Suzuki SQ416 2001 Owner's 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 (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 (air bag (inflator) modules, forward sensor(s),

SDM and/or seat belt pretensioners) beforehand to avoid component damage or unintended activation.

Foreword

This manual contains only different service information of the following applicable model as compared with

SQ416/SQ420/SQ625 SERVICE MANUAL.

Applicable model: GRAND VITARA XL-7

Therefore, whenever servicing the above applicable model, consult this manual first. And for any section, item or description not found in this manual, refer to the related manual below.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, 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

SQ416/SQ420/SQ625 Service Manual

SQ416/SQ420/SQ625 Unit Repair Manual for Manual Transmission, Automatic Transmission, Transfer and Differential

GRAND VITARA XL-7 Wiring Diagram Manual

Manual No.

99500-65D10-01E

99501-65D01-01E

99512-52D00-015

© COPYRIGHT SUZUKI MOTOR CORPORATION 2001

GENERAL INFORMATION

General Information

Maintenance and Lubrication

HEATING AND AIR CONDITIONING

Heater and Ventilation

Air Conditioning

STEERING, SUSPENSION, WHEELS

AND TIRES

0A

0B

1A

1B

Steering, Suspension, Wheels and Tires 3

Front End Alignment

Power Steering (P/S) System

Air Bag Steering Wheel and Column

3A

3B1

3C1

Front Suspension

Rear Suspension

Wheels and Tires

DRIVE SHAFT AND PROPELLER SHAFT

3D

3E

3F

Front Drive Shaft / Shaft Bearing,

Oil Seal

Propeller Shaft

BRAKE SYSTEM

4A2

4B

Brakes

Brake Pipe / Hose / Master Cylinder

Front Brake

Parking and Rear Brake

Antilock Brake System (ABS)

ENGINE

General Information and

Diagnosis (H27 Engine)

Engine Mechanical (H27 Engine)

Engine Cooling

Engine Fuel

Engine and Emission Control System

(SFI For H27 Engine)

5

5A

5B

5C

5E2

6-1

6A2

6B

6C

6E2

Ignition System (H27 Engines)

Cranking System

Charging System

Exhaust System

6F2

6G

6H

6K

Table of Contents

TRANSMISSION, CLUTCH AND

DIFFERENTIAL

Manual Transmission

Automatic Transmission

Clutch

Transfer

Differential (Front)

Differential (Rear)

ELECTRICAL SYSTEM

Electrical System

Wiring Diagram

Lightening System

Instrumentation / Driver Information

Windows, Mirrors, Security and Lock

Cruise Control System

Immobilizer control system (if equipped) 8G

BODY SERVICE

Body Service

RESTRAINT SYSTEM

9

8

8A

8B

8C

8D

8E

Restraint System

Seat Belt

Air Bag System

10

10A

10B

7A1

7B1

7C1

7D

7E

7F

6-1

6A2

6B

6C

6E2

6F2

6G

6H

6K

5 10

5A 10A

5B 10B

5C

5E2

0A 7A1

0B 7B1

7C1

1A

1B

7D

7E

7F

3

3A 8

3B1 8A

3C1 8B

3D 8C

3E

3F

8D

8E

8G

4A2

4B 9

NOTE:

For the screen toned Sections in the above table, refer to the same section of the Related Manuals mentioned in FOREWORD of this manual.

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual.

0A

CONTENTS

Precautions......................................................0A-2

Precaution for Vehicles Equipped with A

Supplemental Restraint

(Air Bag) System ...........................................0A-2

Diagnosis...................................................0A-2

Servicing and handling ..............................0A-3

Identification Information...............................0A-6

Vehicle Identification Number ....................... 0A-6

Engine Identification Number ........................ 0A-7

Transmission Identification Number.............. 0A-7

Warning, Caution and Information Labels.... 0A-8

0A-2 GENERAL INFORMATION

7 5 7 6

3 4

15

2

1

4

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

2. Passenger air bag (inflator) module

3. SDM

4. Seat belt pretensioners

5. Contact coil

6. Driver air bag (inflator) module

7. Forward sensors

Diagnosis

• When troubleshooting air bag system, be sure to follow

“DIAGNOSIS” in SECTION 10B. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement.

• Never use electrical test equipment other than that 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 pretensioners.


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 or use the workbench vise to hold it securely at its lower mounting bracket. 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.

1. Slit on workbench

2. Lower mounting bracket

3. Workbench vise


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

• 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 or to put a seat belt pretensioner on top of another. Otherwise, personal injury may result.

• Never dispose of live (inactivated) seat belt pretensioners (drive 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), forward sensors or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied (e.g., dropped from a height of 91.4 cm (3 feet) or more), never attempt disassembly or repair but replace it with a new one.

• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and 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 temporarily disable air bag system referring to “DIS-

ABLING AIR BAG SYSTEM” in SECTION 10B.

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

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

• After vehicle is completely repaired, perform “AIR BAG DIAGNOSTIC SYSTEM CHECK” in SEC-

TION 10B.


Identification Information

Vehicle Identification Number

The vehicle body number is on the left side of instrument panel and punched on the chassis inside the tire housing on the right front side.


Engine Identification Number

The number is punched on the cylinder block.

H 27 A 100001

Sequential Number

Engine Displacement

(27 2.7 Liter)

Engine Type

Engine Identification Number Specification

Transmission Identification Number

The A/T manufacture’s identification number is located on the transmission case as shown. However, the M/T identification number is not assign.


Warning, Caution and Information Labels

The figure below shows main labels among others that are attached to vehicle component parts.

When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels.

If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.

1. Passenger seat belt label (if equipped) 5. Blank

2. Radiator cap label 6. Air bag label on sun visor

3. Air bag label

4. Engine cooling fan label

7. Air bag label on sun visor (Back side)

Air bag label and utility vehicle label on sun visor (Face side)

8. Jacking instructions

9. Jacking instruction label

10. Transfer label (if equipped)

11. Armrest label on strap

12. Seat label (if equipped)

4

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

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

3. Air bag label on steering column cover

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

3

5

7

6

5. Air bag label on wire harness

6. Air bag label on SDM

7. Pretensioner label on seat belt pretensioner

7

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

WARNING:

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



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

“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

0B

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 and Emission Control....................... 0B-5

Drive belt inspection and replacement ..... 0B-5

Engine oil and filter replacement.............. 0B-6

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 (

× 1,000)

Miles (

× 1,000)

Months

15 30 45 60 75 90

9 18 27 36 45 54

12 24 36 48 60 72

ENGINE

1-1. Drive belt

1-4. Engine oil and oil filter

1-5. Engine coolant

1-6. Exhaust system

V-rib belt (Flat type)

–

–

– –

R R

–

I

R

–

I – –

R R R

–

I

–

–

IGNITION SYSTEM

2-1. Spark plugs When unleaded fuel is used

Vehicle without

HO2S

Vehicle with

HO2S

Nickel plug

Iridium plug

–

–

–

R

–

–

–

–

R

R

R

–

–

–

– Nickel plug

Iridium plug Replace every 105,000 km or

63,000 miles

When leaded fuel is used, refer to “MAINTENANCE RECOMMENDED UNDER

SERVER DRIVING CONDITIONS” in this section.

R

–

R

FUEL SYSTEM

3-1. Air cleaner filter

3-2. Fuel lines and connections

3-3. Fuel filter

I

–

I

I

R

–

I

I

I

–

R

I

Replace every 105,000 km or

63,000 miles

– – I – – I 3-4. Fuel tank

EMISSION CONTROL SYSTEM

4-1. Crankcase ventilation hoses and connections (Vehicle without

HO2S)

4-2. PCV valve Vehicle without HO2S

– – I – – I

4-3. Fuel evaporative emission control system

Vehicle with HO2S

Vehicle without HO2S

Vehicle with HO2S

–

–

–

–

–

–

I

–

I

–

–

–

–

–

I

–

–

–

–

–

I

I

I

I

R

R

R

I

NOTE:

• “R”: Replace or change

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

• For Sweden, item 2-1, 4-2 and 4-3 should be performed by odometer reading only.

• For Item 2-1. Nickel spark plugs, replace every 50,000 km if the local law requires.

• Nickel spark plug: BKR6E-11 or K20PR-U11

• Iridium spark plug: IFR5J11 or SK16PR11


Interval

Km (

× 1,000)

Miles (

× 1,000)

Months

15

9

12

30 45 60 75

18 27 36 45

24 36 48 60

90

54

72

CHASSIS AND BODY

6-1.

6-2.

Clutch (pedal and fluid level)

Brake discs and pads (thickness, wear, damage)

Brake drums and shoes (wear, damage)

6-3.

Brake hoses and pipes (leakage, damage, clamp)

6-4.

Brake fluid

–

I

–

–

–

I

I

I

I

R

–

I

–

–

–

I

I

I

I

R

–

I

–

–

–

6-5.

Brake lever and cable (damage, stroke, operation)

6-6.

Tires (wear, damage, rotation)

6-7.

Wheel discs (damage)

6-8.

Suspension system (tighteness, damage, rattle, breakage)

6-9.

Propeller shafts and drive shafts –

6-10. Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I

6-11. Automatic transmission Fluid level

Fluid change

I

–

Fluid hose

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

I I I I I I

I

I

–

–

I

–

I

R

I

I

–

–

I

–

–

–

I

I

I

R

– I – I –

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

– – – R –

I

–

I

I

I

I

R

6-12. Transfer oil (leakage, level)

6-13. Differential oil (leakage, level) (R: 1st 15,000 km only)

6-14. Steering system (tighteness, damage, breakage, rattle)

6-15. Power steering (if equipped)

6-16. All latches, hinges and locks

6-17. Air conditioning filter (if equipped)

I –

R or I –

–

I

–

– I

I

I

I –

I

I

I

–

R

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 given in the chart below.

Severe condition code :

A: Repeated short trips E: Repeated short trips in extremely cold weather

B: Driving on rough and/or muddy roads F: Leaded fuel use

C: Driving on dusty roads

D: Driving in extremely cold weather and/or salted roads

G: – – – – – – – –

H: Trailer towing (if admitted)

Severe

Condition Code

Maintenance

Maintenance

Operation

Maintenance Interval

– B CD – – –

A – CDEF – H

– B– – – – – –

– – C – – – – –

ABC–EF–H

ITEM 1-1

Drive belt (V-rib belt)

ITEM 1-4

Engine oil and oil filter

ITEM 1-6

Exhaust pipe mountings

ITEM 3-1

Air cleaner filter *1

ITEM 2-1

Spark plugs

Nickel plug

Iridium plug

I

R

R

I

I

R

R

R

Every 15,000 km

(9,000 miles) or 12 months

Every 45,000 km


Every 5,000 km


Every 15,000 km


Every 2,500 km

(1,5000 miles)

Every 30,000 km


Every 10,000 km


Every 30,000 km


Every 15,000 km


– B – D E – – H

– B – – E – – H

– B C D – – – H

– – CD – – – –

ITEM 6-9

Propeller shafts and drive shafts

ITEM 6-10, 6-12, 6-13

Manual transmission, transfer and differential oil

– B – – E – – H

– B – – – – – –

ITEM 6-11

Automatic transmission fluid

ITEM 6-8

Suspension bolts and nuts

ITEM 6-7

Wheel bearing

ITEM 6-17

Air conditioning filter *2

(if equipped)

I

R

R

T

I

I

R

Every 30,000 km


Every 30,000 km


Every 15,000 km


Every 15,000 km


Every 15,000 km


Every 45,000 km


NOTE:

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

”R”: Replace or change

”T”: Tighten to the specified torque

*1: Inspect or replace more frequently if necessary.

*2: Clean or replace more frequently if the air from the air conditioning decreases.


Maintenance Service

Engine and Emission Control

ITEM 1-1

Drive belt inspection and replacement

WARNING:

All inspection and replacement are to be performed with

ENGINE NOT RUNNING.

WATER PUMP AND GENERATOR DRIVE BELT INSPEC-

TION

1) Disconnect negative (–) cable 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”: 9-11 mm

(0.35- 0.43 in.) deflection under 100 N, 10 kg or 22 lb pressure

NOTE:

When replacing belt with a new one, adjust belt tension to 7 - 9 mm (0.28 - 0.35 in.)

1. Crankshaft pulley

2. Water pump pulley

3. 100 N, 10 kg or 22 lb

3) If belt is too tight or too loose, adjust it to specification by adjusting alternator position.

4) Tighten alternator adjusting bolt and pivot bolts.

5) Connect negative (–) cable to battery.

WATER PUMP AND GENERATOR DRIVE BELT REPLACE-

MENT

Replace belt. Refer to Section 6B for replacement procedure of pump belt.


POWER STEERING PUMP AND/OR A/C COMPRESSOR

DRIVE BELTS (IF EQUIPPED) INSPECTION


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

Check belt for tension.

If belt tension is out of above specification, adjust it referring to Section 1B or 3B1.

Power steering pump and/or A/C compressor drive belt tension

“a” : 4 - 7 mm (0.16 - 0.28 in.) deflection under

100 N (10 kg, 22 lb) pressure

[A]: H27 engine with P/S system

[B]: H27 engine with P/S and A/C system


2. P/S pump pulley

3. A/C compressor pulley (if equipped)

4. Tension pulley

5. Tension pulley bolts


POWER STEERING PUMP AND/OR A/C COMPRESSOR

DRIVE BELTS (IF EQUIPPED) REPLACEMENT

Replace belt referring to Section 1B or 3B1 for replacement procedure of belt.

ITEM 1-4

Engine oil and filter replacement

WARNING:

• New and used engine oil can be hazardous.

Be sure to read “WARNING” in General Precaution in

Section 0A and observe what in written there.

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

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

Before draining engine oil, check engine for oil leakage. If any 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

Engine oil drain plug (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) : 09915-47310

NOTE:

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

4) Screw new filter on oil filter stand by hand until the filter Oring 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 3/4 turn from the point of contact with the mounting surface using an oil filter wrench.


(For reference)

Oil filter (b) : 14 N·m (1.4 kg-m, 10.5 lb-ft)

1. Oil filter

2. Oil filter wrench


6) Replenish oil until oil level is brought to FULL level mark on dipstick. (oil pan and oil filter capacity). The filler inlet is at the top of the cylinder head cover.

It is recommended to use engine oil of SE, SF, SG, SH or SJ grade.

NOTE:

Select the appropriate oil viscosity according to the proper engine oil viscosity chart [A].

[A]: Proper engine oil viscosity chart

Engine oil specification :

H27 engine

Oil pan capacity liters (US/lmp pt.) About 5.0 (10.6/8.8)

Oil filter capacity liters (US/lmp pt.) About 0.5 (1.1/0.9)

Others liters (US/lmp pt.) About 0.7 (1.5/1.2)

Total liters (US/lmp pt.) About 6.2 (13.1/10.9)

NOTE:

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

7) Check oil filter and drain plug for oil leakage.

8) Start engine and run it for 3 minutes. Stop it and wait 5 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)

HEATER AND VENTILATION 1A-1

SECTION 1A

HEATER AND VENTILATION

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.



NOTE:


1A

CONTENTS

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

Rear Duct..................................................... 1A-3

1A-2 HEATER AND VENTILATION

General Description

The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet, and the defroster air outlets at places, right and left, along the windshield glass.

The heater and ventilation consist of the following parts.

10

1. Side ventilator outlet

2. Side defroster outlet

3. Center ventilator outlet

4. Heater unit

5. Defroster duct

6. Ventilator duct

7. Heater control lever assembly

8. Heater mode control switch

9. Blower unit

10. Rear duct

Rear Duct

1. Heater unit

2. Rear duct

REMOVAL


2) Remove front and second seats.

3) Remove console box.

4) Take off carpet till rear duct is totally exposed.

5) Remove rear duct.

INSTALLATION

Reverse removal sequence to install rear duct.

1

2

HEATER AND VENTILATION 1A-3

1A-4 HEATER AND VENTILATION

AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

AIR CONDITIONING (OPTIONAL)

WARNING:






1B

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 CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).

Be sure to check which refrigerant is used before any service work including inspection and 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.

NOTE:

• For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

• For basic servicing method of the air conditioning system that is not described in this section, refer to “AIR CONDITIONING BASIC MANUAL (99520-02130)”.

General Description ....................................... 1B-3

Refrigerant Type .......................................... 1B-3

Refrigerant Flow of Air Conditioning System 1B-3

Major Components And Location ................. 1B-4

Diagnosis ........................................................ 1B-6

General ........................................................ 1B-6

Main A/C system (front A/C system) ........ 1B-6

Rear A/C system ...................................... 1B-8

Quickly Checking of Refrigerant Charge

(If Equipped with Sight Glass) ...................... 1B-9

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

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

Detail diagnosis table (at ambient

CONTENTS

temperature within 30 - 35 °C

(85 - 95 °F))............................................ 1B-13

Wiring Circuit.............................................. 1B-14

Inspection of A/C Controller and Its

Circuits ....................................................... 1B-15

Voltage check......................................... 1B-15

Refrigerant Recovery, Evacuation and

Charging ....................................................... 1B-19

Operation Procedure for Charging A/C with

Refrigerant ................................................. 1B-19

Recovery .................................................... 1B-20

Evacuating ................................................. 1B-21

Evacuating procedure ............................ 1B-21

Checking system for pressure leaks ...... 1B-22

1B-2 AIR CONDITIONING (OPTIONAL)

Charging .................................................... 1B-22

On-Vehicle Service ...................................... 1B-25

Precaution.................................................. 1B-25

Piping ..................................................... 1B-25

Handling refrigerant HFC-134a (R-134a) 1B-26

Refrigerant recovery............................... 1B-26

Refrigerant charge ................................. 1B-26

Replenishing compressor oil .................. 1B-27

Rear A/C Unit (Rear A/C Evaporator) ........ 1B-28

Rear Expansion Valve ............................... 1B-29

Rear A/C Evaporator Temperature

Controller ................................................... 1B-30

Refrigerant Pipes and Hoses ..................... 1B-31

Solenoid Valve ........................................... 1B-32

Rear Blower Motor Assembly .................... 1B-33

Rear Blower Motor Relay and Solenoid

Valve Relay................................................ 1B-34

Rear A/C Main Switch................................ 1B-34

Rear Blower Motor Resistor....................... 1B-35

Rear Blower Motor Switch ......................... 1B-36

Rear A/C No.1 and No.2 Duct ................... 1B-37

Rear A/C No.1 duct................................ 1B-37

Rear A/C No.2 duct................................ 1B-37

Compressor Assembly............................... 1B-38

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

Required Service Materials......................... 1B-44

Tightening Torque Specification................ 1B-44

Special Tools ............................................... 1B-44



Refrigerant Type

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

(R-134a) or CFC-12 (R-12) is indicated on LABEL on the compressor. Also, it can be checked by the shape of the service

(charge) valve.

[A] : HFC-134a (R-134a)

[B] : CFC-12 (R-12)

1. Compressor label

2. Service valve

Refrigerant Flow of Air Conditioning System

NOTE:

For single A/C model, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

10

[A]

8

9

7

6

[A] : Dual A/C model

1. Compressor

2. Magnet clutch

: Liquid

: Vapor

: Superheated Vapor

3. Condenser assembly

4. Receiver/dryer

5. Dual pressure switch

2

4

1

6. Expansion valve

7. A/C evaporator

8. Solenoid valve

3

9. Rear expansion valve

10. Rear A/C evaporator

5


Major Components And Location

[A]

17

16

1 2

18

8

15

3

12

5

6

17

18

7

13 19

14

22

19

23

11

21

[B]

4

17

10

17

9

24

16

1 2

18

8

18

15

[A] : Dual A/C model

[B] : Single A/C model

1. Front cooling unit

2. Front A/C evaporator

3. Front blower fan motor

4. Compressor

5. Condenser assembly

12

7

14

6

5

6. Receiver/dryer

7. Front expansion valve

8. Heater unit

9. Rear A/C unit

10. Rear blower fan motor


12. Liquid pipe

19

4

13

19

13. Suction pipe

14. Discharge pipe

15. Recirculation air

16. Fresh air

17. Defroster air

18. Demister air

19. Foot air

20

20

20. Ventilation air

21. Rear A/C air

22. Room air

23. Solenoid valve


21


[A]

1

2

8

10

7

[B]

11

5

6

4

3 9

11

2

1

16

13

15

12

16

13

15

14

14

12

7 10

9

8

5

[C]

6

1

4

3

2

[D]

8

10

7

7

10

11

5

6

5

6

4

3 9

[A] : Dual A/C LH steering model

[B] : Dual A/C RH steering model

[C] : Single A/C LH steering model

[D] : Single A/C RH steering model

1. Front cooling unit

2. Heater unit

3. Compressor

4. Condenser

5. Sight glass

6. Refrigerant (dual) pressure sensor

7. Discharge pipe

8. Liquid pipe

9. Suction pipe

10. High pressure charge valve

4

11. Low pressure charge valve

12. Floor liquid pipe

13. Floor suction pipe

14. Rear A/C unit

15. Rear A/C duct No.1

16. Rear A/C duct No.2

3

11 2

1

9

8


Diagnosis

General

Main A/C system (front A/C system)

tive))

Condition

Cool air does not come out (A/C system does not operative)

Cool air does not come out (A/C compressor does not operative (won’t rota-

No refrigerant

Fuse blown

Possible Cause

Wiring or grounding faulty

A/C ON permission signal in ECM faulty

A/C controller and its circuit faulty

Magnet clutch faulty

Compressor relay faulty

Compressor relay faulty

Drive belt loose or broken

Compressor faulty

A/C ON permission signal in ECM faulty

A/C controller faulty

Condenser cooling fan motor relay faulty Cool air does not come out (A/C condenser cooling fan motor does not operative)


A/C condenser fan motor relay signal in ECM faulty

Condenser cooling fan motor faulty

Cool air does not come out (Blower motor does not operative)

A/C switch faulty

Blower motor switch faulty

A/C evaporator temperature sensor (A/C evaporator thermistor) faulty

Refrigerant (dual) pressure switch faulty

Fuse blown

Blower motor relay faulty

Blower motor resistor faulty

Blower motor switch faulty


Blower motor faulty

Correction

Perform recover, evacuation and charging.

Check “IG METER”, “REAR DEFG” and “A/C” fuses, and check for short circuit to ground.

Check A/C switch.

Check blower motor switch.

Check A/C evaporator temperature sensor (A/C evaporator thermistor).

Check refrigerant (dual) pressure switch.

Repair as necessary.

Check A/C ON permission signal.

Check A/C controller and its circuit.

Check magnet clutch.

Check compressor thermal switch.

Check compressor relay.

Adjust or replace drive belt.

Check compressor.

Check A/C ON permission signal.

Check A/C controller.

Check condenser cooling fan motor relay.


Check A/C condenser cooling fan motor relay signal.

Check condenser cooling fan motor.

Check “FRONT BLOW” and

“REAR DEFG” fuses, and check for short circuit to ground.

Check blower motor relay.

Check blower motor resistor.

Check blower motor switch.


Check blower motor.


Condition

Cool air does not come out or insufficient cooling (A/C system normal operative)

Cool air does not come out or insufficient cooling (A/C system normal operative)

Cool air does not comes out only intermittently

Cool air comes out only at high speeds

Cool air does not comes out only at high speeds

Insufficient velocity of cooled air

Possible Cause Correction

Insufficient or excessive charge of refrigerant Check charge of refrigerant.

Refrigerant leak in system Check system for leaks.

Condenser clogged

A/C evaporator clogged or frosted

A/C evaporator temperature sensor (A/C evaporator thermistor) faulty

Check condenser.

Check A/C evaporator.

Check A/C evaporator temperature sensor (A/C evaporator thermistor).


Expansion valve faulty

Drive belt slipping

Magnetic clutch faulty

Compressor faulty

Air in A/C system

Air leaking from cooling unit or air duct

Heater and ventilation system faulty


Check expansion valve.

Check or replace drive belt.

Check magnetic clutch.

Check compressor.

Replace condenser dryer, and then perform evacuation and charging.


Check air inlet box assembly.

Check heater control lever assembly.

Check heater assembly.

Check blower motor.

Blower motor faulty

Excessive compressor oil existing in A/C system

Wiring connection faulty

Expansion valve faulty

Excessive moisture in A/C system

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





Magnetic clutch faulty

Excessive charge of refrigerant

Condenser clogged

Insufficient charge of refrigerant

Air in A/C system

Drive belt slipping

Compressor faulty

Excessive charge of refrigerant

A/C evaporator frosted

A/C evaporator clogged or frosted

Air leaking from cooling unit or air duct

Blower motor faulty



Check magnetic clutch.

Check charge of refrigerant.

Check condenser.

Check charge of refrigerant.


Adjust or replace drive belt.

Check compressor.

Check charge refrigerant.


Check A/C thermistor.



Check blower motor.



Rear A/C system

Condition

Cool air dose not come out (Rear blower motor normal operative)

Possible Cause

Solenoid valve relay faulty

Solenoid valve faulty

Diode in rear A/C harness faulty

Rear A/C evaporator temperature controller faulty

Rear blower motor switch faulty

Rear A/C evaporator clogged or frosted

Rear expansion valve faulty

Air leaking from rear A/C unit or air duct

Insufficient or excessive charge of refrigerant

Cool air dose not come out (Rear blower motor dose not operative)

Refrigerant pipe or hose deformed

Fuse blown

Rear blower motor relay faulty

Rear A/C main switch faulty

Rear blower motor switch faulty

Rear blower motor resister faulty


Rear blower motor faulty

Cool air dose not come out at only intermittently

Loose or poor connected wiring connector

Rear expansion valve faulty

Rear A/C evaporator temperature controller faulty


Rear A/C evaporator frosted Cool air dose not come out at only high speed

Insufficient velocity of cooled air

Rear A/C evaporator clogged or frosted

Air leaking from rear A/C unit or air duct

Rear blower motor faulty


Correction

Check solenoid valve relay, and then replace if necessary

Check solenoid valve, and then replace if necessary

Check diode, and then replace rear A/C harness if necessary

Check rear A/C evaporator temperature controller, and then replace if necessary

Check rear blower motor switch, and then repair rear A/C evaporator and check rear A/C evaporator temperature controller if necessary

Check rear A/C evaporator, and then replace if necessary

Check rear expansion valve, and then replace if necessary

Check and repair if necessary

Check charge of refrigerant, and then perform recovery, evacuation and charging if necessary

Check pipe (hose), and then replace if necessary

Check “A/C” and “REAR BLOW” fuses, and then check for short circuit to ground

Check rear blower motor relay, and then replace if necessary

Check rear A/C main switch, and then replace if necessary

Check rear blower motor switch, and then replace if necessary

Check rear blower motor resister, and then replace if necessary

Check and repair

Check rear blower motor, and then replace if necessary

Connect connector correctly

Check rear expansion valve, and then replace if necessary

Check rear A/C evaporator temperature controller, and then replace if necessary

Check and repair

Check rear A/C evaporator temperature, evaporator drain hose and then replace if necessary

Check rear A/C evaporator, and then repair rear A/C evaporator or check rear

A/C evaporator temperature if necessary

Check rear A/C unit and air duct, and then repair if necessary

Check rear blower motor, and then replace if necessary

Check and repair


Quickly Checking of Refrigerant Charge (If

Equipped with Sight Glass)

The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not.

1) Run engine at fast idle.

2) Operate A/C at the following conditions for a few minutes.

• Main (front) A/C switch at ON position.

• Rear A/C main switch at ON position (if equipped).

• Front blower motor switch at max position.

• Rear blower motor switch at max position (if equipped).

• Air outlet control button at face position.

• Temperature control lever at max cool position.

• Vehicle door at all open.

• Air inlet door at recirculation position.

3) Look at the sight glass (1) and compare what is observed with the symptoms listed in the table given below.

2. Bubbles

2

1

Condition

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

Possible Cause

Insufficient charge of refrigerant in system

No charge or proper or too much charge of refrigerant in system

Empty or nearly empty system

Proper or too much charge of refrigerant in system

Too much charge of refrigerant in system

Proper charge of refrigerant in system

Correction

Check system for leaks with a leak tester.

Refer to the following items.

Perform recovery, evacuating and charging system and then check it for leaks with a leak tester.

Refer to the following items.

Recharge with specified amount of refrigerant.

Perform “PERFORMANCE DIAGNOSIS” in this section.

NOTE:

For specified amount of refrigerant, refer to “OPERATION PROCEDURE FOR CHARGING A/C WITH

REFRIGERANT” in this section.


7

2

6

3

1

4

5

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 (3) are firmly closed.

3) Connect high pressure charging hose (4) to high pressure service valve (5) on vehicle, and connect low pressure charging hose (6) to low pressure service valve (7) on vehicle.

4) Bleed the air in charging hoses (3), (4) by loosening their respective nuts on manifold gauge, utilizing the refrigerant pressure. When a hiss is heard, immediately tighten nut.

CAUTION:

Do not interchange high and low pressure charging hoses by mistake.

5) Warm up engine to normal operating temperature (engine coolant temperature at 80 - 90 °C (176 - 194 °F)) and keep it at specified idle speed.

6) Operate A/C at the following conditions.

• Main (front) A/C switch at ON position.

• Rear A/C main switch at ON position (if equipped).

• Front blower motor switch at max position.

• Rear blower motor switch at max position (if equipped).

• Air outlet control button at face position.

• Temperature control lever at max cool position.

• Vehicle door at all open.

• Air inlet door at recirculation position.

7) Keep all windows, doors and engine food open.

8) With about 20 mm (0.8 in.) of dry bulb thermometer (1) inserted into center face air outlet (2), rear A/C air outlet (3)

(dual A/C model only) and near A/C evaporator air inlet, read temperature indicated on each thermometer.

2

3

1


9) Check for each pressure of low side and high side if it is within shaded range of graph.

If each gauge reading is out of specified pressure, correct defective part referring to “PERFORMANCE DIAGNOSIS

TABLE”.

Example :

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

Pressure on high pressure gauge (HI) :

1400 - 1750 kPa

14.0 - 17.5 kg/cm

199.1 - 248.9 psi

2

Pressure on high pressure gauge (LO) :

230 - 350 kPa

2.3 - 3.5 kg/cm

2

32.7 - 49.8 psi

NOTE:

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

10) Check inlet port temperature-to-outlet port temperature relationship using graph.

For example, if A/C evaporator inlet port temperature is 25

°C (77 °F) and center face air outlet temperature is 8 °C

(46.4 °F), their crossing point is within acceptable range as shown in graph.

11) If crossing point is out of acceptable range, diagnose trouble referring to “PERFORMANCE DIAGNOSIS TABLE”.

12) Check that difference in temperature of center face air outlet air and rear A/C air outlet air are within 5 °C (41 °F).

If the rear A/C air outlet air temperature is higher over 5 °C

(41 °F) than center face air outlet air temperature, check rear

A/C unit.


Performance diagnosis table

HIGH PRESSURE GAUGE

Condition

Pressure high

(“A” area of high side graph)

Pressure low

(“B” area of high side graph)

Possible Cause

Refrigerant overcharged

Expansion valve frozen or clogged

Clogged refrigerant passage of high side

Condenser cooling fan malfunction (Insufficient cooling of condenser)

Recharge.

Correction


Clean or replace.

Check condenser cooling fan.

Dirty or bent condenser fins (Insufficient cooling of condenser)

Clean or repair.

Compressor malfunction (Insufficient oil etc.)

Engine overheat

Check compressor.

Check engine cooling system.

Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary and recharge.

Expansion valve malfunction (valve opens too wide) Check expansion valve.

Compressor malfunction (Insufficient compression) Check compressor.

LOW PRESSURE GAUGE

Condition

Pressure high

(“C” area of low side graph)

Pressure low

(“D” area of low side graph)

Possible Cause

Expansion valve malfunction (valve opens too wide)

Compressor malfunction (Insufficient compression)

Correction


Check compressor.

Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary and recharge.

Expansion valve malfunction (valve opens too narrow) Check expansion valve.

Clogged refrigerant passage (crashed pipe) Repair or replace.

THERMOMETER AT CENTER DUCT

Condition

Outlet air temperature at center duct is high

(Crossing point is in area

“E”)

Outlet air temperature at center duct is low

(Crossing point is in area

“F”)

Possible Cause

Insufficient or excessive charge of refrigerant

Dirty or bent A/C evaporator fins

Air leakage from cooling (heater) unit or air duct

Malfunctioning, switch over function of damper in cooling (heater) unit

Compressor malfunction

Insufficient air volume from center duct (Heater blower malfunction)

Compressor malfunction

Correction

Check refrigerant pressure.

Clean or repair.

Repair or replace.

Repair or replace.

Check compressor.

Check blower motor and fan.

Check compressor.

NOTE:

If ambient temperature is within 30 - 35 °C (85 - 95 °F), it is possible to do using “DETAIL DIAGNOSIS

TABLE” in this section for detail diagnosis.


Detail diagnosis table (at ambient temperature within 30 - 35 °C (85 - 95 °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

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

1.4 - 1.75

(14 - 17.5)

(200 - 249)

0.5 - 0.6

(5 - 6)

(71.2 - 85.3)

Detail

Normal condition

Normal :

1.4 - 1.75

(14 - 17.5)

(200 - 249)

Abnormal :

0.7 - 1.0

(7 - 10)

(100 - 142)

0.7 - 1.0

(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.

Both low and high pressure sides indicate low readings.

Continuous air bubbles are visible through sight glass.

Output air is slightly cold.

–

Possible Cause

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

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

Insufficient refrigerant in system. (Refrigerant leaking)

–

Correction

Clean expansion valve.

Replace it if it cannot be cleaned.

Replace condenser/dryer.

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

Replace expansion valve.

Replace condenser/dryer.

Evacuate A/C system and recharge with fresh refrigerant.

Using a gas 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.

2.0 - 2.5

(20 - 25)

(285 - 355)

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.

High pressure reading on both low and high pressure sides.

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


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.

Internal leak in compressor

Overcharged A/C system.

Faulty condenser cooling operation.

Faulty condenser fan operation.

Presence of air in A/C system. (Improperly evacuated)

Faulty expansion valve.

Refrigerant flow is not regulated properly.

Adjust refrigerant to specified amount.

Clean condenser.

Inspect and repair condenser fan.

Replace condenser dryer.

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

Evacuate system and recharge with fresh refrigerant.

Replace expansion valve.


Wiring Circuit

17

18 21

22

16

19

14

15 26 25 24 23

ACG RED/BLK RED/BLU

LT GRN YEL/GRN

20

1

BLK/WHT

BLU/WHT

BLK

29

30

2

RED/BLK

BLK

BLU/WHT

PNK

3

PNK/BLK

PNK/BLU

PNK/GRN

PNK

PNK/WHT

A/C

4

7

BLK

33

5 6

31

28

32

34

BLU/WHT

BLK

BLK

27

YEL/GRN

RED/BLK

YEL/GRN

RED/BLK

RED/BLU

BLU/ORN

13

12

BLK

35

WHT/RED

PNK

10

A

BLK

11

YEL/BLU

9

8

ORN

1. Front blower motor main relay

2. Front blower motor

3. Front blower motor resistor

4. Front blower motor switch

5. A/C controller

6. ECM (PCM)

7. Heater mode control switch

8. Dual (refrigerant) pressure switch

9. A/C evaporator thermistor

(A/C evaporator temperature sensor)

10. Compressor relay

11. Compressor

12. Condenser cooling fan motor relay

19. Battery

20. Generator

21. Ignition main fuse 60 A

13. Condenser cooling fan motor 22. Heater/A/C main fuse 60 A

14. Fuse box 23. “IG METER” fuse 20 A

15. “A/C” fuse 25 A

16. Ignition switch

24. “REAR DEFG” fuse 25 A

25. “REAR BLOW” fuse 20A

17. Main fuse box

18. Battery main fuse 100 A

26. “FRONT BLOW” fuse 30A

27. Solenoid valve

28. Solenoid valve relay

29. Rear blower motor relay

30. Rear blower motor resistor

31. Rear blower motor

32. Rear blower motor switch

33. Rear A/C main switch

34. Rear A/C evaporator temperature controller

35. Rear A/C evaporator temperature sensor

[A] : Rear A/C wiring circuit (if equipped)


Inspection of A/C Controller and Its Circuits

CAUTION:

A/C controller and ECM cannot be checked by itself.

It is strictly prohibited to connect voltmeter or ohmmeter to A/C controller and ECM with couplers disconnected from it.

A/C Controller (1) and its circuits can be checked at A/C controller wiring couplers by measuring voltage.

Voltage check

1) Remove A/C controller (1) from vehicle referring to “A/C

CONTROLLER” in this section.

2) Remove ECM (2) from vehicle.

3) Connect A/C controller couplers to A/C controller and connect ECM couplers to ECM.

4) Check each terminal voltage with couplers connected by referring to “A/C CONTROLLER VOLTAGE VALUES TABLE”.

3. Terminal AC-A-2

4. Terminal C51-3-6

NOTE:

For “Fig. A”, “Fig. B”, “Fig. C” in the figure, refer to “A/C

CONTROLLER VOLTAGE VALUES TABLE”.


SYSTEM CIRCUIT

1

3

2

4

A

D

B C

B

8

6

7

5

12V

12

5V

AC-A-1

AC-A-7

AC-A-4

AC-B-2

AC-B-1

AC-A-16

12V

12V

12V

5V

AC-A-9

AC-A-13

AC-A-2

9

11

10

E61-22

13

E61-8

E61-17

5V

A: To “FRONT BLOW” fuse

B: To “REAR DEFG” fuse

C: To “IG METER” fuse

D: To “A/C” fuse

1. Front blower motor relay

2. Front blower motor


3. Front blower motor resistor 8. Compressor relay

11. Condenser cooling fan motor

7. A/C thermistor (evaporator temperature sensor) 12. A/C controller

13. ECM

4. Front blower motor switch

5. A/C switch

9. Compressor

10. Condenser cooling fan motor relay

Terminal arrangement of A/C controller

AC-B AC-A

1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Terminal arrangement of ECM

E61 C51-3 C51-1 C51-2

8 7

6 5 4 3 2 1

23 22

21 20 19 18 17 16 15 14 13 12 11 10 9

35 34 33 32 31 30 29 28 27 26 25 24

6 5

4 3

17 16

15 14 13 12 11 10 9

2 1

8 7

26 25 24 23 22 21 20 19 18

7 6 5 4 3

2 1

19 18 17 16 15 14 13 12 11 10 9 8

28 27 26 25 24 23 22 21 20

2 1

7 6 5 4 3

20 19 18 17 16 15 14 13 12 11 10

9 8

30 29 28 27 26 25 24 23 22 21


A/C CONTROLLER VOLTAGE VALUES TABLE

Terminal

AC-A-1

AC-A-2

Wire

BLK/

WHT

BLK/

YEL

Circuit

Controller main power supply

Controller main ground

Measurement ground

Ground to engine (Fig B)

Ground to body

(Fig A)

AC-A-4

AC-A-7

AC-A-9

ORN

GRN/

BLK

Refrigerant

(dual) pressure switch input

A/C switch and/ or defroster switch input



GRY/

WHT

Signal input from

ECM (A/C ON permission signal)


Normal value

10 – 14 V

–0.4 – 0 V

0 – 1 V

10 – 14 V

8 – 14 V

0 – 1.5 V

10 – 14 V

Condition

Ignition switch ON with engine stopped

Engine running

Refrigerant pressure within 225 kpa (2.3 kg/cm

2

, 32.7 psi) to

2548 kpa (26 kg/cm

2

, 370 psi) with engine running

Refrigerant pressure below 196 kpa (2.0 kg/cm

2

, 28 psi) or above

3140 kpa (32 kg/cm

2

, 455 psi) with engine running

Blower fan motor switch or A/C or defroster switch OFF with engine running

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

Approve of A/C ON

0 – 1 V A/C ON forbid

AC-A-13

AC-A-16

AC-B-1

YEL/

BLK

PNK

BLU/

YEL

Signal output to

ECM (A/C ON request signal)

Compressor magnet clutch relay output

Sensor ground



Ground to body

(Fig A)

0 – 1.5 V

10 – 14 V

0 – 1 V

10 – 14 V

–0.4 – 0 V

Blower fan motor switch and A/C or defroster switch ON with engine running at A/C evaporator temperature sensor temperature input more than approx. 2.5 °C

(less than 2.5 V (5840

Ω)) and refrigerant pressure switch is ON

Except the above-mentioned with engine running


(less than 2.5 V (5840 Ω)), refrigerant pressure switch ON and signal input from ECM ON


Engine running


Terminal

AC-B-2

E61-8

Wire

WHT/

BLK

GRY/

WHT

Circuit

A/C evaporator temperature sensor (A/C evaporator thermistor) input

Signal output to

A/C controller

(A/C ON permission signal)

Measurement ground


Ground to engine (Fig C)

Normal value

1.8 V

(3520 Ω)

2.51 V

(5.855

Ω)

10 – 14 V

0 – 1 V

0 – 1.5 V

Condition

A/C evaporator temperature sensor temperature at approx. 15 °C

(59 °F) with engine running

A/C evaporator temperature sensor temperature at approx. 4.5 °C

(34 °F) with engine running

If the temperature is less than approx. 4.5 °C, in this case compressor and condenser fan should be stop (come back at more than approx. 6.1 °C (less than 5403 Ω, 2.4 V))

Required A/C ON (terminal AC-

A13) at engine running with normal condition (refer to “INSPEC-

TION OF ECM AND ITS

CIRCUIT” in Section 6E)


In this case compressor should be stop

Require A/C ON

E61-17

YEL/

BLK

Signal input from

A/C controller

(A/C ON request signal)

Ground to engine (Fig C) 10 – 14 V Turn off the A/C

E61-22

YEL/

BLU

Condenser cooling fan motor relay output

Ground to engine (Fig C)

0 – 1 V

10 – 14 V


(less than 2.5 V (5840 Ω)), refrigerant pressure switch ON and signal input from ECM ON

Engine coolant temperature sensor more than 113 °C (236 °F) with engine running



Refrigerant Recovery, Evacuation and Charging

WARNING:

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

Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6 °C

(21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a serious injury. To protect your eyes against such accident, it is necessary to always wear goggles.

Should it occur that HFC-134a (R-134a) strikes your eye(s), consult a doctor immediately.

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

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

• Should the 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 Charging A/C with Refrigerant

Start evacuating

20 minutes

Stop evacuating

Wait 10 minutes

Check system for pressure tightness

Inspect and repair connections

If gauge shows abnormal conditions

Charge A/C with refrigerant

Charge proper amount of refrigerant in gas form

Amount of refrigerant

Dual A/C model : 750±50g (1.65±0.11 lb, 26.45±1.76 oz)

Single A/C model : 500±50g (1.1±0.11 lb, 17.64±1.76 oz)

Check system for refrigerant leaks and refrigerant charging quantity

Performance test


1

Recovery

NOTE:

• When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment (1). Discharging it into atmosphere would cause adverse effect to environments.

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

5

2

8

11

3

10

6

9

7

4

1


Evacuating

Evacuating procedure

CAUTION:

Do not evacuate before recovering refrigerant in system.

NOTE:

Whenever opened (exposed to atmospheric air), air conditioning system must be evacuated by using a vacuum pump. The A/C system should be attached with a manifold gauge set, and should be evacuated for approx. 20 minutes.

1) Connect high charging hose (1) and low charging hose (2) of manifold gauge set (3) respectively as follows:

High Charging Hose (1)

→ High pressure charging valve (4) on Discharge Hose

Low Charging Hose (2) → Low pressure charging valve (5) on Suction Pipe

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

3) Operate vacuum pump (7), and then open discharge-side valve (9) (Hi) of manifold gauge set (3).

If there is no blockage in the system, there will be an indication on high pressure gauge (10).

When this occurs, open the other-side valve (8) (Lo) of the set.

4) Approx. 10 minutes later, low pressure gauge (11) should show –10 kPa (–1.0 kg/cm

2

, –760 mmHg, –14.2 psi) providing no leakage exists.

NOTE:

• If the system does not show –10 kPa (–1.0 kg/cm

2

, –

760 mmHg, –14.2 psi), close both valves, stop vacuum pump and watch movement of low pressure gauge.

• Increase in the gauge reading suggests existence of leakage. In this case, repair the system before 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 20 minutes.

6) Continue evacuation until low pressure gauge indicates –10 kPa (–1.0 kg/cm

2

, –760 mmHg, –14.2 psi), and then close both valves (8), (9).

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


Checking system for pressure leaks

After completing the evacuation, close manifold gauge high pressure valve (HI) and low-pressure valve (LO) and wait 10 minutes.

Verify that low-pressure gauge reading has not changed.

CAUTION:

If the gauge reading moves closer to “0”, there is a leak somewhere. Inspect the tubing connections, make necessary corrections, and evacuate system once again, making sure that there are no leaks.

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.

1

5

3

6

4

2


The initial charging of the A/C system is performed from the highpressure side with the engine stopped.

And next, this method must be followed by charging from the lowpressure side with the engine running.

1) Check to make sure that hoses are routed properly after evacuating the system.

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

3) Open the high-pressure side valve (6) and charge refrigerant to system.

4) After a while, open the low-pressure side valve (5) and close the high-pressure side valve (6).

WARNING:

Make sure that high pressure-side valve is closed securely.

5) Start engine and keep engine speed at 1500 rpm. Then, operate air conditioning.

NOTE:

Dual A/C model must be operated rear A/C system, too.

6) Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held upright.

7) When refrigerant container (3) is emptied, the use following procedure to replace it with a new refrigerant container (3).

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 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).


5

6

7

3

1

4

2 c) Purge any air existing in center charging hose

When using refrigerant container tap valve, use following procedure to purge air.

i) Once fully tighten refrigerant container tap valve and then loosen (open) plate nut slightly.

ii) Open low pressure valve of manifold gauge set a little.

iii) As soon as refrigerant comes out with a “hiss” through a clearance between refrigerant container and tap valve, tighten plate nut as well as manifold gauge set low pressure valve.

iv) Turn handle of tap valve clockwise so that its needle is screwed into the new container to make a hole for refrigerant flow.

1. “Hiss”

8) After the system has been charged with specified amount of refrigerant or when low pressure gauge (1) and high pressure gauge (2) must indicated the following specified amount, close low pressure side valve (3) of manifold gauge set (4). If equipped with sight glass in this time, look into the sight glass (6) of condenser outlet pipe (5) and check that there are no bubbles (7) in it, which means that the system is fully charged.

Low pressure gauge when charged with specified amount :

About 200 - 300 kPa (2 - 3 kg/cm

2

, 29 - 43 psi)

(At A/C inlet temperature 30 - 35 °C (86 - 95 °F))

High pressure gauge when charged with specified amount :

About 1370 - 1670 kPa (14 - 17 kg/cm

2

, 200 - 244 psi)

(At A/C inlet temperature 30 - 35 °C (86 - 95 °F))


On-Vehicle Service

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:


A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a).

(For identification between these two types, refer to “REFRIGERANT TYPE” in this section.


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

Precaution

When servicing air conditioning system, the following rules must be observed.

Piping

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

NOTE:

Single A/C model is the same as SQ625 (H25 engine) model. Refer to the same section of the Service

Manual mentioned in FOREWORD of this manual.

[A]

5

9

7

8

3

2

4

6

[A]: Dual A/C model

Apply compressor oil (refrigerant oil) to O-ring.

1

1. Suction hose

2. Discharge hose

3. Front liquid pipe

4. Condenser outlet pipe

5. Expansion valve


7. Front suction pipe

8. Rear liquid pipe

9. Rear suction pipe


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

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

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

• Tighten flared nuts to specified torque.


8 mm (0.31 in.) pipe : 13 N·m (1.3 kg-m, 9.5 lb-ft)

12.7 mm (0.5 in.) pipe : 22 N·m (2.2 kg-m, 16.0 lb-ft)

16 mm (0.63 in.) pipe : 33 N·m (3.3 kg-m, 24.0 lb-ft)

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

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

• When handling refrigerant, always wear goggles to protect your eyes.

• Avoid you direct contact to liquid refrigerant.

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

• Do not discharge refrigerant into atmosphere.

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

• After recovering refrigerant from system, the amount of compressor oil removed must be measured and the same amount added to the system.

Refrigerant recovery

When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environments.

NOTE:

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

Refrigerant charge

Charge a proper amount of refrigerant to A/C system according to charging procedure described in recovery, evacuation and charging.

CAUTION:

Do not perform an additional refrigerant charging to A/C system. This cause it to overcharge.


Replenishing compressor oil

CAUTION:

Be sure to use HFC-134a (R-134a) compressor oil.

When replacing air conditioning parts with new ones, it is necessary to replenish oil by the amount supposedly remaining in each part.

WHEN CHANGING GAS ONLY

When it is unavoidable to change gas without replacing any component part for engine removal and installation or for some other reason, replenish 20 cm

3

(20cc) oil. When replenishing gas only, oil replenishment is not necessary.

WHEN REPLACING COMPRESSOR

Compressor oil is sealed in each new compressor by the amount required for air conditioner cycle. Therefore, when using a new compressor for replacement, drain oil from it 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

NOTE:

Compressor assembly supplied from factory is filled up with the following amount of oil.

