Suzuki SN413 Service manual

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:

• 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 service on or near the air bag system components or wiring. 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 system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury.

• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.

• Do not modify the steering wheel, instrument panel or any other air bag system component on or around air bag system components or wiring. Modifications can adversely affect air bag system performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93°C (200°F), for example, during a paint baking process, remove the air bag system components, 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, replacement 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.

JSAFJA43V00140001

JSAFJB43V00140001

JSAFJB43V20140001

JSAFJB43V24140001

JSAFJB43V34140001

JS3JB43V 24140001

JS3JB43V 34140001

The contents are classified into sections each 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 information 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

JIMNY (SN413) WIRING DIAGRAM MANUAL

Manual No.

99512-81A20-015

© COPYRIGHT SUZUKI MOTOR CORPORATION 2002

GENERAL INFORMATION

HEATING AND AIR CONDITIONING

TABLE OF CONTENTS

STEERING, SUSPENSION, WHEELS AND

TIRES

DRIVE SHAFT AND PROPELLER SHAFT

BRAKE SYSTEM

ENGINE

TRANSMISSION, CLUTCH AND

DIFFERENTIAL

ELECTRICAL SYSTEM

BODY SERVICE

RESTRAINT SYSTEM

General Information

Maintenance and Lubrication

Heater and Ventilation

Air Conditioning (Optional)

Steering, Suspension, Wheels and Tires

Front Wheel Alignment

Steering Gear Box (Manual Type) and Linkage

Power Steering (P/S) System (if equipped)

Steering Wheel and Column

Front Suspension

Rear Suspension

Wheels and Tires

Propeller Shafts

Brakes

Antilock Brake System (ABS)

Engine General Information and Diagnosis

Engine Mechanical (M13 Engine)

Engine Cooling

Engine Fuel

Engine and Emission Control System

Ignition System (Electronic Ignition System)

Cranking System

Charging System

Exhaust System

Manual Transmission

Automatic Transmission (4 A/T)

Clutch

Transfer

Front Differential

Rear Differential

Body Electrical System

Immobilizer Control System (if equipped)

Restraint System

Air Bag System

7D

7E

7F

8

6K

7A

7B

7C

6E

6F

6G

6H

6

6A1

6B

6C

8G

9

10

10B

3F

4B

5

5E

3B1

3C

3D

3E

0A

0B

1A

1B

3

3A

3B

7D

7E

7F

8

6K

7A

7B

7C

6

6A1

6B

6C

6E

6F

6G

6H

8G

9

10

10B

3B1

3C

3D

3E

3F

4B

5

5E

0A

0B

1A

1B

3

3A

3B

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

0A

6F2

6G

6H

6K

How to Use This Manual.................................0A-2

Precautions......................................................0A-3

Precaution for Vehicles Equipped with a

Supplemental Restraint (Air Bag) System.....0A-3

Diagnosis...................................................0A-3

Servicing and handling ..............................0A-4

General Precautions .....................................0A-7

Precautions For Catalytic Converter ...........0A-10

Precautions For Electrical Circuit Service ...0A-10

Electrical Circuit Inspection Procedure........0A-13

Open circuit check...................................0A-13

Short circuit check (wire harness to ground) ....................................................0A-15

Intermittent and Poor Connection ...............0A-15

Precaution For Installing Mobile

Communication Equipment .........................0A-16

CONTENTS

Identification Information.............................0A-17

Body Number .............................................. 0A-17

Engine Identification Number ...................... 0A-17

Transmission Identification Number............ 0A-17

Warning, Caution and Information

Labels............................................................. 0A-18

Vehicle Lifting Points ...................................0A-19

When Using Frame Contact Hoist .............. 0A-19

When Using Floor Jack ............................... 0A-20

Abbreviations May Be Used In This

Manual............................................................0A-21

Abbreviations .............................................. 0A-21

Fasteners Information ..................................0A-24

Metric Fasteners ......................................... 0A-24

Fastener Strength Identification .................. 0A-24

Standard Tightening Torque ....................... 0A-24

8A

8B

8C

8D

8E

7A

7A1

7B1

7C1

7D

7E

7F

9

10

10A

10B

0A-2 GENERAL INFORMATION

How to Use This Manual

1) There is a “Table of Contents” on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of each section, where the main items in that section are listed.

2) Each section of this manual has its own pagination. It is indicated at the top of each page along with the Section name.

3) The special tool usage and torque specification are given as shown in figure.

4) A number 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 “Tightening Torque Specifications” that should be used for the servicing work described in that section.


Precautions

Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System

WARNING:

• The configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be sure to follow procedures described in Section 10B. Failure to follow proper procedures could result in possible air bag system activation, personal injury, damage to parts or air bag system being unable to activate when necessary.

• If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.

• Do not modify the steering wheel, dashboard, or any other air bag system components. Modifications can adversely affect air bag system performance and lead to injury.

• If the vehicle will be exposed to temperatures over

93°C (200°F) (for example, during a paint baking process), remove the air bag system components beforehand to avoid component damage or unintended air bag system activation.

1. Air bag wire harness (in instrument panel wire harness and floor wire harness)

2. Passenger air bag (inflator) module

3. SDM

4. DLC

5. Contact coil

6. Driver air bag (inflator) module

7. Seat belt pretensioner (if equipped)

Diagnosis

• 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.

• Never use electrical test equipment other than that specified in this manual.

WARNING:

Never attempt to measure the resistance of the air bag

(inflator) modules (driver and passenger) and seat belt pretensioners (driver and passenger). It is very dangerous as the electric current from the tester may deploy the air bag or activate the pretensioner.


Servicing and handling

WARNING:

Many of service procedures require disconnection of “Air

Bag” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment.

Driver and Passenger Air Bag (Inflator) Modules

• For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise.

• When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. Never carry the air bag

(inflator) 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 passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3). This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result.

• Never dispose of live (undeployed) air bag (inflator) modules (driver and passenger). If disposal is necessary, be sure to deploy them according to deployment procedures described in Section 10B before disposal.

• The air bag (inflator) module immediately after deployment is very hot. Wait for at least half an hour to cool it off before proceeding the work.

• After an air bag (inflator) module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch

(used to lubricate the bag as it inflates) and by-products of the chemical reaction. As with many service procedures, 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.


WARNING:

SDM

• 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 attached to the vehicle which could cause deployment and result in personal injury.

WARNING:

Driver and Passenger Seat Belt Pretensioners (If equipped)

• For handling and storage of a live seat belt pretensioner, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise.

• Never carry seat belt pretensioner by wire or connector of pretensioner. When placing a live seat belt pretensioner 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.

• Never dispose of live (inactivated) seat belt pretensioners (driver and passenger). If disposal is necessary, be sure to activate them according to activation procedures described in Section 10B before disposal.

• The seat belt pretensioner immediately after activation is very hot. Wait for at least half an hour to cool it off before proceeding the work.

• With many service procedures, gloves and safety glasses should be worn to prevent any possible irritation of the skin or eyes.


CAUTION:

• Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after an Accident” in Section 10B.

• When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, remove those parts beforehand.

• 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.

• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and passenger) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth.

• Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very careful when handling it.

• When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly.

• Do not apply power to the air bag system unless all components are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code.

• Never use air bag system component parts from another vehicle.

• When using electric welding, be sure to disconnect air bag (inflator) module connectors (driver and passenger) and seat belt pretensioner connectors (driver and passenger) respectively.

• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames.

• WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to follow the instructions.

• After vehicle is completely repaired, perform “Air Bag Diagnostic System Check” in Section 10B.


General Precautions

The WARNING and CAUTION below describe some general precautions that you should observe when servicing 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:

• Whenever raising a vehicle for service, be sure to follow the instructions under “Vehicle Lifting

Points” in this section.

• 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 automatic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts when the engine is running.

• When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

• 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 refrigerant), make sure that the area you work in is well-ventilated.

• To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tailpipe, muffler, etc.

• 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 animals. 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.

• 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.

• 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.

• When performing service to electrical parts that does not require use of battery power, disconnect the negative cable of the battery.


• When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover.

• When removing parts that are to be reused, 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 certain 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.

• Make sure that all parts used in reassembly are perfectly clean.

• When use of a certain type of lubricant, bond or sealant is specified, be sure to use the specified type.

“A”: Sealant 99000-31150

• Be sure to use special tools when instructed.

Special tool

(A): 09917-98221

(B): 09916-58210


• When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly.

• After servicing fuel, oil, coolant, vacuum, 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 releasing the fuel pressure, or fuel can be sprayed out under pressure.

• 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.

• Use care not to expose connectors and electrical parts to water which will be a cause of a trouble.

• Always be careful not to handle electrical parts (computer, relay, etc.) in a rough manner or drop them.


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.

• Conduct a spark jump test only when necessary, make it as short as possible, and do not open the throttle.

• Conduct engine compression checks within the shortest possible time.

• 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

• When replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire.

• When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get damaged.

• When disconnecting connectors, never pull the wiring harnesses. Unlock the connector lock first and then pull them apart by holding connectors themselves.


• When connecting connectors, also hold connectors and push them together until they lock securely (a click is heard).

• When installing the wiring harness, fix it with clamps so that no slack is left.

• When installing vehicle parts, be careful so that the wiring harness is not interfered with or caught by any other part.

• 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.

• 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 electricity from your body can damage these parts.


• Never connect any tester (voltmeter, ohmmeter, or whatever) to electronic control unit when its coupler is disconnected. 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. Otherwise, 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 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.


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.

• Loose connection of connector

• Poor contact of terminal (due to dirt, corrosion or rust on it, poor contact tension, entry of foreign object etc.)

• Wire harness being open

When checking system 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.

3) 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 procedure, check the wire harness for open circuit and poor connection with its terminals. Locate abnormality, if any.

1. Looseness of crimping

2. Open

3. Thin wire (single strand of wire)


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 in 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 indicated, 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 circuit 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 circuit 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 corresponds 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)


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 connectors 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 indicated, it means that there is a short to ground between terminals 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:

• Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).

• Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. However, cleaning the terminal with a sand paper or the like is prohibited.

• Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector.


• Improperly formed or damaged terminals.

Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal.

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 connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.

• Wire insulation which is rubbed through, causing an intermittent 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 Communication 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 with other wire harnesses.

• Confirm that the antenna and feeder are correctly adjusted.


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.


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)

2. Air bag label on engine hood

3. Air bag label on sun visor

4. Radiator cap label

5. Engine cooling fan label

1. Air bag warning label on driver air bag (inflator) module

2. Air bag warning label on contact coil and combination switch assembly

3. Air bag warning label on steering column

4. Air bag label on SDM

5. Air bag label on passenger air bag (inflator) module

6. Seat belt pretensioner label on retractor


Vehicle Lifting Points

WARNING:

• Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed.

• Before lifting up the vehicle, check to be 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 trying 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


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 parts (i.e., stabilizer, 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 chassis frame does not slide on safety stands (1) and the vehicle is held stable for safety’s sake.

[A]: Front

[B]: Rear


Abbreviations

Abbreviations May Be Used In This Manual

A

ABC

ATDC

API

ATF

ALR

AC

A/T

A/C

ABDC

A/F

A-ELR

B

B+

BTDC

BBDC

CKT

CMP Sensor

C

CO

CPP Switch

CPU

CRS

DC

DLC

D DOHC

DOJ

DRL

DTC

Anti-lock Brake System

After Top Dead Center

American Petroleum Institute

Automatic Transmission Fluid

Automatic Locking Retractor

Alternating Current

Automatic Transmission

Air Conditioning

After Bottom Dead Center

Air Fuel Mixture Ratio

Automatic-Emergency

Locking Retractor

Battery Positive Voltage

Before Top Dead Center

Before Bottom Dead Center

Circuit

Camshaft Position Sensor

(Crank Angle Sensor, CAS)

Carbon Monoxide

Clutch Pedal Position Switch

(Clutch Switch, Clutch Start

Switch)

Central Processing Unit

Child Restraint System

Direct Current

Data Link Connector

(Assembly Line Diag. Link, ALDL,

Serial Data Link, SDL)

Double Over Head Camshaft

Double Offset Joint

Daytime Running Light

Diagnostic Trouble Code

(Diagnostic Code)

I

E

EBCM

ECM

ECT Sensor

EGR

EGRT Sensor

EFE Heater

ELR

EPS

EVAP

EVAP Canister

F 4WD

G

GEN

GND

Electronic Brake Control Module,

ABS Control Module

Engine Control Module

Engine Coolant Temperature

Sensor (Water Temp. Sensor,

WTS)

Exhaust Gas Recirculation

EGR Temperature Sensor

(Recirculated Exhaust Gas Temp.

Sensor, REGTS)

Early Fuel Evaporation

Heater (Positive Temperature

Coefficient, PTC Heater)

Emergency Locking Retractor

Electronic Power Steering

Evaporative Emission

Evaporative Emission Canister

(Charcoal Canister)

4 Wheel Drive

Generator

Ground

H

HC

HO2S

IAC Valve

IAT Sensor

ICM

IG

ISC Actuator

Hydrocarbons

Heated Oxygen Sensor

Idle Air Control Valve (Idle Speed

Control Solenoid Valve, ISC

Solenoid Valve)

Intake Air Temperature Sensor

(Air temperature Sensor, ATS)

Immobilizer Control Module

Ignition

Idle Speed Control Actuator

(Motor)


L

LH

LSPV

MAF Sensor

MAP Sensor

M

Max

MFI

Min

MIL

M/T

N NOx

OBD

O

O/D

OHC

PNP

P/S

PSP Switch

P

PCM

PCV

R RH

SAE

SDM

S

SFI

SOHC

Left Hand

Load Sensing Proportioning Valve

Mass Air Flow Sensor

(Air Flow Sensor, AFS, Air Flow

Meter, AFM)

Manifold Absolute Pressure

Sensor (Pressure Sensor, PS)

Maximum

Multiport Fuel Injection

(Multipoint Fuel Injection)

Minimum

Malfunction Indicator Lamp

(“CHECK ENGINE” Light)

Manual Transmission

T

TBI

TCC

TCM

TP Sensor

TVV

TWC

Nitrogen Oxides V

2WD

VIN

VSS

WU-OC On-Board Diagnostic System

(Self-Diagnosis Function)

Overdrive

Over Head Camshaft

Park/Neutral Position

Power Steering

Power Steering Pressure Switch

(P/S Pressure Switch)

Powertrain Control Module

Positive Crankcase Ventilation

Right Hand

Society of Automotive Engineers

Sensing and Diagnostic Module

(Air bag controller, Air bag control module)

Sequential Multiport Fuel Injection

Single Over Head Camshaft

W

WU-TWC

Throttle Body Fuel Injection

(Single-Point Fuel Injection, SPI)

Torque Converter Clutch

Transmission Control Module

(A/T Controller, A/T Control Module)

Throttle Position Sensor

Thermal Vacuum Valve

(Thermal Vacuum Switching Valve,

TVSV, Bimetal Vacuum Switching

Valve, BVSV)

Three Way Catalytic Converter

(Three Way Catalyst)

2 Wheel Drive

Vehicle Identification Number

Vehicle Speed Sensor

Warm Up Oxidation Catalytic

Converter

Warm Up Three Way Catalytic

Converter


SYMBOLS

SYMBOL DEFINITION

Tightening torque

Apply oil (engine, transmission, transfer, differential)

Apply fluid (brake, power steering or automatic transmission fluid)

Apply SUZUKI SUPER GREASE A

99000-25010

Apply SUZUKI SUPER GREASE C

99000-25030

Apply SUZUKI SUPER GREASE E

99000-25050

Apply SUZUKI SUPER GREASE H

99000-25120

Apply SUZUKI SUPER GREASE I

99000-25210

Apply SUZUKI BOND NO. 1215

99000-31110

Apply SUZUKI BOND NO. 1207C

99000-31150

SYMBOL DEFINITION

Apply SUZUKI BOND NO. 1216

99000-31160

Apply SILICONE SEALANT

99000-31120

Apply SEALING COMPOUND 366E

99000-31090

Apply THREAD LOCK 1322

99000-32110

Apply THREAD LOCK 1333B

99000-32020

Apply THREAD LOCK 1342

99000-32050

Do not reuse

Note on reassembly

WIRE COLOR SYMBOLS

B

Bl

Br

G

Gr

Lbl

Lg

Symbol

BLK

BLU

BRN

GRN

GRY

LT BLU

LT GRN

Wire Color

Black

Blue

Brown

Green

Gray

Light blue

Light green

O, Or

R

W

Y

P

V

Symbol

ORN

RED

WHT

YEL

PNK

PPL

Wire Color

Orange

Red

White

Yellow

Pink

Violet

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).


Fasteners Information

Metric Fasteners

Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners 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 original 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 division.

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 original fastener.

NOTE:

• 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.

• The chart below is applicable only where the fastened parts are made of steel light alloy.


Tightening torque chart

An equivalent of 4T strength fastener

4

Thread Diameter (Nominal Diameter) (mm)

5 6 8 10 12 14 16 18

N·m 1.5

3.0

5.5

13 29 45 65 105 160 kg-m 0.15

0.30

0.55

1.3

2.9

4.5

6.5

10.5

16 lb-ft 1.0

2.5

4.0

9.5

21.0

32.5

47.0

76.0 116.0

An equivalent of 6.8 strength fastener without flange

N·m 2.4

4.7

8.4

20 42 80 125 193 280 kg-m 0.24

0.47

0.84

2.0

4.2

8.0

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


N·m 2.4

4.9

8.8

21 44 84 133 203 298 kg-m 0.24

0.49

0.88

2.1

4.4

8.4

13.3

20.3

29.8

Strength

An equivalent of 7T strength fastener lb-ft 2.0

3.5

6.5

15.5

32.0

61.0

96.5 147.0 215.5

N·m 2.3

4.5

10 23 50 85 135 210 240 kg-m 0.23

0.45

1.0

2.3

5.0

8.5

13.5

21 24 lb-ft 2.0

3.5

7.5

17.0

36.5

61.5

98.0 152.0 174.0


N·m 3.1

6.3

11 27 56 105 168 258 373 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


N·m 3.2

6.5

12 29 59 113 175 270 395 kg-m 0.32

0.65

1.2

2.9

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


MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

0A

0B

1A

1B

WARNING:

For vehicles equipped with Supplemental Restraint (Air Bag) System:

3 7A

7A1

3B1 7B1 may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

3C1 7C1

3D vice Precautions” under “On-Vehicle Service” in air bag system section before performing service

3E on or around the air bag system components or wiring. Failure to follow WARNINGS could result in

3F unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury.

4A2

• Technical service work must be started at least 90 seconds after the ignition switch is turned to the

4B

“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system

5

5A

7D

7E

7F

8A

8B

8C

8D

8E

CONTENTS

Maintenance Schedule .................................. 0B-2

Maintenance Schedule Under Normal

Driving Conditions ........................................ 0B-2

Maintenance Recommended Under Severe

Driving Conditions ........................................ 0B-4

Maintenance Service...................................... 0B-5

Engine .......................................................... 0B-5

Drive Belt.................................................. 0B-5

Valve Lash................................................ 0B-6

Engine Oil and Filter................................. 0B-6

Engine Coolant......................................... 0B-8

Exhaust System ....................................... 0B-8

Ignition System............................................. 0B-9

Spark Plugs .............................................. 0B-9

Fuel System ................................................. 0B-9

Air Cleaner Filter ...................................... 0B-9

Fuel Lines and Connections................... 0B-10

Fuel Filter ............................................... 0B-10

Fuel Tank ............................................... 0B-10

Emission Control System ........................... 0B-10

Crankcase Ventilation Hoses and

Connections ........................................... 0B-10

PCV (Positive Crankcase Ventilation)

Valve ..................................................... 0B-11

Fuel Evaporative Emission Control

5B

5C

5E

Chassis and Body ...................................... 0B-11

Power Steering (P/S) System

6-1

Brake Drums and Shoes ........................ 0B-12

6A1

Brake Hoses and Pipes.......................... 0B-12

Brake Fluid ............................................. 0B-12

6C

Propeller Shafts...................................... 0B-15

6E1

Manual Transmission Oil........................ 0B-16

Automatic Transmission Fluid ................ 0B-16

Transfer and Differential Oil ................... 0B-17

Steering System..................................... 0B-18

Steering Knuckle Seal............................ 0B-18

(if equipped) ........................................... 0B-19

All Hinges, Latches and Locks ............... 0B-19

Final Inspection............................................ 0B-20

Recommended Fluids and Lubricants....... 0B-22

9

10

10A

10B

6F1

0B

6G

6H

6K

0B-2 MAINTENANCE AND LUBRICATION

Maintenance Schedule

Maintenance Schedule Under Normal Driving Conditions

NOTE:

• This interval should be judged by odometer reading or months, whichever comes first.

• This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km

(54,000 miles), carry out the same services at the same intervals respectively.

Interval

Km (x 1,000)

Miles (x 1,000)

Months

15

9

12

30

18

24

45

27

36

60

36

48

75

45

60

90

54

72

ENGINE

Drive belt

Valve lash (clearance)

Engine oil and oil filter

Engine coolant

Exhaust system

IGNITION SYSTEM

✱Spark plugs When unleaded fuel is used

V-belt

V-rib belt (Flat type)

Vehicle without

HO2S

Vehicle with

HO2S

Nickel spark plug

Iridium spark plug

Nickel spark plug

Iridium spark plug

I

–

–

R

–

–

–

–

–

–

R

–

I

R

–

I

R

–

–

–

I

I

–

R

R

–

–

R

R

–

R

–

R

–

I

I

R

–

–

R

I

–

–

R

–

–

–

–

–

–

R

R

R

–

FUEL SYSTEM

When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Conditions” in this section.

Air cleaner filter

Fuel lines and connections

I

–

I

I

R

–

I

I

I

–

R

I

Replace every 210,000 km (126,000 miles).

– – I – – I

Fuel filter

Fuel tank

EMISSION CONTROL SYSTEM

Crankcase ventilation hoses and connections

(Vehicle without HO2S)

✱PCV valve

Vehicle without HO2S

✱Fuel evaporative emission control system

Vehicle with HO2S

Vehicle without HO2S

Vehicle with HO2S

–

–

–

–

–

–

–

–

I

–

I

I

–

–

–

–

–

–

I

–

–

–

–

–

–

I

I

I

I

I

R

R

I

R

R

I

NOTE:

“R”: Replace or change

“I”: Inspect and correct, replace or lubricate if necessary

• For Sweden, items with

✱

• For spark plugs, replace every 50,000 km if the local law requires.

• Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)

• Iridium spark plug: IFR5E11 (NGK) or SK16PR-A11 (DENSO)


Interval

Km (x 1,000)

Miles (x 1,000)

Months

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

Brake lever and cable (damage, stroke, operation)

Tires (wear, damage, rotation)

Wheel discs (damage)

Suspension system (tightness, damage, rattle, breakage)

Propeller shafts

Manual transmission oil (leakage, level) (I: 1st 15,000 km only)

Automatic transmission Fluid level

Fluid change

Fluid hose

Transfer oil (leakage, level)

Differential oil (leakage, level) (R: 1st 15,000 km only)

Steering system (tightness, damage, breakage, rattle)

Power steering (if equipped)

All latches, hinges and locks

15

9

12

30

18

24

45

27

36

60

36

48

75

45

60

90

54

72

–

I

–

–

–

I

I

I

I

R

–

I

–

–

–

I

I

I

I

R

–

I

–

–

–

Inspect at first 15,000 km (9,000 miles) only.

I

I

–

I

I

I

I

I

–

I

I

I

I

I

–

I

I

I

–

I

–

–

I

R

–

–

–

–

I

R

– I – I – I

Replace every 165,000 km (99,000 miles).

–

I

–

–

–

I

R

–

–

I

–

–

R or I –

– I

I

– I

I I

–

I

–

I

I

–

I

I

–

I

–

I

I

–

I

I

I

I

I

R

NOTE:

“R”: Replace or change

“I”: Inspect and correct, replace or lubricate if necessary


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 following 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

G : – – – – –

H : Trailer towing (if admitted)

Severe

Condition Code

– B C D – – – –

A – C D E F – H

– B – – – – – –

– – C – – – – –

– B C D – – – H

– B – – – – – –

– B – D E – – H

– B – – E – – H

– B – – E – – H

– B C D – – – –

Maintenance

Drive belt (V-rib belt)

Engine oil and oil filter

Exhaust pipe mountings

Air cleaner filter

✱1

A B C – E F – H Spark plugs

Nickel spark plug

Iridium spark plug

Wheel bearing

Suspension bolts and nuts

Propeller shafts

Manual transmission, transfer and differential oil

Automatic transmission fluid

Steering knuckle seal

Maintenance

Operation

I

I

R

R

I

I

R

R

R

I

T

I

R

R

Maintenance Interval

Every 15,000 km

(9,000 miles) or 12 months

Every 45,000 km


Every 5,000 km (3,000 miles) or 4 months

Every 15,000 km


Every 2,500 km (1,500 miles)

Every 30,000 km


Every 10,000 km (6,000 miles) or 8 months

Every 30,000 km


Every 15,000 km


Every 15,000 km


Every 15,000 km


First time only:

15,000 km (9,000 miles) or 12 months

Second time and after: Every 30,000 km

(18,000 miles) or 24 months reckoning from

0 km (0 mile) or 0 month

Every 30,000 km


Every 15,000 km


NOTE:

• “I”: Inspect and correct, replace or lubricate if necessary

• “R”: Replace or change

• “T”: Tighten to the specified torque

•

✱


Maintenance Service

Engine

Drive Belt

WARNING:

All inspection and replacement are to be performed with

ENGINE NOT RUNNING.

WATER PUMP AND GENERATOR DRIVE BELT INSPEC-

TION

1) Disconnect negative cable at battery.

2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. 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 lb) 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 Section 6B for replacement procedure of pump belt.

POWER STEERING PUMP AND/OR A/C COMPRESSOR

DRIVE BELTS INSPECTION (IF EQUIPPED)


2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any defect exists, replace.


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 lb) 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. Camshaft 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 necessary.

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:

• New and used engine oil can be hazardous.

Be sure to read “WARNING” in General Precaution in

Section 0A and observe what in written there.

• Step 1) – 7) outlined below must be performed with

ENGINE NOT RUNNING. For step 8), be sure to have adequate ventilation while engine is running.

Before draining engine oil, check engine for oil leakage. If any evidence of leakage is found, make sure to correct defective part before proceeding to the following work.


1) Drain engine oil by removing drain plug.

2) After 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 lb-ft)

3) Loosen oil filter by using oil filter wrench (special tool).

Special tool

(A) : 09915-47330

NOTE:

Before fitting new oil filter, be sure to oil its O-ring. Use engine oil for this purpose.

4) Screw new filter on oil filter stand by hand until the filter

O-ring contacts the mounting surface.

CAUTION:

To tighten oil 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).


(b) : 14 N·m (1.4 kg-m, 10.5 lb-ft) (for reference)


6) Replenish oil until oil level is brought to FULL level mark on 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/lmp pt.)

Oil filter capacity About 0.2 liters (0.4/0.3 US/lmp pt.)

Others About 0.3 liters (0.6/0.5 US/lmp pt.)

Total About 4.3 liters (9.1/7.6 US/lmp pt.)

NOTE:

Engine oil capacity is specified. However, note that the amount of oil required when actually changing oil may somewhat differ from the data in the table depending on various conditions (temperature, viscosity, etc.)

7) 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 system should be performed when it is cool.


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 mispositioned 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 possible damage to the floor carpet.

• 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 filter.

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.


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 damage, 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 section.


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 “Maintenance 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.


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.


Parking Brake Lever and Cable

INSPECTION

1) Inspect brake cable for damage and smooth movement.

Replace cable if it is in deteriorated condition.

2) Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever.

3) Check parking brake lever for proper operation and stroke, and adjust it if necessary.

For checking and adjusting procedures, refer to “Parking

Brake Inspection and Adjustment” in Section 5.

Parking brake lever stroke

“a”: 6 – 8 notches (with 200 N (20 kg, 44 lbs) of pull pressure)

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 Indicators” 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:

• Tire inflation pressure should be checked when tires are cool.

• Specified tire inflation pressure should be found on tire placard or in owner’s manual which came with the vehicle.


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 rear 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


REAR

1) Check shock absorber (1) for damage, deformation, oil leakage 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 or missing parts; also for parts showing signs of wear or lack of lubrication.

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 & 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


Manual Transmission Oil

INSPECTION

1) Inspect transmission case for evidence of oil leakage.

Repair leaky point if any.

2) Make sure that vehicle is placed level for oil level check.

3) Remove level plug (2) of transmission.

4) 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.

CHANGE

Change transmission oil with new specified oil referring to “Maintenance Service” in Section 7A.

Automatic Transmission 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 specified 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


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 leakage.

Repair leaky point if any.

2) Make sure that vehicle is placed level for oil level check.

3) 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 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.

[A] : Transfer

[B] : Front differential

[C] : Rear differential

1. Oil filler/level 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.


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 Section 3B (or 3B1) and 3C for particular check points.

5) Inspect steering 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, detachment, 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.


3) Apply grease to seal lip and install seal and seal cover.

“a”: Grease 99000-25010


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:

• Be sure to use an equivalent of DEXRON

®

-II,

DEXRON

®

-IIE or DEXRON

®

-III for P/S fluid.

• 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 doors 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 secondary latch keeps hood from opening all the way even when pulling 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.


Hood latch bolts

10 N·m (1.0 kg-m, 7.5 lb-ft)


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 battery is equipped with built-in indicator, check battery condition by the indicator.

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.

• Clutch is completely released when depressing clutch pedal,

• No slipping clutch occurs when releasing pedal and accelerating.

• Clutch itself is free from any abnormal condition.


GEARSHIFT OR 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 properly 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:

• that brake pedal has proper travel,

• that brake works properly,

• that it is free from noise,

• that braking force is applied equally on all wheels,

• 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 personal 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

• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling.

• Check that the vehicle does not wander or pull to one side.

ENGINE

• Check that engine responds readily at all speeds.

• 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. 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.


Recommended Fluids and Lubricants

Engine oil

Engine coolant

(Ethylene glycol base coolant)

Brake fluid

Manual transmission oil

Transfer oil

Differential oil (front & rear)

Automatic transmission fluid

Power steering fluid

Clutch linkage pivot points

Steering knuckle seal

Door hinges

Hood latch assembly

Key lock cylinder

SE, SF, SG, SH, SJ or SL

(Refer to “Engine Oil and Oil Filter” in this section for engine oil viscosity.)

“Antifreeze/Anticorrosion coolant”

DOT 3

Refer to “Maintenance Service” in Section 7A.

Refer to “Oil Change” in Section 7D.

Refer to “Oil Change” in Section 7E and 7F.

An equivalent of DEXRON

®

-IIE or DEXRON

®

-III


®

-II, DEXRON

®

-IIE or DEXRON

®

-III

Water resistance chassis grease

(SUZUKI SUPER GREASE A 99000-25010)

Engine oil or water resistance chassis grease

Spray lubricant

HEATER AND VENTILATION 1A-1

WARNING:

For vehicles equipped with Supplement Restraint (Air Bag) System


“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 Precautions” 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 activation of the system or could render the system inoperative. Either or these two conditions may result in severe injury.


“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:

SECTION 1A

HEATER AND VENTILATION

The link mechanism of the heater varies depending on the specifications.

8A

8B

8C

8D

8E

6F1

6G

1A

6K

6K

7A

7A1

7B1

7C1

7D

7E

7F

9

General Description ....................................... 1A-2

Diagnosis ........................................................ 1A-3

Diagnosis Table ........................................... 1A-3

Wiring Circuit ................................................ 1A-3

On Vehicle Service......................................... 1A-4

CONTENTS

Heater Blower Motor .................................... 1A-4

Heater Blower Resistor ................................ 1A-5

Heater Control Lever Assembly ................... 1A-5

Heater Blower Fan Switch ........................... 1A-7

Heater Unit/Boost Ventilation ....................... 1A-7

10

10A

10B

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

2. Side defroster outlet

3. Center ventilator outlet

4. Heater unit

5. Defroster duct

6. Ventilator duct

7. Control lever

8. Blower motor

9. Blower resistor

10. Blower fan switch/Blower fan and A/C switch (if equipped with air conditioning)

11. Heater core

12. Damper

13. Air inlet box (without air conditioning, without other parts marked *)/cooling unit (if equipped with air conditioning)


Diagnosis

Diagnosis Table

Condition

Heater blower won’t work even when its switch is ON.

Incorrect temperature output.

When mode control lever is changed, air outlet port is not changed.

Possible Cause

Blower fuse blown

Blower resistor faulty

Blower fan switch faulty

Blower motor faulty

Wiring or grounding faulty

Control cables broken or binding

Temperature control lever faulty

Control cable clamp position is faulty

Air damper broken

Air ducts clogged

Heater radiator leaking or clogged

Heater hoses leaking or clogged

Control cable broken or binding

Mode control lever faulty

Control cable clamp position is faulty

Air damper broken

Air ducts leaking on clogged

Wiring Circuit

Correction

Replace fuse to check for short.

Check resistor.

Check blower fan switch.

Replace motor.

Repair as necessary.

Check cables.

Check control lever.

Check and adjustment.

Repair damper.

Repair air ducts.

Replace radiator.

Replace hoses.

Check cable.

Check control lever.

Check and adjustment.

Repair damper.

Repair air ducts.

1. Heater motor

2. Fuse box

3. Heater blower motor switch

4. Heater resister

5. To ECM

6. To combination switch

7. To 4WD controller or A/C controller

(if equipped)


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

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 Blower Resistor

REMOVAL




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

Ω

Me-Hi: approx. 1.2

Ω

INSTALLATION

1) Reverse removal procedure for installation.

2) Enable air bag system, if equipped.


Heater Control Lever Assembly

REMOVAL




3) Remove meter cluster hood, ashtray, center garnish, instrument glove box and radio or accessory case (if equipped),

Then remove mounting screws (2) from heater control lever assembly (1).


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.

• Move control lever fully in arrow direction

• Push heater lever and air inlet box lever fully in arrow direction 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.

1. Heater unit

2. Air inlet box

3. Mode control cable

4. Temperature control cable

5. Fresh air control cable

2) If equipped with air bag, enable air bag system. Refer to

“Enabling Air Bag System” in Section 10B.


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.

POSITION

OFF

TERMINAL

Lo

M

Hi

B E I L M H

Heater Unit/Boost Ventilation

REMOVAL


2) If equipped with air bag system disable air bag system.


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 following 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,



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

M4

×L16 (1) as shown in the figure, or air may leak from its

joint section.

AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

6F1

6F2

AIR CONDITIONING (OPTIONAL)

1B

WARNING:






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 maintenance. For identification between these two types, refer to “Refrigerant Type” in this section.

When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.

Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

9

10

10A

10B

8A

8B

8C

8D

8E

7A

7A1

7B1

7C1

7D

7E

7F

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 ....................................... 1B-3

Major Components and Location ................. 1B-3

Refrigerant Circulation ................................. 1B-4

Refrigerant Type .......................................... 1B-4

Diagnosis ........................................................ 1B-5

General Diagnosis Table.............................. 1B-5

Abnormal Noise Diagnosis ........................... 1B-7

Abnormal noise from compressor ............ 1B-7

Abnormal noise from magnetic clutch ...... 1B-7

Abnormal noise from tubing ..................... 1B-7

Abnormal noise from condenser .............. 1B-7

Abnormal noise from crankshaft pulley .... 1B-8

Abnormal noise from tension pulley ......... 1B-8

Abnormal noise from A/C evaporator ....... 1B-8

Abnormal noise from blower fan motor .... 1B-8

Quick Checking of Refrigerant Charge......... 1B-9

Performance Diagnosis.............................. 1B-10

Performance diagnosis table.................. 1B-12

Detail diagnosis table (Ambient temperature at 30°C (86°F)) .................. 1B-13

Compressor Drive Belt ............................... 1B-15

Electronical Diagnosis ................................ 1B-16

Wiring Diagram .......................................... 1B-16

A/C System Inspection of ECM and ITS

Circuits ....................................................... 1B-17

Refrigerant Recovery, Evacuating and

Charging ....................................................... 1B-21

Operation Procedure for Refrigerant

Charging .................................................... 1B-21

Recovery .................................................... 1B-22

Replenishing Compressor Oil .................... 1B-22

1B-2 AIR CONDITIONING (OPTIONAL)

Evacuating ................................................. 1B-23

Evacuating procedure ............................ 1B-23

Charging .................................................... 1B-25

Charging procedure ............................... 1B-25

Removing Manifold Gauge Set .................. 1B-28

Leak Test ................................................... 1B-28

On-Vehicle Service ...................................... 1B-29

Service Precaution..................................... 1B-29

Refrigerant line....................................... 1B-29

Handling refrigerant HFC-134a

(R-134a) ................................................. 1B-30

Condenser Assembly................................. 1B-31

Receiver / Dryer ......................................... 1B-32

Condenser Cooling Fan Assembly ............ 1B-33

Cooling Unit (Evaporator) .......................... 1B-34

A/C Evaporator Thermistor (A/C Evaporator

Temperature Sensor)................................. 1B-37

Expansion Valve ........................................ 1B-37

Dual Pressure Switch ................................ 1B-38

A/C Switch ................................................. 1B-39

Condenser Cooling Fan Motor Relay ........ 1B-39

Compressor ............................................... 1B-39

Magnet Clutch............................................ 1B-41

Lip Type Seal............................................. 1B-45

Tightening Torque Specification................ 1B-46

Required Service Materials......................... 1B-47

Special Tools ............................................... 1B-47


Major Components and Location


1. Cooling unit

2. Compressor

3. Condenser assembly

4. Receiver / dryer

5. Discharge hose

6. Suction hose

7. Receiver / dryer outlet pipe

8. Condenser outlet pipe

9. Expansion valve

10. Ventilation air

11. Foot air

12. Defroster air

13. Demister air

14. Fresh air

15. Recirculation air

16. Heater unit

17. A/C evaporator

18. Dual pressure switch

19. Low pressure service (charge) valve

20. High pressure service (charge) valve


Refrigerant Circulation

A: Liquid

B: Vapor

C: Superheated vapor

1. Compressor

2. Magnet clutch

3. Condenser assembly

4. Receiver / dryer


6. Expansion valve

7. Evaporator

Refrigerant Type

Whether the A/C in the vehicle being serviced uses HFC-134a

(R-134a) 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

Condition

Cool air won’t come out (A/C system won’t operative)

Cool air won’t come out (A/C compressor won't operative)

Cool air won’t come out (A/C condenser cooling fan motor won’t operative)

Cool air won’t come out (Blower fan motor won’t operative)

Fuse blown

Possible Cause

No refrigerant

A/C switch faulty


A/C evaporator thermistor faulty

Dual pressure switch faulty


ECT sensor faulty

ECM and its circuit faulty

4WD controller faulty

Correction

Perform recover, evacuation and charging.

Check fuses in main and circuit fuse boxes, and check short circuit to ground.

Check A/C switch.

Check blower fan switch referring to Section 1A.

Check A/C evaporator thermistor.

Check dual pressure switch.


Check ECT sensor referring to Section 6E.

Check ECM and its circuit referring to Section 6E.

Check 4WD controller referring to Section

3D.

ECM faulty Check ECM and its circuit referring to Section 6E.

Check magnet clutch.

Magnet clutch faulty

Compressor drive belt loosen or broken Adjust or replace drive belt.

Compressor faulty Check compressor.

Fuse blown Check “A/C” fuse in main fuse box, and check short circuit to ground.


Condenser cooling fan motor relay faulty


Check condenser cooling fan motor relay.

Condenser cooling fan motor faulty

Fuse blown

Blower fan motor resistor faulty



Blower fan motor faulty

Check condenser cooling fan motor.

Check fuses in main and circuit fuse boxes, and check short circuit to ground.

Check blower fan motor resistor referring to Section 1A.

Check blower fan switch referring to Section 1A.


Check blower fan motor referring to Section 1A.


Condition

Cool air won’t come out or insufficient cooling (A/C system normal operative)

Possible Cause

Insufficient or excessive charge of refrigerant

Check charge of refrigerant and system for leaks.

Correction

Condenser clogged

A/C evaporator clogged or frosted

Check condenser.

Check A/C evaporator and A/C evaporator thermistor.

Check A/C evaporator thermistor.

A/C evaporator thermistor faulty

Expansion valve faulty

Receiver / dryer clogged

Check expansion valve.

Check receiver / dryer.


Magnetic clutch faulty

Compressor faulty

Air in A/C system

Check magnetic clutch.

Check compressor.

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.


Excessive compressor oil existing in

A/C system

Wiring connection faulty


Pull out compressor oil in A/C system circuit, and replace compressor.


Cool air won’t come out only intermittently

Cool air comes out only at high speed

Cool air won’t come out only at high speed

Expansion valve faulty

Excessive moisture in A/C system

Magnetic clutch faulty

Excessive charge of refrigerant

Check expansion valve.


Check magnetic clutch.

Check charge of refrigerant.

Thermal switch faulty

Condenser clogged

Check thermal switch.

Check A/C condenser.

Check charge of refrigerant.

Insufficient charge of refrigerant

Air in A/C system


Compressor faulty Check compressor.

Excessive charge of refrigerant

A/C evaporator frosted


Check charge refrigerant.

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.






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

Condition

During compressor operation, a rumbling noise is heard proportional to engine revolutions.

A loud noise is heard at a certain rpm, disproportionately to engine revolution.

A loud rattle is heard at low engine rpm.

Possible Cause

Inadequate clearance in piston area (piston or swash-plate).

Loose or faulty compressor drive belt.

Loose compressor mounting bolts.

Loose compressor clutch plate bolt.

Correction

Repair or replace compressor as necessary

Adjust drive belt tension, or replace belt.

Retighten mounting bolts.

Retighten clutch plate bolt.

Replace compressor if it was operated in this condition for a long time.

Abnormal noise from magnetic clutch

Condition

A rumbling noise is heard when compressor is not operating.

A chattering noise is heard when compressor is engaged.

Possible Cause

Worn or damaged bearings.

Faulty clutch clearance (excessive).

Worn clutch friction surface.

Compressor oil leaked from lip type seal.

Contaminating the friction surface.

Correction

Replace magnet clutch assembly.

Adjust clutch clearance.

Replace magnet clutch assembly.

Replace lip type seal.

Replace compressor body assembly.

Abnormal noise from tubing

Condition

A droning noise is heard inside vehicle, but not particularly noticeable in engine compartment.

Possible Cause

Faulty tubing clamps.

Resonance caused by pulsation from variations in refrigerant pressure.

Correction

Reposition clamps or increase the number of clamps.

Attach a silencer to tubing, or modify its position and length.

Abnormal noise from condenser

Condition

Considerable vibration in condenser.

Possible Cause Correction

Resonance from condenser bracket and body.

Firmly insert a silencer between condenser bracket and body.


Abnormal noise from crankshaft pulley

Condition

A large rattling noise is heard at idle or sudden acceleration.

Possible Cause

Loosen crankshaft pulley bolt.

Abnormal noise from tension pulley

Condition

Clattering noise is heard from pulley.

Pulley cranks upon contact.

Possible Cause

Worn or damaged bearing.

Cracked or loose bracket.

Correction

Retighten bolt.

Correction

Replace tension pulley.

Replace or retighten bracket.

Abnormal noise from A/C evaporator

Condition

Whistling sound is heard from A/C evaporator.

Possible Cause

Depending on the combination of the interior / exterior temperatures, engine rpm and refrigerant pressure, the refrigerant flowing out of the expansion valve may, under certain conditions, make a whistling sound.

Correction

At times, slightly decreasing refrigerant volume may stop this noise.

Inspect expansion valve and replace if faulty.

Abnormal noise from blower fan motor

Condition

Blower fan motor emits a chirping sound in proportion to its speed of rotation.

Possible Cause

Worn or damaged motor brushes or commutator.

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.

Correction

Repair or replace blower fan motor.

Remove debris and make sure that the screen at fresh air inlet is intact.


Quick Checking of Refrigerant Charge

The following procedure can be used for quickly 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 symptoms listed in below.

3. Bubbles

CHECKING REFRIGERANT CHARGE

Symptom

Bubbles observed in sight glass

No bubbles observed in sight glass

No temperature difference between compressor inlet and outlet

Noticeable temperature difference between compressor inlet and outlet

When A/C is turned OFF, refrigerant in sight glass clears immediately and remains clear

When A/C is turned OFF, refrigerant in sight glass once produces bubbles and then clears

Charge of refrigerant condition Correction

Insufficient charge of refrigerant in system

Check system for leaks with a leak tester.

Refer to the items 3 and 4.

No or insufficient charge of refrigerant in system

Empty or nearly empty system Evacuate and charge system and then check it for leaks with a leak tester.

Proper or too much charge of refrigerant in system

Too much charge of refrigerant in system

Proper charge of refrigerant in system

Refer to the items 5 and 6.

Discharge excess refrigerant in order to obtain a specified charge.

No correction needed because charge of refrigerant is normal.


Performance Diagnosis

1) Confirm that vehicle and environmental conditions are as follows.

• Vehicle is not exposed to direct sun.

• Ambient temperature is within 15 – 35 °C (59 – 95 °F).

2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge 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 refrigerant 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 position), 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 / condenser cooling fan are working.)

Keep all windows, doors and engine food open.

