045 DTC 45 DTC C1046 DTC 46 Left Front Solenoid Circuit 5E 24 DTC C1055 DTC 55 DTC C1056 ABS Diagnostic Flow Table 0000 5E 6 ABS Warning Lamp Check ece 5E 9 Diagnostic Trouble Code DTC Check 5E 9 DTC Check Using SUZUKI Scan Tool 5E 10 el sy Rear Solenoid Circuit 5E 24 Diagnostic Trouble Code DTC Circuit Der AD TG ai Fowersearce 5E 25 Gl ara NGE enea casdsceebceciweeccee aaaea ket BETO ARAA ie ee ee eae Ni AOF Reade Trouble Code DTC Table 5E 11 vice ae alle OF EBT MnP 5E 26 ystem Circuit ccc ccceeeeeeeeeeeeseseeeeeeeees 5E T2 AEA AAAA IATA AAN AO na a Table A ABS Warning Lamp Circuit ne a
612. y A to direction P and if it is lower to direction r Repeat steps 3 and 4 until rear brake pressure is within specification After adjustment be sure to torque bolt to specification Tightening torque LSPV adjust bolt a 25 N m 2 5 kg m 18 Ib ft 1 LSPV lever 2 LSPV spring 3 LSPV stay Disconnect brake pipe 2 connecting between master cylin der secondary side and 4 way joint from master cylinder 1 Tighten plug special tool to master cylinder Depress brake pedal If rear brake pressure is 95 100 kg cm when front brake pressure is 100 kg cm it means that front fail safe system functions properly Front brake Rear brake 10000 kPa 9500 10000 kPa 100 kg cm 95 100 kg cm 1422 psi 1350 1422 psi Special tool A 09956 02210 BRAKES 5 17 On Vehicle Service Air Bleeding of Brake System CAUTION Brake fluid is extremely damaging to paint If fluid should accidentally touch painted surface immediately wipe fluid from paint and clean painted surface Bleeding operation is necessary to remove air whenever it entered hydraulic brake system Hydraulic lines of brake system consists of two separate lines one for front wheel brakes and the other for rear wheel brakes Air bleeding is necessary at right and left front wheel brakes left rear wheel brake and LSPV if equipped i e 3 4 for vehicle with LSPV places i
613. y defects are found repair or replace condenser e Check condenser fittings for leakage If any defects are found repair or replace condenser REMOVAL 1 Disconnect negative cable at battery 2 Recover refrigerant from A C system by referring to Recov ery in this section NOTE The amount of removed compressor oil must be mea sured for replenishing compressor oil 3 Remove front bumper referring to Front Bumper in Section 8 4 Disconnect A C condenser cooling fan motor and dual pres sure switch connectors 5 Remove radiator mounting bolts 6 Disconnect discharge hose 1 from condenser 2 7 Disconnect receiver dryer outlet hose 3 and condenser outlet pipe 4 from receiver dryer 5 8 Remove condenser cooling fan assembly 6 from con denser 2 9 Remove receiver dryer 5 with its bracket 7 from con denser 2 10 Remove condenser 2 from radiator INSTALLATION Reverse removal procedure to install condenser and then noting the following instructions e Replenish specified amount of compressor oil to compressor suction side by referring to Replenishing Compressor Oil in this section e Evacuate and charge refrigerant by referring to Evacuating and Charging in this section 1B 32 AIR CONDITIONING OPTIONAL Receiver Dryer REMOVAL 1 Recover refrigerant from A C system by referring to Recov ery in this section NOTE The amount o
614. yte temperature e The battery is in FULLY CHARGED STATE if the electrolyte S G is 1 280 e The battery is in HALF CHARGED STATE if the S G is 1 220 e The battery is in NEARLY DISCHARGED STATE if the S G is 1 150 and is in danger of freezing As the S G varies with the temperature if battery temperature is not at 20 C 68 F you have to correct your S G reading taken with your hydrometer to the value at 20 C 68 F and apply the corrected S G value to the three point guide stated value For the manner of correction refer to the graph showing the relation between S G value and temperature FAULTY INDICATOR LAMP OPERATION CHARGING SYSTEM 6H 7 How to use the temperature corrected state of charge graph Suppose your S G reading is 1 28 and the battery temperature is 5 C 23 F Locate the intersection of the 5 C line and the 1 28 S G line The intersection is within the A zone shaded area in the graph and that means CHARGED STATE To know how much the battery is charged draw a line parallel to the zone demarcation line and extend it to the right till it meets with the percentage scale In the present example the line meets at about 85 point on the percentage scale Therefore the bat tery is charged up to the 85 level Generator CAUTION e Do not mistake polarities of IG terminal and L terminal e Do not make a short circuit between IG and L termi nals Always connect
615. z 15 a2 O O w 2 j w alo 2 4 m Slz2 a 2 S 8 al z 3 0 lt O O 5 clo a d 8 S Ele 218 8 2 lt el e 2 2 S a z 2 S S 2 DIAGNOSIS SWITCH TERMINAL VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP O BAROMETRIC PRESSURE SENSOR O O O VEHICLE WITH IMMOBILIZER INDICATOR LAMP STOP LAMP SWITCH O lu STARTER SWITCH O O O Q IGNITION SWITCH OIOIOIOIOIOIO OIO P Q LIGHTING SWITCH O Z REAR DEFOGGER SWITCH IF EQUIPPED O 2 BLOWER SWITCH A C SWITCH IF EQUIPPED O O gt A C EVAPORATOR TEMP SENSOR IF EQUIPPED IO O g vss fol lololo O Q HEATED OXYGEN SENSOR 1 IF EQUIPPED O O O Pa Ww HEATED OXYGEN SENSOR 2 For detecting deterioration of O Z IF EQUIPPED three way catalytic converter iE 2 IAT SENSOR OI IOIOIO OO O ECT SENSOR OJOJOJOJOJOJOJOIO O dp TP SENSOR O OIO O O O MAP SENSOR OIOIOIOIO IO IO O CMP SENSOR OIOIOCIO IOIO IO IO Cy CKP SENSOR OIOIOIOIOIO O TEST SWITCH TERMINAL VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP Q KNOCK SENSOR O QO ENGINE AND EMISSION CONTROL SYSTEM 6E 9 ECM INPUT OUTPUT CIRCUIT DIAGRAM For TYPE A See NOTE RW 25 T 12V w 26 Toy 7 RIG 27 5 d G

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