Amount of oil in new compressor :

Dual A/C model 140 cm

3

(140 cc)

Single A/C model 100 cm

3

(100 cc)

WHEN REPLACING OTHER PART

Amount of compressor oil :

Replaced part

Evaporator

Rear evaporator

(for dual A/C model)

Condenser

Receiver/dryer

Hoses

Pipes

Amount of compressor oil to be replenished

25 cm

3

(25 cc)

25 cm

3

(25 cc)

15 cm

20 cm

10 cm

10 cm

3

3

3

3

(15 cc)

(20 cc)

(10 cc) each

(10 cc) each

1. New compressor

2. Removed compressor

3. Excess oil (A–B)


Rear A/C Unit (Rear A/C Evaporator)

2

3

2

1

4

5

14 8

14

4

9

12

11

14

13 6

7

6

15

10

14

1. Rear blower fan cover 6. Rear A/C unit mounting clip

2. Rear A/C unit mounting bush 7. Rear blower motor assembly

3. Rear blower fan resistor

4. Rear A/C unit cover


11. Solenoid valve mounting bracket

12. Solenoid valve

Do not reuse

Apply compressor

(refrigerant) oil to O-ring

8. Rear A/C evaporator temperature controller


10. Rear suction pipe

13. Rear liquid pipe

14. O-ring

15. Packing

REMOVAL


2) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment.

The amount of compressor oil removed must be measured and the same amount added to the system.

5

4

3

2

3) Remove rear luggage mat end garnish (1), rear luggage box

(2) (if equipped), rear side sill scuff (3) rear quarter lower trim

(4) and rear quarter upper trim (5).

1

2

3

4

1

2


4) Loosen floor suction pipe and floor liquid pipe mounting bolt

(1).

2. Muffler

1

5) Remove rear A/C No.1 duct (1).

6) Disconnect rear A/C unit wire couplers (2).

7) Remove rear A/C unit mounting bolts (3), and then remove rear A/C unit (4).

NOTE:

Cap open fitting immediately to keep moisture out of system.

INSPECTION

Check the following.

• Clog of rear A/C evaporator fins.

If any clogs are found, rear A/C evaporator fins should be washed with water, and should be dried with compressed air.

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

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

INSTALLATION

Reverse removal procedure to install rear A/C unit noting the following points.

• Evacuate and charge system. Refer to “RECOVERY” and

“EVACUATING” in this section.

• When the rear A/C evaporator thermistor (temperature sensor) removed, it should be reinstalled in original position.

• If rear A/C unit or rear A/C evaporator is replaced, pour 25 cm

3

(25 cc) of refrigerating oil to compressor suction-side.

Rear Expansion Valve

INSPECTION

Refer to “PERFORMANCE DIAGNOSIS” in this section.


1

REMOVAL

1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section.

2) Disconnect solenoid valve connector (1).

3) Loosen solenoid valve bracket mounting screws (2).

2

2

3

5

2

1

4

4) Remove rear liquid pipe and rear suction pipe bolt (1), and then disconnect rear liquid pipe (2) and rear suction pipe (3) with solenoid valve and its bracket from rear expansion valve

(4).

5) Remove rear expansion valve (4) from rear A/C unit (5).

NOTE:


INSTALLATION

Reverse removal procedure to install rear expansion valve.

Rear A/C Evaporator Temperature Controller

REMOVAL


2) Disconnect rear A/C evaporator temperature controller connector (1).

3) Remove rear A/C evaporator temperature controller (2) from rear A/C unit.

1


INSPECTION

1) Connect battery positive (+) cable to terminal “b” and battery negative (–) cable to terminal “c” as shown.

2) Using ohmmeter, check continuity between terminal “a” and terminal “b” at specified temperature as shown.

Rear A/C evaporator temperature controller specification :

“A” : Approximately 3.5 °C (38.3 °F)

“B” : Approximately 5.0 °C (41 °F)

INSTALLATION

Reverse removal procedure to install rear A/C evaporator temperature controller noting the following instruction.

• When the rear A/C evaporator thermistor (temperature sensor) removed, it should be reinstalled in original position.

Refrigerant Pipes and Hoses

INSPECTION

• Use a leak tester to check hoses and pipes for any gas leakage.

• Check each hose or pipe clamp for tightness. Retighten or replace loose clamp as required, if any.

REMOVAL

CAUTION:

As soon as the above hose or pipe is disconnected, cap its opened fitting to prevent moisture and dust from entering.

1) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment.

The amount of compressor oil removed must be measured and the same amount must be added to the system when reinstalling.

2) Replace defective hose or pipe.

NOTE:

Remove EVAP canister and fuel tank cover, if necessary

INSTALLATION

Reverse removal procedure to install refrigerant line noting the following instruction.

• Evacuate and charge system. Refer to “EVACUATING” and “CHARGING” in this section.


2

1

5

4 3

3 6

1

7

(A)

Solenoid Valve

REMOVAL


2) Disconnect solenoid valve connector (1).

3) Loosen solenoid valve flared nuts (2).

4) Remove solenoid valve bracket mounting screws (3), and then remove rear liquid pipe (4) and rear suction pipe (5) from rear expansion valve.

5) Remove rear liquid pipe (4), rear suction pipe (5) and solenoid valve bracket (6) from solenoid valve (7).

NOTE:


INSPECTION

1) Connect special tool to solenoid valve (1).

Special tool

(A) : 09917-47910

2) Check that solenoid valve is closed when vacuum is applied to solenoid valve.

If solenoid valve is opened, replace solenoid valve.

1

3) Check that solenoid valve (1) is opened when connect battery to solenoid valve as shown in figure.

NOTE:

Solenoid valve terminal is no polarity.

INSTALLATION

Reverse removal procedure to install solenoid valve.

1

2


Rear Blower Motor Assembly

REMOVAL

1) Remove solenoid valve referring to “SOLENOID VALVE” in this section.

2) Disconnect rear blower motor coupler (1).

3) Remove rear blower motor assembly (2) from rear A/C unit

(3).

3

INSPECTION

1) Check continuity between two terminal as shown.

If check results are no continuity, replace rear blower motor assembly (1).

2) Check operate and current.

a) Fix rear blower motor assembly (1) by using vise.

b) Connect battery to rear blower motor assembly (1) as shown.

c) Check that there is smoothly operates and no noise.

d) Check that ammeter indicates specified current.

If measure current is incorrect, replace blower motor assembly.

Rear blower fan motor specified current at 12V

: 16 A maximum

INSTALLATION

Reverse removal procedure for installation.


2

1

Rear Blower Motor Relay and Solenoid Valve

Relay

INSPECTION


2) Remove rear blower motor relay (1) and/or solenoid valve relay (2) from vehicle.

3) Check that there is no continuity between terminal “c” and

“d”. If there is continuity, replace relay.

4) Connect battery positive (+) terminal to terminal “a” of relay.

5) Connect battery negative (–) terminal “b” of relay.

6) Check continuity between terminal “c” and “d”.

If there is no continuity when relay is connected to the battery, replace relay.

1

3

4

2

3

5

2

Rear A/C Main Switch

REMOVAL

1) Remove rear console box (1).

2) Remove front console box mounting screws (2) and clips (3).

3) Disconnect console box wire coupler.

4) Remove rear console box (4).

5) Disconnect rear A/C main switch connector.

6) Remove A/C main switch (5) from front console box (4).

1

2


INSPECTION

• Check rear A/C main switch for each terminal-to-terminal continuity.

If check results are not specified, replace rear A/C main switch.

POSITION

ON

TERMINAL a b c d e

OFF

INSTALLATION


Rear Blower Motor Resistor

REMOVAL


2) Disconnect rear blower motor resistor connector (1).

3) Remove rear blower motor resistor (2) from rear A/C unit (3).

3

Mo L

1

MH ML

INSPECTION

Measure each terminal-to-terminal resistance.

If measured resistance is incorrect, replace rear blower motor resistor (1).

Rear blower motor resister resistance

Mo-L : Approx. 2.4 Ω

Mo-ML : Approx. 1.2 Ω

Mo-MH : Approx. 0.6 Ω

INSTALLATION

Reverse removal procedure to install rear blower motor resistor.


Rear Blower Motor Switch

2

3

1

4

5

6

5

7

6

1. Rear blower motor switch

2. Bulb

3. Bracket

4. Rear A/C air louver case d a b e

5. Rear A/C air louver holder

Install proper direction as shown in figure

6. Rear A/C air louver

7. Knob f c

INSPECTION

• Check rear blower motor switch for each terminal-to-terminal continuity.

If check results are not specified, replace rear blower motor switch.

POSITION

TERMINAL a b d e

OFF

Low

Middle

High

• Check rear blower motor switch bulb come ON when connect battery positive (+) cable to terminal “c” and battery negative (–) cable to terminal “f”.

If A/C blower fan switch bulb does not come ON, replace it.

2

1


Rear A/C No.1 and No.2 Duct

Rear A/C No.1 duct

REMOVAL



INSTALLATION

Reverse removal procedure to install rear A/C No.1 duct (1).

Rear A/C No.2 duct

CAUTION:

Never remove rear A/C No.2 duct (2) from head lining.

Performing this prohibited service will break head lining.


Compressor Assembly

CAUTION:


A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a).

For identification between these two types, refer to page 66.


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

When servicing the compressor, keep dirt or foreign material away from getting on or into the compressor parts and system. Clean tools and a clean work area are important for proper service.

The compressor connection and the outside of the compressor should be cleaned before any “Onvehicle” repair or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichloromethane, naphtha, kerosene or equivalent solvent and dried with dry air. Use only lint free cloths to wipe parts.

The operations described are based on bench overhaul with compressor removed from the vehicle, except as noted. They have been prepared in order of accessibility of the components.

When compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be discarded and new refrigerant oil added to the compressor.

Minor repair procedures may be done on the vehicle without discharging the system. Major repair procedures require that the system be discharged of refrigerant.

5

1

4

INSPECTION

1) Install manifold gauge set (1) as shown in the figure.

2) Close Hi (4) and Lo (5) side valves.

2. High pressure side (Delivery side hose)

3. Low pressure side (Suction side pipe)

2

3

3) Run engine at fast idle.

4) Check compressor for the following items.

If any of the above checks indicated a defect, repair compressor.

• High pressure gauge reading is not low and low pressure gauge reading is not higher than normal.

• Metallic sound.

• Leakage from compressor.

2

1

1

2


REMOVAL

1) Run engine at idle with A/C ON for 10 minutes.


3) Recover refrigerant from refrigeration system using recovery and recycling equipment.

NOTE:

The amount of compressor oil at removed must be measured and the same amount must be poured when installing the compressor.

4) Remove P/S pump referring to step 4) to 7) of “REMOVAL” under “P/S PUMP” in Section 3B1.

NOTE:

It is not necessary to drain P/S fluid.

5) Disconnect magnet clutch connector.

6) Disconnect suction hose (1) and discharge hose (2) from compressor.

NOTE:


7) Remove compressor (1) from its mount (2).

NOTE:

If compressor assembly is replaced. Drain oil from compressor, and measure its amount.


INSTALLATION

CAUTION:

Be sure to use HFC-134a (R-134a) compressor oil.

Reverse removal procedure to install compressor assembly noting the following instructions.

• If compressor was replaced, pour new compressor oil with the same amount as that drained from compressor.

Refer to “REPLENISHING COMPRESSOR OIL” in this section.

1. New compressor

2. Removed compressor

3. Excess oil (A–B)

• Install P/S pump referring to “P/S PUMP” in Section 3B1.

• Evacuate and charge system. Refer to “EVACUATING” and

“CHARGING” in this section.

Magnet Clutch

1

2

5

3

4

3

8

6

7


1. Armature plate bolt

2. Armature plate

4

5

(A)

3

2

1

3. Circlip

4. Magnet clutch

1

5. Shim (s)

6. Magnet clutch coil

7. Compressor body assembly

8. Magnet clutch assembly

INSPECTION

Check the following items.

• Check no sigh of compressor oil leakage

• Check magnet clutch pulley bearing for noise and grease leakage.

• Check magnet clutch operation as follows : a) Connect battery (1) and ammeter (2) to compressor (3) as shown.

b) Check that steadily locks between armature plate (4) and magnet clutch pulley (5).

c) Check that ammeter (2) indicates specified current.

Specified current of magnet clutch :

4A MAX at 12V

If any detects are found, repair or replace magnet clutch assembly.

REMOVAL

1) Remove compressor from vehicle. Refer to “COMPRESSOR

ASSEMBLY” in this section.

2) Fix armature plate (1) with special tool and remove armature plate bolt.

Special tool

(A) : 09920-53740

NOTE:

Do not reuse armature plate bolt.

3) Remove armature plate (1).

4) Remove shims from shaft.


5) Using special tool, remove circlip.

Special tool

(A) : 09900-06107

6) Remove magnet clutch lead wire clamp screw, and remove magnet clutch read wire ground terminal.

7) Remove magnet clutch with puller.

NOTE:

Be careful not to damage pulley when tapping magnet clutch.

1. Puller

2. Compressor

8) Remove circlip using special tool.

Special tool

(A) : 09900-06107

9) Remove magnet clutch coil (1).

INSTALLATION

1) Install magnet clutch coil (2).

NOTE:

Protrusion on under side of magnet clutch coil (2) must match hole in compressor assembly (3) to prevent movement and correctly locate lead wire.

2) Using special tool, install new circlip (1) as shown.

Special tool

(A) : 09990-06107

3) Install clamp portion and ground terminal of lead wire.

2

1, (a)

(A)


4) Install magnet clutch (1).

a) Set magnet clutch squarely over clutch installation boss.

b) Place special tool onto clutch bearing.

Ensure that edge rests only on inner race of bearing.

Special tool

(A) : 09991-06010 c) Install new circlip.

CAUTION:

Be careful not to scratch bearing seal.

1

2

“a”

5) Adjust clearance between armature plate (1) and magnet clutch (2) by putting shim(s) on compressor shaft.

Standard clearance between armature plate and magnet clutch “a” :

0.35 - 0.6 mm (0.014 - 0.023 in.)

6) Tighten new armature plate nut (1) to specified torque.


Armature plate nut (a) :18 N·m (1.8 kg-m, 13.0 lb-ft)

Special tool

(A) : 09920-53740

2. Armature plate

7) Install compressor to vehicle. Refer to “COMPRESSOR

ASSEMBLY” in this section.


Required Service Materials

Material

Recommended SUZUKI product

(Part Number)

Compressor oil (refrigerant oil) COMPRESSOR OIL (ND-OIL8, 250 cc)

(99000-27080)

Use

• O-ring

• Each component

Tightening Torque Specification

Fastening part

Refrigerant pipe (8 mm (0.31 in.))

Refrigerant pipe (12.7 mm (0.5 in.))

Refrigerant pipe (16 mm (0.63 in.))

Armature plate nut

N•m

13

22

33

18

Tightening torque kg-m

1.3

2.2

3.3

1.8

lb-ft

9.5

16.0

24.0

13.0

Special Tools

09900-06107

Snap ring pliers

(Opening type)

09920-53740

Armature plate holder

09990-06010

Manifold gauge set

See NOTE below.

09990-86011

Gas leak detector

09991-06010

Magnet clutch pulley installer

NOTE:

This kit includes the following items.

1. Manifold gauge, 2. Changing hose, 3. Quick connector, 4. Refrigerant container tap valve,

5. Refrigerant container T joint, 6. Packing set

FRONT END ALIGNMENT 3A-1

SECTION 3A

FRONT END ALIGNMENT

NOTE:


3A

CONTENTS

General Information ........................................3A-1

Alignment Service Data (without Load) .........3A-1

On-Vehicle Service ......................................... 3A-1

Reference Information .................................. 3A-1

General Information

Alignment Service Data (without Load)

Toe-in (Toe-in gauge measurement) “B” – “A” :

1 ± 2 mm (0.04 ± 0.08 in.)

Camber angle “C” :

0 ± 1° 30’

Caster :

2° 30’ ± 1°

[A] : Top view

[B] : Front view

1.

Center line of wheel ✱1.

Forward

✱2.

Body center


Reference Information

SIDE SLIP

For inspecting front wheel side slip with side slip tester

Side slip limit :

IN 4 mm/m – OUT 2 mm/m

(IN 0.158 in/3.3 ft – OUT 0.078 in/3.3 ft)

If side slip exceeds above limit, toe-in or front wheel alignment may out not be correct.

3A-2 FRONT END ALIGNMENT

POWER STEERING (P/S) SYSTEM 3B1-1

SECTION 3B1

POWER STEERING (P/S) SYSTEM

WARNING:






3B1

NOTE:

• For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual.

• Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed information, refer to the description of “POWER STEERING GEAR BOX ASSEMBLY”.

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

CONTENTS

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

Power Steering (P/S) Pump ........................3B1-2

Diagnosis .......................................................3B1-2

Power Steering Pump Drive Belt.................3B1-2

Belt inspection .........................................3B1-2

Belt tension check ................................... 3B1-2

Belt tension adjustment........................... 3B1-2

Hydraulic Pressure in P/S Circuit ................ 3B1-3

Hydraulic pressure check........................ 3B1-3

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


Power Steering (P/S) Pump

Power steering (P/S) pump specification :

The specification of this power steering pump is the same as the specification of the same section in the service manual mentioned in this manual except for data of relieved pressure shown below.

Relieved pressure :

7850 kPa (78.5 kg/cm

2

, 1116 psi)

Diagnosis

Power Steering Pump Drive Belt

Belt inspection

Check P/S pump drive belt (1) is free from any damage and properly fitted in pulley groove.

Belt tension check

Check belt tension by measuring how much it deflects when pushed at arrow point (2) between pulleys with about 10 kg (22 lb) force.

Deflection of P/S belt :

4 – 7 mm (0.16 – 0.28 in.)

Belt tension adjustment

1) To adjust P/S pump drive belt (1) tension, loosen tension pulley bolts (3) and turn tension pulley (4) using hexagon wrench.

2) Adjust belt tension to above specification.

Then tighten tension pulley bolts (3) to specified torque.


Tension pulley bolts (a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)

5. P/S pump pulley

6. A/C compressor pulley (if equipped)


[A] : With A/C

[B] : Without A/C

POWER STEERING (P/S) SYSTEM 3B1-3

Hydraulic Pressure in P/S Circuit

Hydraulic pressure check

1) After cleaning joint of high pressure hose and P/S pump thoroughly, disconnect hose from pump and install special tool (oil pressure gauge, attachment and hose).

CAUTION:

Take care not to cause damage to A/C condenser during service operation, if equipped.

Special tool

(A) : 09915-77410

(B) : 09915-77420

2) Check each connection for fluid leakage and bleed air.

Refer to “AIR BLEEDING PROCEDURE” in this section.

1. P/S fluid reservoir

2. Attachment

3. Gasket

4. Union bolt

5. High pressure side

6. Low pressure side

3) With engine idling, turn steering wheel and warm up engine till temperature of fluid in P/S fluid reservoir rises to 50 –

60°C (122 – 140°F).

4) Check back pressure by measuring hydraulic pressure with engine idling and hands off steering wheel.

When back pressure is higher than specified values, check control valve and piping for clogging.

Back pressure :

Lower than 1000 kPa (10 kg/cm

2

, 142 psi)


2. Gauge valve (open)

3. P/S pump

4. P/S gear box

5. High pressure side

6. Low pressure side

3B1-4 POWER STEERING (P/S) SYSTEM

5) Check relief pressure.

a) Increase engine speed to about 1500 r/min (rpm). Close gauge valve gradually while watching pressure increase indicated by gauge and take reading of relief pressure

(maximum hydraulic pressure).

When it is higher than specified values, possible cause is malfunction of relief valve.

When it is lower than specified values, possible cause is either failure of P/S pump or settling of relief valve spring.

Relief pressure (when gauge valve is closed) :

7650 – 8350 kPa (76.5 – 83.5 kg/cm

2

, 1088 – 1187 psi)

CAUTION:

Be sure not to close gauge valve for longer than 10 seconds.


2. Gauge valve (shut)

3. Oil pressure gauge

4. P/S pump

5. P/S gear box b) Next, open gauge valve fully and increase engine speed to about 1500 r/min (rpm). Then turn steering wheel to the left or right fully and take reading of relief pressure.

When it is higher than specified values, possible cause is malfunction of relief valve.

When it is lower than specified values, possible cause is failure in steering gear box. Replace gear box.

Relief pressure (when gauge valve is opened) :

7650– 8350 kPa (76.5 – 83.5 kg/cm

2

, 1088 – 1187 psi)

CAUTION:

Be sure not to hold steering wheel at fully turned position for longer than 10 seconds.


2. Gauge valve (open)

3. Oil pressure gauge

4. P/S pump

5. P/S gear box

AIR BAG STEERING WHEEL AND COLUMN 3C1-1

SECTION 3C1

AIR BAG STEERING WHEEL AND COLUMN

WARNING:

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

Vehicle Service” in air bag system section before performing service on or around the air bag 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 disable the air bag system temporarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could result in possible activation of the air bag system, personal injury or otherwise unneeded air bag system repairs.

3C1

CAUTION:

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

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

NOTE:


General Description ..................................... 3C1-2

Diagnosis ...................................................... 3C1-3

Inspection and Repair Required after

Accident ..................................................... 3C1-3

On-Vehicle Service....................................... 3C1-3

Service Precautions ................................... 3C1-3

Diagnosis and servicing ......................... 3C1-3

Disabling air bag system ........................ 3C1-3

Enabling air bag system ......................... 3C1-3

CONTENTS

Handling and storage ............................. 3C1-3

Disposal ................................................. 3C1-3

Steering Column ........................................ 3C1-4

Steering Upper Shaft Assembly ................. 3C1-7

Steering Lower Shaft Assembly ................. 3C1-9

Checking Steering Column and Steering

Upper Shaft for Accident Damage ........... 3C1-11

Tightening Torque Specification .............. 3C1-12

3C1-2 AIR BAG 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 WARN-

INGS in this section. Refer to “SERVICE PRECAUTIONS” in Section 10B.


2. Steering wheel

3. Steering wheel nut

4. Contact coil and combination switch assembly

5. Steering column upper cover

6. Steering column lower cover

7. Steering column assembly

8. Steering lock assembly

9. Steering column hole cover

10. Steering shaft joint

11. Steering lower shaft assembly

12. Adjustable steering column release lever

13. Steering column lower seal

14. Cap (if equipped)

15. Steering upper shaft assembly


Diagnosis

For diagnosis of the steering wheel and steering column, refer to Section 3. For diagnosis of the air bag system, refer to Section 10B.

Inspection and Repair Required after Accident

After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and repairs described under “CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE” in this section as well as “REPAIRS AND INSPECTIONS REQUIRED AFTER ACCIDENT” in Section 10B.


Service Precautions

For service precautions, refer to “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B.

Diagnosis and servicing

For diagnosis and servicing, refer to “DIAGNOSIS AND SERVICING” under “SERVICE PRECAUTIONS” in

Section 10B.

Disabling air bag system

For disabling air bag system, refer to “DISABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in

Section 10B.

Enabling air bag system

For enabling air bag system, refer to “ENABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in

Section 10B.

Handling and storage

For handling and storage, refer to “HANDLING AND STORAGE” under “SERVICE PRECAUTIONS” in Section

10B.

Disposal

For disposal, refer to “DISPOSAL” under “SERVICE PRECAUTIONS” in Section 10B.


Steering Column

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.

When loosening steering column mounting bolts and nuts, make sure that steering column assembly and steering upper shaft assembly have been separated. Loosening them with steering column assembly and steering upper shaft assembly assembled could cause damage to upper joint and mounting bracket in steering upper shaft assembly.

NOTE:

When servicing steering column or any column-mounted component, remove steering wheel. But when removing steering column simply to gain access to instrument panel components, leave steering wheel installed on steering column.

REMOVAL

WARNING:

Never rest a steering column assembly on the steering wheel with air bag (inflator) module face down and column vertical. Otherwise personal injury may result.

CAUTION:

Never turn steering wheel while steering column with steering wheel is removed. Turning steering wheel more than about two and a half turns will break contact coil.


2) Disable air bag system. Refer to “DISABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in

Section 10B.

3) Remove steering wheel and contact coil and combination switch assembly, if necessary. Refer to “STEER-

ING WHEEL” and “CONTACT COIL AND COMBINATION SWITCH ASSEMBLY” in this section.

Perform the following procedure if not removing steering wheel and/or combination switch.

a) 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 for the following parts.

• Contact coil and combination switch

• Ignition switch

1


6) Remove steering upper shaft upper joint bolt (1) and nut (2) and disconnect steering upper shaft upper joint removing in arrow direction in the figure.

2

1

7) Remove steering column (1) mounting bolts (2 pieces) (2) and nuts (2 pieces) (3).

3

2

8) If equipped with shift (key) interlock cable (1), remove shift

(key) interlock cable screw (2) and then disconnect its cable

(1) from ignition switch.

9) Remove steering column from vehicle.

INSPECTION

Check steering column for damage and operation referring to

CHECKING STEERING COLUMN AND STEERING UPPER

SHAFT FOR ACCIDENT DAMAGE later in this section.

INSTALLATION

CAUTION:

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

1) Be sure that front wheels and steering wheel are in straightahead position.

2) If equipped with shift (key) interlock cable (1), install shift

(key) interlock cable (1) to ignition switch.


Shift (key) interlock cable screw (a) :

2.2 N·m (0.22 kg-m, 1.6 lb-ft)


1

3) Install steering column assembly (1) with contacting upper side of lower bracket slits to mounting bolts. Tighten steering column lower mounting nuts (3) first and then upper mounting bolts (2) to specified torque.


Steering column mounting bolts and nuts (b) :

25 N·m (2.5 kg-m, 18.0 lb-ft)

“B”

3, (b)

2, (b)

4) Align cutting point “A” of steering column assembly (1) with bolt hole “B” of steering upper shaft upper joint as shown in the figure. Then connect steering upper shaft upper joint.

2

“A”

1, (a)

1

5) Install steering upper shaft upper joint bolt (2) and nut (1).

Tighten steering upper shaft upper joint nut (1) to specified torque.


Steering upper shaft upper joint nut (a) :

23 N·m (2.3 kg-m, 17.0 lb-ft)

6) If contact coil and combination switch assembly is removed, install it, referring to “CONTACT COIL AND COMBINATION

SWITCH ASSEMBLY” in this section.

7) Connect all connectors that have been removed in removal.

8) Install steering column hole cover (1).

9) If steering wheel is removed, install it by referring to

“STEERING WHEEL” in this section.


11) After installing steering column assembly, be sure to enable air bag system by referring to “ENABLING AIR BAG SYS-

TEM” under “SERVICE PRECAUTIONS” in Section 10B.

2

1


Steering Upper Shaft Assembly

CAUTION:

Never turn steering wheel while steering upper shaft assembly is removed.

Should it have been turned and contact coil (on 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 shaft joint (2) and shaft (upper shaft assembly side) (1) for a guide during reinstallation.

4) After removing bolt (4) on upper shaft assembly (1) side of shaft joint (2) and loosening bolt (5) on its lower shaft assembly (3) side, move shaft joint (2) to lower shaft assembly (3) side (in arrow direction in the figure).

5) Remove steering upper shaft upper joint bolt (1) and nut (2) and disconnect steering upper shaft upper joint removing in arrow direction in the figure.

6) Remove steering upper shaft mounting bolts (4 pieces).

7) Remove steering upper shaft assembly from vehicle.


1, (a)

INSPECTION

Check steering shaft damage and operation referring to CHECK

STEERING COLUMN AND STEERING UPPER SHAFT FOR

ACCIDENT DAMAGE later in this section.

INSTALLATION

1) Be sure that front tires and steering wheel are in straight ahead position.

2) Install steering upper shaft assembly to dash panel. Tighten steering upper shaft mounting bolts (1) to specified torque.


Steering upper shaft mounting bolts (a) :

23 N·m (2.3 kg-m, 17.0 lb-ft)

3) Install steering shaft joint (1) to steering upper shaft (2) by matching it to marks (3) made before removal.

“B”

“A”

1

4) Install shaft joint bolt (upper shaft assembly side) (2) to steering shaft joint (1). Tighten shaft joint bolt (upper shaft assembly side) (2) to specified torque first and then shaft joint bolt (lower shaft assembly side) (3) to specified torque.


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

5) Align cutting point “A” of steering column assembly (1) with bolt hole “B” of steering upper shaft upper joint as shown in the figure. Then connect steering upper shaft upper joint.

2

1, (a)


6) Install steering upper shaft upper joint bolt (2) and nut (1).

Tighten steering upper shaft upper joint nut (1) to specified torque.


Steering upper shaft upper joint nut (a) :

23 N·m (2.3 kg-m, 17.0 lb-ft)

Steering Lower Shaft Assembly

CAUTION:

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

Should it have been turned and contact coil (on 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) After removing bolt (4) on upper shaft assembly (1) side of shaft joint (2) and loosening bolt (5) on its lower shaft assembly (3) side, move shaft joint (2) to lower shaft assembly side

(3) (in arrow direction in figure).

4) Remove lower shaft assembly lower joint bolt (2) and then remove lower shaft assembly (1).

5) Remove shaft joint bolt (lower shaft assembly side) from shaft joint (3) and then remove shaft joint (3) from lower shaft assembly (1).


INSTALLATION

1) Be sure that front wheels and steering wheel are in straight ahead position.

2) Align flat part “A” of lower shaft assembly (1) with bolt hole

“B” of shaft joint as shown in the figure. Then insert shaft joint (1) into lower shaft assembly (2).

3) Install shaft joint bolt (lower shaft assembly side) to shaft joint (2). Then tighten it by hand.

4) Insert pinion shaft into lower shaft assembly lower joint (2) with slit (1) of lower joint, marks (4) on pinion shaft (5) and gear case (6) aligned.

And then install lower shaft assembly lower joint bolt (3) to lower shaft assembly lower joint (2). Tighten it to specified torque.


Lower shaft assembly lower joint bolt (a) :

25 N·m (2.5 kg-m, 18.0 lb-ft)

5) Install steering shaft joint (2) to steering upper shaft (1).

NOTE:

Be sue that front wheels and steering wheel are in straight-ahead position.

6) Install shaft joint bolt (upper shaft assembly side) (2) to shaft joint (1). Tighten shaft joint bolt (upper shaft assembly side)

(2) to specified torque first and then shaft joint bolt (lower shaft assembly side) (3) to specified torque.


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

1

2

“a”


Checking Steering Column and Steering

Upper Shaft for Accident Damage

NOTE:

Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering column.

• Check that 2 capsules are attached to steering column bracket securely. Check clearance between capsules and steering column bracket. Clearance should be 0 mm (0 in.) on both sides. If found loose or clearance, replace steering column assembly.

1. Capsule

2. Steering column bracket

• Take measurement “a” as shown in the figure. If it is shorter than specified length, replace column assembly with new one.

Steering column assembly length “a” :

490.3 ± 1.0 mm (19.30 ± 0.04 in.)

• Check steering shaft for smooth rotation.

If found defective, replace as column assembly.

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

If found defective, replace as column assembly.

• Check steering upper shaft lower seal (1) for breakage or deformation.

If found defective, replace.

• Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play.

If anything is found faulty, replace steering upper shaft assembly, steering lower shaft assembly or steering column assembly.


“b”

• Take measurement “b” as shown in the figure. If it is shorter than specified length, replace steering upper shaft assembly with new one.

Steering upper shaft assembly length “b” :

419.0 ± 1.0 mm (16.50 ± 0.04 in.)


Fastening part

Driver air bag (inflator) module bolt

Steering shaft nut

Steering column mounting bolt and nut

Steering shaft joint bolt

Steering lower shaft assembly lower joint bolt

Shift (key) interlock cable screw

Steering upper shaft mounting bolt

Steering upper shaft upper joint nut

N•m

9

33

25

25

25

2.2

23

23


0.9

3.3

2.5

2.5

2.5

0.22

2.3

2.3

lb-ft

6.5

23.5

18.0

18.0

18.0

1.6

17.0

17.0

FRONT SUSPENSION 3D-1

SECTION 3D

FRONT SUSPENSION

CAUTION:

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

3D

NOTE:


CONTENTS

On-Vehicle Service......................................... 3D-1

Suspension Control Arm/Bushings .............. 3D-1

Tightening Torque Specification .................. 3D-2

(b)


Suspension Control Arm/Bushings

INSTALLATION

For the details, refer to the same item of the same section in the

Service Manual mentioned in the FOREWORD of this manual noting following point.

• Install control arm to chassis.

Tighten suspension arm nuts to specified torque after lowering hoist and vehicle in non-loaded condition.


Front suspension arm nut (a) :

85 N·m (8.5 kg-m, 61.5 lb-ft)

Front suspension arm nut (b) :

100 N·m (10.0 kg-m, 72.5 lb-ft)

NOTE:

Don’t reuse front suspension arm nut (b).

3D-2 FRONT SUSPENSION


REAR SUSPENSION 3E-1

SECTION 3E

REAR SUSPENSION

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.

3E

CONTENTS

On-Vehicle Service......................................... 3E-1

Rear Axle Shaft and Wheel Bearing ............ 3E-1

Rear Axle Shaft Inner Oil Seal ..................... 3E-5

Rear Axle Housing ....................................... 3E-5

Tightening Torque Specification .................. 3E-6

Required Service Material ............................. 3E-6

Special Tool.................................................... 3E-7


Rear Axle Shaft and Wheel Bearing

REMOVAL

1) Remove axle shaft from axle housing according to Step1) to

6) in the same section in the service manual mentioned in the FOREWORD of this manual noting following points.

3E-2 REAR SUSPENSION

2) Remove circlip from axle shaft.

3) In order to remove retainer ring (1) from axle shaft (3), grind with a grinder two portion (2) of bearing retainer ring as illustrated till it becomes thin.

CAUTION:

Be careful not to grind axle shaft.

[A]: Vehicle with ABS

[B]: Vehicle without ABS

4) Break with a chisel (1) the thin ground sensor rotor and retainer ring, and it can be removed.

5) Remove wheel bearing (1) and bearing retainer (2) using special tools as shown in figure.

Special tool

(A) : 09927-18411

(B) : 09921-57810

NOTE:

If inner race of wheel bearing is left in axle shaft, remove it from axle shaft with the same procedure as abovementioned.

CAUTION:

Do not reuse wheel bearing.


6) 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

(4), install new stud bolt(s) (1) by tightening nut (2) as shown in the figure.

3. Washer

2) Install bearing retainer (2) to axle shaft (1).

3) Press fit new wheel bearing (1) and new retainer ring (2) using press (3).

NOTE:

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

• Seal side (4) of wheel bearing must face bearing retainer (5) side.

4) Install circlip to axle shaft.


(b)

5) Apply grease “A” to axle shaft inner oil seal lip as shown in the figure.

“A” : Grease 99000-25010

1. Axle housing

6) Apply water tight sealant “B” to mating surfaces of brake back plate and rear axle hub (2).

“B” : Water tight sealant 99000-31110

7) Install rear axle shaft to rear axle housing and tighten bearing retainer nuts to specified torque.

Rear axle shaft length “L”

Left side : 700.5 mm (27.6 in.)

Right side : 769.5 mm (30.3 in.)

NOTE:

When installing rear axle shaft, be careful not to cause damage to oil seal lip in axle housing.


Bearing retainer nut (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

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


Wheel speed sensor bolt (b) : 21 N·m (2.1 kg-m, 15.5 lb-ft)

9) Refill rear axle housing with new specified gear oil.

Refer to “MAINTENANCE SERVICE” in Section 7F.

10) Install brake drum. Refer to “BRAKE DRUM” in Section 5C.


Rear Axle Shaft Inner Oil Seal

INSTALLATION

1) Using special tool drive in oil seal until it contacts oil seal protector in axle housing.

NOTE:

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

• Refer to the figure so that oil seal is installed in proper direction.

Special tool

(A) : 09924-74510

(B) : 09944-88210

“A” : Grease 99000-25010

“B” : Sealant 99000-31110

1. Hammer

2. Rod

3. Oil seal protector

4. Oil seal

5. Body center

2) For procedure hereafter, refer to steps 6) to 11) of “INSTAL-

LATION” under “REAR AXLE SHAFT” in the service manual mentioned in the FOREWORD of this manual.

Rear Axle Housing

INSTALLATION

For Step 1) to 4), 7) and 9) to 30), refer to the same section in the

Service Manual mentioned in the FOREWORD of this manual.

3) Clean mating surfaces of axle housing (1) and differential carrier and apply sealant “A” to housing side.

“A” : Sealant 99000-31110

4) Install differential carrier assembly to axle housing and tighten carrier bolts to specified torque.


Differential carrier bolt (a) :

55 N·m (5.5 kg-m, 40.0 lb-ft)


5) Apply thread lock cement to thread of propeller shaft flange bolt if reused. Install propeller shaft to joint flange aligning match marks and torque flange nuts to specification.

“A” : Cement 99000-32110


Propeller shaft nut (a) :

60 N·m (6.0 kg-m, 43.5 lb-ft)


Fastening part

Shock absorber nut

Shock absorber lower nut

Lower rod bolt and nut

Upper rod bolt and nut

Lateral rod bolt

Differential carrier bolt

Propeller shaft nut

Brake pipe flare nut

Bearing retainer nut

Differentiation gear oil filler & drain plug (filler plug)

Differentiation gear oil filler & drain plug (drain plug)

Wheel nut

Wheel speed sensor bolt

N•m

29

85

100

100

100

55

60

16

50

50

27

100

21


2.9

8.5

10.0

10.0

10.0

5.5

6.0

1.6

5.0

5.0

2.7

10.0

2.1

lb-ft

21.0

61.5

72.5

72.5

72.5

40.0

43.5

11.5

36.5

36.5

16.0

72.5

15.5

Required Service Material

Material


(Part Number)

Lithium grease SUZUKI SUPER GREASE A

(99000-25010)

Brake fluid

Sealant

Gear oil

Thread lock cement

• Oil seal lip

Use

DOT 3

SUZUKI BOND NO. 1215

(99000-31110)

• Brake reservoir tank

• Joint seam of axle and brake back plate

• Joint seam of bearing retainer and brake back plate

• Joint seam of differential carrier and axle housing

• Drain plug

• Mating surface of oil seal and axle housing

For gear oil information, refer to Section 7F • Differential gear (Rear axle housing)

THREAD LOCK CEMENT SUPER 1322 • Rear propeller shaft flange bolts

(99000-32110)

Special Tool


09921-57810

Counter shaft holder

09924-74510

Bush remover handle

09926-88310

Oil seal installer

09927-18411

Universal puller

09942-15510

Sliding hammer

09943-35512

Brake drum remover

09944-88210

Bearing installer


WHEELS AND TIRES 3F-1

SECTION 3F

WHEELS AND TIRES

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.

3F

CONTENTS

General Description ....................................... 3F-1 Tires ............................................................. 3F-1

Wheels ......................................................... 3F-1


Tires

This vehicle is equipped with following tire.

Tire specification :

P235/60 R16 or 235/60 R16

The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressure.

Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration, and unnecessary sharp braking increase tire wear.

Wheels

Standard equipment wheels are following steel wheels.

Wheel specification :

16 x 7 JJ

3F-2 WHEELS AND TIRES

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-1

SECTION 4A2

FRONT DRIVE SHAFT/SHAFT BEARING,

OIL SEAL

NOTE:


CONTENTS

Required Service Material ........................... 4A2-4

On-Vehicle Service....................................... 4A2-2

Drive Shaft ................................................. 4A2-2

4A2

4A2-2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL


Drive Shaft

ASSEMBLY

CAUTION:

• To prevent any problem caused by washing solution, do not wash joint boots. Degreasing of those parts with cloth is allowed.

• Bend each boot band against forward rotation.

• Do not squeeze or distort boot when fastening it with bands.

Distorted boot caused by squeezing air may reduce its durability.

1) Fully apply joint grease to wheel side joint.

Use joint grease in the tube included in spare part.

“A” : Joint Grease (about 85- 95 g (3.0 - 3.4 oz) (Yellow))

[A] : Wheel side

2) Fit wheel side boot (1) on shaft.

Fill up inside of boot (1) with joint grease.

Before fixing boot band (2), insert screwdriver into boot (1) on joint side and allow air to enter boot so that air pressure in boot (1) becomes the same as atmospheric pressure.

3) Fixing boot band (2).

4) Install boot (1) onto drive shaft till its small diameter side fits to shaft groove and fix there with boot band (2).

5) Install cage (1) to shaft.

CAUTION:

Install cage (1) directing smaller outside diameter side to shaft end.

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-3

6) Install circlip (1) by using snap ring plier.

7) Apply grease to entire surface of cage.

Use joint grease in tube included in spare part.

8) Insert cage into outer race and fit circlip (1) into groove of outer race.

CAUTION:

Position opening of circlip “a” so that it will not be lined up with a ball.

9) Apply grease in tube included in spare part to inside of outer race, and fit boot to outer race.

Fill up inside of boot with joint grease.

“A” : Joint Grease

(about 90 - 100 g (3.2 - 3.5 oz) (Black))

10) Fitting boot to outer race, adjust so that measurements “b” and “c” become as shown in the figure.

Differential side (RH) boot installation position

(Length “b”) : 196.8 - 206.8 mm (7.75 - 8.14 in.)

Differential side (LH) boot installation position

(Length “c”) : 127.5 - 137.5 mm (5.02 - 5.41 in.)

11) Before fixing boot band, insert screwdriver into boot on joint side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.

12) Clamp boot band. Check boots for distortion or dent.

[A] : Differential side (RH)

[B] : Differential side (LH)

4A2-4 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL


Material

Lithium grease

Sealant


(Part Number)

SUZUKI SUPER GREASE A

(99000-25010)

SEALING COMPOUND 366E

(99000-31090)

Use

• Drive shaft oil seal

• Wheel spindle part of differential side drive shaft (RH)

• Axle shaft drive flange

PROPELLER SHAFTS 4B-1

SECTION 4B

PROPELLER SHAFTS

NOTE:


CONTENTS

General Description ....................................... 4B-1

On-Vehicle Service......................................... 4B-2

Propeller Shaft ............................................. 4B-2

Tightening Torque Specification .................. 4B-2

Required Service Material ............................. 4B-2

4B


Two universal non-constant velocity joints which are called cardan joints are provided on front propeller shaft and one universal non-constant velocity joint, two universal constant velocity joints and a rubber mounting center support are provided on rear propeller shaft. On the front end of rear propeller shaft, cardan joint same as that of front propeller shaft is provided. On the rear end of rear propeller shaft, ball fixed type constant velocity joint (BJ) is provided. On the middle of rear propeller shaft, double offset type constant velocity joint (DOJ) is provided just behind the center support.

Most universal joints require no maintenance. They are lubricated for life and can not be lubricated on the vehicle. If a universal joint becomes noisy or worn, it must be replaced.

The propeller shaft is a balanced unit. Handle it carefully so that balance can be maintained.

1. Front propeller shaft

2. Rear propeller shaft

4B-2 PROPELLER SHAFTS


Propeller Shaft

For the descriptions other than those mentioned below, refer to the same item in the same section of the Service Manual mentioned in the FOREWORD of this manual.

INSTALLATION

Use the following specification to torque universal joint flange nuts. For rear propeller shaft flange bolt, apply thread lock cement to thread part of bolts if reused.

“A” : Cement 99000-32110


Front propeller shaft flange nuts (a) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

Rear propeller shaft flange nuts (a) :

60 N·m (6.0 kg-m, 43.5 lb-ft)


Fastening part

Front propeller shaft flange nuts

Rear propeller shaft flange nuts

Center support bolts

N•m

50

60

50


5.0

6.0

5.0

lb-ft

36.5

46.5

36.5

Material

Thread lock cement



(Part Number)

THREAD LOCK CEMENT SUPER 1322

(99000-32110)

Use

• Rear propeller shaft flange bolts

BRAKES 5-1

SECTION 5

BRAKES

WARNING:






NOTE:

• For the description (items) not found in this section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual.

• When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E2 first.

• All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

5

CONTENTS

Diagnosis .......................................................... 5-2 Diagnosis Table ............................................. 5-2

5-2 BRAKES

Diagnosis

Diagnosis Table

For the item not found in this column, refer to the same item of the same section in the service manual mentioned in the FOREWORD of this manual.

Brake warning light turns on after engine start

Condition Possible Cause

Parking brake applied

Insufficient amount of brake fluid

Brake fluid leaking from brake line

Brake warning light circuit faulty

Malfunctioning EBD system

ABS warning light does not turn on for 2

– 3 sec. after ignition switch has turned ON.

ABS warning light remains on after ignition switch has turned on for 2 – 3 sec.

Bulb burnt out

ABS warning light circuit open (including check relay)

Malfunctioning ABS

Correction

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.

Check system referring to “DIAG-

NOSIS” of Section 5E2.

Replace bulb.


NOSIS” in Section 5E2.


NOSIS” in Section 5E2.

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-1

SECTION 5A

BRAKES PIPE/HOSE/MASTER CYLINDER

WARNING:






NOTE:



5A

General Description ....................................... 5A-2

Master Cylinder Assembly............................ 5A-2

On-Vehicle Service......................................... 5A-3

Front Brake Hose/Pipe ................................. 5A-3

Master Cylinder Reservoir............................ 5A-6

CONTENTS

Master Cylinder Assembly ........................... 5A-7

Brake Booster .............................................. 5A-8

Tightening Torque Specification ................ 5A-10

Special Tool.................................................. 5A-10

5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER


Master Cylinder Assembly

The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the figure below) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber

(“a”) acts on the rear wheel brakes.

Also, the hydraulic pressure produced in the secondary chamber (“b”) acts on the front wheel brakes.

WARNING:

Brake master cylinder cannot be disassembled. When anything faulty is found in it, it must be replaced as an assembly.

CAUTION:

Brake master cylinder cannot be disassembled in principle. Should primary piston have come off from cylinder while dismounting or handling it, wash it in the same specified fluid as that in reservoir and place it back in cylinder.

1. Piston cup

2. Primary piston

3. Secondary piston

4. Sleeve

5. Ring guide

6. Primary piston return spring

7. Secondary piston return spring

8. O-ring

9. Master cylinder body



Front Brake Hose/Pipe

REMOVAL

1) Raise and suitably support vehicle. Remove tire and wheel.

This operation is not necessary when removing pipes connecting master cylinder and flexible hose.

2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.

INSTALLATION

1) Reverse removal procedure for brake hose and pipe installation procedure.

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.


Brake pipe flare nut (a) : 16 N·m (1.6 kg-m, 12.0 lb-ft)

Brake flexible hose bolt (brake caliper/2 joint) (b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

2-way joint mounting bolt (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)

Brake hose/pipe bracket bolt (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)

ABS actuator bracket bolt (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)

ABS actuator mounting bolt (d) : 9 N·m (0.9 kg-m, 6.5 lb-ft)

NOTE:

Insert E-ring till its end surface is flush with or lower than bracket end surface.


For RH steering vehicle

[D]: View D

[a]: Clamp a

[b]: Clamp b

[c]: Clamp d

T: Top side

F: Front side

1. E-ring

2. Flexible hose

3. Hose washer

4. Hose bolt

5. Brake caliper

6. 2 way joint

For LH steering vehicle


[D]: View D

[a]: Clamp a

[b]: Clamp b

[d]: Clamp d

T: Top side

F: Front side

1. E-ring

2. Flexible hose

3. Hose washer

4. Hose bolt

5. Brake caliper

6. 2 way joint


1

Master Cylinder Reservoir

REMOVAL

1) Disconnect reservoir lead wire at coupler.

2) Clean outside of reservoir (1).

3) Take out fluid with syringe or such.

4) Remove reservoir stopper (3).

2. Master cylinder

3

2

2

3

1

3

5) Remove reservoir (1).

NOTE:

Do not allow brake fluid to get on painted surfaces.

2. Stopper

3. Grommets

1

INSTALLATION

NOTE:

See NOTE at the beginning of this section.

1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir (1) with. Then press-fit grommets to master cylinder (2). Grommets must be seated in place.

2) Install reservoir (1) and then insert stopper (3).

3

2

3) Connect reservoir lead wire.

4) Fill reservoir (1) with specified fluid.

5) Upon completion of installation, check for fluid leakage.

2 1

3

4

1

(c)

(b)

“A”


Master Cylinder Assembly

REMOVAL

NOTE:

Do not allow brake fluid to get on painted surfaces.

1) Disconnect reservoir lead wire (1) at coupler.

2) Clean around reservoir cap (2) and take out fluid with syringe or such.

3) Disconnect brake pipes from master cylinder (3) and ABS actuator (4).

INSPECTION

Inspect distance “A” to be the following.

Distance “A” :

57.4 mm (2.26 in) or more

If measurement is out of above specification, replace master cylinder assembly.

INSTALLATION

NOTE:


1) Install master cylinder to brake booster.

2) Tighten master cylinder attaching nuts to specified torque.


Master cylinder attaching nut (b) :

13 N·m (1.3 kg-m, 9.5 lb-ft)

3) Connect hydraulic lines to master cylinder and ABS actuator and tighten flare nuts to specified torque.


Brake pipe flare nut (c) : 16 N·m (1.6 kg-m, 12.0 lb-ft)

4) Connect reservoir lead wire (1).

5) Fill reservoir with specified brake fluid.

6) After installing, check brake pedal play and bleed air from system (Refer to “BRAKE PEDAL PLAY CHECK” and

“BLEEDING BRAKE” in Section 5).