Performance diagnosis condition

Ambient temperature

Engine rpm

Blower fan motor switch

Temperature control

Air outlet control

Vehicle doors

Air inlet door position

15 – 35 °C (59 – 95 °F)

Keep to 1,500 rpm.

“H” (3rd position)

“Cool”

“Face”

All open

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.


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 registered on gauge varies with ambient temperature. Therefore, use graph when determining if pressures are normal or not.

Low side and high side pressure example :

Gauges should read as follows when ambient temperature is 30 °C (86 °F).

Pressure on high pressure gauge

1400 – 1750 kPa

14.0 – 17.5 kg/cm

2

199.1 – 248.9 psi

Pressure on low pressure gauge

230 – 350 kPa

2.3 – 3.5 kg/cm

2

32.7 – 49.8 psi

9) Check inlet port temperature-to-outlet port temperature relationship 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.


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

Pressure in higher than acceptable range

(“A” area)

Possible Cause

Refrigerant overcharged

Expansion valve frozen or clogged

Clogged refrigerant passage of high side

Condenser cooling fan malfunction (Insufficient cooling of condenser)

Dirty or bent condenser fins (Insufficient cooling of condenser)

Compressor malfunction (Insufficient oil etc.)

Engine overheat

Pressure is lower than acceptable range

(“B” area)

Insufficient refrigerant (Insufficient charge or leakage)

Expansion valve malfunction (valve opens too wide)

Compressor malfunction (Insufficient compression)

Correction

Recharge

Check expansion valve

Clean or replace

Check condenser cooling fan

Clean or repair

Check compressor

Check engine cooling system referring to Section 6B.

Check for leakage, repair if necessary and recharge


Check compressor

LOW PRESSURE GAUGE

Condition

Pressure is higher than acceptable range

(“C” area)

Possible Cause

Expansion valve malfunction (valve opens too wide)

Pressure is lower than acceptable range

(“D” area)

Compressor malfunction (Insufficient compression)

Insufficient refrigerant (Insufficient charge or leakage)

Expansion valve malfunction (valve opens too narrow)

Clogged refrigerant passage (crashed pipe)

Correction


Check compressor

Check for leakage, repair if necessary and recharge


Repair or replace


CROSSING POINT OF CENTER VENTILATION LOUVER TEMPERATURE AND RECIRCULATION AIR

INLET TEMPERATURE

Condition

Crossing point is higher than acceptable range

(“E” area)

Crossing point is lower than acceptable range

(“F” area)

Possible Cause Correction

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

Insufficient air volume from center duct (Heater blower malfunction)

Compressor malfunction

Check compressor

Check blower motor and fan

Check compressor

Detail diagnosis table (Ambient temperature at 30°C (86°F))

MANIFOLD

GAUGE

Lo

0.23 – 0.35

(2.3 – 3.5)

(33 – 50)

Negative pressure

Normal :

0.23 – 0.35

(2.3 – 3.5)

(33 – 50)

Abnormal :

Negative pressure

Condition

MPa

(kg/cm

2

)

(psi)

Hi

1.4 – 1.75

(14 – 17.5)

(200 – 249)

Detail

Normal condition

0.5 – 0.6

(5 – 6)

(71.2 – 85.3)

Normal :

1.4 – 1.75

(14 – 17.5)

(200 – 249)

Abnormal :

0.69 – 0.98

(7 – 10)

(100 – 142)

The low pressure side reads a negative pressure, and the high pressure side reads an extremely low pressure.

Presence of frost around tubing to and from receiver / dryer and expansion valve.

During A/C operation, the low pressure side sometimes indicates negative pressure, and sometimes normal pressure. Also high pressure side reading fluctuates between the abnormal and normal pressure.

Possible Cause

–

Dust particles or water droplets are either stuck or frozen inside expansion valve, preventing the refrigerant from flowing.

Correction

–

Clean expansion valve.

Replace it if it cannot be cleaned.

Replace receiver / dryer.

Evacuate the A/C system and recharge with fresh refrigerant.

Expansion valve is frozen due to moisture in the system, and temporarily shuts off the refrigeration cycle.

Replace expansion valve.


Evacuate A/C system and recharge with fresh refrigerant.


MANIFOLD

GAUGE

Lo

0.05 – 0.15

(0.5 – 1.5)

(4.2 – 21.3)

0.4 – 0.6

(4 – 6)

(56.9 – 85.3)

0.35 – 0.45

(3.5 – 4.5)

(50 – 64)

0.45 – 0.55

(4.5 – 5.5)

(64 – 78)

Condition

MPa

(kg/cm

2

)

(psi)

Hi

Detail

Both low and high pressure sides indicate low readings.

Continuous air bubbles are visible through sight glass.

Output air is slightly cold.

0.69 – 0.98

(7 – 10)

(100 – 142)

1.96 – 2.45

(20 – 25)

(285 – 355)

Possible Cause

Insufficient refrigerant in system.

(Refrigerant leaking)

Pressure on low pressure side is high.

Pressure on high pressure side is low.

Both pressure becoming equal right after A/C is turned OFF.

Pressure on both low and high pressure sides is high.

Air bubbles are not visible even when engine rpm is lowered.

Internal leak in compressor.

Overcharged A/C system.

Faulty condenser cooling operation.

Faulty condenser cooling fan operation.

Presence of air in A/C system.

(Improperly evacuated)


Low pressure side tubing is not cold when touched.

Air bubbles are visible through sight glass.


Large amount of frost or dew on the low pressure side tubing.

Faulty expansion valve.

Refrigerant flow is not regulated properly.

Correction

Using leak detector, check for leaks and repair as necessary.

Recharge refrigerant to a specified amount.

If the pressure reading is almost 0 when the manifold gauges are attached, check for any leaks, repair them, and evacuate the system.

Inspect compressor and repair or replace as necessary.

Adjust refrigerant to specified amount.

Clean condenser.

Inspect and repair condenser cooling fan.


Inspect quantity of compressor oil and presence of contaminants in oil.

Evacuate system and recharge with fresh refrigerant.

Replace expansion valve.


Compressor Drive Belt

INSPECTION

• Check belt for wear and cracks, and replace as required.

• Check belt tension by measuring how much it deflects when pushed at intermediate point between compressor pulley (1) and crankshaft pulley (2) with about 100 N (10 kg, 22 lb) force.

If belt tension is out of above specification, adjust belt tension 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.


Tension pulley bolts

(a) : 25N·m (2.5 kg-m, 18.0 lb-ft)

For Vehicle Without P/S

1) Loosen tension pulley tightening nut (6).

2) Adjust belt tension by tighten or loosen tension pulley adjusting 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


Wiring Diagram

Electronical Diagnosis

[A]: 4WD model

[B]: 2WD model

1. Blower fan motor

2. Blower fan motor resistor

3. Blower fan motor switch and A/C switch


5. 4WD controller

6. Condenser cooling fan motor relay

7. Condenser cooling fan motor

8. Compressor

9. Thermal switch

10. Ignition switch

11. A/C evaporator thermistor

12. ECT sensor

13. Lighting switch

14. Circuit fuse box

15. Main fuse box

16. Generator

17. ECM


A/C System Inspection of ECM and ITS Circuits

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


1. Blower fan motor


3. A/C switch


5. ECT sensor

6. Condenser cooling fan motor relay

7. Condenser cooling fan motor

8. Compressor

9. Thermal switch

10. Main relay

11. Engine earth

12. Blower fan motor switch

13. 4WD controller

14. ECM

Terminal arrangement of ECM coupler (Viewed from harness side)

[A]: To “A/C” fuse (25A) in main fuse box

[B]: To “HEATER” fuse (20A) in circuit fuse box

[C]: To “FI” fuse (15A) in main fuse box

[D]: 4WD model

[E]: 2WD model


ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL

Terminal

E18-1

E18-5

E18-6

E18-10

E18-16

E18-18

Wire

P

Bl/B

Bl/B

Main power supply for ECM

Main power supply for ECM

Ground to engine (Fig B)


Bl Main relay drive


G/W

P/B

Circuit

Compressor magnet clutch output

A/C switch input

Compressor cooling fan relay output

Measurement ground

Normal value

10 – 14 volt


0 – 1 volts



10 – 14 volts

10 – 14 volts

0.5 – 1.2 volt

0 volts

12 – 15 volts

0 – 1 volt

12 – 15 volts

0 – 1 volt

12 – 15 volts

Condition

Blower fan motor switch and A/C switch ON with engine running

Except the above-mentioned condition with engine running

Ignition switch ON with engine stopped



Ignition switch OFF

Blower fan motor switch or A/C switch

OFF with engine running

Blower fan motor switch and A/C switch ON with engine running

Within several seconds after operate transfer lever between 2WD and 4WD with above condition

Blower fan motor switch and A/C switch ON or engine coolant temperature at more than 110 °C (230 °F) with engine running.

Except the above-mentioned condition with engine running

E18-20 B/Bl

Sensor ground for A/C evaporator

Ground to body (Fig A)

–0.5 – 0 volt Engine running

E18-24

E19-1

Bl/Y

B

Blower fan speed input


0 – 1 volt

4 – 7 volts

12 – 15 volts

Blower fan motor switch 2nd or 3rd with engine running

Blower fan motor switch 1st with engine running

Blower fan motor switch and A/C switch OFF with engine running

–0.5 – 1 volt Engine running

E19-2

E19-3

E19-10

B/R

B/R

B/Bl

Main ground for

ECM

ECM ground for power circuit

ECM ground for power circuit

Sensor ground for ECT sensor

Ground to engine (Fig A)



Ground to body (Fig A)

–0.5 – 1 volt

–0.5 – 1 volt

–0.5 – 1 volt

Engine running

Engine running

Engine running


Terminal Wire

E19-14

E19-27

G/B

W/R

ECT sensor input

Circuit

A/C evaporator thermistor temperature input

Measurement ground



Normal value Condition

0.73 – 0.83 volts

(315 – 355

Ω)

0.35 – 0.45 volts

(145 – 165

Ω)

2.0 – 2.3 volts

(1800 – 2200

Ω)

3.5 – 3.6 volts

(6300 – 7000

Ω)

Engine coolant temperature at approximately 80 °C (176 °F) with engine running

Engine coolant temperature at approximately 110 °C (230 °F) with engine running

*If the temperature is more than

113 °C (235 °F), compressor should be stop (come back at less than

111 °C (232 °F)

Evaporator thermistor temperature at approximately 25 °C (77 °F) with engine running

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), compressor cooling fan should be stop

(come back at less than approximately 4 °C (39.2 °F)


Refrigerant Recovery, Evacuating and Charging

WARNING:

• Your eyes should not be exposed to refrigerant (liquid).

Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately

–6 °C (21 °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 goggles. 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.

• Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be treated in the same manner as when skin is frostbitten or frozen.

• Refrigerant must not be handled near where welding or steam cleaning is performed.

• Refrigerant should be kept at a cold and dark place. It should never be stored where a high temperature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including trunk room).

• Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous to health.

Operation Procedure for Refrigerant Charging

Replenish compressor oil

Start evacuating

15 minutes (–760 mmHg)

Stop evacuating

Wait 10 mintues

Check system for pressure tightness

Inspect and repair connections

If gauge shows abnormal conditions

Charge 550 50 g of refrigerant in gas form

Check A/C system

With refrigerant

Check system for refrigerant leaks and refrigerant charging quantity

Performance test


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:

• After recover refrigerant from system, the amount of removed compressor oil must be measured for replenishing compressor oil.

• When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.

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 refrigerant (if not measure, replenish 30 cc oil).


WHEN REPLACING COMPRESSOR

Compressor oil is sealed in each new compressor by the amount required for A/C system. Therefore, when using a new compressor for replacement, drain oil from new compressor by the amount calculated as follows.

“C” = “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

Evaporator

Condenser

Receiver / dryer

Hoses

Pipes

Amount of compressor oil to be replenished

30 cm

3

(30 cc, 1.83 cu-in)

30 cm

3

(30 cc, 1.83 cu-in)

20 cm

3

(20 cc, 1.22 cu-in)

10 cm

3

(10 cc, 0.61 cu-in) each

10 cm

3

(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 replenishing compressor oil.


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

2) Attach center charging hose (6) of manifold gauge set (3) to vacuum pump (7).

3) Operate vacuum pump (7), and then open discharge side valve (Hi) (8) of manifold gauge set (3).

If there is no blockage in the system, there will be an indication on high pressure gauge (9).

In this case, open the other side valve (Lo) (10) of the set and repair the system.

4) Approximately 10 minutes later, low pressure gauge (11) should show a vacuum lower than –760 mmHg providing no leakage exists.

NOTE:

• 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 continuing its evacuation.

• If the gauge shows a stable reading (suggesting no leakage), continue evacuation.

5) Evacuation should be carried out for a total of at least 15 minutes.

6) Continue evacuation until low pressure gauge (9) indicates a vacuum less than –760 mmHg, and then close both valves

(8), (10).

7) Stop vacuum pump (7). Disconnect center charging hose (6) from pump inlet. Now, the system is ready for charging refrigerant.


Charging

CAUTION:

• Always charge through low pressure side of A/C system at after the initial charging is performed from the high pressure side with the engine stopped.

• Never charge to high pressure side of A/C system with engine running.

• Do not charge while compressor is hot.

• When installing tap valve to refrigerant container to make a hole there through, carefully follow directions given by manufacturer.

• A pressure gauge should always be used before and during charging.

• The refrigerant container should be emptied of refrigerant when discarding it.

• The refrigerant container should not be heated up to

40 °C (104 °F) or over.

• Refrigerant container should not be reversed in direction during charging. Reversing in direction causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid refrigerant and the like.

NOTE:

The air conditioning system contains HFC-134a (R-134a).

Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service container.

When charging refrigerant recovered by using the refrigerant and recycling equipment (when recycling refrigerant), 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.


2) Connect Low charging hose (1) and High charging hose (2) of the manifold gauge set (3) in position. Thus open refrigerant container valve (4) to purge the charging line.

3) Open the high pressure side valve (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 refrigerant container (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 procedure for replacement.

i) Retract needle (1) and remove refrigerant container tap valve (4) by loosening its plate nut (2).

ii) Install previously-removed refrigerant container tap valve

(4) to a new refrigerant container (3).

c) Purge any air existing in center charging hose

When using refrigerant container tap valve, use the following 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 refrigerant flow.


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 manifold gauge set (4). At this time, look into the sight glass (5) of receiver / dryer (6) and check that there are no bubbles (7) in the sight glass, which means that the system is fully charged.

Gauges should read as follows when ambient temperature is 30 °C (86 °F).

Pressure on high pressure gauge

1400 – 1750 kPa

14.0 – 17.5 kg/cm

2

199.1 – 248.9 psi

Pressure on low pressure gauge

230 – 350 kPa

2.3 – 3.5 kg/cm

2

32.7 – 49.8 psi


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 disturbing 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 a service performed on the system.

LIQUID LEAK DETECTOR

There are a number of fittings and places throughout the air conditioning 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.

For confined areas, such as sections of the evaporator and condenser, an electronic (refrigerant) leak detector (1) is more practical for determining leaks.

On-Vehicle Service

Service Precaution

When servicing air conditioning system, note the following instructions.

Refrigerant line


1. Suction hose:

Apply compressor oil to O-ring.

2. Discharge hose:


3. Receiver / dryer outlet pipe:


4. Condenser outlet pipe:


5. Expansion valve:


6. Dual pressure switch:


• Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.

• Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.

• When connecting hoses and pipes, apply a few drops of compressor oil to seats of coupling nuts and O-ring.

• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.

• 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 lb-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 lb-ft)

• Route drain hose so that drained water does not make any contact to vehicle components.

• Before evacuating and charging refrigerant, replenish specified amount of compressor oil to compressor suction side by referring to “Replenishing Compressor Oil” in this section.


Handling refrigerant HFC-134a (R-134a)

WARNING:

Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.

• Do not use your hand to rub affected eye(s). Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.

• Obtain proper treatment as soon as possible from a doctor or eye specialist.

Should liquid refrigerant HFC-134a (R-134a) get on your skin, such affected part should be treated in the same manner as when skin is frostbitten or frozen.

CAUTION:

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 maintenance. 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.

• Always wear goggles to protect your eyes.

• Avoid you direct contact to liquid refrigerant.

• Do not heat refrigerant container higher than 40 °C (104 °F).

• Do not discharge refrigerant into atmosphere.

• Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and will tarnish surfaces of bright metals including chrome.


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.

• Check clog of condenser fins.

If, any clogs are found, condenser fins should be washed with water, and should be dried with compressed air.

• Check condenser fins for leakage and breakage.

If any defects are found, repair or replace condenser.

• Check condenser fittings for leakage.

If any defects are found, repair or replace condenser.

REMOVAL


2) Recover refrigerant from A/C system by referring to “Recovery” in this section.

NOTE:

The amount of removed compressor oil must be measured 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 pressure 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 condenser (2).

9) Remove receiver / dryer (5) with its bracket (7) from condenser (2).

10) Remove condenser (2) from radiator.

INSTALLATION

Reverse removal procedure to install condenser, and then noting the following instructions.

• 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.


Receiver / Dryer

REMOVAL


NOTE:


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.




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 condenser 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) Remove front bumper.

2) Disconnect condenser cooling fan motor connector (1).

3) Remove radiator mounting bolts.

4) Remove condenser cooling fan assembly (2) from condenser (3).

INSTALLATION

Reverse removal procedure for installation.


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


(A/C evaporator temperature sensor)

3. Expansion valve

4. Evaporator case

5. Packing

6. Air inlet door

7. O-ring

8. Door link

REMOVAL



NOTE:



3) Drain engine coolant and disconnect heater hoses (1) from heater unit.

4) Disable air bag system referring to “Disabling Air Bag System” 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 following.

• 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.

• Check A/C evaporator fins for leakage and breakage.

If any defects are found, repair or replace A/C evaporator.

• Check A/C evaporator fittings for leakage.

If any defects are found, repair or replace A/C evaporator.


INSTALLATION

Reverse removal procedure to install cooling unit, and then noting the following instructions.

• If A/C evaporator thermistor removed, its should be reinstalled in original position.

• Install uniformly the packing (1) to installation hole.



• 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.


A/C Evaporator Thermistor (A/C Evaporator

Temperature Sensor)

INSPECTION

Check resistance between terminals for A/C evaporator thermistor (1).

If check results are as not specified, replace thermistor.

A/C evaporator temperature sensor resistance

Sensor Temperature (°C (°F))

0 (32)

25 (77)

Resistance (k

Ω)

6.4 – 7.0

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


2) Recover refrigerant from A/C system by referring to

“Recover” in this section.

NOTE:


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).


INSTALLATION

Reverse removal procedure for installation, and then note the following instructions.


• Evacuate and charge refrigerant by referring to “Evacuation” and “Charging” in this section.

Dual Pressure Switch

INSPECTION

1) Check dual pressure switch (1) for continuity at normal temperature (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.

A : Approximately 195 kPa (1.95 kg/cm

2

, 27.5 psi)

B : Approximately 3140 kPa (31.4 kg/cm

2

, 446.5 psi)

C : Approximately 225 kPa (2.25 kg/cm

2

, 32.0 psi)

D : Approximately 2550 kPa (25.5 kg/cm

2

, 362.5 psi)


Dual pressure switch

(a) : 10 N·m (1.0 kg-m, 7.0 lb-ft)


A/C Switch

REMOVAL AND INSTALLATION

Refer to “Heater Control Lever Assembly” in Section 1A.

INSPECTION

• Press A/C switch button and check if there is continuity between terminals “A” and “B”.

• 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


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 connected 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 minutes. After that stop the engine.


3) Recover refrigerant from refrigeration system by referring to

“Recovery” in this section.

NOTE:



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

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 compressor. And then, measure its amount.

INSTALLATION

Reverse removal procedure for installation, and then noting the following instructions.


• Evacuate and charge system by referring to “Recovery” in this section.

• Adjust drive belt tension by referring to “Compressor Drive

Belt” in this section.

Magnet Clutch


1. Thermal switch

2. Compressor body assembly

3. O-ring

4. Lip seal

5. Front head

6. Magnet clutch coil

7. Compressor pulley

8. Circlip

9. Shim

10. Clutch plate a. Front head bolt

: Tighten bolt “a” first, and next “b”.

b. Front head bolt

: Tighten bolt “a” first, and next “b”.

c. Clutch plate bolt

Tightening torque

Do not reuse.


INSPECTION

• Check clutch plate and clutch pulley for leaks of compressor oil.

• Check clutch bearing of compressor pulley for noise, wear and grease leakage.

• Measure resistance of magnet clutch coil (1) between magnet clutch lead wire (2) and compressor body assembly.

If measured resistance is not within tolerance, replace magnet clutch coil.

Magnet Clutch coil resistance

: 3.4 – 4.1

Ω at 20 °C (68 °F)

• 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


4) Remove circlip (1) using special tool.

Special tool

(A) : 09900-06107

5) Remove magnet clutch lead wire clamp screw, and disconnect magnet clutch lead wire.

6) Remove magnet clutch pulley (1) by using a puller (2).

NOTE:

• 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:

• 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


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 (1) as specified torque.


Clutch plate bolt

(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)

Special tool

(A) : 09991-06020


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.


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.


Front heat bolts

(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)

(b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

NOTE:

Tighten bolt (a) first, and next (b).

Tightening Torque Specification

Fastening part

Tension pulley bolt (for vehicle with P/S)

Refrigerant 8 mm pipe (0.31 in.)

Refrigerant 12 mm pipe (0.47 in.)

Refrigerant 14.5 mm pipe (0.57 in.)

Dual pressure switch

Clutch plate bolt

Front head bolt (5 mm)

Front head bolt (8 mm)

N•m

25

13

23

33

10

14

14

23

Tightening torque kg-m

2.5

1.3

2.3

3.3

1.0

1.4

1.4

2.3

lb-ft

18.0

9.5

16.6

23.8

7.0

10.5

10.5

16.6

Material

Compressor oil

(Refrigerant oil)


Required Service Materials

Recommended SUZUKI product

(Part Number)

COMPRESSOR OIL RS20 (150 cc)

99000-99088-00D0

Use

• O-ring

• Each component

Special Tools

09900-06107

Snap ring pliers

(Open type)

09991-06010

Magnet clutch pulley installer

09991-06020 09991-06030

Armature plate spanner Armature plate remover

09991-06040

Lip type seal protector

09991-06050

Lip type seal installer


STEERING, SUSPENSION, WHEELS AND TIRES 3-1

SECTION 3

STEERING, SUSPENSION, WHEELS AND TIRES

6F1

6F2

6G

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

FRONT END ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3A-1

STEERING GEAR BOX AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B-1

POWER STEERING SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B1-1

STEERING WHEEL, COLUMN AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3C-1

FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3D-1

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3E-1

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3F-1

3

7B1

7C1

7B1

7B1

7C1

7D

7E

7F

CONTENTS

General Diagnosis............................................. 3-2

Diagnosis Table .............................................. 3-2

Tire Diagnosis ................................................... 3-5

Irregular and/or Premature Wear .................... 3-5

Wear Indicators ............................................... 3-5

Radial Tire Waddle ......................................... 3-5

Radial Tire Lead.............................................. 3-7

Vibration Diagnosis .......................................... 3-7

8A

8B

8C

8D

8E

9

10

10A

10B

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 considered 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.

Diagnosis Table

Condition Possible Cause

Vehicle Pulls (Leads)

Mismatched or uneven tires

Tires not adequately inflated

Broken or sagging springs

Abnormal or

Excessive Tire Wear

Radial tire lateral force

Disturbed front wheel alignment

Disturbed rear wheel alignment

Brake dragging in one road wheel

Loose, bent or broken front or rear suspension parts

Sagging or broken springs

Tire out of balance

Wheel Tramp


Faulty shock absorber

Hard driving

Overloaded vehicle

Not rotating tire

Worn or loose road wheel bearings

Wobbly wheel or tires


Blister or bump on tire

Improper shock absorber action

Replace tire.

Correction

Adjust tire pressure.

Replace spring.

Replace tire.

Check and adjust wheel alignment.

Check and adjust wheel alignment.

Repair front brake.

Tighten or replace suspension part.

Replace spring.

Adjust balance or replace tire.

Check wheel alignment.

Replace shock absorber.

Replace tire.

Replace tire.

Replace or rotate tire.

Replace wheel bearing.

Replace wheel or tire.

Adjust the pressure.

Replace tire.


Condition

Shimmy, Shake or

Vibration

Hard Steering

Too Much Play in

Steering

Poor Returnability

Steering Noise

(Rattle or Chuckle)


Possible Cause

Tire or wheel out of balance

Loose wheel bearings

Loose wheel hub nuts

Worn tie rod ends

Worn king pin bearings or king pins

Correction

Balance wheels or replace tire and/or wheel.


Retighten.

Replace tie rod end.

Replace king pin bearing and/or king pin.

Repair or replace wheel and/or tire.

Replace tire.

Replace tire or wheel.

Excessive wheel runout

Blister or bump on tire

Excessively loaded radial runout of tire / wheel assembly


Loose or worn steering linkage

Loose steering gear box bolts

Worn steering knuckle oil seal

Bind in tie rod end ball studs or king pin bearings


Steering gear box adjustment

Check and adjust front wheel alignment.

Tighten or replace steering linkage.

Tighten box bolts.

Replace.

Replace tie rod end or king pin bearing.


Check and adjust steering gear box.

Inflate tires to proper pressure.

Repair or replace.

Check and correct.

Tire not adequately inflated

Bind in steering column

Low fluid level, loose drive belt or malfunction of power steering system (if equipped with P/S)

Wheel bearings worn

Steering gear box attachments loose

Steering gear box adjustments

Worn steering shaft joints

Worn tie rod ends drug rod ball joints

Worn king pin bearings or king pin


Tighten or repair.

Check and adjust steering gear box.

Replace joint.


Replace king pin bearing and/or king pin.

Bind in tie rod end ball studs

Bind in king pin bearings

Bind in steering column

Steering gear box needing lubricant



Replace king pin bearing.

Repair or replace.

Check, repair or lubricate steering gear box.


Steering gear box not properly adjusted


Loose bolts and nuts

Check and adjust steering gear box torque.

Adjust pressure.

Retighten.

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.


Condition

Abnormal Noise,

Front End

Possible Cause

Worn, sticky or loose tie rod ends, drug rod ball joints, king pin bearings or axle shaft joints

Damaged shock absorbers or mountings

Worn leading arm bushings

Correction

Replace tie rod end, king pin bearing or axle shaft joint.

Replace or repair.

Replace.

Wander or Poor

Steering Stability

Erratic Steering when

Braking

Body Leans or Sways in Corners

Defective wheel cylinders


Ride Too Soft

Faulty shock absorber

Suspension bottoms

Overloaded

Faulty shocks absorber

Incorrect, broken or sagging springs

Loose stabilizer bar

Cupped Tires

Worn stabilizer bar bushings

Worn Iateral rod bushings


Loose wheel nuts

Loose suspension bolts or nuts

Broken or otherwise damaged wheel bearings Replace wheel bearing.

Broken suspension springs Replace spring.

Mismatched or uneven tires

Tighten wheel nuts.

Tighten suspension bolts or nuts.

Loose king pin bearings and tie rod ends

Faulty shock absorbers or mounting


Replace tire or inflate tires to proper pressure.

Replace king pin bearing or tie rod end.

Replace absorber or repair mounting.

Tighten or replace stabilizer bar or bushes.


Steering gear box not properly adjusted

Replace.

Replace.

Tighten bolts or replace bushes.

Front wheel alignment

Replace spring.

Check or adjust steering gear box torque.



Worn wheel bearings


Leaking wheel cylinder or caliper

Warped discs

Badly worn brake linings

Drum is out of round in some brakes

Wheel tires are inflated unequally

Replace spring.

Repair or replace wheel cylinder or caliper.

Replace brake disc.

Replace brake shoe lining.

Replace brake drum.

Inflate tires to proper pressure.

Replace or repair wheel cylinder.

Check front wheel alignment

Faulty shocks absorbers or mounting


Overloaded

Worn wheel bearings

Excessive tire or wheel run-out

Tire out of balance


Check loading.


Replace spring.

Tighten stabilizer bar bolts or replace bushes.

Replace shock absorber or tighten mounting.

Replace spring.

Check loading.


Replace tire or wheel disc.

Adjust tire balance.


Tire Diagnosis

Irregular and/or Premature Wear

Irregular and premature wear has many possible causes. Some of them are: incorrect inflation pressures lack of tire rotation, driving habits, improper alignment.

If the following conditions are noted rotation is in order:

• Front tire wear is different from rear.

• Uneven wear exists across the tread of any tire.

• Left front and right front tire wear is unequal.

• Left rear and right rear tire wear is unequal.

• There is cupping, flat spotting, etc.

A wheel alignment check is in order if the following conditions are noted:

• Left front and right front tire wear is unequal.

• Wear is uneven across the tread of any front tire.

• 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] : Incorrect 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 vehicle. Waddle can be quickly diagnosed by using a Tire Problem

Detector (TPD) and following the equipment manufacturer’s recommendations.

If a TPD is not available, the more time consuming method of substituting known good tire / wheel assemblies on the problem vehicle can be used as follows:


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 manner 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 IN SAME

DIRECTION

LEAD CORRECTED IF

ROUGHNESS RESULTS.

REPLACE TIRES

LEAD REVERSES

DIRECTION

PUT TIRES BACK IN

ORIGINAL POSITION

AND CHECK ALIGNMENT

LEAD CORRECTED

REPLACE TIRE

INSTALL A KNOWN GOOD TIRE

ON ONE FRONT SIDE

LEAD REMAING

INSTALL A KNOWN GOOD TIRE IN

PLACE OF OTHER FRONT TIRE

LEAD CORRECTED

REPLACE TIRE

LEAD REMAING

KNOWN GOOD TIRES ARE NOT GOOD


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 caused 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 mistaken 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, although it takes a longer time.

[A] : Tire out of round

[B] : Tire stiffness variation

[C] : Rim bent or out of round

1. Smooth road

2. Suspension movement (loaded runout)


FRONT WHEEL ALIGNMENT 3A-1

SECTION 3A

FRONT WHEEL ALIGNMENT

CONTENTS

General Description ........................................3A-2

Toe Setting ....................................................3A-2

Camber .........................................................3A-2

Alignment Service Data (Reference).............3A-2

Diagnosis .........................................................3A-3

Diagnosis Table ............................................3A-3

Preliminary Checks Prior To Adjusting Front

Wheel Alignment ...........................................3A-3

Toe Adjustment............................................. 3A-3

Camber And Caster Check And

Adjustment .................................................... 3A-4

Steering Angle Check And Adjustment ......... 3A-4

Side Slip(Reference) ..................................... 3A-4

8A

8B

8C

8D

8E

6F1

6F2

6G

6H

7A

3A

7B1

7C1

7D

7C1

7D

7E

7F

9

10

10A

10B

3A-2 FRONT WHEEL ALIGNMENT

[A]

[A]

1

2

“A”

1

“B”

90 o


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 conditions or collision, whether the damage is in body or in suspension should be determined. If the body is damaged, 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

2. Center line of wheel

[A]: Front view

C

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 tires. “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 manual 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 corrected 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 this adjustment, right and left tie rod should become equal in length (“A”).

After adjustment, tighten lock nuts to specified torque.


Tie rod end lock nuts

(a) : 65 N·m (6.5 kg-m, 47.0 lb-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 specifications.

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 LINKAGE

6F1

6F2

6G

6H

WARNING:

For vehicles equipped with Supplemental Restraint (Air Bag) System




“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)

3B

7C1

7D

7E

7D

7E

7F

8A

8B

8C

8D

8E

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 during reassembly to assure proper retention of these parts.

9

10

10A

10B

CONTENTS


Diagnosis ........................................................ 3B-3

Diagnosis Table ........................................... 3B-3

Steering Wheel Play Check ......................... 3B-3

Tie Rod And Drag Rod Check...................... 3B-3

Steering Gear Box Oil Level Check ............. 3B-4

Adjustment of Worm Shaft Starting Torque . 3B-4

On-Vehicle Service ........................................ 3B-6

Steering Gear Box ....................................... 3B-6

Tie Rod And Drag Rod................................. 3B-8

Tightening Torque Specifications .............. 3B-10

Required Service Material ........................... 3B-10

Special Tools................................................ 3B-10

3B-2 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE


1. Steering gear box

2. Pitman arm

3. Drag rod

4. Knuckle arm

5. Tie rod

6. Steering lower shaft

7. Steering wheel

8. Steering upper shaft

9. Worm shaft

10. Ball

11. Ball nut

12. Gear case

13. Sector shaft

14. Rack gear


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.


“a” : 10 – 30 mm (0.4 – 1.2 in.)

If play is not within specification, inspect for the following. If found defective, replace.

• Wear of tie rod end ball stud.

• Wear of king pin bearing

• Wear of steering shaft joint.

• Loosely install or joined parts.

• 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.


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 breathing plug to specified torque.

(A) : Sealant 99000-31110


Breathing plug

(a) : 4 N·m (0.4 kg-m, 3.0 lb-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.)


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 lb-ft)

Special tool

(A) : 09944-18211

1. Adjusting bolt

If measured torque is not within specification, carry out adjustment with adjusting bolt (1) to meet specification and check to confirm it again.


Steering gear box adjusting bolt lock nut

(a) : 30 N·m (3.0 kg-m, 22.0 lb-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 lb-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.


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.



Steering Gear Box

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 special 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.


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.


Pitman arm mounting nut

(a) : 135 N·m (13.5 kg-m, 98.0 lb-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.


Steering lower shaft joint bolt

(a) : 25 N·m (2.5 kg-m, 18.0 lb-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.


Steering gear box mounting bolt and nuts

(a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)


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 × 1.25) to about 20 N·m

(2.0 kg-m, 14.5 Ib-ft) and remove it.

Then tighten new nut to specified torque.


Drag rod end nut (pitman arm side)

(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)


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.


2) Adjust tie rod (and/or drag rod) length to the measurement shown in figure; then tighten tie rod 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 × 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.


Tie rod end nut

(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)

4) Inspect for proper toe and steering angle (inside & outside).

(Refer to “Preliminary Checks Prior To Adjusting Front Alignment” in Section 3A).

Adjust tie rod (2) and drag rod length as required, if necessary.

5) After confirming proper toe, tighten tie rod end lock nut (3) to specified torque.


Tie rod end lock nut

(b) : 65 N·m (6.5 kg-m, 47.0 lb-ft)

6) Tighten wheel nuts to specified torque and lower hoist.


Tightening Torque Specifications

Fastening part

Steering gear box oil plug

Steering gear box adjusting bolt lock nut

Pitman arm mounting nut

Steering shaft joint bolt

Steering gear box nuts and bolt

Tie rod end nut and drag rod end nut

(knuckle side)

Wheel nut

Tie rod end lock nut

Drag rod end nut (pitman arm side)

43

95

65

50

N•m

4

30

135

25

80


0.4

3.0

13.5

2.5

8.0

4.3

9.5

6.5

5.0

Sealant

Material

Required Service Material


(Part Number)

SUZUKI BOND NO. 1215

(99000-31110)

Use

• Thread of oil breathing plug

Special Tools lb-ft

3.0

22.0

98.0

18.0

58.0

31.5

69.0

47.0

36.5

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 :




“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).

3B1

7D

7E

7F

7E

7F

8A

8B

8C

8D

8E

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 during reassembly to assure proper retention of these parts.

9

10

10A

10B

6F1

6F2

6G

6H

6K

CONTENTS

General Description ......................................3B1-2

Diagnosis .......................................................3B1-3

Diagnosis Table ..........................................3B1-3

Steering Wheel Play Check ........................3B1-5

Steering Force Check .................................3B1-5

Power Steering Belt Check .........................3B1-6

Power Steering Belt Tension Adjustment....3B1-6

Power Steering Fluid Level Check ..............3B1-6

Idle-Up System Check ................................3B1-7

Power Steering Fluid Leakage Check .........3B1-7

Air Bleeding Procedure ............................... 3B1-8

Hydraulic Pressure In P/S Circuit Check .. 3B1-10

On-Vehicle Service ..................................... 3B1-12

Power Steering Belt .................................. 3B1-12

Power Steering (P/S) Pump ...................... 3B1-12

Power Steering (P/S) Gear Box ................ 3B1-18

Tightening Torque Specifications ............. 3B1-21

Required Service Materials ........................ 3B1-21

Special Tools............................................... 3B1-21

3B1-2 POWER STEERING (P/S) SYSTEM (If equipped)


The power steering system in this vehicle reduces the driver’s effort needed in turning the steering wheel by utilizing 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.

1. Steering gear box 2. Power steering (P/S) pump 3. P/S fluid reservoir

1. Power steering gear box

2. Control valve section

3. Spool valve

4. Power steering (P/S) pump

5. P/S fluid reservoir


Diagnosis

Diagnosis Table

Condition

Steering wheel feels heavy

(at low speed)

Steering wheel feels heavy momentarily when turning it to the left or right.

No idle-up (See NOTE

“B”.)

Possible Cause

Fluid deteriorated, low viscosity, different type of fluid mixed

Pipes or hoses deformed, air entering through joint

Insufficient air bleeding from piping

Belt worn, lacking in tension

Tire inflation pressure too low

Wheel alignment out of adjustment

Steering wheel installed improperly (twisted)

Hydraulic pressure failing to rise (See NOTE

“A”.)

Slow hydraulic pressure rise (See NOTE “A”.)

Air drawn in due to insufficient amount of fluid

Slipping belt

Defective pressure switch

Inflate tire.

Correction

Change fluid.

Correct or replace.

Bleed air.

Adjust belt tension or replace belt as necessary.

Adjust front wheel alignment.

Install steering wheel correctly.

Replace P/S pump.

Add fluid and bleed air.

Adjust belt tension or replace belt as necessary.

Replace pressure switch

(terminal set).

NOTE:

• “A” : Be sure to warm up engine fully before performing this check. Pump vanes are sometimes hard to come out where temperature is low.

• “B” : Acceptable if idling speed does not drop.

Condition

Steering wheel returns slowly from turns.

(See NOTE “C”.)

Vehicle pulls to one side during straight driving.

Steering wheel play is large and vehicle wanders.

Fluid leakage

Possible Cause

Dust or foreign object mixed in fluid

Deformed pipes or hoses

Steering column installed improperly

Wheel alignment maladjusted

Linkage or joints not operating smoothly

Low or uneven tire inflation pressure

Wheel alignment maladjusted

Defective spool valve

Loose steering shaft nut

Loose linkage or joint

Loose gear box fixing bolt

Front wheel bearing worn

Loose joints of hydraulic pressure pipes and hoses

Deformed or damaged pipes or hoses

Gear box

Correction

Change fluid.

Correct or replace.

Install correctly.

Adjust.

Correct.

Inflate tire (s) as necessary.

Adjust.

Replace gear box assembly.

Retighten.

Retighten.

Retighten.

Replace.

Retighten.

Correct or replace.



Condition

Abnormal noise

(See NOTE “D”.)

Possible Cause

Air drawn in due to insufficient fluid

Air drawn in through pipe or hose joints

Belt slipping (loose)

Worn belt

Loose steering linkage

Loose gear box fixing bolt

Loose pitman arm

Pipes or hoses in contact with chassis

Defective pump vane

Malfunction of flow control valve

Defective pump shaft bearing

Correction

Replenish fluid.

Retighten or replace.

Adjust.

Replace.

Retighten.

Retighten.

Retighten.

Correct.

Replace pump assembly.


Replace pump assembly.

NOTE:

• “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.

• “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.


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.


“a” : 30 mm (1.18 in.) or less

• 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 tangential direction.

Steering force

Less than 6.0 kg (13.2 lb)


Power Steering Belt Check

INSPECTION

• Check that belt is free from any damage and properly fitted in pulley groove.

• Check belt tension by measuring how much it deflects when pushed at mid-point between pulley with about 10 kg (22 lb) force.

Deflection of oil pump belt

“a” : 6 – 9 mm (0.25 – 0.35 in.)

Power Steering Belt Tension 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.


Tension pulley bolts

(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

1. P/S pump pulley

2. Crank pulley

4. A/C compressor pulley (if equipped)

Power Steering Fluid Level Check

CAUTION:

• Make sure to use an equivalent of DEXRON

®

-II,

DEXRON

®

-IIE or DEXRON

®

-III for P/S fluid.

• Fluid level should be checked when fluid is cool before starting engine.

With engine stopped check fluid level indicated on P/S fluid reservoir (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


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 connector disconnected. Momentary drop of engine idle speed should be less when it is connected than when disconnected.

Power Steering Fluid Leakage 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.


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 serviced 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 system 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 specified level.

7) Check steering condition and P/S system for fluid leakage.

AIR BLEEDING FROM GEAR BOX

NOTE:

Bleed air from gear box:

• When steering gear box has been replaced with a new one.

• 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


2. Low pressure hose / pipe

3. High pressure hose / pipe


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:

• Add fluid into P/S fluid reservoir whenever its level lowers while servicing.

• 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 position (straight position).

NOTE:

As input shaft makes 4 full turns from lock to lock, neutral position is obtained by turning it till it locks and turning it back by 2 full turns.

2. Vinyl tube (See-through tube)

8) Remove (special) tools and install steering gear box to vehicle and P/S pipe / hose to steering gear box referring to

“Power Steering (P/S) Gear Box” in this section.

NOTE:

• 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.

• 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.


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

2. Attachment

3. Washer

4. Union bolt

5. Pressure hose

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)

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/cm

2

, 142 psi), check control valve and pipes for obstruction.

Back pressure : 980 kPa (10 kg/cm

2

, 142 psi)


2. P/S pump


4. Oil pump pressure gauge

5. Low pressure side

6. High pressure side

7. Valve (open)


5) Relief pressure check

CAUTION:

• Be sure not to keep gauge valve closed for longer than

10 seconds.

• 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

2

, 1208 psi), malfunction of relief valve.

If lower than 6,400 kPa (65 kg/cm

2

, 925 psi), failure of P/S pump or settling of relief valve spring.

Relief pressure

6,400 – 8,400 kPa (65 – 85 kg/cm

2

, 925 – 1208 psi)


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

2

, 1280 psi), failure in steering gear.

Relief pressure

6,400 – 8,400 kPa (65 – 85 kg/cm

2

, 925 – 1208 psi)


2. P/S pump


4. Oil pressure gauge

5. High pressure side



Power Steering Belt

REMOVAL


2) Loosen tension pulley bolts (2).

3) Remove power steering belt (1).

INSPECTION

• Check power steering belt for wear and cracks, and replace as required.

INSTLLATION

1) Install belt to power steering pump pulley (1), crankshaft pulley (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.


5) Remove P/S pump (1) removing 3 mounting bolts (3).

CAUTION:

• Clean couplers at intake and discharge ports completely before disconnection.

• 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 aluminum 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

2. Pump body

3. Pump cover


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

• Check sliding surfaces of rotor and vane for wear and damage.

• 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

• Check fluid passage of relief valve and orifice of connector for obstruction (clogged).

• Check sliding surface of relief valve for wear and damage.


• 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 following.

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.


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 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.


Oil pump cover bolts

(a) : 28 N·m (2.8 kg-m, 20.0 lb-ft)


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.


Plug

(a) : 60 N·m (6.0 kg-m, 43.5 lb-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.


Pressure switch

(a) : 28 N·m (2.8 kg-m, 20.0 lb-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 pump body as shown in figure. Tighten suction connector bolt (3) to specified torque.


Suction connector bolt

(a) : 12 N·m (1.2 kg-m, 8.5 lb-ft)

1. P/S pump


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.

• Tighten each bolt as specified below.


Oil pump mounting bolts

(a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)

Oil pump high pressure union bolt

(b) : 60 N·m (6.0 kg-m, 43.5 lb-ft)

1. Union bolt

• Adjust P/S belt referring to “Power Steering Belt Check” in this section.

• 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 “Radiator” in Section 6B

5) Remove radiator support member.

6) Disconnect suction hose and return hose from P/S fluid reservoir, and remove P/S fluid reservoir assembly (for leftsteering vehicle).

7) Remove steering lower shaft joint bolt (2).



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:

• Don’t disassemble P/S gear box.

• 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 following points.

• Tightening torque specification.


Power steering gear box mounting bolt and nuts

(a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)

Gear box high pressure union bolt

(b) : 35 N·m (3.5 kg-m, 25.5 lb-ft)

• Before servicing, set steering wheel and wheel / tire at straight position.


2. Bolt (long)

3. Bolt (short)

4. High pressure hose

5. Return hose


• 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.


Pitman arm mounting nut

(a) : 135 N·m (13.5 kg-m, 98.0 lb-ft)

• 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 straightforward state and insert upper joint onto steering shaft.

3) Torque lower shaft joint bolt to specification.


Steering shaft lower joint bolt

(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

• Fill engine coolant to radiator.

• Bleed air in P/S circuit referring to “Air Bleeding Procedure” in this section.



Fastening part

Tension pulley bolt

Oil pump mounting bolt

Oil pump high pressure union bolt

Oil pump cover bolts

Pressure switch

Suction connector bolt

Power steering gear box mounting bolt and nuts

Gear box high pressure union bolt

Pitman arm mounting nut

Steering shaft joint bolt

Plug

N•m

25

25

60

28

28

12

80

35

135

25

60


2.5

2.5

6.0

2.8

2.8

1.2

8.0

3.5

13.5

2.5

6.0

lb-ft

18.0

18.5

43.5

20.0

20.0

8.5

58.0

25.5

98.0

18.5

43.5


Material

Power steering fluid

Lithium grease


(Part Number)


®

-II,

DEXRON

®

-IIE or DEXRON

®

-III.

SUPER GREASE (A)

(99000-25010)

Use

• To fill P/S fluid reservoir

• Parts lubrication when installing

• Oil seal lip of P/S pump pulley shaft

Special Tools

09915-77411

Oil pressure gauge

09915-77420

Oil pressure gauge attachment & hose set

09944-18211

Torque check socket

09945-35010

Air bleeding hose set


STEERING WHEEL AND COLUMN 3C-1

SECTION 3C

STEERING WHEEL AND COLUMN

WARNING:


• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-

Vehicle Service” in air bag system section before performing service on or around the air bag 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.

• 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 repairs.

7A

3C

7E

7F

7F

CAUTION:

When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application.

If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called out. The correct torque value must be used when installing fasteners that require it. If the above procedures are not followed, parts or system damage could result.

6F1

6F2

6G

6H

6K

8A

8B

8C

8D

8E

9

10

10A

10B

General Description ....................................... 3C-2

Diagnosis ........................................................ 3C-3

Inspection and Repair Required

After Accident ............................................... 3C-3

On-Vehicle Service......................................... 3C-3

Service Precautions (For Vehicle with

Air Bag System) ........................................... 3C-3

Diagnosis and servicing ........................... 3C-3

Disabling air bag system .......................... 3C-3

Enabling air bag system ........................... 3C-3

Handling and storage ............................... 3C-3

Disposal.................................................... 3C-3

Drive Air Bag (Inflator) Module (For Vehicle with Air Bag System) .................................... 3C-4

Steering Wheel............................................. 3C-5

CONTENTS

Centering contact coil (for vehicle with air bag system)......................................... 3C-8

Combination Switch (For Vehicle without

Air Bag System)/Contact Coil and

Combination Switch Assembly (For Vehicle with Air Bag System).................................... 3C-9

Steering Column Assembly........................ 3C-11

Steering Lock Assembly

(Ignition Switch) ......................................... 3C-15

Steering Lower Shaft ................................. 3C-16

Checking Steering Column for Accident

Damage ......................................................... 3C-18

Tightening Torque Specifications .............. 3C-19

Required Service Material ........................... 3C-19

Special Tool.................................................. 3C-19

3C-2 STEERING WHEEL AND COLUMN


This double tube type steering column has the following three important features in addition to the steering function:

• The column is energy absorbing, designed to compress in a front-end collision.

• The ignition switch and lock are mounted conveniently on this column.

• With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.

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 column length and position.

The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the restraint of the driver’s and passenger’s seat belts by deploying the air bags.

The air bag (inflator) module should be handled 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.

1. Driver air bag (inflator) module

2. Steering wheel

3. Steering wheel side cap

4. Steering wheel nut

5. Combination switch or contact coil and combination switch assembly

6. Steering column upper cover

7. Steering column lower cover

8. Steering column assembly

9. Steering lock assembly (ignition switch)

10. Steering column hole cover


[A] : For vehicle with air bag system

[B] : For vehicle without air bag system


Diagnosis

For maintenance service of the steering wheel and column, refer to “Steering System Inspection” in Section 0B.

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

• 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” in this section.

• 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.


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


Enabling air bag system


Handling and storage

Refer to “Handling and Storage” in Section 10B.

Disposal

Refer to “Disposal” in Section 10B.


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 steering 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.


Check air bag (inflator) module visually and if any of the following is found, replace it with a new one.

• Air bag being deployed

• Trim cover (1) (pad surface) being cracked

• Wire harness (3) or connector being damaged

• 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) module (3) pushing connector till it is locked.

3) Install driver air bag (inflator) module to steering wheel, taking 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 bag (inflator) module mounting bolts (1) to specified torque.


Driver air bag (inflator) module mounting bolts

(a) : 9 N·m (0.9 kg-m, 6.5 lb-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 combination 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.


REMOVAL


2) Remove steering wheel pad (for vehicle without air bag system) or driver air bag (inflator) module (for vehicle with air bag system) as follows.

• Vehicle without air bag system for TYPE A a) Remove steering wheel pad.

b) Disconnect horn connector.

• 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 TYPE A

[B] : For TYPE B

• Vehicle with air bag system a) Remove driver air bag (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.


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:


These two conditions are prerequisite for installation of steering wheel. If steering wheel has been installed without these conditions, contact coil will break when steering wheel is turned.

2) Install steering wheel as follows.

• 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.


Install steering wheel to steering shaft with 2 lugs (2) on contact coil fitted in two grooves (3) in the back of steering wheel and also aligning marks (4) on steering wheel and steering shaft.

[A] : For vehicle without air bag system

[B] : For vehicle with air bag system


3) Tighten steering shaft nut to specified torque.


Steering shaft nut (a) : 33 N·m (3.3 kg-m, 23.5 lb-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.

• 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.

• 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 system)

1) Check that vehicle’s wheels (front tires) are set at straightahead 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 further.

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.


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:


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 counterclockwise 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 tapping 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.


7) Remove combination switch/contact coil and combination switch assembly (1) from steering column.

INSPECTION


Check contact coil and combination switch wire harness for any signs of scorching, melting or other damage. If it is damaged, replace.

1. Contact coil and combination switch assembly

2. To horn

3. Connector to driver air bag (inflator) module

4. 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:


New contact coil and combination switch assembly is supplied with contact coil set and held at its center position 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 combination switch lead wirer is not caught between covers.


5) Tighten steering column mounting nuts and bolts by hand and then tighten mounting nuts (1) first, and then tighten mounting bolts (2).


Steering column mounting bolts and nuts

(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)

6) Install steering column hole cover (1).

7) Install steering wheel to steering column referring to “Steering Wheel” in this section.

Steering Column Assembly

CAUTION:

Once the steering column is removed from the vehicle, the column is extremely susceptible to damage.

• Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length.

• Leaning on the column assembly could cause it to bend or deform.

Any of the above damage could impair the column’s collapsible design.

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.


REMOVAL

WARNING:


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.


2) For vehicle equipped with air bag system, disable air bag system referring to “Disabling Air Bag System” in Section

10B.

3) 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.

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).


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 assembly into steering column and shaft. If column or shaft is defective, replace as and assembly.

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 assembly.

2) Check two plates (3) for any damages such as crack or breakage.

If anything is found faulty, replace as steering column assembly.


3) Take measurement “a” as shown.

If it is shorter than specified length, replace column assembly (1) with new one.

Steering column assembly length

“a” : 733.2 – 734.8 mm (28.87 – 28.93 in.)

4) 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.

5) Check steering shaft for smooth rotation.

If found defective, replace as column assembly.

6) Check steering shaft and column for bend, cracks or deformation.

If found defective, replace.

7) Check steering column lower seal (1) for breakage or deformation. If found defective, replace.

INSTALLATION

CAUTION:

After tightening steering column mounting bolts and nuts shaft joint bolts should be tightened.

1) Be sure that front wheels and steering wheel are in straight forward state.

2) If equipped, install shift (key) interlock cable to ignition switch.

3) 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


4) Insert steering lower shaft (1) to steering shaft.

5) Put the steering column upper cover (3) on top of the steering column (2), if necessary and then tighten steering column mounting nuts (5) and bolts (4) by hand.

6) Tighten mounting nuts (5) first and then mounting bolts (4) to specified torque.


Steering column mounting bolts and nuts

(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)

7) Tighten steering column side joint bolt (1) first, and then tighten steering gear box side joint bolt (2).


Steering shaft joint bolts (b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

8) If combination switch is removed, install combination switch referring to “Combination Switch/Contact Coil and Combination 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 steering 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


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 steering 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 Lower Shaft

CAUTION:


Never turn steering wheel while steering shaft lower joint is removed.

Should it have been turned and contact coil (on combination 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.


3) Make alignment marks (3) on lower shaft (2) and shaft (column 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.


Steering shaft joint bolts (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

1. Steering column assembly



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 assembly.

2) Check two plates (3) for any damages such as crack or breakage.

If anything is found faulty, replace as steering column assembly.

3) Take measurement “a” as shown.

If it is shorter than specified length, replace column assembly (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 P/S system)

5) Check steering column lower seal (1) for breakage or deformation.



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 deformation.



Fastening part

Driver air bag (inflator) module bolts

Steering shaft nut

Steering column mounting bolts and nuts

Steering shaft joint bolts

N•m

9

33

14

25


0.9

3.3

1.4

2.5

lb-ft

6.5

23.5

10.5

18.0

Material

Water tight sealant

Lithium grease



SEALING COMPOUND 366E

(99000-31090)

SUZUKI GREASE CE-T

(99000-25290)

Use

• To apply to steering column seal.

• Contact plate

Special Tool

09944-36011

Steering wheel remover


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 Section 0A.

6F1

6F2

6G

1A

6K

7A

7A1

NOTE:

• All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part.

• Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or damage to the part may result.

General Description ....................................... 3D-2

4WD Control System.................................... 3D-2

Diagnosis ........................................................ 3D-8

Diagnosis Table ........................................... 3D-8

4WD Controller and ITS Circuit Check....... 3D-10

4WD Control System Check ...................... 3D-11

Stabilizer bar / bushing check ................ 3D-13

Shock Absorber and/or Coil Spring

Check ......................................................... 3D-14

Leading Arm / Lateral Rod / Steering

Knuckle Check ........................................... 3D-14

Leading Arm Bushing / Lateral Rod

Bushing Check ........................................... 3D-15

Kingpin / Kingpin Bearing Check................ 3D-15

Barfield Joint Check ................................... 3D-15

Steering Knuckle Seal Check..................... 3D-15

Wheel Disc, Nut and Bearing Check .......... 3D-16

3D

7F

8A

CONTENTS

On-Vehicle Service ...................................... 3D-17

Stabilizer Bar / Bushings ............................ 3D-17

Front Shock Absorber ................................ 3D-19

Coil Spring ................................................. 3D-19

Bump Stopper and Spring Upper Seat ...... 3D-21

Wheel Hub / Bearing / Oil Seal .................. 3D-21

Steering Knuckle / Wheel Spindle.............. 3D-28

Front Axle Shaft / Oil Seal / Kingpin

Bearing Outer Race ................................... 3D-32

Steering Knuckle Seal................................ 3D-34

Lateral Rod ................................................ 3D-35

Leading Arm / Bushing............................... 3D-36

Front Axle Housing .................................... 3D-38

Tightening Torque Specifications .............. 3D-44

Required Service Material ........................... 3D-44

Special Tool.................................................. 3D-45

9

10

10A

10B

8A

8B

8C

8D

8E

3D-2 FRONT SUSPENSION



2. Shock absorber

3. Steering knuckle

4. Kingpin

5. Wheel spindle

6. Wheel hub

7. Wheel bearing

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 locking) to apply vacuum from the vacuum tank so that the front axle and the wheel hub are disengaged or engaged.


1. Air locking hub assembly

2. VSV1

3. Check valve

4. VSV2

5. Vacuum accumulation tank

6. Vacuum switch

7. 4WD controller

8. Intake manifold

9. Wheel spindle

10. 4WD indicator light

11. 4WD switch

12. Combination meter

13. ABS controller

14. Transfer


SYSTEM CIRCUIT

1. 4WD controller

2. VSV1

3. VSV2

4. 4WD indicator lamp

5. ECM

6. Blower fan motor

7. Blower fan switch

8. A/C switch (if equipped)

9. 4WD switch

10. Vacuum switch

11. Main fuse

12. IG switch

13. IG fuse

14. A/C controller (if equipped)

15. Coupler of 4WD controller


Components and Functions

Component

4WD switch

4WD controller

VSV1

VSV2

Vacuum switch

“4WD” indicator lamp

Function

When the transfer shift lever is shifted to 4L or 4H position from 2H, this switch turns ON and cause the 4WD control system to turn ON.

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 indicator 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 seconds to unlock the hubs and at the same time makes the 4WD indicator light turn off.

VSV1 operates according to the signal from the 4WD controller. When it is activated, 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 operates according to the signal from the 4WD controller. When it is activated, 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.

When VSV2 receives the “ON” signal 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.

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).


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 manifold 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

2. 4WD controller


4. 4WD switch


6. Vacuum switch

7. A/C cut signal (if equipped)

8. Engine speed signal

9. Intake manifold

10. Check valve

11. Vacuum tank

12. VSV1

13. VSV2

14. Outer gear

15. Chamber B

16. Piston A

17. Magnet

18. Housing

19. Spring

20. Diaphragm

21. Sleeve

22. Slide gear

23. Wheel hub

24. Spindle

25. Front axle shaft

26. To opposite side

27. A/C controller

A: Vacuum circuit


4WD

→ 2WD

When the transfer shift control lever is shifted from the 4WD (4H or 4L) to the 2WD (2H) position, the 4WD controller 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 & A/C controller

2. 4WD controller


4. 4WD switch


6. Vacuum switch

7. A/C cut signal (if equipped)

8. Engine speed signal

9. Intake manifold

10. Check valve

11. Vacuum tank

12. VSV1

13. VSV2

14. Outer gear

15. Chamber A

16. Piston A

17. Magnet

18. Housing

19. Spring

20. Diaphragm

21. Sleeve

22. Slide gear

23. Wheel hub

24. Spindle

25. Front axle shaft

26. To opposite side

27. A/C controller

A: Vacuum circuit


Diagnosis

Diagnosis Table

For description not found in the table below, refer to “Diagnosis Table” in Section 3.

4WD CONTROL SYSTEM

Condition

4WD Indicator light flashing

Possible Cause

• Hub locking procedure error

2WD/4WD switching error

• Defective VSV2

• Defective vacuum switch

• Defective check valve or vacuum tank

• Air leak from vacuum circuit

• Clogged vacuum hose or pipe

• Faulty 4WD controller

• Defective air locking hub assembly

• Abnormality in 4WD control system

• Air leakage from vacuum circuit

• Clogged vacuum hose or pipe

• Defective check valve or vacuum tank

Correction

Shift transfer shift control lever

2WD

→ 4WD once again

Replace

Replace

Replace

Check and repair

Replace

Check and replace

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 section for air leakage.

[NOTES ON SYSTEM CIRCUIT INSPECTION]

• Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before circuit inspection and observe what is written there.

• For system circuit, refer to the figure of “System Circuit” in this section.

Step Action

1 Check ground circuit.

1) Disconnect coupler from 4WD controller with ignition switch OFF.

2) Check for proper connection to 4WD controller at all terminals.

3) If OK, check continuity between A5 terminal and body ground.

Is there continuity between A5 terminal and body ground?

2 Check power circuit.

1) Disconnect coupler from 4WD controller.

2) Turn ignition switch ON.

3) Check voltage between A10 terminal and ground.

Is it 10 – 14 V?

Yes

Go to Step 2.

Go to Step 3.

No

“B” wire is open.

“Y/R” circuit is open or short.


Step

4H or 4L range?

4H or 4L range?

Action

3 Check 4WD switch circuit.

1) Connect coupler to 4WD controller.

2) Turn ignition switch ON and check voltage between A7 terminal and ground.

Transfer lever is in 2H : about 10 – 14 V

Transfer lever is in 4L or 4H : about 0 V

Is check result satisfactory?

4 Check VSV1 circuit.



Is it 10 – 14 V when transfer lever is in 4H or 4L range and about 0 V for 10 seconds after it is shifted to 2H range?

5 Check VSV2 circuit.



Is it 10 – 14 V when transfer lever is in 2H range and about 0 V for 5 seconds after it is shifted to

6 Check vacuum switch circuit.

1) Turn ignition switch ON (stating engine).


Is it 10 – 14 V when transfer lever is in 2H range and about 0 V for 5 seconds after it is shifted to

Yes

Go to Step 4.

Go to Step 5.

Go to Step 6.

Go to Step 7.

7 Check 4WD indicator light circuit.



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?

Substitute a known-good

4WD controller and recheck.

No

Check 4WD switch (refer to “4WD Switch” in Section 7D), “Bl/B” and “B” circuits of 4WD switch.

If OK, substitute a knowngood 4WD controller and recheck.

Check VSV1 (refer to

“4WD Control System

Check” in this section),

“Y/R” and “Gr/B” circuits of VSV1.


Check VSV2 (refer to

“4WD Control System

Check” in this section),

“Y/R” and “Gr/R” circuits of VSV2.


Check vacuum switch

(refer to “4WD Control

System Check” in this section), “Gr” and “B” circuits of vacuum switch.


Check “Bl” circuit (including indicator light and combination meter refer to

“Combination Meter” in

Section 8).



4WD Controller and ITS Circuit Check

VOLTAGE CHECK

Check for input or output voltage of 4WD controller (1) (voltage between each circuit and body ground) with 4WD controller connector connected and ignition switch turned START (engine run).

CAUTION:

• Disable air bag system (if equipped with Air Bag), refer to “Disabling Air Bag System” in Section 10B.

• This check must be carried out in a well-ventilated place.

Terminal

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

Circuit

VSV1

VSV2

4WD indicator lamp

A/C controller

Ground

Vacuum switch

4WD switch

Ignition coil

Ignition switch

* : With engine running

A/C switch

Wire Color

Gr/B

Gr/R

Bl

G/W

B

Gr

Bl/B

G/B

Br

Y/R

Normal Voltage

about 0 V

10 – 14 V

*about 0 V

10 – 14 V

*about 0 V

10 – 14 V

*10 – 12 V about 0 V

Condition

10 seconds after transfer shift control lever : 4WD

→ 2WD

Transfer shift control lever: 4WD


→ 4WD




5 – 10 seconds after engine starts or transfer shift control lever switches.

A/C switch and blower fan switch

ON.

about 0 V

*about 0 V

10 – 14 V about 0 V

10 – 14 V about 0 V any time


→ 4WD

Other than above



A/C switch ON and blower fan switch

ON

10 – 14 V

0 – 1 V

Other than above

IG: ON

Voltage varies according to engine speed.

10 – 14 V IG: ON


4WD Control System Check

AIR LOCKING HUB

1) Start engine and shift transfer shift control lever to 2H position.

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

2

, 5.70 Psi)

Special tool

(A) : 09917-47910

3) Connect hose, then start engine and shift transfer shift control lever to 4H or 4L position.

4) Connect vacuum pump gauge to the spindle hose (2) disconnected 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

2

, 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 – 39

Ω


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.

VACUUM SWITCH

1) Disconnect coupler from vacuum switch and check resistance between two terminals of vacuum switch.


Resistance of vacuum switch

: More than 1 M

Ω

2) Connect vacuum pump gauge and apply vacuum more than

40 kPa (0.40 kg/cm

2

, 5.70 Psi), then check resistance between terminals of vacuum switch.


Vacuum switch resistance

: Less than 0.8

Ω

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.


CHECK VALVE

1) 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.


Shock Absorber and/or Coil Spring Check

1) Inspect shock absorber for oil leakage. If shock absorber is found faulty, replace 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 rebounding.

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 suspected, compare them with known good vehicle or shock absorber.

3) Inspect for damage or deformation.

4) Inspect for cracks or deformation in spring seat.

5) Inspect for deterioration of bump stopper.

6) Inspect shock absorber mount for wear, cracks or deformation.Replace any parts found defective in steps 2) – 6).

Leading Arm / Lateral Rod / Steering Knuckle

Check

Inspect for cracks, deformation or damage.


Leading Arm Bushing / Lateral Rod Bushing

Check

Inspect for damage, wear or deterioration.


Kingpin / Kingpin Bearing Check

1) Inspect for wear or deterioration.

2) Inspect for crack, damage or deformation of kingpin.


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 spindle 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

0 mm (no play)

Service Limit

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 damping effect decreases and thus make the front wheel develop a tendency to “shimmy” not only that road dust begins to creep into the sliding clearance to promote the wear of the spherical sliding surfaces.

Check the knuckle seal for wear or damage. If defective, replace with new one.


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.


Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-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.



Stabilizer Bar / Bushings

REMOVAL

1) Hoist vehicle.

2) Remove front bumper.

3) Disconnect stabilizer ball joints (right & left) (1) from front axle housing (2).

4) Remove stabilizer bar mount bush bracket bolts (1).

5) Remove stabilizer bar with its ball joint.

6) Disconnect stabilizer ball joints (right & left) from its bar.

INSTALLATION

1) Connect stabilizer ball joints (right & left) to its bar.


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 condition.


Stabilizer mount bracket bolts

(a) : 20 N·m (2.0 kg-m, 14.5 lb-ft)

Stabilizer ball joint nuts

(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

4) Install front bumper.

5) Lower hoist.

3. Stabilizer ball joint



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 “Vehicle Lifting Points” in Section 0A.

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, noting the followings.

• As shown in figure, install washer (4) and bush (5) first and after tightening absorber nut (3) tighten lock nut (2) to specified torque.


Shock absorber lock nut

(a) : 29 N·m (2.9 kg-m, 21.0 lb-ft)

• Install absorber lower mounting bolt (6) in proper direction as shown in the figure and tighten it with no load applied to axle housing.


Shock absorber lower nut

(b) : 90 N·m (9.0 kg-m, 65.0 lb-ft)

• 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 Spring

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.


4) Support front axle housing by using floor jack.

NOTE:

When supporting axle housing, it should be in non-load condition.


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, noting the followings.

1) Install coil spring (3).

NOTE:

• Make sure that coil spring direction as shown.

• When seating coil spring, mate spring end with stepped part (4) of lower spring seat (2).


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.


Brake caliper carrier bolts

(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)

4) Connect stabilizer ball joint to axle housing and tighten nut referring to “Stabilizer Bar” in this section for tightening torque specification.


5) Install wheel and tighten wheel nuts to specified torque.


Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

6) Lower hoist.

7) Confirm front end (wheel) alignment, referring to “Preliminary 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


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).


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 and wheel spindle thrust washer.

c) Uncaulk front wheel bearing lock nut.

1. Wheel hub


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.

1. Sensor rotor

2. Wheel hub

3. Vise

4. Flat end rod

10) Remove wheel bearing oil seal and circlip.


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 serrations 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 (3) until 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


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:

• 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).

• 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 turning wheel hub by hand.

Special tool

(A) : 09944-77020 (For 4WD)

(A) : 09951-16050 (For 2WD)


Wheel bearing lock nut

(a) : 220 N·m (22.0 kg-m, 160 lb-ft)

11) Install hub cap (for 2WD model) or air locking hub assembly

(for 4WD model) as follows.


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.


Wheel bearing lock washer screw

(a) : 1.5 N·m (0.15 kg-m, 1.0 lb-ft)

b) Remove grease, old sealant and dusts from mating surfaces 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:

• When installing hub cap (1), hammer lightly several locations on the collar of cap until collar comes closely into contact with wheel hub (2).

• 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


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 wheel hub and tighten bolts to specified torque.


Air locking hub bolts

(a) : 48 N·m (4.8 kg-m, 35.0 lb-ft)

12) Install ABS wheel sensor (if equipped with ABS).

13) Install brake disc and caliper assembly.

Tighten carrier bolts to specified torque.



(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)

14) Install wheel and tighten wheel nuts specified torque.


Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

15) Lower hoist.

16) For 4WD model:

Check air locking hub for air leakage, refer to “4WD System

Check” in this section.


Steering Knuckle / Wheel Spindle

REMOVAL


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 disconnect 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.


7) Remove lower and upper kingpins (1).

NOTE:

Upper and lower kingpins (1), when removed, must be marked off one from the other.

8) Remove steering knuckle (1).

NOTE:

• When steering knuckle (1) is pulled, lower kingpin bearing sometimes falls off. So remove bearing while pulling off the knuckle gradually.

• 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


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 kingpin bolts to specified torque.


Kingpin bolts

(a) : 25 N·m (2.5 kg-m, 18.0 lb-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.


Knuckle seal cover bolts

(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)

4. Steering knuckle 5. Split part


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 mating 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.


Wheel spindle bolts

(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)


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.



Wheel nuts

: 95 N·m (9.5 kg-m, 69.0 lb-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).



5) Remove oil seal (1) from axle housing (for 4WD).

6) Drain out kingpin bearing outer race (1) from front axle housing (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


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.


2) Apply grease to oil seal 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).


Knuckle seal cover bolts

(a) : 10 N·m (1.0 kg-m, 7.5 lb-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.


Lateral rod bolt and nut

(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)

[A] : Right hand steering vehicle

[B] : Left hand steering vehicle


Leading Arm / Bushing

REMOVAL

1) Hoist vehicle.

2) Remove air locking hub vacuum pipe clamp bolts (2) (for

4WD).

1. Leading arm (right side)


4) Remove shock absorber lower mounting bolt, refer to “Front

Shock Absorber” in this 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


INSTALLATION

1) Install bushings (1) by using hydraulic press and special tools, noting the following point.

• 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).


Vacuum pipe clamp bolts

(b) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)

5) Lower hoist and with vehicle in non-loaded condition, tighten nuts of leading arm to specified torque.


Leading arm nuts

(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)

2. Vacuum hose

3. Body outside

[A] : Front

[B] : Rear


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&L) and suspend caliper.

CAUTION:


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&L) with special tool.

Special tool

(A) : 09913-65210


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 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).


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.


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 & 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 as shown in figure. At this time, mount nuts (3) but don’t tighten them.


3) Install air locking hub vacuum pipe and tighten clamp bolts to specified torque (for 4WD).


Vacuum pipe clamp bolts

(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-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).


Front differential carrier bolts

(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

8) Install front propeller shaft (1) to joint flange aligning match marks (3) and torque flange bolts to specification (for 4WD).


Front propeller shaft flange bolts

(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)


9) Install right and left axle shafts to axle housing (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&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.



(a) : 85 N·m (8.5 kg-m, 61.5 lb-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&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 Ib-ft) and remove it. Then tighten new nut to specified torque.


Tie rod end nuts and drag rod end nut (Knuckle side)

(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)

15) Install wheels and tighten wheel nuts to specified torque.


Wheel nuts

: 95 N·m (9.5 kg-m, 69.0 lb-ft)

16) Lower hoist.


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 and in non loaded condition.



(a) : 90 N·m (9.0 kg-m, 65.0 lb-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.


Shock absorber lower nuts and leading arm nuts

(a) : 90 N·m (9.0 kg-m, 65.0 lb-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.


Fastening part

Stabilizer mount bracket bolt

Stabilizer ball joint nut

Shock absorber lock nut

Shock absorber lower nut

Brake caliper carrier bolt

Wheel bearing lock nut

Wheel bearing lock washer screw

Air locking hub bolt

Wheel spindle bolt

Kingpin bolt

Knuckle seal cover bolt

Tie-rod end nut

Drag-rod end nut (Knuckle side)

Lateral rod bolt and nut

Leading arm nut

Front differential carrier bolt

Front propeller shaft flange bolt

Wheel nut

Vacuum pipe clamp bolt


220

1.5

48

50

25

10

N•m

20

50

29

90

85

43


2.0

5.0

2.9

9.0

8.5

22.0

0.15

4.8

5.0

2.5

1.0

4.3

160.0

1.0

35.0

36.5

18.0

7.5

lb-ft

14.5

36.5

21.0

65.0

61.5

31.5

90

23

50

95

5.5

9.0

2.3

5.0

9.5

0.55

65.0

17.0

36.5

69.0

4.0

Material

Lithium grease

Sealant

Sealing compound



(Part Number)

SUZUKI SUPER GREASE (A)

(99000-25010)

SUZUKI SUPER GREASE (C)

(99000-25030)


(99000-31110)

SUZUKI SEALING COMPOUND

366E

(99000-31090)

Use

• Knuckle seal / axle shaft oil seal

• Recess of wheel spindles

• Wheel hub oil seal

• Wheel bearing

• Spindle thrust washer

• Spindle bush (inside and flange part)

• Spindle oil seal

• Kingpin bearing

• Axle shaft joint (for 4WD)

• Mating surfaces of wheel spindle and knuckle

• Mating surface of differential carrier and axle housing

• Mating surface of wheel spindle and knuckle

• Kingpin

• Mating surfaces of hub cap and wheel hub

Special Tool


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 09942-15510

Bearing installer handle Sliding hammer

09943-35511 or 09943-

35512

Brake drum remover

09944-66010

Wheel hub / knuckle oil seal installer

09944-68510

Bearing installer attachment

09951-16050

Wheel bearing tightening tool

09944-77020

Ring nut wrench

09944-78210 09917-88210

Bearing installer support Valve guide installer attachment

09916-58210

Valve guide installer handle

09922-55131

Bearing installer


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 Section 0A.

NOTE:

• 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 specified during reassembly to assure proper retention of this part.

• Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage to the part may result.

CONTENTS

3E

8A

8B

8A

8B

8C

8D

8E

6F1

6F2

6G

1A

6K

7A

7A1

7B1

General Description ....................................... 3E-2

Diagnosis ........................................................ 3E-3

Diagnosis Table ........................................... 3E-3

Rear Shock Absorber Check........................ 3E-3

Trailing Arm, Lateral Rod, Axle Housing and Coil Spring Check ................................. 3E-3

Trailing Arm and Lateral Rod Bush Check ... 3E-3

Rear Suspension Fasteners......................... 3E-4

Bearing Retainer and Axle Shaft Oil Seal

Check ........................................................... 3E-4

Bump Stopper and Spring Rubber Seat

Check ........................................................... 3E-4

Wheel Disc, Nut and Bearing Check ............ 3E-4

On-Vehicle Service ........................................ 3E-5

Rear Shock Absorber................................... 3E-5

Coil Spring ................................................... 3E-6

Bump Stopper .............................................. 3E-9

Lateral Rod .................................................. 3E-9

Trailing Arm / Bushing................................ 3E-10

Rear Axle Shaft and Wheel Bearing .......... 3E-12

Rear Axle Shaft Inner Oil Seal ................... 3E-17

Rear Axle Housing ..................................... 3E-18

Tightening Torque Specifications .............. 3E-22

Required Service Materials ......................... 3E-22

Special Tools................................................ 3E-23

9

10

10A

10B

3E-2 REAR SUSPENSION


1. Rear axle housing

2. Rear wheel bearing

3. Bearing retainer ring

4. Bearing oil seal

5. Oil seal protector

6. Lateral rod

7. Brake drum

8. Rear axle shaft

9. Shock absorber

10. Bump stopper

11. Coil spring

12. Trailing arm


Diagnosis

Diagnosis Table


Rear Shock Absorber Check

• Inspect for deformation or damage.

• Inspect bushings for wear or damage.

• Inspect for evidence of oil leakage.

Replace any defective part.

WARNING:

When handling rear shock absorber in which high-pressure gas is sealed, make sure to observe the following precautions.

• Don’t disassemble it.

• Don’t put it into the fire.

• Don’t store it where it gets hot.

• 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.

• The gas itself is harmless but it may issue out of the hole together with chips generated by the drill. Therefore, 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.


Rear Suspension Fasteners

Check each bolt and nut fastening suspension parts for tightness.

Tighten loose one, if any, to specified torque, referring to “Tightening Torque Specifications” of this section.

Bearing Retainer and Axle Shaft Oil Seal

Check

• When brake drum has been removed, check inside of brake drum for gear oil leakage.

• Also, check backside of brake back plate for oil leakage.If oil leakage is found, replace defective oil seal.

• Whenever it is possible 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

• Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced.

• Check wheel hub nuts for tightness and, as necessary, retighten to specification.


Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)


• 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.)

• By rotating wheel actually, check wheel bearing for noise and smooth rotation. If it is defective, replace bearing.


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 jack (2) to prevent it from lowering.


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 nonloaded condition.


Shock absorber upper and lower bolts

(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)

Coil Spring

REMOVAL


2) Support rear axle housing (1) by using floor jack (2).

3) Remove brake flexible hose E-ring (2).

1. Brake flexible hose



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).

7) Remove spring rubber seat (1).


INSTALLATION

1) Install spring rubber seat (1).

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.

NOTE:

• Upper and lower diameters of coil spring (2) are different.

Bring larger diameter end at bottom and set its open end in place on spring seat (1).

• 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.



Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

6) Lower hoist and tighten absorber lower bolt (2) to specified torque.


Shock absorber lower bolt

(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)

NOTE:

For tightening of lower bolt (2), refer to NOTE given under

“Shock Absorber” in this section.


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 special tool.

Special tool

(A) : 09941-66010


Bump stopper

(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)



Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

3) Lower hoist.

Lateral Rod

REMOVAL

1) Hoist vehicle.

2) Remove lateral rod mounting bolt (2) and nut (3).



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.



(a) : 90 N·m (9.0 kg-m, 65.0 lb-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).


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

• 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


• Install 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.


Trailing arm nuts

(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)

Rear Axle Shaft and Wheel Bearing

REMOVAL


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.


4) Remove wheel speed sensor (4) from rear axle housing (if equipped with ABS).

CAUTION:

• Do not pull wire harness or twist more than necessary when removing rear wheel speed sensor (4).

• Do not cause damage to surface of rear wheel speed sensor (4) or pole piece and do not allow dust, etc. to 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).


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).


INSTALLATION

Install removed parts in reverse order of removal procedure, noting the following.

1) Aligning serrations between new stud bolt(s) (1) and 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:

• Use care not to cause any damage to outside of retainer ring (2).

• 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


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).


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.


Brake pipe flare nut

(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)

9) Tighten wheel speed sensor bolt to specified torque (if equipped with ABS).


Wheel speed sensor bolt

(c) : 10 N·m (1.0 kg-m, 7.5 lb-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.)



Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.5 lb-ft)


16) Upon completion of all jobs, depress brake pedal with about

30 kg (66 lbs) 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

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:

• Make sure that oil seal (1) is free from inclination as it is installed.

• 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


Rear Axle Housing

REMOVAL

1) Hoist vehicle and remove wheels.

2) Remove rear axle shaft, refer to “Rear Axle Shaft and Wheel


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).



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 following.

1) Place rear axle housing (1) on floor jack. Then install trailing arm (2) rear mounting bolts (right & 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 & left) on spring seat (1) of axle housing and raise axle housing.

NOTE:

• Upper and lower diameters of coil spring (2) are different. Bring larger diameter end at bottom and set its open end in place on spring seat (1).

• 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 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 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.


Rear differential carrier bolts

(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

7) Install propeller shaft (2) to joint flange aligning match marks

(1) and tighten flange bolts to specified torque.


Rear propeller shaft bolts

(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

8) Install LSPV stay to axle housing and adjust LSPV stay position, referring to “LSPV Assembly Inspection and Adjustment” 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.


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.



(a) : 16 N·m (1.6 kg-m, 11.5 lb-ft)

13) Clean mating surface of axle housing (2) (right & left) with brake back plate and apply sealant as shown.

“B” : Sealant 99000-31090

14) Apply grease to axle shaft oil seals lip (1) (right & 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


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 vehicle is off hoist and in non loaded condition.


Trailing arm nuts and lateral rod bolt and nut

(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)

Shock absorber lower bolts

(b) : 85 N·m (8.5 kg-m, 61.5 lb-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



Fastening portion

Shock absorber upper and lower bolt

Bump stopper

Lateral rod bolt and nut

Trailing arm nut (Front and Rear)

Brake back plate nut

Brake pipe flare nut

Rear differential carrier bolt

Rear propeller shaft bolt (Differential case side)

Rear propeller shaft bolt (Shaft No.3 transfer case side)

Wheel nut

Wheel speed sensor bolt and harness clamp bolt

N•m

85

50

90

23

16

23

50

33

95

10


8.5

5.0

9.0

2.3

1.6

2.3

5.0

3.3

9.5

1.0

lb-ft

61.5

36.5

65.0

17.0

11.5

17.0

36.5

24.0

69.0

7.5


Material

Lithium grease

Sealant

Water tight sealant

Gear oil


(Part Number)

SUZUKI SUPER GREASE A

(99000-25010)


(99000-31110)


(99000-31090)

For gear oil information, refer to “Maintenance Service” in Section 7E of this manual.

Oil seal lip

Use

• Joint seam of differential carrier and axle housing

• To apply to mating surfaces of brake back plate and rear axle.

Differential gear

(Rear axle housing)

Special Tools


09913-75520

Bearing installer

09913-85210

Oil seal installer

09924-74510 1) 09927-18411

Universal puller

Bearing installer handle 2) 09921-57810

Bearing remover

09941-66010 09942-15510

Bump stopper wrench 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


WHEELS AND TIRES 3F-1

SECTION 3F

WHEELS AND TIRES

6F1

6F2

6G

NOTE:

All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts.

There is to be no welding as it may result in extensive damage and weakening of the metal.

CONTENTS

General Description ........................................ 3F-2

Tires .............................................................. 3F-2

Wheels .......................................................... 3F-2

Replacement Tires ........................................ 3F-2

Replacement Wheels ................................ 3F-3

How To Measure Wheel Runout ............... 3F-3

Metric Lug Nuts and Wheel Studs............. 3F-3

Diagnosis ......................................................... 3F-4

Diagnosis Table ............................................ 3F-4

Balancing Wheels ......................................... 3F-4

General Balance Procedure .......................... 3F-4

Off-vehicle balancing................................. 3F-4

On-vehicle balancing................................. 3F-4

Maintenance and Minor Adjustments ........... 3F-6

Wheel and Tire.............................................. 3F-6

Studs ......................................................... 3F-6

Matched tires and wheels

(For vehicle equipped with steel wheels)...................................................... 3F-6

Inflation of Tires ............................................ 3F-6

Tire placard ............................................... 3F-7

Tire rotation ............................................... 3F-7

On-Vehicle Service ......................................... 3F-8

Wheel............................................................ 3F-8

Tire ................................................................ 3F-9

Mounting and demounting......................... 3F-9

Repair........................................................ 3F-9

3F

8A

8B

8C

8B

8C

8D

8E

9

10

10A

10B

3F-2 WHEELS AND TIRES


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, because 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

160

180

200

220

240

260

280

300

320

340 kgf/cm

2

2.4

2.6

2.8

3.0

1.6

1.8

2.0

2.2

3.2

3.4

psi

35

38

41

44

23

26

29

32

47

50


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 / odometer calibration, ground clearance to the body and chassis.

How To Measure Wheel Runout

To measure 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 measurement.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 correction 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


Diagnosis

Diagnosis Table


Balancing Wheels

There are two types of wheel and tire balance: static and 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

2. Balance weights addition point

3. C/L of spindle

[A] : Before correction

[B] : Corrective weights

Dynamic balance, 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

2. Balance weights addition point

3. C/L of spindle

[C] : Before correction

[D] : Corrective weights

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 manufacturer’s recommendation.

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 onvehicle 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 manufacturer’s instructions during balancing operation.


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 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.


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’s paint dot should be aligned with the tire’s paint dot as shown in left figure.

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 pressure 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.


Lower than Recommended Pressure Can Cause:

1) Tire squeal on turns

2) Hard steering

3) Rapid and uneven wear 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

To equalize wear, rotate tires according to left figure. Radial tires 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.

[A] : RH steering vehicle

[B] : LH steering vehicle

F : Front



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 corrosion on wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing 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”


Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)


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 specified 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 materials 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.


PROPELLER SHAFTS 4B-1

SECTION 4B

PROPELLER SHAFTS

NOTE:

• 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 specified during reassembly to assure proper retention of this part.

• Never attempt to heat, quench or straighten any propeller shaft part. Replace it with a new part, or damage to the part may result.

4B

8D

8E

7A

7A1

7B1

7C1

7D

CONTENTS

9


Components ................................................. 4B-2

Diagnosis ........................................................ 4B-2

Diagnosis Table ........................................... 4B-2

Propeller Shaft Joint Check.......................... 4B-2

On-Vehicle Service......................................... 4B-3

Propeller Shafts ........................................... 4B-3

Universal Joint ............................................. 4B-5

Tightening Torque Specification .................. 4B-7

Required Service Material ............................. 4B-7

Special Tool.................................................... 4B-8

8E

9

10

10A

10B

6F1

6F2

6G

6H

6K

4B-2 PROPELLER SHAFTS

Components


1. Propeller shaft No.1



Tightening Torque

Diagnosis Table

Condition

Abnormal noise

Vibration

Diagnosis

Possible Cause

• Loose universal joint bolt.

• Spider bearing worn out or stuck.

• Wear spider.

• Performed propeller shaft.

Correction

Tighten universal joint bolt.

Replace.

Replace propeller shaft.

Replace.

Propeller Shaft Joint Check

If universal joints are suspected of producing chattering or rattling noise, inspect them for wear. Check to see if cross spider rattles in yokes or if splines are worn down and replace defective propeller 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

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) 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.)


INSTALLATION

Install propeller shaft(s) reversing removal procedure noting following points :

• When installing propeller shaft, align the match marks.

Otherwise, vibration may occur during driving.

• Use following specification to torque universal joint flange.


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 lb-ft)

Propeller shaft bolt (propeller shaft No.3 transfer case side)

(b) : 33 N·m (3.3 kg-m, 24 lb-ft)

NOTE:

If transmission oil was drained for front propeller shaft removal, pour specified gear oil into transmission case to specified level.

• Grease splines of propeller shaft No. 2 and No. 3.

“A” : Chassis Grease 99000-25030

• Match marks (1) are provided on slip-on spline connections of propeller shaft No. 2 and No. 3. Inserting splined end into spIined bore without regard to match marks can be a possible cause of noise or vibration of propeller shaft. Be sure to index marks.


Universal Joint

DISASSEMBLY

1) Using special tool, remove 4 circlips (1).

Special tool

(A) : 09900-06108

2) Apply penetrate lubricant between bearing race outer diameter and shaft yoke bore.

3) Using a set of special tool, push spider bearing race (1) out

3 – 4 mm (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.


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. Otherwise 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 rollers in race from coming out, insert bearing race (2) into shaft yoke (3) until it is flush with side face of shaft yoke (3), tapping it by a copper hammer (1).


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 diameter 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:

• After reassembly, ensure that both shaft yoke and flange yoke move smoothly.

• Make sure that each circlip is fitted in groove securely.


Fastening portion

Propeller shaft bolt (propeller shaft No.1 No.2 and No.3 rear differential side)

Propeller shaft bolt (propeller shaft No.3 transfer case side)

N•m

50

33


5.0

3.3

lb-ft

36.5

24

Material

Lithium grease



(Part Number)

SUPER GREASE C

(99000-25030)

Use

• To apply to spider bearing race and propeller shaft No.2 and No.3 splines.


Special Tool

09900-06108

Snap ring pliers (Closing type)

09926-48010

Universal joint disassembling tool set

BRAKES 5-1

SECTION 5

BRAKES

WARNING:

For lifting point of vehicle, refer to Section 0A.

WARNING:

For vehicles equipped with Supplement Restraint (Air Bag) System:





5

7A

7A1

7B1

7C1

7D

7E

9

10

10A

10B

9

6F1

6F2

6G

6H

6K

NOTE:

• When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E first.

• All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

10

10A

10B

CONTENTS

General Description ......................................... 5-3

Diagnosis .......................................................... 5-4

Road Testing Brakes...................................... 5-4

Brake Fluid Leaks .......................................... 5-4

Substandard or Contaminated Brake Fluid .... 5-4

Diagnosis Table ............................................. 5-5

Brake Pedal Free Height Adjustment ............. 5-8

Brake Pedal Play Check ................................ 5-8

Stop Light Switch Adjustment ........................ 5-8

Excessive Pedal Travel Check....................... 5-9

Front Brake Disc Check ................................. 5-9

Front Brake Pad Check .................................. 5-9

Rear Brake Shoe Check .............................. 5-10

Master Cylinder and Brake Fluid Level

Check ........................................................... 5-10

Rear Drum Brake Shoe Adjustment ............. 5-11

Parking Brake Inspection and Adjustment ... 5-11

Booster Operation Check ............................. 5-12

Fluid Pressure Test

(If Equipped with LSPV)............................... 5-15

On-Vehicle Service ........................................ 5-17

Air Bleeding of Brake System ...................... 5-17

Brake Hose and Pipe Inspection.................. 5-18

Front Disc Brake .......................................... 5-19

Brake pad................................................. 5-20

Caliper assembly...................................... 5-22

Brake Disc.................................................... 5-26

Rear Brake ................................................... 5-29

Brake drum............................................... 5-29

Brake shoe ............................................... 5-32

Wheel Cylinder............................................. 5-33

Brake back plate ...................................... 5-34

Master Cylinder .............................................. 5-36

Master Cylinder Reservoir ........................... 5-36

Master Cylinder Assembly ........................... 5-37

5-2 BRAKES

Master Cylinder............................................ 5-38

Fill Reservoir ................................................ 5-40

LSPV (Load Sensing Proportioning Valve)

Assembly (If Equipped) ................................. 5-42

LSPV Assembly ........................................... 5-43

P (Proportioning) Valve ................................. 5-44

Brake Booster ................................................ 5-45

Inspection and adjustment ....................... 5-46

Brake Hose/Pipe .......................................... 5-48

Front brake hose/pipe ............................... 5-48

Rear Brake Hose/Pipe .................................. 5-51

Parking Brake Lever/Cable........................... 5-52

Parking brake lever ................................... 5-52

Parking Brake Cable ..................................... 5-53

Tightening Torque Specifications................. 5-54

Required Service Material.............................. 5-54

Special Tool .................................................... 5-55

BRAKES 5-3


When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (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 cylinder 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 & 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] : Vehicle without ABS, LSPV

[B] : Vehicle with LSPV

[C] : Vehicle with ABS

1. Master cylinder

2. 5-way joint (4-way joint)

3. LSPV (Load Sensing Proportioning valve)

4. P & B valve

5. P (Proportioning) valve

6. Hydraulic Unit

F: Forward

5-4 BRAKES

Diagnosis

Road Testing 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 leakage. 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 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 evidenced 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.