7) Perform brake test and check each installed part for fluid leakage.


Brake Booster

3

7

8

5

4

6

9 2

1

1. Brake master cylinder assembly

2. Brake booster assembly

3. Gasket

4. Push rod clevis

5. Nut

6. Clevis pin

7. Clip

8. Plate

9. Seal

CLEARANCE BETWEEN BOOSTER PISTON ROD AND

MASTER CYLINDER PISTON CHECK AND ADJUSTMENT

The length of booster piston rod (1) is adjusted to provide specified clearance “0” between piston rod (1) end and master cylinder piston (2).

1) Before measuring clearance, push piston rod several times so as to make sure reaction disc is in place.

2) Keep inside of booster at atmospheric pressure for measurement.

3) Check depth of piston rod, i.e. distance between piston rod and mating surface of booster-to-master cylinder.

Depth “c” of piston rod for check :

15.8 – 16.6 mm (0.623 – 0.653 in.)


4) If measured depth is out of above specifications, adjust to specifications below by turning adjusting screw of piston rod.

Special tool

(F) : 09952-16021

Depth “d” of piston rod for adjustment :

16.3 – 16.6 mm (0.642 – 0.653 in.)



Fastening part

Brake flexible hose bolt (Brake caliper/2 way joint)

Brake hose / pipe bracket bolt

ABS actuator bracket bolt

Master cylinder attaching nut

Booster nut

Clevis nut

2-way joint mounting bolt


Brake bleeder plug (Front caliper (M8))

Brake bleeder plug (Wheel cylinder)

Wheel nut

25

10

16

8

7.5

100

N•m

23

10

10

13

13


2.3

1.0

1.0

1.3

1.3

2.5

1.0

1.6

0.8

0.75

10.0

18.0

7.5

12.0

6.0

5.5

72.5

lb-ft

17.0

7.5

7.5

9.5

9.5

Special Tool

09952-16021

Booster piston rod adjuster

09950-78220

Flare nut wrench

(10 mm)

PARKING AND REAR BRAKE 5C-1

SECTION 5C

PARKING AND REAR BRAKE

WARNING:






NOTE:



5C

CONTENTS

General Description ....................................... 5C-2

Drum Brake Assembly ................................. 5C-2

On-Vehicle Service......................................... 5C-3

Parking Brake Cable .................................... 5C-3

Brake Drum .................................................. 5C-3

Wheel Cylinder............................................. 5C-5

Brake Back Plate ......................................... 5C-5

Tightening Torque Specification .................. 5C-7

5C-2 PARKING AND REAR BRAKE


Drum Brake Assembly

The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is depressed and when parking brake is applied on level road.

It also uses duo servo operation when parking brake is applied on gradient road and load is applied in longitudinal direction of vehicle.

NOTE:

Replace all components included in repair kits to service this drum brake. Lubricate parts as specified.

WARNING:

If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque values specified are for dry, unlubricated fasteners.

1. Brake back plate

2. Brake shoe

3. Shoe return upper spring

4. Adjuster

5. Shoe return lower spring

6. Adjuster lever

7. Adjuster spring

8. Shoe hold down spring

9. Shoe hold down pin

10. Wheel cylinder

11. Link

12. Brake strut

Tightening torque

Parking Brake Cable



1. Parking brake switch

2. Parking brake lever

3. Parking brake lever bolt

4. Floor

5. Locking nut

6. Equalizer

7. Pin

8. Equalizer

9. Adjust rod

10. Coupler

11. Color ring

12. Cable

13. Grommet

14. Bolt

15. Clamp (if equipped)

16. Crossmember

17. Chassis frame

18. Hanger

19. Rear axle

20. G-sensor (if equipped)

21. Parking brake cable nut

Tightening torque

Brake Drum

INSPECTION

Brake drum

Inspect drum for cleanliness. Check wear of its braking surface by measuring its inside diameter.

Whenever brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves.

Brake dram inside diameter “a”

Standard : 254 mm ( 9.99 in.)

Service Limit : 256 mm (

10.07 in.)


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 no be turned.

NOTE:

When drum is removed, visually inspect wheel cylinder for brake fluid leakage. Correct leaky point, if any.

Brake shoe

Where lining is worn out beyond service limit, replace shoe.

If one of brake linings is to service limit, all linings must be replaced at the same time.

Rear brake drum shoe thickness “a”

Standard : 7.1 mm (0.28 in.)

Service limit : 3.6 mm (0.14 in.)

CAUTION:

Never polish lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage drum. When it is required to correct lining, replace it with a new one.

INSTALLATION

NOTE:


For the details, refer to the same item of the same section in the service manual mentioned in the FOREWORD of this manual noting the following.

• Before installing brake drum, check outer diameter of brake shoes (3). If it is not within value as specified below, adjust it to specification by turning adjuster (2).

Rear brake shoe outer diameter “a” :

253.3 – 253.7 mm (9.972 – 9.988 in.)

1. Pawl lever


Wheel Cylinder

INSTALLATION

For the details, refer to the same item of the same section in the service manual mentioned in the FOREWORD of this manual noting the following points.

• Take off bleeder plug cap from brake pipe and connect pipe

(or pipes) to wheel cylinder (1) just enough to prevent fluid from leaking.

• Tighten wheel cylinder to brake back plate (1) to specified torque.


Wheel cylinder bolt (for non sealed type) (a):

13.5 N·m (1.35 kg-m, 10.0 lb-ft)

Brake pipe flare nut (b):

16 N·m (1.6 kg-m, 12.0 lb-ft)

Brake Back Plate

INSTALLATION

1) Install brake back plate (3) to rear axle shaft (1).

2. Wheel beaning

2) Apply sealant “A” to joint seam of rear axle housing (1) and brake back plate.

“A” : Sealant 99000-31110

NOTE:

Make sure to remove old sealant before applying it anew.

3) Install rear axle shaft to rear axle housing.


(a)

4) Tighten brake back plate nuts to specified torque.


Brake back plate nut (a) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

5) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut (or nuts) to specified torque.


Wheel cylinder bolt :

13.5 N·m (1.35 kg-m, 10.0 lb-ft)

Brake pipe flare nut : 16 N·m (1.6 kg-m, 12.0 lb-ft)

6) Install parking brake cable (3) to brake back plate (1) and tighten parking brake cable nut (2) to specified torque.


Parking brake cable nut (a) : 10 N·m (10 kg-m, 7.5 lb-ft)

7) Install brake shoes, referring to steps 1) to 4) of “INSTALLA-

TION” under “BRAKE SHOE” in this section.

8) Install brake drum. Refer to steps 1) to 2) of “INSTALLA-

TION” under “BRAKE DRUM” in this section.

9) Refill differential housing with new specified gear oil. Refer to

“ON-VEHICLE SERVICE” in Section 7F for refill.

10) Fill reservoir with brake fluid and bleed brake system. (For bleeding operation, refer to “BLEEDING BRAKE” in Section

5).

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


Wheel nut (b) : 100 N·m (10.0 kg-m, 72.5 lb-ft)

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

30 kg (66 lbs) load 3 to 10 times so as to obtain proper drumto shoe clearance.

Adjust parking brake cable. (For adjustment, refer to “PARK-

ING BRAKE CHECK AND ADJUSTMENT” in Section 5).

13) Tighten parking brake lever cover screws.

14) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and perform brake test (foot brake and parking brake).

15) Check each installed part for oil leakage.



Fastening part

Wheel cylinder bleeder plug

Parking brake lever bolt

Wheel cylinder bolt


Brake back plate nut

Wheel nut

Parking brake cable nut

N•m

7.5

23

13.5

16

50

100

10


0.75

2.3

1.35

1.6

5.0

10.0

1.0

lb-ft

5.5

17.0

10.0

12.0

36.5

72.5

7.5


ANTILOCK BRAKE SYSTEM (ABS) 5E2-1

SECTION 5E2

ANTILOCK BRAKE SYSTEM (ABS)

WARNING:






NOTE:

• For the descriptions (items) not found in this section, refer to Section 5E1 of the Service Manual mentioned in the FOREWORD of this manual.


5E2

General Description ..................................... 5E2-3

Components/Parts Location ....................... 5E2-3

ABS Hydraulic Unit/control Module

Assembly.................................................... 5E2-4

Self-diagnosis function ........................... 5E2-4

Fail-safe function .................................... 5E2-5

Diagnosis ...................................................... 5E2-5

Precautions in Diagnosing Troubles .......... 5E2-5

ABS Diagnostic Flow Table........................ 5E2-6

ABS Warning Lamp Check ........................ 5E2-9

EBD Warning Lamp (Brake Warning Lamp)

Check ......................................................... 5E2-9

Diagnostic Trouble Code (DTC) Check

(Using ABS Warning Lamp) ..................... 5E2-10

Diagnostic Trouble Code (DTC) Check

(Using SUZUKI Scan Tool) ...................... 5E2-11

Diagnostic Trouble Code (DTC)

Clearance ................................................. 5E2-11

Diagnostic Trouble Code (DTC) Table ..... 5E2-12

System Circuit .......................................... 5E2-14

CONTENTS

Table-A ABS Warning Lamp Circuit Check

– Lamp Does Not Come “ON” at Ignition

Switch ON ................................................ 5E2-15

Table-B ABS Warning Lamp Circuit Check

– Lamp Comes “ON” Steady.................... 5E2-16

Table-C ABS Warning Lamp Circuit Check

– The Lamp Flashes Continuously While

Ignition Switch Is ON................................ 5E2-17

Table-D Code (DTC) Is Not Outputted

Even with Diagnosis Switch Terminal

Connected to Ground............................... 5E2-18

Table-E EBD Warning Lamp (Brake

Warning Lamp) Check – Lamp Comes

“ON” Steady ............................................. 5E2-19

DTC C1015 (DTC 15) – G Sensor Circuit

and 4WD Lamp Circuit ............................. 5E2-20

DTC C1021 (DTC 21), DTC C1022

(DTC 22) – Right-Front Wheel Speed

Sensor Circuit or Sensor Ring ................. 5E2-22

DTC C1025 (DTC 25), DTC C1026

(DTC 26) – Left-Front Wheel Speed

5E2-2 ANTILOCK BRAKE SYSTEM (ABS)


DTC C1031 (DTC 31), DTC C1032

(DTC 32) – Right-Rear Wheel Speed


DTC C1035 (DTC 35), DTC C1036

(DTC 36) – Left-Rear Wheel Speed


DTC C1041 (DTC 41) – Right-Front Inlet

Solenoid Circuit........................................ 5E2-24

DTC C1045 (DTC 45) – Left-Front Inlet


DTC C1055 (DTC 55) – Rear Inlet


DTC C1042 (DTC 42) – Right-Front

Outlet Solenoid Circuit ............................. 5E2-24

DTC C1046 (DTC 46) – Left-Front Outlet


DTC C1056 (DTC 56) – Rear Outlet


DTC C1057 (DTC 57) – Power Source

Circuit....................................................... 5E2-25

DTC C1061 (DTC 61) – ABS Pump Motor

Circuit....................................................... 5E2-26

DTC C1063 (DTC 63) – ABS Fail-Safe

Relay Circuit ............................................ 5E2-27

DTC C1071 (DTC 71) – ABS Control

Module ..................................................... 5E2-28

On-Vehicle Service .................................... 5E2-29

Precautions.............................................. 5E2-29

ABS Hydraulic Unit Operation Check

(Using SUZUKI Scan Tool)...................... 5E2-29

ABS Hydraulic Unit Operation Check

(Not Using Suzuki Scan Tool).................. 5E2-29

ABS Hydraulic Unit/Control Module

Assembly ................................................. 5E2-31

Rear Sensor Rotor (Retainer Ring) ......... 5E2-33

Tightening Torque Specification.............. 5E2-34

Special Tool ............................................... 5E2-34



Components/Parts Location

The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied.

This ABS has also the following function.

While braking is applied, but before ABS control becomes effective, braking force is distributed between the front and rear so as to prevent the rear wheels from being locked too early for better stability of the vehicle.The

main component parts of this ABS include the following parts in addition to those of the conventional brake system.

• Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.

• ABS warning lamp which lights to inform abnormality when system fails to operate properly.

• ABS hydraulic unit/control module assembly is incorporated ABS control module, ABS hydraulic unit (actuator assembly), fail-safe relay and pump motor relay.

– ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure applied to each wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking.

– ABS hydraulic unit which operates according to signal from ABS control module to control fluid pressure applied to wheel cylinder of each 4 wheels.

– Fail-safe relay (solenoid valve) relay which supplies power to solenoid valve in ABS hydraulic unit and pump motor relay.

– Pump motor relay which supplies power to pump motor in ABS hydraulic unit.

• G sensor which detects body deceleration speed. (For 4WD model only)

This ABS is equipped with Electronic Brake force Distribution (EBD) system that controls a fluid pressure of rear wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sensor independently of change of load due to load capacity and so on. And if the EBD system fails to operate properly, the brake warning lamp lights to inform abnormality.

1. Wheel speed sensor (Right-front)

2. Stop lamp switch

3. Data link connector

4. “ABS” warning lamp

5. Wheel speed sensor (Right-rear)

6. Wheel speed sensor (Left-rear)

7. Ground

8. Diagnosis connector (Black connector)

9. Wheel speed sensor (Left-front)

10. ABS hydraulic unit/control module assembly

(with ABS pump motor relay and fail-safe relay)

11. G sensor (For 4WD model only)

12. Wheel speed sensor rotor (ring)

13. 4WD switch (For 4WD model only)

14. EBD warning lamp (Brake warning lamp)

NOTE:

Above figure shows left-hand steering vehicle.

For right-hand steering vehicle, parts with (*) are installed at the side of symmetry.


ABS Hydraulic Unit/control Module Assembly

ABS control module is a component of ABS hydraulic unit/control module assembly and has the following functions.

Self-diagnosis function

ABS control module diagnoses conditions of the system 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 lamp lights for 2 seconds to check its bulb and circuit.

2) When no abnormality has been detected (the system is in good condition), ABS warning lamp turns OFF after 2 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 of EEPROM in ABS control module.

4) When Diag. switch terminal (2) of diagnosis connector (1)

(monitor connector) is grounded, the abnormal area is output as DTC. It is indicated by flashing of ABS warning lamp.

(Refer to the table below.)

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

ABS WARNING LAMP

Diag. switch terminal is not grounded

OFF

Diag. switch terminal is grounded

DTC 12

OFF

ON

ON

History DTC

Current DTC

Current and history DTCs

5) For procedure to clear all DTC’s, refer to “DIAGNOSTIC

TROUBLE CODE CLEARANCE” in this section.

3. Ground terminal

4. Service wire

Also ABS control module turns ON EBD warning lamp (brake warning lamp) depending on the trouble that detected by the module and EBD warning lamp does not indicate DTC.

Fail-safe function

When an abnormality occurs (an abnormal DTC is detected),

ABS control module turns OFF the fail-safe relay which supplies power to ABS hydraulic unit. Thus, with ABS not operating, brakes function just like the brake system of the vehicle without

ABS.


Diagnosis

To ensure that the trouble diagnosis is done accurately and smoothly, observe “PRECAUTIONS IN DIAGNOSING TROU-

BLES” and follow “ABS DIAGNOSTIC FLOW TABLE”.

Precautions in Diagnosing Troubles

• If the vehicles was operated in any of the following ways,

ABS warning lamp may light momentarily but this does not indicate anything abnormal in ABS.

– The vehicle was driven with parking brake pulled.

– The vehicle was driven with brake dragging.

– The vehicle was stuck in mud, sand, etc.

– Wheel spin occurred while driving.

– Wheel(s) was rotated while the vehicle was jacked up.

• Be sure to read “PRECAUTIONS FOR ELECTRONIC CIR-

CUIT SERVICE” in Section 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 diagnosis trouble code may be stored by mistake in the memory of ABS control module during inspection.)

• When disconnecting ABS hydraulic unit/control module connector (1), pull up lock (2) of connector.

When connecting, set the connector on ABS hydraulic unit/ control module assembly and push the lock (2) down.

D : Disconnect

C : Connect


ABS Diagnostic Flow Table

Refer to the following pages for the details of each step.

Step Action

1 1) Perform “Customer Complaint Analysis”.

2) Perform “Problem Symptom Confirmation”.

3) Perform “Diagnostic Trouble Code Check, Record and

Clearance”.

Is there any malfunction DTC?

2 1) Perform “DRIVING TEST”.

Is trouble symptom identified?

3 1) Check diagnostic trouble code.

Is it malfunction code?

4 1) Inspect and repair referring to applicable diagnostic trouble code table in this section.

2) Perform “FINAL CONFIRMATION TEST” after cleared

DTC.

Does trouble recur?

5 1) Inspect and repair referring to “DIAGNOSIS” in “BRAKES” section.

2) Perform “FINAL CONFIRMATION TEST”.

6 1) Check intermittent troubles referring to “INTERMITTENT

AND POOR CONNECTION” in “GENERAL INFORMA-

TION” section and related circuit of trouble code recorded in Step 2.

2) Perform “FINAL CONFIRMATION TEST” after cleared diagnostic trouble code.

Does trouble recur?

7 1) Perform “Diagnostic Trouble Code Check, Record and

Clearance”.

Is there any malfunction 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 2.

No

Go to Step 5.

Go to Step 6.

Go to Step 5.

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 that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) Check warning lamps related to brake system referring to “EBD WARNING LAMP

(BRAKE WARNING LAMP) CHECK” and “ABS WARNING LAMP CHECK” in this section.

c) Diagnostic Trouble Code (DTC) Check, Record and Clearance

Perform “DIAGNOSTIC TROUBLE CODE CHECK” procedure in this section, record it and then clear it referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section.

If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again when the ignition switch is 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 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 light) 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” as shown in the following page.

4) DIAGNOSTIC TROUBLE CODE FLOW TABLE

According to Diagnostic flow table for the diagnostic trouble code confirmation in Step 3), locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator assembly or other part and repair or replace faulty parts.

5) “DIAGNOSIS” IN “BRAKES” SECTION

Check the parts or system suspected as a possible cause referring to “DIAGNOSIS” in “BRAKES” section and based on symptoms appearing on the vehicle (symptom obtained through Steps 1)-a, 1)-b and 2) and repair or replace faulty parts, if any).

6) CHECK FOR INTERMITTENT PROBLEM

Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to

“INTERMITTENT TROUBLE” in “GENERAL INFORMATION” section and related circuit of trouble code recorded in Step 1)-c.

7) FINAL CONFIRMATION TEST

Confirm that the problem symptom 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 no DTC is indicated.


ABS Warning Lamp Check

1) Turn ignition switch ON.

2) Check that ABS warning lamp (1) comes ON for about 2 seconds and then goes off.

If any faulty condition is found, advance to Diagnostic Flow

Table-A, B, C or D.

EBD Warning Lamp (Brake Warning Lamp)

Check

NOTE:

Perform this check on a level place.

1) Turn ignition switch ON with parking brake applied.

2) Check that EBD warning lamp (brake warning lamp) (1) is turned ON.

3) Release parking brake with ignition switch ON and check that EBD warning lamp (brake warning lamp) goes off.

If it doesn’t go off, go to “TABLE-E” in this section.


Diagnostic Trouble Code (DTC) Check (Using

ABS Warning Lamp)

1) Perform ABS WARNING LAMP CHECK described above.

2) Using service wire (4), connect diagnosis switch terminal (2) of monitor coupler (1) to ground (3).


4) Read flashing of ABS warning lamp which represents DTC as shown in example below and write it down. When more than 2 DTCs are stored in memory, flashing for each DTC is repeated three times starting with the smallest DTC number in increasing order.

For details of DTC, refer to “DTC TABLE”.

Example : When right-front wheel speed sensor circuit opens (DTC 21)

5) After completing the check, turn ignition switch off, disconnect service wire from monitor coupler.


Diagnostic Trouble Code (DTC) Check (Using

SUZUKI Scan Tool)

1) After setting cartridge for ABS to SUZUKI scan tool, connect

SUZUKI scan tool to data link connector.

Special tool

(A) : SUZUKI scan tool


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 performing 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 DTCs by performing the following procedure.

1) Turn ignition switch OFF.

2) Using service wire (4), connect diagnosis switch terminal (2) of diagnosis monitor coupler (1) to ground terminal (3).

3) With connection described in above Step 2) maintained, turn ignition switch ON.


4) Repeat disconnecting and reconnecting of service wire between diagnosis and ground terminals 5 times or more at about 1sec. interval within 10 seconds.

O : Open

S : Short

T : About 10 seconds

5) Turn ignition switch OFF and disconnect service wire from monitor coupler.

6) Perform “DRIVING TEST” (Step 2 of “ABS DIAGNOSTIC

FLOW TABLE” in this section) and “DTC CHECK” and confirm that normal DTC (DTC 12) is displayed ; not malfunction

DTC.

NOTE:

It is also possible to clear DTC by using SUZUKI scan tool. Refer to Cartridge Manual for procedure to clear

DTC.

Diagnostic Trouble Code (DTC) Table

CAUTION:

Be sure to perform “ABS DIAGNOSTIC FLOW TABLE” before starting diagnosis.

DTC

(displayed on SUZUKI scan tool)

DTC

(indicated by

ABS warning lamp)

ABS warning lamp flashing pattern

NO DTC 12 Normal

DIAGNOSTIC ITEMS

C1015

C1021

C1025

C1031

C1035

25

31

35

15

21

G sensor circuit and 4WD lamp circuit

RF

LF

RR

Wheel speed sensor circuit

LR

C1056

C1057

C1061

C1063

C1071

C1036

C1041

C1042

C1045

C1046

C1055


DTC

(displayed on SUZUKI scan tool)

DTC

(indicated by

ABS warning lamp)

ABS warning lamp flashing pattern

C1022 22 RF

C1026

C1032

26

32

DIAGNOSTIC ITEMS

LF

RR

Wheel speed sensor circuit or sensor ring

36

41

42

45

46

55

56

57

61

63

71

LR

RF

Inlet solenoid valve circuit

Outlet solenoid valve circuit


LF


REAR



Power source

ABS pump motor and/or motor relay circuit

Fail safe-relay

ABS control module


System Circuit

1. Battery

2. Main fuses

3. Ignition switch

4. Circuit fuses

5. Combination meter

6. ABS warning lamp

7. Brake warning lamp (“EBD” warning lamp)

8. Warning lamp driver module (for ABS)


10. Terminal arrangement of connector E136 for

ABS hydraulic unit/control module assembly

11. ABS fail-safe transistor (Solenoid valve transistor)

12. ABS pump motor transistor

13. Pump motor

14. Solenoid valves

15. Diagnosis monitor coupler

16. Right-rear wheel speed sensor

17. Left-rear wheel speed sensor

18. Right-front wheel speed sensor

19. Left-front wheel speed sensor


TERMINAL

3

4

1

2

E136

CIRCUIT

Idle up signal

Stop lamp switch

Right-front wheel speed sensor (+)

Right-front wheel speed sensor (–)

5

6

7

–

Right-rear wheel speed sensor (–)

Right-rear wheel speed sensor (+)

8

9

10 Brake warning lamp (EBD warning lamp)

11 G sensor (For 4WD vehicle only)

12 Diagnosis switch terminal

–

–

13 Ground (For G sensor) (For 4WD vehicle only)

21. To ECM and SDM (if equipped)

22. Stop lamp

23. Stop lamp switch

24. G sensor (For 4WD vehicle only)

25. 4WD lamp (For 4WD vehicle only)

26. ECM (PCM) (For 4WD vehicle only)

27. 4WD switch (For 4WD vehicle only)

28. ECM (PCM)

TERMINAL CIRCUIT

14 ABS warning lamp

15 Left-front wheel speed sensor (+)

16 Left-front wheel speed sensor (–)

17 4WD switch

E136

18 Ignition switch

19 Left-rear wheel speed sensor (+)

20 Left-rear wheel speed sensor (–)

21 Data link connector

22 Ground (for ABS pump motor)

23 ABS pump motor relay

24 Ground (for ABS control module)

25 ABS fail-safe relay


Table-A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at

Ignition Switch ON

1. Main fuse

2. Ignition switch

3. Circuit fuse


5. ABS warning lamp

6. Brake warning lamp

7. Lamp driver module

8. Parking brake switch

9. Brake fluid level switch


11. ABS hydraulic unit/control module connector

CIRCUIT DESCRIPTION

Operation (ON/OFF) of ABS warning lamp is controlled by ABS control module through lamp driver module in combination meter.

If the Antilock brake system is in good condition, ABS control module turns ABS warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF. If an abnormality in the system is detected, ABS warning lamp is turned ON continuously by ABS control module. Also, it is turned ON continuously by lamp driver module when the connector of ABS control module is disconnected.

INSPECTION

Step Action

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?

3 1) Remove combination meter.

Is bulb of ABS warning lamp in good condition?

Go to Step 2.

Yes

Substitute a known-good ABS hydraulic unit/control module assembly and recheck.

4 Is IG fuse in good condition?

No

Go to Step 4.

Go to Step 3.

“BLU/ORN” circuit shorted to ground. If OK, replace combination meter (lamp driver module).

Open in “BLK/WHT” wire to combination meter or poor connection.

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 Does malfunction DTC (other than code No.12) exist at Step 1?

Yes

Go to Step 2.

Go to Step 7 of “ABS

DIAGNOSTIC FLOW

TABLE” in this section.

Go to Step 4.


2) Check for proper connection to ABS hydraulic unit/control module connector at terminals “E136-14”, “E136-18” and “E136-

24”.

3) If OK then ignition switch ON and measure voltage at terminal “E136-18” of connector.

Is it 10 – 14 V?

4 1) With ABS hydraulic unit/control module connector disconnected, turn ignition switch ON and light ABS warning lamp.

2) Connect terminal “E136-14” of disconnected connector to ground using service wire.

Does ABS warning lamp turn off?

5 1) Measure resistance from connector terminal

“E136-24” to body ground.

Is continuity indicated?

Go to Step 5.

Substitute a known-good

ABS hydraulic unit/control module assembly and recheck.

“BLU/ORN” circuit open.

If wire and connection are

OK, replace combination meter (lamp driver module).

No

Go to Step 3.

Go to Step 3.

“BLK/WHT” circuit open.

“BLK” circuit open.


Table-C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously

While Ignition Switch Is ON

1. ABS warning lamp in combination meter



3-1. Diagnosis switch terminal

3-2. Diagnosis ground terminal



When diagnosis switch terminal is shorted or connected to the ground with ignition switch ON, diagnosis trouble code (DTC) is indicated by flashing of ABS warning lamp only in the following cases.

• Normal DTC (12) is indicated if no malfunction DTC is detected in the ABS.

• A history malfunction DTC is 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 diagnosis switch terminal connected to ground via service wire?

2 1) Ignition switch ON.

2) Measure voltage between diagnosis switch terminal and ground.

Is it 10 – 14 V?

3 1) Ignition switch ON.

2) Does flashing of ABS warning lamp indicate

DTC?

Yes

Go to Step 3.



Go to Step 7 of “ABS

DIAGNOSTIC FLOW


No

Go to Step 2.

“PNK” wire circuit shorted to ground.




Table-D Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal

Connected to Ground

1. ABS warning lamp in combination meter



3-1. Diagnosis switch terminal

3-2. Diagnosis ground terminal



When diagnosis switch terminal is connected to ground with ignition switch turned ON, the ABS control module outputs diagnostic trouble code by flashing ABS warning lamp.

INSPECTION

Step Action

1 Is it shorted diagnosis 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 diagnosis switch terminal and connector terminal

“E136-12”.

Is it infinite (

∞)?

3 1) Measure resistance between ground terminal of monitor coupler and body ground.


4 1) Check for proper connection to ABS hydraulic unit/control module at terminal

“E136-12”.

2) If OK, then check ABS warning lamp circuit referring to TABLE A, B and C.

Is it in good condition?

Yes

Go to Step 2.

“PNK” circuit open.

Go to Step 4.


ABS hydraulic with/control module assembly and recheck.

No

Connect service wire securely.

Go to Step 3.

“BLK” circuit open or poor connection.

Repair “ABS” warning lamp circuit.


Table-E EBD Warning Lamp (Brake Warning Lamp) Check – Lamp Comes

“ON” Steady


EBD warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS control module/hydraulic unit assembly through lamp driver module in combination meter. Refer to “TABLE – A” for circuit diagram.

INSPECTION

Step Action

1 1) Make sure that :

• Parking brake is completely released.

• Brake fluid level is upper than the minimum level.

Are the check results OK?

2 Does “ABS” warning lamp come on?

Yes

Go to Step 2.


2) Check for proper connection to ABS hydraulic unit/control module connector at terminals “E136-10”.

3) If OK, apply chocks to wheels and select gear in neutral position (P range for A/T).

4) Keep brake pedal depressed and start engine.

Release parking brake.

5) Connect terminal “E136-10” of disconnected connector to ground using service wire.

Does EBD warning lamp (brake warning lamp) turn off?

No

Release parking brake completely and/or replenish brake fluid.

Perform “TABLE – B” previously outlined.



Go to Step 3.

“BRN” circuit open.


OK, replace combination meter.


DTC C1015 (DTC 15) – G Sensor Circuit and 4WD Lamp Circuit

1. Ignition switch

2. G sensor



5. 4WD lamp

6. ECM (PCM)

7. 4WD switch

DESCRIPTION

G sensor

While a vehicle is at stop or running, if the potential difference between the sensor signal terminal “E136-11” and the sensor ground terminal “E136-13” is not within the specified voltage value, or if the signal voltage while at a stop does not vary from that while running, this DTC is set.

Therefore, this DTC may be set when a vehicle is lifted up and its wheel(s) is turned. In such case, clear the

DTC and check again.

When G sensor is installed to 2WD vehicle, this DTC is set.

4WD lamp

When 4WD lamp circuit open or shorted, this DTC is set.


INSPECTION

Step Action

1 1) Turn ignition switch ON.

Does 4WD lamp turn ON when 4WD switch turns ON?

2 1) Ignition switch OFF.

2) Check for proper connection to ECM (PCM) and 4WD switch.

3) If OK, then check 4WD control system referring to DIAGNOSIS in SECTION 7E.

Is it good condition?


2) Disconnect connector from ABS hydraulic with/control module assembly.

3) Check for proper connection to ABS control module at terminal “E136-17”

4) If OK, then turn ignition switch ON and 4WD switch ON.

5) Measure voltage between terminal “E136-

17” of module connector and body ground.

Is it 10 – 14 V?

4 Is G sensor installed to 2WD vehicle?

5 Is G sensor installed floor securely?

Yes

Go to Step 2.

Go to Step 3.

Go to Step 4.

Remove G sensor.

Go to Step 6.

Replace bulb or repair its circuit.

No

Repair 4WD control system.

“ORN/BLK” circuit open or short to ground.


2) Remove G sensor with bracket.

3) Check for proper connection to G sensor.

4) If OK then check G sensor referring to

INSPECTION of “G SENSOR”.

8 Measure voltage between “ORN/WHT” terminal of sensor connector and body ground.

Is it 0 V?


2) Check that “ORN/WHT” circuit is free from open or short to ground and “ORN/GRN” circuit.


Go to Step 7.


7 1) Disconnect connectors from ABS hydraulic unit/control module assembly and G sensor.

2) Check for proper connection to ABS control module at terminals “E136-11” and “E136-

13”.

3) If OK, then turn ignition switch ON and measure voltage between “BLK/WHT” terminal of sensor connector and body ground.

Is it 10 – 14 V?

Go to Step 8.

Go to Step 9.

“ORN/GRN” circuit open.

If circuit is OK, substitute a known-good ABS hydraulic unit/control module assembly.

Go to Step 5.

Tighten sensor or bracket screw securely. If not, using new screw.

Replace G sensor.

“BLK/WHT circuit open.

“ORN/WHT” circuit shorted to power circuit.

“ORN/WHT” circuit open or shorted to ground or

“ORN/GRN” circuit.


DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right-Front Wheel Speed Sensor

Circuit or Sensor Ring

DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left-Front Wheel Speed Sensor


DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right-Rear Wheel Speed Sensor


DTC C1035 (DTC 35), DTC C1036 (DTC 36) – Left-Rear Wheel Speed Sensor


1. Ignition switch

2. ABS control module/hydraulic unit assembly

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 terminal of each sensor while the ignition switch is ON.

When the voltage is not within the specified range, an applicable DTC will be set. Also, when no sensor signal is inputted at starting or while running, an applicable DTC will be set.

NOTE:

When the vehicle was operated in any of the following ways, one of these DTCs may be set even when the sensor is in good condition. If such possibility is suspected, repair the trouble (dragging of brake, etc.) of the vehicle, clear DTC once and then after performing the driving test as described in Step 2 of

“ABS DIAGNOSIS FLOW TABLE”, check whether 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 applicable ABS wheel speed sensor coupler with ignition switch OFF.

2) Measure resistance between terminals of ABS wheel speed sensor. Refer to “FRONT WHEEL SPEED SEN-

SOR” and/or “REAR WHEEL SPEED SENSOR” in this section.

Is measured resistance value as specified?

2 1) Turn ignition switch OFF.


3) Check for proper connection to ABS control module at each sensor terminal.

4) If OK, then turn ignition switch ON and measure voltage between sensor terminal of module connector and body ground.

Is it 0V?

Yes

Go to Step 2.

Go to Step 3.

3 1) Turn ignition switch OFF.

2) Connect ABS wheel speed sensor coupler.

3) Measure resistance between the following points.

• Both ABS hydraulic unit/control module connector terminals of the corresponding sensor.

This check result should be the same as above Step 1.

• Either terminal of wheel speed sensor coupler and body ground.

This check result should be no continuity.

Are both check results OK?

4 1) Remove applicable ABS wheel speed sensor.

2) Check sensor for damage or foreign material attached.


5 Check front and/or rear sensor ring for the following

(remove rear drum as necessary) :

• Rotor serration (teeth) neither missing nor damaged.

• No foreign material being attached.

• Rotor not being eccentric.

• Wheel bearing free from excessive play.

Are they in good condition?

6 1) Install ABS wheel speed sensor to knuckle.

2) Tighten sensor bolt to specified torque and check that there is no clearance between sensor and knuckle.

Is it OK?

7 Referring to “Reference” of “FRONT WHEEL SPEED SEN-

SOR” and/or “Reference” of “REAR WHEEL SPEED SEN-

SOR” in this section, check output voltage or waveform.

Is specified voltage and/or waveform obtained?

Go to Step 4.

Go to Step 5.

Go to Step 6.

Go to Step 7.

Substitute a knowngood ABS hydraulic unit/control module assembly and recheck.

No

Replace ABS wheel speed sensor assembly.

ABS wheel speed sensor circuit shorted to power.

Circuit open or shorted to ground.

Clean, repair or replace.


Replace ABS wheel speed sensor.

Replace sensor and recheck.


DTC C1041 (DTC 41) – Right-Front Inlet Solenoid Circuit

DTC C1045 (DTC 45) – Left-Front Inlet Solenoid Circuit

DTC C1055 (DTC 55) – Rear Inlet Solenoid Circuit

DTC C1042 (DTC 42) – Right-Front Outlet Solenoid Circuit

DTC C1046 (DTC 46) – Left-Front Outlet Solenoid Circuit

DTC C1056 (DTC 56) – Rear Outlet Solenoid Circuit


2. ABS hydraulic unit/control module assembly connector

3. ABS control module

4. Signal

5. Fail-safe relay

DESCRIPTION

The ABS control module monitors the output from the valve.

When the output of each valve exceeds the specified value compared with the signal sent from ABS control module, this DTC is set.

INSPECTION

Step Action

1 1) Check solenoid operation referring to item “ABS

HYDRAULIC UNIT OPERATION CHECK” in this section.




3) Check for proper connection to ABS hydraulic unit/ control module connector at terminal “E136-25”.

4) If OK, then measure voltage between terminal

“E19-25” of module connector and “E136-24”.

Is it 10 – 14 V?

Yes

Check terminal “E136-25” connection. If connection is

OK, substitute a known-good




No

Go to Step 2.

“WHT/BLU” or


DTC C1057 (DTC 57) – Power Source Circuit


1. Ignition switch

2. Main fuse



DESCRIPTION

The ABS control module monitors the power source voltage at terminal “E136-18”. When the power source voltage becomes extremely high or low, this DTC will be set. As soon as the voltage rises or lowers to the specified level, the set DTC will be cleared.

INSPECTION

Step Action

1 1) Connect a voltmeter between battery positive (+) terminal and body ground.

2) Start the engine and measure the maximum voltage when racing the engine.

Is it over 18V?


2) Keep the engine idling, measure the voltage between terminal “E136-18” of ABS control module and body ground.

Is it always under 9V?

Yes

Check charging system referring to “CHARGING

SYSTEM” section.


SYSTEM” section.

Imperfect short between wire “GRN/ORN” and ground.

No

Go to Step 2.

Poor connection of terminal “E136-18” or “E136-

24” of the ABS control module.

If the above are in good condition, substitute a known-good ABS hydraulic unit/control module and recheck.


DTC C1061 (DTC 61) – ABS Pump Motor Circuit


2. ABS pump motor relay

3. ABS pump motor

4. ABS fail safe relay


DESCRIPTION

The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition switch turned ON. It sets this DTC when the voltage at the monitor terminal does not become high/low according to ON/OFF commands to the motor relay of the module (does not follow these commands).

INSPECTION

Step Action

1 1) Check pump motor referring to “ABS





3) Check for proper connection to ABS hydraulic unit/control module connector at terminal “E136-23”.

4) If OK, then measure voltage between terminal “E136-23” of module connector and body ground.

Is it 10 – 14 V?

3 Measure resistance between terminal “E136-

22” of ABS hydraulic unit/control module connector and body ground.

Is it infinite (

∞)?

Yes

Check terminals “E136-

25” and “E136-23” connection. If connections

OK, substitute a knowngood ABS hydraulic unit/ control module assembly and recheck.

Go to Step 3.


No

Go to Step 2.

“WHT/BLU” circuit open.



DTC C1063 (DTC 63) – ABS Fail-Safe Relay Circuit


1. Ignition switch



4. To solenoid valves

5. Fail-safe relay

DESCRIPTION

ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned

ON. Also, immediately after ignition switch is turned ON, perform initial check as follows.

Switch fail-safe relay in the order of OFF → ON and check if voltage changes to Low → High. If anything faulty is found in the initial check and when the voltage is low with ignition switch turned ON, this DTC will be set.

INSPECTION

Step Action

1 Check battery voltage. Is it about 11 V or higher?

Yes

Go to Step 2.

2 Check ABS main fuse and connection.




3) Check proper connection to ABS hydraulic unit/control module at terminal “E136-25”.

4) If OK, then measure voltage between connector terminal “E136-25” and body ground.

Is it 10 – 14 V?

Go to Step 3.



No


SYSTEM” section.

Repair and/or replace fuse.

“WHT/BLU” circuit open or short to ground.


DTC C1071 (DTC 71) – ABS Control Module


2. ABS pump motor relay

3. ABS pump motor

4. ABS fail safe relay


DESCRIPTION

This DTC will be set when an internal malfunction is detected in the ABS control module.

INSPECTION

Step Action

1 Clear all DTCs and check DTC.

Is it DTC 71?

Yes

Go to Step 2.

2 1) Check proper connection of ABS hydraulic unit/control module connector.

2) If OK, disconnect ABS hydraulic unit/control module connector and check the followings.

• Voltage “E136-25” terminal : 10 – 14 V

• Resistance between “E136-22” and body ground : Continuity

Are the check result as specified above?

Replace ABS hydraulic unit/control module assembly.

No

Could be a temporary malfunction of the ABS control module.

Repair and recheck.



Precautions

When connector are connected to ABS hydraulic unit/control module assembly, do not disconnect connectors of sensors and turn ignition switch ON. Then DTC will be set in ABS control module.

ABS Hydraulic Unit Operation Check (Using

SUZUKI Scan Tool)

1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.

Special tool


2) Turn ignition switch to ON position and check actuator operation using “HYDRAULIC CONTROL TEST” under “miscellaneous test” (“MISC. TEST”) mode of SUZUKI scan tool.

ABS Hydraulic Unit Operation Check

(Not Using Suzuki Scan Tool)

1) Check that basic brake system other than ABS is in good condition.

2) Check that battery voltage is 11V or higher.

3) With “ABS” warning lamp, check that no abnormality is detected in ABS. Refer to “DIAGNOSTIC TROUBLE CODE

(DTC) CHECK” in this section.

4) Lift up vehicle.

5) Set transmission to neutral and release parking brake.

6) Turn each wheel gradually by hand to check if brake dragging occurs. If it does, correct.

7) With diag. switch terminal (2) of diagnosis connector (1) connected to ground by using service wire (4), turn ignition switch to ON position and check that “ABS” warning lamp indicates normal DTC (DTC 12) referring to “DIAGNOSTIC

TROUBLE CODE (DTC) TABLE” in this section.

8) Turn ignition switch to OFF position.


9) Perform following checks with help of another person.

10) Brake pedal (1) should be depressed.

a) Ignition switch turned to ON position by one person.

b) Wheel should be turned by another person’s hand. At this time, check that:

• Operation sound of solenoid is heard and wheel turns only about 0.5 sec. (brake force is depressurized).

• Operation sound of pump motor is heard and pulsation is felt at brake pedal.

11) If all 4-wheels cannot be checked during one ignition cycle

(OFF

→ ON), repeat Steps 8) and 9) till all 4 wheels are checked.

If a faulty condition is found in Steps 9) and 10), replace hydraulic unit/control module assembly.

Turn ignition switch to OFF position and remove service wire from diagnosis connector.


ABS Hydraulic Unit/Control Module Assembly

CAUTION:

Never disassemble ABS hydraulic unit/control module assembly, loosen blind plug or remove motor.

Performing any of these prohibited services will affect original performance of ABS hydraulic unit/ control module assembly.

1

16 N·m (1.6 kg-m)

2

10 N·m (1.0 kg-m)

4

3

1. Brake pipe


9 N·m (0.9 kg-m)

3. Bracket

4. Connector

HYDRAULIC UNIT INSPECTION

Check hydraulic unit for fluid leakage.

If any, repair or replace.

REMOVAL

1) Disconnect negative cable at battery.

2) Disconnect ABS hydraulic unit/control module assembly connector (1) by pulling up lock (2).


(c)

2

1

3

(a)

(b)

(c)

3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit/control module assembly

(3).

Special tool

09950-78220

NOTE:

Put bleeder plug cap onto pipe to prevent fluid from spilling. Do not allow brake fluid to get on painted surfaces.

4) Remove three bolts and take out ABS hydraulic unit/control module assembly (1) from bracket using flat end rod or the like (2).

CAUTION:

• Do not give an impact to hydraulic unit.

• Use care not to allow dust to enter hydraulic unit.

• Do not place hydraulic unit on its side or upside down.

Handling it in inappropriate way will affect its original performance.

INSTALLATION

1) Install hydraulic unit/control module assembly by reversing removal procedure.


Brake pipe flare nut (a) :

16 N·m (1.6 kg-m, 11.5 lb-ft)

ABS hydraulic unit/control module assembly bolt (b) :

9 N·m (0.9 kg-m, 6.5 lb-ft)

Bracket bolt (c) : 10 N·m (1.0 kg-m, 6.5 lb-ft)

2) Bleed air from brake system referring to “BRAKES” section.

3) Check each installed part for fluid leakage and perform “ABS


NOTE:

For new ABS hydraulic unit/control module assembly, if

“ABS HYDRAULIC UNIT OPERATION CHECK” procedure has not been performed, “ABS” warning lamp may flash when ignition switch is turned ON position.

Accordingly preform “ABS HYDRAULIC UNIT OPERA-

TION CHECK” to stop flashing of ABS warning lamp.

(b)


Rear Sensor Rotor (Retainer Ring)

REMOVAL

1) Remove rear axle shaft assembly. Refer to “REAR AXLE

SHAFT” in Section 3E.

2) In order to remove sensor rotor (retainer ring) (2) from shaft

(1), grind with a grinder one part “A” of the sensor rotor

(retainer ring) as shown till it becomes thin.

CAUTION:

• Cover vinyl sheet (3) or the like over wheel bearing so that fine grains from grinding will not enter there.

• Be careful not to go so far as to grind the retainer ring.

3) Break with a chisel (1) the thin ground sensor rotor (retainer ring) (2), and it can be removed.

INSTALLATION

1) Press-fit sensor rotor (retainer ring) (1) as shown in the figure.

2) Install rear axle shaft assembly. Refer to “REAR AXLE

SHAFT” in Section 3E.



Fastening part

Brake pipe flare nut : (a)

ABS hydraulic unit bolt : (b)

ABS hydraulic unit bracket bolt : (c)

Wheel speed sensor bolt (Front) : (d)

Wheel speed sensor bolt (Rear) : (e)

Parking lever assembly mounting bolt : (f)

N•m

16

9

10

23

21

23


1.6

0.9

1.0

2.3

2.1

2.3

lb-ft

11.5

6.5

7.5

17.0

15.5

17.0

(a)

(c)

(b)

(c)

(b)

Special Tool

09950-78220 09931-76011

Flare nut wrench (10 mm) Tech 1A kit (SUZUKI scan tool)

(See NOTE A.)

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.)

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 adapter, 8. Self-test adapter

B. This kit includes the following items and substitutes for the Tech 1A kit.

1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector, 11.

Storage case, 12. Power supply


ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-1

SECTION 6-1

ENGINE GENERAL INFORMATION AND

DIAGNOSIS (H27 ENGINE)

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.

• Monitor connector

• CKP sensor

• MAP sensor

• EGR valve

• Heated oxygen sensor or CO adjusting resistor

• Three way catalytic converter, Warm-up three way catalytic converter

6-1

General Information ...................................... 6-1-3

Statement of Cleanliness and Care ............ 6-1-3

General Information on Engine Service ...... 6-1-3

Precaution on Fuel System Service ............ 6-1-4

Fuel Pressure Relief Procedure .................. 6-1-5

Fuel Leakage Check Procedure.................. 6-1-5

Engine Diagnosis .......................................... 6-1-6

General Description .................................... 6-1-6

On-Board Diagnostic System (Vehicle without Monitor Connector) ......................... 6-1-6

On-Board Diagnostic System (Vehicle with

Monitor Connector) ..................................... 6-1-9

Precaution in Diagnosing Trouble ............. 6-1-10

Engine Diagnostic Flow Table................... 6-1-11

Malfunction Indicator Lamp (MIL) Check... 6-1-16

Diagnostic Trouble Code (DTC) Check..... 6-1-16

Diagnostic Trouble Code (DTC) Clearance 6-1-17

Diagnostic Trouble Code (DTC) Table ...... 6-1-18

CONTENTS

For A/T system (Refer to Section 7B1 for diagnosis)......................................... 6-1-21

For immobilizer control system (Refer to

Section 8G for diagnosis)...................... 6-1-22

Fail-Safe Table.......................................... 6-1-23

Scan Tool Data ......................................... 6-1-24

Scan tool data definitions ...................... 6-1-27

Engine Diagnosis Table ............................ 6-1-31

Inspection of PCM (ECM) and its Circuits. 6-1-36

Table A-1 Malfunction Indicator Lamp

Circuit Check – Lamp Does Not Come

“ON” or Dims at Ignition Switch ON

(But Engine at Stop).................................. 6-1-43


Circuit Check – Lamp Remains “ON” after

Engine Starts ............................................ 6-1-44


Check – MIL Flashes at Ignition Switch

ON (Vehicle with Monitor Connector) ....... 6-1-45

6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)


Check – MIL Does Not Flash or Just

Remains ON Even with Grounding

Diagnosis Switch Terminal (Vehicle with

Monitor Connector) ................................... 6-1-45

Table A-5 ECM (PCM) Power and Ground

Circuit Check – MIL Doesn’t Light at

Ignition Switch ON and Engine Doesn’t

Start Though It Is Cranked Up .................. 6-1-46

DTC P0100 (DTC No.33, 34) Mass Air

Flow Circuit Malfunction............................ 6-1-48

DTC P0110 (DTC No.23, 25) Intake Air

Temp. (IAT) Circuit Malfunction ................ 6-1-50

DTC P0115 (DTC No.14, 15) Engine

Coolant Temp. Circuit Malfunction ............ 6-1-52

DTC P0120 (DTC No.21, 22) Throttle

Position Circuit Malfunction....................... 6-1-54

DTC P0121 Throttle Position Circuit

Range/Performance Problem ................... 6-1-56

DTC P0130 (DTC No.13) HO2S-1 (Bank 1)

Circuit Malfunction or No Activity

Detected.................................................... 6-1-58

DTC P0133 HO2S-1 (Bank 1) Circuit Slow

Response.................................................. 6-1-60

DTC P0135 HO2S-1 (Bank 1) Heater

Circuit Malfunction .................................... 6-1-61

DTC P0136 HO2S-2 (Bank 1) Circuit

Malfunction................................................ 6-1-63



DTC P0150 (DTC No.26) HO2S-1 (Bank 2)

Circuit Malfunction or No Activity

Detected.................................................... 6-1-67

DTC P0153 HO2S-1 (Bank 2) Circuit Slow

Response.................................................. 6-1-69



DTC P0156 HO2S-2 (Bank 2) Circuit

Malfunction................................................ 6-1-72



DTC P0171/P0172 Fuel System Too

Lean/Rich (Bank 1) ................................... 6-1-76

DTC P0174/P0175 Fuel System Too

Lean/Rich (Bank 2) ................................... 6-1-78

DTC P0300/P0301/P0302/P0303/P0304/

P0305/P0306 Random Misfire/Cylinder 1

Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/

Cylinder 4 Misfire Detected/Cylinder 5

Misfire Detected/Cylinder 6 Misfire

Detected.................................................... 6-1-80

DTC P0325 (DTC No.43) Knock Sensor

Circuit Malfunction ..................................... 6-1-82

DTC P0335 Crankshaft Position Sensor

Circuit Malfunction ..................................... 6-1-84

DTC P0340 (DTC No.42) Camshaft

Position Sensor Circuit Malfunction ........... 6-1-86

DTC P0400 Exhaust Gas Recirculation

Flow Malfunction ........................................ 6-1-89

DTC P0403 (DTC No.51) Exhaust Gas

Recirculation Circuit Malfunction ............... 6-1-92

DTC P0420 Catalyst System Efficiency

Below Threshold (Bank 1) ......................... 6-1-94

DTC P0430 Catalyst System Efficiency

Below Threshold (Bank 2) ......................... 6-1-96

DTC P0443 Evap Control System Purge

Control Valve Circuit Malfunction............... 6-1-98

Evap canister purge system inspection............................................. 6-1-100

Vacuum passage inspection ................ 6-1-100

Vacuum hose inspection...................... 6-1-101

Evap canister purge valve and its circuit inspection .................................. 6-1-101

Evap canister purge valve inspection .. 6-1-101

DTC P0460 Fuel Level Sensor Circuit

High Input ................................................ 6-1-103

DTC P0500 (DTC No.24) Vehicle Speed

Sensor Malfunction .................................. 6-1-105

DTC P0505 Idle Air Control System

Malfunction .............................................. 6-1-108

DTC P0601 (DTC No.71) Internal Control

Module Memory Check Sum Error .......... 6-1-110

DTC P1408 Manifold Absolute Pressure

Sensor Circuit Malfunction ....................... 6-1-111

DTC P1450/P1451 Barometric Pressure

Sensor Circuit Malfunction/Performance

Problem ................................................... 6-1-113

DTC P1500 Engine Starter Signal Circuit

Malfunction .............................................. 6-1-114

DTC P1510 Ecm Back-Up Power Supply

Malfunction .............................................. 6-1-115

Table B-1 Fuel Pump Circuit Inspection .. 6-1-116

Table B-2 Fuel Injectors and Circuit

Inspection ................................................ 6-1-117

Table B-3 Fuel Pressure Inspection ........ 6-1-119

Table B-4 Idle Air Control System

Inspection ................................................ 6-1-121

Table B-5 A/C Signal Circuits Inspection

(If Equipped) ............................................ 6-1-123

Table B-6 A/C Condenser Fan Motor

Relay Control System Inspection

(If Equipped) ............................................ 6-1-124

Special Tool ............................................... 6-1-125


General Information

Statement of Cleanliness and Care

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.