BRAKES 5-5

Diagnosis Table

Not enough braking force

Condition

Brake pull (Brakes not working in unison)

Possible Cause

Brake oil leakage from brake lines

Brake disc or pads stained with oil

Overheated brakes

Poor contact of shoes on brake drum

Brake shoes linings stained with oil or wet with water

Badly worn brake shoe linings

Defective wheel cylinders

Malfunctioning caliper assembly

Air in system

Maladjusted sensor spring length of LSPV

Broken sensor spring of LSPV

Defective collar of LSPV

Malfunctioning ABS (Antilock brake system), if equipped

Pad or shoe linings are wet with water or stained with oil in some brakes

Drum-to-shoe clearance out of adjustment in some brakes (Malfunctioning auto adjusting mechanism)

Drum is out of round in some brakes

Wheel tires are inflated unequally

Malfunctioning wheel cylinders


Unmatched tires on same axle

Restricted brake tubes or hoses

Malfunctioning caliper assembly

Loose suspension parts

Loose calipers

Correction

Locate leaking point and repair.

Clean or replace.

Determine cause and repair.

Repair for proper contact.

Replace.

Replace.

Repair or replace.

Repair or replace.

Bleed system.

Check or adjust.

Replace.

Replace.

Check system and replace as necessary.

Replace.

Check for inoperative auto adjusting mechanism.

Replace.

Inflate equally.

Repair or replace.

Adjust as prescribed.

Tires with approximately the same amount of tread should be used on the same axle.

Check for soft hoses and damaged lines.

Replace with new hoses and new double-walled steel brake tubing.

Check for stuck or sluggish pistons and proper lubrication of caliper slide bush.

Caliper should slide.

Check all suspension mountings.

Check and torque bolts to specifications.

Replace brake pads.

Noise (high pitched squeak without brake applied)

Rear brake locked prematurely

Front lining worn out

Maladjusted sensor spring length of LSPV

Malfunctioning LSPV assembly

Malfunctioning ABS, if equipped

Brake locked

(For vehicles equipped with ABS)

Check or adjust.

Replace assembly.


5-6 BRAKES

large)

Condition

Excessive pedal travel

(Pedal stroke too

Possible Cause

Partial brake system failure

Insufficient fluid in master cylinder reservoirs

Correction

Check brake systems and repair as necessary.

Fill reservoirs with approved brake fluid.

Check for leaks and air in brake systems.

Check warning light. Bleed system if required.

Dragging brakes (A very light drag is present in all disc brakes immediately after pedal is released)

Air in system (pedal soft/spongy)

Rear brake system not adjusted (malfunctioning auto adjusting mechanism)

Bent brake shoes

Worn rear brake shoes

Bleed system.

Repair auto adjusting mechanism.

Adjust rear brakes.

Replace brake shoes.

Replace brake shoes.

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 adjust to correct specifications.

Weakened or broken return springs in the brake Replace.

Sluggish parking-brake cables or linkage

Wheel cylinder or caliper piston sticking

Malfunctioning ABS, if equipped with ABS

Repair or replace.



Replace wheel bearings.

Pedal pulsation (Pedal pulsates when depressed for braking.)

Damaged or loose wheel bearings

Distorted steering knuckle or rear axle shafts

Excessive disc lateral runout

Replace knuckle or rear axle shaft.

Check per instructions. If not within specifications, replace or machine

Braking noise

Parallelism not within specifications

Rear drums out of round.

the disc.

Check per instructions. If not with specifications, replace or machine the disc.

Check runout.

Repair or replace drum as necessary.

Repair or replace brake shoe.

Glazed shoe linings, or foreign matters stuck to linings

Worn or distorted shoe linings

Loose front wheel bearings

Distorted backing plates or loose mounting bolts

Parking brake applied

Brake warning light turns on after engine start

Insufficient amount of brake fluid

Brake fluid leaking from brake line

Brake warning light circuit faulty

Replace brake shoe (or pad).


Replace or retighten securing bolts.

Release parking brake and check that brake warning light turns off.

Add brake fluid.

Investigate leaky point, correct it and add brake fluid.

Repair circuit.

BRAKES 5-7

Condition

Brake warning light turns on when brake is applied

Brake warning light fails to turn on even when parking brake is applied

ABS warning light does not turn on for 2 sec. after ignition switch has turned ON.

ABS warning light remains on after ignition switch has turned on for 2 sec.

Possible Cause

Brake fluid leaking from brake line

Correction

Investigate leaky point, correct it and add brake fluid.

Insufficient amount of brake fluid Add brake fluid.

Faulty P & Differential valve (Differential switch) Replace.

Bulb burnt out

Brake warning light circuit open

Replace bulb.

Repair circuit.

Bulb burnt out

ABS warning light circuit open, if equipped with

ABS (including check relay)

Malfunctioning ABS, if equipped with ABS

Replace bulb.

Check system referring to “TABLE-

A” in Section 5E.

Check system referring to “TABLE-

B” in Section 5E.

5-8 BRAKES

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 – 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 Adjustment” in this section.)

3) Check stop light switch position. Adjust it if it is out of specification.

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.)


Stop light switch lock nut

(a) : 6.5 N·m (0.65 kg-m, 4.7 lb-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

Ibs) load, measure brake pedal to wall clearance “d” or “e”.

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 possible 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 system, 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 System” 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)

Limit : 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 driving, replenish fluid to MAX level.

When fluid decreases quickly, inspect brake system for leakage.

Correct leaky points and 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 button.

One click sound corresponds to one notch.

5-12 BRAKES

If number of notches is out of specification, adjust cable by referring 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 adjustment.

• No air is trapped in brake system.

• Brake pedal travel is proper.

• Brake pedal has been depressed a few times with about 30 kg (66 Ibs) load.

• Parking brake lever (1) has been pulled up a few times with about 20 kg force.

• 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 brake 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.

• Fuel tank is filled with fuel fully.

• Vehicle is equipped with spare tire, tools, jack and jack handle.

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 lb)

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

5000 kPa

50 kg/cm

2

711 psi

Rear brake

3800 – 5100 kPa

38 – 51 kg/cm

2

540 – 725 psi

As done above, apply 100 kg/cm

2

pressure to front brake and check that rear brake pressure is within specification as given below.

Front brake

10000 kPa

100 kg/cm

2

1422 psi

Rear brake

5100 – 6500 kPa

51 – 65 kg/cm

2

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 stay

“A” to direction “l” 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.


LSPV adjust bolt

(a) : 25 N·m (2.5 kg-m, 18 Ib-ft)

1. LSPV lever

2. LSPV spring

3. LSPV stay

5) Disconnect brake pipe (2) (connecting between master cylinder 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

2

when front brake pressure is 100 kg/cm

2

, it means that front fail-safe system functions properly.

Front brake

10000 kPa

100 kg/cm

1422 psi

Special tool

(A) : 09956-02210

2

Rear brake

9500 – 10000 kPa

95 – 100 kg/cm

2

1350 – 1422 psi

BRAKES 5-17


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 in all.

Be sure to bleed air of brake system according to following procedure 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.


Front caliper bleeder plug

(b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

Rear wheel cylinder and LSPV bleeder plug

(c) : 8 N·m (0.8 kg-m, 6.0 lb-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 mirror may be needed for an adequate inspection. 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.

1. Caliper pin bolt

2. Boot

3. Cylinder slide bush

: Apply rubber grease to mating surface of caliper

4. Bleeder plug cap

5. Bleeder plug

6. Anti noise shim

7. Disc brake piston

: Apply brake fluid to contact surface of cylinder

8. Cylinder boot

9. Seat ring (boot ring)

10. Carrier bolt

11. Brake caliper carrier

12. Pad clip

13. Disc brake caliper

14. Disc brake pad

15. Piston seal

: Apply brake fluid to all around part of piston seal

Tightening torque

Do not reuse.

5-20 BRAKES

Brake pad

REMOVAL


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) removed.

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 polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining 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.


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.


Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

4) Upon completion of installation, perform brake test.

5-22 BRAKES

Caliper assembly

REMOVAL


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.

DISASSEMBLY

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 fingers 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.

5-24 BRAKES

ASSEMBLY

CAUTION:

• Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir.

• Never use other fluid or thinner.

• 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, damage, 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.


Front caliper bleeder plug

(a) : 11 N·m (1.1 g-m, 8.0 lb-ft)


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 fingers.

6) Insert 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 cylinder’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.


Brake caliper pin bolts

(a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)

5-26 BRAKES

3) Install brake flexible hose (4) as shown and torque hose mounting bolt (3) to specification.


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


2) Remove caliper assembly by loosening carrier bolts (2 pcs).

CAUTION:


3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).

BRAKES 5-27

INSPECTION

Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replacement are normal and disc is not defective unless they are serious.

But when there are deep scratches or scratches all over disc surface, replace it. When only one side is scratched, polish and correct 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 measurement.

INSTALLATION

NOTE:


1) Install disc to wheel hub.

2) Install caliper assembly to steering knuckle.

3) Torque caliper carrier bolts to specification.



(a) : 85 N·m (8.5 kg-m, 61.5 lb-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.

• Jack up front wheels, both right and left, off the ground.

• Shift transfer shift lever to 2H (rear wheel) position (if equipped) and start engine for a few seconds then stop.

• Side figure shows outer periphery of tire.

• Be careful not to depress brake pedal when checking tire for rotation.

If tire rotation is heavy, check the following:

• Piston, piston seal and cylinder slide bush of caliper for installation.

• Wheel bearings for breakage.

• 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

Rear Brake

BRAKES 5-29

1. Brake back plate

2. Brake shoe

3. Spring and rod assembly

4. Parking brake shoe lever

5. Shoe return spring lower

6. Adjuster lever

7. Adjuster spring

8. Shoe hold down spring

9. Shoe hold down pin

10. Wheel cylinder

: Apply brake fluid to piston cap

Tightening torque

Brake drum

REMOVAL

1) Hoist vehicle and pull up parking brake lever.

2) Remove wheel.

3) Release parking brake lever.

4) 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).

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 necessary 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 correct lining, replace it with a new one.

INSTALLATION

NOTE:


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.)


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 lbs) load about 30 times so as to obtain proper drum-to-shoe clearance.

Adjust parking brake cable.



Wheel nuts

(a) : 95 N·m (9.5 kg-m, 69.0 lb-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 section.

2) Remove shoe return spring lower (3), spring and rod assembly (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.

3) Remove parking brake shoe lever (5) from brake back plate.

INSPECT

• Inspect lever for free movement against brake shoe web. If defective, correct or replace.

• Inspect ratchet or thread rod part for wear, sticking and corrosion.

• Inspect for damage or weakening.

• 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.


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 section.

3. Shoe return spring lower


5. Adjuster lever

6. Adjuster spring

Wheel Cylinder

REMOVAL


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 cylinder disassembled parts for wear, cracks, corrosion 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 connected in step 1) to specification.


Wheel cylinder mounting bolts

(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)


(b) : 16 N·m (1.6 kg-m, 11.5 lb-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 section.

NOTE:

Be sure to bleed brake system.

Brake back plate

REMOVAL


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 parking 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 plate.

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).

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:


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:

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:



4) Remove master cylinder attaching nuts (5).

5) Remove master cylinder (3).

For vehicle equipped with P & B valve (6), remove master cylinder (3) with P & B valve (6) and its bracket, then separate P & B valve (6) from master cylinder (3).

2. Reservoir

5-38 BRAKES

INSTALLATION

NOTE:

• See NOTE at the beginning of this section.

• Check clearance between booster piston rod and primary.

1) Install master cylinder as shown and torque attaching nuts to specification.


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.


Brake pipe flare nuts

(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)

3) Connect reservoir lead wire.

4) Fill reservoir with specified brake fluid.

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

[A] : For vehicle without ABS

[B] : For vehicle with ABS

1. Piston stopper circlip

2. Piston stopper

3. Cylinder cup and plate

: Apply brake fluid confirm installing direction.

4. Primary piston

5. Piston cup


6. Secondary piston pressure cup


7. Piston cup


8. Secondary piston

9. Sealing


10. Secondary piston return spring

11. Secondary piston stopper bolt

12. Master cylinder body

Tightening Torque

Do not reuse

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 flange with a piece of wood or something soft.

4) [For vehicle without ABS]

Remove piston stopper bolt (1). Then remove secondary piston by blowing compressed air (2) into hole from which piston stopper bolt was removed.

Be cautions during removal as secondary piston jumps out.

INSPECTION

• Inspect all disassembled parts for wear or damage, and replace parts if necessary.

NOTE:

• Wash disassembled parts with brake fluid.

• Do not reuse piston cups.

• 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

• 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:


• Before assembling, wash each part in fluid recommended 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 specified torque (For vehicle without ABS).


Piston stopper bolt

(a) : 10 N·m (1.0 kg-m, 7.5 lb-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. Mineral 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 containers capped to prevent contamination.

BRAKES 5-41

Fluid to fill reservoir with is indicated on reservoir cap of that vehicle 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:


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 bolt and nut to specification as indicated respectively.


LSPV bolts

(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)


(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)

2) Upon completion of installation, fill reservoir tank with specified fluid and bleed air from brake system.

NOTE:

Make sure to bleed air from LSPV bleeder without fail.


LSPV bleeder plug

(a) : 8 N·m (8.0 kg-m, 6.0 lb-ft)

3) After bleeding air, check that LSPV is installed properly, referring to following INSPECTION & ADJUSTMENT.

BRAKES 5-43

LSPV Assembly

INSPECTION AND ADJUSTMENT

1) Confirm the following before inspection and adjustment.

• Fuel tank is filled with fuel fully.

• Vehicle is equipped with spare tire, tools, jack and jack handle.

• Vehicle is free from any other load.

• Place it on level floor.

2) Push up LSPV lever with finger till it stops and measure length of coil spring (“a” in figure).

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.


LSPV adjust bolt

(a) : 25 N·m (2.5 kg-m, 18.0 lb-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) Valve

REMOVAL

CAUTION:


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).


P valve bolts

(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

2) Tighten flare nuts to specified torque.



(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)

3) Fill reservoir with specified brake fluid.

4) Bleed air from system.

1. Flare nuts

Brake Booster

BRAKES 5-45

1. Brake master cylinder assembly

2. Brake booster assembly

3. Gasket

4. Push rod clevis

5. Nut

6. Clevis pin

7. Clip

8. Nut

9. Brake vacuum hose

Tightening torque

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 Cylinder” 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) Remove attaching nuts (6) and then booster as shown.

1. Steering column

2. Push rod clevis

5. Clip

INSTALLATION

NOTE:


• Check length of push rod clevis and adjust clearance between booster piston rod and master cylinder piston. Refer to “Brake Booster Inspection and Adjustment” in this section

• Apply silicone grease to master cylinder piston.

1) 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).

2) Tighter booster attaching nuts to the specified 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.


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 specified clearance “a” between 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 measurement.

• Remove piston (push) rod seal from booster, if equipped.

1) 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



F : Front side

R : Right side

T : Top side

V : View V

W : View W

X : View X

Y : View Y

Z : View Z

1. E-ring

2. Flexible hose

3. Hose washer

4. Hose bolt

5. Brake caliper

6. 4 way joint

7. 5 way joint

8. ABS hydraulic unit/control module assembly

9. P valve

10. Hose bracket

11. To front right brake caliper

12. To front left brake caliper

13. To rear brake a-d: Clamp

Tightening torque

For right-hand steering vehicle

BRAKES 5-49



F : Front side

R : Right side

T : Top side

V : View V

W : View W

X : View X

Y : View Y

Z : View Z

1. E-ring

2. Flexible hose

3. Hose washer

4. Hose bolt

5. Brake caliper

6. 4 way joint

7. 5 way joint

8. ABS hydraulic unit

9. P valve

10. Hose bracket

11. To front right brake caliper

12. To front left brake caliper

13. To rear brake

14. Front brake master cylinder a-f: Clamp

Tightening torque

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 and 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:

• Position clamps to white marks on two brake pipes.

• Be sure to obtain more than 3 mm (0.118 in.) clearance between axle housing and brake pipe.

• Install clamps properly referring to figure below and tighten bolts.

• When installing hose, make sure that it has no twist or kink.

T : Top side

R : Right side

1. Clamp

2. Rear axle housing

3. Rear wheel cylinder

4. LSPV (if equipped)

5. Fuel tank

6. Chassis frame

7. Fuel pipe

8. Brake pipe (vehicle with LSPV) a-b: Clamp

Tightening torque

5-52 BRAKES

Parking Brake Lever/Cable

Parking brake lever

REMOVAL

1) Hoist vehicle and release parking brake lever.


3) Remove parking brake lever cover.

4) Disconnect lead wire of 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


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 Adjustment” 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.

• Install clamps properly referring to figure below.

• 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 from hoist, brake test should be performed.

E : View E

G : View G

H : View H

J : View J

K : View K

1. Bracket

2. Floor

3. Cross member

4. Clamp

Tightening torque

5-54 BRAKES


Fastening part

Brake caliper carrier bolt

Brake caliper pin bolt

Front brake flexible hose bolt

Rear brake back plate nut

Master cylinder nut

Booster nut

Brake pipe 5-way 4-way joint bolt

Brake pipe flare nut

LSPV bolt/P valve bolt

Brake bleeder plug

Front caliper

Rear wheel cylinder, LSPV

Wheel nut

Hose bracket bolt

Booster clevis nut

Stop light switch lock nut

Parking brake lever bolt

Wheel cylinder mounting bolt

Piston stopper bolt

LSPV adjust bolt

13

11

16

25

11

8

N•m

85

22

23

23

13

95

11

25

6.5

23

9

10

25


8.5

2.2

2.3

2.3

1.3

1.3

1.1

1.6

2.5

1.1

0.8

9.5

1.1

2.5

0.65

2.3

0.9

1.0

2.5

9.5

8.0

12.0

18.0

8.0

6.0

lb-ft

61.5

16.0

17.0

17.0

9.5

69.0

8.0

18.0

4.7

17.0

6.5

7.5

18.0

Material

Brake fluid

Water tight sealant

Sealant


Recommended SUZUKI products

Indicated on reservoir tank cap or described in owner’s manual of vehicle


99000-31090


99000-31110

Use

• To fill master cylinder reservoir.

• To clean and apply to inner parts of master cylinder caliper and wheel cylinder when they are disassembled.

• To apply to mating surfaces of brake back plate and rear wheel cylinder.

• 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.

BRAKES 5-55

Special Tool

09900-20205 09900-20602 09900-20701

Micrometer (0 – 25 mm) Dial gauge (1/1000 mm) Magnetic stand

09956-02210

Brake circuit plug

09922-85811

Connector pin remover

09942-15510

Sliding hammer

09943-35511

Brake drum remover

(Front wheel hub remover)

09950-78220

Flare nut wrench (10 mm)

09950-96010 09952-16010

Booster piston rod gauge Booster piston rod adjuster

09956-02310

Fluid pressure gauge

5-56 BRAKES

ANTILOCK BRAKE SYSTEM (ABS) 5E-1

NOTE:

SECTION 5E

ANTILOCK BRAKE SYSTEM (ABS)

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 extensive damage and weakening of the metal.

CONTENTS


System Schematic ....................................... 5E-3

ABS Component Parts Location .................. 5E-4

ABS Control Module..................................... 5E-5

Self-diagnosis function ............................. 5E-5

Fail-safe function ...................................... 5E-5

Diagnosis ........................................................ 5E-6

Precaution in Diagnosing Troubles .............. 5E-6

ABS Diagnostic Flow Table.......................... 5E-6

“ABS” Warning Lamp Check ........................ 5E-9

Diagnostic Trouble Code (DTC) Check........ 5E-9

DTC Check (Using SUZUKI Scan Tool)..... 5E-10

Diagnostic Trouble Code (DTC)

Clearance ................................................... 5E-10

Diagnostic Trouble Code (DTC) Table ....... 5E-11

System Circuit ............................................ 5E-12

Table – A “ABS” Warning Lamp Circuit

Check – Lamp Does Not Come “ON” at Ignition Switch ON.................................. 5E-14

Table – B “ABS” Warning Lamp Circuit

Check – Lamp Comes “ON” Steady........... 5E-15

Table – C “ABS” Warning Lamp Circuit

Check – Lamp Flashes Continuously

While Ignition Switch is ON ........................ 5E-16

Table – D Code (DTC) is Not Outputted

Even With Diag. Switch Terminal

Connected to Ground. ................................ 5E-17

DTC C1015 (DTC 15) – G Sensor

Circuit ......................................................... 5E-18

DTC C1016 (DTC 16) – Stop Lamp

Circuit ......................................................... 5E-20

DTC C1021 (DTC 21), DTC C1022

(DTC 22) – Right Front Wheel Speed

Sensor Circuit............................................. 5E-21

DTC C1025 (DTC 25), DTC C1026

(DTC 26) – Left Front Wheel Speed

Sensor Circuit............................................. 5E-21

DTC C1031 (DTC 31), DTC C1032

(DTC 32) – Right Rear Wheel Speed

Sensor Circuit ............................................ 5E-21

DTC C1035 (DTC 35), DTC C1036

(DTC 36) – Left Rear Wheel Speed

Sensor Circuit ............................................ 5E-21

DTC C1041 (DTC 41), DTC C1042

(DTC 42) – Right Front Solenoid Circuit .... 5E-24

DTC C1045 (DTC 45), DTC C1046

(DTC 46) – Left Front Solenoid Circuit....... 5E-24

DTC C1055 (DTC 55), DTC C1056

(DTC 56) – Rear Solenoid Circuit .............. 5E-24

DTC C1057 (DTC 57) – Power Source

Circuit......................................................... 5E-25

DTC C1061 (DTC 61) – ABS Pump

Motor Circuit............................................... 5E-26

DTC C1063 (DTC 63) – ABS Fail Safe

Circuit......................................................... 5E-27

DTC C1071 (DTC 71) – ABS Control

Module ....................................................... 5E-28

On-Vehicle Service ...................................... 5E-29

Precaution.................................................. 5E-29

ABS Hydraulic Unit Operation Check ........ 5E-29

ABS Hydraulic Unit / Control Module

Assembly ................................................... 5E-30

Front Wheel Speed Sensor........................ 5E-32

Front Wheel Sensor Ring........................... 5E-35

Rear Wheel Speed Sensor ........................ 5E-36

Rear Wheel Sensor Ring ........................... 5E-38

G Sensor.................................................... 5E-39

Tightening Torque Specification ................ 5E-40

Special Tool.................................................. 5E-40

6F1

6F2

6G

6H

6K

7A

7A1

7B1

7C1

7D

7E

7F

8E

5E

9

10

10A

10B

10

10A

10B

5E-2 ANTILOCK BRAKE SYSTEM (ABS)


The ABS (Antilock Brake System) is a system to prevent each wheel to lock during hard braking or braking on a 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 failsafe 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.

1. Front disc brake

2. Proportioning valve

3. Rear drum brake

4. ABS hydraulic unit / control module assembly

5. Brake master cylinder / booster

[A] : For LH steering vehicle

[B] : For RH steering vehicle

System Schematic


INPUT

Wheel speed sensor (RF)

Wheel speed sensor (RR)

Wheel speed sensor (LR)

Wheel speed sensor (LF)

Stop lamp switch

G sensor

Diag. switch terminal

Battery voltage

4WD switch (for 4WD model only)

ABS hydraulic unit/control module assembly

1. Wheel speed sensor (Right front)

2. Stop lamp switch

3. ABS control module

4. Wheel speed sensor (Right rear)

5. Monitor connector

6. ABS lamp driver module

OUTPUT

Pump motor transistor

Fail-safe transistor

Pump motor

ABS control module

LF hold solenoid

LF release solenoid

RF hold solenoid

RF release solenoid

Rear hold solenoid

Rear release solenoid

Idle-up

“ABS” warning lamp

ECM

Data link connector

7. Wheel speed sensor (Left rear)

8. “ABS” warning lamp

9. ABS pump motor transistor

10. ABS solenoid valve transistor


12. Wheel speed sensor (Left front)

13. ABS hydraulic unit

14. G sensor

15. Data link connector


17. 4WD switch (for 4WD model only)


ABS Component Parts Location

1. Wheel speed sensor (Right front)

2. Stop lamp switch


4. Wheel speed sensor (Right rear)

5. Wheel speed sensor (Left rear)



8. Wheel speed sensor (Left front)

9. Wheel speed sensor ring

10. G sensor


[A] : For LH steering vehicle

[B] : For RH steering vehicle


ABS Control Module

Self-diagnosis function

ABS control module diagnoses conditions of the system component 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 seconds.

3) When an abnormality in the system is detected, “ABS” warning 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.

SYSTEM CONDITION

In good condition at present

Abnormality exists at present

No trouble in the past

Trouble occurred in the past

No trouble in the past

Trouble occurred in the past

DIAGNOSIS

SWITCH

TERMINAL

“ABS”

WARNING

LAMP

Open

Grounded

Open

OFF

DTC 12

OFF

Grounded History DTC

Open ON

Grounded Current DTC

Open ON

Grounded

Current and 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.

1. Ignition switch



3-1. Diag. switch terminal

3-2. Ground terminal

4. ABS control module

5. Sensed information

6. Output

7. Lamp driver module

Fail-safe function

When an abnormality occurs (an abnormal DTC is detected),

ABS control module turns OFF the fail-safe transistor which supplies power to ABS hydraulic unit. Thus, with ABS not operating, brakes function just like the brake system of the vehicle without

ABS.


Diagnosis

To ensure that the trouble diagnosis is done accurately and smoothly, observe “Precautions in Diagnosing Troubles” and follow “ABS Diagnostic Flow Table”.

Precaution in Diagnosing Troubles

• If the vehicles was operated in any of the following ways, “ABS” warning lamp may light momentarily but this does not indicate anything abnormal in ABS.

– The vehicle was driven with parking brake pulled.

– The vehicle was driven with brake dragging.

– The vehicle was stuck in mud, sand, etc.

– Wheel spin occurred while driving.

– Wheel(s) was rotated while the vehicle was jacked up.

• Be sure to read “Precautions for Electronic Circuit Service” in Section 0A before inspection and observe what is written there.

• 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

ABS control module during inspection.

ABS Diagnostic Flow Table

Refer to the following for the details of each step.

Step Action

1 Perform customer complaint analysis, problem symptom confirmation and diagnostic trouble code check record and clearance.

Is there any trouble code?

2 Perform driving test.

Is trouble symptom identified?

3 Check diagnostic trouble code.

Is it malfunction code?

4 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?

5 Inspect and repair referring to “Diagnosis Table” in Section 5.

Then perform final confirmation test after clearing diagnostic trouble code.

Is trouble recur?

6 Check for intermittent problems referring to “Intermittent and

Poor Connection” in Section 0A and related circuit of trouble code recorded in Step 3. Then perform final confirmation test after clearing diagnostic trouble code.

Is trouble recur?

7 Perform diagnostic trouble code check record and clearance.

Is there any trouble code?

Yes

Go to Step 2.

Go to Step 3.

Go to Step 4.

Go to Step 7.

Go to Step 7.

Go to Step 7.

Go to Step 4.

No

Go to Step 5.

Go to Step 6.

Go to Step 5.

End.

End.

End.

Go to Step 5.


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)

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 customer if possible.) When “ABS” warning lamp is not operating correctly, proceed to “Diagnostic Flow Table-

A, B or C” in this section.

c) Diagnostic Trouble Code (DTC) Check, Record and Clearance

Perform “Diagnostic Trouble Code Check” procedure in this section, record it and then clear it referring to

“Diagnostic Trouble Code Clearance” in this section.

If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again when the ignition switch is 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 Step 2 to check ABS control module 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.


2) DRIVING TEST

Test drive the vehicle at 40 km/h for more than a minute and check if any trouble symptom (such as abnormal 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 necessary. Proceed to Step 3.

3) DIAGNOSTIC TROUBLE CODE CHECK

Recheck diagnostic trouble code referring to “DTC Check” in this section.

4) 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.

5) “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.

6) CHECK FOR INTERMITTENT PROBLEM

Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to

Intermittent Trouble in Section 0A and related circuit of trouble code recorded in Step 1)-c.

7) 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.


“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 connector (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)

NOTE:

“ABS” warning lamp indicates only following DTCs, DTC

12 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, disconnect service wire from monitor connector.


DTC Check (Using SUZUKI Scan Tool)

1) Connect SUZUKI scan tool to data link connector after setting cartridge for ABS to it.

Special tool

(A) : SUZUKI scan tool


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 disconnect 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 possibility and be very careful during testing to avoid occurrence of an accident.

After repair or replace malfunction part(s), clear all DTC’s by preforming 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 wire (4) at ground terminal (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

DTC

(displayed on

SUZUKI scan tool)

DTC

(indicated by

ABS warning lamp)

– 12

ABS warning light flashing pattern

Normal

DIAGNOSTIC ITEMS

C1035

C1022

C1026

C1032

C1036

C1041

C1042

C1045

C1046

C1055

C1056

C1015

C1016

C1021

C1025

C1031

32

36

41

42

35

22

26

55

56

45

46

15

16

21

25

31

G sensor circuit (for 4WD model only)

Stop lamp switch circuit

RF

LF

RR

LR

RF

Wheel speed sensor circuit and/or sensor ring

LF

RR

LR

RF

Hold solenoid valve circuit

Release solenoid valve circuit

LF



Rear




DTC

(displayed on

SUZUKI scan tool)

DTC

(indicated by

ABS warning lamp)

C1057 57

ABS warning light flashing pattern

Power source

DIAGNOSTIC ITEMS

C1061

C1063

C1071

61

63

71

ABS pump motor circuit

ABS solenoid valve circuit

ABS control module

System Circuit

1. Battery

2. Main fuses

3. Ignition switch

4. Circuit fuses


5-1. Terminal arrangement for ABS hydraulic unit

/ control module assembly

5-2. ABS fail-safe transistor

5-3. ABS pump motor transistor

5-4. Pump motor

5-5. Solenoid valves


7. Right rear wheel speed sensor

8. Left rear wheel speed sensor

9. Right front wheel speed sensor

10. Left front wheel speed sensor



13. Stop lamp

14. Stop lamp switch

15. ECM

16. G sensor

17. 4WD switch (for 4WD model only)

18. 4WD indicator lamp (for 4WD model only)

19. 4WD controller (for 4WD model only)


21. ABS lamp driver module


B :

B/BI :

B/W :

B/Or :

Bl :

Bl/W :

G :

G/B :

TERMINAL

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

CIRCUIT

Idle up signal

Stop lamp switch

Right front wheel speed sensor (+)

Right front wheel speed sensor (–)

–

Right rear wheel speed sensor (–)

Right rear wheel speed sensor (+)

–

–

–

G sensor signal

Diagnosis switch terminal

G sensor ground

“ABS” warning lamp

Left front wheel speed sensor (+)

Left front wheel speed sensor (–)

4WD switch (for 4WD model only)

Ignition switch

Left rear wheel speed sensor (+)

Left rear wheel speed sensor (–)

Data link connector

Ground (for ABS pump motor)

ABS pump motor power supply

Ground (for ABS control module)

Solenoid valve power supply

Black

Black / Blue

Black / White

Black / Orange

Blue

Blue / White

Green

Green / Black

G/W :

Lg/B :

Lg/R :

Or :

Or/B :

P/B :

P/G :

R/Bl :

Wire color

Green / White R/W :

Light green / Black W/Bl :

Light green / Red W/G :

Orange W/R :

Orange / Black

Pink / Black

Pink / Green

Red / Blue

Y :

Y/B :

Red / White

White / Blue

White / Green

White / Red

Yellow

Yellow / Black


Table – A “ABS” Warning Lamp Circuit Check – Lamp Does Not Come “ON” at

Ignition Switch ON

1. Main fuse

2. Ignition switch

3. IG fuse

4. “ABS” warning lamp in combination meter


6. Monitor connector (Blue)


6-2. Diag. ground terminal


7-1. ABS lamp driver module

8. ABS hydraulic unit / control module connector of harness

8-1. Lock position

8-2. Unlock position

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

1 1) Turn ignition switch ON.

Do other warning lamp come ON?

2 1) Disconnect ABS hydraulic unit / control module connector.

Does ABS warning lamp light with ignition switch ON?

Go to step 2.

Yes

Replace ABS hydraulic unit / control module assembly.

No

Go to step 4.

Go to step 3.


Step Action

3 1) Remove combination meter.

Is bulb of ABS warning lamp in good condition?

4 Is IG fuse in good condition?

Yes

“R/Bl” circuit shorted to ground.

If OK, replace ABS warning circuit (lamp driver module).

Open in “B/W” wire to combination meter or poor connection.

No

Replace bulb.

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

1 Perform diagnostic trouble code check. Is there any DTC (including code No.12, NO CODES on

SUZUKI scan tool) exists?

2 Is malfunction DTC (other than code No.12) exists at step 1?

Yes

Go to step 2.

Go to step 7 of ABS diagnostic flow table in this section.

Go to step 4.

3 1) Disconnect ABS hydraulic unit / control module connector.

2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “A14” and “A18”.

3) If OK, turn ignition switch “ON” and measure voltage at terminal “A18” of connector.

Is it 10 – 14 V?

4 1) With ABS control module connector disconnected, 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?

5 1) Measure resistance from connector terminal “A24” to body ground.

Is continuity indicated?

Go to step 5.


ABS hydraulic unit / control module assembly and recheck.

No

Go to step 3.

Go to step 3.

“B/W” circuit open.

“R/Bl” circuit open.

If wire and connection are

OK, replace ABS lamp driver module.

“B” circuit open.


Table – C “ABS” Warning Lamp Circuit Check – Lamp Flashes Continuously

While Ignition Switch is ON






4. Service wire

5. Pedal bracket


When the diag. switch terminal is shorted or connected to the ground with the ignition switch ON, the diag. trouble code (DTC) is indicated by flashing of the “ABS” warning lamp only in following cases.

• Normal DTC (12) is indicated if no malfunction DTC is detected in the ABS.

• 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

1 Is diag. switch terminal connected to ground via service wire?

2 1) Ignition switch ON.

2) Measure voltage between diag. switch terminal and ground.

Is it 10 – 14 V?

3 1) Ignition switch ON.

2) Does flashing of ABS warning lamp indicate

DTC (DTC 12 or history DTC)?

Yes

Go to step 3.



Go to step 7 of “ABS diagnostic flow table” in this section.

No

Go to step 2.

“P/B” wire circuit shorted to ground.




Table – D Code (DTC) is Not Outputted Even With Diag. Switch Terminal Connected to Ground.







4-1. Lock position



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

1 Is it shorted diag. switch terminal and ground terminal by service wire properly?

2 1) Disconnect service wire.

2) Disconnect ABS hydraulic unit / control module connector.

3) Measure resistance between diag. switch terminal and connector terminal “A12”.

Is it infinite (

∞)?

3 1) Measure resistance between ground terminal of monitor connector and body ground.


4 1) Check for proper connection to ABS hydraulic unit / control module at terminal “A12” and “A24”.

2) If OK, then check “ABS” warning lamp circuit referring to TABLE A, B and C.

Is it in good condition?

Yes

Go to step 2.

“P/B” circuit open.

Go to step 4.



No

Connect service wire securely.

Go to step 3.

“B” circuit open or poor connection.

Repair “ABS” warning lamp circuit.


DTC C1015 (DTC 15) – G Sensor Circuit

1. Ignition switch

2. G sensor



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

Step

1

Action

Is G sensor installed floor securely?

Yes

Go to step 2.

2 1) Ignition switch OFF.

2) Remove G sensor with bracket.

3) Check for proper connection to G sensor.

4) If OK, then check G sensor referring to “G

Sensor” in this section.

4 Measure voltage between “R/W” terminal of sensor connector and body ground.

Is it 0 V?


2) Check that “R/W” circuit is free from open or short to ground and “Or/B” circuit. (See [B])


Go to step 3.


3 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 measure voltage between “B/W” terminal of sensor connector and body ground.

Is it 10 – 14 V?

Go to step 4.

Go to step 5.

“Or/B” circuit open.

If circuit is OK, substitute a known-good ABS hydraulic unit / control module assembly.

No

Tighten sensor or bracket screw securely. If not, use new screw.

Replace G sensor.


“R/W” circuit shorted to power circuit.

“R/W” circuit open or shorted to ground or “Or/

B” circuit.

1. ABS hydraulic unit / control module connector

2. Lock position

3. Unlock position


DTC C1016 (DTC 16) – Stop Lamp Circuit

1. Main fuse

2. Ignition switch

3. Tail stop fuse

4. IG fuse

5. Stop lamp switch

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

1 1) Turn IG switch OFF.

2) Disconnect connectors from ABS hydraulic unit / control module assembly.

3) Depress the brake pedal.

4) Measure the voltage between the stop lamp terminal “A2” and body ground.

Is it 10 – 14 V?

Yes

Check for proper connection to

ABS control module at terminal

“A2”. If OK, substitute a knowngood ABS control module and recheck.

No

“G/W” circuit open.


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

1. Ignition switch


3. Left front wheel speed sensor

4. Right front wheel speed sensor

5. Left rear wheel speed sensor

6. Right rear wheel speed sensor


DESCRIPTION

The ABS control module monitors the voltage at the positive (+) terminal of each sensor while the ignition switch is ON. When the voltage is not within the specified range, an applicable DTC will be set. Also, when no sensor signal is inputted at starting or while running, an applicable DTC will be set.

NOTE:

When the vehicle was operated in any of the following ways, one of these 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.

• The vehicle was driven with parking brake pulled.

• The vehicle was driven with brake dragging.

• Wheel spin occurred while driving.

• Wheel(s) was turned while the vehicle was jacked up.

• The vehicle was stuck.


INSPECTION

Step Action

1 1) Disconnect the applicable sensor connector with ignition switch OFF.

2) Measure resistance between sensor terminals.

Resistance of wheel speed sensor: 1.4 – 1.8 k

Ω (at

20°C, 68°F)

3) Measure resistance between each terminal and body ground.

Insulation resistance: 1M

Ω or higher

Were measured resistance values in step 2) and 3) as specified? (See [A])


2) Disconnect connector from ABS hydraulic unit / control module assembly. (See [B])

3) Check for proper connection to ABS hydraulic unit / control 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 0V?


2) Connect connector to sensor.

3) Measure resistance between sensor terminals at module 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.

2) Check sensor for damage or foreign material being attached.

Is it in good condition? (See [C])

5 Check visually through wheel speed sensor installation hole for following.

• Ring serration (teeth) neither missing or damaged.

• No foreign material being attached.

• Ring not being eccentric.

• Wheel bearing free from excessive play.

Are they in good condition? (See [D])

6 1) Install sensor to knuckle or axle housing.

2) Tighten sensor bolt to specified torque and check that there is not any clearance between sensor and knuckle or axle housing. (See [E])

Replace sensor if any.

Referring to “Front Wheel Speed Sensor” in this section, check output voltage or waveform of sensor. Is proper output voltage or waveform obtained?

Yes

Go to step 2.

Go to step 3.

Go to step 4.

Go to step 5.

Go to step 6.

Substitute a knowngood ABS hydraulic unit / control module assembly and recheck.

Sensor positive circuit shorted to power.

No

Replace sensor.

Circuit open or shorted to ground.

Clean or replace sensor.

Clean, repair or replace.

Replace sensor and recheck.


2. Lock position

3. Unlock position



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



2-1. Lock 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 command to the solenoid or the voltage difference between solenoid circuit terminals exceeds the specified value with the solenoid turned OFF.

INSPECTION

Step Action

1 1) Check solenoid referring to “ABS Hydraulic Unit

Operation Check” in this section.




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 it 10 – 14 V?

Yes

Check terminals “A25” and

“A23” connection.

If connections OK, substitute a known-good ABS hydraulic unit / control module assembly and recheck.



No

Go to step 2.

“W/Bl” circuit open.

DTC C1057 (DTC 57) – Power Source Circuit


1. Ignition switch

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

1

Action

Check battery voltage. Is it about 11 V or higher?

2 Check ABS main fuse, circuit fuse and connection. Is it in good condition?



3) Check proper connection to ABS hydraulic unit / control module connector at terminal

“A18”.

4) If OK, then measure voltage between connector terminal “A18” and body ground.

Is it 10 – 14 V?

Yes

Go to step 2.

Go to step 3.



No

Check charging system referring to “Undercharged Battery” in Section 6H.

Repair and/or replace fuse.



DTC C1061 (DTC 61) – ABS Pump Motor Circuit


1-1. ABS pump motor transistor

1-2. ABS pump motor

1-3. ABS fail safe transistor


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

1 1) Check pump motor referring to “ABS

Hydraulic Unit Operation Check” in this section.


Yes

Check terminal “A23” connection.

If connections OK, substitute a known-good ABS hydraulic unit / control module assembly and recheck.

Go to step 3.

No

Go to step 2.

“W/Bl” circuit open.



3) Check for proper connection to ABS hydraulic unit / control module connector at terminal “A23”.

4) If OK, then measure voltage between terminal “A23” of module connector and body ground.

Is it 10 – 14V?

3 Measure resistance between connector terminal “A22” of ABS hydraulic unit / control module assembly and body ground.

Is it infinite (

∞)?

“B” circuit open.



DTC C1063 (DTC 63) – ABS Fail Safe Circuit


1. Ignition switch



3-1. Lock position


DESCRIPTION

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

→ OFF → ON and check if the voltage at 6 solenoid circuit terminals 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

1 Check battery voltage. Is it about 11 V or higher?

2 Check ABS main fuse and connection.




3) Check proper connection to ABS hydraulic unit / control module at terminal “A25”.

4) If OK, then measure voltage between connector terminal “A25” and body ground.

Is it 10 – 14 V?

Yes

Go to step 2.

Go to step 3.



No

Check charging system referring to “Undercharged Battery” in Section 6H.

Repair and / or replace fuse.

“W/Bl” circuit open or short to ground.


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


2) Disconnect connectors from ABS control module.

3) Check for proper connection to ABS control module at all terminals.

Are they in good condition?

Yes


ABS control module and recheck.

No

Repair or replace.



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 control 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 dragging occurs. If it does, correct.

7) With diag. switch terminal (3) of monitor connector (1) connected 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 Diagnostic Flow Table” in this section.


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 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.


12) Remove service wire from monitor connector.


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. Brake pipe


3. Bracket

4. Connector

Tightening torque

HYDRAULIC UNIT INSPECTION

Check hydraulic unit for fluid leakage.

If any, repair or replace.

REMOVAL


2) Using special tool, disconnect brake pipes from ABS hydraulic unit / control module assembly (1).

Special tool

(A) : 09950-78220

NOTE:

Put bleeder plug cap onto pipe to prevent fluid from spilling. Do not allow brake fluid to get on painted surfaces.


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:

• Do not give an impact to hydraulic unit.

• Use care not to allow dust to enter hydraulic unit.

• Do not place hydraulic unit on its side or upside down.

Handling it in inappropriate way will affect its original performance.

INSTALLATION

1) Install hydraulic unit by reversing removal procedure.



(a) : 16 N·m (1.6 kg-m, 12.0 lb-ft)

ABS hydraulic unit / control module assembly bracket bolts

(b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

ABS hydraulic unit / control module assembly bolts

(c) : 9 N·m (0.9 kg-m, 6.5 lb-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.

1. To left front

2. To right front

3. To rear

4. From proportioning valve


Front Wheel Speed Sensor

1. Front wheel speed sensor

2. Sensor ring

3. Knuckle

OUTPUT VOLTAGE INSPECTION


2) Hoist vehicle a little.

3) Disconnect connector of wheel speed sensor.

4) Connect voltmeter between connector terminals.

5) While turning wheel at a speed of approximately 1 full rotation to 1 1/3 rotation per second, check AC voltage of sensor.

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


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


2) Disconnect front wheel speed sensor coupler (3).


4) Remove harness clamp bolts (2) and front wheel speed sensor (1) from knuckle.

CAUTION:

• Do not pull wire harness when removing front wheel speed sensor.

• Do not cause damage to surface of front wheel speed sensor and do not allow dust, etc. to enter its installation hole.

SENSOR INSPECTION

• Check sensor for damage.

• Check sensor for resistance.

If any malfunction is found, replace.

Resistance between terminals of sensor

: 1.2 – 1.6 k

Ω at 20 °C (68 °F)

Resistance between terminal and sensor body

: 1 M

Ω or more

1. Right wheel sensor terminals

2. Left wheel sensor terminals


SENSOR RING INSPECTION

• Check ring teeth for being missing, damaged or deformed.

• Turn drive shaft and check if ring rotation is free from eccentricity and looseness.

• 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.


Front wheel speed sensor bolt and front wheel speed sensor harness clamp bolts

(a) : 10 N·m (1.0 kg-m, 7.2 lb-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


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. Attempt to pull it out partially may cause it to be deformed.

3. Vise

4. Lever

INSPECTION


• Check sensor ring (1) for being deformed.


If any malcondition is found, repair or replace.

INSTALLATION

1) Install sensor ring (3) as shown.

NOTE:

• 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.

• 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.


Rear Wheel Speed Sensor

1. Left rear wheel sensor

2. Trailing arm

3. Sensor ring

4. Clamp bolt

Tightening torque

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) Disconnect negative cable from battery.

2) Hoist vehicle.

3) Disconnect rear wheel speed sensor coupler (1).

4) Detach ABS wheel sensor wire harness from suspension frame.

2. Rear wheel sensor


5) Remove rear wheel speed sensor (1) from rear axle housing.

CAUTION:

• Do not pull wire harness when removing rear wheel speed sensor (1).

• Do not cause damage to surface of rear wheel speed sensor and do not allow dust, etc. to enter its installation hole.

2. Rear wheel sensor ring

SENSOR INSPECTION

• Check sensor for damage.

• Check sensor for resistance.

Resistance between terminals of sensor

: 1.4 – 1.8 k

Ω at 20 °C (68 °F)

Resistance between sensor terminal and sensor body

: 1 M

Ω or more

If any malcondition is found, replace.

SENSOR RING INSPECTION


• Turn wheel and check if ring rotation is free from eccentricity and looseness.


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.


Rear wheel speed sensor bolt and rear wheel speed sensor harness clamp bolts

(a) : 10 N·m (1.0 kg-m, 7.2 lb-ft)

CAUTION:

Do not pull wire harness or twist more than necessary 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.


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 (3) as illustrated till it becomes thin.

CAUTION:

• Cover vinyl sheet (4) or the like over wheel bearing so that fine grains from grinding will not enter there.

• 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.


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. 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] : Horizontal

[B] : Upright with arrow upward

[C] : Upright with arrow downward

INSTALLATION

1) Connect connector to sensor securely.

2) Install sensor onto floor so that arrow mark directs vehicle forward.


G sensor bolts

(a) : 23 N·m (2.3 Kg-m, 17.0 lb-ft)

3) Install rear console box.



Fastening part

Brake pipe flare nuts

ABS hydraulic unit / control module assembly bracket bolts

ABS hydraulic unit / control module assembly bolts

Front wheel speed sensor bolt

Front wheel speed sensor harness clamp bolts

Rear wheel speed sensor bolt

Rear wheel speed sensor harness clamp bolts

G sensor bolts

N•m

16

11

9

10

10

10

10

23


1.6

1.1

0.9

1.0

1.0

1.0

1.0

2.3

lb-ft

11.6

8.0

6.5

7.2

7.2

7.2

7.2

17.0

Special Tool

09950-78220 09931-76011

Flare nut wrench (10 mm) 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:

• “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

• “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

6F2

6G

6H

6K

WARNING:

For vehicles equipped with Supplemental Restraint (Air Bag) System :





8B

6

8D

8E

8B

7A

7A1

7B1

7C1

7D

7E

7F

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.

• EGR valve

• Heated oxygen sensor(s) or CO adjusting resistor

• Three-way catalytic converter (TWC) and warm up three-way catalytic converter (WU-TWC)

9

10A

10B

GENERAL INFORMATION AND ENGINE DIAGNOSIS .............................................................................. 6-1

ENGINE MECHANICAL ........................................................................................................................... 6A1-1

ENGINE COOLING..................................................................................................................................... 6B-1

ENGINE FUEL ............................................................................................................................................ 6C-1

ENGINE AND EMISSION CONTROL SYSTEM ........................................................................................ 6E-1

IGNITION SYSTEM .................................................................................................................................... 6F-1

CRANKING SYSTEM ................................................................................................................................. 6G-1

CHARGING SYSTEM................................................................................................................................. 6H-1

EXHAUST SYSTEM ................................................................................................................................... 6K-1

General Information .......................................... 6-3

Statement on Cleanliness and Care ............... 6-3

General Information on Engine Service .......... 6-3

Precaution on fuel system service............... 6-4

Fuel pressure relief procedure .................... 6-5

Fuel leakage check procedure .................... 6-5

Engine Diagnosis .............................................. 6-6

General Description ........................................ 6-6

On-Board Diagnostic System (Vehicle with

Immobilizer Indicator Lamp) ............................ 6-6

CONTENTS

On-Board Diagnostic System (Vehicle without

Immobilizer Indicator Lamp)............................ 6-9

Precaution in Diagnosing Trouble ................. 6-10

Engine Diagnostic Flow Table ...................... 6-11

Customer problem inspection form

(example) .................................................. 6-13

Malfunction indicator lamp (MIL) check..... 6-14

Diagnostic trouble code (DTC) check ....... 6-14

Diagnostic trouble code (DTC) clearance................................................... 6-15

6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS

Diagnostic trouble code (DTC) table ......... 6-16

Fail-safe table............................................ 6-19

Visual inspection ....................................... 6-20

Engine basic inspection ............................ 6-21

Engine diagnosis table .............................. 6-23

Scan Tool Data ............................................. 6-28

Scan tool data definitions .......................... 6-30

Inspection of ECM and Its Circuits ................ 6-33

Component Location..................................... 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


Check - Lamp Remains “ON” after Engine

Starts............................................................. 6-44


Check - Mil Flashes at Ignition Switch ON .... 6-45


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................................................... 6-46

DTC P0105 (DTC No.11) Manifold Absolute

Pressure (MAP) Circuit Malfunction .............. 6-48

DTC P0110 (DTC No.18) Intake Air Temp.

(IAT) Circuit Malfunction ............................... 6-51

DTC P0115 (DTC No.19) Engine Coolant

Temperature (ECT) Circuit Malfunction ........ 6-53

DTC P0120 (DTC No.13) Throttle Position

Circuit Malfunction ........................................ 6-55

DTC P0121 Throttle Position Circuit Range /

Performance Problem ................................... 6-57

DTC P0130 (DTC No.14) Heated Oxygen

Sensor (HO2S) Circuit Malfunction

(Sensor-1) ..................................................... 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

(Sensor-1) ..................................................... 6-62


Circuit Malfunction (Sensor-2) ...................... 6-64


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 P0325 (DTC No.17) Knock Sensor Circuit

Malfunction ....................................................6-77

DTC P0335 (DTC No.23) Crankshaft Position

(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 ....................................................6-85

DTC P0420 Catalyst System Efficiency below

Threshold.......................................................6-88

DTC P0443 Purge Control Valve Circuit

Malfunction ....................................................6-91

DTC P0481 A/C Condenser Fan Control

Circuit Malfunction .........................................6-92

DTC P0500 (DTC No.16) Vehicle Speed

Sensor (VSS) Malfunction .............................6-94

DTC P0505 Idle Control System

Malfunction ....................................................6-96

DTC P0601 Internal Control Module Memory

Check Sum Error (DTC No.71)......................6-98

DTC P1450 Barometric Pressure Sensor

Low / High Input.............................................6-99

DTC P1451 Barometric Pressure Sensor

Performance Problem....................................6-99

DTC P1500 Engine Starter Signal Circuit

Malfunction ..................................................6-101

DTC P1510 ECM Back-up Power Supply

Malfunction ..................................................6-103

DTC P1570 (DTC No.21) ABS Signal Circuit

Malfunction ..................................................6-104

DTC P1600 Serial Communication Problem

Between ECM and TCM ..............................6-105

DTC P1717 A/T Drive Range (Park / Neutral

Position) Signal Circuit Malfunction .............6-107

Table B-1 Fuel Injector Circuit Check ..........6-109

Table B-2 Fuel Pump and Its Circuit

Check...........................................................6-110

Table B-3 Fuel Pressure Check...................6-112

Table B-4 Idle Air Control System Check ....6-114

Table B-5 A/C Signal Circuits Check

(Vehicle with A/C) ........................................6-117

Table B-6 Electric Load Signal Circuit

Check...........................................................6-119

TAble B-7 A/C Condenser Fan Control

System Check..............................................6-121

Special Tool ...................................................6-123


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.

• A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation.

• Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order.

At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

• Battery cables should be disconnected before any major work is performed on the engine.

Failure to disconnect cables may result in damage to wire harness or other electrical parts.

• 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.

• 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 resulting 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 cylinder and cause extensive damage when engine is started.


Precaution on fuel system service

• Work must be done with no smoking, in a well-ventilated area and away from any open flames.

• As fuel feed line (between fuel pump and fuel 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.

• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.

• Fuel or fuel vapor hose connection varies with each type of pipe. When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to the figure

Hose Connection.

After connecting, make sure that it has no twist or kink.

[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] : With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79 – 1.18 in.) into the hose.

1. Hose

2. Pipe

3. Clamp

4. Clamp securely at a position 3 to 7 mm (0.1 2 – 0.27 in.) from hose end.

5. 20 to 30 mm (0.79 – 1.18 in.)

• When installing injector or fuel delivery pipe, lubricate its Oring with spindle oil or gasoline.

• When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified torque.


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 follows.

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.

2) Remove relay box cover.

3) 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.

6) Upon completion of servicing, connect fuel pump relay (1) to its connector.

Fuel leakage check procedure

After performing 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 pressure 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.


Engine Diagnosis


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 Diagnostic 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 according 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 (Vehicle 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 driving cycle detection logic is adopted to prevent erroneous detection.

• When a malfunction is detected, engine and driving conditions 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 coolant temperature has risen by at least 22 °C (40 °F) from engine starting and reaches a minimum temperature of 70 °C

(160 °F).


DRIVING CYCLE

A “Driving Cycle” consists of engine startup 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 malfunction in its memory. This data is called “Freeze frame data”.

Therefore, it is possible to know engine and driving conditions

(e.g., whether the engine was warm or not, where the vehicle was running or stopped, where air / fuel mixture was lean or rich) when a malfunction was detected by checking the freeze frame data. Also, ECM 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

1

2

FREEZE FRAME DATA IN FRAME 1

Freeze frame data at initial detection of malfunction 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


In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the malfunction is detected.

These data are not updated.

Shown in the table below are examples of how freeze frame data are stored when two or more malfunctions are detected.

MALFUNCTION

DETECTED

ORDER

No malfunction

1 P0400 (EGR) detected

2 P0171 (Fuel system) detected

3 P0300 (Misfire) detected

4 P0301 (Misfire) detected

FRAME 1

FREEZE FRAME

DATA to be updated

No freeze frame data

Data at P0400 Data at P0400 detection

Data at P0171 detection detection

Data at P0400 detection



FRAME

FRAME 2

1st FREEZE

FRAME DATA

FRAME 3

2nd FREEZE

FRAME DATA



–




FRAME4

3rd FREEZE

FRAME DATA

–

–



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 position, 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 communicate with immobilizer control module.

2. B+

4. ECM ground

5. Body ground


On-Board Diagnostic System (Vehicle without


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 malfunction 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 occurrence of trouble and at the same time it stores the trouble area in ECM back-up memory. (The memory is kept as it is even if the trouble was only temporary and disappeared immediately. And it is not erased unless the power to ECM is shut off for specified time 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 disappears 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 condition is restored.

• Time required to erase diagnostic trouble code memory thoroughly varies depending on ambient temperature as follows.


AMBIENT TEMPERATURE TIME TO CUT POWER TO

ECM

Over 0 °C (32 °F) 60 sec. or longer

Under 0 °C (32 °F)

Not specifiable.

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 generic 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 0A 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 Diagnostic Flow Table

Refer to the following pages for the details of each step.

Step Action

1 Customer Complaint Analysis

1) Perform customer complaint analysis referring to the followings.

Was customer complaint analysis performed?

2 Diagnostic Trouble Code (DTC) and Freeze Frame Data

Check, Record and Clearance

1) Check for DTC (including pending DTC) referring to the followings.

Is there any DTC(s)?

Yes

Go to Step 2.

Print DTC and freeze frame data or write them down and clear them by referring to “DTC Clearance” section.

Go to Step 3.

Repair or replace malfunction part.

Go to Step 11.

No

Perform customer complaint analysis.

Go to Step 4.

Go to Step 5.

Go to Step 8.

3 Visual Inspection

1) Perform visual inspection referring to the followings.

Is there any faulty condition?

4 Visual Inspection

1) Perform visual inspection referring to the followings.


5 Trouble Symptom Confirmation

1) Confirm trouble symptom referring to the followings.

Is trouble symptom identified?

6 Rechecking and Record of DTC / Freeze Frame Data

1) Recheck for DTC and freeze frame data referring to

“DTC Check” section.


7 Rechecking and Record of DTC / Freeze Frame Data

1) Recheck for DTC and freeze frame data referring to

“DTC Check” section.


8 Engine Basic Inspection and Engine Diagnosis Table

1) Check and repair according to “Engine Basic Inspection” and “Engine Diagnosis Table” section.

Are check and repair complete?

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

1) Check for intermittent problems referring to the followings.


11 Final Confirmation Test

1) Clear DTC if any.

2) Perform final confirmation test referring to the followings.

Is there any problem symptom, DTC or abnormal condition?

Go to Step 6.

Go to Step 9.

Go to Step 11.

Repair or replace malfunction part(s).

Go to Step 11.

Go to Step 6.

Go to Step 7.

Go to Step 8.

Go to Step 10.

Check and repair malfunction part(s).

Go to Step 11.

Go to Step 11.

End.


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 analysis 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 indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now. To check which case applies, check the symptom in question according to Step 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 on symptoms appearing on the vehicle (symptoms obtained through steps of customer complaint analysis, trouble symptom confirmation and / or basic engine check) and repair or replace faulty parts, if any.

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 0A 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.

Customer problem inspection form (example)


NOTE:

The above form is a standard sample. It should be modified according to conditions characteristic of each market.


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.

2) With ignition switch OFF, connect it to data link connector

(DLC) (1) located on underside of instrument panel at driver’s seat side.

Special 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 operator’s manual for further details.

If communication between scan tool and ECM is not possible, 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 with which communication was not possible.

5) After completing the check, turn ignition switch off and disconnect scan tool from data link connector.

[Without Using SUZUKI Scan Tool] (Vehicle Without


1) Check malfunction indicator lamp referring to “Malfunction

Indicator Lamp Check” in this section.

2) With the ignition switch OFF position, connect diagnosis switch terminal (3) and ground terminal (2) in monitor connector (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 “Diagnostic Flow Table A-4”.


NOTE:

• If abnormality or malfunction lies in two or more areas, malfunction indicator lamp indicates applicable codes three times each.

And flashing of these codes is repeated as long as diagnosis terminal is grounded and ignition switch is held at ON position.

• Take a note of diagnostic trouble code indicated first.

4) After completing the check, turn the ignition switch OFF position 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 check.


3) Erase DTC and pending DTC according to instructions displayed 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.

• When power to ECM is cut off (by disconnecting battery cable, removing fuse or disconnecting ECM connectors)

• 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

Over 0 °C (32 °F)

Under 0 °C (32 °F)

Time to cut power to ECM

30 sec. or longer

Not specifiable.

Select a place with higher than

0 °C (32 °F) temperature.


Diagnostic trouble code (DTC) table

DTC

NO.

DETECTING ITEM DETECTING CONDITION

(DTC will set when detecting :)

MIL

(vehicle with immobilizer indicator lamp)

MIL

(vehicle without immobilizer indicator lamp)

P0105

(No.11)

P0110

(No.18)

P0115

(No.19)

P0120

(No.13)

P0121

Manifold absolute pressure circuit malfunction

Intake air temp. circuit malfunction

Engine coolant temp. circuit malfunction

Throttle position circuit malfunction

Throttle position circuit performance problem

Low pressure-high vacuum-low voltage

(or MAP sensor circuit shorted to ground)

High pressure-low vacuum-high voltage

(or MAP sensor circuit open)

Intake air temp. circuit low input

Intake air temp. circuit high input

Engine coolant temp. circuit low input

Engine coolant temp. circuit high input

Throttle position circuit low input

Throttle position circuit high input

Poor performance of TP sensor

P0130

(No.14)

P0133

P0135

(No.14)

P0136

P0141

P0171

P0172

HO2S circuit malfunction

(Sensor-1)

HO2S circuit slow response

(Sensor-1)

HO2S heater circuit malfunction (Sensor-1)

HO2S circuit malfunction

(Sensor-2)

HO2S heater circuit malfunction (Sensor-2)

Fuel system too lean

Fuel system too rich

Min. output voltage of HO2S-higher than specification

Max. output voltage of HO2S-lower than specification

Response time of HO2S-1 output voltage between rich and lean is longer than specification.

Terminal voltage is lower than specification at heater OFF or it is higher at heater ON.

HO2S-2 voltage is higher than specification

Terminal voltage is lower than specification at heater OFF or it is higher at heater ON.

(or heater circuit or short)

Short term fuel trim or total fuel trim (short and long terms added) is larger than specification for specified time or longer.

(fuel trim toward rich side is large.)

Short term fuel trim or total fuel trim (short and long term added) is smaller than specification for specified time or longer.

(fuel trim toward lean side is large.)

1 driving cycle

1 driving cycle

1 driving cycle

1 driving cycle

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

1 driving cycle

1 driving cycle

1 driving cycle

1 driving cycle

Not applicable

1 driving cycle

Not applicable

1 driving cycle

Not applicable

Not applicable

Not applicable

Not applicable

P0300

P0301

P0302

P0303

P0304

Random misfire detected

Cylinder 1 misfire detected




P0325

(No.17)

Knock sensor circuit malfunction

Misfire of such level as to cause damage to three way catalyst

Misfire of such level as to deteriorate emission but not to cause damage to three way catalyst

Knock sensor circuit low input

Knock sensor circuit high input

MIL flashing during misfire detection

Not applicable

2 driving cycles

1 driving cycle

Not applicable

1 driving cycle


DTC

NO.



P0335

(No.23)

P0340

(No.15)

P0400

Crankshaft position sensor circuit malfunction

Camshaft position sensor circuit malfunction

Exhaust gas recirculation flow malfunction detected

No signal for 2 sec. During engine cranking

No signal during engine running

Excessive or insufficient EGR flow

P0420

Catalyst system efficiency below threshold

P0443

P0481

Purge control valve circuit malfunction

A/C condenser fan control circuit malfunction

P0500

(No.16)

Vehicle speed sensor malfunction

P0505 Idle control system malfunction

P0601

(No.71)

P1450

Internal control module memory check sum error

Barometric pressure sensor circuit malfunction

P1451

P1500

Barometric pressure sensor performance problem

Starter signal circuit malfunction

Output waveforms of HO2S-1 and HO2S-2 are similar.

(Time from output voltage change of

HO2S-1 to that of HO2S-2 is shorter than specification.)

Purge control valve circuit is open or shorted to ground

A/C condenser fan relay terminal voltage is low when fan command is not outputted

No signal while running in “D” range or during fuel cut at decelerating

No closed signal to IAC valve is detected

Data write error (or check sum error) when written into ECM

Barometric pressure is lower or higher than specification. (or sensor malfunction)

Difference between manifold absolute pressure (MAP sensor value) and barometric pressure (barometric pressure sensor value) is larger than specification during cranking.

Starter signal is not inputted from engine cranking till its start and after or it is always inputted

P1510

P1600

P1717

P1570

ECM backup power source malfunction

Serial communication problem between ECM and

TCM

AT D-range signal circuit malfunction

ABS signal circuit malfunction

No backup power after starting engine

No signal or check sum error while engine running

No “D” range (park / neutral position signal) is inputted while vehicle running

ABS signal ON (low voltage) when engine start

MIL

(vehicle with immobilizer indicator lamp)

1 driving cycle

1 driving cycle

2 driving cycles

MIL

(vehicle without immobilizer indicator lamp)

1 driving cycle

1 driving cycle

Not applicable

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

1 driving cycle

2 driving cycles

2 driving cycles

1 driving cycle

1 driving cycle

2 driving cycles

Not applicable

Not applicable

Not applicable

Not applicable

1 driving cycle

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

1 driving cycle


DTC NO.



MIL

P0702 Transmission Control System Electrical

P0705 Temperature Sensor Circuit Malfunction

Transmission Temperature Sensor Circuit Mal-

P0710 function

P0715

Input / Turbine Speed Sensor Circuit Malfunction

P0720

Output Shaft Speed Sensor Circuit Malfunction

P0725 Engine Speed Input Circuit Malfunction

P0730 Incorrect Gear Ratio

P0743 Torque Converter Clutch Circuit Electrical

P0753 Shift Solenoid A Electrical

P0758 Shift Solenoid B Electrical

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)

P1621

(No.83)

P1622

(No.82)

P1623

(No.81)

ECU code not registered

No ECU code transmitted from Immobilizer

Control Module

Faulty in ECM

ECU code not matched

Refer to Section 7B.

These DTCs can not be read on vehicle without

Immobilizer indicator lamp (by ECM application of

SUZUKI scan tool).

Refer to Section 8G.

NOTE:

• For ( ) marked No. in DTC column, it is used for vehicle without Immobilizer indicator lamp.

• DTC No.12 appears when none of the other codes is identified (vehicle without Immobilizer indicator 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.

DTC NO.

P0105

(No.11)

P0110

(No.18)

P0115

(No.19)

P0120

(No.13)

P0335

(No.23)

P0340

(No.15)

Manifold absolute pressure sensor circuit malfunction

DETECTED ITEM

Intake air temp. sensor circuit malfunction

Engine coolant temp. sensor circuit malfunction

Throttle position sensor circuit malfunction

Crankshaft position sensor circuit malfunction

Camshaft position sensor circuit malfunction

FAIL-SAFE OPERATION (SYMPTOM)

ECM uses value determined by throttle opening and engine speed.

ECM controls actuators assuming that intake air temperature is 20 °C (68 °F).

ECM controls actuators assuming that engine coolant temperature is 80 °C (176 °F).

ECM controls actuators assuming that throttle opening is 20°. (High idle speed)

ECM controls injection system sequential injection to synchronous injection. (Cranking for a few seconds to start engine)

ECM controls injection system sequential injection to synchronous injection. (Cranking for a few seconds to start engine)

P0500

(No.16)

Vehicle speed sensor malfunction ECM stops idle air control.

P1450

P1570

(No.21)

Barometric pressure sensor low / high input

ABS signal circuit malfunction

ECM controls actuators assuming that barometric pressure is 100 kPa (760 mmHg).

ECM controls actuators assuming that ABS signal is

OFF.


Visual inspection

Visually check following parts and systems.

INSPECTION ITEM

• Engine oil – level, leakage

• Engine coolant – level, leakage

• Fuel – level, leakage

• A/T fluid – level, leakage

REFERRING SECTION

Section 0B

Section 0B

Section 0B

Section 0B

Section 0B • 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

Section 0B

Section 6E

Section 8

• 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

Section 6

Section 6H

Section 8 (Section 6 for pressure check)

Section 8

Section 8

• 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


Engine basic inspection

This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in visual inspection.

Follow the flow table carefully.

Step

1

Action

Was “Engine Diag. Flow Table” performed?

Yes

Go to Step 2.

No

Go to “Engine Diag. Flow

Table”.

Charge or replace battery.

2 Check battery voltage.

Is it 11 V or more?

3 Is engine cranked?

Go to Step 3.

Go to Step 4.

4 Does engine start?

5 Check idle speed as follows :

1) Warm up engine to normal operating temp.

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 Is SUZUKI scan tool available?

Go to Step 5.

Go to Step 6.

7 Check ignition timing as follows :

1) Connect test switch terminal (2) of monitor coupler (1) to ground. See Fig. 2.

2) Remove air cleaner bolt and crips and shift air cleaner position to observe ignition timing.

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 :

1) Select “MISC” mode on SUZUKI scan tool and fix ignition timing to initial one. See Fig.

3.

2) Remove air cleaner bolt and crips and shift air cleaner position to observe ignition timing.

3) Using timing light (1), check initial ignition timing. See Fig. 4.

Is it 5° ± 3° BTDC at specified idle speed?

Go to Step 8.

Go to “Engine Diagnosis

Table”.


Table”.

9 Check immobilizer system malfunction as follows (if equipped) :

1) Check immobilizer indicator lamp or MIL

(malfunction indicator lamp) for flashing.

Is it flashing when ignition switch is turned to

ON position?

Go to “Diagnosis” in Section 8G.


Go to Step 9.


Table”.

Go to Step 7.

Check ignition control related parts referring to

Section 6F.

Check ignition control related parts referring to

Section 6F.

Go to Step 10.


Step Action

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?

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?

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.


13 Check fuel injector for operation as follows :

1) Install spark plugs and connect injector connectors.

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?

Yes

Go to Step 12.

Go to “Diag. Flow Table

B-3”.

Go to Step 13.


Table”.

No

Go to Step 11.


B-2”.

Go to “Ignition Spark Test” in Section 6F.


B-1”.

[A] Fig. 1 for Step 5 / [B] Fig. 2 for Step 7 / [C] Fig. 3 for Step 8

[B] : When not using SUZUKI scan tool :

[C] : When using SUZUKI scan tool

[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

Hard Starting

(Engine cranks OK)

Possible Cause

• Faulty ignition coil

• Faulty CMP sensing rotor or CKP sensing rotor

• Faulty idle air control system

• Faulty ECT sensor, TP sensor, CKP sensor, CMP sensor or MAP sensor

• Fuel pressure out of specification

• Faulty fuel injector

• Faulty ECM

Reference Item

Ignition coil assembly in Section 6F.

CMP sensing rotor or CKP sensing rotor inspection in Section 6E.

Diagnostic Flow Table B-4

ECT sensor, TP sensor, CKP sensor,

CMP sensor or MAP sensor in Section 6E.



Inspection of ECM and its circuit in this section.

PCV system in Section 6E.

• Malfunctioning PCV system

Low compression

• Improper valve lash

• Improper valve timing

• Compression leak from valve seat

• Sticky valve stem

• Weak or damaged valve springs

Compression check in Section 6A1.

Valve lash in Section 6A1.

Timing chain and chain tensioner in

Section 6A1.

Valves and cylinder head in Section

6A1.


6A1.


6A1.

• Compression leak at cylinder head gasket Valves and cylinder head in Section

6A1.

• Sticking or damaged piston ring Pistons, piston rings, connecting rods and cylinders in Section 6A1.

• Worn piston, ring or cylinder Pistons, piston rings, connecting rods and cylinders in Section 6A1.


Condition

Engine has no power

Engine overheating

Improper engine idling or engine fails to idle

Low compression

• Dragging brakes

• Slipping clutch


Engine overheating


• Faulty idle air control system

• Faulty evaporative emission control system

• Faulty injector

• Faulty ECT sensor, TP sensor or MAP sensor


• Faulty ECM

Engine hesitates

(Momentary lack of response as the accelerator is depressed.

Can occur at all vehicle speeds.

Usually most severe when first trying to make the vehicle move, as from a stop sign.)

sensor

• Faulty ECM

Possible Cause


• Faulty knock sensor


• Faulty injector

• Faulty TP sensor, ECT sensor or MAP

• Malfunctioning EGR valve (if equipped)

• Maladjusted accelerator cable play

• Faulty EGR system (if equipped)

Low compression


Engine overheating


• Faulty injector

• Faulty TP sensor, ECT sensor or MAP sensor

• Faulty ECM

Surges

(Engine power variation under steady throttle or cruise.

Feels like the vehicle speeds up and down with no change in the accelerator pedal.)


Low compression

• Faulty ignition coil or high-tension cord

• Variable fuel pressure

• Faulty MAP sensor

• Faulty injector

• Faulty ECM


Reference Item

Refer to “Overheating” of this table.


Knock sensor malfunction in this section.



TP sensor, ECT sensor or MAP sensor in Section 6E.


EGR system in Section 6E.

Accelerator cable adjustment in Section 6E.

Previously outlined.

Diagnosis table in Section 5.

Diagnosis table in Section 7C.





EVAP control system in Section 6E.


ECT sensor, TP sensor or MAP sensor in Section 6E.

PCV system in Section 6F.












Ignition coil assembly or high-tension cords in Section 6F.


MAP sensor in Section 6E.





Condition

Excessive detonation

(The engine makes sharp metallic knocks that change with throttle opening.

Sounds like pop corn popping.)

Overheating

Poor gasoline mileage

Possible Cause

Engine overheating

• Faulty spark plug

• Poor water pump performance

• Clogged or leaky radiator

• Improper engine oil grade

Reference Item


Spark plugs in Section 6F.

• Clogged fuel filter and fuel lines


• Poor performance of knock sensor, ECT sensor or MAP sensor



Knock sensor in this section, ECT sensor or MAP sensor in Section 6E.

Diagnostic Flow Table B-1 • Faulty injector

• Faulty ECM Inspection of ECM and its circuit in this section.

• Excessive combustion chamber deposits Piston and cylinder head in Section

6A1.

• Inoperative thermostat Thermostat in Section 6B.

• Faulty A/C condenser fan motor or its circuit

• Loose or slip water pump belt

A/C condenser fan control system check in Section 6E.

ITEM1-1 Drive belt inspection and change in Section 0B.

Water pump in Section 6B.

Radiator in Section 6B.

ITEM1-3 Engine oil and oil filter change in Section 0B.

• Clogged oil filter or oil strainer

• Poor oil pump performance

• Dragging brakes

• Slipping clutch

• Blown cylinder head gasket



• Faulty TP sensor, ECT sensor or MAP sensor

• Faulty injector

• Faulty ECM


• High idle speed

Oil pressure check in Section 6A1.

Oil pressure check in Section 6A1.

Diagnosis Table in Section 5.

Diagnosis Table in Section 7C.


6A1.







Low compression

• Poor valve seating

• Dragging brakes

• Slipping clutch

• Thermostat out of order

• Improper tire pressure

Refer to item “Improper Engine Idle

Speed” previously outlined.



6A1.

Diagnosis Table in Section 5.

Diagnosis Table in Section 7C.

Thermostat in Section 6B.

Refer to Section 3F.


Condition

Excessive engine oil consumption

Low oil pressure

Engine noise

See NOTE below.

Possible Cause

• Sticky piston ring

• Worn piston and cylinder

• Worn piston ring groove and ring

• Improper location of piston ring gap

• Worn or damaged valve stem seal

• Worn valve stem

• Improper oil viscosity

• Malfunctioning oil pressure switch

• Clogged oil strainer

Reference Item

Pistons, piston rings, connecting rods and cylinders in Section 6A1.





6A1.


6A1.

ITEM1-3 Engine oil and oil filter change in Section 0B.

Oil pressure switch in Section 8.

Oil pan and oil pump strainer in Section 6A1.

Oil pump in Section 6A1.

Oil pump in Section 6A1.

Refer to Section 6A1.

• Functional deterioration of oil pump

• Worn oil pump relief valve

• Excessive clearance in various sliding parts

• Improper valve lash

• Worn valve stem and guide

• Weak or broken valve spring

• Warped or bent valve

• Loose camshaft housing bolts

• Worn piston, ring and cylinder bore

• Worn crankpin bearing

• Worn crankpin

Valve lash in Section 6A1.


6A1.

Valve springs in Section 6A1.


6A1.

Camshaft in Section 6A1.

Pistons and cylinders in Section 6A1.

Crankpin and connecting rod bearing in Section 6A1.

Crankpin and connecting rod bearing in Section 6A1.

• Loose connecting rod nuts

• Low oil pressure

Connecting rod in Section 6A1.


• Worn crankshaft journal bearing

• Worn crankshaft journal

Main bearings, Crankshaft and cylinder block in Section 6A1.

Main bearings, Crankshaft and cylinder block in Section 6A1.

• Loose lower crankcase (bearing cap) bolts Main bearings, Crankshaft and cylinder block in Section 6A1.

• Excessive crankshaft thrust play Main bearings, Crankshaft and cylinder block in Section 6A1.

NOTE:

Before checking the mechanical noise, make sure that :

• Ignition timing is properly adjusted.

• Specified spark plug is used.

• Specified fuel is used.


Condition

Excessive hydrocarbon (HC) emission or

Excessive carbon monoxide (CO) emission

Excessive nitrogen oxides (NOx) emission

Possible Cause



• Lead contamination of three way catalytic converter


• Faulty EVAP control system

• Closed loop system (A/F feed back compensation) fails

– Faulty TP sensor

– Faulty ECT sensor or MAP sensor

– Faulty oxygen sensor

• Faulty injector

• Faulty ECM

Reference Item



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.

Low compression


• Lead contamination of three way catalytic converter

• Closed loop system (A/F feed back compensation) fails

– Faulty TP sensor

– Faulty ECT sensor or MAP sensor

– Faulty oxygen sensor

• Faulty injector

• Faulty ECM

• Faulty EGR system (if equipped)





Maintenance in Section 6K.

Check oxygen sensor output voltage

Refer to DTC P0130 (No.14) Table in this section.





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 condition, 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 condition) as indicated by the scan tool. Be sure to use the timing light to check the ignition timing.

NOTE:

• With the generic scan tool, only star (

✱

• The triangle (

∆∆∆∆) marked data in the table below can not be read for vehicle without immobilizer indi-

cator lamp at combination meter.

• When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park” position and pull the parking brake fully. Also, if nothing or “no load” is indicated, turn OFF A/C, all electric loads, P/S and all the other necessary switches.

SCAN TOOL DATA

SYSTEM STATUS)

(CALCULATED LOAD

VALUE)

CONDITION

At specified idle speed after warming up

At specified idle speed with no load after warming up

At 2500 r/min with no load after warming up

REFERENCE VALUES

CLOSED (closed loop)

3 – 9 %

12 – 17 %

80 – 100 °C, 176 – 212 °F (ENGINE COOLANT

TEMP.)



TERM FUEL TRIM)


FUEL TRIM)

ABSOLUTE PRESSURE)

ENGINE SPEED

At specified idle speed with no load after

At idling with no load after warming up

At stop

(IGNITION TIMING

ADVANCE FOR NO.1 CYL-

INDER)


INTAKE AIR TEMP.


RATE)

THROTTLE POS

(THROTTLE POSITION)

GEN SENSOR-1)


Throttle valve fully closed Ignition switch

ON / engine stopped

Throttle valve fully open


– 20 – +20 %

– 15 – +15 %

30 – 37 kPa,

220 – 340 mmHg

Desired idle speed

±50 r/min

0 km/h, 0 MPH

5 – 16° BTDC

Ambient temp. :

+15 °C (59 °F)

–5 °C (23 °F)

1 – 4 gm/sec

7 – 18 %

70 – 90 %

0.01 – 0.95 V

∆


SCAN TOOL DATA

GEN SENSOR-2)

DESIRED IDLE

(DESIRED IDLE SPEED)

TP SENSOR VOLT

(THROTTLE POSITION

SENSOR OUTPUT VOLT-

AGE)

INJ PULSE WIDTH (FUEL

INJECTION PULSE

WIDTH)

CONDITION

When engine is running at 2000 r/min. for

3 min or longer after warming up.

No load to power steering.

At idling with no load after warming up, M/T at neutral, A/T at “P” range

Ignition switch

ON / engine stopped

Throttle valve fully closed

Throttle valve fully open


At 2500 r/min with no load after warming up

IAC FLOW DUTY (IDLE

AIR CONTROL FLOW

DUTY)

TOTAL FT B1

BATTERY VOLTAGE

CANIST PRG DUTY

(EVAP CANISTER PURGE

FLOW DUTY)

CLOSED THROT POS

(CLOSED THROTTLE

POSITION)

At idling with no load after warming up


Ignition switch ON / engine stop

–

FUEL CUT

A/C CONDENSER FAN

ELECTRIC LOAD

A/C SWITCH

Throttle valve at idle position

Throttle valve opens larger than idle position

When engine is at fuel cut condition

Other than fuel cut condition

Ignition switch

ON

A/C not operating

A/C operating

Ignition switch ON / Headlight, small light, heater fan and rear window defogger all turned OFF

Ignition switch ON / Headlight, small light, heater fan or rear window defogger turned

ON

Engine running after warming up, A/C not operating

Engine running after warming up, A/C operating

PNP SIGNAL (PARK / NEU-

TRAL POSITION SIGNAL)

A/T only

EGR VALVE

FUEL TANK LEVEL

Ignition switch

ON

Selector lever in “P” or “N” position

Selector lever in “R”, “D”,

“2” or “L” position


–

BAROMETRIC PRESS –


M/T

A/T

0.01 – 0.95 V

OFF

700 r/min

750 r/min

More than 0.2 V

Less than 4.8 V

2.0 – 3.6 msec.

2.0 – 3.6 msec.

5 – 25 %

– 35 – +35 %

12 – 15 V

0 – 100 %

ON

OFF

ON

OFF

OFF

ON

OFF

ON

OFF

ON

P/N Range

D Range

0 %

0 – 100 %

Display the barometric pressure

FUEL PUMP

Within 3 seconds after ignition switch ON or engine running

Engine stop at ignition switch ON.

ON

OFF


SCAN TOOL DATA

BRAKE SW

BLOWER FAN

A/C MAG CLUTCH

Ignition switch

ON

Ignition switch

ON

CONDITION

Brake pedal is depressing

Brake pedal is releasing

Blower fan switch ON

Blower fan switch OFF

Ignition switch

ON

A/C operating

A/C not operating


ON

OFF

ON

OFF

ON

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 sensor 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 indicates 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.

INTAKE 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, lb/min)

It represents total mass of air entering intake manifold which is computed based on signals from MAP sensor,

IAT sensor, TP sensor, etc.


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 deterioration.

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 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 for A/C operation being output from ECM to A/C amplifier.

OFF : Command for A/C operation not being output.


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.

1. ECM

2. ECM connectors (Viewed from harness side)


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 the battery voltage, confirm that it is 11 V or more when ignition switch is ON.


ECM TERMINAL VOLTAGE VALUES TABLE

For TYPE A (See NOTE)

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.

TERMINAL

NO.

E19

1 Ground

CIRCUIT

2 Ground

3 Ground

4 EVAP canister purge valve

5

6

7

8 Fuel injector NO.4


10

11

12

13

14

15

16

Power steering pressure switch

(if equipped)

Heater of HO2S-1

Sensor ground

–

Heater oxygen sensor-1

CO adjusting resistor (w/o HO2S)

17

18

EGR valve (stepper motor coil 3, if equipped)


19 Ignition coil #2

20 Ignition coil #1


22 Power source for sensors

23

24

25

Idle air control valve

Camshaft position sensor

Engine coolant temp. sensor

Intake air temp. sensor

Throttle opening signal

Crankshaft position sensor

Knock sensor

–

NORMAL

VOLTAGE

–

CONDITION

–

–

10 – 14 V Ignition switch ON

–

–

–

0 – 1.3 V

While engine running at idle speed, turn steering wheel to right or left as far as it stops


0 – 13 V

At specified idle speed after engine warmed up




–

0 – 0.8 V and

4 – 6 V

–

Ignition switch ON

–

–

Refer to DTC P0130 diag. flow table

0 – 5 V Ignition switch ON position

0.55 - 0.95 V

2.0 – 2.7 V

0.2 – 1.0 V

2.8 – 4.8 V

Ignition switch ON

Engine coolant temp. : 80 °C (176 °F)

Ignition switch ON

Intake air temp. : 20 °C (68 °F)

Ignition switch ON position and throttle valve at idle position

Ignition switch ON position and throttle valve fully open

10 – 14 V

10 – 14 V

–

–

Ignition switch ON position leaving engine

OFF


OFF

–

–


4.75 – 5.25 V Ignition switch ON

0 – 0.8 or

Ignition switch ON position

4 – 5 V

–

About 2.5 V

–



TERMINAL

NO.

E19

CIRCUIT NORMAL

VOLTAGE

CONDITION

26

27

28

29

30

Manifold absolute pressure sensor

A/C evaporator temp. sensor



–


3.3 – 4.0 V

2.0 – 2.3 V

Ignition switch ON

Barometric pressure : 100 kPa

(760 mmHg)

Ignition switch ON A/C evaporation temp. sensor at 25 °C (77 °F)


10 – 14 V

10 – 14 V

OFF


OFF

–


–

For TYPE B (See NOTE)

NOTE:

See NOTE in “ECM TERMINAL VOLTAGE VALUES TABLE” for applicable model.

TERMINAL

NO.

E19

1 Ground

2 Ground

CIRCUIT

3 Ground

4 EVAP canister purge valve

5

6

7

8

9

10

11

12

13

14

15

16

17


(if equipped)

Idle air control valve

Heater of HO2S-1

Fuel injector NO.4

Fuel injector NO.1

Sensor ground

Camshaft position sensor

–

Heater oxygen sensor-1


Engine coolant temp. sensor

Intake air temp. sensor

Throttle opening signal


NORMAL

VOLTAGE

–

–

CONDITION

–

–

– –


0 – 1.3 V

While engine running at idle speed, turn steering wheel to right or left as far as it stops


0 – 13 V





– –

0 – 0.8 V and

4 – 6 V

–

Ignition switch ON

0.55 - 0.95 V

–


0 – 5 V Ignition switch ON position

Ignition switch ON

Engine coolant temp. : 80 °C (176 °F)

2.0 – 2.7 V

0.2 – 1.0 V

2.8 – 4.8 V

10 – 14 V

Ignition switch ON

Intake air temp. : 20 °C (68 °F)

Ignition switch ON position and throttle valve at idle position

Ignition switch ON position and throttle valve fully open


OFF


TERMINAL

NO.

E19

CIRCUIT

18


19 Ignition coil #2

20 Ignition coil #1


22 Power source for sensors

23

24

25

26

Crankshaft position sensor

Knock sensor

–

Manifold absolute pressure sensor

NORMAL

VOLTAGE

CONDITION

10 – 14 V

–


OFF

–

– –



0 – 0.8 or

4 – 5 V

–

Ignition switch ON position

About 2.5 V

3.3 – 4.0 V

–


Ignition switch ON

Barometric pressure : 100 kPa

(760 mmHg)

27

28

29

–



30 –


–

10 – 14 V

–


OFF

10 – 14 V

–


OFF

–



NOTE:


TERMINAL

NO.

CIRCUIT

1 A/C compressor clutch

2 Malfunction indicator lamp

E18

3 Data link connector

4 Heater of HO2S-2 (if equipped)

5 Power source

6 Power source

7 Power source for buck-up

Immobilizer indicator lamp

(with immobilizer indicator lamp)

8

Duty output terminal (without immobilizer indicator lamp)

9 –

10 Main relay

11 Tachometer


13 Heated oxygen sensor-2

NORMAL

VOLTAGE

CONDITION

0 V Ignition switch ON

10 – 14 V Engine running

0 – 1.0 V Ignition switch ON leaving engine OFF





10 – 14 V Ignition switch ON and OFF



0 – 1.0 V Ignition switch ON

–

10 – 14 V Ignition switch OFF


–

–



–


TERMINAL

NO.

CIRCUIT

14

15

Diag. Switch terminal (without immobilizer indicator lamp)

Test switch terminal (without immobilizer indicator lamp)

E18

16

17

18

19

20

21

22

23

24

A/C (input) signal

Lighting switch

A/C condenser fan motor relay

(if equipped)

Fuel pump relay

Sensor ground

Throttle opening signal for

TCM (A/T)

Fuel level sensor (gauge)


–

Heater blower switch

NORMAL

VOLTAGE

4 – 5 V

CONDITION

Ignition switch ON


10 – 14 V

0 – 2 V

Ignition switch ON

A/C switch OFF

Ignition switch ON

A/C switch ON

10 – 14 V Lighting switch ON

0 – 1.3 V Lighting switch OFF

0 – 1.0 V A/C is operating

10 – 14 V A/C is not operating

0 – 1 V For 2 seconds after ignition switch ON

10 – 14 V After the above time

–

Indication

– deflection repeated

0 V and

10 – 14 V

Ignition switch ON

0 – 2 V

4.5 – 7.5 V

–

0 – 2.0 V

10 – 14 V

Ignition switch ON

Fuel tank fully filled

Ignition switch ON

Fuel tank emptied

–

Ignition switch ON and heater blower switch ON

Ignition switch ON and heater blower switch OFF


NOTE:


TERMINAL

NO.

3

4

5 Power source

CIRCUIT

1 A/C compressor clutch

2 –

–

–

E18 6 Power source

7 Power source for buck-up

8



Duty output terminal (without immobilizer indicator lamp)

NORMAL

VOLTAGE

0 V

–

–

CONDITION

Ignition switch ON

–

–

– –



10 – 14 V Ignition switch ON and OFF



0 – 1.0 V Ignition switch ON


TERMINAL

NO.

E18

CIRCUIT

9 Ignition switch

10 Main relay

11 Ignition switch

12 Rear defogger switch (if equipped)

17 Lighting switch

18

A/C condenser fan motor relay

(if equipped)

19 Fuel pump relay

20 Engine start signal

NORMAL

VOLTAGE

CONDITION


10 – 14 V Ignition switch OFF



Ignition switch ON and rear defogger

10 – 14 V switch ON

0 – 1.3 V

–

Ignition switch ON and rear defogger switch OFF

–


13

14

15

–

Diag. Switch terminal (without immobilizer indicator lamp)

Test switch terminal (without immobilizer indicator lamp)

16

21

22

23

24

A/C (input) signal

Stop lamp switch

Vehicle speed sensor

–

–


10 – 14 V

Ignition switch ON

A/C switch OFF

0 – 2 V

Ignition switch ON

A/C switch ON

10 – 14 V Lighting switch ON

0 – 1.3 V Lighting switch OFF

0 – 1.0 V A/C is operating

10 – 14 V A/C is not operating

0 – 1 V For 2 seconds after ignition switch ON

10 – 14 V After the above time

6 – 14 V While engine cranking

0 V

10 – 14 V

Ignition switch ON

Stop lamp switch OFF

Ignition switch ON

Stop lamp switch ON deflect between

0 – 1.6 and

4 – 14 V

–

–

Ignition switch ON and rear right wheel turned slowly with rear left wheel locked

–

–


NOTE:


TERMINAL

NO.

1

E17 2

3 Blank

CIRCUIT

–

R-range signal (A/T)

NORMAL

VOLTAGE

–

10 – 14 V

0 – 1.3 V

–

CONDITION

–

Ignition switch ON and shift select switch in R range

Ignition switch ON and shift select switch in other than R range

–


TERMINAL

NO.