• A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surface on initial operation.

• Whenever valve train components, pistons, piston rings, connecting rods, rod bearings and crankshaft 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 6 cylinders of the engine are identified by numbers; No.1, No.2, No.3, No.4, No.5 and No.6

as counted from crankshaft pulley side to flywheel side.

• Figure at the left shows engine with intake manifold removed and viewed from the top.

LH (No.1) bank consists of No.1, No.3 and No.5 cylinders.

RH (No.2) bank consists of No.2, No.4 and No.6 cylinders.

1. No.1 cylinder

2. No.2 cylinder

3. No.3 cylinder

4. No.4 cylinder

5. No.5 cylinder

6. No.6 cylinder

7. LH (No.1) bank

8. RH (No.2) bank

9. Crank shaft pulley side

General Information on Engine Service

CAUTION:

The following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reliable engine performance.

• When raising or supporting engine for any reason, do not use a jack under oil pan. Due to small clearance between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer 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 could possibly be grounded, ground cable of the battery should be disconnected at battery.

• Any time the air cleaner, air cleaner outlet hose, throttle body, surge tank pipe, intake collector 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.


• When disconnecting couplers, don’t pull wire harness but make sure to hold coupler itself. With lock type coupler, be sure to unlock before disconnection. Attempt to disconnect coupler without unlocking may result in damage to coupler.

When connecting lock type coupler, insert it till clicking sound is heard and connect it securely.

Precaution on Fuel System Service

• Work must be done with no smoking, in a well-ventilated area and away from any open flames.

• As fuel feed line (between fuel pump and fuel pressure regulator) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected. Before loosening or disconnecting fuel feed line, make sure to release fuel pressure according to “FUEL PRESSURE RELIEF PROCEDURE” in this section.

A small amount of fuel may be released after the fuel line is disconnected.

In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop cloth. Put that cloth in an approved container when disconnection is completed.

• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.

• Fuel or fuel vapor hose 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 left figure.

After connecting, make sure that the hose 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 far 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

“a” : Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.

“b” : 20 to 30 mm (0.79 – 1.18 in.)

• When installing fuel union bolt gasket, always use new gasket and tighten union bolt to specified torque according to

“TIGHTENING TORQUE SPECIFICATION” in Section 6C.

• When installing injector, fuel feed pipe or fuel pressure regulator, lubricate its O-ring with gasoline.

• When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified torque.


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, relief fuel pressure as follows.

1) Place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T vehicle), set parking brake, and block drive wheels.

2) Remove fuel pump relay (1) from its connector.

3) Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it.

4) Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2 – 3 times of about 3 seconds each time to dissipate fuel pressure in lines. Fuel connections are now safe for servicing.

5) Upon completion of servicing, install fuel pump relay to relay box.

[A] : Left hand steering vehicle

[B] : Right hand steering vehicle

2. Fuse box

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 return 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 (PCM).

The engine and emission control system in this vehicle are controlled by ECM (PCM). ECM (PCM) 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” in this section.

There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust system, etc. and the engine and emission control system in their structure and operation. In case of an engine trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to

“ENGINE DIAGNOSTIC FLOW TABLE” in this section.

On-Board Diagnostic System (Vehicle without

Monitor Connector)

ECM (PCM) in this vehicle has following functions.

• 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 (PCM) 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 (PCM) 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.)

1. TROUBLE CODE

2. COOLANT TEMP.

3. ENGINE SPEED

4. SHORT FT B1

5. SHORT FT B2

6. LONG FT B1

7. LONG FT B2

8. CALC LOAD

9. FUEL SYSTEM B1

10. FUEL SYSTEM B2

11. MAP

12. VEHICLE SPEED

P0100

80 C

750 RPM

– 0.8

– 0.1

– 1.3

– 1.5

20.5

CLOSED

CLOSED

30.6 kPa

0 km/h

(1st)

1


WARM-UP CYCLE

A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22°C (40°F) from engine starting and reaches a minimum temperature of 70 °C

(160 °F).

DRIVING CYCLE

A “Driving Cycle” consists of engine startup, driving mode where a malfunction would be detected if present and engine shutoff.

2 DRIVING CYCLE DETECTION LOGIC

The malfunction detected in the first driving cycle is stored in

ECM (PCM) memory (in the form of pending DTC) but the 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 (PCM) stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”.

Therefore, it is possible to know engine and driving conditions

(e.g., whether the engine was warm or not, where the vehicle was running or stopped, where air/fuel mixture was lean or rich) when a malfunction was detected by checking the freeze frame data.

Also, ECM (PCM) has a function to store each freeze frame data for three different malfunctions in the order as the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been detected. Its use is helpful when rechecking or diagnosing a trouble.

1. 1st, 2nd or 3rd in parentheses here represents which position in the order the malfunction is detected.


Priority of Freeze Frame Data

ECM (PCM) has 4 frames where the freeze frame data can be stored. The first frame stores the freeze frame data of the malfunction which was detected first. However, the freeze frame data stored in this frame is updated according to the priority described below. (If malfunction as described in the upper square “1” below is detected while the freeze frame data in the lower square “2” has been stored, the freeze frame data “2” will be updated by the freeze frame data “1”.)

PRIORITY

1

2

FREEZE FRAME DATA IN FRAME 1

Freeze frame data at initial detection of malfunction among misfire detected (P0300-P0306), fuel system too lean (P0171, P0174) and fuel system too rich (P0172, P0175)

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 regardless of the priority.

Shown in the table below are examples of how freeze frame data are stored when two or more malfunctions are detected.

1

2

3

4

No malfunction No freeze frame data

P0110 (IAT) detected

P0171 (Fuel system) detected

P0300 (Misfire) detected

P0301 (Misfire) detected

FRAME 1

FREEZE FRAME

DATA to be updated

Data at P0110 detection




FRAME 2

1st FREEZE

FRAME DATA

No freeze frame data





FRAME 3

2nd FREEZE

FRAME DATA






FRAME 4

3rd FREEZE

FRAME DATA






Freeze Frame Data Clearance

The freeze frame data is cleared at the same time as clearance of DTC.

DATA LINK CONNECTOR (DLC)

DLC (1) is in compliance with SAEJ1962 in its installation position, the shape of connector and pin assignment.

K line of ISO 9141 is used for SUZUKI scan tool or generic scan tool to communicate with ECM (PCM), ABS control module and

Air bag SDM. SUZUKI serial data line is used for SUZUKI scan tool to communicate with Immobilizer control module.

2. B+

3. SUZUKI Serial data line

4. K line of ISO 9141

5. Body ground

6. ECM ground


On-Board Diagnostic System (Vehicle with


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 of flashing malfunction indicator lamp (1).

• Heated oxygen sensor (if equipped)

• ECT sensor

• TP sensor

• IAT sensor

• CMP sensor

• MAF sensor

• Knock sensor

• EGR (if equipped)

• VSS

• CPU (Central Processing Unit) of ECM

ECM and malfunction indicator lamp (1) operate as follows.

• Malfunction indicator lamp (1) light 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.)

ECM also indicates trouble area in memory by means of flashing of malfunction indicator lamp (1) at the time of inspection. (i.e. when diagnosis switch terminal (2) is connected to ground terminal (3) with a service wire 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 the trouble exists but it turns

OFF when the normal condition is restored.


DATA LINK CONNECTOR (DLC)

DLC (1) is in compliance with SAEJ1962 in its installation position, the shape of connector and pin assignment.

K line of ISO 9141 is used for SUZUKI scan tool to communicate with ECM (PCM), ABS control module and air bag SDM. SUZUKI serial data line is used for SUZUKI scan tool to communicate with

Immobilizer control module.

2. B+

3. SUZUKI Serial data line

4. K line of ISO 9141

5. Body ground

6. ECM ground

Precaution in Diagnosing Trouble

• Don’t disconnect couplers from ECM (PCM), battery cable from battery, ECM (PCM) ground wire harness from engine or main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in

ECM (PCM) memory. Such disconnection will erase memorized information in ECM (PCM) memory.

• Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.

• Priorities for diagnosing troubles (Vehicle without monitor connector)

If two or more diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which was detected earliest in the order and follow the instruction in that table.

If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.

– Diagnostic trouble codes (DTCs) other than DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too rich), DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire detected) and DTC P0400 (EGR flow malfunction)

– DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too rich) and DTC P0400 (EGR flow malfunction)

– DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire detected)

• Be sure to read “PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A before inspection and observe what is written there.

• ECM (PCM) Replacement

When substituting a known-good ECM (PCM), check for following conditions. Neglecting this check may cause damage to a known-good ECM (PCM).

– Resistance value of all relays, actuators is as specified respectively.

– MAF sensor, MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted to ground.


Engine Diagnostic Flow Table

Refer to following pages for the detail of each step.

Step Action

1 Customer Complaint Analysis

1) Perform customer complaint analysis.

Was customer complaint analysis performed?

2 DTC(s)/Freeze Frame Data Check

1) Check DTC(s)/Freeze frame data.

Is there any malfunction DTC(s)?

3 Visual Inspection

1) Perform visual inspection.

Is there any faulty condition?

4 Visual Inspection

1) Perform visual inspection.


5 Trouble Symptom Confirmation

1) Confirm trouble symptom based on customer complaint analysis, DTC(s)/freeze frame data in Step 1.


6 DTC/Freeze Frame Data Recheck

1) Recheck DTC/freeze frame data.


7 DTC/Freeze Frame Data Recheck

1) Recheck DTC/freeze frame data.


8 Engine Basic Inspection

1) Check and repair according to “ENGINE

BASIC INSPECTION FLOW TABLE” and

“ENGINE DIAGNOSIS TABLE” in this section.

Are check and repair complete?

9 DTC Trouble Shooting

1) Check and repair according to applicable

“DTC Diag. flow table” in this section.


10 Intermittent Problems Check

1) Check for intermittent problems referring to

“Check for Intermittent Problem” in “GEN-

ERAL INFORMATION” section.


11 Final Confirmation Test

1) Clear DTC if any.

2) Perform final confirmation test referring to

“DTC CONFIRMATION PROCEDURE” in this section.

Is there any problem symptom, malfunction

DTC or abnormal condition?

Yes

Go to Step 2.

Record DTC(s)/Freeze frame data.

Clear DTC(s).

Go to Step 3.

Repair or replace malfunction part.

Go to Step 11.


Go to Step 11.

Go to Step 6.

Go to Step 9.

Go to Step 9.

Go to Step 11.

Go to Step 11.


Go to Step 11.

Go to Step 6.

No

Perform customer complaint analysis.

Go to Step 4.

Go to Step 5.

Go to Step 8.

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.

Go to Step 11.

END.


STEP 1. CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.

NOTE:

The above form is a standard sample. It should be modified according to conditions characteristic of each market.


STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK

First, check DTC, referring to “DIAGNOSTIC TROUBLE CODE CHECK” in this section. If DTC is indicated, record DTC and freeze frame data.

After that clear DTC referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now. To check which case applies, check the symptom in question according to Step 5 and recheck DTC according to Step 6, 7.

Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC (including pending DTC) in this step will lead to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.

NOTE:

For A/T vehicle, if only DTC P0705, P0715, P0720, P0741, P0743, P0751, P0753, P0756, P0758, or P1875 is indicated in this step, proceed to “DIAGNOSIS” in SECTION 7B1.

STEP 3. and 4. VISUAL INSPECTION

Be sure to perform visual check of the following items that support proper function of the engine.

INSPECTION ITEM

• Engine oil - - - - - level, leakage

• Engine coolant - - - - - level, leakage

• Fuel - - - - - level, leakage

• A/T fluid - - - - - level, leakage

• Air cleaner element - - - - - dirt, clogging

• Battery - - - - - fluid level, corrosion of terminal

• Water pump belt and/or cooling fan belt - - - - - tension, damage

• Accelerator cable - - - - - play, installation

• A/T throttle cable - - - - - play, installation

• Vacuum hoses of air intake system

- - - - - disconnection, looseness, deterioration, bend

• Connectors of electric wire harness - - - - - disconnection, friction

• Fuses - - - - - burning

• Parts - - - - - installation, bolt - - - - - looseness

• Parts - - - - - deformation

• Other parts that can be checked visually

• Also check following items at engine start, if possible

– Malfunction indicator lamp - - - - - operation

– Charge warning lamp - - - - - operation

– Engine oil pressure warning lamp - - - - - operation

– Engine coolant temp. meter - - - - - operation

– Fuel lever meter - - - - - operation

– Abnormal air being inhaled from air intake system

– Exhaust system - - - - - leakage of exhaust gas, noise

– Other parts that can be checked visually

REFERRING SECTION

SECTION 0B

SECTION 0B

SECTION 0B

SECTION 0B

SECTION 0B

SECTION 0B

SECTION 6C

SECTION 6E2

SECTION 6E2

SECTION 6A2

SECTION 8

SECTION 6-1

SECTION 6H

SECTION 8/6A2

SECTION 8

SECTION 8

STEP 5. TROUBLE SYMPTOM CONFIRMATION

Based on information obtained in Step 1 “CUSTOMER COMPLAINT ANALYSIS” and Step 2 “DTC/FREEZE

FRAME DATA CHECK”, confirm trouble symptoms. Also, reconfirm DTC according to “DTC CONFIRMATION

PROCEDURE” described in each “DTC FLOW TABLE”.


STEP 6. AND 7. RECHECKING AND RECORD OF DTC

Refer to “DTC Check” in this section for checking procedure.

STEP 8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE

Perform basic engine check according to the “ENGINE BASIC INSPECTION FLOW TABLE” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referring to

“ENGINE DIAGNOSIS TABLE” and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or replace faulty parts, if any.

Engine Basic Inspection Flow Table

Step Action

1 Was “ENGINE DIAG. FLOW TABLE” performed?

Yes

Go to Step 2.

No

Go to “ENGINE DIAG.

FLOW TABLE” in this section.

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 engine idle speed/IAC duty referring to

“IDLE SPEED/IAC DUTY INSPECTION” in

Section 6E2.

Is check result as specified?

6 Check ignition timing referring to “IGNITION

TIMING INSPECTION” in Section 6F2.


7 Check fuel supply as follows :

1) Check to make sure that enough fuel is filled in fuel tank.

2) Turn ON ignition switch for 3 seconds and then OFF.

Repeat this a few times.

Is fuel return pressure (returning sounds) felt from fuel return hose when ignition switch is turned ON?

8 Check fuel pump for operating.

1) Was fuel pump operating sound heard from fuel filler for about 3 seconds after ignition switch ON and stop?

9 Check ignition spark referring to “IGNITION

SPARK TEST” in Section 6E2.


10 Check fuel injector referring to “Fuel INJECTOR

INSPECTION” in Section 6E2.


Go to Step 5.

Go to Step 6.

Go to “ENGINE DIAGNO-

SIS TABLE” in this section.

Go to Step 9.

Go to “DIAG. FLOW

TABLE B-3” in this section.

Go to Step 10.



Go to “DIAGNOSIS” in

Section 6H.

Go to Step 7.



Adjust ignition timing.

Go to Step 8.

Go to “DIAG. FLOW


Go to “DIAGNOSIS” in

Section 6F2.

Go to “DIAG. FLOW



STEP 9. TROUBLESHOOTING FOR DTC

Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM (PCM) or other part and repair or replace faulty parts.

STEP 10. CHECK FOR INTERMITTENT PROBLEM


“INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in step 2.

STEP 11. FINAL CONFIRMATION TEST

Confirm that the problem symptom has gone and the 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 malfunction DTC (a normal code) is indicated.


Malfunction Indicator Lamp (MIL) Check

1) Turn ON ignition switch (but the engine at stop) and check that MIL (1) lights.

If MIL does not light up, go to “Diagnostic Flow Table A-1” for troubleshooting.

2) Start engine and check that MIL turns OFF.

3) If MIL remains ON, and no DTC is stored in ECM (PCM), go to “Diagnostic Flow Table A-2” for troubleshooting.

Diagnostic Trouble Code (DTC) Check

[Using SUZUKI scan tool]

1) Prepare generic scan tool or SUZUKI scan tool (2).

2) With ignition switch OFF, connect it to data link connector

(DLC) (3) located on underside of instrument panel at driver’s seat side.

Special tool


3) Turn ignition switch ON and confirm that MIL lights.

4) Read DTC and freeze frame data according to instructions displayed on scan tool and print them or write them down.

Refer to scan tool operator’s manual for further details.

If communication between scan tool and ECM (PCM) is not possible, check if scan tool is communicable by connecting it to ECM (PCM) 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 with Monitor

Connector)

1) Check malfunction indicator lamp referring to “Malfunction

Indicator Lamp Check” in this section.

2) With the ignition switch OFF position, disconnect SUZUKI scan tool if connected and using service wire (4), connect diagnosis switch terminal (1) to ground terminal (2) in monitor connector (3).

3) With the ignition switch ON position and leaving engine OFF, read DTC from flashing pattern of malfunction indicator lamp. Refer to “Diagnostic Trouble Code Table”.

If lamp remains ON, go to “Diagnostic Flow Table A-4”.

NOTE:

• 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 scan tool]

1) With ignition switch OFF, connect generic scan tool or

SUZUKI scan tool to data link connector (DLC).


3) Erase DTC according to instructions displayed on scan tool.

Freeze frame data is cleared with the DTC. Refer to scan tool operator’s manual for further details.

4) After completing the clearance, turn ignition switch off and disconnect scan tool from data link connector.

NOTE:

DTC and freeze frame data stored in ECM (PCM) memory are also cleared in following cases. Be careful not to clear them before keeping their record.

• When power to ECM (PCM) is cut off (by disconnecting battery cable, removing fuse or disconnecting ECM

(PCM) connectors)

• When the same malfunction (DTC) is not detected again during 40 engine warm-up cycles (refer to

“WARM-UP CYCLE” of “ON-BOARD DIAGNOSTIC SYS-

TEM” in this section) (Vehicle without monitor connector)


[Without using scan tool]

1) Turn the ignition switch OFF position.

2) Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM memory and reconnect it.

Time required to erase DTC:

Ambient temperature

Time to cut power to ECM

Over 0°C (32°F) 30 sec. or longer

Under 0°C

(32°F)

Not specifiable.

Select a place with higher than 0°C

(32°F) temperature.

Diagnostic Trouble Code (DTC) Table

DTC NO.

DETECTED ITEM

DETECTING CONDITION

(DTC will set when detecting : )

P0100

(No.34) Mass air flow circuit malfunc-

P0100

(No.33) tion

P0110

(No.25) Intake air temp. circuit mal-

P0110

(No.23) function

P0115

(No.15) Engine coolant temp. circuit

P0115

(No.14) malfunction

P0120

(No.22) Throttle position circuit mal-

P0120

(No.21) function

P0121

Throttle position circuit performance problem

*P0130

**P0130

(No.13)

Sensor output too low

Sensor output too high

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

HO2S circuit malfunction

(Bank 1 - Sensor 1)

HO2S (Bank 1 - Sensor 1) no activity detected

Min. output voltage of HO2S-1 is higher than specification.

Min. output voltage of HO2S-1 is lower than specification.

Output voltage of HO2S-1 fails to go above specification.

Output voltage of HO2S-1 fails to go above specification (or HO2S-1 circuit open).

MIL

(vehicle without monitor connector)

MIL

(vehicle with monitor connector)

1 driving cycle

1 driving cycle

1 driving cycle

1 driving cycle

2 driving cycles

2 driving cycles

2 driving cycles

1 driving cycle

1 driving cycle

1 driving cycle

1 driving cycle

Not applicable

Not applicable

2 driving cycles


DTC NO.

DETECTED ITEM



P0133

P0135

P0136

P0141

*P0150

**P0150

(No.26)

P0153

P0155

P0156

P0161

P0171

P0172

HO2S circuit slow response

(Bank 1 - Sensor 1)

HO2S heater circuit malfunction (Bank 1 - Sensor 1)


(Bank 1 - Sensor 2)



(Bank 2 - sensor 1)

HO2S (Bank 2 - Sensor 1) no activity detected

HO2S circuit slow response

(Bank 2 - Sensor 1)



(Bank 2 - Sensor 2)


Fuel system too lean (Bank 1)

Fuel system too rich (Bank 1)

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.

Max. voltage of HO2S-2 is lower than specification or its min. voltage is higher than specification.

Terminal voltage is lower than specification at heater OFF or it is higher at heater ON.

Min. output voltage of HO2S-1 is higher than specification.

Min. output voltage of HO2S-1 is lower than specification.

Output voltage of HO2S-1 fails to go above specification.

Output voltage of HO2S-1 fails to go above specification (or HO2S-1 circuit open).

Response time HO2S-1 output voltage between rich and lean is longer than specification.

Terminal voltage i lower than specification at heater OFF or it is higher at heater ON.

Max. voltage of HO2S-2 is lower than specification or its min. 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 and long terms added) is smaller than specification for specified time or longer. (Fuel trim toward lean side is large.)

MIL


MIL


2 driving cycles

Not applicable

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

Not applicable

Not applicable

Not applicable

Not applicable

2 driving cycles

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable


DTC NO.

DETECTED ITEM



MIL


P0300

P0301

P0302

P0303

P0304

P0305

P0306

P0325

(No.43)

P0174

P0175

P0335

P0340

(No.42)

P0400

Fuel system too lean (Bank 2)

Fuel system too rich (Bank 2)


(short and long terms added) is larger than specification for specified time or longer. (Fuel trim toward rich side is large.)


(short and long terms added) is smaller than specification for specified time or longer. (Fuel trim toward lean side is large.)

Random misfire detected

Cylinder 1 misfire detected






Knock sensor circuit malfunction

Crankshaft position sensor circuit malfunction

Camshaft position 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

Sensor output too low

Sensor output too high

No signal during engine running and

CMP sensor signal inputting

No signal for 3 sec. during engine cranking, REF signal pattern incorrect or POS signal voltage too high or too low

Exhaust gas recirculation flow malfunction detected

Excessive or insufficient EGR flow.

P0403

(No.51)

P0420

P0430

P0443

P0500

(No.24)

EGR valve circuit malfunction

Catalyst system efficiency below threshold (Bank 1)

Catalyst system efficiency below threshold (Bank 2)

Purge control valve circuit malfunction

Vehicle speed sensor malfunction

EGR valve electrical circuit open or shot to ground

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.)

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.

No signal while running in “D” range or during fuel cut at decelerating.

2 driving cycles

2 driving cycles

MIL flashing during misfire detection

2 driving cycles

1 driving cycle

1 driving cycle

1 driving cycle

2 driving cycles

1 driving cycle

2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

MIL


Not applicable

Not applicable

Not applicable

Not applicable

1 driving cycle

Not applicable

Not applicable

Not applicable

1 driving cycle

Not applicable

Not applicable

Not applicable

1 driving cycle


DTC NO.

DETECTED ITEM



P0505

P0601

(No.71)

P1408

P1450

P1451

P1500

P1510

Idle air control system malfunction

Internal control module memory check sum error

Manifold absolute pressure sensor circuit malfunction

Barometric pressure sensor circuit malfunction

Barometric pressure sensor performance problem

Engine starter signal circuit malfunction

ECM back-up power supply malfunction

Difference between desired idle speed and actual idle speed continues to exceed specified value for longer than specified time.

Data write error (or check sum error) when written into ECM

Manifold absolute pressure sensor output voltage is higher or lower than specified value (or sensor circuit shorted to ground or open).

Barometric pressure is lower or higher than specification.

Difference between intake manifold pressure and barometric pressure is larger than specification.

Engine starts with no starter signal or signal input during long period after start.

No back-up power after starting engine.

MIL


MIL


2 driving cycles

1 driving cycle

2 driving cycles

1 driving cycle

2 driving cycles

2 driving cycles

1 driving cycle

Not applicable

1 driving cycle

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

For A/T system (Refer to Section 7B1 for diagnosis)

DTC NO.

DETECTED ITEM



P0705

(No.72)

P0715

(No.76)

P0720

(No.75)

P0741

P0743

(No.65)

(No.66)

P0751

Transmission range switch circuit malfunction

Input speed sensor circuit malfunction

Output speed sensor circuit malfunction

TCC (lock-up) solenoid performance or stuck off

TCC (lock-up) solenoid electrical

Shift solenoid A (#1) performance or stuck off

Multiple signals inputted simultaneously or P, R, N, D, 2 or L range signal not inputted while running at

60km/h or more.

Input speed sensor signal is lower than specification while running.

Output speed sensor signal not inputted while VSS signal being inputted.

Actual TCC operation does not agree with ON/OFF control from PCM to

TCC.

Monitor signal OFF is detected when

TCC control solenoid is ON or monitor signal ON is detected when it is OFF.

Gear change control from PCM to A/T does not agree with actual gear position of A/T.

MIL


MIL


2 driving cycles

2 driving cycles

2 driving cycles

2 driving cycles

1 driving cycle

2 driving cycles

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable


DTC NO.

DETECTED ITEM



P0753

(No.61)

(No.62)

P0756

P0758

(No.63)

(No.64)

P1875

Shift solenoid A (#1) electrical

Shift solenoid B (#2) performance or stuck off

Shift solenoid B (#2) electrical

4WD low switch circuit malfunction

Monitor signal OFF is detected when shift solenoid A (#1) is ON or monitor signal ON is detected when it is OFF.

Gear change control from PCM to A/T does not agree with actual gear position of A/T.

Monitor signal OFF is detected when shift solenoid B (#2) is ON or monitor signal ON is detected when it is OFF.

Difference between vehicle speed detected by VSS and vehicle speed detected by output speed sensor and compensated by 4WD low switch is larger than specification.

MIL


MIL


1 driving cycle

Not applicable

2 driving cycles

1 driving cycle

2 driving cycles

Not applicable

Not applicable

Not applicable

For immobilizer control system (Refer to Section 8G for diagnosis)

DTC NO.

DETECTED ITEM



MIL


MIL


P1620

(No.84)

P1621

(No.83)

P1622

(No.82)

P1623

(No.81)

ECU code not registered

NO ECU code transmitted from Immobilizer Control Module Refer to Section 8G

Fault ECM

ECU code not matched

NOTE:

• DTC NO. with (*) is detected only vehicle without monitor connector.

• DTC No. with (**) is detected only vehicle with monitor connector.

• For ( ) marked No. in DTC column, it is used for vehicle with monitor connector.

• DTC No.12 appears when none of the other codes is identified.


Fail-Safe Table

When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM (PCM) detects normal condition after that.

DTC NO.

P0100

(No.33, 34)

TROUBLE AREA

MAF SENSOR

FAIL SAFE OPERATION

• Injector drive time (fuel injection volume) is determined according to throttle valve opening and engine speed.

• EGR valve stops.

• Air flow of IAC valve is limited.

P0110

(No.23, 25)

P0115

(No.14, 15)

P0120

(No.21, 22)

• Each control except 4-A/T is performed on the basis of 29.9°C engine coolant temp.

• 4-A/T control is performed assuming 31°C (engine warmed up) or higher after 15 min. from engine start.

• Each control except 4-A/T is performed on the basis of 124.5° throttle valve opening.

• 4-A/T control is performed on the basis of 0° throttle valve opening.

P0460 FUEL LEVEL SENSOR Each control is performed in the basis of full fuel level.

VEHICLE SPEED

P0500 Air flow of IAC valve is limited.

SENSOR

P1450

BAROMETRIC

PRESSURE SENSOR

Each control is performed based on 760 mmHg barometric pressure.

P0705 TR SWITCH A/T control is performed in priority order of L, 2, N, D, R and P.

P0720

ECT SENSOR

TP SENSOR

OUTPUT SPEED

SENSOR CIRCUIT

MALFUNCTION

A/T control is performed by using signal from VSS.

P0753

P0758

SHIFT SOLENOID

A (#1)

SHIFT SOLENOID

B (#2)

• A/T control using 3rd gear is performed when D range, 1st, or 2nd gear is used.

• TCC solenoid OFF

• A/T control using 4th gear is performed when D range, 2nd or 3rd gear is used.

• When both shift solenoids A (#1) and B (#2) failed simultaneously,

A/T control using 4th gear is always performed in D range.

• TCC solenoid OFF

P0743

IAT SENSOR

TCC (Lock-up)

SOLENOID

Each control is performed on the basis of 22.1°C intake air temp.

TCC (Lock-up) solenoid OFF


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 output from ECM (PCM) as

Commands and there may be cases where the engine or actuator is not operating (in the condition) as indicated by the scan tool. Be sure to use the timing light to check the ignition timing referring to Section 6F2.

NOTE:

• For asterisk (

✱) marked item in “OTHER” column, item can be read only SUZUKI scan tool.

• When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park” position and pull the parking brake fully. Also, if nothing or “no load” is indicated, turn OFF A/C, all electric loads, P/S and all the other necessary switches.

SCAN TOOL DATA

COOLANT TEMP.

(Engine Coolant Temp.)

INTAKE AIR TEMP.

CONDITION

At specified idle speed after warming up


NORMAL CONDITION/

REFERENCE VALUE

80 – 100 °C

(176 – 212 °F)

Environmental temp.

+20 °C (+36 °F)

–5 °C (–9 °F)

700 rpm

OTHER

✱

DESIRE IDLE

(Desired idle speed)

CLOSED THROT POS

(Closed Throttle Position)

IAC FLOW DUTY

ENGINE SPEED

At idling with no load after warming up

With ignition switch ON, accelerator pedal released

With ignition switch ON, accelerator pedal depressed


At idling with no load after warming up

ON

OFF

5 – 40 %

Desired idle speed

± 50 rpm

✱

✱

SHORT FT B1

(Short term fuel trim)

SHORT FT B2

(Short term fuel trim)

LONG FT B1

(Long term fuel trim)

LONG FT B2

(Long term full trim)

IGNITION ADVANCE




At specified idle speed after warning up

–15 ~ +15 %

–15 ~ +15 %

–15 ~ +15 %

–15 ~ +15 %

BATTERY VOLTAGE

MAF (Mass Air Flow

Rate)

At specified idle speed with no load after warming up

Ignition switch ON/engine stopped

At specified idle speed with no load after warming up.

At 2500 r/min with no load after warming up.

6 – 17°

10 – 14 V

2.6 – 4.5 g/s

0.34 – 0.59 lb/min

10 – 16 g/s

1.32 – 2.11 lb/min

✱

INJ PULSE WIDTH B1

(Fuel Injection Pulse

Width)



2.0 – 3.3 msec

2.2 – 3.2 msec

✱


SCAN TOOL DATA CONDITION

INJ PULSE WIDTH B2 At specified idle speed with no load after warming up.


THROTTLE POS

(Absolute Throttle Position)

With ignition switch ON/warmed up engine stopped, accelerator pedal released

With ignition switch ON/warmed up engine stopped, accelerator pedal depressed fully

With ignition switch ON/warmed up engine stopped, accelerator pedal released

TP SENSOR VOLT

(TP Sensor Output Voltage)

O2S B1 S1

(HO2S-1 Output Voltage)

O2S B1 S2


O2S B2 S1


O2S B2 S2


With ignition switch ON/warmed up engine stopped, accelerator pedal depressed fully.


When engine is running at 2000 r/min. for 3 min or longer after warming up.



At specified idle speed after warming up.

FUEL SYSTEM B1

(Fuel System Status)

FUEL SYSTEM B2

(Fuel System Status)

CALC LOAD

(Calculated Load Value)





TOTAL FT TRIM B1

TOTAL FT TRIM B2

MAP




CANIST PRG DUTY

(EVAP Canister Purge

Flow Duty)

VEHICLE SPEED.

FUEL CUT

EGR VALVE

BLOWER FAN

PSP SWITCH

At stop.

When engine is at fuel cut condition

Other than fuel cut condition


Ignition switch ON, blower fan switch ON

Ignition switch ON, blower fan switch OFF

A/C CONDENSER FAN Ignition switch ON, A/C not operating

Ignition switch ON, A/C operating

Engine running at idle speed and steering wheel at straight ahead position

Engine running at idle speed and steering wheel turned to the right or left as far as it stops

A/C SWITCH

(if equipped)

When A/C not operating

When A/C operating


REFERENCE VALUE

2.0 – 3.3 msec

2.2 – 3.2 msec

9.8 – 18.2 %

OTHER

✱

72 – 87.2 %

0.49 – 0.91 V

3.76 – 4.36 V

0.05 – 0.95 V

0.05 – 0.95 V

0.05 – 0.95 V

0.05 – 0.95 V

Closed

Closed

10 – 25 %

14 – 23 %

–30 – +30 %

–30 – +30 %

25 – 35 kPa

0 %

0 km/h 0 MPH

ON

OFF

0 %

ON

OFF

OFF

ON

OFF

ON

OFF

ON

✱

✱

✱

✱

✱

✱

✱

✱

✱

✱


SCAN TOOL DATA CONDITION


REFERENCE VALUE

PNP SIGNAL (Transmission Range Switch) (for 4-

A/T)

FUEL TANK LEVEL

ELECTRIC LOAD

With ignition switch ON, selector lever in “P” or “N” position

With ignition switch ON, selector lever in “R”,

“D”, “2” or “L” position

Ignition switch ON

Ignition ON, small light OFF

Ignition switch ON, small light ON

At stop.

VSS (Vehicle speed sensor) (for 4-A/T)

GEAR POSITION (for 4-

A/T)

THROT POS LEVEL

(Throttle position level for

4-A/T)

SHIFT SOL #1 (A)

CON (Shift solenoid #1 command signal)

MON (Shift solenoid #1 monitor) (for 4-A/T)

SHIFT SOL #2 (B)

CON (Shift solenoid #2 command signal)

MON (Shift solenoid #2 monitor) (for 4-A/T)

TCC SOL (for 4-A/T)

CON (Torque converter clutch solenoid command signal)

MON (Torque converter clutch solenoid monitor)

TRANS RANGE

(for 4-A/T)

BRAKE SW

(Brake, stop lamp, switch)

(for 4-A/T)

O/D OFF SW

(Overdrive cut switch)

MODE SELECT SW

(Power/Normal change switch) (for 4-A/T)

4WD-L SW

(4WD low switch)

Ignition switch ON, selector lever is shifted at

“R”, “D”, “2” or “L” range and vehicle stops.

P/N Range

D Range

0 – 100 %

OFF

ON

0 km/h 0 MPH

1st

“0” (about idle position), “1”,“2”,“3”,“4”,“5”,“6” or “7” (about full open) appears according to throttle valve opening.

Ignition switch ON

Selector lever is shifted at “P”, “R”, “N”, “D”,

“2” or “L” range.

Vehicle stops.

Ignition switch ON



Vehicle stops.

Ignition switch ON



Vehicle stops.

Ignition switch ON, selector lever is at “P”,

“R”, “N”, “D”, “2” or “L” range.

Ignition switch ON, Brake pedal is released.

Ignition switch ON, Brake pedal is depressed.

Ignition switch ON, Overdrive cut switch OFF

Ignition switch ON, Overdrive cut switch ON

Ignition switch ON, P/N change switch is at normal position.

Ignition switch ON, P/N change switch is at power position.

Ignition switch ON, Transfer lever is shifted at “4H” or “2H” position.

Ignition switch ON, Transfer lever is shifted at “4L” position.

ON

OFF

OFF

P, R, N, D, 2 or L

OFF

ON

OFF

ON

NORMAL

POWER

OFF

ON

OTHER

✱

✱

✱

✱

✱

✱

✱

✱

✱

✱

✱

✱

✱

✱

✱


Scan tool data definitions

COOLANT TEMP (Engine Coolant Temp., °C/°F)

It is detected by engine coolant temp. sensor.

INTAKE AIR TEMP (°C/°F)

It is detected by intake air temp. sensor.

DESIRE IDLE (Desired Idle Speed RPM)

The desired idle speed is an ECM (PCM) internal parameter which indicates the ECM (PCM) requested idle. If the engine is not running, the number is not valid.

CLOSED THROT POS (Closed Throttle Position ON/OFF)

This parameter will read ON when the throttle valve is fully closed. Or OFF when the throttle is not fully closed.

IAC FLOW DUTY (%)

This parameter indicates IAC valve opening rate which controls bypass air flow.

ENGINE SPEED (RPM)

It is computed by reference pulses from the Camshaft Position Sensor.

SHORT FT B1 (Short Term Fuel Trim Bank 1, %) / SHORT FT B2 (Short Term Fuel Trim Bank 2, %)

Short term fuel trim value represents short term corrections to the air/fuel mixture computation. A value of 0 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 Bank 1, %) / LONG FT B2 (Long Term Fuel Trim Bank 2, %)

Long term fuel trim value represents long term corrections to the air/fuel mixture computation. A value of 0 indicates no correction, a value greater than 0 means an enrichment correction, and a value less than 0 implies an enleanment correction.

IGNITION ADVANCE (Ignition Timing Advance For No.1 Cylinder, °)

Ignition timing of No.1 cylinder is commanded by ECM (PCM). The actual ignition timing should be checked by using the timing light.

BATTERY VOLTAGE (V)

This parameter indicates battery positive voltage inputted from main relay to ECM (PCM).

MAF (Mass Air Flow Rate, g/s, lb/min)

It represents total mass of air entering intake manifold which is measured by mass air flow sensor.

INJ PULSE WIDTH B1 (Fuel Injection Pulse Width Bank 1, msec) / INJ PULSE WIDTH B2 (Fuel Injection Pulse Width Bank 2, msec)

This parameter indicates time of the injector drive (valve opening) pulse which is output from ECM (PCM).

THROTTLE POS (Absolute Throttle Position, %)

When throttle position sensor is fully closed position, throttle opening is indicated as 0 % and 100 % for full open position.


TP SENSOR VOLT (TP Sensor Output Voltage, V)

Throttle Position Sensor reading provides throttle valve opening information in the from of voltage.

O2S B1 S1 (HO2S Bank 1 Sensor 1 Output Voltage, V) / O2S B2 S1 (HO2S Bank 2 Sensor 1 Output

Voltage, V)

It indicates output voltage of HO2S SENSOR 1 installed on exhaust manifold (pre-catalyst).

O2S B1 S2 (HO2S Bank 1 Sensor 2 Output Voltage, V) / O2S B2 S2 (HO2S Bank 2 Sensor 2 Output

Voltage, V)

If indicates output voltage of HO2S SENSOR 2 installed on exhaust pipe (post-catalyst). It is used to detect catalyst deterioration.

FUEL SYSTEM B1 (Fuel System Bank 1 Status) / Fuel System B2 (Fuel System Bank 2 Status)

Air/fuel ratio feedback loop status displayed as one of the followings.

OPEN : Open loop-has not yet satisfied conditions to go closed loop.

CLOSED : Closed loop-using oxygen sensor(s) as feedback for fuel control.

OPEN-DRIVE COND : Open loop due to driving conditions (Power enrichment, etc.).

OPEN SYS FAULT : Open loop due to detected system fault.

CLOSED-ONE O2S : Closed loop, but fault with at least one oxygen sensor may be using single oxygen sensor for fuel control.

CALC LOAD (Calculated Load Value, %)

Engine load displayed as a percentage of maximum possible load. Value is calculated mathematically using the formula : actual (current) intake air volume ÷ maximum possible intake air volume x 100%.

TOTAL FUEL TRIM (%)

The value of total fuel trim is obtained by putting values of short term fuel trim and long term fuel trim together.

This value indicates how much correction is necessary to keep the air/fuel mixture stoichiometrical.

CANIST PRG DUTY (EVAP Canister Purge Flow Duty, %)

This parameter indicates valve ON (valve open) time rate within a certain set cycle of EVAP canister purge valve which controls the amount of EVAP purge.

VEHICLE SPEED (km/h, MPH)

It is computed based on pulse signals from vehicle speed sensor on transfer or transmission.

FUEL CUT (ON/OFF)

ON : Fuel being cut (output signal to injector is stopped).

OFF : Fuel not being cut.

MAP (Manifold Absolute Pressure, mmHg, kPa)

This parameter indicates the pressure in the intake manifold absolute pressure.

A/C CONDENSER FAN (ON/OFF)

This parameter indicates the state of the A/C Condenser Fan control signal.

BLOWER FAN (ON/OFF)

This parameter indicates the state of the blower fan motor switch.


EGR VALVE (%)

This parameter indicates opening rate of EGR valve which controls the amount of EGR flow.

A/C SWITCH (ON/OFF)

ON : Command for operation being output from A/C amplifier to compressor.

OFF : Command for operation not being output.

PSP SWITCH (ON/OFF)

ON : PSP switch detects P/S operation. (high P/S pressure)

OFF : PSP switch not detects P/S operation.

PNP SIGNAL (Transmission Range Switch, P/N or D range)

Whether the transmission range switch (P/N position switch) at P or N range or at R, D, 2 or L range is displayed.

If at P or N range, “P/N range” is displayed and if at R, D, 2 or L range, “D range” is displayed.

FUEL TANK LEVEL (%)

This parameter indicates approximate fuel level in the fuel tank. As the detectable range of the fuel level sensor is set as 0 to 100 %, however, with some models whose fuel tank capacity is smaller, the indicated fuel level may be only 70 % even when the fuel tank is full.

ELECTRIC LOAD (ON/OFF)

ON : Small light switch ON or rear window defogger switch ON.

OFF : Small light switch OFF and rear window defogger switch OFF.

VSS (4-A/T) (km/h, MPH)

It is computed by using pulse signals from vehicle speed sensor on 4-speed automatic transmission.

THROT POS LEVEL (Throttle Position Level For 4-A/T, “0”, “1”, “2”, “3”, “4”,“5”,“6” or “7”)

This parameter indicates which level (zone) the throttle valve opening is in.

The throttle opening is divided into 8 levels (zones) from “0” (about idle position) to “7” (about full open) and signals are assigned to each opening level (zone). PCM controls the automatic gear change of the automatic transmission by using these signals according to the signal from the TP sensor.

GEAR POSITION (1ST, 2ND, 3RD or 4TH)

The gear position is determined on the basis of the command state signals generated from PCM to shift solenoids A and B (#1 and #2) and displayed as shown in the table below.

DISPLAY

1ST

2ND

3RD

4TH

SHIFT SOLENOID-A SHIFT SOLENOID-B

ON OFF

ON

OFF

OFF

ON

ON

OFF

SHIFT SOL #1 CON/MON (Shift Solenoid #1, A Command/monitor, ON/OFF)

CON-ON : ON command being output to shift solenoid #1, A.

CON-OFF : ON command not being output.

MON-ON : Electricity being passed to shift solenoid #1, A.

MON-OFF : Electricity not being passed.


SHIFT SOL #2 CON/MON (Shift Solenoid #2, B Command/monitor, ON/OFF)

CON-ON : ON command being output to shift solenoid #2, B.


MON-ON : Electricity being passed to shift solenoid #2, B.


TCC SOL CON/MON (Torque Converter Clutch Solenoid Command/monitor, ON/OFF)

CON-ON : ON command being output to TCC solenoid.


MON-ON : Electricity being passed to TCC solenoid.


TRANS RANGE (Transmission Range, P, R, N, D, 2 or L)

It indicates transmission range according to transmission range switch signal.

BRAKE SW (Brake, Stop Lamp, Switch, ON/OFF)

OFF : Brake pedal is released.

ON : Brake pedal is depressed.

O/D OFF SW (Overdrive Cut Switch, ON/OFF)

OFF : Overdrive cut switch OFF.

ON : Overdrive cut switch ON.

MODE SELECT SW (Power/normal Change Switch, Power/normal)

POWER : Switch button is at POWER position.

NORMAL : Switch button is at NORMAL position.

4WD-L SW (4WD-LOW Switch, ON/OFF)

ON : Transfer lever is shifted to 4L position.

OFF : Transfer lever is shifted to 4H or 2H position.


Engine Diagnosis Table

Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously.

Condition

Hard starting

(Engine cranks OK)

Possible Cause

Faulty idle air control system

Faulty ECT sensor or MAF sensor

Faulty ECM (PCM)

Low compression

Faulty hydraulic valve lash adjuster

Compression leak from valve seat

Sticky valve stem

Weak or damaged valve springs

Compression leak at cylinder head gasket

Sticking or damaged piston ring

Correction

“DIAG. FLOW TABLE B-4” in this section.

ECT sensor or MAF sensor in Section 6E2.

Inspection of ECM (PCM) and its circuit in this section.

Compression check in Section

6A2.

Valve lash adjuster in Section 6A2.

Valves inspection in Section 6A2.


Valves spring inspection in Section

6A2.

Cylinder head inspection in Section

6A2.

Piston ring inspection in Section

6A2.

Engine has no power

Worn piston, ring or cylinder

Malfunctioning PCV valve

Engine overheating

Defective spark plug

Faulty ignition coil with ignitor

Fuel pressure out of specification

(dirty fuel filter, dirty or clogged fuel hose or pipe, malfunctioning fuel pressure regulator, malfunctioning fuel pump)

Cylinders, pistons and piston rings inspection in Section 6A2.

PCV system inspection in Section

6E2.

Refer to “OVERHEATING” in this table.

Spark plugs in Section 6F2.

Ignition coil in Section 6F2.


Maladjusted TP sensor installation angle

Faulty EGR system

Low compression

TP sensor in Section 6E2.

“DTC P0400 DIAG. FLOW TABLE” in this section.

Fuel injector in Section 6E2.

Faulty injector

Faulty TP sensor, ECT sensor or MAF sensor TP sensor, ECT sensor or MAF sensor in Section 6E2.

Faulty ECM (PCM) Inspection of ECM (PCM) and its circuit in this section.

Refer to the same item in “HARD

Dragging brakes

Slipping clutch

STARTING” of this table.

Diagnosis in Section 5.

Diagnosis in Section 7C1.


Condition

Improper engine idling or engine fails to idle

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.)

Possible Cause

Faulty spark plug

Faulty ignition coil with ignitor


Correction


Ignition coil in Section 6F2.


Engine overheating Refer to “OVERHEATING” in this table.

TP sensor in Section 6E2.

Maladjusted TP sensor installation angle if adjustable

Faulty idle air control system

Faulty FIA (fast idle air) valve

Faulty evaporative emission control system

Faulty EGR system

Malfunctioning PCV valve

6E2.


Fuel injection in Section 6E2.

Faulty injector

Faulty ECT sensor, TP sensor or MAF sensor ECT sensor, TP sensor or MAF sensor in Section 6E2.

Faulty ECM (PCM) Inspection of ECM (PCM) and its circuit in this section.

Low compression Refer to the same item in “HARD


PCV system inspection in Section

6E2.


Spark plug faulty or plug gap as out of adjustment


(clogged fuel filter, faulty fuel pressure regula-


tor, clogged fuel filter, hose or pipe)

Engine overheating


FIA valve in Section 6E2.

EVAP control system in Section

Faulty EGR system



Faulty injector

Faulty ECM (PCM)




Low compression Refer to the same item in “HARD



Condition

Surges

(Engine power variation under steady throttle or cruise.

Feels like the vehicle speeds up and down with no change in the accelerator pedal.)

Excessive detonation

(The engine makes sharp metallic knocks that change with throttle opening. Sounds like pop corn popping.)

Overheating

Possible Cause

Defective spark plug

(excess carbon deposits, improper gap, and burned electrodes, etc.)

Variable fuel pressure

(clogged fuel filter, kinky or damaged fuel hose and line, faulty fuel pressure regulator)

Faulty EGR system

Correction



Faulty MAF sensor

Faulty injector

Faulty ECM (PCM)

Engine overheating

Faulty spark plug

Improper ignition timing

Clogged fuel filter and fuel lines

Faulty EGR system

Faulty ECT sensor or MAF sensor

Faulty injector

Faulty ECM (PCM)

Excessive carbon deposits in combustion chamber

Poor knock sensor performance

Inoperative thermostat

Poor water pump performance

Clogged or leaky radiator

Improper engine oil grade

Clogged oil filter or oil strainer

Poor oil pump performance

Dragging brakes

Slipping clutch

Blown cylinder head gasket


MAF sensor in Section 6E2.





Ignition timing in Section 6F2.

Fuel pressure check in Section

6E2.


ECT sensor or MAF sensor in Section 6E2.



Piston and cylinder head cleaning in Section 6A2.


Thermostat in Section 6B.

Water pump in Section 6B.

Radiator in Section 6B.

Engine oil and oil filter change in

Section 0B.

Oil pressure check in Section 6A2.

Oil pressure check in Section 6A2.



Cylinder head inspection in Section

6A2.



Poor gasoline mileage Faulty spark plug (improper gap, heavy deposits, and burned electrodes, etc.)


Correction




Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”

Faulty injector

Faulty ECM (PCM) in this section.



Excessive engine oil consumption

Low oil pressure

Low compression

Poor valve seating

Dragging brakes

Slipping clutch

Thermostat out of order

Improper tire pressure

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

Refer to the same item in “HARD





Thermostat in Section 6B.


Piston cleaning in Section 6A2.

Cylinders, pistons and piston rings inspection in Section 6A2.

Pistons and piston rings inspection in Section 6A2.

Pistons installation in Section 6A2.

Valves and cylinder head in Section 6A2.


Malfunctioning oil pressure switch

Clogged oil strainer

Functional deterioration of oil pump

Worn oil pump relief valve

Excessive clearance in various sliding parts

Engine oil and oil filter change in

Section 0B.

Oil pressure switch inspection in

Section 8.

Oil pan and oil pump strainer cleaning in Section 6A2.

Oil pump in Section 6A2.

Oil pump in Section 6A2.

“INSPECTION” for each parts in

Section 6A2.

Condition

Engine noise

(Note : Before checking the mechanical noise, make sure the followings : Ignition timing is properly adjusted, Specified spark plug is used,

Specified fuel is used.)

Possible Cause

Faulty hydraulic valve lash adjuster

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

Low oil pressure

Worn crankshaft journal


Loose connecting rod nuts

Worn crankshaft journal bearing

Loose lower crankcase (bearing cap) bolts

Excessive crankshaft thrust play

Correction

Hydraulic valve lash adjuster in

Section 6A2.


Valve springs inspection in Section

6A2.


Camshafts in Section 6A2.

Pistons and cylinders inspection in

Section 6A2.

Crankpin and connecting rod bearing inspection in Section 6A2.

Crankpin and connecting rod bearing inspection in Section 6A2.

Connecting rod installation in Section 6A2.

Refer to “LOW OIL PRESSURE” of this table.

Crankshaft and bearing inspection in Section 6A2.

Crankshaft and bearing inspection in Section 6A2.

Crankshaft installation in Section

6A2.

Crankshaft inspection in Section

6A2.


Inspection of PCM (ECM) and its Circuits

PCM (ECM) and its circuits can be checked at PCM (ECM) wiring couplers by measuring voltage and resistance.

CAUTION:

PCM/ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to PCM (ECM) with couplers disconnected from it.

VOLTAGE CHECK

1) Remove PCM (ECM) cover from bracket referring to PCM

(ECM) REMOVAL.

2) Check voltage at each terminal of couplers connected.

NOTE:

As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when ignition switch is ON.

1. PCM (ECM)

2. PCM (ECM) connector (Viewed from harness side)


TERMINAL

E61-1

E61-4

CIRCUIT

Power source for CO adjusting resistor (if equipped)

E61-2 Power source for back up

E61-3 –

Cruise control module

(throttle opening signal)

(if equipped)

E61-5

Duty output terminal

(vehicle with monitor connector)

E61-6 Tachometer

E61-7

Malfunction indicator lamp

(“SERVICE ENGINE SOON” lamp)

E61-8

E61-9

A/C cut signal (if equipped)

Main relay

NORMAL VOLTAGE

10 – 14 V

0 – 2 V

–

–

CONDITION

Ignition switch ON

10 – 14 V

–

Ignition switch ON and OFF

–

Ignition switch ON, Voltage varies as specified at figure in cruise control diagnosis of Section 8E while throttle valve is opened gradually.

0 – 1 V

0 – 1 V

0 – 2.5 V

10 – 14 V

0 – 1.5 V

10 – 14 V

10 – 14 V

Ignition switch ON

Ignition switch ON, engine stops

Ignition switch ON, engine stops

Engine running

A/C is not operating

A/C is operating

Ignition switch OFF

Ignition switch ON or for 4 seconds after ignition switch OFF

–

–

E61-10 CO adjusting resistor (if equipped)

E61-11 –

E61-12

Data link connector (5V)

(Vehicle with monitor connector)

E61-13 Data link connector (12V)

E61-14

Test switch terminal

(Vehicle with monitor connector)

4 – 6 V

10 – 14 V

10 – 14 V

Ignition switch ON

Scan tool not connected to DLC

Ignition switch ON

E61-15

E61-16

E61-17

E61-18

E61-19

E61-20

E61-21

Rear defogger switch (if equipped)

Heater blower switch

A/C signal (if equipped)

“4WD” lamp

–

“O/D OFF” lamp (A/T vehicle)

“POWER” lamp (A/T vehicle)

0 – 1.5 V

10 – 14 V

10 – 14 V

0 – 1.5 V

10 – 14 V

0 – 1 V

–

0 – 1 V

10 – 14 V

0 – 1 V

10 – 14 V

0 – 1 V

10 – 14 V

Ignition switch ON, rear defogger switch OFF

Ignition switch ON, rear defogger switch

Ignition switch ON, heater blower switch OFF

Ignition switch ON, heater blower switch ON

Ignition switch ON, A/C switch or heater blower switch OFF

Ignition switch ON, A/C switch ON and heater blower switch ON

–

Ignition switch ON, Transfer lever :

4H or 4L range


2H range

For 4 sec. after ignition switch ON or overdrive cut switch ON

After 4 sec. from ignition switch ON and overdrive cut switch OFF

Ignition switch ON, P/N change switch : POWER mode

Ignition switch ON, P/N change switch : NORMAL mode


TERMINAL

E61-22

E61-23

E61-24

E61-25

E61-26

E61-27

Ground for CO adjusting resistor

(if equipped)

–

–

–

E61-28 Fuel level sensor

E61-29

Diag. switch terminal

(vehicle with monitor connector)

E61-30 ABS control module

E61-31

E61-32

E61-33

E61-34

CIRCUIT

A/C condenser fan motor relay

(if equipped)

Fuel pump relay

Power/Normal change switch

(A/T vehicle)

Lighting switch

Overdrive cut switch (A/T vehicle)

Stop lamp switch

E61-35 Cruise control module (if equipped)

NORMAL VOLTAGE

10 – 14 V

0 – 2.5 V

10 – 14 V

CONDITION

Ignition switch ON, A/C not operated and Engine coolant temp. : less than 113°C, 235°F

For 3 sec. after ignition switch ON or while engine running

After 3 sec. from ignition switch ON with engine stopped

–

–

–

–

0 – 6 V

–

–

–

–

Ignition switch ON

Voltage depends on fuel level

10 – 14 V

10 – 14 V

0 – 1 V

10 – 14 V

0 – 1 V

10 – 14 V

10 – 14 V

0 – 1 V

0 – 1 V

10 – 14 V

10 – 14 V

Ignition switch ON

Ignition switch ON

Ignition switch ON, P/N change switch : POWER mode

Ignition switch ON, P/N change switch : NORMAL mode

Ignition switch ON, lighting switch

OFF

Ignition switch ON, lighting switch

ON

Ignition switch ON, overdrive cut switch released

Ignition switch ON, overdrive cut switch pressed

Brake pedal released (switch OFF),

Ignition switch ON

Brake pedal depressed (switch ON),

Ignition switch ON

Ignition switch ON

C51-3-1

C51-3-2

C51-3-3

Intake air temp. sensor

Engine coolant temp. sensor

Knock sensor

C51-3-4 Power source

C51-3-5 Ground for MAF sensor

C51-3-6 Ground

C51-3-7

C51-3-8

4WD switch

Manifold absolute pressure sensor

2.2 – 3.0 V

0.5 – 0.9 V

About 2.5 V

10 – 14 V

–

–

0 – 1 V

10 – 14 V

3.3 – 4.3 V

Ignition switch ON, Sensor ambient temp. : 20°C, 68°F

Ignition switch ON, Engine coolant temp. : 80°C, 176°F

With engine running at idle after warned up

Ignition switch ON

–

–


4H or 4L range


2H range

Ignition switch ON and engine stops


TERMINAL

C51-3-9

C51-3-10

CIRCUIT

Throttle position sensor

Mass air flow sensor

NORMAL VOLTAGE

0.5 – 1.2 V

3.4 – 4.7 V

1.0 – 1.6 V

1.7 – 2.0 V

Deflects between

over and under 0.45 V

–

CONDITION

Ignition switch ON, Throttle valve at idle position

Ignition switch ON, Throttle valve at full open position

Ignition switch ON and engine stops

With engine running at idle speed

While engine running at 2,000 r/min. for 1 min. or longer after warmed up

–

C51-3-11

Heated oxygen sensor-1 (bank 1)

(if equipped)

C51-3-12 Ground for TP sensor

C51-3-13 Power source for TP sensor

C51-3-14 Power source for MAP sensor


C51-3-16

C51-3-17

C51-3-18

Ground

Pressure switch in 4WD air pump assembly

–

C51-3-19 –

C51-3-20 Ignition switch


C51-3-21

(if equipped)

C51-3-22

C51-3-23


(if equipped)


(if equipped)

C51-3-24 Ground for ECT sensor

C51-3-25 Ground for IAT sensor, MAP sensor

C51-3-26 Ground for CMP sensor

4.75 – 5.25 V Ignition switch ON

10 – 14 V

–

–

10 – 14 V

0 – 1 V

–

10 – 14 V

Deflects between over and under 0.45 V



–

–

–

Ignition switch ON

–

–


4H or 4L range


2H range

–

Ignition switch ON




–

–

–

C51-1-1

C51-1-2

C51-1-3

C51-1-4

C51-1-5

C51-1-6

C51-1-7

C51-1-8

C51-1-9

Shift solenoid B (A/T vehicle)

Shift solenoid A (A/T vehicle)

(A/T vehicle)

–

IAC valve (stepper motor coil 2)


Transmission range switch “R”

Transmission range switch “P”

(A/T vehicle)

TCC solenoid (A/T vehicle)

4WD air pump assembly

0 – 1 V

10 – 14 V

–

–

–

10 – 14 V

0 – 1 V

10 – 14 V

0 – 1 V

0 – 1 V

10 – 14 V

0 – 1 V

Ignition switch ON

Ignition switch ON

–

–

–

Ignition switch ON, selector lever :

“R” range


Other than “R”


“P” range


Other than “P” range

Ignition switch ON


4H or 4L range


2H range


TERMINAL

C51-1-10

C51-1-11

CIRCUIT

A/T input speed sensor (–)

(A/T vehicle)

A/T input speed sensor (+)

(A/T vehicle)

C51-1-12 Camshaft position sensor 1

C51-1-13

C51-1-14

C51-1-15

Camshaft position sensor 2

Vehicle speed sensor

EVAP canister purge valve

C51-1-16 IAC valve (stepper motor coil 4)


C51-1-18

C51-1-19

Transmission range switch “D”

(A/T vehicle)

Transmission range switch “N”

(A/T vehicle)

NORMAL VOLTAGE

About 2.5 V

About 2.5 V

Deflects between

0 – 1 V and 4 – 6 V

Deflects between

0 – 1 V and 4 – 6 V

Deflects between

0 – 1 V and over 4V

10 – 14 V

–

–

10 – 14 V

0 – 1 V

10 – 14 V

0 – 1 V

–

CONDITION

Ignition switch ON

Ignition switch ON

Ignition switch ON, crankshaft turned slowly

Ignition switch ON, crankshaft turned slowly

Ignition switch ON, Rear right tire turned slowly with rear left tire locked

Ignition switch ON

–

–


“D” range


Other than “D” range


“N” range


Other than “N” range

– C51-1-20

C51-1-21

C51-1-22

C51-1-23

Shield wire ground for A/T output speed sensor (A/T vehicle)

Shield wire ground for A/T input speed sensor (A/T vehicle)

A/T output speed sensor (–)

(A/T vehicle)

A/T output speed sensor (+)

(A/T vehicle)

C51-1-24 Engine start signal

–

About 2.5 V

About 2.5 V

10 – 14 V

0 – 1 V

10 – 14 V

Ignition switch ON

–

C51-1-25

C51-1-26

C51-1-27

C51-1-28

Power steering pressure switch

4WD low switch

Transmission range switch “L”

(A/T vehicle)

Transmission range switch “2”

(A/T vehicle)

0 – 1 V

0 – 1 V

10 – 14 V

10 – 14 V

0 – 1 V

10 – 14 V

0 – 1 V

Ignition switch ON

While engine cranking

Other than above

Ignition switch ON

With engine running at idle speed, turning steering wheel to the right or left as far as it stops


4WD low range


4H or 2H range


“L” range


Other than “L” range


“2” range


Other than “2” range


TERMINAL CIRCUIT

C51-2-1 Fuel injector No.2


C51-2-3 –

C51-2-4

Heater of HO2S-1 (bank 1)

(if equipped)

NORMAL VOLTAGE

10 – 14 V

–

10 – 14 V

C51-2-5


(if equipped)

0 – 2 V

10 – 14 V

0 – 2 V

C51-2-6

C51-2-7

– –

Ground –


10 – 14 V


C51-2-10 – –

C51-2-11 – –

C51-2-12

C51-2-13

C51-2-14

C51-2-15

EGR valve (stepper motor coil 4)

(if equipped)


(if equipped)


(if equipped)


(if equipped)

0 – 1 V

10 – 14 V

10 – 14 V

0 – 1 V

10 – 14 V

C51-2-16


(if equipped) 0 – 1 V

10 – 14 V

C51-2-17


(if equipped) 0 – 1 V

– C51-2-18

C51-2-19

C51-2-20

–

Crankshaft position sensor (+)

(if equipped)

Crankshaft position sensor (–)

(if equipped)



C51-2-23 Ignition coil assembly for No.6






C51-2-29 –

C51-2-30

Ground for CKP sensor shield wire

(if equipped)

–

–

10 – 14 V

–

–

–

–

–

–

–

–

At specified idle speed after engine warmed up


CONDITION

Ignition switch ON

Ignition switch ON

Ignition switch ON

Ignition switch ON

Ignition switch ON

Ignition switch ON


Ignition switch ON


Ignition switch ON

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–


RESISTANCE CHECK

1) Disconnect couplers (1) from ECM/PCM with ignition switch

OFF.

CAUTION:

Never touch terminals of ECM/PCM itself or connect voltmeter or ohmmeter (2).

2) Check resistance between each pair of terminals of disconnected couplers (1) as listed in following table.

CAUTION:

• Be sure to connect ohmmeter (2) probe from wire harness side of coupler.

• Be sure to turn OFF ignition switch for this check.

• Resistance in table represents that when parts temperature is 20°C (68°F).

TERMINALS

E61-9 and E61-2

E61-22 and C51-3-20

Main relay

CIRCUIT

A/C fan motor relay (if equipped)

E61-23 and C51-3-20 Fuel pump relay

C51-3-6 and Body ground Ground


C51-1-1 and Body ground Shift solenoid B (A/T)

C51-1-2 and Body ground Shift solenoid A (A/T)

C51-1-4 and C51-3-4 IAC valve (stepper motor coil 2)

C51-1-5 and C51-3-4 IAC valve (stepper motor coil 1)

C51-1-8 and Body ground TCC solenoid (A/T)

C51-1-15 and C51-3-4

C51-1-16 and C51-3-4



C51-1-17 and C51-3-4

C51-2-1 and C51-3-4


Fuel injector No.2

C51-2-2 and C51-3-4 Fuel injector No.1

C51-2-4, C51-2-5 and E61-9 Heater of HO2S-1


C51-2-8 and C51-3-4 Fuel injector No.4

C51-2-9 and C51-3-4

C51-2-12 and C51-3-4

Fuel injector No.3


C51-2-13 and C51-3-4

C51-2-14 and C51-3-4

C51-2-15 and C51-3-4

C51-2-16, C51- 2-17 and

E61-9

C51-2-21 and C51-3-4

C51-2-22 and C51-3-4




Heater of HO2S-2

Fuel injector No.6

Fuel injector No.5

STANDARD CONDITION

RESISTANCE

79 – 95

Ω

–

75 – 110

Ω

Battery disconnected and ignition switch ON

79 – 95

Ω

Continuity

–

–

Continuity

11 – 15

Ω

–

–

25.5 – 33.5 Ω

11 – 15

Ω

28 – 35

Ω

25.5 – 33.5 Ω

13 – 16

Ω

–

–

–

–

–

5.0 – 6.4 Ω

Continuity

13 – 16

Ω

20 – 24 Ω

–

–

–

–

11.7 – 14.3

13 – 16

Ω

Ω –

–


Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come

“ON” or Dims at Ignition Switch ON (But Engine at Stop)

WIRING DIAGRAM

1. MIL

2. To ignition switch

3. Main fuse

4. Main relay

5. ECM (PCM)

6. Monitor connector (if equipped)


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 METER” fuse blown, main fuse blown, Ignition switch malfunction, “BLK/

WHT” circuit between “IG

METER” 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 E61-7.

3) If OK, then using service wire, ground terminal E61-7 in connector disconnected.

Does MIL turn on at ignition switch ON?


ECM (PCM) and recheck.

No

Go to “TABLE A-3 ECM

(PCM) POWER AND

GROUND CIRCUIT

CHECK” in this section.

If engine is not cranked, go to “DIAGNOSIS” in

Section 6G.

Bulb burned out or “PPL/

YEL” wire circuit open.

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 DTC check :

1) With ignition switch OFF, install scan tool.

2) Start engine and check DTC.

Is there any malfunction DTC (s).

2 MIL circuit check :

1) With ignition switch OFF, disconnect couplers from ECM (PCM).

Does MIL turn ON at ignition switch ON?

Yes

Go to Step 2 of “ENGINE

DIAG. FLOW TABLE” in this section.

No

Go to Step 2.

“PPL/YEL” wire shorted to ground circuit.




Table A-3 Malfunction Indicator Lamp Check – MIL Flashes at Ignition Switch

ON (Vehicle with Monitor Connector)


Refer to TABLE A-1.

TROUBLESHOOTING

Step Action

1 MIL Flashing Pattern check:


Does lamp flashing pattern indicate diagnostic trouble code?

2 Diag. Switch Circuit check:

Is diag. switch terminal connected to ground via service wire?

Yes

Go to Step 2.

System is in good condition.

No

Go to “Diagnosis” in Section 8G.

“YEL” circuit shorted to ground. If circuit is OK substitute a known-good


Table A-4 Malfunction Indicator Lamp Check – MIL Does Not Flash or Just

Remains ON Even with Grounding Diagnosis Switch Terminal (Vehicle with



Refer to TABLE A-1.

TROUBLESHOOTING

Step Action

1 MIL Circuit check:

1) Turn ignition switch OFF and disconnect connectors from ECM (PCM).

Does MIL turn ON at ignition switch ON?

2 ECM (PCM) Connection check:


Is connector (E61-29 connection) connected to

ECM (PCM) properly?

3 Diag. switch Terminal Circuit check:

1) Connect connectors to ECM (PCM).

2) Using service wire, ground E61-29 terminal with connectors connected to ECM (PCM).


Does MIL flash?

Yes

“PPL/YEL” circuit shorted to ground.

Go to Step 3.

“YEL” or “BLK” circuit open.

No

Go to Step 2.

Poor connector connection.




Table A-5 ECM (PCM) Power and Ground Circuit Check – MIL Doesn’t Light at

Ignition Switch ON and Engine Doesn’t Start Though It Is Cranked Up

WIRING DIAGRAM

1. MIL


3. Main fuse

4. Main relay

5. ECM (PCM)


When the ignition switch is turned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM (PCM).


INSPECTION

Step Action

1 Main relay operating sound check :

Is operating sound of main relay heard at ignition switch ON?

2 Fuse check :

Is main “FI” fuse in good condition?

Yes

Go to Step 5.

Go to Step 3.

3 Main relay check :

1) Turn OFF ignition switch and remove main relay.

2) Check for proper connection to main relay at terminal 3 and 4.

3) If OK, check main relay for resistance and operation referring to “MAIN RELAY


Is check result satisfactory?

4 ECM (PCM) power circuit check :

1) Turn OFF ignition switch, disconnect connectors from ECM (PCM) and install main relay.

2) Check for proper connection to ECM (PCM) at terminals C51-3-20, E61-9, C51-3-15 and

C51-3-4.

3) If OK, then measure voltage between terminal C51-3-20 and ground, E61-9 and ground with ignition switch ON.

Is each voltage 10 – 14 V?

5 ECM power circuit check :

1) Using service wire, ground terminal E61-9 and measure voltage between terminal

C51-3-15 and ground at ignition switch ON.

Is it 10 – 14 V?

Go to Step 4.

Go to Step 5.

Check ground circuits

“BLK/GRN” and “BLK/

ORN” for open.

If OK, then substitute a known-good ECM (PCM) and recheck.

Go to Step 7.

6 Is operating sound of main relay heard in Step

1?

7 Main relay check :

1) Check main relay according to procedure in

Step 3.

Is main relay in good condition?

“BLK/RED” or “BLU/BLK” wire open.

No

Go to Step 2.

Check for short in circuits connected to this fuse.

Replace main relay.

“BLK/WHT”, “BLU” or

“BLK/RED” circuit open.

Go to Step 6.

“BLK/RED” or “BLU/BLK” wire open.

Replace main relay.


DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction

WIRING DIAGRAM

1. Main fuse

2. Main relay

3. ECM/PCM

4. Mass air flow sensor

DTC DETECTING CONDITION AND TROUBLE AREA

DTC DETECTING CONDITION

Any one of the following conditions are detected for 5 sec. continuously.

• Engine running and more than 3 sec. after ignition switch ON and less than 0.64 mA MAF sensor output current continues for 100 msec.

• Engine running and more than 3 sec. after ignition switch ON and more than 4.90 mA MAF sensor output current continues for 100 msec.

TROUBLE AREA

• MAF sensor circuit

• MAF sensor

• ECM (PCM)


DTC CONFIRMATION PROCEDURE

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 person, a driver and a tester, on a level road.

NOTE:

Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION

PROCEDURE”.

Intake air temp. : – 8°C (18°F) or higher

Engine coolant temp. : – 8 – 110°C (18 – 230°F)

Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) Connect scan tool to DLC with ignition switch OFF.

2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run engine at idle speed for 20 sec. or more.

3) Check DTC by using scan tool.

TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 MAF sensor check :


2) Start engine and check MAF value displayed on scan tool. (Refer to “SCAN TOOL

DATA” in this section for normal value.)

Is normal value indicated?

3 MAF sensor power supply check :

1) With ignition switch OFF, disconnect MAF sensor coupler.

2) With ignition switch ON, check voltage between E154-3 of MAF sensor coupler and

Intermittent trouble.

Check for intermittent referring to “INTERMIT-

TENT AND POOR CON-

NECTION” in Section 0A.

Go to Step 4.

ground.

Is voltage 10 – 14 V?

4 MAF sensor output voltage check :

1) With ignition switch OFF, connect MAF sensor coupler.

2) Remove ECM (PCM) cover.

3) With ignition switch ON leaving engine OFF, check voltage between C51-3-10 and C51-

3-5 terminal.

Is voltage 1.0 – 1.6 V?

Poor C51-3-10 or/C51-3-5 terminal connection.

If OK, substitute a knowngood ECM (PCM) and recheck.

No



Go to Step 3.

Faulty “BLU/BLK” wire.

Faulty “PPL/WHT” wire.

Poor E154 coupler terminal connection.


OK, substitute a knowngood MAF sensor and recheck.


DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction

WIRING DIAGRAM

1. IAT sensor

2. ECM (PCM)



Any one of the conditions are detected for 5 sec. continuously.

• Low intake air temperature (high voltage-high resistance)

• High intake air temperature (Low voltage-low resistance)

TROUBLE AREA

• IAT sensor circuit

• IAT sensor

• ECM (PCM) malfunction



2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run engine at idle speed and engine coolant temp. 110°C (230°F) or lower for 10 sec. or more.



TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Check IAT sensor and its circuit :

1) Connect scan tool with ignition switch OFF.


3) Check intake air temp. displayed on scan tool.

Is – 40°C (– 40°F) or 165°C (329°F) indicated?

3 Check wire harness :

1) Disconnect IAT sensor connector with ignition switch OFF.

2) Check for proper connection to IAT sensor at “LT BLU” and “GRY/YEL” wire terminals.

If OK, then with ignition switch ON, is voltage applied to “LT BLU” wire terminal about 4 – 6 V?


1) Using service wire, connect IAT sensor connector terminals.

2) Turn ignition switch ON and check intake air temp. displayed on scan tool.

Is 165°C (329°F) indicated?

Go to Step 3.

Go to Step 4.

Replace IAT sensor.

No





TENT AND POOR CON-


“LT BLU” wire open or short, or poor C51-3-1 connection.


OK, substitute a knowngood ECM (PCM) and recheck.

“GRY/YEL” wire open or poor C51-3-25 connection.




DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Circuit Malfunction

WIRING DIAGRAM

1. ECT sensor

2. To combination (ECT) meter

3. ECM (PCM)



Any one of the conditions are detected for 5 sec. continuously.

• Low engine coolant temperature (high voltage-high resistance)

• High engine coolant temperature (low voltage-low resistance)

TROUBLE AREA

ECT sensor circuit

ECT sensor

ECM (PCM)


NOTE:


PROCEDURE”.

• Intake air temp. : – 8°C (18°F) or higher

• Engine coolant temp. : – 8 – 110°C (18 – 230°F)

• Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)





TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Check ECT sensor and its circuit :



3) Check engine coolant temp. displayed on scan tool.

Is – 40°C (– 40°F) or 164°C (327°F) indicated?


1) Disconnect ECT sensor connector with ignition switch OFF.

2) Check for proper connection to ECT sensor at “ORN/BLK” and “GRY/YEL” wire terminals.

If OK, then with ignition switch ON, is voltage applied to “ORN/BLK” wire terminal about 4 – 6

V?


1) Using service wire, connect ECT sensor connector terminals.

2) Turn ignition switch ON and check engine coolant temp. displayed on scan tool.

Is 164°C (327°F) indicated?

Go to Step 3.

Go to Step 4.

Replace ECT sensor.

No





TENT AND POOR CON-


“ORN/BLK” wire open or short, or poor C51-3-2 connection.



“GRY/YEL” wire open or poor C51-3-23 connection.




DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction

WIRING DIAGRAM

1. Throttle position sensor

2. ECM (PCM)



Following conditions are detected for 5 sec. continuously.

• Engine running

• Signal voltage low or signal voltage high

TROUBLE AREA

• TP sensor circuit

• TP sensor

• ECM (PCM)

NOTE:


PROCEDURE”.



• Altitude barometric pressure : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)






TROUBLESHOOTING

Step Action


2 Check TP sensor and its circuit.

1) Connect scan tool to DLC with ignition switch OFF and then turn ignition switch

ON.

2) Check throttle valve opening percentage displayed on scan tool.

Is it displayed 3% or less?

3) Check throttle valve opening percentage displayed on scan tool while opening throttle valve from idle position to full open position.

Is it displayed 96% or higher?

3 Check wire harness.

1) Disconnect connector from TP sensor with ignition switch OFF.

2) Check for proper connection to TP sensor at

“GRY/RED”, “RED/GRN” and “GRY/YEL” wire terminal.

3) If OK, then with ignition switch ON, check voltage between each of “GRY/RED” or

“RED/GRN” wire terminals and body ground.

Is voltage about 4 – 6 V at each terminal?

Yes

Go to Step 2.

Go to Step 3.

Go to Step 4.

4 Check TP sensor.

1) Check resistance between terminals of TP sensor referring to “TP SENSOR” in Section

6E2.

Are measured values within specifications?

“RED/GRN” wire shorted to power circuit.

If wire is OK, substitute a known-good ECM (PCM) and recheck.

No


FLOW TABLE”.


Check for intermittent referring to “Intermittent and Poor Connection” in

Section 0A.

“GRY/RED” wire open,

“GRY/RED” wire shorted to ground circuit or power circuit or “RED/GRN” wire, “GRY/YEL” wire open or shorted to ground circuit or poor C51-3-13 or

C51-3-9 connection.


OK, substitute a knowngood ECM and recheck.

Replace TP sensor.


DTC P0121 Throttle Position Circuit Range/Performance Problem


Refer to DTC P0120.



Throttle opening change is smaller than specification while intake air volume changes and engine is running at constant speed. (2 driving cycle detection logic)

• TP sensor

• ECM (PCM)

TROUBLE AREA


WARNING:


• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

NOTE:


PROCEDURE”.



• Altitude barometric pressure : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)


2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and start engine.

3) Increase vehicle speed to 60 km/h (40 mph).

4) Keep driving above vehicle speed for 5 min (Change of vehicle speed is permitted in this step).

5) Stop vehicle and run engine at idle speed for 1 min.

6) Increase vehicle speed till engine speed is reached 2,000 – 3,000 r/min in proper gear.

7) Keep driving at that engine speed for 30 sec or more (Engine speed is kept constant in this step).

8) Stop vehicle.

9) Repeat step 6) to 8).

10) Check pending DTC by using scan tool.


TROUBLESHOOTING

Step

1

Action

Was “ENGINE DIAG. FLOW TABLE” performed?

Yes

Go to Step 2.

2 Is there a DTC related to TP sensor (DTC P0120)? Go to applicable DTC

Diag. Flow Table.

3 Do you have SUZUKI scan tool ?

Go to Step 4.

4 Check TP sensor and its circuit (using SUZUKI scan tool) :

1) Turn ignition switch OFF and connect SUZUKI scan tool to DLC.

2) Turn ignition switch ON and check TP sensor output voltage when throttle valve is at idle position and fully opened.

Does voltage vary within specified value linearly as shown in the figure?

5 Check TP sensor and its circuit (not using SUZUKI scan tool) :


2) Check voltage at terminal C51-3-9 of ECM connector connected, when throttle valve is at idle position and fully opened.

Does voltage vary within specified value linearly as shown in the figure?

6 Check TP sensor :




If voltmeter was used, check terminal C51-3-9 for poor connection.


2) Disconnect TP sensor connector.

3) Check for proper connection to TP sensor at each terminal.

4) If OK, check TP sensor for resistance referring to “TP SENSOR” in Section 6E2.


High resistance in “GRY/

RED”, “RED/GRN” or

“GRY/YEL” circuit.



No

Go to “ENGINE


Go to Step 3.

Go to Step 5.

Go to Step 6.

Go to Step 6.

Replace TP sensor.

Fig. for Steps 4 and 5

1. Voltage

2. Throttle opening

3. At idle position

4. Fully open


DTC P0130 (DTC No.13) HO2S-1 (Bank 1) Circuit Malfunction or No Activity

Detected

WIRING DIAGRAM

1. HO2S heater relay

2. ECM (PCM)

3. HO2S-1 (Bank-1)


NOTE:

For vehicle with monitor connector, DTC will set when following only (*) mark condition is detected.


Any one of the following conditions are detected in idle state while running under driving conditions described for “DTC CONFIRMATION PROCEDURE”.

• 4.5 V or more HO2S circuit voltage is detected, when 5 V power is connected to HO2S circuit in ECM (PCM), or

• Max. output voltage of HO2S is 0.6 V or lower on average and its minimum voltage on average is 0.3 V or lower.

• Min. output voltage of HO2S is over 3.0 V or

• Max. output voltage of HO2S is 0.74 V or higher on average and its min. voltage on average is 0.33 V or higher.

• *Output voltage of HO2S-1 does not exceed 0.45 V for specified time.

(2 driving cycle detection logic)

TROUBLE AREA

HO2S-1 or its circuit.

Fuel system

ECM (PCM)



WARNING:



NOTE:


PROCEDURE”.






3) Increase vehicle speed to 55 km/h (35 mph) or more.

4) Keep driving above vehicle speed for 2 min. or more (Change of vehicle speed is permitted in this step).

5) Stop vehicle, and run engine at idle speed for 1 min.

6) Check if pending DTC exists by using scan tool. If not, check if oxygen sensor monitoring test has completed by using scan tool. If not in both of above checks (i.e., no pending DTC and oxygen sensor monitoring test not completed), check vehicle condition (environmental) and repeat step 3) through 6).

TROUBLESHOOTING

Step

1

Action


Yes

Go to Step 2.

No

Go to “ENGINE

DIAG. FLOW


Go to Step 3.

2 HO2S-1 output voltage check :


2) Warm up engine to normal operating temperature and keep it at 2000 r/min. for 60 sec.

3) Repeat racing engine (Repeat depressing accelerator pedal 5 to 6 times continuously to enrich A/F mixture and take foot off from pedal to enlean and check HO2S output voltage displayed on scan tool. See Fig.

Is over 0.6 V and below 0.3 V indicated?

3 HO2S-1 check :

1) With ignition switch OFF, disconnect HO2S-1 connector.

2) Check for proper connection to HO2S-1 at each terminal.

3) If OK, connect voltmeter “1” and “2” terminal of HO2S-1 connector.

4) Start engine and check voltmeter while repeating racing engine.


Go to Step 4.

“RED” or “GRY/

YEL” circuit open or short.

If wire and connections are OK, substitute a knowngood ECM (PCM) and recheck.

Replace HO2S-1.


Step Action

4 Short term fuel trim check :

1) Run engine at 2000 r/min. for 60 sec.

2) With engine idling, check short term fuel trim displayed on scan tool.

Is it within – 20 to +20 %?

Yes

Intermittent trouble or faulty ECM

(PCM).

Check for intermittent referring to

“INTERMITTENT

AND POOR CON-


No

Go to DTC P0171/

P0172 Diag. Flow

Table.

Fig. for Step 2

1. Normal

2. NG

DTC P0133 HO2S-1 (Bank 1) Circuit Slow Response


Refer to DTC P0130.



Following conditions are detected in idle state while running under driving conditions described for “DTC CONFIRMATION PROCEDURE”.

Hi/Lo cycle (TRANS TIME displayed on scan tool) of HO2S-1 output voltage is longer than specification or response rates of Hi

→ Lo and Lo → Hi

(TRANS TIME displayed as R

→ L threshold V or L → R threshold V on scan tool) are longer than specification.


TROUBLE AREA

HO2S-1

ECM (PCM)


Refer to DTC P0130.

TROUBLESHOOTING

Step Action


2 1) Replace HO2S-1 and recheck.

Is DTC P0133 detected?

Yes

Go to Step 2.



No



HO2S-1 malfunction.


DTC P0135 HO2S-1 (Bank 1) Heater Circuit Malfunction

WIRING DIAGRAM

Refer to DTC P0130.



Following condition is detected when HO2S heater is electrically live (2 driving cycle detection logic).

• Current of HO2S heater is 5.3 A or more or less than

0.09 A, or

• Voltage of HO2S heater is 14.0 V or higher or lower than 11.7 V.

TROUBLE AREA

HO2S-1 heater circuit

HO2S-1 heater

ECM (PCM)

HO2S heater relay


NOTE:


PROCEDURE”.





2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run engine at idle speed for 5 min.


TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

No

Go to “ENGINE


Replace HO2S-1.

2 HO2S-1 heater check :

1) Disconnect HO2S-1 coupler with ignition switch OFF.

2) Check resistance between “3” and “4” terminal of HO2S-1 coupler.

HO2S-1 heater resistance :

5.0 – 6.4 Ω

Is it within above specification?

Go to Step 3.

3 HO2S heater power supply check :

1) With ignition switch ON leaving engine OFF, check voltage between E139-3 and ground,

E139-1 and ground. (See Fig.)


Go to Step 4.

“HO2S”, and/or “IG

METER” fuse blown.

If OK, faulty “BLK/WHT” wire or “BLU/WHT” wire.


Step Action

4 HO2S heater control circuit check :

1) With ignition switch OFF, install HO2S heater relay.

2) With ignition switch ON leaving engine OFF, check voltage between C51-2-4 and ground.

Is the voltage 10 – 14 V?

Yes



No

Faulty HO2S heater relay or “BLK” wire open, “BLU” wire open or shorted to ground circuit or

“GRY” wire open or shorted to ground circuit.


Fig. for STEP 3 a. HO2S heater relay


DTC P0136 HO2S-2 (Bank 1) Circuit Malfunction

WIRING DIAGRAM


2. ECM (PCM)

3. HO2S-2 (Bank-1)



DTC will set when any one of following conditions is detected (2 driving cycle detection logic).

• 4.5 V or more HO2S circuit voltage is detected when 5 V power is connected to HO2S circuit in ECM (PCM).

• While running with A/F feed back, average output voltage during specified time is too high or too low.

or

• While running with A/F feed back, max output voltage during specified time is lower than specified value or min. output voltage during specified time is higher than specified value.

TROUBLE AREA

• HO2S-2 or its circuit

• Fuel system

• ECM (PCM)


WARNING:




NOTE:


PROCEDURE”.





2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data in ECM memory by using scan tool and start engine.


4) Keep driving above vehicle speed till engine is warmed up completely (Changed of vehicle speed is permitted in this step).

5) Keep driving 50 – 60 km/h (30 – 40 mph) for 8 min. or more.

6) Stop vehicle and check if pending DTC exists by using scan tool. If not, check if oxygen sensor heater monitoring test has completed by using scan tool. If not in both of above checks (i.e., no pending DTC and oxygen sensor heater monitoring test not completed), check vehicle conditions (environmental) and repeat

Steps 3) through 6).

TROUBLESHOOTING

Step

1

Action


Yes

Go to Step 2.

No



Go to Step 3.



2) Drive vehicle about 35 mph, 55 km/h for 2 min. or more.

3) Stop vehicle and check HO2S-2 output voltage displayed on scan tool while repeating racing engine.

Is over and below 0.3 V indicated?

3 HO2S-2 check :

1) With ignition switch OFF, disconnect HO2S-

2 coupler.

2) Connect voltmeter between “2” and “1” of

HO2S-2 coupler.







Go to Step 4.

“RED/BLK” or “GRY/YEL” circuit open/short.



Intermittent trouble or faulty ECM (PCM).


TENT AND POOR CON-


Replace HO2S-2.

Go to DTC P0171/P0172

Diag. Flow Table.



WIRING DIAGRAM

Refer to DTC P0136.



Following condition is detected when HO2S-2 heater operates (2 driving cycle detection logic).

• Current of HO2S-2 heater is more than 11.4 A or less than 0.32 A, or

• Voltage of HO2S-2 heater is more than 13.8 V or less than 8.7 V.

TROUBLE AREA

HO2S-2 heater or its circuit

ECM (PCM)


WARNING:



NOTE:


PROCEDURE”.






3) Increase vehicle speed to 50 – 60 km/h (30 – 40 mph).

4) Keep driving above vehicle speed for 5 min. (Change of vehicle speed is permitted in this step).




TROUBLESHOOTING

Step Action


Yes

Go to Step 2.



2) Check resistance between “3” and “4” terminal of HO2S-2 connector.

HO2S -2 heater resistance :

11.7 – 14.3 Ω (at 20°C (68°F))

Is it within above specification









Go to Step 3.

Go to Step 4.



No



Replace HO2S-2.

Fuse “HO2S” and/or “IG

METER” blown.


Faulty HO2S heater relay or “BLK” wire open, “BLU” wire open or shorted to ground circuit, “WHT/

BLK” wire open or shorted to ground circuit.


Fig. for STEP 2, 3 a. HO2S heater relay


DTC P0150 (DTC No.26) HO2S-1 (Bank 2) Circuit Malfunction or No Activity

Detected

WIRING DIAGRAM


2. ECM (PCM)

3. HO2S-1 (Bank-2)


NOTE:

For vehicle with monitor connector, DTC will set when following only (*) mark condition is detected.


Any one of the following conditions are detected in idle state while running under driving conditions described for “DTC CONFIRMATION PROCEDURE”.

• 4.5 V or more HO2S circuit voltage is detected, when 5 V power is connected to HO2S circuit in ECM (PCM), or

• Max. output voltage of HO2S is 0.6 V or lower on average and its minimum voltage on average is 0.3 V or lower.

• Min. output voltage of HO2S is over 3.0 V or

• Max. output voltage of HO2S is 0.74 V or higher on average and its min. voltage on average is 0.33 V or higher.

• Output voltage of HO2S-1 does not exceed 0.45 V for specified time.


TROUBLE AREA

HO2S-1 or its circuit.

Fuel system

ECM (PCM)



WARNING:



NOTE:


PROCEDURE”.







4) Keep driving above vehicle speed for 2 min. or more (Change of vehicle speed is permitted in this step).

5) Stop vehicle, and run engine at idle speed for 1 min.

6) Check if pending DTC exists by using scan tool. If not, check if oxygen sensor monitoring test has completed by using scan tool. If not in both of above checks (i.e., no pending DTC and oxygen sensor monitoring test not completed), check vehicle condition (environmental) and repeat step 3) through 6).

TROUBLESHOOTING

Step

1

Action


Yes

Go to Step 2.



2) Warm up engine to normal operating temperature and keep it at 2000 r/min. for 60 sec.

3) Repeat racing engine (Repeat depressing accelerator pedal 5 to 6 times continuously to enrich A/F mixture and take foot off from pedal to enlean and check HO2S output voltage displayed on scan tool. See Fig.


3 HO2S-1 check :

1) With ignition switch OFF, disconnect HO2S-1 connector.

2) Check for proper connection to HO2S-1 at each terminal.

3) If OK, connect voltmeter “1” and “2” terminal of HO2S-1 connector.



Go to Step 4.

“RED/BLU” or

“GRY/YEL” circuit open or short.

If wire and connections are OK, substitute a knowngood ECM (PCM) and recheck.

No

Go to “ENGINE

DIAG. FLOW


Go to Step 3.

Replace HO2S-1.


Step Action





Yes

Intermittent trouble or faulty ECM

(PCM).


“INTERMITTENT

AND POOR CON-


No

Go to DTC P0174/

P0175 Diag. Flow

Table.

Fig. for Step 2

1. Normal

2. NG

DTC P0153 HO2S-1 (Bank 2) Circuit Slow Response


Refer to DTC P0150.



Following conditions are detected in idle state while running under driving conditions described for “DTC CONFIRMATION PROCEDURE”.

Hi/Lo cycle (TRANS TIME displayed on scan tool) of HO2S-1 output voltage is longer than specification or response rates of Hi

→ Lo and Lo → Hi

(TRANS TIME displayed as R

→ L threshold V or L → R threshold V on scan tool) are longer than specification.


TROUBLE AREA

HO2S-1

ECM (PCM)


Refer to DTC P0150.

TROUBLESHOOTING

Step Action


2 1) Replace HO2S-1 and recheck.

Is DTC P0153 detected?

Yes

Go to Step 2.



No



HO2S-1 malfunction.



WIRING DIAGRAM

Refer to DTC P0150.



Following condition is detected when HO2S heater is electrically live (2 driving cycle detection logic).

• Current of HO2S heater is 5.3 A or more or less than

0.09 A, or

• Voltage of HO2S heater is 14.0 V or higher or lower than 11.7 V.

TROUBLE AREA

HO2S-1 heater circuit

HO2S-1 heater

ECM (PCM)


NOTE:


PROCEDURE”.





2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run engine at idle speed for 5 min.


TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

No

Go to “ENGINE


Replace HO2S-1.



2) Check resistance between “3” and “4” terminal of HO2S-1 coupler.

HO2S-1 heater resistance :

5.0 – 6.4 Ω

Is it within above specification?





Go to Step 3.

Go to Step 4.

“HO2S”, and/or “IG

METER” fuse blown.



Step Action





Yes



No

Faulty HO2S heater relay or “BLK” wire open, “BLU” wire open or shorted to ground circuit, “BLK/RED” wire open or shorted to ground circuit.




DTC P0156 HO2S-2 (Bank 2) Circuit Malfunction

WIRING DIAGRAM


2. ECM (PCM)

3. HO2S-2 (Bank-2)



DTC will set when any one of following conditions is detected (2 driving cycle detection logic).

• 4.5 V or more HO2S circuit voltage is detected when 5 V power is connected to HO2S circuit in ECM (PCM).

• While running with A/F feed back, average output voltage during specified time is too high or too low.

or

• While running with A/F feed back, max output voltage during specified time is lower than specified value or min. output voltage during specified time is higher than specified value.

TROUBLE AREA

• HO2S-2 or its circuit

• Fuel system

• ECM (PCM)


WARNING:




NOTE:


PROCEDURE”.







4) Keep driving above vehicle speed till engine is warmed up completely (Changed of vehicle speed is permitted in this step).

5) Keep driving 50 – 60 km/h (30 – 40 mph) for 8 min. or more.



TROUBLESHOOTING

Step

1

Action


Yes

Go to Step 2.



2) Drive vehicle about 35 mph, 55 km/h for 2 min. or more.

3) Stop vehicle and check HO2S-2 output voltage displayed on scan tool while repeating racing engine.


3 HO2S-2 check :

1) With ignition switch OFF, disconnect HO2S-

2 coupler.

2) Connect voltmeter between “2” and “1” of

HO2S-2 coupler.







Go to Step 4.

“RED/YEL” or “GRY/YEL” circuit open/short.





TENT AND POOR CON-


No



Go to Step 3.

Replace HO2S-2.

Go to DTC P0174/P0175

Diag. Flow Table.



WIRING DIAGRAM

Refer to DTC P0156.



Following condition is detected when HO2S-2 heater operates (2 driving cycle detection logic).

• Current of HO2S-2 heater is more than 11.4 A or less than 0.32 A, or

• Voltage of HO2S-2 heater is more than 13.8 V or less than 8.7 V.

TROUBLE AREA

HO2S-2 heater or its circuit

ECM (PCM)


WARNING:



NOTE:


PROCEDURE”.







4) Keep driving above vehicle speed for 5 min. (Change of vehicle speed is permitted in this step).




TROUBLESHOOTING

Step Action


Yes

Go to Step 2.



2) Check resistance between “3” and “4” terminal of HO2S-2 connector.

HO2S -2 heater resistance :

11.7 – 14.3 Ω (at 20°C (68°F))

Is it within above specification

Go to Step 3.





Go to Step 4.







No



Replace HO2S-2.

Fuse “HO2S” and/or “IG

METER” blown.


Faulty HO2S heater relay or “BLK” wire open, “BLU” wire open or shorted to ground circuit, “PNK/

WHT” wire open or shorted to ground circuit.




DTC P0171/P0172 Fuel System Too Lean/Rich (Bank 1)

DTC DETECTING CONDITION AND POSSIBLE CAUSE


When running after engine warmed (2 driving cycle detection logic).

• Short term fuel trim exceeding 15 % or long term fuel trim exceeding 20 % and total trim exceeding 43 % is detected.

– Fuel system too lean

• Short term fuel trim less than – 11 % or long term fuel trim less than – 11 % and total trim less than – 30 % is detected.

– Fuel trim too rich

TROUBLE AREA

• Vacuum leaks (air inhaling)

• Exhaust gas leakage

• Fuel pressure out of specification

• Heated oxygen sensor malfunction

• EGR system malfunction

• MAF sensor poor performance

• ECT sensor poor performance

• Fuel level sensor.


WARNING:



NOTE:


PROCEDURE”.

• Intake air temp. at start : – 8 – 60°C (18 – 140°F)

• Engine coolant temp. at start : – 8 – 95°C (18 – 203°F)



• Engine coolant temp. : 110°C (230°F) or lower


2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and warm up engine completely.


4) Keep driving above vehicle speed for 3 min. or more.

5) Stop vehicle and check pending DTC by using scan tool.


TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Is there DTC (s) other than “DTC P0171/

P0172”?

3 Check intake system and exhaust system for leakage.

Are intake system and exhaust system in good condition?