E17

4

5

6

7

8

Blank

CIRCUIT

Overdrive cut signal (A/T)

D-range idle up signal (A/T)

Stop lamp switch

9 Ignition switch

10

11

–

–


12 ABS signal (if equipped)

13 Engine start signal

14

15

16

–

–

Rear defogger switch (if equipped)

17 A/T failure signal (with immobilizer indicator lamp) (A/T)

NORMAL

VOLTAGE

–

CONDITION

0 – 1.0 V

10 – 14 V

10 – 14 V

0 – 1.6 V

0 V

–

Ignition switch ON and ECT less than

60 °C

Ignition switch ON and ECT more than

60 °C

Ignition switch ON and shift select switch in other than P and N range

Ignition switch ON and shift select switch in P and N range

Ignition switch ON

Stop lamp switch OFF

10 – 14 V

Ignition switch ON

Stop lamp switch ON

–


–

– – deflect

between

0 – 1.6 and

4 – 14 V

Ignition switch ON and rear right wheel turned slowly with rear left wheel locked


6 – 14 V

–

While engine cranking

–

– –

10 – 14 V Ignition switch ON and rear defogger switch ON

0 – 1.3 V Ignition switch ON and rear defogger switch OFF

– –


NOTE:


TERMINAL

NO.

E17

1

2

3

4

Blank

Blank

CIRCUIT



NORMAL

VOLTAGE

CONDITION

2.0 – 2.3 V

10 – 14 V

0 – 1.3 V

–

–

Ignition switch ON

A/C evaporator temp. sensor at 25 °C

(77 °F)

Ignition switch ON and shift select switch in R range

Ignition switch ON and shift select switch in other than R range

–

–


TERMINAL

NO.

CIRCUIT

5 Overdrive cut signal (A/T)

E17

6

14

15

D-range idle up signal (A/T)


8 –

9 Malfunction indicator lamp

10 –


12 ABS signal (if equipped)

13 Heater blower switch

Sensor ground

Throttle opening signal for

TCM (A/T)

16 Tachometer

17 –

NORMAL

VOLTAGE

CONDITION

0 – 1.0 V

10 – 14 V

Ignition switch ON and ECT less than

60° C

Ignition switch ON and ECT more than

60 °C

10 – 14 V

0 – 1.6 V

Ignition switch ON and shift select switch in other than P and N range

Ignition switch ON and shift select switch in P and N range

Ignition switch ON

–

4 – 5 V

–



– –



Ignition switch ON and heater blower

0 – 2.0 V switch ON

10 – 14 V

Ignition switch ON and heater blower switch OFF

– –

Indication deflection repeated 0 V and 10 - 14 V

–

–

Ignition switch ON

–

–


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 disconnected.

CAUTION:

• Be sure to connect ohmmeter probe from wire harness side of coupler.

• Be sure to turn OFF ignition switch for this check.

• Resistance in table below represents that when parts temperature is 20 °C (68 °F).

1. ECM coupler disconnected

2. Ohmmeter

TERMINALS

E19-7 to E17-9

(For TYPE A) (See NOTE)

E19-7 to E18-11

(For TYPE B) (See NOTE)

HO2S-1 heater

CIRCUIT

E18-4 to E17-9

(For TYPE A) (See NOTE)

E19-9 to E19-2

E19-21 to E19-2

E19-31 to E19-2

E19-8 to E19-2

E19-28 to E19-2

HO2S-2 heater

No.1 injector

No.2 injector

No.3 injector

No.4 injector

EGR valve (stepper motor coil 4)



E19-17 to E19-2

E19-29 to E19-2

E19-18 to E19-2

E19-4 to E19-2

E18-19 to E17-9 (For

TYPE A) (See NOTE)


EVAP canister purge valve

Fuel pump relay

E18-19 to E18-11 (For

TYPE B) (See NOTE)

E18-1 to Body ground A/C compressor clutch

E18-18 to E19-2

E18-10 to E18-7

A/C condenser fan control relay

Main relay

E19-1 to Body ground Ground



STANDARD RESISTANCE

5 – 6.4

Ω

11.7 – 14.3

12.0 – 13.0

30 – 34

70 – 110

Ω

Ω

12.0 – 13.0

Ω

12.0 – 13.0

Ω

12.0 – 13.0

Ω

20 – 24

Ω

20 – 24

Ω

20 – 24

Ω

20 – 24

Ω

Ω

3 – 4.5

Ω

70 – 110

Ω

70 – 110

Ω

Continuity

Continuity

Continuity

Ω

NOTE:

For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable model.


Component Location

NOTE:

The figure shows left-hand steering vehicle.

For right-hand steering vehicle, parts with (*) are installed at the other side.

1. IAT sensor

2. TP sensor


4. CO adjusting resistor (if equipped)

5. CKP sensor

6. MAP sensor

7. CMP sensor

8. Transmission range switch

9. VSS

10. HO2S-1 (if equipped)


12. ECT sensor

13. Knock sensor a : Immobilizer indicator lamp (if equipped) b : A/C condenser fan motor relay (if equipped) c : Main relay d : Fuel pump relay e : IAC valve f : EVAP canister purge valve g : EGR valve (if equipped) h : Fuel injector

i : Ignition coil assemblies j : MIL

A : ECM

B : A/T control module

C : EVAP canister

D : DLC

E : ABS control module (if equipped)


Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come

“ON” at Ignition Switch ON (But Engine at Stop)


1. Main fuse

2. Ignition switch

3. Fuse box

4. Main relay

5. Malfunction indicator lamp in combination meter

6. “FI” fuse

7. “IG” fuse

8. “IG COIL METER” fuse

[A] : Case of TYPE A is shown

(See NOTE)

[B] : Case of TYPE B is shown

(See NOTE)

NOTE:


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

1 MIL Power Supply Check


Do other indicator / warning lights in combination meter comes ON?

Yes

Go to Step 2.

No

“IG” fuse blown, main fuse blown, ignition switch malfunction, “B/W” circuit between “IG” fuse and combination meter or poor coupler connection at combination meter.


Step Action

2 ECM Power and Ground Circuit Check

Does engine start?

Yes

Go to Step 3.

3 MIL Circuit Check

1) Turn ignition switch OFF and disconnect connectors from ECM.

2) Check for proper connection to ECM at terminal 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 terminal 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?


ECM and recheck.

No

Go to “Table A-5 ECM

Power and Ground Circuit

Check”.

If engine is not cranked, go to “Diagnosis” in Section 8G.

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

1 Diagnostic Trouble Code (DTC) check

1) Check DTC referring to DTC CHECK section.


2 DTC check

1) Start engine and recheck DTC while engine running.


3 MIL Circuit check

1) Turn OFF ignition switch.

2) Disconnect connectors from ECM.

Does MIL turn ON at ignition switch ON?

Yes

Go to Step 2 of “Engine

Diag. Flow Table”.

“V/Y” wire circuit shorted to ground.

No

Go to Step 2.

Go to Step 3.


ECM and recheck.


Table A-3 Malfunction Indicator Lamp Circuit Check - Mil Flashes at Ignition

Switch ON


Refer to table A-1.

INSPECTION

Step Action

1 MIL flashing pattern check :

1) With the ignition switch ON position, check

MIL flashing pattern.

Does MIL flashing pattern indicate DTC (diagnostic trouble code)?

2 Diagnosis switch terminal check :

1) With the ignition switch ON position, check voltage between E18-14 terminal of ECM coupler and ground.

Is voltage 4 – 5 V?

Yes

Go to Step 2.


ECM and recheck.


No

“W/Bl” wire (diagnosis switch terminal) shorted to ground circuit.

If OK, substitute a knowngood 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


Refer to table A-1.

INSPECTION

Step Action

1 MIL flashing pattern check :

1) With grounding diagnosis switch terminal and turn the ignition switch ON position, check voltage between E18-14 terminal of

ECM connector and ground.


2 Test switch terminal circuit check :

1) With the ignition switch ON position, check voltage between E18-15 terminal of ECM connector and ground.


Yes

Go to Step 2.


ECM and recheck.

No

“W/Bl” wire (diagnosis switch terminal), “B” wire of monitor connector open.


“P” wire (test switch terminal) shorted to ground circuit.



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


1. Main fuse

2. Ignition switch

3. Fuse box

4. Main relay


6. “FI” fuse

7. “IG” fuse


[A] : Case of TYPE A is shown (See

NOTE)

[B] : Case of TYPE B is shown (See

NOTE)

NOTE:


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

1 Main Relay Operating Sound Check

Is operating sound of main relay heard at ignition switch ON?

2 Main Relay Check

1) Turn OFF ignition switch and remove main relay (1).

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

Ω (at 20 °C, 68 °F)

4) Check that there is continuity between terminals 1 and 2 when battery is connected to terminals 3 and 4. See Fig. 3.

Is main relay in good condition?

Yes No

Go to Step 5. Go to Step 2.

Go to Step 3. Replace main relay.


Step

3 Fuse Check

Action

Is main “FI” fuse in good condition? See Fig. 1.

4 ECM Power Circuit Check

1) Turn OFF ignition switch, disconnect connectors from ECM and install main relay.

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?

5 ECM Power Circuit Check

1) Using service wire, ground terminal E18-10 and measure voltage between terminal E18-5 and ground at ignition switch ON.

Is it 10 – 14 V?

6

7

Is operating sound of main relay heard in Step 1?

Main Relay Check

1) Check main relay according to procedure in Step 2.

Is main relay in good condition?

Yes No

Go to Step 4. Check for short in circuits connected to this fuse.

Go to Step 5. “B/W”, “Or” or

“Bl/B” circuit open.

Check ground circuits “B” and

“B/R” for open.

If OK, then substitute a known-good

ECM and recheck.

Go to Step 6.

Go to Step 7. “Bl/B” or “B/

R” wire open.

“Or” or “Bl/B” wire open.

Replace main relay.

[A] Fig. 1 for Step 2 and 3 / [B] Fig. 2 for Step 2 / [C] Fig. 3 for Step 2

2. “F1” fuse


DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunction


DTC DETECTING CONDITION

• MAP sensor signal is 0.19 V or lower.

(Low pressure – High vacuums – Low voltage)

• MAP sensor signal is 4.5 V or higher.

(High pressure – Low vacuums – High voltage)

POSSIBLE CAUSE

• “B/Bl” circuit open

• “Lg/R” circuit open or shorted to ground

• “G” circuit open or shorted to ground

• MAP sensor malfunction

• ECM malfunction

NOTE:

• When DTC P0120 is indicated together, it is possible that “Lg/R” circuit is open.

• When DTC P0105 (No.11), P0110 (No.18) P0115 (No.19) P0120 (No.13) and P0460 are indicated together, it is possible that “B/Bl” 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

1 Was “Engine Diag. Flow Table” performed?

Yes

Go to Step 2.

2 Check MAP Sensor and Its Circuit.

1) Connect scan tool to DLC with ignition switch OFF. See Fig. 1.


3) Check intake manifold pressure.

Is it 126 kPa (37.2 inHg) or 0 kPa (0 inHg)?

Go to Step 3.

No


Table”.

Intermittent trouble.

Check for intermittent referring to “Intermittent and Poor Connection” in

Section 0A.


Step Action

3 Check Wire Harness.

1) Disconnect MAP sensor connector with ignition switch OFF.

2) Check for proper connection of MAP sensor at “G” and “B/Bl” wire terminals.

3) If OK, then with ignition switch ON, check voltage at each of “Lg/R” and “G” wire terminals and body ground. See Fig. 2.

Is voltage about 4 – 6 V at each terminal?

4 Check MAP sensor according to “MAP Sensor

Individual Check” below.


Yes

Go to Step 4.

No

“Lg/R” wire open or shorted to ground circuit or shorted to power circuit

(See NOTE), “G” wire open or shorted to ground, poor E19-26 connection or E19-22 connection.


OK, confirm that MAP sensor is normal and then substitute a known-good

ECM and recheck.

“Lg/R” wire shorted to “G” wire, “B/Bl” wire open, poor E19-10 connection.


OK, substitute a knowngood ECM and recheck.

Replace MAP sensor.

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


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

(Reference)

(ft) (m)

0

|

2 000

2 001

|

5 000

5 001

|

8 000

8 001

|

10 000

2 439

|

3 048

0

|

610

611

|

1 524

1 525

|

2 438

BAROMETRIC

PRESSURE

(mmHg) (kPa)

760

|

707

Under 707 over 634

Under 634 over 567

100

|

94

94

|

85

85

|

76

Under 567 over 526

76

|

70

OUTPUT

VOLTAGE

(V)

3.3 – 4.3

3.0 – 4.1

2.7 – 3.7

2.5 – 3.3

4) Install MAP sensor (1) securely.

5) Connect MAP sensor (1) connector securely.


DTC P0110 (DTC No.18) Intake Air Temp. (IAT) Circuit Malfunction



• Low intake air temperature (High voltage-High resistance)

• High intake air temperature (Low voltage-Low resistance)

POSSIBLE CAUSE

• “Lg/R” circuit open or shorted to power.


• IAT sensor malfunction

• ECM malfunction

NOTE:

• When DTC P0105 (No.11), P0110 (No.18), P046, P0115 (No.19) and P0120 (No.13) are indicated together, it is possible that “B/Bl” circuit is open.

• Before inspecting, be sure to check that ambient temperature is higher than –40 °C (–40 °F).



2) Select “DTC” mode no scan tool and check DTC.

INSPECTION

Step Action


Yes

Go to Step 2.

2 Check IAT Sensor and Its Circuit.

1) Connect scan tool to DLC with ignition switch OFF. See Fig. 1.


3) Check intake air temp. displayed on scan tool.

Is –40 °C (–40 °F) or 119 °C (246 °F) indicated?

Go to Step 3.

No


Table”.



Section 0A.


Step Action


1) Disconnect IAT sensor connector with ignition switch OFF.

2) Check for proper connection to IAT sensor at “Lg/B” and “B/Bl” wire terminals.

See Fig. 2.

3) If OK, then with ignition switch ON.

Is voltage applied to “Lg/B” wire terminal about

4 – 6 V?

4 Does scan tool indicate –40 °C (–40 °F) at Step

2.

5 Check Wire Harness

1) Check intake air temp. displayed on scan tool with ignition switch ON.

Is –40 °C (–40 °F) indicated?

Yes

Go to Step 5.

Go to Step 6.

Replace IAT sensor.


1) Using service wire, connect IAT sensor connector terminals.

2) Check intake air temp. displayed on scan tool with ignition switch ON. See Fig. 3.

Is 119 °C (246 °F) indicated?

Replace IAT sensor.


No

“Lg/B” wire open or shorted to power, or poor

E19-15 connection.



Go to Step 5.

“Lg/B” wire shorted to ground.

If wire is OK, substitute a known-good ECM and recheck.

“Lg/B” wire open or poor

E19-10 connection.




DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunction



• Low engine coolant temperature (High voltage-High resistance)

• High engine coolant temperature (Low voltage-Low resistance)

POSSIBLE CAUSE

• “G/B” circuit open or shorted to power


• ECT sensor malfunction

• ECM malfunction

NOTE:

• When DTC P0105 (No.11), P0110 (No.18), P0115 (No.19), P0120 (No.13) and P0460 are indicated together, it is possible that “B/Bl” circuit is open.

• Before inspecting, be sure to check that coolant temp. meter in combination meter indicates normal operating temperature (Engine is not overheating).

• When this DTC and P1709 are stored together, also clear DTC stored in TCM after completion of repair.





INSPECTION

Step Action


Yes

Go to Step 2.

2 Check ECT Sensor and Its Circuit.

1) Connect scan tool with ignition switch OFF.

See Fig. 1.


3) Check engine coolant temp. displayed on scan tool.

Is –40 °C (–40 °F) or 119 °C (246 °F) indicated?


1) Disconnect ECT sensor connector.

2) Check engine coolant temp. displayed on scan tool.

Is –40 °C (–40 °F) indicated?

4 Does scan tool indicate –40 °C (–40 °F) at Step

2.


1) Disconnect ECT sensor connector with ignition switch OFF.

2) Check for proper connection to ECT sensor at “B/Bl” and “G/B” wire terminals.

See Fig. 2.

3) If OK, then with ignition switch ON.

Is voltage applied to “B/Bl” wire terminal about

4 – 6 V?


1) Using service wire, connect ECT sensor connector terminals. See Fig. 3.

2) Turn ignition switch ON and check engine coolant temp. displayed on scan tool.

Is 119 °C (246 °F) indicated?

Go to Step 3.

Replace ECT sensor.

Go to Step 6.

Go to Step 4.

Replace ECT sensor.


No


Table”.



Section 0A.

“G/B” wire shorted to ground.

If wire is OK, substitute a known-good ECM and recheck.

Go to Step 5.

“G/B” wire open or shorted to power, or poor

E19-14 connection.



“B/Bl” wire open or poor

E19-10 connection.




DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction



• Signal voltage high

• Signal voltage low

POSSIBLE CAUSE


• “Lg” circuit open or shorted to ground

• “B/Bl” circuit open or shorted to power or ground

• TP sensor malfunction

• ECM malfunction

NOTE:

• 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/Bl” or “Lg/R” circuit is open.

• When this DTC and P1700 are stored together, also clear DTC stored in TCM after completion of repair.





INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Check TP Sensor and Its Circuit.

1) Connect scan tool to DLC with ignition switch OFF and then turn ignition switch ON.

Go to Step 3.

See Fig. 1.

2) Check throttle valve opening percentage displayed on scan tool.

No


Table”.



Section 0A.

Is it displayed 0% or 100%?


1) Disconnect connector from TP sensor with ignition switch OFF.

2) Check for proper connection to TP sensor at

“Lg/R”, “Lg” and “B/Bl” wire terminal.

3) If OK, then with ignition switch ON, check voltage at each of “Lg/R” and “Lg” wire terminals and body ground. See Fig. 2.

Is voltage about 4 – 6 V at each terminal?

4 Check TP Sensor.

1) Check resistance between terminals of TP sensor. See Fig. 3.

TP sensor resistance

Between 1 and 3 : 4.0 – 6.0 k

Ω

Between 2 and 3 : Varying according to throttle valve opening (0.02 – 6.0 k

Ω

Are measured values within specifications?

Go to Step 4.

“Lg/R” wire open, “Lg/R” wire shorted to ground circuit or power circuit or

“B/Bl” wire, “Lg” wire open or shorted to ground circuit or poor E19-22 or

E19-16 connection.



“B/Bl” wire open or poor

E19-10 connection.



Replace TP sensor.



DTC P0121 Throttle Position Circuit Range / Performance Problem

WIRING DIAGRAM

Refer to DTC P0120 section.



• After engine warmed up.

• Difference between actual throttle opening (detected from TP sensor) and opening calculated by ECM (Obtained on the basis of engine speed and intake manifold pressure) in larger than specified value.

✱2 driving cycle detection logic, continuous monitoring

POSSIBLE CAUSE

• TP sensor malfunction

• High resistance in the circuit

• ECM malfunction


WARNING:

• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.

• Road test should be carried out with 2 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, 158 °F or lower

– Engine coolant temp. : 70 °C, 158 °F or higher


3) 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 “PENDING DTC” mode.

INSPECTION

Step

1

Action


Yes

Go to Step 2.


3 Check TP Sensor and Its Circuit.

1) Turn ignition switch OFF and connect

SUZUKI scan tool to DLC. See Fig. 1.

2) Turn ignition switch ON and check TP sensor 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?

Go to Step 3.


ECM and recheck.

No


Table”.

Go to Step 4.

Go to Step 5.


Step Action

4 Check TP Sensor and its Circuit.


2) Check voltage at terminal E19-16 of ECM connector connected, when throttle valve is at idle position and fully opened. See Fig. 2 and 3.

Dose voltage vary within specified value linearly as shown in figure?

5 Check TP Sensor.


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 k

Ω

Between 1 and 3 : 0.02 – 6.0 k

Ω

according to throttle valve opening.

Are measured values as specified?

Yes

If voltmeter was used, check terminal E19-16 for poor connection.


No

Go to Step 5.

High resistance in “Lg/R”,

“Lg” or “B/Bl” circuit.



Replace TP sensor.

[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 4 / [C] Fig. 3 for Step 3 and 4

[A] : When using SUZUKI scan tool.

[B] : When not using SUZUKI scan tool.

Fig. 4 for Step 5


DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction

(Sensor-1)


1. Heated oxygen sensor-1 (HO2S-1)


• When running at idle speed after engine warmed up and running at specified vehicle speed, HO2S-1 output voltage does not go below 0.3 V or over 0.6 V.

✱2 driving cycle detection logic, Monitoring once / 1 driving.

POSSIBLE CAUSE

• Heated oxygen sensor-1 malfunction

• “B/Bl” or “R” circuit open (poor connection) or short


WARNING:


• 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 :





3) Drive vehicle at 30 – 40 mph, 50 – 60 km/h for 2 min.

4) Stop vehicle and run engine at idle for 2 min.



INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Is there DTC(s) other than HO2S-1

(DTC P0130)?

3 1) Connect scan tool to DLC with ignition switch OFF. See Fig. 1.

2) Warm up engine to normal operating temperature and keep it at 2000 r/min. for 60 sec.

3) Repeat racing engine (Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from pedal 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?

Go to applicable DTC

Diag. Flow Table.



Section 0A.

No

Go to “ENGINE DIAG.

FLOW TABLE”.

Go to Step 3.

Check “R” and “B/Bl” wires for open and short, and connections for poor connection.

If wires and connections are OK, replace HO2S-1.



DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)

WIRING DIAGRAM




• When running at specified idle speed after engine warmed up and 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

POSSIBLE CAUSE


Fig. 1



INSPECTION

Step Action


2 Is there DTC(s) other than HO2S-1 (DTC

P0133)?

Yes

Go to Step 2.


Diag. Flow Table.

No


Table”.

Replace HO2S-1.


DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1)


1. Heated oxygen sensor-1 (HO2S-1) heater


DTC will set when A or B condition is met.

A :

• Low voltage at terminal E19-7 when engine is running at high load.

B :

• High voltage at terminal E19-7 when engine is running under condition other than above.

POSSIBLE CAUSE

• HO2S-1 heater circuit open or shorted to ground

• ECM malfunction


WARNING:




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.



INSPECTION

Step

1

Action


2 Check Heater for Operation.

1) Check voltage at terminal E19-7. See Fig. 1.


3) Stop engine.

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.

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 it 5 – 6.4

Ω at 20 °C, 68 °F?

Yes

Go to Step 2.

Intermittent trouble Check for intermittent referring to

“Intermittent and Poor

Connection” in Section

0A.

No


Table”.

Go to Step 3.

“P/B” wire open or shorted to ground or poor connection at E19-7. If wire and connection are


Replace HO2S-1.



DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)


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:



Engine is warmed up and HO2S-2 voltage is 4.5 V or more.

(circuit open)

POSSIBLE CAUSE

• Exhaust gas leakage

• “W” or “B/Bl” circuit open or short


• Fuel system malfunction


WARNING:




Clear DTC with ignition switch ON, check vehicle and environmental condition for :




– No exhaust gas leakage and loose connection


3) Drive vehicle under usual driving condition for 5 min. and check HO2S-2 output voltage and “short term fuel trim” with “Data List” mode on scan tool, and write it down.

4) Stop vehicle (don’t turn ignition switch OFF).

5) Increase vehicle speed to higher than 20 mph, 32 km/h and then stop vehicle.


6) Repeat above steps 5) 4 times.

7) Increase vehicle speed to about 50 mph (80 km/h) in 3rd gear or 2 range.

8) Release accelerator pedal and with engine brake applied, keep vehicle coasting (fuel cut condition) for

10sec. or more.

9) 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 displayed in “DTC” mode, confirmation test is completed.

If “TEST NOT COMPLTD” is still being displayed, proceed to next step 10).

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)

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.

*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

1

Action


Yes

Go to Step 2.

No


Table”.

Repair or replace.

2 Check exhaust system for leakage, loose connection and damage.

Is it good condition?

3 Check HO2S-2 and Its Circuit.

Was HO2S-2 output voltage indicated on scan tool in step 3) of DTC confirmation test less than 1.275 V?

4 Check Short Term Fuel Trim.

Did short term fuel trim very within –20 – + 20% range in step 3) of DTC confirmation test?

Go to Step 3.

Go to Step 4.

Check “W” and “B/Bl” wire for open and short, and connection for poor connection. If wire and connection are OK, replace

HO2S-2.

“B/Bl” or “W” circuit open or HO2S-2 malfunction.

Check fuel system. Go to

DTC P0171 / P0172 Diag.

Flow Table.


DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2)



DTC will set when A or B condition it met.

1) Low voltage at terminal E18-4 for specified time after engine start or while engine running at high load.

2) High voltage at terminal E18-4 while engine running under other than above condition.

POSSIBLE CAUSE

• HO2S-2 heater circuit open or shorted to ground

• ECM malfunction


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

Step

1

Action


Yes

Go to Step 2.

No


Table”.

Go to Step 3.

2 Check HO2S-2 Heater and Its Circuit.


2) Stop engine.

3) Turn ignition switch ON and check voltage at 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.

1) Disconnect HO2S-2 coupler with ignition switch OFF.

2) Check for proper connection to HO2S-2 at

“B/W” and “R/Bl” wire terminals.

3) If OK, then check heater for resistance.

Is it 11.7 – 14.3

Ω at 20 °C, 68 °F?



Section 0A.

“R/Bl” wire open or shorted to ground or poor connection at E18-4. If wire and connection are


Replace HO2S-2.

Fig. 1 for Step 2


DTC P0171 Fuel System Too Lean

DTC P0172 Fuel System Too Rich


[a] : Signal to decrease amount of fuel injection

[b] : Signal to increase amount of fuel injection

[c] : A/F mixture becomes leaner

(Oxygen concentration increases)

[d] : A/F mixture becomes richer

(Oxygen concentration decreases)

[e] : High voltage

[f] : Low voltage

1. Injector

2. Heated oxygen sensor-1 (HO2S-1)


• When following condition occurs while engine running under closed loop condition.

– Air / fuel ratio too lean

(Total fuel trim (short and long terms added) is more than 30%) or

– Air / fuel ratio too rich

(Total fuel trim is less than –30%)

POSSIBLE CAUSE

• 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 sensor poor performance.

• ECT sensor poor performance.

• IAT sensor poor performance.

• TP sensor poor performance.

• EVAP control system malfunction.

• PCV valve malfunction.



WARNING:


• Road test should be carried out with 2 persons, a driver and a tester on a level road.


2) Clear DTC with ignition switch ON.

3) Check vehicle and environmental condition for :




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).


INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Is there DTC(s) other than fuel system

(DTC P0171 / P0172)?

3 Check HO2S-1 Output Voltage.

1) Connect scan tool to DLC with ignition switch

OFF. See Fig. 1.

2) Warm up engine to normal operating temperature and keep it at 2000 r/min. for 60 sec.

3) Repeat racing engine (Repeat depressing accelerator pedal 5 to 6 times continuously 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 details).

1) Release fuel pressure from fuel feed line.

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

2

, 38.4 – 44.0 psi.

At specified idle speed :

210 – 260 kPa, 2.1 – 2.6 kg/cm

2

, 29.8 – 37.0 psi.

Is measured value as specified?


Diag. Flow Table.

Go to Step 4.

Go to Step 5.

No

Go to “Engine Diag.

Flow Table”.

Go to Step 3.

Go to DTC P0130 Diag.

Flow Table (HO2S-1 circuit check).

Go to Diag. Flow Table

B-3 Fuel Pressure

Check.


Step Action

5 Check Fuel Injectors and Circuit.

1) Using sound scope (4) or such, check operating sound of each injector (5) when engine is running. Cycle of operating sound should vary according to engine speed. See Fig. 3.

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 injector connector.

3) Check for proper connection to fuel injector at each terminal.

4) 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 injector closed.

Fuel leakage

Less than 1 drop / min. (1)

Is check result in step 1) and 3) to 7) satisfactory?

6 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?

Yes

Go to Step 6.

Check EVAP control system (See Section

6E).

7 Check intake manifold absolute pressure sensor for performance (See step 4) of DTC P0105 (No.11)

Diag. Flow Table).


8 Check engine coolant temp. sensor for performance (See Section 6E).


9 Check intake air temp. sensor for performance

(See Section 6E).


10 Check throttle position sensor for performance

(See step 5) of DTC P0121 Diag. Flow Table).


11 Check PCV valve for valve clogging

(See Section 6E).


Go to Step 8.

Go to Step 9.

Go to Step 10.

Go to Step 11.

Substitute a knowngood ECM and recheck.

No

Check injector circuit or replace fuel injector(s).

Go to Step 7.

Repair or replace.

Replace engine coolant temp. sensor.

Replace intake air temp. sensor.

Replace throttle position sensor.

Replace PCV valve.



1. Fuel delivery pipe

2. Fuel feed hose

3. Fuel pressure gauge & 3 way joint

[D] Fig. 4 for Step 5 / [E] Fig. 5 for Step 5 / [F] Fig. 6 for Step 6


DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders)

DTC P0301 Cylinder 1 Misfire Detected




1. Ignition coil assembly (for No.1 and No.4 cylinder)

2. Ignition coil assembly (for No.2 and No.3 cylinder)

3. Fuel injector

4. CKP sensor

5. CMP sensor


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 change 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 driving cycle detection logic.



• Engine under other than high revolution condition

• Not on rough road

• Engine speed changing rate (below specified value)

• Manifold absolute pressure changing rate (below specified value)

• Throttle opening changing rate (below specified value)

• Misfire rate per 200 or 1000 engine revolutions (how much and how often crankshaft revolution speed changes) is higher than specified value

POSSIBLE CAUSE

• Engine overheating

• Vacuum leaks (air inhaling) from air intake system

• Ignition system malfunction (spark plug(s), hightension cord(s), ignition coil assembly)


• Fuel injector malfunction (clogged or leakage)

• Engine compression out of specification

• Valve lash (clearance) out of specification

• Manifold absolute pressure sensor malfunction

• Engine coolant temp. sensor malfunction

• PCV valve malfunction

• EVAP control system malfunction

• EGR system malfunction


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 procedure. 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 confirmation procedure, proceed to the following Diag. Flow Table.

WARNING:





3) Check vehicle and environmental condition for :




– Engine coolant temp. : – 10 – 110 °C, 14 – 230 °F

4) Start engine and keep it at idle for 2 min. or more.


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


2 Is there DTC other than Fuel system (DTC P0171/

P0172) and misfire (DTC P0300 – P0304)?

Yes

Go to Step 2.


Diag. Flow Table.

No

Go to “Engine

Diag. Flow Table”.

Go to Step 3.


Step Action

3 Check Ignition System.

1) Remove spark plugs and check them for;

• Air gap : 1.0 – 1.1 mm (0.040 – 0.043 in.) See Fig. 1.

• 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?



2) Install fuel pressure gauge. See Fig. 3.

3) Check fuel pressure.


With fuel pump operating and engine at stop :

270 – 310 kPa, 2.7 – 3.1 kg/cm

2

, 38.4 – 44.0 psi.

At specified idle speed :

210 – 260 kPa, 2.1 – 2.6 kg/cm

2

, 29.8 – 37.0 psi.

Is measured value as specified?

5 Check Fuel Injectors and Circuit.

1) sing sound scope (1) or such, check operating sound of each injector (2) when engine is running. Cycle of 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 injector 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).


Yes

Go to Step 4.

Go to Step 5.

Go to Step 6.

Go to Step 7.

No

Check ignition system parts (Refer to

Section 6F).

Go to Diag. Flow

Table B-3 fuel pressure check.

Check injector circuit or replace fuel injector(s).

Replace PCV valve.


Step Action

7 Check EVAP Canister Purge Valve for Closing.

1) Disconnect purge hose (1) 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. 7.

Is vacuum felt?

8 Check manifold absolute pressure sensor for performance (See step 4) DTC P0105 Diag. Flow Table).


9 Check engine coolant temp. sensor for performance

(See Section 6E).


10 Check parts or system which can cause engine rough idle or poor performance.

• Engine compression (See Section 6A1).

• Valve lash (See Section 6A1).

• Valve timing (Timing belt installation. See Section

6A1).


Yes

Check EVAP control system

(See Section 6E).

Go to Step 9.

Go to Step 10.

Check wire harness and connection of

ECM ground, ignition system and fuel injector for intermittent open and short.

No

Go to Step 8.

Repair or replace.

Replace engine coolant temp. sensor.

Repair or replace.

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


4. Fuel feed hose

3. Fuel pressure gauge & 3 way joint


[F] Fig. 6 for Step 5 / [G] Fig. 7 for Step 7


DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction



• Knock sensor voltage is 3.91 V or more

• Knock sensor voltage is 1.23 V or less

POSSIBLE CAUSE

• “W” circuit open or shorted to ground

• Knock sensor malfunction

• ECM malfunction




INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 1) With engine running, check voltage from

“E19-25” terminal of ECM connector to body ground. See Fig. 1.

2) Is voltage about 1.25 – 3.75 V?

3 1) Stop engine.

2) With ignition switch at OFF position, disconnect 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 it 4 – 5 V?

Knock sensor and its circuit are in good condition.

Intermittent trouble or faulty ECM.

Recheck, referring to

“Intermittent Trouble” in

Section 0A.

Faulty knock sensor.

Substitute a known-good knock sensor and recheck.

No


Table”.

Go to Step 3.

“W” wire open, shorted to ground circuit or poor

“E19-25” connection.






DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction



• NO CKP sensor signal for 2 seconds at engine cranking.

POSSIBLE CAUSE

• CKP sensor circuit open or short.

• Signal teeth damaged.

• CKP sensor malfunction, foreign material being attached or improper installation.

• ECM malfunction.

REFERENCE

Connect oscilloscope between terminals E19-23 of ECM connector connected to ECM and body ground and check CKP sensor signal.

1. 10° signal

2. 30° signal

[A] : Oscilloscope Waveforms

[B] : Waveforms at idle speed

[C] : Waveforms at 2000 rpm


1) Clear DTC and crank engine for 2 sec.



INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Check CKP Sensor and connector for proper installation.

Is CKP sensor installed properly and connector connected securely?

3 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


4 Was terminal “Vout” voltage out of specification in

Step 3 check?

Go to Step 3.

Go to Step 5.

“G/R” wire open, short or poor connection.



Go to Step 6.

5 Check Ground Circuit for Open.


2) Check for continuity between “GND” terminal of CKP sensor connector and engine ground.


6 Check CKP Sensor for Operation.

1) Remove CKP sensor from sensor case.

2) Remove metal particles on end face of CKP sensor, if any.

3) Connect each connector to ECM and CKP sensor.


5) Check for voltage at terminal E19-23 of connector connected to ECM by passing magnetic substance (iron) (1) while keeping approximately 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?

7 Check signal rotor for the following. See Fig. 4.

• Damage

• No foreign material attached


Go to Step 7.



Section 0A.

No


Flow Table”.

Correct.

Go to Step 4.

“Bl/B” or “B/R” wire open, short or poor connection.

“B/R” wire open or poor ground connection.

Replace CKP sensor.

Clean rotor teeth or replace CKP sensor.



Fig. 4 for Step 7


DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction



• The number of CMP sensor signal pulses is incorrect during 8 revolution of crankshaft.

POSSIBLE CAUSE

• CMP sensor circuit open or short.

• Signal rotor teeth damaged.

• CMP sensor malfunction, foreign material being attached or improper installation.

• ECM malfunction.

• 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.

1. No.1 cylinder

2. No.2 cylinder

3. No.3 cylinder

4. No.4 cylinder

[A] : Oscilloscope Waveforms

[B] : Waveforms at specified idle speed


1) Clear DTC.

2) Start engine and keep it at idle for 1 min.


[C] : CKP sensor waveform

[D] : CMP sensor waveform


INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Check CMP Sensor and connector for proper installation.

Is CMP sensor installed properly and connector connected securely?

3 Check Wire Harness and Connection.

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 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


4 Was terminal “Vout” voltage out of specification in

Step 3 check?

Go to Step 3.

Go to Step 5.

“W” wire open, short or poor connection.

If wire and connection are OK, substitute a known-good ECM and recheck.

Go to Step 6.

5 Check Ground Circuit for Open.


2) Check for continuity between “GND” terminal of

CMP sensor connector and engine ground.


6 Check CMP Sensor for Operation.

1) Remove CMP sensor from sensor case.

2) Remove metal particles on end face of CMP sensor, if any.

3) Connect each connector to ECM and CMP sensor.


5) Check for voltage at terminal E19-11 of connector connected to ECM by passing magnetic substance (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.

See Fig. 4.

• Damage

• No foreign material attached


Go to Step 7.



Section 0A.

No


Flow Table”.

Correct.

Go to Step 4.

“Bl/B” or “B/R” wire open, short or poor connection.

“B/R” wire open or poor ground connection.

Replace CMP sensor.

Clean rotor teeth or replace CMP sensor.



Fig. 4 for Step 7


DTC P0400 Exhaust Gas Recirculation Flow Malfunction


1. EGR valve


• While running at specified vehicle speed after engine warm-up

• During deceleration (engine speed high with closed throttle position

ON) in which fuel cut is involved, difference in intake manifold absolute pressure between when EGR valve is opened at specified value and when it is closed is larger or smaller than specified value.

POSSIBLE CAUSE

• EGR valve or its circuit

• EGR passage

• ECM


WARNING:









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 Confirmation Flow Table.”

Test Result Confirmation Flow Table

Step Action

1 Check DTC in “DTC” mode and pending DTC in

“ON BOARD TEST”.

Is DTC or pending DTC displayed?

2 Set scan tool to “READINESS TESTS” mode and check if testing has been completed.

Is test completed?

Yes

Proceed to applicable

DTC flow table.

No DTC is detected.

(Confirmation test is completed)

No

Go to Step 2.

Repeat DTC confirmation procedure.

INSPECTION

Step Action


Yes

Go to Step 2.

2 1) Turn ignition switch ON.

2) Does EGR stepper motor operation for 0.6 second after ignition switch OFF?

3 With ignition switch at OFF, check voltage between E19-28, 17, 29, 18 terminals of ECM and body ground. See Fig. 2.

Is voltage about 0 V?

Go to Step 3.

Go to Step 4.

No


Table”.

Go to Step 6.

Go to Step 8.


Step Action

4 With ignition switch at ON, check voltage 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?

Yes

Go to Step 5.

No

Go to Step 8.

6 Check EGR system referring to “EGR System” in Section 6E.


7 1) Disconnect EGR valve connector with ignition switch OFF.

2) Check voltage between “Bl/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

Section 6E.


Go to Step 6.


ECM and recheck.

Go to Step 3.

Stuck or faulty EGR valve or clogged EGR gas passage.

If all above are OK, substitute a known-good

ECM and recheck.

Stuck or faulty EGR valve or clogged EGR gas passage.

“Bl/B” wire open or short.

EGR valve harness

(“Gr/B”, “Gr/Bl”, “Gr/R” or

“Gr” wire) open or short or poor connector connection (EGR valve connector, E19-28, 17, 29, 18) If wire harness and connection are OK, substitute a known-good ECM and recheck.

Faulty EGR valve.

[A] Fig. 1 for Step 7 / [B] Fig. 2 for Step 3 and 4


DTC P0420 Catalyst System Efficiency below Threshold


1. Heated oxygen sensor-1

2. Warm up three way catalytic converter

3. Three way catalytic converter

4. Heated oxygen sensor-2

5. To the sensor

[A] : Case of TYPE A is shown

(See NOTE)

[B] : Case of TYPE B is shown

(See NOTE)

NOTE:


ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic 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

1. Engine running at closed loop condition

2. Fuel cut 3. Idle after fuel cut [A] : Oscilloscope waveforms



• While vehicle running at constant speed under other than high load.

• Time from rich or lean switching command is output till HO2S-

2 output voltage crosses 0.45 V less than specified value.

POSSIBLE CAUSE

• Exhaust gas leak

• Three way catalytic converter malfunction

• Fuel system malfunction

• HO2S-2 malfunction

• HO2S-1 malfunction


WARNING:








– 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.

If “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”.


Test Result Confirmation Flow Table

Step Action

1 Check DTC in “DTC” mode and pending DTC in

“ON BOARD TEST” or “PENDING DTC” mode.

Is DTC or pending DTC displayed?

2 Set scan tool to “READINESS TESTS” mode and check if testing has been completed.

Is test completed?

Yes

Proceed to applicable

DTC Diag. Flow Table.

No DTC is detected (confirmation test is completed).

No

Go to Step 2.

Repeat DTC confirmation procedure.

INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Check Short Term Fuel Trim.

Did short term fuel trim vary within –20 % –

+20 % range in step 3) of DTC confirmation test?

3 Check HO2S-2 for Output Voltage.

Perform steps 1) through 9) of DTC confirmation procedure for DTC P0136 (HO2S-2 malfunction) and check output voltage of HO2S-2 then.

Is over 0.6 V and below 0.3 V indicated?

Go to Step 3.

Replace three way catalytic converter.

No


Table”.

Check fuel system.

Go to DTC P0171/P0172

Diag. Flow Table.

Check “W” and “B/Bl” wires for open and short, and connections for poor connection.

If wires and connections are OK, replace HO2S-2.


DTC P0443 Purge Control Valve Circuit Malfunction


1. EVAP canister purge vale


Canister Purge control valve circuit is opened or shorted.

POSSIBLE CAUSE

• “Bl/G” circuit open or short

• “Bl/B” circuit open or short

• Canister purge valve malfunction




INSPECTION

Step

1

Action


Yes

Go to Step 2

2 Check EVAP canister purge valve operation

1) With ignition switch OFF, disconnect coupler from canister purge valve.

2) Check resistance of EVAP canister purge valve.

See Fig.1

EVAP canister purge valve resistance

Between two terminals : 30 – 34

Ω

Between terminal and body : 1M

Ω or higher

Is it as specified?

“Bl/G” circuit open or short.

No


Flow Table”.

Replace EVAP canister purge valve.

Fig. 1 for Step 2


DTC P0481 A/C Condenser Fan Control Circuit Malfunction


1. Ignition switch 3. A/C condenser fan relay 5. A/C condenser fan 7. Fuse box


• Low voltage at terminal E18-18 when ECM doesn’t output A/C ON signal to A/C amplifier or when engine coolant temp. is not 110 °C (230 °F) or more.

POSSIBLE CAUSE

• “P/B” or “Lg” circuit open or short

• Condenser fan motor relay malfunction

• ECM malfunction




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.


INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Check A/C Condenser Fan Control Relay and its

Circuit.


2) Check for voltage at terminal E18-18 of ECM connector connected, under following condition.

When A/C switch turns OFF : 10 – 14 V



Section 0A.

Is voltage as specified?

3 Check A/C Condenser Fan Control Relay.

1) Turn ignition switch OFF and remove A/C condenser 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 terminals C and D. See Fig.2.

Is it 70 - 110

Ω?

“Lg” or “P/B” circuit open or short.

If wires and connections are OK, substitute a known-good ECM and recheck.

No


Flow Table”.

Go to Step 3.

Replace A/C condenser fan control relay.



DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction


1. VSS


3. VSS connector

[A] : Case of TYPE A is shown (See NOTE)

[B] : Case of TYPE B is shown (See NOTE)

NOTE:



• VSS signal not inputted while vehicle running in “D” range or during fuel cut at deceleration.

POSSIBLE CAUSE

• “B/Or” circuit open

• “Y” or “Bl/B” circuit open or short

• VSS malfunction

• ECM malfunction

• Speedometer malfunction


WARNING:



1) Clear DTC and warm up engine to normal operating temperature.

2) Increase vehicle speed to 50 mph, 80 km/h in 3rd 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.


INSPECTION

Step

1

Action


Yes

Go to Step 2.

2

3

Does speedometer indicate vehicle speed?

Check Vehicle Speed Signal.

Is vehicle speed displayed on scan tool in step

2) and 3) of DTC confirmation procedure?

4 1) Turn ignition switch to OFF position.

2) Disconnect combination meter connectors.Refer to Section 8.

3) Turn ignition switch to ON position, without running engine.

4) Measure voltage from terminal “c” of VSS connector to ground. See Fig.2.


5 1) With ignition switch at OFF position, disconnect VSS connector.

2) Turn ignition switch to ON position, without running engine.

3) Measure voltage from terminal “a” to “b” of

VSS connector. See Fig.1.


6 1) Measure voltage from terminal “c” of VSS connector to ground. See Fig.2.

Is voltage more than 4 V?

Go to Step 3.



Section 0A.

Faulty speedometer.

Go to Step 6.

7 1) Remove VSS.

2) Visually inspect VSS sensor signal rotor for damage.

Was any damage found?

No


Table”.

Go to Step 5.

Go to Step 4.

“Y” or “Y/G” wire open or short.

Poor connection of ECM connector terminal.


“Bl/B” or “B/Or” wire open or short.

Go to Step 7.

“Y” or “Y/G” wire open or short.

Poor connection of ECM connector terminal.


Faulty VSS signal rotor.

Poor connection of VSS connector terminal.

If OK, substitute a knowngood VSS and recheck.

[A] Fig. 1 for Step 5 / [B] Fig. 2 for Step 4 and Step 6


DTC P0505 Idle Control System Malfunction


1. IAC valve

2. Main relay

3. Ignition switch


5. “FI” fuse

.


• No closed signal to IAC valve is detected after engine start.

POSSIBLE CAUSE

• “Bl/B”, “G/Y” or “B/R” circuit open or short

• IAC valve malfunction

• ECM malfunction




3) Start engine and run it at idle for 1 min.

4) Check DTC and pending DTC.

INSPECTION

Step Action



Yes

Go to Step 2.

Go to Step 3.

No


Table”.

Go to Step 4.


Step Action

3 Check Idle Air Control System.

1) Connect SUZUKI scan tool to DLC with ignition switch OFF, set parking brake and block drive wheels. See Fig. 1.


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?

Yes



Section 0A.

4 Check Idle Air Control System.

1) Remove IAC valve from throttle boy referring to “IAC Valve” in Section 6E.

2) Check IAC valve for operation referring to

“IAC Valve” in Section 6E. See Fig. 2.


5 Check Wire Harness for Open and Short.


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 “Bl/B”, “G/Y” and “B/R” circuit for open and short.




Section 0A.

Replace IAC valve and recheck.

No

Go to Step 5.

Go to Step 5.

Repair or replace.



DTC P0601 Internal Control Module Memory Check Sum Error (DTC No.71)


DTC P0601 :

Data write error (or check sum error) when written into ECM

ECM

POSSIBLE CAUSE



2) Clear DTC with ignition switch ON and then turn ignition switch OFF.

3) Start engine and run it at idle if possible.


INSPECTION

Substitute a known-good ECM and recheck.


DTC P1450 Barometric Pressure Sensor Low / High Input

DTC P1451 Barometric Pressure Sensor Performance Problem


Barometric pressure sensor is installed in ECM.


DTC P1450 :

• Barometric pressure sensor voltage is 4.7 V or higher, or

1.6 V or lower

DTC P1451 :

• Vehicle stopped

• Engine cranking

• Difference between barometric pressure and intake manifold absolute pressure is 26 kPa, 200 mmHg or more.

• Difference between intake manifold absolute pressure at engine start and pressure after engine start is less than 1.3 kPa, 10 mmHg.

POSSIBLE CAUSE

• ECM (barometric pressure sensor) malfunction

• ECM (barometric pressure sensor) malfunction




3) Turn ignition switch ON for 2 sec., crank engine for 2 sec. and run it at idle for 1 min.


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

1

Action


Yes

Go to Step 2.

2 1) Connect scan tool to DLC with ignition switch OFF. See Fig.1.

2) Turn ignition switch ON and select “DATA

LIST” mode on scan tool.

3) Check manifold absolute pressure.

Is it barometric pressure (approx. 100 kPa, 760 mmHg) at sea level?


ECM and recheck.

No


Table”.

Go to Step 3.


Step Action

3 Check MAP Sensor

1) Remove MAP sensor from intake manifold and connect vacuum pump gauge to MAP sensor. See Fig. 2.

2) Connect scan tool to DLC and turn ignition switch ON.

3) Check intake manifold absolute pressure displayed on scan tool for specified value.

See Table 1.


Yes

Check air intake system for air being drawn in and engine compression.

If OK, then substitute a known-good ECM and recheck.

No

Replace MAP sensor.


Table 1

Applying Vacuum

0

027 kPa

200 mmHg

67 kPa

500 mmHg

Displayed Value on Scan Tool

Barometric pressure

(Approx. 100 kPa, 760 mmHg)

Barometric pressure – 27 kPa


Barometric pressure – 67 kPa



DTC P1500 Engine Starter Signal Circuit Malfunction


1. Starter

2. Transmission range sensor (switch)

3. Ignition switch (starter switch) [A] : Case of TYPE A is shown (See NOTE)

4. Main fuse [B] : Case of TYPE B is shown (See NOTE)

[C] : M/T vehicle

[D] : A/T vehicle

NOTE:



• Low voltage at terminal E17-13 or E18-20 when cranking engine or

• High voltage at terminal E17-13 or E18-20 after starting engine.

POSSIBLE CAUSE

• “B/Y” circuit open

• ECM malfunction



2) Clear DTC with ignition switch ON, crank engine and run it at idle for 3 min.



INSPECTION

Step

1

Action


2 Check for voltage at terminal E17-13 (Case of

TYPE A) (See NOTE) or E18-20 (Case of TYPE

B) (See NOTE) of ECM connector connected, under following condition.

Engine starter signal specification

While engine cranking : 6 – 10 V

After starting engine : 0 V

Is voltage as specified?

Yes

Go to Step 2.

Poor E17-13 (Case of

TYPE A) (See NOTE) or

E18-20 (Case of TYPE B)

(See NOTE) connection or intermittent trouble.


Section 0A.

If wire and connections are OK, substitute a known-good ECM and recheck.

No


Table”.

“B/Y” or “B/R” circuit open.


DTC P1510 ECM Back-up Power Supply Malfunction


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

• Low voltage at terminal E18-7 after starting engine.

• “W” circuit open

• ECM malfunction


1) Clear DTC, start engine and run it at idle for 1 min.


INSPECTION

Step Action

1 Check for voltage at terminal E18-7 of ECM connector connected, under each condition, ignition switch OFF and engine running.

Is it 10 – 14 V at each condition?

Yes

Poor E18-7 connection or intermittent trouble.


Section 0A.

If wire and connections are OK, substitute a known- good ECM and recheck.

No

“W” circuit open.


DTC P1570 (DTC No.21) ABS Signal Circuit Malfunction



• ABS signal input is low when engine start.

POSSIBLE CAUSE

• ABS signal circuit short to ground

• ABS control module




INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 1) With the ignition switch ON position, check voltage between E17-12 terminal of ECM coupler and ground.


3 1) Check “G” wire for shorted to ground circuit.

Is “G” wire in good condition?

4 1) Disconnect coupler of ABS control module.

2) Clear DTC.

3) Start engine and check DTC.

Is DTC P1570 (No.21) detected?



Go to Step 4.


ECM and recheck.

No


Table”.

Go to Step 3.

Repair or replace.


ABS control module and recheck.


DTC P1600 Serial Communication Problem Between ECM and TCM


The serial data line is pulled up to about 12 V by ECM and TCM transmits information to ECM through it by controlling 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.


No signal inputted from TCM to ECM or check sum error while engine running

POSSIBLE CAUSE

• “G/R” circuit open or short

• TCM power or ground circuit open.

• TCM malfunction

• ECM malfunction




3) Start engine and run it at idle for 1 min.


INSPECTION

Step

1

Action


Yes

Go to Step 2.

2 Check signal voltage.

Check voltage between terminal E17-17 and body ground with ignition switch ON. See Fig. 1.

Does it change between 0 – 12 V?

Intermittent trouble or faulty ECM or TCM.

Check for intermittent trouble referring to “Intermittent and Poor Connection” in Section 0A.

No


Table”.

Go to Step 3.


Step Action

3 Is it about 12 V at Step 2?

4 Check signal circuit.

1) Disconnect TCM coupler with ignition switch

OFF.

2) Check voltage between E21-20 terminal and body ground with ignition switch ON.

See Fig. 2.

Is it about 12 V?

Yes

“B/R” wire open, poor

E21-11 connection or

TCM power or ground circuit open.

If wires and connections are OK, substitute a known-good TCM and recheck.

Check TCM power and ground circuit for open.

If OK, substitute a knowngood TCM and recheck.

No

Go to Step 4.

“B/R” wire shorted to ground or poor E17-17 terminal connection.





DTC P1717 A/T Drive Range (Park / Neutral Position) Signal Circuit Malfunction


1. Transmission range switch 2. From ignition switch 3. TCM


• “D” range signal not inputted (Park / Neutral position signal inputted) to ECM while vehicle running

POSSIBLE CAUSE

• “G/Y” circuit open

• Transmission range switch malfunction

• “R”, “D”, “2” or “L” range signal circuit open

• TCM power or ground circuit open

• TCM malfunction

• ECM malfunction


WARNING:





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).



INSPECTION

Step

1

Action



3 Check PNP signal (“D” range signal).

1) Connect SUZUKI scan tool to DLC with ignition switch OFF. See Fig. 1.

2) Turn ignition switch ON and check PNP signal (“P/N” or “D” range) on display when shifting selector lever to each range.

Is “D” range on display (Is 0 – 1 V indicated) no matter which of “R”, “D”, “2” and “L” range positions selector lever may be at? See Table 1.

4 Check PNP Signal (“D” range signal).


2) Check voltage at terminal E17-6 of ECM connector connected. See Fig. 2.

Is “D” range on display (Is 0 – 1 V indicated) no matter which of “R”, “D”, “2” and “L” range positions selector lever may be at? See Table 1.

5 Is “P/N” range on display (Is 10 – 14 V indicated) when selector lever is at one of “R”, “D”,

“2” and “L” range positions only?

6 Check PNP signal circuit.


2) Disconnect TCM connectors.

3) Check for proper connection to TCM at terminal E21-5.

4) If OK, then check voltage at terminal E21-8 in TCM connector disconnected, with ignition switch ON. See Fig. 3

Is it 10 – 14 V?

Yes

Go to Step 2.

Go to Step 3.

Intermittent trouble or faulty ECM. Check for intermittent referring to



0A.

Intermittent trouble or faulty ECM. Check for intermittent referring to



0A.

Check transmission range switch and circuits referring to Section 7B.

“Y/B” circuit open, poor transmission range sensor connector connection, select cable maladjusted, transmission range sensor maladjusted or transmission range sensor malfunction.

If all above are OK, substitute a known-good TCM and recheck.

No


Table”.

Go to Step 4.

Go to Step 5.

Go to Step 5.

Go to Step 6.

“G/Y” circuit open or poor

E17-6 connection.





[D] Table 1 for Step 3 and 4

Selector lever position

“P” and “N” range

“R”, “D”, “2” and “L” range

Scan tool voltmeter

SUZUKI SCAN TOOL

DISPLAY

P/N range

VOLTAGE AT E17-6

10 – 14V

D range 0 – 1V

Table B-1 Fuel Injector Circuit Check

INSPECTION

Step

1

Action


Yes

Go to Step 2.

No


Table”.

Go to Step 3.

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?

3 Dose none of 4 injectors make operating sound at Step 2?

Fuel injector circuit is in good condition.

Go to Step 4.

4 Check power circuit of injectors for open and short.

Is it normal?

Check all 4 injectors for resistance respectively.

If resistance is OK, substitute a known-good ECM and recheck.

Check coupler connection and wire harness of injector not making operating sound and injector itself (Refer to Section

6E).

Power circuit open or short.


Table B-2 Fuel Pump and Its Circuit Check

1. Ignition switch

2. Main relay

3. Main relay

4. Main fuse

5. Fuel pump relay

6. Fuel pump



NOTE:


INSPECTION

Step Action


Yes

Go to Step 2.

No


Table”.

Go to Step 3.

2 Check Fuel Pump Control System for Operation. See Fig. 1.

Is fuel pump heard to operate for 2 sec. after ignition switch ON?

3 Check Fuel Pump for Operation.

1) Remove fuel pump relay from relay box with ignition switch OFF.

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?

Fuel pump circuit is in good condition.

Go to Step 4.

“P”, “B” or “Bl/B” circuit open or fuel pump malfunction.


Step Action

4 Check Fuel Pump Relay for Operation.

1) Check resistance between each two terminals of fuel pump relay. See Fig.3.

Fuel pump relay resistance

Between terminals “A” and “B” : Infinity

Between terminals “C” and “D”: 100 – 150

Ω

2) Check that there is continuity between terminals “A” and “B” when battery is connected to terminals “C” and “D”. See Fig. 3.

Is fuel pump relay in good condition?

Yes

“W/G” circuit open or poor

E18-19 connection.



No

Replace fuel pump relay.

CAUTION:

Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ECM, wire harness, etc.



Table B-3 Fuel Pressure Check

1. Injector

2. Delivery pipe

INSPECTION

3. Fuel pump

(A) : Fuel pressure gauge

(B) : Hose

(C) : Attachment

Step Action



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

2

, 38.4 – 44.0 psi)?

2

Is 250 kPa (2.5 kg/cm

2

, 35.6 psi) or higher fuel pressure retained for 1 minute after fuel pump is stopped at Step 1?

Yes

Go to Step 2.

Normal fuel pressure.

3 Is there fuel leakage from fuel feed line hose, pipe or their joint?

Fuel leakage from hose, pipe or joint.

4 Was fuel pressure higher than spec. in Step 1? Faulty fuel pressure regulator.

No

Go to Step 4.

Go to Step 3.

Faulty fuel pressure regulator.

Clogged fuel filter,

Restricted fuel feed hose or pipe, Faulty fuel pump or Fuel leakage from hose connection in fuel tank.

Fig. 1 for Step 1


Special tool

(A) : 09912-58441

(B) : 09912-58431

(C) : 09912-58490


Table B-4 Idle Air Control System Check

1. Main fuse

INSPECTION

2. Fuse box 3. Main relay 4. IAC valve

Step Action

1 Check engine idle speed and IAC duty referring to

“Idle Speed / IAC Duty Inspection” in Section 6E.

Is idle speed within specification?

2 Is IAC duty within specification in Step 1?

Yes

Go to Step 2.

Go to Step 3.

No

Go to Step 4.

Check for followings :

• Vacuum leak

• EVAP canister purge control system

• Clog of IAC air passage

• Accessory engine load

• Closed throttle position (TP sensor)

• Stuck of PCV valve


Step

with headlight ON?

Action

3 Is engine idle speed kept specified speed even System is in good condition.

Yes No

Check IAC system for operation referring to

Step 3 or Step 4 of DTC

P0505 Diag. Flow Table.

Go to Step 8.

4 Was idle speed higher than specification in Step

1?

5 Check A/C (input) signal circuit referring to Step 1 of Table B-5 A/C Signal Circuit Check, if equipped. (A/C signal can be also checked by using SUZUKI scan tool.)


6 Check IAC system referring to Step 2 to Step 4 of

DTC P0505 Diag. Flow Table.


7 Was IAC duty less than about 3% (or more than about 97% for OFF duty meter) in Step 1 of this table?

Go to Step 5.

Go to Step 6.

Go to Step 7.

Check abnormal air inhaling from air intake system, PCV valve and

EVAP canister purge control system.



1) Connect SUZUKI scan tool to DLC with ignition 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.




2) Check voltage at terminal E17-6 of ECM connector connected. See Fig. 1 and Table 1.


11 Check IAC system referring to Step 2 to Step 4 of

DTC P0505 Diag. Flow Table.


12 Was IAC duty more than about 30% or

✱40% (or less than 70% or

✱60% for OFF duty meter) in

Step 1 of this table? See NOTE.

Go to Step 9.

Go to Step 11.

Go to Step 11.

Go to Step 12.

Check parts or system which can cause engine low idle.

• Accessory engine load

• Clog of air passage

• Etc.

Repair or replace A/C signal circuit or A/C system.

Go to Step 5 of DTC


Check TP sensor

(closed throttle position) and ECT sensor for performance.

If sensors are OK, substitute a known-good

ECM.

Go to Step 10.

Repair or replace.

Repair or replace.

Go to Step 5 of DTC



ECM and recheck.

NOTE:

Duty value with (

✱


Fig. 1 for Step 10

Table 1 for Step 9 and 10

Selector lever position

“P” and “N” range

“R”, “D”, “2” and “L” range

Scan tool or voltmeter

SUZUKI SCAN TOOL

DISPLAY

VOLTAGE AT E17-6

P/N range

D range

10 – 14V

0 – 1V


Table B-5 A/C Signal Circuits Check (Vehicle with A/C)

1. A/C compressor magnet clutch

2. A/C switch

3. Blower fan

4. A/C condenser fan

5. Refrigerant pressure switch

6. ECT sensor

7. Evaporator temp. sensor



NOTE:



INSPECTION

Step Action

1 Check evaporator temp. sensor.

1) Disconnect ECM connectors with ignition 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 k

Ω

At 25°C 1.8 – 2.2 k

Ω

Is it within specification?

2 Check A/C switch circuit.

1) Check voltage at E18-16 terminal under each condition given below.

A/C switch signal specification

Ignition switch ON A/C switch OFF

: 10 – 14 V

Ignition switch ON A/C switch ON

: 0 – 1 V


3 Check A/C compressor signal.

1) Check voltage at E18-1 terminal under each condition given below. See NOTE.

A/C compressor signal specification

While engine running, A/C switch OFF

: 0 V

While engine running, A/C switch ON

: 10 – 14 V


Yes

Go to Step 2.

Go to Step 3.

A/C control system circuits are in good condition.

No

Faulty A/C evaporator thermistor or its circuit.

“G/W” wire open or short

Poor E18-16 terminal connection



Go to Step 3.

“P” wire open or short

Poor E18-1 terminal connection



NOTE:

When A/C evaporator thermistor temp. is below 2.5 °C (36.5 °F), A/C remain OFF (E18-1 terminal voltage become 0 – 1 V). This condition is not abnormal.

Fig. 1 for Step 1

Table B-6 Electric Load Signal Circuit Check


1. Rear defogger switch

2. Light switch

3. Blower fan switch



NOTE:


INSPECTION

Step Action


2 Check Electric Load Signal Circuit.

1) Connect SUZUKI scan tool to DLC with ignition switch OFF. See Fig.1.

2) Start engine and select “DATA LIST” mode on scan tool.

3) Check electric load signal under following each condition. See Table 1.


Yes

Go to Step 2.

Electric load signal circuit is in good condition.

3 Check Electric Load Signal Circuit.


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 connected, under above each condition. See

Fig. 2. and Table 1.

Is each voltage as specified?

Electric load signal circuit is in good condition.

No

Go to Step 3.

“R/W”, “R/Y” and/or “Bl/Y” circuit open or short, Electric load diodes malfunction or Each electric load circuit malfunction.

“R/W”, “R/Y” and/or “Bl/Y” circuit open or short, Electric load diodes malfunction or Each electric load circuit malfunction.



Table 1 for Step 2 and 3

Ignition switch ON, Small light, heater blower fan and rear defogger all turned

OFF

ON

SUZUKI

SCAN TOOL

OFF

Scan tool or voltmeter

VOLTAGE

AT E18-17,

E17-16 or

E18-12

0V

ON 10 – 14V

VOLTAGE

AT E18-24 or

E17-13

10 – 14V

0V


TAble B-7 A/C Condenser Fan Control System Check

INSPECTION

Step Action

1 Check Fan Control System.

1) Connect scan tool to DLC with ignition switch OFF. See

Fig. 1.

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 sensor.)

Is A/C condenser fan started when engine coolant temp. reached above temp.?

2 Check A/C Condenser Fan Relay and Its Circuit.

1) Check DTC and pending DTC with scan tool.

Is DTC P0481 displayed?

3 Check A/C Condenser Fan Relay (1).

1) Turn ignition switch OFF and remove A/C condenser fan 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.


Yes

A/C condenser fan control system is in good condition.

No

Go to Step 2.

Go to DTC P0481 Diag.

Flow Table.

Go to Step 3.

Go to Step 4.

Replace A/C condenser fan relay.


Step Action

4 Check A/C Condenser Fan (1).


2) Disconnect fan motor connector (2).

3) Check for proper connection to motor at “R/Bl” and “B” terminals.

4) If OK, connect battery to motor and check for operation.

See Fig. 3.


Yes

“R”, “R/Bl” or “B” circuit open.

No

Replace A/C condenser fan motor.


Fig. 3 for Step 4


Special Tool

09912-58441

Pressure gauge

09912-58431

Pressure hose

09912-58490

3-way joint & hose

09912-58421

Checking tool set

(See NOTE “A”.)

09912-57610

Checking tool plate

09917-47010

Vacuum pump gauge

09930-88530

Injector test lead

09931-76011

SUZUKI scan tool (Tech

1A) kit (See NOTE “B”.)

Mass storage cartridge

09931-76030

16 / 14 pin DLC cable Tech 2 kit (SUZUKI scan tool) (See NOTE “C”.)

NOTE:

• “A” : This kit includes the following items.

1. Tool body & washer, 2. Body plug, 3. Body attachment, 4. Holder, 5. Return hose & clamp,

6. Body attachment-2 & washer, 7. Hose attachment-1, 8. Hose attachment-2

• “B” : This kit includes the following items and substitutes for the Tech 2 kit.

1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead / probe,

6. Power source cable, 7. DLC cable adaptor, 8. Self–test adaptor

• “C” : This kit includes the following items and substitutes for the Tech 1A kit.

1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,

6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,

10. RS232 loopback connector, 11. Storage case, 12. Power supply


ENGINE MECHANICAL (M13 ENGINE) 6A1-1

SECTION 6A1

6F1

ENGINE MECHANICAL (M13 ENGINE)

6G

6H

6K

WARNING:






8A

8C

6A1

8E

7A

7A1

7B1

7C1

7D

7E

7F

General Description ......................................6A1-2

Engine .........................................................6A1-2

Engine Lubrication ......................................6A1-3

Diagnosis .......................................................6A1-4

Diagnosis Table ..........................................6A1-4

Compression Check ....................................6A1-4

Engine Vacuum Check................................6A1-6

Oil Pressure Check .....................................6A1-7

Valve Lash (Clearance)...............................6A1-9

On-Vehicle Service......................................6A1-13

Air Cleaner Element .................................. 6A1-13

Air Cleaner Assembly................................6A1-14

Knock Sensor ............................................ 6A1-14

Cylinder Head Cover .................................6A1-15

Throttle Body and Intake Manifold ............ 6A1-18

Exhaust Manifold.......................................6A1-21

CONTENTS

9

9

Oil Pan and Oil Pump Strainer.................. 6A1-24

Timing Chain Cover .................................. 6A1-28

Oil Pump ................................................... 6A1-33

Timing Chain and Chain Tensioner .......... 6A1-37

Camshaft, Tappet and Shim ..................... 6A1-42

Valves and Cylinder Head ........................ 6A1-48

Pistons, Piston Rings, Connecting

Rods and Cylinders................................... 6A1-62

Engine Mountings ..................................... 6A1-72

Unit Repair Overhaul .................................. 6A1-73

Engine Assembly ...................................... 6A1-73

Main Bearings, Crankshaft and Cylinder

Block ......................................................... 6A1-79

Required Service Material .......................... 6A1-93

Tightening Torque Specification ............... 6A1-93

Special Tool................................................. 6A1-94

10B

6A1-2 ENGINE MECHANICAL (M13 ENGINE)


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 over the cylinder head; it is driven from crankshaft through timing chain, and no push rods are provided in the valve train system.


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

2

, 56.9 psi).


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 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


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:

• For measuring compression pressure, crank engine at least 250 rpm by using fully charged battery.

• If check results are below the limit valve, check installation condition for special tool.

Compression pressure specification

Standard

Limit

Max. difference between any two cylinders

1400 kPa

(14.0 kg/cm

2

, 199.0 psi)

1100 kPa

(11.0 kg/cm

2

, 156.0 psi)

100 kPa

(1.0 kg/cm

2

, 14.2 psi)

12) Carry out Steps 9) through 11) on each cylinder to obtain 4 readings.

13) After checking, install spark plugs and ignition coil assemblies (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).


Engine Vacuum Check

The engine vacuum that develops in the intake line is a good indicator of the condition of the engine. The vacuum checking procedure is as follows:


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, disconnect special tool (Vacuum gauge) from intake manifold.

7) Install cap to intake manifold.


Oil Pressure Check

NOTE:

Prior to checking oil pressure, check the following items.

• 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 0B.

• 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 temperature.

NOTE:

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.

4) After warming up, raise engine speed to 4,000 rpm and measure oil pressure.

Oil pressure specification

280 – 430 kPa (2.8 – 4.3 kg/cm

2

, 39.8 – 61.1 psi) at 4,000 rpm

5) Stop engine and remove oil pressure gauge and attachment.


6) Before reinstalling oil pressure switch (2), be sure to wrap its screw threads with sealing tape (1) and tighten switch to specified torque.

NOTE:

If sealing tape edge is bulged out from screw threads of switch, cut it off.


Oil pressure switch (a) : 14 N.m (1.4 kg-m, 10.5 lb-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).


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

Intake

Exhaust

When cold

(Coolant temperature is 15 – 25°C or

59 –77°F)

0.18 – 0.22 mm

(0.007 – 0.009 in.)

0.28 – 0.32 mm

(0.011 – 0.013 in.)

When hot

(Coolant temperature is 60 – 68°C or

140 – 154°F)

0.21 – 0.27 mm

(0.008 – 0.011 in.)

0.30 – 0.36 mm

(0.012 – 0.014 in.)

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.


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


Camshaft housing bolts (for tightening of special tool)

(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)

NOTE:

• Check the special tools carved seal as shown, and then install special tool in accordance with the location of each camshaft housing.

• If special tool is holding down the shim, adjust special tool position so as not to hold down the shim by loosening camshaft housing bolt.

Special tool selection table

No. on camshaft housing

I2

I3, I4, I5

E2

E3, E4, E5

Embossed mark on special tool

IN2

IN345

EX2

EX345

A: I : 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


5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating 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 possible to calculated value.

Available new shims No.

Thickness mm (in.)

2.175 (0.0856)

2.200 (0.0866)

2.225 (0.0876)

2.250 (0.0886)

2.275 (0.0896)

2.300 (0.0906)

2.325 (0.0915)

2.350 (0.0925)

2.375 (0.0935)

2.400 (0.0945)

2.425 (0.0955)

2.450 (0.0965)

2.475 (0.0974)

2.500 (0.0984)

2.525 (0.0994)

2.550 (0.1004)

2.575 (0.1014)

2.600 (0.1024)

2.625 (0.1033)

2.650 (0.1043)

253

255

258

260

263

265

228

230

233

235

238

240

243

245

248

250

Shim

No.

218

220

223

225

Thickness mm (in.)

2.675 (0.1053)

2.700 (0.1063)

2.725 (0.1073)

2.750 (0.1083)

2.775 (0.1093)

2.800 (0.1102)

2.825 (0.1112)

2.850 (0.1122)

2.875 (0.1132)

2.900 (0.1142)

2.925 (0.1152)

2.950 (0.1161)

2.975 (0.1171)

3.000 (0.1181)

278

280

283

285

288

290

293

295

298

300

Shim

No.

268

270

273

275

7) Install new shim facing shim No. side with tappet.


8) Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4) and remove special tool.

Special tool

(A) : 09916-67020

1. Tappet

2. Camshaft

9) Install camshaft housing (1) and tighten them to specified torque.


Camshaft housing bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

10) Check valve clearance again.

11) Install cylinder head cover, referring to “Cylinder Head




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 element.

CLEANING

Blow off dust by compressed air from air outlet side of element.

INSTALLATION



Air Cleaner Assembly

REMOVAL


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


Knock Sensor

REMOVAL


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



Knock sensor (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft)


Cylinder Head Cover

REMOVAL


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) Remove 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).


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.

• Cylinder head gasket (1) sealing surface area (2) as shown.

“A” : Sealant 99000-31150

• Timing chain cover (1) and cylinder head (2) matching surface as shown.

“A” : Sealant 99000-31150


3) Install cylinder head cover to cylinder head.

NOTE:

When installing cylinder head cover, use care so that cylinder 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.


Cylinder head cover bolts (a) : 8 N·m (0.8 kg-m, 6.0 lb-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.


Throttle Body and Intake Manifold

1. Intake manifold

2. Intake manifold gasket

3. Throttle body

4. Gasket

5. EGR pipe

6. MAP sensor

7. EVAP canister purge valve

8. TP sensor

9. IAC valve


11. Engine hook

12. Intake manifold stiffener

13. Intake manifold mounting nut

14. Intake manifold mounting bolt (short)

15. Intake manifold mounting bolt (long)

16. EGR pipe gasket

17. O-ring

18. Grommet

19. Injector assembly

20. Cushion

Tightening torque

Do not reuse

REMOVAL

1) Relieve fuel pressure referring to “Fuel Pressure Relief Procedure” in Section 6.


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 off too soon.


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:

• IAC valve (2)

• TP sensor (3)

• EVAP canister purge valve (4)

• MAP sensor (5)

• Fuel injector wire harness at couplers (6)

• Ground terminal (7) from intake manifold

7) Disconnect accelerator cable (1) from throttle body.

8) Disconnect the following hoses:

• Brake booster hose (2) from intake manifold

• PCV hose (3) from PCV valve

• Fuel pressure regulator vacuum hose (4) from intake manifold

• Canister purge hose from EVAP canister purge valve

• Water hoses from throttle body

• Vacuum hose (5) (to check valve) from throttle body

• 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).


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.

• Use new intake manifold gasket and EGR pipe gasket.

• Tighten long bolt (1), short bolt (3) and nuts (2) to specified torque.


Intake manifold bolts and nuts

(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

• Check to ensure that all removed parts are back in place.

Reinstall any necessary parts which have not been reinstalled.

• 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


1. Exhaust manifold

2. Exhaust manifold gasket

3. Heated oxygen sensor (if equipped)

4. Exhaust manifold cover

5. Engine hook

6. Exhaust manifold mounting nut

Tightening torque

Do not reuse.

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


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).


5) Disconnect exhaust pipe (1) from exhaust 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.


Exhaust manifold nuts (a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)

2) Install seal ring and install exhaust pipe (1) to exhaust manifold.

Before installing seal ring, check it for deterioration or damage, and replace as necessary.

Tighten pipe fasteners to specified torque.


Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)


3) Install exhaust manifold stiffener (1).

Tighten exhaust manifold stiffener bolts to specified torque.


Exhaust manifold stiffener bolts

(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

4) Install exhaust manifold cover (1).

5) Connect heated oxygen sensor coupler (2) and fit coupler to bracket securely (if equipped).


7) Check exhaust system for exhaust gas leakage.


Oil Pan and Oil Pump Strainer

[A] : Sealant application amount

“a” : 3 mm (0.12 in.)

“b” : 2 mm (0.08 in.)

1. Oil pan

: Apply sealant 99000-31150 to mating surface.

2. Strainer

3. O-ring

4. Gasket

5. Drain plug

6. Strainer bolt

7. Bracket bolt

8. Oil pan nut

9. Oil pan bolt

Tightening torque

Do not reuse.

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 clearance between engine and vehicle body according to the following 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.


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

• Inside of oil pan and oil pump strainer screen.

• Clean sealing surface on oil pan and cylinder block.

Remove oil, old sealant and dust from sealing surface.


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) 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.


Oil pump strainer bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

Oil pump strainer bracket bolt

(b) : 11 N·m (1.1 kg-m, 8.0 lb-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.


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.


Oil pan drain plug (b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

5) Install clutch housing (torque converter housing for A/T vehicle) lower plate (1).


6) Lower engine and tighten engine mounting bracket bolts to specified torque.


Engine mounting bracket bolts

(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

7) Install oil level gauge.

8) Refill engine with engine oil referring to “Engine Oil and Filter

Change” in Section 0B.

9) Verify that there is no engine oil leakage at each connection.


Timing Chain Cover


“a” : 3 mm (0.12 in.)

“b” : 2 mm (0.08 in.)

1. Crankshaft pulley bolt

2. Crankshaft pulley

3. Oil seal

: Apply engine oil to oil seal lip.

8. Cylinder head cover

: 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”.

Tightening torque 4. Timing chain cover

: 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.

5. Pin

6. Cylinder head cover gasket

7. Timing chain cover mounting bolts

Do not reuse.

REMOVAL


2) Remove A/C compressor and/or P/S pump belt (if equipped).

3) Remove generator belt.

4) Drain engine oil.


5) Drain coolant.

WARNING:


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 bolts 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 Cooling Fan” in Section 6B.

10) Remove A/C compressor and/or P/S pump belt tension pulley (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.


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 it is 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.



16) Disconnect CMP sensor coupler (1) and release its harness clamps.

17) Remove water outlet pipe (2).

18) Remove timing chain cover (3).

CLEANING

• Clean sealing surface on timing chain cover, cylinder block and cylinder head.

Remove oil, old sealant and dust from sealing surface.


INSPECTION

• 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.


Timing chain cover bolts and nut

(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)


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


Crankshaft pulley bolt (a) : 150 N·m (15.0 kg-m, 108.5 lb-ft)

4) Install P/S pump bracket (1), P/S pump (2) and A/C compressor 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 Section 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 procedure.

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.


Oil Pump


“a” : 3 mm (0.12 in.)

“b” : 2 mm (0.08 in.)

1. Rotor plate

2. Outer rotor

3. Inner rotor

4. Timing chain cover

: Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.

: Apply sealant 99000-31150 to mating surface of timing chain cover referring to the figure of Step 1) in “Timing Chain Cover Installation”.

5. Pin

6. Oil seal

7. Relief valve

8. Spring

9. Retainer

10. Circlip

11. Oil pump mounting bolt

12. Timing chain cover mounting bolts

Tightening torque

Do not reuse.

Apply thin coat of engine oil to sliding surface of each parts.

REMOVAL


2) Remove timing chain cover, referring to “Timing Chain


DISASSEMBLY

1) Remove rotor plate (1) by removing its mounting bolts.


2) Remove outer rotor (1) and inner rotor (2).

3) Remove relief valve (1), spring (2) and retainer (3) by removing circlip (4).

INSPECTION

• Check oil seal lip for fault or other damage. Replace as necessary.

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


• Check outer (1) and inner rotors (2), rotor plate, and oil pump case for excessive wear or damage.

• Check relief valve (1) for excessive wear or damage and operates smoothly.

MEASUREMENT

Radial clearance

Check radial clearance between outer rotor (1) and case (2), using thickness gauge (3).

If clearance exceeds its limit, replace outer rotor or case.

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.)


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 lb-ft) torque or below).


Oil pump rotor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

INSTALLATION

For installation referring to “Timing Chain Cover” in this section.

Timing Chain and Chain Tensioner


1. Crankshaft timing sprocket

2. Timing chain

3. Timing chain No.1 guide

4. Timing chain tensioner

4

3

1

2

1

6

5. Timing chain tensioner adjuster assembly

6. Chain tensioner adjuster mounting bolt

7. Chain tensioner mounting bolt

8. Chain guide mounting bolt

5

Tightening torque

Apply engine oil to sliding surface.

REMOVAL

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.

7


INSPECTION

Timing chain tensioner

• Check shoe (1) for wear or damage.

Crankshaft timing sprocket

• Check teeth of sprocket for wear or damage.

Timing chain

• Check timing chain for wear or damage.

Timing chain tensioner adjuster

• Check that tooth surface (1) are free from damage.

Timing chain No.1 guide

• Check shoe (1) for wear or damage.


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°

“b” : 15°

5. Crankshaft allowable turning range.

By key on crankshaft, within 90° from top on both right and left.

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 guide bolts to specified torque.


Timing chain No.1 guide bolts

(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)


2

1

6) Apply engine oil to sliding surface of chain tensioner (1) and install chain tensioner and spacer.

Tighten tensioner bolt to specified torque


Timing chain tensioner bolt

(a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)

2

7) Check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with dark blue plates (2) of timing chain and match mark (3) on crankshaft timing sprocket is in match with gold plate (4) of timing chain.

4

3

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.


Timing chain tensioner adjuster bolts

(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

1

2

1


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 match mark are no matches, adjust each sprocket and timing chain.

3

11) Install timing chain cover referring to “Timing Chain Cover” in this section.

12) Perform Steps 3) to 8) of “INSTALLATION” of “Timing Chain



Camshaft, Tappet and Shim

1. Intake camshaft

2. Exhaust camshaft

3. Shim

: Shim No. on it faces tappet side.

4. Tappet

5. Camshaft housing

6. Camshaft housing bolt

Tightening torque

Apply engine oil to sliding surface of each part.

REMOVAL

1) Remove cylinder head cover and oil pan referring to “Cylinder 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.

4) Loosen camshaft housing bolts in such order as indicated in figure and remove them.

5) Remove camshaft housings.

6) Remove intake and exhaust camshafts.


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.

Cam height “a” of camshaft

Intake cam

Exhaust cam

Standard

44.919 – 45.079 mm

(1.768 – 1.775 in.)

44.399 – 44.559 mm

(1.748 – 1.754 in.)

Limit

44.80 mm

(1.764 in.)

44.28 mm

(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.


Check clearance by using gauging plastic. Checking procedure is as follows.

1) Clean housings and camshaft journals.

2) Remove all tappets with shims.

3) Install camshafts to cylinder head.

4) Place a piece of gauging plastic to full width of journal of camshaft (parallel to camshaft).

5) Install camshaft housing.

6) Tighten camshaft housing bolts in such order as indicated in figure a little at a time till they are tightened to specified torque.

NOTE:

Do not rotate camshaft while gauging plastic is installed.



7) Remove housing, and using scale (2) on gauging plastic (1) envelop, measure gauging plastic width at its widest point.

Camshaft journal clearance

Standard

0.045 – 0.087 mm

(0.0018 – 0.0034 in.)

Limit

0.12 mm

(0.0047 in.)

If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal.

Replace camshaft or cylinder head assembly whichever the difference from specification is greater.

Camshaft journal outside diameter [A]

No.1

Other

Item Standard

26.934 – 26.955 mm

(1.0604 – 1.0612 in.)

22.934 – 22.955 mm

(0.9029 – 0.9037 in.)

Camshaft journal bore diameter [B]

Item

No.1

Other

Standard

27.000 – 27.021 mm

(1.0630 – 1.0638 in.)

23.000 – 23.021 mm

(0.9055 – 0.9063 in.)


Wear of Tappet and Shim

Check tappet and shim for pitting, scratches or damage.

If any malcondition is found, replace.

Measure cylinder head bore and tappet outside diameter to determine 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]

Standard : 31.000 – 31.025 mm (1.2205 – 1.2215 in.)


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 housings as indicated by these marks.

A. I : Intake side or E : Exhaust side

B. Position from timing chain side

C. Pointing to timing chain side


5) After applying engine oil to housing bolts, tighten them temporarily 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.



6) Install 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 section.





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.



14) Verify that there is no coolant leakage, oil leakage and A/T fluid leakage (vehicle with A/T) at each connection.


Valves and Cylinder Head

1. Valve cotters

2. Valve spring retainer

3. Valve spring

4. Valve stem seal

5. Valve spring seat

6. Intake valve

7. Exhaust valve

8. Valve guide

9. Cylinder head bolt

1) Tighten all bolts at 40 N·m (4.0 kg-m)

2) Turn all bolts to 60°

3) Then, turn all bolts to 60° once again

10. Cylinder head

11. Cylinder head gasket

: “TOP” mark provided on gasket comes to crankshaft pulley side, facing up.

12. Knock pin

Tightening torque

Do not reuse.

Apply engine oil to sliding surface of each part.


REMOVAL




4) Drain coolant by loosening drain plug (1).

WARNING:


5) Remove air cleaner outlet No.1 and No.2 hoses and breather hose.



• EGR valve (if equipped)

• IAC valve (2)

• TP sensor (3)

• MAP sensor (4)

• CMP sensor

• ECT sensor


• Injectors (6)

• Ignition coils

• Heated oxygen sensor

• Ground terminal (7) from intake manifold

• Each wire harness clamps

8) Remove heated oxygen sensor bracket from cylinder head and detach heated oxygen sensor coupler from its bracket.


9) Disconnect accelerator cable (1) from throttle body.



• Canister purge hose (3) from EVAP canister purge valve

• Fuel feed and return hoses (4) from each pipe

• Water hose from thermostat case (5)

• Heater inlet hose from its pipe

• Vacuum hose (to check valve) (6)

11) Remove canister purge hose bracket from intake manifold.

12) Remove intake manifold stiffener (1).

13) Remove oil pan referring to “Oil Pan and Oil Pump Strainer” 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 “Camshaft, Tappet and Shim” in this section.



19) Remove exhaust manifold stiffener (1).

20) Loosen cylinder head bolts in such order as indicated in figure by using a 12 corner socket wrenches and remove them.

NOTE:

Don’t forget to remove bolt (M8) (1) as shown in figure.

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.


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 (Forceps).

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.


INSPECTION

Valve Guides

Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.

If clearance exceeds limit, replace valve and valve guide.

Valve stem-to-guide clearance

In

Ex

Standard

0.020 – 0.047 mm

(0.0008 – 0.0019 in.)

0.045 – 0.072 mm

(0.0018 – 0.0028 in.)

Valve stem diameter [A]

In

Ex

Standard

5.465 – 5.480 mm

(0.2152 – 0.2157 in.)

5.440 – 5.455 mm

(0.2142 – 0.2148 in.)

Limit

0.07 mm

(0.0028 in.)

0.09 mm

(0.0035 in.)

Valve guide bore [B]

In and Ex

Standard

5.485 – 5.510 mm

(0.2159 – 0.2169 in.)

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 deflection.

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.)


Valves

• Remove all carbon from valves.

• Inspect each valve for wear, burn or distortion at its face and stem end, as necessary, replace it.

• 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 – 0.061 in.)

Limit : 0.9 mm (0.035 in.)

• 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.

• 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.)

• 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 continuous 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.)


• Valve seat repair:

A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.

1) EXHAUST VALVE SEAT: Use valve seat cutters (1) to make two cuts as illustrated in figure. Two cutters must be used: the first for making 15° angle, and the second for making 45° angle. The second cut must be made to produce desired seat width.

Seat width for exhaust valve seat

“a” : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)

2) 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 second 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.


• 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 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.)


Valve Springs

• Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention 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 lb / 1.240 in.)

Limit : 102 N (10.2 kg) for 31.5 mm (22.9 lb / 1.240 in.)

• Spring skewness:

Use a square 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


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) contacts 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:

• Do not reuse once-disassembled valve guide.

Make sure to install new valve guide.

• 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 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:

• Do not reuse once-disassembled seal. Be sure to install new seal.

• 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.


6) Install valve to valve guide

Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore and valve stem.

7) Install valve spring and spring retainer.

Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Be 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 hole.

9) Install intake manifold, injectors and exhaust manifold to cylinder 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).


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.


Venturi plug (a) : 5 N·m (0.5 kg-m, 3.5 lb-ft)

1

“A” “B”

1

“a”

2

“b”

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 (“A” – “B”).

If it exceeds limit, replace with new one.

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) 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 figure.

d) Repeat Step c).

e) Tighten bolt “A” to specified torque.

NOTE:

Be sure to tighten M8 bolt (“A”) after securing the other bolt.


Cylinder head bolt for M8 (a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)

Cylinder head bolts for M10

(b) : 40 N·m (4.0 kg-m, 29.0 lb-ft) and extra tightening 60° twice


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 section.

9) Install intake manifold stiffener and connect each hoses and electric lead wires securely.

10) Install air cleaner outlet hoses.







14) Adjust accelerator cable play referring to “Accelerator Cable


15) Check to ensure that all removed parts are back in place.





18) Verify that there is no fuel leakage, coolant leakage, oil leakage, A/T fluid leakage (vehicle with A/T) and exhaust gas leakage at each connection.


Pistons, Piston Rings, Connecting Rods and Cylinders

1. Top ring

2. 2nd ring

3. Oil ring

4. Piston

5. Connecting rod

: Apply engine 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”.

6. Connecting rod bearing cap

: Point arrow mark on cap to crankshaft pulley side.

7. Connecting rod bearing

8. Piston pin

9. Piston pin circlip

10. Bearing cap nut

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

Tightening torque

Apply engine oil to sliding surface of each parts.

Do not reuse.

REMOVAL




4) Drain coolant.

5) Remove cylinder head referring to “Valves and Cylinder

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.


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.

• Ease out piston pin circlips (1), as shown.

• Force piston pin out.

CLEANING

Decarbon piston head and ring grooves, using a suitable tool.

INSPECTION

Cylinder

• 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 oversize piston.


• 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

• Inspect piston for faults, cracks or other damaged.

Damaged or faulty piston should be replaced.

• Piston diameter:

As indicated in figure, piston diameter should be measured at a position 19.5 mm (0.77 in.) from piston skirt end in the direction perpendicular to piston pin.

Piston diameter specification

Standard size

Oversize

0.50 mm (0.0196 in.)

77.953 – 77.968 mm

(3.0690 – 3.0696 in.)

78.453 – 78.468 mm

(3.0887 – 3.0893 in.)

“a” : 19.5 mm (0.77 in.)


• 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.)

• 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 clearance 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

• Check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly worn or damaged, replace pin, connecting rod and/or piston.


• 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

Top ring

2nd ring

Oil ring

Standard

0.20 – 0.35 mm

(0.0079 – 0.0138 in.)

0.30 – 0.45 mm

(0.0118 – 0.0177 in.)

0.20 – 0.70 mm

(0.0079 – 0.0276 in.)

“a” : 120 mm (4.72 in.)

Limit

0.7 mm

(0.0276 in.)

1.0 mm

(0.0039 in.)

1.5 mm

(0.059 in.)

Connecting Rod

• Big-end side clearance:

Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod.

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.)


• 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

• 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

Connecting rod bearing size

Standard

0.25 mm (0.0098 in.) undersize

Crank pin diameter

41.982 – 42.000 mm

(1.6528 – 1.6535 in.)

41.732 – 41.750 mm

(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.)


• Rod bearing :

Inspect bearing shells for signs of fusion, pitting, burn or flaking and observe contact pattern. Bearing shells found in defective condition must be replaced.

Two kinds of rod bearing are available; standard size bearing and 0.25 mm (0.0098 in.) undersize bearing. For identification 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

• 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 lb-ft).

b) Retighten them to 45°.

c) Repeat step b).


Connecting rod bearing cap nuts

(a) : 15 N·m (1.5 kg-m, 11.0 lb-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 bearing 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.)


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 installing 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.