4 Check fuel pressure referring to “TABLE B-3” in this section.


5 Check fuel injectors referring to “FUEL INJEC-

TOR INSPECTION” in Section 6E2.


6 Check fuel level sensor referring to “FUEL

LEVEL SENSOR” in Section 6E2.


7 Check MAF sensor for performance referring to

“MASS AIR FLOW SENSOR” in Section 6E2.


8 Check ECT sensor referring to Section 6E2.


9 Check HO2S-1 referring to “DTC P0130 DIAG.

FLOW TABLE”.


Go to applicable DTC

FLOW TABLE.

Go to Step 4.

Go to Step 5.

Go to Step 6.

Go to Step 7.

Go to Step 8.

Go to Step 9.



No



Go to Step 3.

Repair or replace.

Repair or replace.

Faulty injector (s).

Faulty fuel level sensor or its circuit.

Faulty MAF sensor or its circuit.

Faulty ECT sensor.

Faulty HO2S-1.


DTC P0174/P0175 Fuel System Too Lean/Rich (Bank 2)

DTC DETECTING CONDITION AND POSSIBLE CAUSE


When running after engine warmed (2 driving cycle detection logic).

• Short term fuel trim exceeding 15 % or long term fuel trim exceeding 20 % and total trim exceeding 43 % is detected.

– Fuel system too lean

• Short term fuel trim less than – 11 % or long term fuel trim less than – 11 % and total trim less than – 30 % is detected.

– Fuel trim too rich

TROUBLE AREA

• Vacuum leaks (air inhaling)


• Fuel pressure out of specification

• Heated oxygen sensor malfunction

• EGR system malfunction

• MAF sensor poor performance

• ECT sensor poor performance

• Fuel level sensor.


WARNING:



NOTE:


PROCEDURE”.

• Intake air temp. at start : – 8 – 60°C (18 – 140°F)

• Engine coolant temp. at start : – 8 – 95°C (18 – 203°F)



• Engine coolant temp. : 110°C (230°F) or lower







TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Is there DTC (s) other than “DTC P0174/

P0175”?

3 Check intake system and exhaust system for leakage.

Are intake system and exhaust system in good condition?

4 Check fuel pressure referring to “TABLE B-3” in this section.


5 Check fuel injectors referring to “FUEL INJEC-

TOR INSPECTION” in Section 6E2.


6 Check fuel level sensor referring to “FUEL

LEVEL SENSOR” in Section 6E2.


7 Check MAF sensor for performance referring to

“MASS AIR FLOW SENSOR” in Section 6E2.


8 Check ECT sensor referring to Section 6E2.


9 Check HO2S-1 referring to “DTC P0150 DIAG.

FLOW TABLE”.



FLOW TABLE.

Go to Step 4.

Go to Step 5.

Go to Step 6.

Go to Step 7.

Go to Step 8.

Go to Step 9.



No



Go to Step 3.

Repair or replace.

Repair or replace.

Faulty injector (s).

Faulty fuel level sensor or its circuit.

Faulty MAF sensor or its circuit.

Faulty ECT sensor.

Faulty HO2S-1.


DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder

1 Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/Cylinder 4 Misfire Detected/Cylinder 5 Misfire Detected/Cylinder 6 Misfire Detected

SYSTEM DESCRIPTION

ECM (PCM) measures the angle speed of the crankshaft based on the pulse signal from the CKP sensor and

CMP sensor for each cylinder. If it detects a large change in the angle speed of the crankshaft, it concludes occurrence of a misfire. When the number of misfire is counted by the ECM (PCM) beyond the DTC detecting condition, it determines the cylinder where the misfire occurred and outputs it as DTC.



DTC P0300 :

• Misfire which causes catalyst to overheat during 200 engine revolutions is detected at 2 or more cylinders. (MIL flashes as long as this misfire occurs continuously.)

• Misfire which affects exhaust emission adversely during 1000 engine revolutions is detected at 2 or more cylinders (2 driving cycle detection logic)

DTC P0301, P0302, P0303, P0304, P0305, P0306 :

• Misfire which causes catalyst to overheat during 200 engine revolutions is detected at 1 cylinder. (MIL flashes as long as this misfire occurs continuously.)

• Misfire which affects exhaust emission adversely during 1000 engine revolutions is detected at 1 cylinder


TROUBLE AREA

• Ignition system

• Fuel injector and its circuit

• Fuel line pressure

• Engine compression

• Abnormal air drawn in

• EGR system

• Fuel level sensor

• Valve lash adjuster

• Valve timing


WARNING:



NOTE:


PROCEDURE”.

• Intake air temp. : – 8 – 70°C (18 – 158°F)

• Engine coolant temp. : – 8°C (18°F) or higher




3) Increase vehicle speed to speed recorded as freeze frame data (V) ± 5 km/h when detecting misfire.

4) Keep driving above vehicle speed for 5 min.

5) Stop vehicle and check DTC (or pending DTC) by using scan tool.


TROUBLESHOOTING

Step Action


Yes

Go to Step 2.



Faulty ignition coil, wire harness, or other system parts.

No

2 Ignition system inspection :

1) Check spark plug and ignition spark of cylinder where misfire occurs, referring to “IGNI-

TION SYSTEM” section.


3 Fuel injector circuit inspection :

1) Using sound scope, check each injector operating sound at engine cranking or idling.

Do all injectors make operating sound?

Go to Step 3.

Go to Step 4.

Check coupler connection and wire harness of injector not making operating sound and injector itself.


Repair or replace.

4 Fuel pressure inspection :

1) Check fuel pressure referring to “TABLE B-

3” in this section.


5 Fuel injector inspection :

1) Check fuel injector(s) referring to Section

6E2.


6 Ignition timing inspection :

1) Check ignition timing referring to Section

6F2.


7 EGR system inspection :

1) Check EGR system referring to Section

6E2.


8 Fuel level sensor inspection :

1) Check fuel level sensor referring to Section

6E2.


9 Check engine mechanical parts or system which can cause engine rough idle or poor performance.

• Engine compression (See Section 6A2).

• Valve lash or lash adjuster (See Section

6A2).

• Valve timing (Timing belt or chain installation. See Section 6A2).


Go to Step 5.

Go to Step 6.

Go to Step 7.

Go to Step 8.

Go to Step 9.

Check wire harness and connection of ECM (PCM) ground, ignition system and fuel injector for intermittent open and short.

Replace.

Adjust or check system related parts.

Repair or replace.

Repair or replace.

Repair or replace.


DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction


1. Knock sensor

2. ECM (PCM)



DTC will set when one of the following condition is detected.

• KNOCK sensor voltage is 0.90 V or less, or

• KNOCK sensor voltage is 3.98 V or more

TROUBLE AREA

• “WHT” circuit open or shorted to ground

• KNOCK sensor malfunction

• ECM malfunction



2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.

3) Start engine and run it for 10 sec.



TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Knock sensor and its circuit check :

1) With engine running, check voltage from

“C51-3-3” terminal of ECM connector to body ground. See Fig.

Is voltage about 0.90 – 3.98 V?

Knock sensor and its circuit are in good condition.

Intermittent trouble or faulty ECM.

Recheck, referring to

“INTERMITTENT TROU-

BLE” in Section 0A.

3 Knock sensor power source circuit check :

1) Stop engine.

2) With ignition switch at OFF position, disconnect knock sensor connector.

3) With ignition switch at ON position, check voltage from “WHT” to body ground terminal of knock sensor connector. See Fig.

Is it 4 – 5 V?

Substitute a known-good knock sensor and recheck.

No



Go to Step 3.

“WHT” wire open, shorted to ground circuit or poor

“C51-3-3” connection.


OK, substitute a knowngood substitute a knowngood ECM and recheck.

Fig. for Steps 2 and 3

1. Knock sensor

2. Knock sensor connector


DTC P0335 Crankshaft Position Sensor Circuit Malfunction

WIRING DIAGRAM

1. CKP sensor

2. ECM (PCM)



CKP sensor signal is not input while 100 pulses of

CMP sensor signal are input after engine start.

TROUBLE AREA

CKP sensor circuit

CKP sensor

ECM (PCM)


NOTE:

Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO-

CEDURE”.





2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run engine at idle speed for 10 sec.



TROUBLESHOOTING

Step

1

Action


2 CKP sensor and its circuit resistance check :

1) With ignition switch OFF, disconnect ECM

(PCM) coupler (C51-2).

2) Check for proper connection to ECM (PCM) at

C51-2-19 and C51-2-20 terminals.

3) If OK, check resistance of followings.

CKP sensor resistance between C51-2-19 and

C51-2-20 terminals :

484 – 656 Ω at 20°C (68°F)

CKP sensor resistance between each terminal and ground :

1 M Ω or more


3 CKP sensor resistance check :

1) With ignition switch OFF, disconnect CKP sensor coupler.

2) Check resistance between terminals of CKP sensor coupler. (See Fig.)

Were measured resistance values as specified in

Step 2?

4 CKP sensor visual inspection :

Check visually CKP sensor and signal rotor for the followings. (See Fig.)

• Damage

• No foreign material attached

• Correct installation


Yes

Go to Step 2.

Go to Step 4.

Faulty “WHT/BLU” wire or “ORN/BLU” wire.


Recheck for intermittent referring to

“INTERMITTENT AND

POOR CONNEC-

TION” in Section 0A.

No



Go to Step 3.

Faulty CKP sensor.

Replace or reinstall.

[A] Fig. for Step 3 / [B] Fig. for Step 4

1. Sensor plate


DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction

WIRING DIAGRAM

1. CMP sensor

2. To main relay

3. ECM (PCM)


CMP sensor detects REF signal and POS signal.

• REF signal : 4 pulses/1 revolution of camshaft. There are 2 different kinds of wavelength. Based on REF signal, ECM (PCM) judges which cylinder is at TDC.

• POS signal : 6 pulse/1 revolution of camshaft. Each of POS signals has equivalent wavelength. Based on

POS signal, ECM (PCM) judges the wavelength of REF signals, engine speed and piston position.

REFERENCE

Connect oscilloscope between terminals C51-1-13 (POS) or C51-1-12 (REF) and C51-3-26 (ground) of ECM

(PCM) connector connected to ECM (PCM) and check CMP sensor signal.




CMP sensor signal is not inputted for 3 sec. even though engine start signal is being inputted.

or

REF signal pattern is incorrect while POS signal varies.

or

POS signal voltage too high or too low.

TROUBLE AREA

CMP sensor circuit

CMP sensor

Engine starter signal circuit

ECM (PCM)


NOTE:


CEDURE”.






3) Crank engine for 3 seconds or more and keep it at idle for 1 min.


TROUBLESHOOTING

NOTE:

If starter circuit is open (i.e., starter signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even through CMP sensor is in good condition.

When starter motor fails to run and this DTC appears, check starter circuit first.

Step

1

Action


Yes

Go to Step 2.

No



Go to Section 6G.

Go to Step 4.

2 Is engine cranked?

4 CMP sensor power supply voltage check :

1) With ignition switch OFF, disconnect CMP sen-

Go to Step 3.

3 Is there DTC P1500 (Engine starter signal circuit)? Go to DTC P1500 Diag.

Flow Table.

Go to Step 5.

sor coupler.

2) With ignition switch ON, check voltage between

C09-2 and C09-1 terminal. (See Fig.)


Faulty “BLU/BLK” wire and/or “GRY/YEL” wire.


Step Action

5 CMP sensor (REF) signal check :

1) With ignition switch OFF, connect CMP sensor coupler.

2) Disconnect couplers from ignition coil assembly and fuel injectors.

3) With ignition switch ON and crankshaft turned slowly, check voltage between C51-1-13 and

C51-3-26 terminal.

Does voltmeter indicator deflect between 0 – 1 V and 3 – 5.25 V 4 times while crankshaft turned two revolutions?

6 CMP sensor (POS) signal check :

1) With ignition switch ON and crankshaft turned slowly, check voltage between C51-1-12 and

C51-3-26 terminal.

Does voltmeter indicator deflect between 0 – 1 V and 3 – 5.25 V 6 times while crankshaft turned two revolutions?

Yes

Go to Step 6.

No

Faulty “YEL/GRN” wire or CMP sensor.

If OK, substitute a known-good ECM

(PCM) and recheck.

Poor C51-1-12 and/or

C51-3-13 terminal of

ECM (PCM) coupler connection.

If OK, substitute a known-good ECM (PCM) and recheck.

Faulty “YEL/BLU” wire or CMP sensor.


(PCM) and recheck.

Fig. for Step 4

1. Disconnected CMP sensor coupler

2. “BLU/BLK” wire (C09-2) terminal

3. “GRY/YEL” wire (C09-1) terminal


DTC P0400 Exhaust Gas Recirculation Flow Malfunction

SYSTEM/WIRING DIAGRAM

1. EGR valve

2. Intake manifold

3. Exhaust gas

4. Sensed information

5. ECM (PC)

6. MAP sensor

7. Main fuse

8. Main relay




During deceleration (engine speed high with closed throttle position) in which fuel cut is involved, difference in intake manifold pressure between when EGR valve is opened and when it is closed is smaller than specified value.


TROUBLE AREA

• EGR valve

• EGR passage

• Manifold absolute pressure sensor

• ECM (PCM)


WARNING:



NOTE:


PROCEDURE”.









6) Release accelerator pedal and with engine brake applied, keep vehicle coasting and then stop vehicle.

7) Check if pending DTC exists by using scan tool. If not, check if EGR system monitoring test has completed by using scan tool. If not in both of above checks (i.e., no pending DTC and EGR system monitoring test not completed), check vehicle conditions (environmental) and repeat Steps 3) through 6).

1. Vehicle speed km/h (mph)

2. Step


TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Is there DTC P0403 (EGR circuit malfunction)? Go to DTC P0403 Diag.

Flow Table.

3 Do you have SUZUKI scan tool?

Go to Step 4.

Go to Step 5.

4 EGR valve operation check :

1) With ignition switch OFF, install SUZUKI scan tool.

2) Check EGR system referring to Section

6E2.


5 MAP sensor check :

1) Check MAP sensor for performance referring to Section 6E2.


Intermittent trouble or faulty ECM (PCM). Check for intermittent referring to

“INTERMITTENT AND

POOR CONNECTION” in

Section 0A.

Go to Step 7.

Go to Step 6.

Go to Step 6.

Repair or replace.

Faulty “BLU/BLK” wire.

6 EGR valve power supply circuit check :

1) With ignition switch OFF, disconnect EGR valve coupler.

2) With ignition switch ON, check voltage

No



Go to Step 3.

between C04-2 and ground, C04-5 and ground.


7 EGR valve stepper motor coil circuit check :

1) With ignition switch OFF, connect EGR valve coupler and disconnect ECM (PCM) couplers.

2) Check resistance between C51-3-4 and

C51-2-12, C51-2-13, C51-2-14, C51-2-15.

Is each resistance 20 – 24 Ω at 20°C (68°F)?


1) Check MAP sensor for performance referring to Section 6E2.


Go to Step 8.

EGR passage clogged or

EGR valve malfunction.

If all above are OK, intermittent trouble or faulty

ECM (PCM).


TENT AND POOR CON-


Faulty EGR valve.

Repair or replace.


DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction

WIRING DIAGRAM

1. Main fuse

2. Main relay

3. EGR valve

4. ECM (PCM)



High voltage is detected at EGR valve stepping motor electrical circuit for specified time continuously.

(Circuit open or short).

TROUBLE AREA

EGR valve (stepping motor) or its circuit ECM

(PCM)


NOTE:


CEDURE”.






3) Start engine and run it for 10 sec.



TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

No



EGR valve malfunction.

2 EGR valve check :

1) With ignition switch OFF, disconnect connector from EGR valve.

2) Check for proper connection to EGR valve at each terminal.

3) If OK, check EGR valve for resistance referring to “EGR VALVE INSPECTION” in Section 6E2.


3 Wire harness check :

1) Connect connector to EGR valve.

2) Remove ECM (PCM) cover and disconnect connector from ECM (PCM).

3) Check for proper connection to ECM (PCM) at system related terminals.

4) If OK, check for resistance between the following terminals of ECM (PCM) connector disconnected.

EGR valve resistance :

C51-2-13 and C51-3-4, C51-2-14 and C51-3-4,

C51-2-15 and C51-3-4, C51-2-12 and C51-3-4 :

20 – 24 Ω at 20°C (68°F)

Go to Step 3.


Recheck referring to

“INTERMITTENT AND


Section 0A.

“BLU/BLK”, “LT GRN”,

“LT GRN/WHT” “LT GRN/

YEL” or “LT GRN/RED” circuit open or shorted to ground.

C51-2-13 and ground, C51-2-14 and ground,

C51-2-15 and ground, C51-2-12 and ground :

Infinity ( ∞)



DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1)

SYSTEM DIAGRAM

1. HO2S-1 (Bank-1) 4. TWC

2. HO2S-2 (Bank-1) 5. ECM (PCM)

3. WU-TWC


Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1 and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel injection volume. (Refer to Section 6E2.) While the above control is going on and if WU-TWC is in good condition, the output voltage of HO2S-2 is maintained at specified level. As WU-TWC becomes deteriorated, even when the above control is going on, the exhaust gas which has passed WU-TWC then passes HO2S-2 at the exhaust oxygen concentration similar to that of the pre-catalyst without being oxygenated or converted. Thus, waveforms of HO2S-1 and HO2S-2 output voltages become alike. ECM (PCM) judges deterioration of WU-TWC by comparing waveforms of HO2S-1 and HO2S-2.



While running under conditions described for DTC CON-

FIRMATION PROCEDURE, output waveform of HO2S-1 becomes similar to that of HO2S-2.


TROUBLE AREA


• Warm up three way catalytic converter

• Heated oxygen sensor – 2 or its circuit

• ECM (PCM)



WARNING:



NOTE:


PROCEDURE”.







4) Keep above vehicle speed for 5 min. or more (Throttle valve opening is kept constant in this step).

5) Stop vehicle and check if pending DTC exists by using scan tool. If not, check if catalyst monitoring test has completed by using scan tool. If not in both of above checks (i.e., no pending DTC and catalyst monitoring test not completed), check vehicle condition (environmental) and repeat Step 3) through 5).

TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Exhaust system visual inspection :

1) Check exhaust system for leaks, damage and loose connection.



1) Check output voltage of HO2S-2 referring

Step 2 of DTC P0136 Diag. Flow Table.


Go to Step 3.

Replace warm up three way catalytic converter.

No



Repair or replace.

Check “RED/BLK” and

“GRY/YEL” wires for open and short, and connections for poor connection.

If wires and connections are OK, replace HO2S-2.


DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2)

SYSTEM DIAGRAM

1. HO2S-1 (Bank-2) 4. TWC

2. HO2S-2 (Bank-2) 5. ECM (PCM)

3. WU-TWC


Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1 and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel injection volume. (Refer to Section 6E2.) While the above control is going on and if WU-TWC is in good condition, the output voltage of HO2S-2 is maintained at specified level. As WU-TWC becomes deteriorated, even when the above control is going on, the exhaust gas which has passed TWC then passes HO2S-2 at the exhaust oxygen concentration similar to that of the pre-catalyst without being oxygenated or converted. Thus, waveforms of HO2S-1 and HO2S-2 output voltages become alike. ECM (PCM) judges deterioration of WU-TWC by comparing waveforms of HO2S-1 and HO2S-2.



While running under conditions described for DTC CON-

FIRMATION PROCEDURE, output waveform of HO2S-1 becomes similar to that of HO2S-2.


TROUBLE AREA


• Warm up three way catalytic converter

• Heated oxygen sensor – 2 or its circuit

• ECM (PCM)



WARNING:



NOTE:


PROCEDURE”.







4) Keep above vehicle speed for 5 min. or more (Throttle valve opening is kept constant in this step).

5) Stop vehicle and check if pending DTC exists by using scan tool. If not, check if catalyst monitoring test has completed by using scan tool. If not in both of above checks (i.e., no pending DTC and catalyst monitoring test not completed), check vehicle condition (environmental) and repeat Step 3) through 5).

TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Exhaust system visual inspection :

1) Check exhaust system for leaks, damage and loose connection.



1) Check output voltage of HO2S-2 referring

Step 2 of DTC P0156 Diag. Flow Table.


Go to Step 3.

Replace warm up three way catalytic converter.

No



Repair or replace.

Check “RED/YEL” and

“GRY/YEL” wires for open and short, and connections for poor connection.

If wires and connections are OK, replace HO2S-2.


DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction


1. Main fuse

2. Main relay

3. EVAP canister purge valve

4. ECM (PCM)



Monitor signal of EVAP canister purge valve is different from command signal. (Circuit open or short)


TROUBLE AREA

• EVAP canister purge valve and its circuit

• ECM (PCM)


WARNING:



NOTE:

Check to make sure that following condition is satisfied when using the “DTC Confirmation Procedure.”







3) Start engine and warm up it completely.


5) Keep driving above vehicle speed for 20 min or more (Change of vehicle speed is permitted in this step).

6) Release accelerator pedal, stop vehicle and run engine at speed for 2 min.

7) Check DTC and pending DTC by using scan tool.

TROUBLESHOOTING

Step

2

Action


Check EVAP canister purge system for operation referring to “EVAP CANISTER PURGE

SYSTEM INSPECTION” in this section.


3 Check EVAP canister purge valve for resistance referring to “EVAP CANISTER PURGE VALVE

INSPECTION” in this section.

Is resistance as specified?

Yes

Go to Step 2.



TENT AND POOR CON-


“GRN/BLK” or “BLU/BLK” circuit open or short.

If wire and connections are OK, substitute a known-good ECM (PCM) and recheck.

No



Go to Step 3.

Replace EVAP canister purge valve.


Evap canister purge system inspection

1) Warm up engine to normal operating temperature.

2) Hoist vehicle so that all wheels rotate freely.

3) Set M/T in “Neutral” or A/T in “P” position and parking brake.

1

4) Disconnect purge hose (1) from EVAP canister.

5) Place finger against the end of disconnected hose (1) and check that vacuum is not felt there when engine is running at idle speed.

6) Release parking brake lever, set transfer in “2H” and M/T in

“1st” or A/T in “L”.

WARNING:

Make sure that transfer is set to “2H” range position for this check. If it is set to “4H” or “4L” position, front and rear wheels turn at high speed and a very dangerous situation may occur.

7) Also check that vacuum is felt when engine speed is increased to higher than about 1,500 r/min. and keep it for 3 min. or more. If check result is not described in steps 5) and

7), check EVAP canister purge valve, wire harness and vacuum passage.

Vacuum passage inspection

Start engine and run it at idle speed. With finger placed against vacuum nozzle (1), check that vacuum is applied.

If it is not applied, clean vacuum passage by blowing compressed air.


Vacuum hose inspection

Check hoses for connection, leakage, clog and deterioration.

Replace as necessary.

Evap canister purge valve and its circuit inspection

1) Connect SUZUKI scan tool to DLC (1) with ignition switch

OFF and disconnect vacuum hoses from each pipe.

2) Turn ignition switch ON, clear DTC and select “MISC TEST” mode on SUZUKI scan tool.

3) Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool.

If check result is not described, check vacuum hoses, purge valve, wire harness and connections.

EVAP canister purge valve :

Valve OFF [A] : When blowing into hose “A”, air should not come out of hose “B”.

Valve ON [B] : When blowing into hose “A”, air should come out of hose “B”.

Evap canister purge valve inspection

1) With ignition switch OFF, disconnect coupler from canister purge valve.

2) Check resistance between two terminals of EVAP canister purge valve (1).

If resistance is as specified, proceed to next operation check.

If not, replace.

Resistance of EVAP canister purge valve :

28 – 35 Ω at 20°C (68°F)

3) Disconnect vacuum hoses from intake manifold and its EVAP canister.

4) With coupler disconnected, blow into hose “A” (1). Air should not come out of hose “B” (2).


5) Connect 12 V-battery to EVAP canister purge valve (3) terminals. In this state, blow hose “A” (1).

Air should come out of hose “B” (2).

If check result is not as described, replace EVAP canister purge valve.

WARNING:

Do not suck the air through valve. Fuel vapor inside valve is harmful.

6) Connect vacuum hoses.

7) Connect EVAP canister purge valve coupler securely.


DTC P0460 Fuel Level Sensor Circuit High Input


1. Fuel level sensor

2. Fuel meter in combination meter

3. ECM (PCM)



Fuel level sensor output voltage higher than specified value is detected for specified time.


TROUBLE AREA

• Fuel level gauge or its circuit

• Fuel level sensor or its circuit

• ECM (PCM)


NOTE:


CEDURE”.





2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run engine for 1 min.



TROUBLESHOOTING

Step Action


2 Does fuel level meter in combination meter indicate “E” (Empty)?

3 Check fuel level sensor and its circuit:

1) Check voltage between terminal E61-28 and ground with ignition switch ON.

Is it about 7.1 V or more?

4 Is voltage in Step 3 “9 – 14 V”?

5 Check Fuel Level Sensor:

1) Turn ignition switch OFF and disconnect fuel level sensor connector (L15 – R01).

2) Check for proper connection to fuel level sensor at L15-4 and L15-3 terminals.

3) If OK, then check resistance between R01-4 and R01-3 terminals. (Refer to “FUEL LEVEL

GAUGE (SENDER GAUGE)” in Section 8C.)

Is value close to one of above values indicated?

Yes

Go to Step 2.

No



Go to Step 3.

Replenish fuel tank with fuel and go to Step 3.

Go to Step 4.

“BLU/WHT” wire shorted to power circuit or fuel level meter malfunction.

“BLU/WHT” or “BLK/YEL” circuit open.





TENT AND POOR CON-

NECTION” in Section

0A.

Go to Step 5.

Check “BLU/WHT” and

“BLK/YEL” wires between R01 and R02 connections.

If OK, replace fuel level sensor.


DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction

WIRING DIAGRAM

1. Speedometer

2. Vehicle speed sensor

3. Cruise control module (if equipped)

4. ECM (PCM)



Vehicle speed signal not inputted although fuel is kept cut for longer than 5 seconds


TROUBLE AREA

• Vehicle speed sensor circuit open or short

• Vehicle speed sensor

• Vehicle speed sensor drive gear or driven gear

• Speedometer malfunction

• Cruise control module malfunction (if equipped)

• ECM (PCM)



WARNING:



NOTE:


CEDURE”.







4) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 5 seconds or more and then stop vehicle.


TROUBLESHOOTING

Step Action


Go to Step 2.

Yes

2 Does speedometer indicate vehicle speed? Faulty “BLU/YEL” wire or poor C51-1-14 connection.


OK, intermittent trouble or faulty ECM (PCM).

Check for intermittent referring to “INTERMITTENT

AND POOR CONNECTION” in Section 0A.

Go to Step 4.

3 VSS power supply voltage check:

1) With ignition switch OFF, remove VSS coupler.

2) With ignition switch ON leaving engine

OFF, check voltage between C20-3 and

C20-2 terminal of VSS coupler.


4 VSS signal harness check:




Is voltage 4 V or more?

Go to Step 5.

No



Go to Step 3.

“BLK/BLU” or “BLK/YEL” wire open/short.

Go to Step 6.


Step Action

5 VSS visual inspection:

1) Remove VSS referring to “TRANSFER” section.

2) Check VSS drive and driven gears for damage and excessive wear.


6 Speedometer circuit check:

1) With ignition switch OFF, disconnect

G11 coupler from combination meter.





7 Cruise control module circuit check (if equipped):

1) With ignition switch OFF, disconnect

E132 coupler from cruise control module.





Poor VSS connection or VSS malfunction.

If connection is OK, substitute a known-good VSS and recheck.

Yes

Substitute a known-good combination meter and recheck.

Substitute a known-good cruise control module and recheck.

No

Replace VSS.

Go to Step 7.

“BLU/YEL” wire open/ short or faulty ECM

(PCM).



[A] Fig. for Step 3 / [B] Fig. for Step 4, 6, 7

1. VSS coupler

2. “BLU/YEL” (C20-1) terminal

3. “BLK/YEL” (C20-2) terminal

4. “BLU/BLK” (C20-3) terminal

Fig. for Step 5

1. VSS coupler

2. VSS driven gear

3. VSS drive gear


DTC P0505 Idle Air Control System Malfunction


1. Throttle body

2. Idle air control valve

3. ECM (PCM)


5. FIA valve

6. Main fuse

7. Main relay



• Engine idle speed is 100 r/min. or more lower than target idle speed for longer than 20 sec. continuously.

or

• Engine idle speed is 200 r/min or more higher than target idle speed for longer than 20 sec. continuously.


TROUBLE AREA

• IAC valve or its circuit

• Abnormal air drawn in air intake system

• FIA (fast idle air) valve



NOTE:


CEDURE”.






3) Run engine at idle speed for 1 min.


TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 Idle speed check:

1) Check engine idle speed referring to “IDLE

SPEED/IDLE AIR CONTROL DUTY


Is engine idle speed within specification?

3 IAC valve check:

1) Check IAC valve referring to “IAC VALVE



4 IAC valve circuit check:

1) With ignition switch OFF, disconnect ECM

(PCM) couplers.

2) Check for proper connection to IAC valve at

C51-1-4, C51-1-5, C51-1-16 and C51-1-17 terminals.

3) If OK, check resistance between C51-1-4 and C51-1-5, C51-1-16 and C51-1-17.

Is each resistance 51 – 67

Ω?

5 IAC valve power supply voltage check:

1) Connect ECM (PCM) couplers.

2) With ignition switch OFF, disconnect C29 coupler of IAC valve.

3) With ignition switch ON, check voltage between C29-2 and ground, C29-5 and ground.




TENT AND POOR CON-


Go to Step 6.

Go to Step 5.

IAC valve or ECM (PCM) malfunction.

No



Go to Step 3.

Go to Step 4.

“LT GRN/BLK”, “PPL/

BLK”, “GRY/BLU” or

“PPL/YEL” wire open or short.

If wire and connections are OK, replace IAC valve.

Open “BLU/BLK” wire.


Step Action

6 Was idle speed higher than specification in

Step 2?

Yes

Check FIA valve for malfunction.

Check abnormal air inhaling from intake manifold, throttle body, PCV valve and EVAP canister purge control system.

No

Check parts or system which can cause engine low idle.

Check FIA valve for stuck.

Air inhaling from between throttle body and MAF sensor, EGR valve malfunction (leakage from valve seat), accessory engine load, clog of idle air passage, engine mechanical, engine overheat and etc.

DTC P0601 (DTC No.71) Internal Control Module Memory Check Sum Error


Internal control module is installed in ECM (PCM).



Data write error or check sum error ECM (PCM)

TROUBLE AREA




3) Start engine and run it at idle if possible.


TROUBLESHOOTING

Substitute a known-good ECM (PCM) and recheck.


DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction

WIRING DIAGRAM

1. MAP sensor

2. ECM (PCM)



• While engine is running after being warmed up and with throttle opening smaller than specification, higher than 4.6 V manifold absolute pressure sensor output voltage is detected for specified time or with throttle opening larger than specification, lower than 0.2 V manifold absolute pressure output voltage is detected for specified time.


TROUBLE AREA

• Manifold absolute pressure sensor

• Manifold absolute pressure sensor vacuum passage

• ECM (PCM)


WARNING:



NOTE:


CEDURE”.







3) Run engine at idle speed for 1 min. (engine coolant temp. becomes 76°C (169°F) or more).

4) Increase vehicle speed to 80 km/h (50 mph).

5) Keep driving above vehicle speed for 1 min (Change of vehicle speed is permitted in this step).


TROUBLESHOOTING

Step Action


Yes

Go to Step 2.

2 MAP sensor signal check :


2) Check voltage between C51-3-8 and C51-

3-25 under following conditions.

• With ignition switch ON leaving engine OFF

: 0.2 V or higher

• At idling : 4.6 V or lower



1) Disconnect connector from MAP sensor.

2) Check for proper connection to MAP sensor at each terminal.

3) If OK, check MAP sensor for performance referring to “MAP SENSOR INSPECTION” in Section 6E2.




TENT AND POOR CON-


“RED/WHT”, “GRY/YEL” or “GRY/RED” circuit open/short.

If wire and connections are OK, substitute a known-good ECM (PCM) and recheck.

No



Go to Step 3.

Replace MAP sensor.


DTC P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Performance Problem


Barometric pressure sensor is installed in ECM (PCM).



DTC P1450 :

Barometric pressure out of specification is detected.

DTC P1451 :

While running under conditions described for “DTC CONFIRMATION

PROCEDURE”, barometric pressure value compared with intake manifold vacuum value in fuel cut state is not as specified.


TROUBLE AREA

• Barometric pressure sensor in ECM

(PCM)

• Manifold absolute pressure sensor performance problem

• Barometric pressure sensor in ECM

(PCM)


For DTC P1450


2) Turn ON ignition switch and clear DTC by using scan tool and run engine for 1 min.


For DTC P1451

WARNING:




2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and warm up engine to normal operating temperature.

3) Increase engine speed to 3,000 r/min. in 3rd gear in case of M/T and “2” range in case of A/T.

4) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 5 sec. or more (keep fuel cut condition for 5 sec. or more). If fuel cut condition is not kept for 5 sec. or more, coast down a slope in engine speed 1600 – 3000 r/min for 5 sec. or more.

5) Stop vehicle and run engine at idle.

6) Repeat steps 3) – 5) 2 times.


TROUBLESHOOTING (DTC P1450/P1451)

Step

1

2

Action


Is DTC P1451 set?


1) Check MAP sensor and its circuit referring to

Steps 2 and 3 of “DTC P1408 Diag. Flow Table”.


Yes

Go to Step 2.

Go to Step 3.



No

Go to “ENGINE DIAG. FLOW




MAP sensor or its circuit malfunction.


DTC P1500 Engine Starter Signal Circuit Malfunction

WIRING DIAGRAM

1. Engine start switch in ignition (main) switch 2. Starting motor 3. Transmission range sensor (switch)


4. ECM (PCM)


• Engine starts even though vehicle is at stop and engine start signal is not inputted.

or

• Engine start signal is inputted continuously for specified time while engine is running.



TROUBLE AREA

• Engine start signal circuit

• ECM (PCM)

NOTE:


CEDURE”.





2) Turn ON ignition switch and clear DTC by using scan tool, then start engine and run it for 3 min. or more.


TROUBLESHOOTING

Step

1

2

Action


Check for voltage at terminal C51-1-24 of

ECM (PCM) connector connected, under following condition.

Engine starter signal specification :

While engine cranking : 6 – 14 V

After starting engine : 0 – 1 V

Is voltage as specified?

Go to Step 2.

Yes

Poor C51-1-24 connection or intermittent trouble.


“INTERMITTENT AND POOR

CONNECTION” in Section 0A.

If wire and connections are OK, substitute a known-good ECM

(PCM) and recheck.

No

Go to “ENGINE DIAG. FLOW TABLE” in this section.

“BLK/YEL” circuit open.


DTC P1510 Ecm Back-Up Power Supply Malfunction

WIRING DIAGRAM

1. Main fuse box

2. To DLC

3. ECM (PCM)


Battery voltage is supplied to keep DTC memory, values that ECM has learned to control engine, etc. in ECM even when ignition switch is turned OFF.



Back-up circuit voltage lower than specification is detected while engine is running.


TROUBLE AREA

• ECM (PCM) back-up circuit

• ECM (PCM)

NOTE:


CEDURE”.





2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and run engine at idle speed for 1min.


TROUBLESHOOTING

Step

1

2

Action


Battery voltage supply circuit check :


2) While engine running, check voltage between E61-

2 and ground.


Go to Step 2.

Yes

Poor E61-2 connection or intermittent trouble.

Check for intermittent referring to “INTERMITTENT AND


Section 0A.

If wire and connections are

OK, substitute a known-good


No

Go to “ENGINE DIAG. FLOW


“WHT” circuit open or short.


Table B-1 Fuel Pump Circuit Inspection

WIRING DIAGRAM


2. Main fuse

3. Main relay

INSPECTION

4. Fuel pump relay

5. Fuel pump

6. ECM (PCM)

CAUTION:

Check to make sure that connection is made between correct terminals.

Wrong connection can cause damage to ECM, wire harness etc.

Step Action

1 Fuel pump operation check :

1) Remove fuel filler cap.

2) Turn ON ignition switch.

Is fuel pump operation sound heard for 3 sec. after ignition switch ON?

2 Fuel pump circuit check :

1) With ignition switch OFF, remove fuel pump relay from connector.

2) Check for proper connection to relay at each terminal.

3) If OK, using service wire, connect terminals

E07-7 and E07-8 of relay connector. (See

Fig.)

Is fuel pump heard to operate at ignition switch

ON?

Yes

Fuel pump circuit is in good condition.

Go to Step 3.

No

Go to Step 2.

“BLU/BLK”, “PNK/BLK” or

“BLK” circuit open or fuel pump malfunction.


Step Action

3 Fuel pump relay check :

1) Check fuel pump relay referring to “FUEL

PUMP RELAY INSPECTION” in Section

6E2.


Yes

“BLK/WHT” or “WHT/

GRN” circuit open or poor

E61-23 connection.



No

Replace fuel pump relay.

Fig. for Step 2

1. Fuel pump relay connector

Table B-2 Fuel Injectors and Circuit Inspection

WIRING DIAGRAM


2. Main fuse

3. Main relay

4. Injector No.1

5. Injector No.2

6. Injector No.3

7. Injector No.4

8. Injector No.5

9. Injector No.6

10. ECM (PCM)


INSPECTION

Step Action

1 Check injector for operating sound :

Using sound scope, check each injector for operating sound at engine cranking.

Do all 6 injectors make operating sound?

2 Wire harness check :

1) Remove ECM (PCM) cover and disconnect connectors from ECM (PCM).

2) Check for resistance between following terminals of ECM (PCM) connector disconnected.

Fuel injector and its circuit resistance (C51-

2-1 – C51-3-4, C51-2-2 – C51-3-4, C51-2-8 –

C51-3-4, C51-2-9 – C51-3-4, C51-2-21 – C51-

3-4 and C51-2-22 – C51-3-4) :

14.2 – 14.8 Ω at 20°C (68°F)


3 Does none of 6 injectors make operating sound at Step 1?

Yes

Go to Step 2.

Fuel injector circuit is in good condition.

4 Check power circuit of injectors for open and short.

Is it normal?

No

Go to Step 3.

“PNK”, “PNK/BLK”, “PNK/

GRN”, “PNK/BLU”, “GRY/

GRN” and “GRY/BLK” shorted each other.

Go to Step 4.

Check all 6 injectors for resistance respectively.

It resistance is OK, substitute a known-good ECM

(PCM) and recheck.

Check coupler connection and wire harness of injector not making operating sound and injector itself (Refer to “FUEL

INJECTOR INSPEC-

TION” in Section 6E2).

Power circuit open or short.

Table B-3 Fuel Pressure Inspection

SYSTEM DIAGRAM


1. Injector

2. Delivery pipe

3. Fuel pressure regulator

Special tool

(A) : 09912-58441

(B) : 09912-58431

(C) : 09919-58421

4. Fuel filter

5. Fuel pump

INSPECTION

NOTE:

Before using the following flow table, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.

No

Go to Step 5.

Step Action

1 1) Install fuel pressure gauge, referring to

“FUEL PRESSURE INSPECTION” in Section 6E2.

2) Operate fuel pump.

Is fuel pressure then 270 – 310 kPa

(2.7 – 3.1 kg/cm

2

, 38.4 – 44.0 psi)?

2

Is 200 kPa (2.0 kg/cm

2

, 28.4 psi) or higher fuel pressure retained for 1 minute after fuel pump is stopped at Step 1?

Yes

Go to Step 2.

Go to Step 3.

Go to Step 4.


Step Action

3 1) Start engine and warm it up to normal operating temperature.

2) Keep it running at specified idle speed.

Is fuel pressure then within 210 – 260 kPa

(2.1 – 2.6 kg/cm

2

, 29.8 – 37.0 psi)?

Yes

Normal fuel pressure.

4 Is there fuel leakage from fuel feed line hose, pipe or joint?

Fuel leakage from hose, pipe or joint.

5 Was fuel pressure higher than spec. in Step 1? Go to Step 6.

6 1) Disconnect fuel return hose from fuel pipe and connect new hose to it.

2) Put the other end of new return hose into approved gasoline container.

3) Operate fuel pump.

Is specified fuel pressure obtained then?

7 Was no fuel pressure applied in Step 1?

Restricted fuel return hose or pipe.

Go to Step 8.

8

10

With fuel pump operated and fuel return hose blocked by pinching it, is fuel pressure applied?

9 1) Operate fuel pump.

2) With fuel return hose blocked by pinching it, check fuel pressure.

Is it 450 kPa (4.5 kg/cm

2

, 64.0 psi) or more?

1) Disconnect fuel return hose from fuel pipe and connect new hose to it.

2) Put the other end of new return hose into approved gasoline container.

3) Check again if specified fuel pressure is retained.

While doing so, does fuel come out return hose?

Faulty fuel pressure regulator.



No

Clogged vacuum passage for fuel pressure regulator or faulty fuel pressure regulator.

Go to Step 10.

Go to Step 7.


Go to Step 9.

(Low pressure is measured.)

Shortage of fuel or fuel pump or its circuit defective (Refer to “TABLE B-

1”).

Clogged fuel filter, restricted fuel feed hose or pipe, faulty fuel pump or fuel leakage from hose connection in fuel tank.

Fuel leakage from injector, faulty fuel pump

(faulty check valve in fuel pump) or fuel leakage from fuel pressure regulator diaphragm.


Table B-4 Idle Air Control System Inspection

WIRING DIAGRAM

1. Throttle body


3. ECM (PCM)


5. Main fuse

6. Main relay

INSPECTION

Step Action

1 Check engine idle speed and IAC duty referring to “IDLE SPEED/IAC DUTY


Is idle speed/IAC duty within specification?

2 Is engine idle speed kept specified speed even with headlights turned ON?

Go to Step 2.

Yes


Go to Step 3.

No

Go to Step 3.


Step

4

Action

3 Check IAC valve referring to “IAC VALVE



Was idle speed within specification in

Step 1?

Go to Step 4.

Yes No

IAC valve malfunction, “BLU/

BLK”, “LT GRN/BLK”, “PPL/

BLK”, “GRY/BLU” or “PPL/

YEL” wire open or short or poor coupler connection.

If all above are OK, substitute a known-good ECM

(PCM) and recheck.

Go to Step 5.

Check for following :

FIA valve, Vacuum leaks, air inhaling, EVAP canister purge control system, accessory engine load, stuck of PCV valve, clog of idle air passage, MAF sensor, TP sensor,

ECT sensor, EGR valve malfunction (leakage from valve seat), A/C signal, transmission range switch signal and power steering switch signal.

Go to Step 6.

Go to Step 8.

5 Was idle speed higher than specification in Step 1?

6 Check A/C (input) signal circuit referring to Step 1 of “Table B-5”. (A/C signal can be also checked by using SUZUKI scan tool.)


7 Was IAC duty less than about 2% in Step

1 of this table?

Go to Step 7.

A/C signal circuit open or short, or A/C system malfunction.

8 Check transmission range switch signal referring to “INSPECTION OF ECM

(PCM) AND ITS CIRCUIT” in this section.


9 Was IAC duty more than about 30% in

Step 1 of this table?

Check FIA valve.

Check abnormal air inhaling from intake manifold, throttle body, PCV valve and EVAP canister purge control system.

Go to Step 9.

Check TP sensor (closed throttle position) and ECT sensor for performance.

If sensors are OK, substitute a known-good ECM (PCM) and recheck.

Transmission range switch malfunction or its circuits open or short.

Check parts or system which can cause engine low idle.

Check FIA valve.

Air inhaling from between throttle body and MAF sensor, EGR valve malfunction (leakage from valve seat), accessory engine load, clog of idle air passage and etc.




Table B-5 A/C Signal Circuits Inspection (If Equipped)

WIRING DIAGRAM

1. A/C control module (amplifier)

2. ECM (PCM)

INSPECTION

Step Action

1 Check A/C Signal Circuit.

1) Check voltage at terminal E61-17 with ignition switch ON.

A/C signal circuit specification :

A/C switch and/or heater blower switch OFF (A/

C is not operating) : 10 – 14 V

Both A/C switch and heater blower switch ON :

0 – 1.5 V

Are check result as specified?

2 Check A/C Cut Signal Circuit.

1) Check voltage at terminal E61-8.

A/C cut signal specification :

While engine running and A/C switch and/or heater blower switch OFF

(A/C is not operating) : 0 – 1.5 V

While engine running at idle speed and both A/

C switch and heater blower switch ON

(A/C is operating) : 10 – 14 V

Are check result as specified?

Yes

Go to Step 2.

A/C control signal circuits are in good condition.

No

“YEL/BLK” circuit open or short, Evaporative temperature is below 1°C

(34°F) or faulty A/C system.

“GRY/WHT” circuit open or short, Poor performance of ECT sensor, TP sensor, Engine start signal inputted or A/C amplifier malfunction.

If none of the above exists, substitute a known-good ECM (PCM) and recheck.


Table B-6 A/C Condenser Fan Motor Relay Control System Inspection (If

Equipped)

WIRING DIAGRAM


2. Main fuse

INSPECTION

3. A/C fuse

4. A/C condenser fan motor relay

5. A/C condenser fan motor

6. ECM (PCM)

WARNING:

Keep hands, tools, and clothing away from A/C condenser fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch in the “ON” position.

Step Action

1 1) Check DTC referring to “DTC CHECK” in this section.

Is there any malfunction DTC?

2 1) Check A/C condenser fan for operation.

A/C condenser fan should be operated under following condition A or B only.

A : When engine is running and A/C is operating.

B : When engine coolant temp. is 113°C (235°F) or more with ignition switch ON.


3 1) Remove ECM (PCM) cover.

2) Check voltage between E61-22 terminal of ECM

(PCM) connected coupler and ground.

Other than conditions A and B in Step 2 :

10 – 14 V

Under condition A or B in Step 2 :

0 – 1 V


Yes


Diag. Flow Table.

This system is in good condition.

Fuse blown, “RED”,

“RED/BLK” or “RED/

BLU” circuit open, malfunction of condenser fan motor or relay.

No

Go to Step 2.

Go to Step 3.

“YEL/GRN” circuit open, “YEL/BLU” circuit open or short, or relay malfunction.

If above are OK, substitute a known-good



Special Tool

09912-58441

Pressure gauge

09912-58431

Pressure hose

09912-58490

3-way joint & hose

09912-58421

Checking tool set

(See NOTE “A”.)

09917-47011

Vacuum pump gauge

09930-88521

Injector test lead

09931-76011

Tech 1A kit (SUZUKI scan tool) (See NOTE “B”.)


Tech 1A

09931-76030


Tech 1A

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-1, 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 (H27 ENGINE) 6A2-1

SECTION 6A2

ENGINE MECHANICAL (H27 ENGINE)

WARNING:






NOTE:

• For the descriptions (items) not found in this section, refer to the same section of service manual mentioned in the FOREWORD of this manual.

• Whether following systems (parts) are used in the particular vehicle or not depends on specifications. Be sure to bear this in mind when performing service work.

– EGR valve

– Warm up three way catalytic converter

– Heated oxygen sensor(s)

– Three way catalytic converter

– CKP sensor

– MAP sensor

6A2

CONTENTS

On-Vehicle Service........................................6A2-2

Throttle Body and Intake Manifold ..............6A2-2

Exhaust Manifold.........................................6A2-9

LH (No.1) Bank 2nd Timing Chain and Chain Tensioner .................................6A2-13

Camshaft and Valve Lash Adjuster ...........6A2-14

Valves and Cylinder Heads .......................6A2-17

Piston, Piston Rings, Connecting Rods and Cylinders ............................................ 6A2-21

Unit Repair Overhaul .................................. 6A2-26

Engine Assembly ...................................... 6A2-26

Main Bearings, Crankshaft and Cylinder Block .................................... 6A2-30

Special Tool................................................. 6A2-36

6A2-2 ENGINE MECHANICAL (H27 ENGINE)


Throttle Body and Intake Manifold

1. Air cleaner box

2. Intake air hose

3. Intake air pipe

4. Surge tank pipe

5. Gasket

6. Intake manifold

7. Intake manifold gasket

8. Throttle body assembly

9. Throttle body gasket

10. Intake collector

11. Gasket

12. IAT sensor

13. MAF sensor

14. MAP sensor

15. Throttle body nut

16. Throttle body bolt

Tightening Torque

Do not reuse

2


REMOVAL

1) Release fuel pressure in fuel feed line by referring to Section

6.

CAUTION:



3) Drain coolant.

WARNING:

To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.

1. Radiator

2. Radiator drain plug

4) Remove strut tower bar (2).

5) Disconnect coupler from intake air temp. sensor, and MAF sensor.

6) Remove surge tank cover (1).

1

1

2

7) Remove air cleaner upper case, intake air hose, intake air pipe (1) and surge tank pipe (2) as one component. Do not disassemble them, when removing and reinstalling.


1

3

2

3

8) Disconnect accelerator cable (1) and A/T throttle cable (2)

(for A/T vehicle) from throttle body.

9) Disconnect water hoses (3) from throttle body.

1

2

10) Disconnect injector wire (1) coupler.

11) Disconnect brake booster hose (2) from intake manifold.

2

12) Disconnect couplers of TP sensor (1) and IAC valve (2).