1. Arrow mark

2. 1st ring end gap

3. 2nd ring end gap and oil ring spacer gap

4. Oil ring upper rail gap

5. Oil ring lower rail gap


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.

3) When installing piston and connecting rod assembly into cylinder bore, point front mark on piston head to crankshaft pulley side.

A : Crankshaft pulley side

B : Flywheel side

4) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft.

Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore.

Special tool

(A) : 09916-77310


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) gradually as follows.

NOTE:

Before installing bearing cap, make sure to check connecting rod bolt diameter.

Refer to “Inspection” of “Connecting Rod” in this section.

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).


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 outlined.








11) Refill cooling system with coolant engine with engine oil and





Engine Mountings

Tightening torque


Unit Repair Overhaul

Engine Assembly

REMOVAL



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.


7) Drain coolant.

WARNING:


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 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.


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 recovery and recycling equipment.

ii) Disconnect magnet clutch lead wire.

iii) Remove suction pipe and disconnect discharge pipe from

A/C compressor.

iv) Remove A/C compressor from its bracket.

When servicing above steps, refer to “Compressor” in Section 1B.

14) Remove air cleaner outlet No.1 and No.2 hoses.


• TP sensor (1)

• MAP sensor (2)

• CKP sensor (if equipped) (3)

• CMP sensor

• ECT sensor

• Heated oxygen sensor

• EGR valve (if equipped)

• IAC valve (4)


• Injectors (6)

• Ignition coils

• Generator

• Starting motor

• Oil pressure switch

• Ground terminal from intake manifold and cylinder block

• Each wire harness clamps


17) Remove starting motor referring to “Dismounting” in Section

6G.


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.



• Canister purge hose (4) from EVAP canister purge valve

• Fuel feed and return hoses (5) from each pipe

• Heater inlet and outlet hoses from each pipe

• Vacuum hose (6) (to check valve)


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 transmission.


26) Remove bolts and nuts fastening cylinder block and transmission.

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.


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 specified torque.


Engine mounting bracket bolts

(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

3) Tighten bolts and nuts fastening cylinder block and transmission to specified torque.


Vehicle with M/T

Cylinder block and transmission fastening bolts and nuts

(a) : 94 N·m (9.4 kg-m, 68.0 lb-ft)

Vehicle with A/T

Cylinder block and transmission fastening bolts and nuts

(a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)

4) Remove lifting device.

5) Reverse removal procedure for installation, noting the following points.

• Tighten torque converter bolts to specified torque (vehicle with A/T).


Torque converter bolts (a) : 20 N·m (2.0 kg-m, 14.5 lb-ft)


• Install seal ring and exhaust pipe to exhaust manifold.

Tighten pipe fasteners to specified torque.


Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

6) Reverse disconnected hoses, cables and electric wires for connection.

7) Install air cleaner outlet hoses.











13) Refill cooling system with coolant engine with engine oil and




Main Bearings, Crankshaft and Cylinder Block


Tightening torque

Do not reuse.

Apply engine oil to inside / sliding surface.

“a” : 3 mm (0.12 in.)

“b” : 2 mm (0.08 in.)

1. CKP sensor (if equipped)

2. Knock sensor

3. Cylinder block

4. Venturi plug

5. Main bearing

6. Sensor plate

7. Crankshaft timing sprocket key

8. Crankshaft

9. Thrust bearing

10. Rear oil seal housing

: Apply specified amount [A] of sealant 99000-31150 to mating surface.

11. Rear oil seal

12. Input shaft bearing

13. Flywheel

14. Main bearing cap

15. Flywheel mounting bolt

: Apply sealant 99000-31110 to thread part.

16. Rear oil seal housing mounting bolt

17. Main bearing cap No.2 bolt

18. Main bearing cap No.1 bolt

1) Tighten all bolts to 50 N·m (5.0 kg-m)

2) Then, turn all bolts to 60°


REMOVAL

1) Remove engine assembly from vehicle as previously outlined.

2) Remove clutch cover, clutch disc and flywheel (drive plate for A/T) by using special tool.

Special tool

(A) : 09924-17810

3) Remove the following parts from engine as previously outlined.

• Oil pan and oil pump strainer

• Intake manifold and exhaust manifold

• Cylinder head cover

• Timing chain cover

• Timing chain guide, chain tensioner adjuster, chain tensioner, timing chain and crankshaft timing sprocket

• Camshaft, tappet and shim

• Cylinder head assembly

• Piston and connecting rod

4) Remove rear oil seal housing (1).

5) Loosen bearing cap No.1 and No.2 bolts in such order as indicated in figure and remove them.

6) Remove crankshaft from cylinder block.

1

“A” “B”

1

“a”

“b”

2


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 crankshaft.

Crankshaft runout

Limit : 0.04 mm (0.0016 in.)

Crankshaft thrust play

Measure this play with crankshaft set in cylinder block in the normal 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.)


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 lb-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.


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 lb-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 play.

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 deformation 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 difference, 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

• Service main bearings are available in standard size and

0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance.


• Upper half of bearing (1) has an oil groove (2) as shown in figure.

Install this half with oil groove to cylinder block.

• Lower half of bearing does not have an oil groove.

Visual inspection

Check bearings for pitting, scratches, wear or damage.

If any 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 following 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.


(5.0 kg-m, 36.5 lb-ft).

c) In the 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 lb-ft) according to numerical order in figure.


Crankshaft bearing No.1 bolts (1) – (10) :

50 N·m (5.0 kg-m, 36.5 lb-ft) and extra tightening 60°

Crankshaft bearing No.2 bolts (11) – (20) :

22 N·m (2.2 kg-m, 16.0 lb-ft)

NOTE:

Do not rotate crankshaft while gauging plastic is installed.


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 upper and lower inserts as a unit.

A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use 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 specification, select a new standard bearing according to the following procedure and install it.

1) First check journal diameter. As shown in figure, crank web

No.2 has stamped numbers.

Three kinds of numbers (“1”, “2” and “3”) represent the following 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 corresponding journal diameter is 44.994 – 45.000 mm (1.7714 –

1.7717 in.).

Crankshaft journal diameter

Stamped numbers

1

2

3

Journal diameter

44.994 – 45.000 mm

(1.7714 – 1.7717 in.)

44.988 – 44.994 mm

(1.7712 – 1.7714 in.)

44.982 – 44.988 mm

(1.7709 – 1.7712 in.)


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 following cap bore diameters.

Stamped alphabets on cylinder block represent bearing cap bore diameter marked with an arrow in figure respectively.

For example, stamped “A” indicates that corresponding bearing cap bore diameter is 49.000 – 49.006 mm (1.9291 –

1.9294 in.).

Crankshaft bearing cap bore

Stamped alphabet

A

B

C

Bearing cap bore diameter

(without bearing)

49.000 – 49.006 mm

(1.9291 – 1.9294 in.)

49.006 – 49.012 mm

(1.9294 – 1.9296 in.)

49.012 – 49.018 mm

(1.9296 – 1.9298 in.)

3) There are five kinds of standard bearings differing in thickness. 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

Pink

Purple

Brown

Green

Black

Bearing thickness

1.990 – 1.994 mm

(0.0783 – 0.0785 in.)

1.993 – 1.997 mm

(0.0785 – 0.0786 in.)

1.996 – 2.000 mm

(0.0786 – 0.0787 in.)

1.999 – 2.003 mm

(0.0787 – 0.0789 in.)

2.002 – 2.006 mm

(0.0788 – 0.0790 in.)

1. Paint


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

Alphabet stamped on cylinder block

(Cap bore dia.)

A

Number stamped on crank web

No.2 (Journal diameter)

1

Pink

B Purple

2

Purple

Brown

3

Brown

Green

C Brown Green Black

New standard bearing to be installed.

5) Using scale (1) on gauging plastic (2), check bearing clearance with newly selected standard bearing.

If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

6) When replacing crankshaft or cylinder block due to any reason, 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):

• 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 crankshaft main bearing

Color painted

Red and Pink

Red and Purple

Red and Brown

Red and Green

Red and Black

Bearing thickness

2.115 – 2.119 mm

(0.0833 – 0.0834 in.)

2.118 – 2.122 mm

(0.0834 – 0.0835 in.)

2.121 – 2.125 mm

(0.0835 – 0.0837 in.)

2.124 – 2.128 mm

(0.0836 – 0.0838 in.)

2.127 – 2.131 mm

(0.0837 – 0.0839 in.)

1. Paint


• 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 perpendicular 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

Alphabets stamped on cylinder block

A

B

C

44.744 – 44.750 mm

(1.7616 – 1.7618 in.)

Red and Pink

Red and Purple

Measured journal diameter

44.738 – 44.744 mm

(1.7613 – 1.7616 in.)

Red and Purple

Red and Brown

44.732 – 44.738 mm

(1.7611 – 1.7613 in.)

Red and Brown

Red and Green

Red and Brown Red and Green

Undersize bearing to be installed

Red and Black

Rear Oil Seal

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 housing (2) by using special tool as shown in the figure.

Special tool

(A) : 09911-97820

Crank rear oil seal installing position

“a” : 3 mm (0.12 in.)


Flywheel

• If ring gear is damaged, cracked or worn, replace flywheel.

• If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel.

• 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

• Check sensor plate for crack or damage. If malcondition is found, replace it.

Cylinder Block

Distortion of gasketed surface

• Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct it.

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

Oversize 0.50

Piston diameter

78.453 – 78.468 mm

(3.0887 – 3.0893 in.)


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.


INSTALLATION

NOTE:

• All parts to be installed must be perfectly clean.

• Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores.

• Journal bearings, bearings caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination 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.


Sensor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-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.


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:

• If bearing cap No.1 bolts are reused, check thread diameters of them for deformation according to previous mentioned “Main Bearing Cap No.1 Bolt” and replace them with new ones if thread diameter exceeds 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 corner socket wrenches.


(5.0 kg-m, 36.5 lb-ft).

c) In the 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 lb-ft) according to numerical order as shown.


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 lb-ft)

NOTE:

After tightening cap bolts, check to be sure that crankshaft rotates smoothly when turning it by 12 N·m (1.2 kgm, 9.0 lb-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.


8) Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool.

Special tool

(A) : 09911-97720


Rear oil seal housing bolts : 11 N·m (1.1 kg-m, 8.0 lb-ft)

A : Crankshaft side

9) Install flywheel (drive plate for A/T).

Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts applied with sealant to specification.

“A” : Sealant 1215 99000-31110

Special tool

(A) : 09924-17810


Flywheel or drive plate bolts

(a) : 70 N·m (7.0 kg-m, 51.0 lb-ft)

10) Install 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 tensioner, timing chain and crankshaft timing sprocket

• Timing chain cover

• Cylinder head cover

• Intake manifold and exhaust manifold

• Oil pan and oil pump strainer

11) 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.

Material

Sealant




(Part Number)

SUZUKI BOND NO. 1207C

(99000-31150)

SUZUKI BOND NO. 1207B

(99000-31140)


(99000-31110)

Use

• To apply to mating surface of cylinder block and oil pan.

• To apply to mating surface of cylinder block and timing chain cover.

• To apply to sealing surface of cylinder head cover.

• To apply to mating surface to rear oil seal housing.

• To apply to mating surface of cylinder block, cylinder head and timing chain cover.

• To flywheel (M/T) or drive plate (A/T) bolts.


Fastening part

Oil pressure switch

Camshaft housing bolts

(for replacement of shim)

Camshaft housing bolts

Cylinder head cover bolts

Intake manifold bolts and nuts

Exhaust manifold bolts and nuts

Exhaust pipe bolts

Exhaust manifold stiffener bolts

Oil pump strainer bolt

Oil pump strainer bracket bolt

Oil pan bolts and nuts

Oil pan drain plug

Timing chain cover bolts and nut

Crankshaft pulley bolt

Oil pump rotor plate bolts

Timing chain No.1 guide bolts

Timing chain tensioner adjuster bolts

Venturi plug

Cylinder head bolt for M8

Cylinder head bolts for M10

Connecting rod bearing cap nuts

Engine mounting bolts

N•m

14.0

8.0

11.0

8.0

25.0

55.0

50.0

50.0

11.0

11.0

11.0

50.0

23.0

150.0

11.0

9.0

11.0

5.0

22.0

a) Tighten 40 N·m b) Turn 60° c) Turn 60° a) Tighten 15 N·m b) Turn 45° c) Turn 45°

50.0


1.4

0.8

1.1

0.8

2.5

5.5

5.0

5.0

1.1

1.1

1.1

5.0

2.3

15.0

1.1

0.9

1.1

0.5

2.2

a) Tighten 4.0 kg-m b) Turn 60° c) Turn 60° a) Tighten 1.5 kg-m b) Turn 45° c) Turn 45°

5.0

lb-ft

10.5

6.0

8.0

6.0

18.0

40.0

36.5

36.5

8.0

8.0

8.0

36.5

17.0

108.5

8.0

6.5

8.0

3.5

16.0

a) Tighten 29.0 lb-ft b) Turn 60° c) Turn 60° a) Tighten 11.0 lb-ft b) Turn 45° c) Turn 45°

36.5


Fastening part

Crankshaft bearing cap No.1 bolts

(for inspection of crankshaft thrust play)


Sensor plate bolts


Rear oil seal housing bolts

Flywheel or drive plate bolts

Torque converter bolts

Timing chain tensioner bolt

Knock sensor

Cylinder block and transmission fastening bolts and nuts (vehicle with M/T)

Cylinder block and transmission fastening bolts and nuts (vehicle with A/T)

N•m

50.0

22.0

11.0

a) Tighten 50 N·m b) Turn 60°

11.0

70.0

20.0

22.0

23.0

94.0

80.0


5.0

2.2

1.1

a) Tighten 5.0 kg-m b) Turn 60°

1.1

7.0

2.0

2.2

2.3

9.4

lb-ft

36.5

16.0

8.0

a) Tighten 36.5 lb-ft b) Turn 60°

8.0

51.0

14.5

16.0

16.5

68.0

8.0

58.0

Special Tool

09911-97720

Oil seal guide

09911-97820

Oil seal installer

09913-75520

Bearing installer

09915-47330

Oil filter wrench

09915-64510-001

Compression gauge

09915-64510-002

Connector

09915-64530

Hose

09915-67010

Attachment


09915-67310

Vacuum gauge

09915-77310

Oil pressure gauge

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

09916-56011

Valve guide installer attachment

09916-58210

Valve guide installer handle

09916-67020

Tappet holder

09916-77310

Piston ring compressor

09916-84511

Forceps

09917-68221

Camshaft lock holder

09917-98221

Valve stem seal installer


09924-17810

Flywheel holder

09926-58010 09944-36011

Bearing puller attachment Steering wheel remover

ENGINE COOLING 6B-1

SECTION 6B

ENGINE COOLING

CONTENTS

General Description ........................................6B-2

Cooling System Circulation ...........................6B-2

Radiator Cap .................................................6B-3

Coolant Reservoir .........................................6B-3

Water Pump ..................................................6B-4

Thermostat ....................................................6B-4

Cooling Fan Clutch........................................6B-4

Coolant (Water) Temperature Gauge............6B-4

Diagnosis .........................................................6B-5

Maintenance ....................................................6B-6

Coolant ..........................................................6B-6

Coolant Level ................................................6B-7

Cooling System Service ................................6B-7

Cooling System Flush and Refill ................... 6B-8

Water Pump Belt Tension ............................. 6B-9

On-Vehicle Service ....................................... 6B-10

Cooling System Component ....................... 6B-10

Coolant Draining ......................................... 6B-11

Cooling Water Pipes or Hoses .................... 6B-11

Thermostat .................................................. 6B-11

Water Pump Belt and Cooling Fan ............. 6B-13

Radiator ...................................................... 6B-14

Water Pump ................................................ 6B-15

Required Service Material ............................6B-17

Tightening Torque Specification ................. 6B-17

6B

6B-2 ENGINE COOLING


The cooling system consists of the radiator cap, radiator, reservoir, hoses, water pump, cooling fan & clutch, thermostat. The radiator is of tube-and-fin type.

Cooling System Circulation

1. Radiator inlet hose

2. Radiator outlet hose

3. Water inlet pipe

4. Thermostat

5. Water pump

6. Fast idle control plunger of throttle body

7. Cylinder block/cylinder head

8. Heater inlet hose

9. Heater outlet hose

10. Radiator


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

2

(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 causing 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 antifreeze such as alcohol (not recommended for use at any time), there is also the possibility or causing a serious fire.

[A]: At air bleed

[B]: At valves closed

[C]: At pressure relief

[D]: At vacuum relief

3. From reservoir

4. To reservoir

5. Pressure in radiator

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.


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 provided; 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, tools, and clothing away from engine cooling 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.

Condition

Engine overheats

Diagnosis

Possible Cause

• 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


Correction

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.


Maintenance

Coolant

The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is collected 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 provides freezing protection to – 36 °C ( – 33 °F).

• 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.

• 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

Anti-freeze / Anti-corrosion coolant concentration

Ratio of compound to cooling water

°C

°F

%

Itr.

US pt.

Imp pt.

Coolant capacity

Engine radiator and heater

Reservoir

Total

– 16

3

30

1.35/3.15

2.85/6.65

2.37/5.53

5.2 liters (11.0/9.2 US/lmp. pt.)

0.7 liters (1.5/1.2 US/lmp. pt.)

5.9 liters (12.5/10.5 US/lmp. pt.)

– 36

– 33

50

2.25/2.25

4.75/4.75

3.95/3.95

NOTE:

• Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time as damage to cooling system could occur.

• Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethylene glycol antifreeze (Antifreeze / Anticorrosion coolant) should be used for the purpose of corrosion protection and lubrication.


Coolant Level

WARNING:

To help avoid danger of being burned:

• Do not remove reservoir cap while coolant is “boiling”, and

• Do not remove radiator cap while engine and radiator are still hot.

Scalding fluid and steam can be blown out under pressure 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:

• 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.

• 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 pressure 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 removing radiator cap when engine is cold.

3) Check coolant for proper level and freeze protection.

4) Using a pressure tester, check system and radiator cap for proper pressure holding capacity 1.1 kg/cm

2

(15.6 psi, 110 kPa). If replacement of cap is required, use proper cap specified for this vehicle.


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. Scalding 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 coolant.

4) Close drain plug. Add water until system is filled and run engine until upper radiator hose is hot again.

5) Repeat steps 3 and 4 several times until drained liquid is nearly colorless.

6) Drain system and then close radiator drain plug tightly.

7) 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


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 cleanliness. 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 pressure (about 10 kg or 22 lb.).

Water pump belt tension

“a” : 4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection / 10 kg (22 lbs)

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.


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 lb-ft)

5) Connect negative cable at battery terminal.



CAUTION:

• Check to make sure that engine coolant temperature is cold before removing any part of cooling system.

• Disconnect negative cable at battery before removing any part.

Cooling System Component

1

4 2

3

10 15 N·m (1.5 kg-m)

11

9

7

6

5

12

14 25 N·m (2.5 kg-m)

1. Radiator

2. Reservoir

3. Cooling fan shroud

4. Water outlet pipe

5. Thermostat case

13 11 N·m

(1.1 kg-m)

8

6. Thermostat

7. Thermostat cap

8. Radiator outlet pipe

9. Heater pipe

10. ECT sensor

11. Water outlet cap

12. Thermostat case outlet pipe

13. Thermostat cap bolt

14. Thermostat case bolt

Tightening Torque


Coolant Draining

1) Remove radiator cap (1).

2) Loosen drain plug on radiator to drain coolant.

3) After draining coolant, be sure to tighten drain plug securely.

4) Fill cooling system. Refer to “Coolant” in this section.

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, noting the following.

• Tighten each clamp bolt securely.

• 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).


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 overheating tendency.

Thermostat functional specification

Temp. at which valve begins to open

Temp. at which valve becomes fully open

80 – 84 °C (176 – 183 °F)

93 – 97 °C (199 – 207 °F)

Valve lift

More than 8 mm at 95 °C

(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.


Thermostat cap bolts

(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

Thermostat case bolts

(b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

3) Install intake manifold by referring to “Throttle Body and

Intake Manifold” in Section 6A1.

4) Fill the cooling system.


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 BELT 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.


Radiator

REMOVAL


2) Remove radiator shroud.

3) Disconnect water hoses from radiator.

4) With automatic transmission (A/T) vehicle, disconnect additional two fluid hoses from radiator.

Place some container under radiator to receive A/T fluid which will flow out when hose is disconnected.

5) Install radiator protection board to between radiator and cooling fan.

6) Remove radiator after removing two bolts (1).

INSPECTION

If the water side of the radiator is found excessively rusted or covered 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 economical.

Inspect the radiator cores and straighten 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:

• Refill cooling system with proper coolant referring to

“Coolant” and “Cooling System Flush and Refill” in this section.

• 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.

• After installation, check each joint for leakage.


Water Pump

COMPONENTS

1. Water pump

2. Water pump pulley

3. Radiator cooling fan clutch

4. Radiator cooling fan

5. Water pump mounting bolts

6. Water pump pulley and fan clutch mounting nuts

7. Radiator cooling fan mounting bolt

Tightening Torque

REMOVAL


Refer to Step 6) of “Cooling System Flush and Refill” in this section.

1. Drain plug

2) Remove the radiator shroud.

3) Remove radiator referring to “Radiator” in this section.

4) Loosen water pump drive belt tension.

Then remove water pump pulley (2) with fan clutch (3) and pump drive belt.

5) Remove water pump assembly (1).


INSPECTION

NOTE:

Do not disassemble water pump.

If any repair is required on pump, replace it as assembly.

• Rotate water pump by hand to check for smooth operation.

If pump does not rotate smoothly or makes 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.


Water pump bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

3) Install water pump pulley (2) with fan clutch (3).


Water pump pulley nuts (b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

Fan clutch bolts (c) : 11 N·m (1.1 kg-m, 8.0 lb-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.


7) Fill the cooling system.



Material

Ethylene glycol base coolant (Anti-freeze /

Anti-corrosion coolant)

Sealant


(Part Number)

SUZUKI BOND NO.1207C

(99000 – 31150)

–

Use

Additive to engine cooling system for improving cooling efficiency and for protection against rusting.

To apply to water pump mating surface.


Fastening part

Water pump bolt

Thermostat cap bolt

Thermostat case bolt

Fun clutch bolt

N•m

23

11

25

11


2.3

1.1

2.5

1.1

lb-ft

17.0

8.0

18.0

8.0


ENGINE FUEL 6C-1

SECTION 6C

6F1

ENGINE FUEL

7A

7A1

General Description ....................................... 6C-2

Fuel System ................................................. 6C-2

Fuel Tank ..................................................... 6C-2

Fuel Pump Assembly ................................... 6C-3

Fuel Filler Cap .............................................. 6C-3

On-Vehicle Service......................................... 6C-4

CONTENTS

Fuel Lines .................................................... 6C-4

Fuel Filler Cap.............................................. 6C-4

Fuel Tank ..................................................... 6C-4

Fuel Pump Assembly ................................... 6C-7

Tightening Torque Specification ................ 6C-10

Special Tool.................................................. 6C-10

7A

7A

7A1

7B1

7C1

7D

7E

7F

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.

8A

8B

8C

6G

6C

6K

9

10

10A

10B

6C-2 ENGINE FUEL


Fuel System

The main components of the fuel system are fuel tank, fuel 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.

1. Fuel tank

2. Fuel pump assembly

3. Breather hose

4. Fuel filler cap

5. Fuel feed line

6. Fuel return line

7. Fuel vapor line

8. Fuel filler neck

9. Fuel tank mounting bolt

10. Fuel filler hose clamp

Tightening torque

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.


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 Delivery 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 filler 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 contact, 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.



Before work, refer to “Precaution on Fuel System Service” in Section 6.

Fuel Lines

Due to the fact that fuel feed line is under high pressure, use special 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 features should be used. Failure to use correct cap can result in critical malfunction of system.

Fuel Tank

REMOVAL

WARNING:

• Before starting the following procedure, be sure to observe “Precaution on Fuel System Service” in Section 6.

• Keep fuel tank horizontally and stably when removing it. Fuel may come out if tank is tilted. Also, fuel tank may drop and cause personal injury.

1) Relieve fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure” in Section 6.


3) Remove fuel filler cap.


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.

7) Disconnect coupler (1) for fuel pump assembly.

The coupler is close by left rear suspension coil spring (3).

2. Fuel tank

8) Remove fuel tank filler hose protector.

Disconnect filler hose and breather hose from fuel filler neck.

9) Disconnect fuel vapor hose from pipe.

10) With fuel tank supported on a jack, remove fuel tank bolts.

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

4. Insert special tool

5. Disconnect joint


12) Remove fuel tank (1) from vehicle. Remove fuel tank protector (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.


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, 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.


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 Pressure Check” in Section 6.

For inspection of fuel level gauge, refer to “Fuel Meter / Fuel

Gauge Unit” in Section 8.

2. Fuel filter & bracket assembly

3. Fuel pump motor & level gauge assembly

DISASSEMBLY / REASSEMBLY

“A” : Apply oil

1. Bracket sub assembly (including fuel filter)

2. Grommet

3. Tube

4. Housing

5. Lead wire

6. Fuel level gauge

7. Fuel pump

8. Cushion

9. Bracket

10. Spacer


CAUTION:

• While removing fuel level gauge, do not contact resistor plate (2) or deform arm (3). It may cause fuel level gauge to fail.

• 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:

• When removing fuel level gauge, press snap-fit part (1) and slide it in the arrow direction as shown in figure.

• When installing fuel level gauge to housing, fit protrusion (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.


Fuel pump assembly bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-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 section.



Fastening part

Fuel pump assembly bolt

N•m

10


1.0

lb-ft

7.5

Special Tool

09919-47020

Quick joint remover

ENGINE AND EMISSION CONTROL SYSTEM 6E-1

SECTION 6E

ENGINE AND EMISSION CONTROL SYSTEM

WARNING:






NOTE:

Whether following systems (parts) are used in the particular vehicle or not depends on specifications.

Be sure to bear this in mind when performing service work.

• EGR valve

• Heated oxygen sensor (s) or CO adjusting resistor

• Three way catalytic converter (TWC) and warm up three-way catalytic converter (WU-TWC)

8A

8B

8C

8D

6H

6E

10

10A

10B

7E

7A

7A1

7B1

7C1

7D

7E

7F

6F1

6F2

6G

7C1

7D


Air Intake System ......................................... 6E-5

Fuel Delivery System ................................... 6E-6

Fuel pump ................................................ 6E-6

Electronic Control System ............................ 6E-7

Engine & emission control input / output table.......................................................... 6E-8

On-Vehicle Service....................................... 6E-15

Accelerator cable adjustment ................. 6E-15

Idle speed / idle air control (IAC) duty inspection ............................................... 6E-15

Idle mixture inspection / adjustment

(vehicle without heated oxygen sensor) ................................................... 6E-17

Air Intake System ....................................... 6E-18

Throttle body .......................................... 6E-18

Idle air control valve (IAC valve)............. 6E-21

Fuel Delivery System ................................. 6E-22

Fuel pressure inspection ........................ 6E-22

Fuel pump .............................................. 6E-23

Fuel pressure regulator .......................... 6E-24

Fuel injector............................................ 6E-25

Electronic Control System .......................... 6E-29

CONTENTS

Engine control module (ECM) ................ 6E-29

Manifold absolute pressure sensor (MAP sensor) ................................................... 6E-29

Throttle position sensor (TP sensor) ...... 6E-30

Intake air temperature sensor

(IAT sensor) ........................................... 6E-31

Engine coolant temperature sensor

(ECT sensor).......................................... 6E-32

Heated oxygen sensor

(Sensor-1 and sensor-2) ........................ 6E-33

Camshaft position sensor....................... 6E-34

Crankshaft position sensor..................... 6E-35

Vehicle speed sensor (VSS) .................. 6E-36

Fuel level sensor (GAUGE).................... 6E-36

Knock sensor ......................................... 6E-36

Main relay, fuel pump relay and A/C condenser fan control relay.................... 6E-36

Fuel cut operation .................................. 6E-37

A/C condenser fan control system ......... 6E-37

A/C condenser fan ................................. 6E-37

Output signals of throttle valve opening and engine coolant temp.

(Vehicle with A/T only) ........................... 6E-38

Emission Control System ........................... 6E-38

6E-2 ENGINE AND EMISSION CONTROL SYSTEM

EGR system (If equipped)...................... 6E-38

Evaporative emission (EVAP) control system.................................................... 6E-39

PCV system ........................................... 6E-41

Special Tools ............................................... 6E-42

Tightening Torque Specifications.............. 6E-43



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, delivery pipe, fuel pressure regulator, etc. Electronic control system includes ECM, various sensors and controlled devices.

Emission control system includes EGR, EVAP and PCV system.



1. Air Cleaner


3. IAT sensor

4. TP sensor

5. IAC valve

6. MAP sensor

7. EGR valve (if equipped)

8. EVAP canister

9. Tank pressure control valve (built-in fuel pump)

10. Fuel pump

11. Fuel level sensor

12. Ignition coil assembly

13. Fuel injector

14. Heated Oxygen Sensor (HO2S)-1 (if equipped)

15. Heated Oxygen Sensor (HO2S)-2 (if equipped)

16. Three way catalytic convertor (if equipped)

17. Knock sensor

18. ECT sensor

19. CMP sensor

20. CKP sensor

21. VSS

22. A/C condenser fan (if equipped)


24. Park/Neutral position switch in TR switch (A/T)

25. Ignition switch

26. Starter magnetic switch

27. TCM (A/T)

28. Transmission range switch (A/T)

29. DLC

30. Electric load

31. Monitor connector (if equipped)

31-1. Diagnosis switch terminal

(vehicle w/o immobilizer indicator lamp)

31-2. Test switch terminal


31-3. Duty output terminal


32. Immobilizer indicator lamp (if equipped)


34. ECM

35. Barometric pressure sensor

(vehicle with immobilizer indicator lamp)

36. Battery

37. Immobilizer control module (if equipped)

38. ABS control module (if equipped)


40. Power steering pressure switch

(if equipped)

41. A/C compressor clutch (if equipped)

42. A/C EVAP TEMP. sensor (if equipped)


Air Intake System

The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air control valve (4) and intake manifold (5).

The air (by the amount corresponding to the 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).


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.

4. Fuel cut valve

5. Fuel tank pressure control valve

6. To EVAP canister

7. Fuel feed line

12. To intake manifold (vacuum passage)

Fuel pump

An in-tank type electric pump has been adopted for the fuel pump

(1). Incorporated in the pump assembly are;

• 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.

• Relief valve (3) which prevents the pressure in tank from rising excessively.

• 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.


Electronic Control System

The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 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:

• Fuel injection control system

• Idle speed control system

• Fuel pump control system

• A/C control system (if equipped)

• A/C condenser fan control system

• EGR system (if equipped)

• Evaporative emission control system

• Oxygen sensor heater control system

• Ignition 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.

1. IAT sensor

2. TP sensor



5. CKP sensor

6. MAP sensor

7. CMP sensor

8. Transmission range switch

9. VSS



12. ECT sensor

13. Knock sensor a : Immobilizer indicator lamp (if equipped) b : A/C condenser fan motor relay (if equipped) c : Main relay d : Fuel pump relay e : IAC valve f : EVAP canister purge valve g : EGR valve (if equipped) h : Fuel injector i : Ignition coil assemblies

J : MIL

A : ECM

B : A/T control module

C : EVAP canister

D : DLC

E : ABS control module (if equipped)


Engine & emission control input / output table

ELECTRIC CONTROL DEVICE

OUTPUT

INPUT

DIAGNOSIS SWITCH TERMINAL

(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)

BAROMETRIC PRESSURE SENSOR

(VEHICLE WITH IMMOBILIZER INDICATOR LAMP)

STOP LAMP SWITCH

STARTER SWITCH

IGNITION SWITCH

LIGHTING SWITCH

REAR DEFOGGER SWITCH (IF EQUIPPED)

BLOWER SWITCH

A/C SWITCH (IF EQUIPPED)

A/C EVAPORATOR TEMP. SENSOR (IF EQUIPPED)

VSS

HEATED OXYGEN SENSOR-1 (IF EQUIPPED)

HEATED OXYGEN SENSOR-2

(IF EQUIPPED)

IAT SENSOR

ECT SENSOR

TP SENSOR

MAP SENSOR

CMP SENSOR

CKP SENSOR

TEST SWITCH TERMINAL

(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)

KNOCK SENSOR

For detecting deterioration of three way catalytic converter

ECM INPUT / OUTPUT CIRCUIT DIAGRAM



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.


1. CKP sensor

2. CMP sensor

3. VSS

4. MAP sensor

5. Knock sensor

6. TP sensor

7. ECT sensor

8. IAT sensor

9. Heated oxygen sensor-1 (if equipped)


11. A/C evaporator temp. sensor (if equipped)

12. Speedometer


14. TCM (A/T)


16. Shift lock solenoid (A/T, if equipped)

17. Backup lamp

18. Heater fan motor

19. Heater fan switch


(if equipped)

21. A/C switch

22. A/C refrigerant pressure switch

(if equipped)



25. Injector No.1

26. Injector No.2

27. Injector No.3

28. Injector No.4

29. IAC valve


31. Fuel pump relay

32. Fuel pump

33. A/C condenser fan relay (if equipped)

34. A/C condenser fan motor (if equipped)


36. Malfunction indicator lamp


38. Monitor connector (vehicle without immobilizer indicator lamp)

39. Ignition coil assembly (for No.1 and No.4 spark plugs)



42. Stop lamp

43. Lighting switch

44. Position lamp

45. Rear defogger switch (if equipped)

46. Rear defogger (if equipped)


48. Ignition switch

49. Main relay

50. CO adjusting register (if equipped)

51. Starting motor

52. 4WD controller (4WD)


54. Engine ground

55. Body ground



NOTE:

See NOTE in “ECM INPUT / OUTPUT CIRCUIT DIAGRAM” for applicable model.


1. CKP sensor

2. CMP sensor

3. VSS

4. MAP sensor

5. Knock sensor

6. TP sensor

7. ECT sensor

8. IAT sensor



11. A/C evaporator temp. sensor (if equipped)

12. Speedometer


14. TCM (A/T)


16. Shift lock solenoid (A/T, if equipped)

17. Backup lamp

18. Heater fan motor

19. Heater fan switch


(if equipped)

21. A/C switch

22. A/C refrigerant pressure switch

(if equipped)



25. Injector No.1

26. Injector No.2

27. Injector No.3

28. Injector No.4

29. IAC valve


31. Fuel pump relay

32. Fuel pump

33. A/C condenser fan relay (if equipped)

34. A/C condenser fan motor (if equipped)


36. Malfunction indicator lamp


38. Monitor connector (vehicle without immobilizer indicator lamp)




42. Stop lamp

43. Lighting switch

44. Position lamp

45. Rear defogger switch (if equipped)

46. Rear defogger (if equipped)


48. Ignition switch

49. Main relay

50. CO adjusting register (if equipped)

51. Starting motor

52. 4WD controller (4WD)


54. Engine ground

55. Body ground


ECM TERMINAL ARRANGEMENT TABLE


10

14

15

16

17

11

12

13

18

19

20

21

22

23

24

25

26

27

28

29

30

31

CONNEC-

TOR

TERMINAL

1

2

5

6

7

8

3

4

E19

E18

9

1

2

3

4

5

6

WIRE COLOR

B

B/R

B/R

Bl/G

Bl/Or

G/Y

P/B

W/B

R/W

B/Bl

W

–

R

R/Bl

G/B

Lg/B

Lg

Gr/BI

Gr

Br/B

Br/W

R/G

Lg/R

G/R

–

W

G

W/R

Gr/B

Gr/R

–

W/G

P

V/Y

P/G

R/BI

Bl/B

Bl/B

CIRCUIT

Ground for ECM

Ground for drive circuit


Canister purge valve


(if equipped)

IAC valve

Heater of HO2S-1 (if equipped)

No.4 fuel injector

No.1 fuel injector

Ground for sensor circuit

CMP sensor

–

Heated oxygen sensor-1

(if equipped)


ECT sensor

IAT sensor

TP sensor



IG coil assembly for No.2 and 3 spark plugs


No.2 fuel injector

Power supply for sensor

CKP sensor

–

Knock sensor

MAP sensor




–

No.3 fuel injector

A/C compressor clutch (if equipped)

Malfunction indicator lamp

Data link connector (12 V)


Power source

Power source

CONNEC-

TOR

TERMINAL

7

E18

8

9

10

11

12

13

14

15

19

20

21

22

16

17

18

23

24

WIRE COLOR

W

R/G

–

Bl

Br

Y/B

W

W/BI

P

G/W

R/Y

CIRCUIT

Backup power source


(if equipped)

Duty output terminal (vehicle without immobilizer indicator lamp)

–

Main relay

Tachometer



(if equipped)


(vehicle without immobilizer indicator lamp)

Test switch terminal


A/C SW signal (if equipped)

Lighting switch

P/B

W/G

B/Bl

B/R

Y/R

–

Bl/Y

A/C condenser fan relay (if equipped)

Fuel pump relay

Ground for sensor

Throttle opening signal output for A/T

(A/T)

Fuel level gauge (vehicle with immobilizer indicator lamp)

–


E17

3

4

1

2

5

6

7

8

9

10

11

12

13

14

15

16

17

–

–

–

R

B/Or

G/Y

G/W

–

B/W

–

Y

G

B/Y (M/T)

B/R (A/T)

–

–

R/W

G/R

–



D-range idle-up signal (A/T)

Stop lamp switch

Ignition switch

–

–

–

–


ABS signal (if equipped)

Engine start signal

–

–

Rear defogger switch (if equipped)

A/T failure signal (A/T) (vehicle with immobilizer indicator lamp)

NOTE:




13

14

15

16

17

18

19

10

11

12

29

30

31

20

25

26

27

21

22

23

24

28

CONNEC-

TOR

TERMINAL

1

2

5

6

7

8

3

4

9

E19

E18

1

2

3

4

5

6

Gr

Br/B

Br/W

R/G

Lg/R

G/R

–

W

G

–

Gr/B

Gr/R

–

W/G

B/Bl

W

–

R

R/Bl

G/B

Lg/B

Lg

Gr/BI

WIRE COLOR

B

B/R

B/R

Bl/G

Bl/Or

G/Y

P/B

W/B

R/W

P

–

–

R/BI

Bl/B

Bl/B

CIRCUIT

Ground for ECM



Canister purge valve


(if equipped)

IAC valve


No.4 fuel injector

No.1 fuel injector

Ground for sensor circuit

CMP sensor

–


(if equipped)


ECT sensor

IAT sensor

TP sensor





No.2 fuel injector

Power supply for sensor

CKP sensor

–

Knock sensor

MAP sensor

–



–

No.3 fuel injector

A/C compressor clutch (if equipped)

–

–


Power source

Power source

CONNEC-

TOR

TERMINAL

7

E18

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

WIRE COLOR

W

R/G

–

Bl

B/W

R/W

–

W/BI

P

G/W

R/Y

CIRCUIT

Backup power source


(if equipped)

Duty output terminal (vehicle without immobilizer indicator lamp)

–

Main relay

Ignition switch

Rear defogger switch

–



Test switch terminal


A/C SW signal (if equipped)

Lighting switch

P/B

W/G

B/Y (M/T)

B/R (A/T)

G/W

Y

–

–

A/C condenser fan relay (if equipped)

Fuel pump relay

Engine start signal

Stop lamp switch


–

–

E17

5

6

7

1

2

3

4

8

9

10

11

12

13

14

15

16

17

W/R

R

–

–

B/Or

G/Y

Y/B

–

V/Y

–

P/G

G

Bl/Y

B/Bl

B/R

Br

–



–

–


D-range idle-up signal (A/T)

Data link connector

–

Malfunction indicator lamp

–


ABS signal (if equipped)


Ground for sensor

Throttle opening sensor

Tachometer

–

NOTE:




Accelerator cable adjustment

1) With throttle valve closed, check accelerator pedal play which should be within following specification.

If measured value is out of specification, adjust it to specification with cable adjusting nut (1).

Accelerator pedal play

“a” : 2 – 7 mm (0.08 – 0.27 in.)

2) With accelerator pedal depressed fully, check clearance between throttle lever (2) and lever stopper (3) (throttle body) which should be within following specification.

If measured value is out of specification, adjust it to specification 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 maintenance 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 condition.

• 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.


1) Connect SUZUKI scan tool to DLC with ignition switch OFF, if it is available.


3) Check engine idle speed and “IAC duty” as follows: a) When using SUZUKI scan tool: i) Select “Data List” mode on scan tool to check “IAC duty”.


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.

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

M/T vehicle

A/T vehicle at P/N range

A/C OFF

700 ± 50 r/min (rpm)

5 – 25 %

750 ± 50 r/min (rpm)

5 – 25 %

A/C ON

900 ± 50 r/min

(rpm)

900 ± 50 r/min

(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 system.


Idle mixture inspection / adjustment (vehicle without heated oxygen sensor)

All vehicles not equipped with heated oxygen sensor are shipped with their CO % factory adjusted as follows.

Engine idle mixture (CO %)

0.5 – 1.5 % at specified idle speed

Idle mixture adjustment should never be changed from the original factory setting. However, if during diagnosis, the check indicates 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.


Air Intake System

Throttle body

1. Throttle body

2. Throttle body gasket

3. TP sensor

4. Gasket

5. Idle air control valve

6. IAC valve screws

7. TP sensor screws

Tightening torque

Do not reuse

ON-VEHICLE INSPECTION

• Check that throttle valve lever (1) moves smoothly.

REMOVAL



3) Disconnect accelerator cable (1) from throttle valve lever.


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 Position Sensor” in this section for installation.


INSTALLATION

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 specification.

7) Refill cooling system.



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 lAC valve opens and closes once and then stops in about 60 ms as soon as ignition switch is turned ON.

NOTE:

• This check should be performed by two people, one person turns on ignition switch while the other checks valve operation.

• As valve operation is momentary, it may be overlooked. To prevent this, perform this operation check 3 times or more continuously.

If rotary valve of lAC valve does not operate at all, check wire harness for open and short. If wire harness is in good condition, replace lAC valve and recheck.

INSTALLATION

1) Install new O-ring (2) to IAC valve (1).

2) Install IAC valve (1) to throttle body (3).

Tighten IAC valve screws to specified torque.


IAC valve screws (a) : 3.5 N·m (0.35 kg-m, 2.5 lb-ft)

3) Install throttle body to intake manifold referring to “Throttle

Body” in this section for installation.


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 Pressure 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 container.

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 seconds turn it OFF. Repeat this 3 or 4 times and then check fuel pressure.


CONDITION

With fuel pump operating and engine stopped

At specified idle speed

With 1 min. after engine (fuel pump) stop (Pressure reduces as time passes)

FUEL PRESSURE

270 – 310 kPa

2.7 – 3.1 kg/cm

2

,

38.4 – 44.0 psi

210 – 260 kPa

2.1 – 2.6 kg/cm

2

,

29.8 – 37.0 psi over 200 kPa

2.0 kg/cm

2

, 28.4 psi


6) Start engine and warm it up to normal operating temperature.

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 procedures.

• Place fuel container under joint.

• Cover joint with rag and loosen joint nut slowly to release fuel pressure gradually.

9) Remove special tools from fuel delivery pipe.

10) Connect

Suzuki SN413 Service manual

Assistant Bot

WARNING/CAUTION/NOTE

GENERAL INFORMATION

CONTENTS

Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System

Diagnosis

Servicing and handling

General Precautions

Precautions For Catalytic Converter

Precautions For Electrical Circuit Service

Electrical Circuit Inspection Procedure

Open circuit check

Short circuit check (wire harness to ground)

Intermittent and Poor Connection

Precaution For Installing Mobile Communication Equipment

Body Number

Engine Identification Number

Transmission Identification Number

When Using Frame Contact Hoist

When Using Floor Jack

Abbreviations

Metric Fasteners

Fastener Strength Identification

Standard Tightening Torque

MAINTENANCE AND LUBRICATION

CONTENTS

Maintenance Schedule Under Normal Driving Conditions

Maintenance Recommended Under Severe Driving Conditions

Engine

Drive Belt

Valve Lash

Engine Oil and Filter

Engine Coolant

Exhaust System

Ignition System

Spark Plugs

Fuel System

Air Cleaner Filter

Fuel Lines and Connections

Fuel Filter

Fuel Tank

Emission Control System

Crankcase Ventilation Hoses and Connections

PCV (Positive Crankcase Ventilation) Valve

Fuel Evaporative Emission Control System

Chassis and Body

Clutch

Brake Discs and Pads

Brake Drums and Shoes

Brake Hoses and Pipes

Brake Fluid

Parking Brake Lever and Cable

Tires/Wheels

Suspension System

Propeller Shafts

Manual Transmission Oil

Automatic Transmission Fluid

Transfer and Differential Oil

Steering System

Steering Knuckle Seal

Power Steering (P/S) System (if equipped)

All Hinges, Latches and Locks

HEATER AND VENTILATION

CONTENTS

Diagnosis Table

Wiring Circuit

Heater Blower Motor

Heater Blower Resistor

Heater Control Lever Assembly

Heater Blower Fan Switch

Heater Unit/Boost Ventilation

AIR CONDITIONING (OPTIONAL)

CONTENTS

Major Components and Location

Refrigerant Circulation

Refrigerant Type

General Diagnosis Table

Abnormal Noise Diagnosis

Abnormal noise from compressor