13) Disconnect earth terminal (3) from intake collector.

14) Remove clamp bracket (4) from intake collector.

1

4

3

7

6

2

3

8

5

4

1

9

15) Disconnect couplers from manifold absolute pressure (MAP) sensor, EVAP canister purge valve, earth terminal and EGR valve.

16) Disconnect PCV hose from cylinder head cover.

Disconnect breather hoses from throttle body or cylinder head cover.

17) Disconnect hoses of EVAP canister purge valve and heater.

18) Remove EGR pipe.


2. EGR valve

3. EGR pipe

4. EVAP canister purge valve hose

5. Heater hose

6. PCV hose

7. Water hose

8. Breather hose

9. Earth terminal coupler


19) Disconnect hoses of heater, EVAP canister, fuel feed and fuel return.

1. Heater hose

2. Fuel feed hose

3. Fuel return hose

4. EVAP canister hose

4

2

2

3

1

1

3

20) Remove throttle body (1) and intake collector (2) from intake manifold (3).

1

21) Disconnect hoses of PCV valve and EVAP canister purge valve from intake collector.

22) Remove throttle body (1) from intake collector.

23) Remove EGR valve and EVAP canister purge valve from intake collector.

24) Remove intake manifold bolts (8 pc.) and nuts (4 pc.).

25) Remove intake manifold.


INSTALLATION

1) Install new intake manifold gaskets (1) to cylinder heads.

(a)

(a)

(a)

1

(a)

2) Install intake manifold (1).

Tighten bolts and nuts to specified torque.


Intake manifold bolt and nut (a) :

23 N·m (2.3 kg-m, 16.5 lb-ft)

1

1

3

2

(b)

3) Install throttle body (2) to intake collector (1) with new throttle body gasket.

Tighten bolts and nuts to specified torque.


Throttle body bolt and nut (b) :

23 N·m (2.3 kg-m, 16.5 lb-ft)

(b)

2

4) Install EGR valve (1), EVAP canister purge valve (2), manifold absolute pressure (MAP) sensor and each hoses to intake collector and throttle body if removed.

Use new gasket, when installing IAC valve and EGR valve.


5) Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.

4


6) Connect hoses of heater, EVAP canister, fuel feed and fuel return.

1. Heater hose

2. Fuel feed hose

3. Fuel return hose

4. EVAP canister hose

2

7

6

2

2

3

1

3

1

8

5

4

1

9

7) Install EGR pipe with new gaskets.

8) Connect hoses of EVAP canister purge valve and heater.

9) Connect hoses of PCV, breather and water.


2. EGR valve

3. EGR pipe


5. Heater hose

6. PCV hose

7. Water hose

8. Breather hose

9. Earth terminal coupler

10) Connect couplers of manifold absolute pressure (MAP) sensor, EVAP canister purge valve and EGR valve.

Fix wire harness with clamps.

11) Install clamp bracket (4) to intake collector.

12) Connect earth terminal (3) to intake collector.

13) Connect couplers of TP sensor (1) and IAC valve (2).

4

3

1

2

14) Connect brake booster hose (2) to intake manifold.

15) Connect injector wire (1) coupler.


2

3

3

1

16) Connect water hoses (3) to throttle body.

17) Connect accelerator cable (1) and A/T throttle cable (2) (for

A/T vehicle) to throttle body.

18) Install surge tank pipe (2) to intake manifold with new gaskets and intake air pipe (1) to throttle body.

1

2

19) Install surge tank cover (1).

1

20) Install air cleaner upper case.

21) Connect coupler to intake air temp. sensor and MAF sensor.

22) Install strut tower bar (1).

23) Check to ensure that all removed parts are back in place.

Reinstall any necessary parts which have not been reinstalled.

24) Refill cooling system referring to “COOLING SYSTEM

FLUSH AND REFILL” in Section 6B.

25) Connect negative cable at battery.


26) Upon completion of installation, verify that there is no fuel leakage at each connection according to procedure described in Section 6.

Exhaust Manifold

WARNING:

To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system has cooled off.

1. Left (No.1) exhaust manifold

Right (No.2) exhaust manifold

2. Exhaust manifold cover

3. Exhaust No.1 pipe

A. Without WU-TWC

B. With WU-TWC

REMOVAL


2) Remove air cleaner upper case and intake air hose if right side exhaust manifold is removed.

3) Detach couplers from their bracket and disconnect oxygen sensor lead wires at couplers.

1. HO2S-1 (Green connector)

2. HO2S-2 (Black connector)


4

1

3

2

4) Disconnect EGR pipe from right (No.2) bank exhaust manifold if right side exhaust manifold is removed.

5) Remove oil level gauge guide (3) if left side exhaust manifold is removed.

6) Detach P/S pump assembly as following, if left side exhaust manifold is removed.

a) Loosen P/S pump drive belt by loosening tensioner bolt.

b) Remove P/S pump mounting bolts.

c) Detach P/S pump assembly (4) with its hoses from cylinder block.

7) Remove exhaust manifold covers (2) from exhaust manifolds

(1).

8) Hoist vehicle.

9) For 4WD vehicle, before disconnecting front propeller shaft, put match mark (1) on joint flange and propeller shaft to facilitate their installation as shown in the figure.

10) For 4WD vehicle, disconnect propeller shaft from front differential.

11) Remove exhaust manifold stiffeners (1).


A. Without WU-TWC

B. With WU-TWC

12) Remove stabilizer bar mounting bolt and pull down stabilizer bar if right side exhaust manifold is removed.

13) Remove exhaust manifolds and their gaskets from cylinder heads.


INSTALLATION

1) Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe.

2) Install exhaust manifolds.

• Always install new bolts with pre-coated adhesive to the locations with ✱ mark.

• Tighten both manifold nuts and bolts to specified torque.


Exhaust manifold bolt and nut (a) :

30 N·m (3.0 kg-m, 21.5 lb-ft)

1. Left (No.1) exhaust manifold

2. Right (No.2) exhaust manifold

3) Install stabilizer bar if it was removed. Refer to “STABILIZER

BAR / BUSHINGS” in Section 3D.

4) Install exhaust manifold stiffeners (if removed).

5) Install exhaust No.1 pipe (1).

Tighten exhaust No.1 pipe bolts to specified torque.


Exhaust No.1 pipe bolt (b) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

2. Exhaust No. 2 pipe

6) Tighten exhaust No.1 pipe nuts to specified torque.


Exhaust No.1 pipe nut (b) :

50 N·m (5.0 kg-m, 36-5 lb-ft)


2. Exhaust manifold

A. Without WU-TWC

B. With WU-TWC


4

1

3

2

7) Reverse removal procedure to install front propeller shaft if removed.

When installing propeller shaft, align match mark (1).

Use following specification to torque universal joint flange.


Universal joint flange bolt (c) :

55 N·m (5.5 kg-m, 40.0 lb-ft)

8) Connect EGR pipe to left (No.1) bank exhaust manifold (1).

9) Install exhaust manifold covers (2).

10) Install oil level gauge guide (3) using new O-ring.

11) Install P/S pump assembly (4) if it was removed. Refer to

“POWER STEERING PUMP” in Section 3B1.

12) Adjust P/S pump drive belt tension, refer to “POWER

STEERING BELT CHECK AND ADJUSTMENT” in Section

3B1.

13) Connect oxygen sensor lead wire couplers.

Be sure to clamp its lead wires.

1. HO2S-1 (Green connector)

2. HO2S-2 (Black connector)


Upon completion of installation, start engine and check that no exhaust gas leakage exists.


LH (No.1) Bank 2nd Timing Chain and Chain Tensioner

1. LH bank 2nd timing chain

2. Timing chain tensioner adjuster No.3

3. LH bank intake camshaft sprocket

4. LH bank exhaust camshaft sprocket

5. Camshaft sprocket bolt

6. Timing chain guide No.4


8. Idler sprocket No.2

9. Timing chain tensioner adjuster No. 3 bolt

10. Timing chain tensioner adjuster No. 3 nut

11. Timing chain guide No. 4 bolt

Tightening Torque


Camshaft and Valve Lash Adjuster

1. RH bank 2nd timing chain

2. RH bank exhaust camshaft

3. RH bank intake camshaft

4. RH bank exhaust camshaft holder

5. RH bank intake camshaft holder

6. LH bank intake camshaft

7. LH bank exhaust camshaft

8. LH bank intake camshaft holder

9. LH bank exhaust camshaft holder

10. LH bank camshaft holder


12. Valve lash adjuster

13. Camshaft housing bolt

Tightening Torque

Apply engine oil to sliding surface of each parts.


INSPECTION

Cam wear

Using a micrometer, measure cam height. If measured height is below its limit, replace camshaft.

Intake cam height :

Standard : 40.402 – 40.562 mm (1.5906 – 1.5969 in.)

Limit : 40.300 mm (1.3581 in.)

Exhaust cam height :

Standard : 39.428 – 39.588 mm (1.5523 – 1.586 in.)

Limit : 39.400 mm (1.5512 in.)

Camshaft runout

Set camshaft between two “V” blocks, and measure its runout by using a dial gauge.

If measured runout exceeds below specified limit, replace camshaft.

Camshaft runout limit :

0.04 mm (0.002 in.)

Camshaft journal wear

Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.

If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing housings.

Check clearance by using gaging plastic. The procedure is as follows.

1) Clean housings and camshaft journals.

2) Make sure that all valve lash adjusters are removed and install camshaft to cylinder head.

3) Place a piece of gaging plastic the full width of journal of camshaft (parallel to camshaft).

4) Install camshaft housing.

5) Tighten camshaft housing bolts in such order ([A] : “1”

→

“17”, [B] : “1”

→ “19”) as shown in the figure a little at a time till they are tightened to specified torque.

NOTE:

Do not rotate camshaft while gaging plastic is installed.

[A] : RH bank

[B] : LH bank


6) Remove housing, and using scale (2) on gaging plastic (1) envelop, measure gaging plastic (1) width at its widest point.

Camshaft journal clearance :

Standard : 0.045 – 0.099 mm (0.0018 – 0.0039 in.)

Limit : 0.12 mm (0.0047 in.)

If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal.

Replace camshaft or cylinder head assembly whichever the difference from specification is greater.

Camshaft journal bore dia. (IN & EX) :

Standard : 26.000 – 26.033 mm (1.0236 – 1.0249 in.)

Camshaft journal O.D. (IN & EX) :

Standard : 25.934 – 25.955 mm (1.0210 – 1.0218 in.)

Wear of hydraulic valve lash adjuster

Check adjuster for pitting, scratches, or damage.

If any malcondition is found, replace.

Measure cylinder head bore and adjuster outside diameter to determine cylinder head-to-adjuster clearance. If clearance exceeds limit, replace adjuster or cylinder head.

Hydraulic valve lash adjuster O.D. :

Standard : 30.959 – 30.975 mm (1.2188 – 1.2194 in.)

Cylinder head bore :

Standard : 31.000 – 31.025 mm (1.2205 – 1.2214 in.)

Cylinder head to adjuster clearance :

Standard : 0.025 – 0.066 mm (0.0010 – 0.0025 in.)

Limit : 0.15 mm (0.0059 in.)

Valves and Cylinder Heads


1. Cylinder block

2. RH bank cylinder head

3. LH bank cylinder head

4. RH bank cylinder head gasket :

Carved lot number on cylinder head gasket should face up (toward cylinder head side).

5. LH bank cylinder head gasket :

Carved lot number on cylinder head gasket should face up (toward cylinder head side).

6. Exhaust valve

7. Intake valve

11. Valve stem oil seal

12. Valve spring retainer

8. Valve spring seat 13. Valve cotter

9. Outer valve spring :

Be sure to position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side).

10. Inner valve spring :

Be sure to position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side).

14. Valve guide

15. Cylinder head bolt

16. Cylinder head bolt

(hex hole bolt)

Tightening Torque

Do not reuse



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 :

Valve stem diameter

Standard

Intake 5.965 – 5.980 mm

(0.2348 – 0.2354 in.)

Exhaust 5.940 – 5.955 mm

(0.2339 – 0.2344 in.)

Valve guide

I.D.

Stem-to-guide clearance

In & Ex 5.985 – 6.010 mm

(0.2356 – 0.2366 in.)

Intake 0.035 – 0.045 mm)

(0.0014 – 0.0018 in.)

Exhaust 0.060 – 0.070 mm

(0.0024 – 0.0028 in.)

Limit

–

–

–

0.07 mm

(0.0027 in.)

0.09 mm

(0.0035 in.)

INSTALLATION

1) Clean mating surface on cylinder head and cylinder block.

Remove oil, old gasket and dust from mating surface.

2) Install knock pin (4) to cylinder block.

3) Apply sealant “A” to cylinder head gasket (1) as shown in the figure.

“A” : Sealant 99000-31150

Sealant amount (Width “w”) :

4 mm (0.158 in.)

4) Install new cylinder head gasket (1) to cylinder block as shown in the figure. carved lot number (5) on cylinder head gasket (1) should face up (toward cylinder head side).

[A] : RH ( No.2) bank

[B] : LH (No.1) bank

2. Crankshaft pulley side

3. Flywheel side


5) Install cylinder head to block.

After applying oil to cylinder head bolts, tighten them gradually as follows.

a) Tighten all bolts to 53 N·m (5.3 kg-m, 38.5 lb-ft) according to numerical order in the figure.

b) In the same manner as in a), tighten them to 84 N·m (8.4

kg-m, 61.0 lb-ft).

c) Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.

d) In the same manner as in a), tighten them to 53 N·m (5.3

kg-m, 38.5 lb-ft).

e) In the same manner as in a) again, tighten them to specified torque.


Cylinder head bolt (a) : 105 N·m (10.5 kg-m, 76.0 lb-ft)

Cylinder head bolt (hex hole bolt) (b) :

11 N·m (1.1 kg-m, 7.5 lb-ft)

NOTE:

Don’t forget to install (b) bolts as shown in the figure.

1. Hex hole bolt


3. Flywheel side

[A] RH bank

[B] LH bank

6) Install water outlet cap.

7) Check timing mark on crankshaft as shown in the figure.

1. Crank timing pulley key

2. Oil jet

8) Install valve lash adjuster, camshaft, CMP sensor and RH bank 2nd timing chain.

Refer to “CAMSHAFT AND VALVE LASH ADJUSTER” and

“RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TEN-

SIONER” in this section. For CMP sensor, refer to “CMP

SENSOR” in Section 6F2.

9) Install 1st timing chain.

Refer to “1ST TIMING CHAIN AND CHAIN TENSIONER” in this section.

10) Install LH bank 2nd timing chain.

Refer to “LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN

TENSIONER” in this section.

11) Install timing chain cover.

Refer to “TIMING CHAIN COVER” in this section.


12) Install oil pan and oil pump strainer.

Refer to “OIL PAN AND OIL PUMP STRAINER” in this section.

13) Install cylinder head cover.

Refer to “CYLINDER HEAD COVER” in this section.

14) Install exhaust manifold.

Refer to “EXHAUST MANIFOLD” in this section.

15) Install radiator outlet pipe, radiator, cooling fan and water hose.

Refer to “COOLING WATER PIPES OR HOSES”, “RADIA-

TOR” and “COOLING FAN AND FAN CLUTCH” in Section

6B.

16) Install throttle body and intake manifold.

Refer to “THROTTLE BODY AND INTAKE MANIFOLD” in this section.

17) Adjust water pump drive belt tension.

Refer to “COOLING FAN BELT TENSION CHECK AND

ADJUSTMENT” in Section 6B.

18) Adjust power steering pump drive belt tension.

Refer to “POWER STEERING PUMP DRIVE BELT” in Section 3B1.

19) Adjust accelerator cable play and A/T throttle cable play.

Refer to “ACCELERATOR CABLE ADJUSTMENT” and “A/T

THROTTLE CABLE ADJUSTMENT (A/T VEHICLE)” in Section 6E2.

20) Check to ensure that all removed parts are back in place.

Reinstall any necessary parts which have not been reinstalled.

21) Refill engine with engine oil, referring to “ENGINE OIL

CHANGE” in Section 0B.

22) Refill cooling system referring to “COOLING SYSTEM


23) Refill front differential housing with gear oil if drained, referring to “MAINTENANCE SERVICE” in Section 7E.

24) Connect negative cable at battery.

25) Check ignition timing and adjust as necessary, referring to

“IGNITION TIMING CHECK AND ADJUSTMENT” in Section

6F2.

26) Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each connection.

27) Check wheel alignment, referring to “STEERING ANGLE” in

Section 3A.


Piston, Piston Rings, Connecting Rods and Cylinders

1. Top ring

2. 2nd ring

3. Oil ring

4. Piston

5. Connecting rod :

Clean bearing installing surface when install.

6. Connecting rod bearing cap :

Clean bearing installing surface when install.

7. Connecting rod bearing :

Clean outer surface when install.

8. Piston pin

9. Piston pin circlip

10. Cylinder block

11. Bearing cap nut

Tightening Torque

Do not reuse



INSPECTION

Cylinders

• Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston.

• Using a cylinder gauge, measure cylinder bore in thrust and axial directions at 2 positions (1, 2) as shown in the figure.

If any of the following conditions is noted, rebore cylinder.

– Cylinder bore dia. exceeds limit.

– Difference of measurements at 2 positions exceeds taper limit.

– Difference between thrust and axial measurements exceeds out-of-round limit.

Cylinder bore dia. limit :

88.050 mm (3.4665 in.)

Taper and out-of-round limit :

0.10 mm (0.004 in.)

NOTE:

If any one of six cylinders has to be rebored, rebore all six to the same next oversize. This is necessary for the sake of uniformity and balance.

1. 50 mm (1.96 in.)

2. 95 mm (3.74 in.)

Pistons

• Inspect piston for faults, cracks or other damages.

Damaged or faulty piston should be replaced.

• Piston diameter :

As shown in the figure, piston diameter should be measured at a position 26.5 mm (1.04 in.) (1) from piston skirt end in the direction perpendicular to piston pin.

Piston diameter :

Standard

Oversize :

0.50 mm (0.0196 in.)

87.970 – 87.990 mm

(3.4634 – 3.4642 in.)

88.470 – 88.490 mm

(3.4831 – 3.4839 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 :

0.02 – 0.04 mm (0.0008 – 0.0015 in.)

NOTE:

Cylinder bore diameters used here are measured in thrust direction at 2 positions.

1. 26.5 mm (1.04 in.)

• Ring groove clearance :

Before checking, piston grooves must be clean, dry and free of carbon.

Fit new piston ring (1) into piston groove, and measure clearance between ring and ring land by using thickness gauge

(2). If clearance is out of specification, replace piston.

Ring groove clearance :

Top : 0.03 – 0.07 mm (0.0012 – 0.0027 in.)

2nd : 0.02 – 0.06 mm (0.0008 – 0.0023 in.)


ASSEMBLY

1) 2 sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows.

a) Each piston has stamped number (1 or 2) on its piston head. It represents outer diameter of piston.

b) There are also stamped numbers of 1 and 2 on the cylinder block as shown in the figure. c) Stamped number on piston and cylinder block must correspond. That is, install number “2” stamped piston to cylinder which is stamped also number “2” and a number “1” piston to cylinder with number “1”.

Also, a letter A, B or C is stamped on piston head but ordinarily it is not necessary to distinguish each piston by this letter.

Piston-to-cylinder clearance

Piston :

Number at the top (mark)

1

2

Outer diameter

87.98 – 87.99 mm

(3.4638 – 3.4642 in.)

87.97 – 87.98 mm

(3.4634 – 3.4638 in.)

Cylinder :

Number on cylinder block (mark)

1

2

Outer diameter

88.01 – 88.02 mm

(3.4650 – 3.4653 in.)

88.00 – 88.01 mm

(3.4646 – 3.4650 in.)

Piston-to-cylinder clearance :

0.02 – 0.04 mm (0.0008 – 0.0015 in.)

2) Install piston pin to piston and connecting rod :

After applying engine oil to piston pin and piston pin holes in piston and connecting rod, fit connecting rod to piston as shown in the figure and insert piston pin to piston and connecting rod, and install piston pin circlips.

NOTE:

“86F” mark on connecting rod must face toward crankshaft pulley side.

1. Piston

2. Arrow mark

3. Connecting rod


NOTE:

• Install circlip with its cut part facing as shown in the figure.

• Install so that circlip end gap comes within such range as indicated by arrow “A”.

1. Piston

2. Arrow mark

3. Connecting rod

4. Oil hole


3) Install piston rings to piston :

• As shown in the figure, 1st and 2nd rings have “RN” or “R” mark respectively. When installing these piston rings to piston, direct marked side of each ring toward top of piston.

• 1st rings differs from 2nd ring in thickness, shape and color of surface contacting cylinder wall.

Distinguish 1st ring from 2nd ring by referring to the figure.

• When installing oil ring, install spacer first and then 2 rails.

1. 1st ring

2. 2nd ring

3. Oil ring

4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the 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

6. Intake side

7. Exhaust side


1

2

Unit Repair Overhaul

Engine Assembly

REMOVAL

1) Release fuel pressure in fuel feed line. Refer to “FUEL

PRESSURE RELIEF PROCEDURE” in Section 6.


3) Remove engine hood.

4) Drain engine oil.

5) Drain coolant.

6) Remove radiator, radiator fan shroud, cooling fan and radiator reservoir. Refer to “COOLING FAN AND FAN CLUTCH” and “RADIATOR” in Section 6B.

7) Disconnect accelerator cable (1) and A/T throttle cable (for

A/T vehicle) (2) from throttle body.

8) Remove strut tower bar and surge tank cover.

9) Disconnect IAT sensor coupler and MAF sensor coupler then remove air cleaner upper case, intake air hose, intake air pipe and surge tank pipe as a component.

10) Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).

11) Remove ignition coil covers.

2

6

1

7

4

3

5


12) Disconnect the following electric lead wires :

• Injector wire coupler

• CMP sensor coupler

• Ignition coil couplers

• CKP sensor coupler

• MAP sensor coupler

• TP sensor (1) coupler

• IAC valve (2) coupler

• Earth wire (3) from surge tank

• EVAP canister purge valve coupler

• EGR valve coupler

• Oxygen sensor -1 and -2 couplers referring to “Exhaust Manifold” in this section

• Coolant temperature sensor coupler

• Knock sensor coupler

• Generator wires

• Starter wires

• Oil pressure wire

• P/S pump wire

• Earth wire from generator bracket

• Engine block heater (if equipped)

13) Remove clamps and brackets.

14) Disconnect the following hoses :

• Heater hose from heater water pipe

• Heater hose from water outlet cap

• EVAP canister hose from canister pipe

• Brake booster vacuum hose

15) Remove EVAP canister purge valve (5).

4. Clamp bracket

6. EGR valve

7. Heater hose

16) Disconnect the following hoses at the location shown in the figure :

• Fuel feed hose (1) from fuel feed pipe

• Fuel return hose from (2) fuel return pipe

17) Remove P/S pump assembly. Refer to “POWER STEERING

PUMP” in Section 3B1.

18) Remove A/C compressor assembly. Refer to “COMPRES-

SOR ASSEMBLY” in Section 1B.

19) Remove steering shaft lower assembly. Refer to “STEERING

LOWER SHAFT ASSEMBLY” in Section 3C1.

20) Raise vehicle.

21) Remove front differential housing with differential from chassis if equipped. Refer to “DISMOUNTING” in Section 7E.

22) Remove exhaust No.1 pipe. Refer to “EXHAUST MANI-

FOLD” in this section.

23) Remove exhaust manifold stiffener from transmission.


24) Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle)

25) Remove clutch housing lower plate.

26) Remove torque converter bolts (for A/T vehicle).

27) Remove starter motor.

28) Lower vehicle.

29) Support transmission. For A/T vehicle, don’t jack under A/T oil pan to support transmission.

30) Remove bolts and nuts fastening cylinder block and transmission.

31) Install lifting device.

32) Disconnect engine side mounting brackets (1) to engine mountings.

33) Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.

34) Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assembly.

INSTALLATION

Reverse removal procedure for installation, noting the following points.

1) Lower engine assembly into engine compartment. Connect engine to transmission and engine side mounting brackets to engine mountings.

2) Tighten nuts fastening engine side mounting brackets and engine mountings.


Engine side mounting bracket nut (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.


Transmission to cylinder block bolt and nut (b) :

85 N·m (8.5 kg-m, 61.5 lb-ft)

1. Bolt (short)

2. Bolt (Long)

4) Remove lifting device

5) Tighten torque converter bolts to specified torque (for A/T vehicle).


Torque converter bolt (c) :

65 N·m (6.5 kg-m, 47.0 lb-ft)

6) Tighten bolts and nuts of exhaust No.1 pipe (1) to specified torque.


Exhaust No.1 pipe bolt and nut (d) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

7) Install front differential housing with differential to chassis if removed. Refer to “REMOUNTING” in Section 7E.

8) Install steering shaft lower assembly. Refer to “STEERING

LOWER SHAFT ASSEMBLY” in Section 3C1.

9) Install A/C compressor assembly. Refer to “COMPRESSOR

ASSEMBLY” in Section 1B.

10) Install P/S pump assembly. Refer to “POWER STEERING

PUMP” in Section 3B1.

11) Connect hoses, cables and electric wires.

12) Adjust accelerator cable play and A/T throttle cable play (for

A/T vehicle). Refer to “ACCELERATOR CABLE ADJUST-

MENT” and “A/T THROTTLE CABLE ADJUSTMENT (A/T

VEHICLE)” in Section 6E2.

13) Refill engine with engine oil referring to “ENGINE OIL

CHANGE” in Section 0B.

14) Refill cooling system, referring to “COOLING SYSTEM


15) Check to ensure that all fasteners and clamps are tightened.

16) Upon completion of installation, verify that there is no fuel leakage, coolant leakage, P/S fluid leakage or exhaust gas leakage at each connection.


Main Bearings, Crankshaft and Cylinder Block

1. Cylinder block

2. Lower crankcase :

Apply sealant 99000-31150 to lower crankcase mating surface.

3. Crankshaft

4. Main bearing

5. Thrust bearing :

Set bearing facing grooved side to crank weds.

6. Rear oil seal

7. Flywheel (M/T) Drive plate

(A/T)

8. Water pump

9. O-ring

10. Timing chain oil jet

11. O-ring

12. Clutch housing plate

13. Cap bolt

14. Lower crankcase bolt

15. Knock sensor

[A]: Sealant application amount

Tightening Torque

Do not reuse


“a”: Width 3 mm (0.12 in.)

“b”: Height 2 mm (0.08 in.)


Main bearing clearance

Check clearance by using gaging plastic (1) according to the following procedure.

1) Remove crankcase.

2) Clean bearings and main journals.

3) Place a piece of gaging plastic to full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.

4) Install crankcase to cylinder block.

Tighten crankcase bolts, following sequence in the figure.

Tighten crankcase bolts to specified torque.

NOTE:

Tighten 10 mm thread diameter bolts first (following the order shown in the figure) then tighten 8 mm thread diameter bolts.


Thrust and journal bearing cap bolt (8 mm thread diameter) (a) :

60 N·m (6.0 kg-m, 43.5 lb-ft)

Thrust and journal bearing cap bolt (10 mm thread diameter) (b) :

27 N·m (2.7 kg-m, 19.5 lb-ft)

NOTE:

Do not rotate crankshaft while gaging plastic is installed.

1. Lower crankcase

2. Bolt (10 mm thread diameter)

3. Bolt (8 mm thread diameter)

4. Long bolt (8 mm thread diameter)

5) Remove crankcase and using scale (2) on gaging plastic (1) envelop, measure gaging plastic (1) width at its widest point.

If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit.

A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use of 0.25 mm undersize bearing.

After selecting new bearing, recheck clearance.

Main Bearing Clearance

Standard : 0.024 – 0.044 mm (0.0009 – 0.0017 in.)

Limit : 0.060 mm (0.0023 in.)


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 the figure, crank web has stamped numbers and alphabet at the center.

3 kinds of numbers (“1”, “2” and “3”) represent the following journal diameters.

Journal diameter :

Stamped numbers

1

2

3

Journal diameter

65.000 – 65.006 mm

(2.5590 – 2.5593 in.)

64.994 – 65.000 mm

(2.5588 – 2.5590 in.)

64.988 – 64.994 mm

(2.5586 – 2.5588 in.)

1. Crankshaft

2. Crank web

2) Next, check crankcase (bearing cap) bore diameter without bearing. On lower surface of lower crankcase 4 alphabets are stamped as shown in the figure.

3 kinds of alphabets (A, B and C) represent the following cap bore diameters.

Main bearing cap bore diameter :

Stamped numbers

A

B

C

Bearing cap bore diameter

(without bearing)

70.000 – 70.006 mm

(2.7559 – 2.7561 in.)

70.006 – 70.012 mm

(2.7561 – 2.7563 in.)

70.012 – 70.018 mm

(2.7563 – 2.7566 in.)


2. Stamped alphabets

3. No.1 bearing

4. No.2 bearing

5. No.3 bearing

6. No.4 bearing


3) There are 5 kinds of standard bearings differing in thickness.

To distinguish them, they are painted in following colors at the position as shown in the figure.

Each color indicates the following thickness at the center of bearing.

Standard size Main bearing thickness :

Color painted

Black

Colorless (no paint)

Yellow

Blue

Pink

Bearing thickness

2.496 – 2.500 mm

(0.0983 – 0.0984 in.)

2.499 – 2.503 mm

(0.0984 – 0.0985 in.)

2.502 – 2.506 mm

(0.0985 – 0.0986 in.)

2.505 – 2.509 mm

(0.0986 – 0.0987 in.)

2.508 – 2.512 mm

(0.0987 – 0.0988 in.)

1. Paint

4) From number stamped on crank webs at its center and alphabets stamped on crankcase lower side, determine new standard bearing to be installed to journal, by referring to table shown below.

For example, if number stamped on crank webs is “1” and alphabet stamped on crankcase is “B”, install a new standard bearing painted in “Black” to its journal.

New standard size bearing specification :

Alphabet stamped on lower crankcase

(Cap bore dia.)

Number stamped on crank web

(Journal diameter)

A

1

Black

2

Colorless

B Colorless Yellow

C Yellow Blue

3

Yellow

Blue

Pink

5) Using gaging plastic, check bearing clearance with newly selected standard bearing.

If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

6) When replacing crankshaft or cylinder block and crank case due to any reason, select new standard bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new crankcase lower side.


• UNDERSIZE BEARING (0.25 mm) :

0.25 mm undersize bearing is available, in 5 kinds varying in thickness.

To distinguish them, each bearing is painted in the following colors at such position as shown in the figure.

Each color represents the following thickness at the center of bearing.

Under size main bearing thickness

Color painted

Black & Red

Red

Red & Yellow

Red & Blue

Red & Pink

Bearing thickness

2.621 – 2.625 mm

(0.1032 – 0.1033 in.)

2.624 – 2.628 mm

(0.1033 – 0.1034 in.)

2.627 – 2.631 mm

(0.1034 – 0.1035 in.)

2.630 – 2.634 mm

(0.1035 – 0.1036 in.)

2.633 – 2.637 mm

(0.1036 – 0.1037 in.)

1. Paint

• If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.

1) Regrind journal to the following finished diameter.

Finished journal diameter :

64.738 – 64.756 mm (2.5487 – 2.5494 in.)

2) Using micrometer, measure reground journal diameter.

Measurement should be taken in 2 directions perpendicular to each other in order to check for out-of-round.

3) Using journal diameter measured above and alphabets stamped on lower crankcase, select an undersize bearing by referring to table given below.

Check bearing clearance with newly selected undersize bearing.

Under size bearing specification :

Alphabets stamped on lower crankcase

A

B

C

64.750 – 64.756 mm

(2.5492 – 2.5494 in.)

Black & Red

Red

Red & Yellow

Measured journal diameter

64.744 – 64.750 mm

(2.5489 – 2.5492 in.)

Red

Red & Yellow

Red & Blue

64.738 – 64.744 mm

(2.5487– 2.5489 in.)

Red & Yellow

Red & Blue

Red & Pink


INSPECTION

Honing or reboring cylinders

1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.

2) Select oversized piston according to amount of cylinder wear.

Oversize piston specification :

Size

Standard

Piston diameter

87.970 – 87.990 mm (3.4634 – 3.4642 in.)

Oversize 0.25

88.220 – 88.240 mm (3.4732 – 3.4740 in.)

Oversize 0.50

88.470 – 88.490 mm (3.4831 – 3.4839 in.)

3) Using micrometer, measure piston diameter.

4) Calculate cylinder bore diameter to be rebored as follows.

D = A + B – C

Cylinder bore diameter to be rebored

A : Piston diameter as measured

B : Piston clearance = 0.02 – 0.04 mm (0.0008 – 0.0015 in.)

C : Allowance for honing = 0.02 mm (0.0008 in.)

5) Rebore and hone cylinder to calculated dimension.

NOTE:

Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores.

6) Measure piston clearance after honing.


Special Tool

09911-97810

Oil seal installer

09913-75510

Bearing installer

09915-47310

Oil filter wrench

09915-64510

Compression gauge

09915-64530 09915-67010

Compression gauge hose Compression gauge attachment (c)

09915-67310

Vacuum gauge

09915-77310

Oil pressure gauge

09916-14510

Valve lifter

09916-14910

Valve lifter attachment

09916-34541

Reamer handle

09916-37810

Reamer (6 mm)

09916-38210

Reamer (11 mm)

09916-44910

Valve guide remover

09916-58210

Valve guide installer handle

09916-77310

Piston ring compressor


09916-84511

Forceps

09917-68221

Camshaft lock holder

09917-87810

Valve guide installer

09917-98221

Valve stem seal installer

09918-08210 09919-28610

Vacuum gauge hose joint Protective sleeve

09924-17810

Flywheel holder

09926-58010

Bearing puller attachment

09944-36011 09911-97710

Steering wheel remover Oil seal guide

09915-76510

Oil pressure gauge attachment


ENGINE COOLING 6B-1

SECTION 6B

ENGINE COOLING

NOTE:

• For the descriptions (items) not found in this section, refer to the descriptions of H25 engine in the same section of service manual mentioned in the FOREWORD of this manual.

CONTENTS

Maintenance ....................................................6B-2 Coolant.......................................................... 6B-2

6B

6B-2 ENGINE COOLING

Maintenance

Coolant

Anti-freeze proportioning chart :

Freezing temperature

Antifreeze/Anticorrosion coolant concentration

Ratio of compound to cooling water

°C

°F

% ltr.

US pt

Imp. pt.

Coolant capacity : ltr. (US/Imp. pt.)

Engine, radiator and heater

8.2 (17.5 / 14.4)

Reservoir

0.9 (1.9 / 1.6)

–16

3

30

2.7/6.4

5.8/13.7

4.8/11.3

–36

–33

50

4.6/4.6

9.8/9.8

8.1/8.1

Total

9.1 (19.4 / 16.0)

NOTE:

• Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time as damage to cooling system could occur.

• Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethylene glycol antifreeze (Antifreeze/Anticorrosion coolant) should be used for the purpose of corrosion protection and lubrication.

• “Hard water”, if used, will foul up the cooling circuit by scale formation. Tap water available from city water supply is the best available water, in a practical sense, for the cooling system. Distilled water is ideal but is a luxury in most cases.

ENGINE FUEL 6C-1

SECTION 6C

ENGINE FUEL

NOTE:

For the descriptions (items) not found in this section, refer to the same section of Service Manual mentioned in the FOREWORD of this manual.

CONTENTS

General Description ....................................... 6C-1

Fuel System ................................................. 6C-1

On-Vehicle Service ........................................ 6C-2

Fuel Tank ..................................................... 6C-2

Fuel Lines .................................................... 6C-5


Fuel System

The main components of the fuel system are fuel tank, fuel pump, fuel filter and fuel level gauge and it includes three lines, fuel feed line, fuel return line and fuel vapor line.

For the details of fuel flow and fuel vapor flow, refer to Section 6E2.

6C

1. Fuel tank

2. Fuel pump (with fuel level gauge)

3. Fuel filter

4. Fuel filter cap

5. Breather hose

6. Fuel feed line (to delivery pipe)

7. Fuel return line (from delivery pipe)

8. Fuel vapor line (to EVAP canister)

9. Fuel tank protector

10. Belt

6C-2 ENGINE FUEL


Fuel Tank

REMOVAL

1) Relieve fuel pressure in fuel feed line referring to Section 6 or Section 6-1.

CAUTION:



3) Before disconnecting fuel filler hose, give match marks on fuel filler hose and fuel filler neck.

4) Disconnect fuel filler hose from fuel filler neck.

5) Insert hose of a hand operated pump into fuel filler hose and drain fuel in space “A” in the figure (drain fuel through it till fuel stops).

CAUTION:

Do not force hose of a hand operated pump into fuel tank. Doing so can damage inlet valve.

1. Fuel filler hose

2. Fuel tank inlet (check) valve

6) Remove fuel tank filler hose protector.

Disconnect filler hose from fuel tank and breather hose from fuel filler neck.

7) Remove fuel tank inlet valve. Use care not to damage inlet valve when removing.

1. Tank

2. Breather hose

3. Filler hose

4. Inlet valve

8) Drain fuel tank by pumping fuel out through fuel tank filler.

Use hand operated pump device to drain fuel tank.

CAUTION:

Never drain or store fuel in an open container due to possibility of fire or explosion.

9) Disconnect fuel filter inlet hose from filter.

1. Fuel filter

2. Fuel filter outlet hose

3. Fuel filter inlet hose


10) Disconnect fuel vapor hose and return hose from pipes.

11) Remove fuel tank protector (if equipped) from vehicle.

12) Lower fuel tank gradually while holding it horizontally and pull out coupler at fuel pump.

1. Fuel pump

2. Coupler

INSPECTION

After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage.

Also check fuel pump and level gauge gaskets for leaks, visually inspect fuel tank for leaks and damage.

Replace any damaged or malconditioned parts.


INSTALLATION

1) Install fuel pump assembly, fuel cut valve and vapor control valve to fuel tank. Refer to “FUEL PUMP” in this section.

2) Connect fuel hoses to fuel tank, fuel cut valve, and vapor control valve, check valve and fuel pump assembly.

After connecting, clamp hoses securely.

3) Install inlet valve to fuel tank. If deformed or damaged in any other way, replace with a new one.

4) Install fuel tank by using fuel tank belts and then install protector to vehicle.


Fuel tank bolt (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

Fuel tank protector bolt (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

5) Connect fuel filler hose to fuel filler neck with match the match marks. And then clamp the securely.

6) Connect fuel filler hose to fuel tank and breather hose to fuel filler neck. Clamp them securely.


Breather hose clamp (b) : 2.0 N·m (0.2 kg-m, 2.0 lb-ft)

Fuel filler hose clamp (c) : 4.0 N·m (0.4 kg-m, 3.0 lb-ft)

7) Install fuel filler hose protector.

1. Fuel tank

2. Fuel pump (with fuel level gauge)

3. Fuel filter

4. Fuel filler cap

5. Breather hose

6. Fuel feed line (to delivery pipe)

7. Fuel return line (from delivery pipe)

8. Fuel vapor line (to EVAP canister)

9. Fuel tank protector

10. Belt

11. Filler neck

12. Breather pipe

13. Filler hose

14. Tank inlet valve

15. Fuel cut valve

8) Connect fuel vapor hose (1) and return hose (2) to fuel pipe and clamp them securely.

9) Connect fuel filter inlet hose to fuel filter.

1. Fuel filter

2. Fuel filter outlet hose

3. Fuel filter inlet hose

10) Connect coupler to fuel pump assembly.


12) Upon completion of installation, check fuel system for leakage.


Fuel Lines

Due to the fact that fuel feed line is under high pressure, this system requires special consideration for service.

The feed pipe uses screw couplings and hose clamps.

INSPECTION

Visually inspect fuel lines for evidence of fuel leakage, hose cracking and deterioration, or damage. Make sure all clamps are secure. Replace parts as needed.


ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-1

SECTION 6E2

ENGINE AND EMISSION CONTROL SYSTEM

(SEQUENTIAL MULTIPORT FUEL INJECTION

FOR H27 ENGINE)

WARNING:






NOTE:

Whether following systems (parts) are used in the particular vehicle or not depends on specifications.

Be sure to bear this in mind when performing service work.

• Monitor connector

• CKP sensor

• MAP sensor

• EGR valve

• Heated oxygen sensor or CO adjusting resistor

• Three way catalytic converter, Warm-up three way catalytic converter

6E2

General Description ..................................... 6E2-2

System Flow............................................... 6E2-3

System Diagram......................................... 6E2-4

Air Intake System ....................................... 6E2-6

Fuel Delivery System ................................. 6E2-7

Electronic Control System .......................... 6E2-8

Engine and Emission Control Input/Output

Table ........................................................ 6E2-12

Diagnosis .................................................... 6E2-12

On-Vehicle Service..................................... 6E2-13

General .................................................... 6E2-13

Accelerator Cable Adjustment.................. 6E2-14

A/T Throttle Cable Adjustment

(A/T Vehicle) ............................................ 6E2-14

CONTENTS

Idle Speed/Idle Air Control (IAC) Duty

Inspection................................................. 6E2-15

[Using SUZUKI scan tool] .................... 6E2-15

[Not using SUZUKI scan tool]

(vehicle with monitor connector) .......... 6E2-16

Idle mixture inspection/adjustment

(vehicle without heated oxygen sensor) 6E2-17

Air Intake System ..................................... 6E2-18

Throttle body ........................................ 6E2-18

Idle air control valve (IAC valve) .......... 6E2-21

Fast idle air valve ................................. 6E2-22

Fuel Delivery System ............................... 6E2-23

Fuel pressure inspection ...................... 6E2-23

Fuel pump ............................................ 6E2-24

Fuel pressure regulator ........................ 6E2-25

6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)

Fuel injector.......................................... 6E2-26

Electronic Control System........................ 6E2-31

Engine control module (ECM)/ powertrain control module (PCM) ........ 6E2-31

Mass air flow sensor (MAF sensor)...... 6E2-32

Intake air temperature (IAT) sensor ..... 6E2-34

Throttle position sensor (TP sensor) .... 6E2-35

Engine coolant temperature sensor

(ECT sensor)........................................ 6E2-36

Heated oxygen sensor (sensor 1) ........ 6E2-37

Heated oxygen sensor (sensor 2) ........ 6E2-38

Vehicle speed sensor (VSS) ................ 6E2-39

Manifold absolute pressure sensor ...... 6E2-39

Fuel level sensor (sender gauge)......... 6E2-41

Crankshaft position sensor................... 6E2-41

Main relay ............................................ 6E2-41

Fuel pump relay ................................... 6E2-42

Fuel cut operation ................................ 6E2-43

Emission Control System......................... 6E2-44

EGR system (if equipped).................... 6E2-44

EVAP canister...................................... 6E2-45

Vacuum passage ................................. 6E2-46

PCV System ............................................ 6E2-47

PCV hose............................................. 6E2-47

PCV valve ............................................ 6E2-47

PCV system ......................................... 6E2-48

Tightening Torque Specification.............. 6E2-48

Special Tool ............................................... 6E2-48


The engine and emission control system has 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system.

Air intake system includes air cleaner, mass air flow sensor, throttle body, idle air control valve and intake manifold.

Fuel delivery system includes fuel pump, delivery pipe, fuel pressure regulator, fuel injectors, etc.

Electronic control system includes ECM (PCM), various sensors and controlled devices.

Emission control system includes EGR, EVAP and PCV systems.


System Flow


System Diagram


1. Air cleaner

2. Intake air temp. sensor





7. Camshaft position sensor

8. EGR valve

9. Manifold absolute pressure sensor

(if equipped)

10. Fuel injector

11. PCV valve

12. Ignition coil assembly

13. Engine coolant temperature sensor

14. Heated oxygen sensor

(bank 1 sensor 1) (if equipped)







18. Warm-up three way catalytic converter

(if equipped)

19. Three way catalytic converter

(if equipped)

20. Crankshaft position sensor

(if equipped)

21. Fuel pump

22. Fuel level sensor


23-1. Diag. switch terminal

23-2. Test switch terminal

23-3. Output duty select switch terminal

23-4. Duty output terminal

24. Fuel filter


26. Immobilizer indicator lamp (if equipped)

27. Tank pressure control valve

28. EVAP canister

29. Knock sensor

30. ECM/PCM (Engine control module/Powertrain control module)

31. Malfunction indicator lamp

32. Electric loads (rear defogger (if equipped), lighting)

33. Power steering pressure switch

34. Heater blower fan switch

35. Cruise control module



38. A/C condenser fan relay (if equipped)

39. A/C controller (if equipped)

40. Data link connector/Immobilizer control module (if equipped)


42. Main relay

43. Ignition switch

44. Park/Neutral position switch in TR switch (A/T)

45. Battery

46. Starter magnetic switch

47. “O/D OFF” lamp (A/T)

48. “POWER” lamp (A/T)

49. Lighting switch (A/T)

50. Stop lamp switch (A/T)

51. O/D cut switch (A/T)

52. POWER/NORMAL change switch (A/T)

53. 4WD low switch (A/T)

54. Transmission range switch (A/T)

55. Solenoid valve A (A/T)

56. Solenoid valve B (A/T)

57. TCC solenoid valve (A/T)

58. A/T input speed sensor (A/T)

59. A/T vehicle (output) speed sensor (A/T)


Air Intake System

The main components of the air intake system are air cleaner, mass air flow sensor, air cleaner, intake air pipe, throttle body, intake collector, idle air control valve and intake manifold.

The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each combustion chamber.

When the idle air control valve is opened according to the signal from ECM (PCM), the air bypasses the throttle valve through bypass passage and is finally drawn into the intake manifold.

10

17

18

15

16

“A” : Air

“B” : EGR

“C” : Engine coolant

1. Air cleaner

2. IAT sensor

3. Resonator

4. Intake manifold

5. Intake collector

6. PCV hose

7. Brake booster

8. Fuel pressure regulator hose

9. Intake air pipe

10. Throttle body

11. Breather hose

12. MAF sensor

13. EGR valve

14. TP sensor

15. IAC valve

16. IAC valve and fast idle control system

17. FIA valve

18. Thermo - WAX


Fuel Delivery System

The fuel delivery system consists of the fuel tank, fuel pump, fuel filter, fuel pressure regulator, delivery pipe and fuel injectors.

The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each injector through the delivery pipe.

As the fuel pressure applied to the injector (the fuel pressure in the fuel feed line) is always kept a certain amount higher than the pressure in the intake manifold by the fuel pressure regulator, the fuel is injected into the intake port of the cylinder head when the injector opens according to the injection signal from ECM (PCM).

The fuel relieved by the fuel pressure regulator returns through the fuel return line to the fuel tank.

[A] : Fuel

[B] : Air

1. Fuel tank

2. Fuel pump

3. Fuel filter

4. Fuel feed line

5. Fuel return line


7. Vacuum hose for fuel pressure regulator

8. Intake manifold surge tank

9. Fuel injector

10. Fuel delivery pipe

11. Throttle valve


Electronic Control System

The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various controlled devices.

Functionally, it is divided into the following sub systems:

• Fuel injection control system

• Heated oxygen sensor heater control system (if equipped)

• Idle air control system

• Fuel pump control system

• Evaporative emission control system

• Ignition control system

• EGR system (if equipped)

Also, with A/T model, PCM controls A/T.

INFORMATION SENSORS

1. IAT sensor

2. MAP sensor (if equipped)

3. Heated oxygen sensor (sensor 1) (if equipped)

4. ECT sensor

5. TP sensor

6. MAF sensor

7. Camshaft position sensor (CMP sensor)


9. Crankshaft position sensor (CKP sensor) (if equipped)

10. Power steering pressure switch (PSP switch)

11. CO adjusting resistor (if equipped)


13. Transmission range switch (A/T)

14. Knock sensor

CONTROLLED DEVICES a : A/C condenser fan motor relay (if equipped) b : Ignition coil assemblies c : EVAP canister purge valve d : EGR valve (if equipped) e : Idle air control valve f : Injectors g : Malfunction indicator lamp h : Fuel pump relay i : Main relay j : Oxygen sensor heater relay (if equipped)

OTHERS

A : Main fuse box

B : ECM (PCM)

C : Data link connector

D : Combination meter

E : Fuse box

F : EVAP canister

NOTE:

Above figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the side of symmetry.

50

O2 HTRRLY

BLU

BLU

IG2

41

41-1

42

42-1

49

48

47

46

45

44

43

24-1

40

39

38

WHT/BLU

ORN/BLU

C51-2-19

C51-2-20

C51-2-30

YEL/GRN

YEL/BLU

C51-1-12

C51-1-13

GRY/YEL C51-3-26

PPL/WHT

GRY/YEL

C51-3-10

C51-3-5

RED/WHT

GRY/RED

GRY/RED

GRY/BLK

GRY/YEL

RED/GRN

GRY/RED

GRY/YEL

C51-3-8

C51-3-14

E61-1

E61-10

E61-24

C51-3-9

C51-3-13

C51-3-12

ORN/BLK C51-3-2

GRY/YEL C51-3-24

LT BLU

GRY/YEL

C51-3-1

C51-3-25

RED C51-3-11

GRY

RED/BLU

BLK/RED

C51-2-4

C51-3-21

C51-2-5

RED/BLK C51-3-22

WHT/BLK C51-2-16

RED/YEL C51-3-23

PNK/WHT C51-2-17

PNK/BLU

GRY

PNK/BLK

GRY/WHT

YEL/BLK

E61-35

E61-4

E61-30

E61-8

E61-17

PNK/WHT E61-16

37

BLK/RED E61-15

BB+

36

35

34

IG1

33

32

31

RED/YEL

GRN/WHT

E61-32

E61-34

BLU/ORN C51-1-25

WHT

ORN

BLU/YEL

BLU/GRN

ORN/GRN

RED

ORN/BLU

YEL/GRN

GRN/ORN

GRN/BLU

C51-1-23

C51-1-22

C51-1-20

C51-1-21

C51-1-11

C51-1-10

C51-1-7

C51-1-6

C51-1-19

C51-1-18

C51-1-28

C51-1-27

30

29

GRN

GRN/RED

GRN/YEL

C51-1-2

C51-1-1

C51-1-8

28

BB+

27

PPL/RED E61-13

25


26 BRN E61-6

BLU/YEL C51-1-14

52

C51-2-2

C51-2-1

C51-2-9

C51-2-8

C51-2-22

C51-2-21

PNK

PNK/BLK

PNK/GRN

PNK/BLU

GRY/GRN

GRY/BLK

C51-2-15

C51-2-14

C51-2-13

C51-2-12

LT GRN

LT GRN/WHT

LT GRN/YEL

LT GRN/RED

C51-1-5

C51-1-4

C51-1-17

C51-1-16

LT GRN/BLK

PPL/BLK

GRY/BLU

PPL/YEL

C51-1-15 GRN/BLK

8

C51-2-28 BRN

C51-2-27 BRN/BLK

9

C51-2-26 BRN/WHT

C51-2-25 BRN/YEL

10

C51-2-24 BRN/RED

C51-2-23 BLK/BRN

E61-23 WHT/GRN

E61-22 YEL/BLU

1

2

3

4

4-1

4-2

5

7

8-1

9-1

6

B+

BLU/BLK

10-1

12

14

15

11

IG1

BB+

13

C51-3-3

E61-29

E61-3

E61-14

E61-5

WHT

YEL

WHT/BLU

WHT/RED

PPL

E61-7

E61-20

E61-21

E61-19

C51-1-9

PPL/YEL

WHT/BLK

GRY/BLU

ORN/BLK

RED

AF DN

GND TS MON

16

51

17

18

18-1

18-2

C51-3-18 PNK

C51-3-7

E61-31

E61-33

C51-1-26

BLK/ORN

ORN/BLU

YEL/RED

ORN/WHT

C51-3-20

E61-2

BLK/WHT

WHT

E61-9

C51-3-4

C51-3-15

C51-1-24

BLU

BLU/BLK

BLU/BLK

BLK/YEL

C51-3-6

C51-2-7

C51-3-17

BLK/GRN

BLK/GRN

BLK/ORN

22

24

23

19

20

21

21-1

IG2

GND1

:5V

:12V


TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE)

1. Fuel injector No.1




4-1. Fuel injector No.5

4-2. Fuel injector No.6

5. EGR valve (if equipped)

6. Idle air control


8. Ignition coil for No.1

8-1. Ignition coil for No.2





11. Fuel pump relay

12. Fuel pump

13. A/C condenser fan relay (if equipped)

14. A/C condenser fan motor (if equipped)

15. Knock sensor

16. Malfunction indicator lamp

17. “O/D OFF” lamp (A/T)

18. “POWER” lamp (A/T)

18-1. “4WD” lamp (4WD)

18-2. 4WD air pump assembly (4WD)

19. 4WD switch (4WD)

20. Power/Normal change switch (A/T)

21. O/D cut switch (A/T)

21-1. 4WD low switch (4WD)

22. Main relay

23. Transmission range switch (Park/Neutral

Position Switch) or clutch pedal position switch

24. Starter magnetic switch

24-1. Cruise control module (if equipped)




28. TCC solenoid (A/T)

29. Shift solenoid-B (A/T)

30. Shift solenoid-A (A/T)

31. Transmission range switch (sensor) (A/T)

32. A/T input speed sensor (A/T)

33. A/T vehicle (output) speed sensor (A/T)

34. Power steering pressure switch

35. Stop lamp switch (Brake pedal switch)

36. Lighting switch

37. Rear defogger switch (if equipped)

38. Heater blower motor (if equipped)

39. A/C control module (amplifier)


41. Heated oxygen sensor-1 (Bank1) (if equipped)

41-1. Heated oxygen sensor-1 (Bank2) (if equipped)

42. Heater oxygen sensor-2 (Bank1) (if equipped)

42-1. Heater oxygen sensor-2 (Bank2) (if equipped)

43. Intake air temp. sensor

44. Engine coolant temp. sensor


46. CO adjusting resistor (if equipped)

47. Manifold absolute pressure sensor (if equipped)


49. Camshaft position sensor

50. Crankshaft position sensor (if equipped)


52. Engine control module

(Powertrain control module)

TERMINAL CIRCUIT

E61-1 Power source for CO adjusting resistor

(if equipped)

E61-2 Power source for back up

E61-3 —

E61-4 Cruise control module

(Throttle opening signal)

E61-5 Duty output terminal (if equipped)

E61-6 Tachometer

E61-7 MIL (“SERVICE INGINE SOON” lamp)

E61-8 A/C cut signal (if equipped)

E61-9 Main relay

E61-10 CO adjusting resistor (if equipped)

E61-11 —

E61-12 —

TERMINAL CIRCUIT

E61-13 Data link connector

E61-14 Test switch terminal (if equipped)

E61-15 Rear defogger switch (if equipped)

E61-16 Heater blower switch

E61-17 A/C signal (if equipped)

E61-18 —

E61-19 “4WD” lamp

E61-20 “O/D OFF” lamp (A/T)

E61-21 “POWER” lamp (A/T)

E61-22 A/C fan motor relay (if equipped)

E61-23 Fuel pump relay

E61-24 Ground for CO adjusting resistor (if equipped)

TERMINAL CIRCUIT

E61-25 —

E61-26 —

E61-27 —

E61-28 —

E61-29 Diag. switch terminal (if equipped)

E61-30 ABS control module (if equipped)

E61-31 Power/Normal change switch (A/T)

E61-32 Lighting switch

E61-33 O/D cut switch (A/T)

E61-34 Stop lamp switch (Brake pedal switch)

E61-35 Cruise control module (if equipped)


TERMINAL CIRCUIT

C51-3-1 Intake air temp. (IAT) sensor

C51-3-2 Engine coolant temp. (ECT) sensor

C51-3-3 Knock sensor


C51-3-5 Ground for MAF sensor

C51-3-6 Ground

C51-3-7 4WD switch

C51-3-8 Manifold absolute pressure (MAP) sensor (if equipped)

C51-3-9 Throttle position (TP) sensor

C51-3-10 Mass air flow (MAF) sensor

C51-3-11 Heated oxygen sensor-1 (Bank1) (if equipped)

C51-3-12 Ground for TP sensor

TERMINAL CIRCUIT

C51-1-1 Shift solenoid-B (A/T)

C51-1-2 Shift solenoid-A (A/T)

C51-1-3 —



C51-1-6 Transmission range switch “R” (A/T)

C51-1-7 Transmission range switch “P” (A/T)

C51-1-8 TCC solenoid (A/T)

C51-1-9 4WD air pump assembly

C51-1-10 A/T input speed sensor (–)

C51-1-11 A/T input speed sensor (+)

C51-1-12 CMP sensor

TERMINAL CIRCUIT

C51-3-13 Power source for TP sensor

C51-3-14 Power source for MAP sensor (if equipped)


C51-3-16 —

C51-3-17 Ground

C51-3-18 Pressure switch in 4WD air pump assembly

C51-3-19 —

C51-3-20 Ignition switch




C51-3-24 Ground for ECT sensor

TERMINAL CIRCUIT

C51-1-13 CMP sensor

C51-1-14 Vehicle speed sensor

C51-1-15 EVAP canister purge valve



C51-1-18 Transmission range switch “D” (A/T)

C51-1-19 Transmission range switch “N” (A/T)

C51-1-20 Shield wire ground for A/T output speed sensor

C51-1-21 Shield wire ground for A/T input speed sensor

C51-1-22 A/T output speed sensor (–)

C51-1-23 A/T output speed sensor (+)

C51-1-24 Engine start signal

TERMINAL CIRCUIT

C51-3-25 Ground for IAT sensor, MAP sensor and oxygen sensor (if equipped)

C51-3-26 Ground for CMP sensor

TERMINAL CIRCUIT

C51-1-25 Power steering pressure switch

C51-1-26 4WD Low switch

C51-1-27 Transmission range switch “L” (A/T)

C51-1-28 Transmission range switch “2” (A/T)

TERMINAL CIRCUIT



C51-2-3 —

C51-2-4 Heater of HO2S-1 (Bank1) (if equipped)


C51-2-6 —

C51-2-7 Ground



C51-2-10 —

C51-2-11 —

C51-2-12 EGR valve (stepper motor coil 4) (if equipped)

TERMINAL CIRCUIT






C51-2-18 —

TERMINAL CIRCUIT





C51-2-29 —

C51-2-30 Ground for CKP sensor shield wire (if equipped)

C51-2-19 CKP sensor (+) (if equipped)

C51-2-20 CKP sensor (–) (if equipped)






Engine and Emission Control Input/Output Table

Input

Function

Output

Main relay control

Fuel pump control

Injection control

Idle air control

Ignition control

MIL control

EVAP purge control

EGR control

HO2S heater control

A/C control

A/C condensor fan control

Main relay

Fuel pump relay

Injectors

IAC valve

Ignition coil with igniter

MIL


EGR valve (if equipped)

HO2S (if equipped)

A/C amplifier

(if equipped)

A/C condensor fan relay (if equipped)

Diagnosis

Refer to Section 6-1.



1. Brake booster hose pipe

2. Vacuum hose for fuel pressure regulator


4. MAP sensor (if equipped)

5. Engine coolant hose


7. Breather hose

8. EGR pipe (if equipped)

9. Exhaust manifold


11. EGR valve (if equipped)

12. PCV hose

13. IAC valve

14. IAC hose

15. EVAP canister

16. Tank pressure control valve

17. To fuel tank

18. Cap

[A]: Vehicle without monitor connector

[B]: Vehicle with monitor connector

General

When hoses are disconnected and system components are removed for service, reinstall components properly, and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of hoses.


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 accelerator cable (1) to specification with cable adjusting nut (2).

Accelerator pedal play “a”:

2 – 5 mm (0.08 – 0.20 in.)

2) With accelerator pedal depressed fully, check clearance between throttle lever (2) and lever stopper (1) (throttle body) which should be within following specification.

If measured value is out of specification, adjust it to specification by changing height of pedal stopper bolt (3).

Clearance “b” between throttle lever and lever stopper

(throttle body) (with accelerator pedal depressed fully):

0.5 – 2.0 mm (0.02 – 0.07 in.)

A/T Throttle Cable Adjustment (A/T Vehicle)

1) Make sure that accelerator cable is adjusted as specified.

2) With throttle valve closed, check clearance “c” which should be within the following specification.

If it is out of specification, adjust A/T throttle cable (1) by turning cable adjusting nut (2).

A/T throttle cable installing position specification clearance “c”:

0.8 – 1.5 mm (0.03 – 0.06 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 engine/emission control systems are connected securely.

• Accelerator cable is adjusted.

• Ignition timing is within specification.

• All accessories (wipers, heater, lights, A/C, etc.) are out of service.

• Air cleaner has been properly installed and is in good condition.

• ECM (PCM) does not detect any malfunction DTC.

After above items are all confirmed, check idle speed and IAC duty as follows.

NOTE:

Before starting engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels.

[Using SUZUKI scan tool]

1) Connect SUZUKI scan tool to DLC with ignition switch OFF.

Special tool



3) Check IAC duty and idle speed by using “Data List” mode of

SUZUKI scan tool.

Engine idle speed:

A/C OFF: 700 ± 50 r/min.

A/C ON: 750 ± 50 r/min.

IAC duty at specified idle speed:

5 – 40 % (at A/C OFF)

4) If duty and/or idle speed is out of specifications, check idle air control system referring to “DIAG. FLOW TABLE B-4” in

Section 6-1.

5) Check that specified engine idle speed is obtained with A/C

ON if vehicle is equipped with A/C. If not, check A/C ON signal circuit and idle air control system.


[Not using SUZUKI scan tool] (vehicle with monitor connector)

1) Disconnect scan tool from DLC if connected.


3) Stop engine and connect duty meter (3) between duty output terminal and ground terminal of monitor connector (1).

4) Using service wire (2), ground diagnosis switch terminal in monitor connector.

5) Set tachometer.

6) Start engine and warm it up completely.

7) Check IAC duty and idle air control system referring to Diagnostic Flow Table B-4 “IDLE AIR CONTROL SYSTEM


A: Output duty select switch terminal

B: Diagnosis switch terminal

C: Blank

D: Ground terminal

E: Test switch terminal

F: Duty output terminal

Engine idle speed:

IAC duty at specified idle speed:

A/C OFF

700 ± 50 r/min.

5 – 40 % (0.7 – 5.6 V when battery voltage is 14 V)

A/C ON

750 ± 50 r/min.

–

NOTE:

IAC duty can be checked roughly by using voltmeter. I

AC duty to voltage relation is as follows.

ON DUTY METER

INDICATION

(%)

0

50

100

OFF DUTY

INDICATION

(%)

10

50

0

VOLT METER

INDICATION

(V)

0

0.5 x V B

V B

• “OFF DUTY METER” is such duty meter that indicates approx. 100% when terminal voltage is approx. “0 V”.

• “V B ” represents battery voltage while engine of vehicle being checked is running.

8) Remove service wire from monitor connector.

9) Install cap to monitor connector.

10) Check that specified engine idle speed is obtained with 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 %)

0.8 – 1.3 % 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

Duty Inspection” in this section.

2) Using exhaust gas tester, check that idle mixture CO % is within above specification. If it is out of specification, adjust it to specification by turning resistor knob (1).

3) If idle mixture has been adjusted, confirm that idle speed is within specification.


Air Intake System

Throttle body

1. Throttle body

2. Intake collector

3. Breather hose

4. Water hose

5. MAF sensor

6. TP sensor

REMOVAL


2) Drain cooling system.

3) Remove strut tower bar.

4) Disconnect accelerator cable (1) and or A/T throttle cable (2) from throttle body.

5) Disconnect water hoses from throttle body.


6) Remove surge tank cover.

Remove intake air pipe (1) and surge tank pipe (2).

7) Disconnect connectors of TP sensor and IAC valve.

8) Disconnect ground wire at connector.

9) Remove clamp bracket (1) and harness clamps from intake collector.

10) Disconnect connectors of EVAP canister purge valve (1),

MAP sensor and EGR valve (5).

11) Disconnect PCV valve (6) from cylinder head with hose connected, breather hose (3) from cylinder head and EVAP canister purge valve hose (2).

12) Detach EGR pipe (4) from intake air collector.

13) Remove throttle body (3) and intake collector (2) from intake manifold (1).

14) Disconnect hoses of PCV from throttle body.

15) Remove throttle body from intake collector.

NOTE:

• TP sensor (4), or other components containing rubber must not be placed in a solvent or cleaner bath. A chemical reaction will cause these parts to swell, harden or get distorted.

• Don’t put drills or wires into passages for cleaning. It causes damages in passages.


CLEANING

CAUTION:

• Do not blow compressed air through bypass air passage with IAC valve installed to throttle body. This will cause IAC valve to malfunction.

• TP sensor, idle air control valve or other components containing rubber must not be places in a solvent or cleaner bath.

A chemical reaction will cause these parts to swell, harden or get distorted.

Clean throttle body bore and bypass air passages (1) by blowing compressed air.

INSTALLATION

1) Clean mating surfaces and install throttle body gasket to intake collector (1) with new gasket (2).

2) Install throttle body to intake collector and tighten bolts.

3) Connect PCV hose.

4) Install throttle body and intake collector to intake manifold with new intake collector gaskets.

5) Install EGR pipe with new gaskets.

6) Connect breather hose and EVAP canister purge valve hose and install PCV valve to cylinder head.

7) Connect connectors of EVAP canister purge valve, MAP sensor and EGR valve.

Fix wire harness with clamps.

8) Install clamp bracket to intake collector.

9) Connect ground wire connector.

10) Connect connectors of TP sensor, ground and IAC valve.

11) Install surge tank pipe to intake manifold with new gaskets and intake air pipe to throttle body. Install surge tank cover.

12) Connect engine coolant hoses to throttle body.

13) Connect accelerator cable and A/T throttle cable (A/T).


14) Install strut tower bar (1) and tighten bolts.

15) Refill cooling system.

16) Connect negative (–) cable at battery.

17) Adjust accelerator cable and A/T throttle cable, refer to

“ACCELERATOR CABLE ADJUSTMENT” and “A/T THROT-

TLE CABLE ADJUSTMENT” in this section.

Idle air control valve (IAC valve)

REMOVAL


2) Disconnect IAC valve connector.

3) Remove IAC valve (1) from throttle body.

INSPECTION

1) Disconnect connector from IAC valve.

2) Check each coil of IAC valve for resistance.

If resistances is out of specification, replace.

IAC valve resistance:

Terminals

Between “1” and “2”




Resistance

25.5 - 33.5

Ω


3) Remove air cleaner outlet hose and remove IAC valve from throttle body.

4) Connect connector to IAC valve.

5) Check that plunger (1) of IAC valve moves once and then stops as soon as ignition switch (2) is turned OFF after cranking engine for 2 sec.

If plunger (1) of IAC valve does not operate at all, check wire harnesses for open and short. If wire harnesses are in good condition, replace IAC valve and recheck.

NOTE:

This check should be performed by two people, one person operates ignition switch while the other checks plunger operation.

INSTALLATION

1) Install new O-ring to throttle body.

2) Install IAC valve to throttle body.

3) Tighten IAC valve screws to specified torque.


IAC valve screw (a) : 3.5N·m (0.35 kg-m, 2.5 lb-ft)

4) Connect IAC valve connector securely.


Fast idle air valve

1) Disconnect IAC valve coupler with ignition switch OFF.

2) Check that with cold engine started, as cooling water temperature rises, engine idle speed reduces gradually.

If check result is as described above, fast idle air valve is in good condition.

If not, fast idle air valve, air passage or coolant passage is faulty.


Fuel Delivery System

Fuel pressure inspection

1) Relieve fuel pressure in fuel feed line referring to “FUEL

PRESSURE RELIEF PROCEDURE” in Section 6-1.

2) Disconnect fuel feed hose from (3) delivery fuel feed pipe (1).

CAUTION:

A small amount of fuel may be released when fuel feed hose is removed. Place container under the fuel feed hose or fuel feed pipe with a shop cloth so that released fuel is caught in container or absorbed in cloth. Place that cloth in an approved container.

3) Connect special tools and hose (2) between fuel feed hose and fuel feed pipe as shown in figure, and clamp hose securely to ensure no leaks occur during checking.

Special tool

(A) : 09912-58441

(B) : 09912-58431

(C) : 09912-58490

4) Check that battery voltage is above 11 V.

5) Turn ignition switch ON to operate fuel pump and after 3 seconds turn it OFF. Repeat this 3 or 4 times and then check fuel pressure.

6) Start engine.

7) Measure fuel pressure at idling.

If measure pressure doesn’t satisfy specification, refer to

“Diagnostic Flow Table B-3” in Section 6-1 and check each possibly defective part. Replace if found defective.

Fuel pressure specification:

CONDITION

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


8) After checking fuel pressure, remove fuel pressure gauge

(1).

CAUTION:

As fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to following procedures.

• Place fuel container under joint.

• Cover joint with rag and loosen joint nut slowly to release fuel pressure gradually.

9) Remove fuel pressure gauge, hose and 3-way joint.

10) Connect fuel feed hose and clamp it securely.

11) With engine “OFF” and ignition switch “ON”, check for fuel leaks.

Fuel pump

ON-VEHICLE INSPECTION

CAUTION:

When fuel filler cap is removed in any procedure, work must be done in a well-ventilated area, keep away from any open flames and without smoking.

1) Remove filler cap and turn ON ignition switch (2). Then fuel pump operating sound should be heard from fuel filler (1) for about 3 seconds and stop. Be sure to reinstall fuel filler cap after checking.

If above check result is not satisfactory, advance to “DIAG-

NOSTIC FLOW TABLE B-1” in Section 6-1

2) Fuel pressure should be felt at fuel return hose (1) for 3 seconds after ignition switch ON.

If fuel pressure is not felt, advance to “DIAGNOSTIC FLOW

TABLE B-3” in Section 6-1.


REMOVAL

Remove fuel tank from body according to procedure described in

Section 6C and remove fuel pump from fuel tank.

INSPECTION

Check fuel pump filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in fuel tank.

INSTALLATION

Install fuel pump to fuel tank and then install fuel tank to body according to procedure described in “Section 6C”.

Fuel pressure regulator

REMOVAL



2) Disconnect negative (–) cable from battery.

3) Disconnect vacuum hose (1) from fuel pressure regulator.

4) Remove fuel pressure regulator (1) from fuel delivery pipe

(3).

CAUTION:

A small amount of fuel may be released when it is from delivery pipe.

Place a shop cloth under delivery pipe so that released fuel is absorbed in it.

5) Disconnect fuel return hose (2) from fuel pressure regulator.

CAUTION:

A small amount of fuel may be released when hose is disconnected. Cover hose to be disconnected with a shop cloth.


INSTALLATION

For installation, reverse removal procedure and note the followings.

• Use new O-ring.

• Apply thin coat of gasoline to O-ring to facilitate installation.

• Tighten fuel pressure regulator (1) bolts to specified torque.


Fuel pressure regulator bolt

(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)

• With engine “OFF” and ignition switch “ON”, check for fuel leaks around fuel line connection.

Fuel injector


1) Using sound scope (1) or such, check operating sound of injector when engine is running or cranking.

Cycle of operating sound should vary according to engine speed.

If no sound or an unusual sound is heard, check injector circuit (wire or coupler) or injector.

2) Disconnect connector from injector, connect ohmmeter between terminals of injector and check resistance.

If resistance is out of specification, replace.

Fuel injector resistance:

14.2 – 14.8 Ω (at 20°C, 68°F)

3) Connect connector to injector securely.


REMOVAL



2) Remove throttle body intake collector, refer to “THROTTLE

BODY” in this section.

3) Disconnect fuel feed hose (1) and fuel return hose (2).

4) Disconnect vacuum hose (4) and fuel return hose from fuel pressure regulator (5).

5) Remove fuel feed pipe (8) and fuel connect pipe (7) from delivery pipes (6) (right and left).

CAUTION:

A small amount of fuel may be released when it is from delivery pipe.

Place a shop cloth under delivery pipe so that released fuel is absorbed in it.

6) Disconnect connector (3) from each injector.

7) Remove delivery pipes (1) (right and left) from intake manifold.

8) Remove fuel injector(s).

INSPECTION

WARNING:

As fuel is injected in this inspection, perform in a well ventilated area and away from open flames.

Use special care to prevent sparking when connecting and disconnecting test lead to and from battery.


1) Install injector (1) and fuel pressure regulator (2) to special tool (injector checking tool).

NOTE:

Remove grommet from injector, then install injector to special tool and tighten bolts by hand.

Special tool

(A) : 09912-58421

2) Connect special tools (hoses and attachment) to pipes of vehicle.

Special tool

(B) : 09912-58431

3) Connect special tool (test lead) to injector.

Special tool

(C) : 09930-88521

4) Install suitable vinyl tube onto injector (3) nozzle to prevent fuel from splashing out when injecting.

5) Put graduated cylinder under injector as far apart as possible.

6) Disconnect fuel pump relay.

7) To operate fuel pump and apply fuel pressure to injector, using wire harness (2) as thick as the one used for fuel pump circuit, connect two terminals of relay connector (1) as shown in the figure.

8) Apply battery (4) voltage to injector for 15 seconds and measure injected fuel volume with graduated cylinder.Test each injector two or three times.If not within specification, replace injector.

Injected fuel volume:

56 – 60 cc/15 sec. (1.89/1.97 – 2.02/2.11 US/lmp. oz/15 sec.)

[A]: Left-hand steering vehicle

[B]: Right-hand steering vehicle

9) Check fuel leakage from injector (1) nozzle. Do not operate injector for this check (but fuel pump should be at work). If fuel leaks more than following specifications, replace.

Fuel leakage:

Less than 1 drop/min.


INSTALLATION

1) Replace injector O-ring (1) with new one using care not to damage it. Install grommet (2) to injector.

2) Check if insulator (1) is scored or damaged. If it is, replace with new one.

Install insulators and cushions (2) to intake manifold.

3) Apply thin coat of fuel to O-rings (1) and then install injectors into delivery pipes (right and left) and intake manifold.

Make sure that injectors rotate smoothly. If not, probable cause is incorrect installation of O-ring or grommet (2).

Replace O-ring with new one.

4) Tighten delivery pipe bolts (3) and make sure that injectors rotate smoothly.


5) Install fuel connect pipe (1) and tighten union bolts to specified torque with new gaskets (3).


Fuel connect pipe union bolt

(b) : 30 N·m (3.0 kg-m, 22.0 lb-ft)

6) Install fuel feed pipe (2) and tighten union bolt to specified torque with new gaskets.


Fuel feed pipe union bolt

(a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)

7) Connect vacuum hose (5) and fuel return hose (4) to fuel pressure regulator.

8) Connect fuel feed hose (1) and fuel return hose (2).

9) Connect connectors of injector wire (3) to injectors.

10) Install throttle body and intake collector, refer to “THROTTLE

BODY” in this section.

11) With engine “OFF” and ignition switch “ON”, check for fuel leaks around fuel line connection.


Electronic Control System

Engine control module (ECM)/powertrain control module (PCM)

CAUTION:

As ECM (PCM) consists of precision parts, be careful not to expose it to excessive shock.

REMOVAL


2) Disable air bag system (if equipped) referring to “DIS-

ABLING THE AIR BAG SYSTEM” in Section 10B.

3) Remove ECM (PCM) cover (1) from bracket.

4) Disconnect connectors from ECM (PCM) (1).

5) Remove ECM (PCM) (1) with bracket (2).

INSTALLATION

1) Install ECM (PCM) with bracket to vehicle.

2) Connect connectors to ECM (PCM) securely.

3) Install ECM (PCM) cover to bracket.

4) Enable air bag system (if equipped) referring to “ENABLING

AIR BAG SYSTEM” in Section 10B.



Mass air flow sensor (MAF sensor)

INSPECTION

NOTE:

Use voltmeter with high-impedance (10 k Ω or digital type voltmeter.

1) Connect voltmeter (1) to “B+” terminal of MAF sensor (2) coupler disconnected and ground (3).

2) Turn ignition switch ON and check that voltage is battery voltage.If not, check if wire harness is open or connection is poor.

3) Turn ignition switch OFF and remove ECM/PCM cover (1) from bracket.

4) Connect MAF sensor coupler to MAF sensor.

5) Turn ignition switch ON and check voltage at MAF sensor output terminal of ECM/PCM connector (1).

MAF sensor output voltage

Voltage: 1.0 - 1.6 V

6) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.

(Reference data: 1.7 – 2.0 V at specified idle speed)

If check result is not as specified above, cause may lie in wire harness, coupler connection, MAF sensor or ECM/

PCM.


REMOVAL

1) Disconnect negative (–) cable at battery and coupler (1) from

MAF sensor (3).

2) Remove air cleaner outlet hose (2) from throttle body and

MAF sensor (3).

3) Remove MAF sensor from air cleaner case.

CAUTION:

• Don’t disassemble MAF sensor.

• Do not expose MAF sensor to any shock.

• Do not blow compressed air by using air gun or the like.

• Do not put finger or any other object into MAF sensor.

Malfunction may occur.

INSTALLATION

1) Check MAF sensor seal (1) for deterioration and damage.

2) Install MAF sensor to air cleaner case.

3) Install air cleaner outlet hose.

4) Connect MAF sensor coupler securely.



Intake air temperature (IAT) sensor

REMOVAL


2) Disconnect IAT sensor coupler.

3) Remove IAT sensor from air cleaner case.

INSPECTION

Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.

If measured resistance doesn't show such characteristic as shown in the figure, replace IAT sensor.

INSTALLATION

1) Clean mating surface of sensor and seal (2) on air cleaner case.

2) Install IAT sensor (1) into seal.

3) Connect connector to IAT sensor securely.


Throttle position sensor (TP sensor)

INSPECTION

1) Disconnect negative (–) cable at battery and coupler from TP sensor (4).

2) Using ohmmeter, check resistance between terminals under each condition given in table below.

If check result is not satisfactory, replace TP sensor.

TP sensor specification:

TERMINALS

Between 1 and

3 terminals

Between 1 and

2 terminals

RESISTANCE

4.0 – 6.0 k Ω

0.02 – 6.0 k

Ω varying linearly according to throttle valve opening

1. Ground terminal

2. Output voltage terminal

3. Reference voltage terminal

3) Connect TP sensor coupler securely.

4) Connect negative cable to battery.

REMOVAL


2) Disconnect coupler from TP sensor.

3) Remove TP sensor from throttle body.

INSTALLATION

1) Install TP sensor (1) to throttle body (2).

Fit TP sensor (1) to throttle body (2) in such way that its holes are a little away from TP sensor screw holes as shown in the figure and turn TP sensor (1) clockwise so that those holes align.


TP sensor screw

(a) : 3.5 N·m (0.35 kg-m, 2.5 lb-ft)

2) Connect coupler to TP sensor securely.

3) Connect battery negative (–) cable to battery.


Engine coolant temperature sensor (ECT sensor)

REMOVAL


2) Drain cooling system.

3) Disconnect coupler from ECT sensor (1).

4) Remove ECT sensor from water outlet cap (2).

INSPECTION

Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water gradually.

If measured resistance doesn’t shown such characteristic as shown in the figure, replace ECT sensor.

INSTALLATION

Reverse removal procedure noting the followings.

• Clean mating surfaces of sensor and water outlet cap (1).

• Use new O-ring.

• Tighten ECT sensor to specified torque.


ECT sensor (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)

• Connect coupler to sensor securely.

• Refill cooling system.


Heated oxygen sensor (sensor 1)

REMOVAL

WARNING:

To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool.


2) Disconnect coupler of oxygen sensor (s).

3) Remove oxygen sensor (s) from exhaust manifold (s).

NOTE:

Be careful not to expose it to excessive shock.

1. Left (No.1) bank oxygen sensor (sensor 1)

INSTALLATION


• Tighten oxygen sensor (s) to specified torque.


Heated oxygen sensor 1

(a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)

• Connect connector of oxygen sensor (s) and clamp wire harness securely.

• After installing oxygen sensor (s), start engine and check that no exhaust gas leakage exists.

INSPECTION

Inspect HO2S-1 and its circuit referring to “DTC P0130 or P0150

Diag. Flow Table” in Section 6-1. If malfunction is found, replace.


HEATER INSPECTION

1) Disconnect HO2S-1 or -2 coupler.

2) Using ohmmeter, measure resistance between terminals

“VB” and “GND” of HO2S coupler (1).

If found faulty, replace HO2S.

NOTE:

Temperature of HO2S affects resistance value largely.

Make sure that HO2S heater is at correct temperature.

Resistance of HO2S heater:

11.7 – 14.3

Ω

5.0 – 6.4

Ω

3) Connect HO2S coupler securely.

Heated oxygen sensor (sensor 2)

REMOVAL

WARNING:

To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool.


2) Disconnect coupler (3) of oxygen sensor(s).

3) Remove oxygen sensor(s) (2) from exhaust manifold(s) (1).

NOTE:

Be careful not to expose it to excessive shock.

INSTALLATION


• Tighten oxygen sensor(s) to specified torque.


Heated oxygen sensor 2 (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)

• Connect connector of oxygen sensor(s) and clamp wire harness securely.

• After installing oxygen sensor(s), start engine and check that no exhaust gas leakage exists.


HEATER INSPECTION

Refer to “HEATED OXYGEN SENSOR (SENSOR 1) HEATER

INSPECTION”

Vehicle speed sensor (VSS)


1) Hoist vehicle.

2) Release parking brake lever, set transmission in neutral and transfer in “2H”.


4) Connector voltmeter between VSS terminal C51-3-1 of ECM

(PCM) connector and body ground.

5) Turn ignition switch ON and turn rear right tire slowly with rear left tire locked.

Voltmeter should indicate deflection between 0 – 1 V and 8 –

14 V a few times while tire (1) is turned one revolution.

If check result is not satisfactory, proceed to flow table of

“DTC P0500” in Section 6-1.

[A]: Terminal arrangement of ECM (PCM) coupler

(viewed from harness side)

REMOVAL, INSPECTION AND INSTALLATION

Refer to “VSS Removal, Inspection or Installation” in Section 7D.

1. VSS

Manifold absolute pressure sensor

REMOVAL


2) Disconnect connector from manifold absolute pressure sensor.

3) Remove manifold absolute pressure sensor from intake manifold.


INSPECTION

1) Check sensor O-ring (1) for damage and deterioration.


2) Arrange 3 new 1.5 V batteries (2) in series and connect its positive terminal to “Vin” terminal of MAP sensor (1) and negative terminal to “Ground” terminal. Then check voltage between “Vout” and “Ground”.

Also, check if voltage reduces when vacuum is slowly applied up to 400 mmHg by using vacuum pump (3).

If check result is not satisfactory, replace manifold absolute pressure sensor.

CAUTION:

As connection to wrong terminal will cause damage to manifold absolute pressure sensor, make absolutely sure to connect properly as shown in the figure.

MAP sensor output voltage (Vin voltage 4.5 – 5.5 V, ambient temp. 20 – 30°C (68 – 86°F))

ALTITUDE

(Reference)

(ft) (m)

0

–

2000

2001

–

5000

5001

–

8000

8001

–

10000

0

–

610

611

–

1524

1525

–

2438

2439

–

3048

BAROMETRIC

PRESSURE

(mmHg) (kPa)

760

–

707

Under 707 over 634



100 – 94

94 – 85

85 – 76

76 – 70

OUTPUT

VOLTAGE

(V)

3.3 – 4.3

3.0 – 4.1

2.7 – 3.7

2.5 – 3.3


INSTALLATION

1) Confirm that vacuum passage on intake manifold is free from clog.

2) Apply engine oil to O-ring of sensor.

3) Install sensor (1) to intake manifold (2).

4) Connect connector to sensor (1) securely.

Fuel level sensor (sender gauge)

Refer to Section 8C.

Crankshaft position sensor

REMOVAL AND INSTALLATION

Refer to Section 6A4.

INSPECTION


Main relay

INSPECTION


2) Remove main relay (1) from its connector.

2. Fuel pump relay

3. Fuse box

4. Instrument panel




3) Check resistance between each two terminals as in table below.

If check results are as specified, proceed to next operation check. If not, replace.

Main relay resistance:

TERMINALS

Between “A” and “B”

Between “C” and “D”

RESISTANCE

79 – 95

Ω (at 20 °

C (68

°

F))

4) Check that there is continuity between terminals “A” and “B” when battery is connected to terminals “C” and “D”.

If malfunction is found, replace.

Fuel pump relay

INSPECTION


2) Remove fuel pump relay (2) from connector.

3) Structure of fuel pump relay is the same as that of main relay.

Check its resistance and operation using the same procedure as that for main relay.

If malfunction is found, replace.

1. Main relay

3. Fuse box

4. Instrument panel




Fuel cut operation

INSPECTION

NOTE:

Before inspection, check to make sure that gear shift lever is in Neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up.


2) While listening to sound of injector by using sound scope (1) or such, increase engine speed to higher than 3,000 r/min.

3) Check to make sure that sound to indicate operation of injector stops when throttle valve is closed instantly and it is heard again when engine speed is reduced to less than about 2,000 r/min.


Emission Control System

EGR system (if equipped)

EGR SYSTEM INSPECTION (USING SUZUKI SCAN TOOL)

1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.

Special tool


NOTE:

For operation procedure of cartridge, refer to its cartridge operator's manual.

2) Start engine and warm up it to normal operating temperature.

3) With engine idling (without depressing accelerator pedal), open EGR valve by using “MISC. TEST” mode.

In this state, according as EGR valve opening increases engine idle speed drops. If not, possible cause is clogged

EGR gas passage, stuck or faulty EGR valve.

1. SUZUKI scan tool display

2. EGR valve opening (0: Close, 100: Full Open)

REMOVAL


2) Disconnect EGR valve coupler.

3) Remove wire harness bracket from intake collector.

4) Remove EGR valve (5) and gasket from intake collector.

1. EVAP canister purge valve 4. EGR pipe

2. EVAP canister purge valve hose 6. PCV hose

3. Breather hose


INSPECTION

1) Check resistance between following terminals of EGR valve

(1) in each pair.

If found faulty, replace EGR valve assembly.

EGR valve resistance:

Terminals

A – B

C – B

F – E

D – E

B - valve body

E - valve body

Standard resistance

20 – 24

Ω infinity (

∞)

2) Remove carbon from EGR valve gas passage.

NOTE:

Do not use any sharp-edged tool to remove carbon.

Be careful not to damage or bend EGR valve, valve seat and rod.

3) Inspect valve (2), valve seat (3) and rod for fault, cracks, bend or other damage.

If found faulty, replace EGR valve (1) assembly.

INSTALLATION


• Clean mating surface of valve and intake manifold.

• Use new gasket.

EVAP canister

INSPECTION

WARNING:

DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful.


1) Disconnect vacuum hoses from EVAP canister and remove

EVAP canister.

2) When air is blown into tank pipe, there should be no restriction of flow through purge pipe and air pipe.

If operation differs from above description, EVAP canister must be replaced.

3) Install EVAP canister and connect hoses to canister.

1. Tank pipe

2. Purge pipe

3. Air pipe

4. Blow air

Vacuum passage

INSPECTION

Start engine and run it at idle speed. Disconnect vacuum hose from EVAP canister purge valve. With finger placed against hose disconnected, check that vacuum is applied.

If it is not applied, clean vacuum passage by blowing compressed air.

TANK PRESSURE CONTROL VALVE INSPECTION

1) Remove tank pressure control valve installed around EVAP canister.

2) Air should pass through valve smoothly from black side (3) of tank pressure control valve (1) to orange side (2) when blown hard.

3) From orange side, even when blown softly, air should come out of black side.

4) If air doesn’t pass through valve in Step 2) or hard blow is required in Step 3), replace tank pressure control valve.

WARNING:

DO NOT SUCK air through tank pressure control valve.

Fuel vapor inside the valve is harmful.

5) Plug orange nozzle and apply 26 kPa (20 cmHg) vacuum to black nozzle. Check that vacuum is held at that level (there is no leakage).

If vacuum leaks, replace.

6) Install tank pressure control valve.

4. To canister

5. From fuel tank


PCV System

NOTE:

Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/IAC duty for obstructed PCV valve or hose hampers its accurate checking.

PCV hose

INSPECTION

Check hoses for connection, leakage, clog, and deterioration.


PCV valve


1) Disconnect PCV valve from cylinder head cover and plug head cover hole.

2) Run engine at idle.

3) Place your finger over end of PCV valve (1) to check for vacuum. If there is no vacuum, check for clogged valve. Replace as necessary.

4) After checking vacuum, stop engine and remove PCV valve

(1). Shake valve and listen for the rattle of check needle inside the valve (1). If valve does not rattle, replace.

5) After checking, connect PCV valve (1), PCV hose and clamp securely.


PCV system

NOTE:

Be sure to check that there is no obstruction in PCV valve or its hoses (6) before checking engine idle speed/

IAC duty for obstructed PCV valve or hose hampers its accurate checking.

PCV HOSE

Check hoses for connection, leakage, clog, and deterioration.


1. EVAP canister purge valve 4. EGR pipe

2. EVAP canister purge valve hose 5. EGR valve

3. Breather hose 6. PCV hose


Fastening part

Heated oxygen sensor

Fuel pressure regulator bolts

Fuel pipe union bolts

Engine coolant temp. sensor

N•m

45

10

30

15


4.5

1.0

3.0

1.5

lb-ft

32.5

7.5

22.0

11.0

Special Tool

09912-58441

Pressure gauge

09912-58431

Pressure hose

09912-58490

3-way joint & hose

09912-58421

Checking tool set

(See NOTE “A”.)


09917-47010 09930-88521 09931-76011

Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan tool) (See NOTE “B”.)


Tech 1A

09931-76030


Tech 1A

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-1, 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


IGNITION SYSTEM (FOR H27 ENGINE) 6F2-1

SECTION 6F2

IGNITION SYSTEM (FOR H27 ENGINE)

WARNING:






General Description ...................................... 6F2-2

Components ................................................ 6F2-2

System Wiring ............................................. 6F2-3

Diagnosis ....................................................... 6F2-4

Diagnostic Flow Table ................................. 6F2-4

Ignition Spark Check ................................... 6F2-6

Ignition Timing Check and Adjustment........ 6F2-6

CONTENTS

On-Vehicle Service ....................................... 6F2-8

Ignition Coil Assembly (Igniter and Ignition

Coil)............................................................. 6F2-8

Spark Plug .................................................. 6F2-8

CMP Sensor.............................................. 6F2-10

Noise Suppressor ..................................... 6F2-12

Special Tool................................................. 6F2-13

6F2

6F2-2 IGNITION SYSTEM (FOR H27 ENGINE)


The ignition system is a direct ignition system. It consists of the parts as described below and has an electronic ignition control system.

• ECM (or PCM)

It detects the engine condition through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter (in ignition coil assembly).

• Ignition coil assembly (including an igniter and an ignition coil)

The ignition coil assembly has a built-in igniter and ignition coil which turns ON and OFF the primary current of the ignition coil according to the signal from ECM (or PCM). When the ignition coil primary current is turned OFF, a high voltage is induced in the secondary wiring. One ignition coil is in charge of ignition of one cylinder only.

• Spark plug and noise suppressor

• CMP sensor, TP sensor, ECT sensor, IAT sensor, VSS, knock sensor and MAF sensor

For their details, refer to Section 6E2.

This ignition system does not have a distributor and high-tension cords but each cylinder has an ignition coil assembly (igniter and ignition coil) and the secondary voltage which occurred in the ignition coil is sent to the spark plug directly. Also, the signal(s) are sent from the CMP sensor to ECM (or PCM) so as to control each ignition coil independently through the igniter (in ignition coil assembly).

Components

NOTE:

For other components not found in this figure, refer to Section 6E2.

1. Ignition coil assembly (igniter and ignition coil)

2. CMP sensor

3. Noise suppressor

4. ECM (or PCM)

5. Spark plug

System Wiring

NOTE:

For ECM (PCM) terminal assignment, refer to Section 6E2.



2. “IG COIL METER” fuse

3. ECM (or PCM)

4. CMP sensor

5. Noise suppressor

6. Ignition coil assembly (For No.1 cylinder)




10. Spark plug



13. To main relay



Diagnosis

Condition

Engine cranks, but will not start or hard to start (No spark)

Possible Cause Correction

Blown fuse for ignition coil assembly Replace.

Loose connection or disconnection of lead wire Connect securely.

Faulty spark plug (s)

Faulty ignition coil assembly (s)

Faulty CMP sensor

Faulty ECM (or PCM)

Replace.

Replace.

Replace.

Replace.

Poor fuel economy or engine performance

Maladjusted ignition timing

Incorrect ignition timing

Faulty spark plug(s)

Faulty ignition coil assembly (s)

Faulty CMP sensor

Faulty ECM (or PCM)

Faulty knock sensor

Adjust.

Adjust.

Replace.

Replace.

Replace.

Replace.

Replace.

Diagnostic Flow Table

Step Action

1 Was “ENGINE DIAGNOSTIC FLOW TABLE” in

Section 6-1 performed?

2 Ignition Spark Test

1) Check all spark plug for condition and type, referring to “SPARK PLUG” in this section.

2) If OK, perform ignition spark test, referring to “IGNITION SPARK CHECK” in this section.

Is spark emitted from all spark plugs?

3 Diagnostic Trouble Code (DTC) Check

1) Check DTC stored in ECM (or PCM), referring to “DIAGNOSTIC TROUBLE CODE

(DTC) CHECK” in Section 6E2.

Is DTC stored?

4 Electrical Connection Check

1) Check ignition coil assemblies for electrical connection.

Are they connected securely?

5 Ignition Coil Assembly Power Supply, Ground and Trigger Signal Circuits Check

1) Check these circuits for open and short.

Are circuits in good condition?

6 Ignition Coil Assembly Check

1) Substitute a known-good ignition coil assembly and then repeat Step 2.

Is check result of Step 2 satisfactory?

Yes

Go to Step 2.

Go to Step 8.

Go to applicable flow table corresponding to that code No. in Section 6E2.

Go to Step 5.

Go to Step 6.

Malfunction of ignition coil assembly.

No

Go to “ENGINE DIAG-

NOSTIC FLOW TABLE” in

Section 6-1.

Go to Step 3.

Go to Step 4.

Connect securely.

Repair or replace.

Go to Step 7.


Step Action

7 CMP Sensor Check

1) Check CMP sensor.

Refer to Step 6 or 7 of “DTC P0340 DIAG.

FLOW TABLE” in Section 6-1.


8 Ignition Timing Check

1) Check initial ignition timing and ignition timing advance, referring to “IGNITION TIM-

ING CHECK AND ADJUSTMENT” in this section.


Yes


ECM (or PCM) and then repeat Step 2.


No

Tighten CMP sensor bolt or replace CMP sensor.

Adjust ignition timing or check ECM (PCM) input signals related to this system.

REFERENCE

Oscilloscope waveforms of CMP sensor REF signal and No.1

ignition trigger signal are as shown in figure when connecting oscilloscope between terminal C51-1-13 of ECM (PCM) connector connected to ECM (PCM) and ground, and between terminal

C51-2-28 and ground.

1. REF signal of CMP sensor

2. No.1 ignition trigger signal

3. Primary coil current flow time


Ignition Spark Check

WARNING:

Without disconnection of injector coupler, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.

1) Remove surge tank cover.

2) Disconnect injector coupler (1).

3) Remove spark plug and check it for condition and type, referring to “SPARK PLUG” in this section.

4) If OK, connect ignition coil coupler to ignition coil assembly and connect spark plug to ignition coil assembly. Ground spark plug.

5) Crank engine and check if each spark plug sparks.

If no spark is emitted, inspect the related parts as described under “DIAGNOSIS” in this section.

6) After checking, install spark plug, referring to “SPARK PLUG” in this section.

7) Connect injector coupler (1).

8) Install surge tank cover.

Ignition Timing Check and Adjustment

NOTE:

Before starting engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake.

1) Start engine and warm it up to normal operating temperature.

2) Make sure that all of electrical loads except ignition are switched off.

3) Check to be sure that idle speed is within specification.

Refer to Section 6E2.

4) Connect SUZUKI scan tool to DLC (1) with ignition switch

OFF, restart engine and fix ignition timing by using fixed spark mode of SUZUKI scan tool.

Special tool



5) Set timing light to ignition harness for No.1 cylinder.

6) Using timing light, check that timing observed from viewpoint is within specification.

Initial ignition timing of viewpoint

(when it is fixed by SUZUKI scan tool) :

5 ± 1° BTDC

Ignition order :

1-6-5-4-3-2

Special tool

(A) : 09930-76420

1. Timing mark on crankshaft pulley

7) If ignition timing is out of specification, loosen flange bolt, adjust timing by turning CMP sensor (1) while engine is running, and then tighten bolt (2).


CMP sensor bolt (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)

8) After tightening bolt (2), recheck that ignition timing is within specification.

9) After checking and/or adjusting, end fixed spark mode of

SUZUKI scan tool.

NOTE:

In this state, ignition timing may vary more or less of initial ignition timing but it is nothing abnormal.

10) With engine idling (closed throttle position and vehicle stopped), check that ignition timing is about BTDC 12-16°

(shown in the figure). Also, check that increasing engine speed advances ignition timing.

If above check results are not satisfactory, check input signals related to this system.

1. Timing mark on crankshaft pulley



Ignition Coil Assembly (Igniter and Ignition

Coil)

REMOVAL

1) Remove ignition coil cover.

2) Disconnect ignition coil coupler.

3) Remove ignition coil bolt (1), and then pull out ignition coil assembly (2).

INSPECTION

Check ignition coil assembly for the following :

• Damage

• Deterioration

• Terminal for corrosion

INSTALLATION

Install in reverse order of removal.

Spark Plug

REMOVAL

1) Remove ignition coil cover.

2) Disconnect ignition coil coupler.

3) Remove ignition coil bolt (1), and then pull out ignition coil assembly (2).

4) Remove spark plug (3).


INSPECTION

CAUTION:

When servicing the iridium/platinum spark plugs (slender center electrode type plugs), do not touch the center electrode to avoid damage to it. The electrode is not strong enough against mechanical force as it is slender and its material is not mechanically tough.

Inspect them for electrode wear, carbon deposits and Insulator damage.

If any abnormality is found, replace them with specified new plug.

Spark plug air gap “a” :

1.0 – 1.1 mm (0.039 – 0.043 in.)

Spark plug type :

DENSO K20PR-U11/SK16PR11

NGK BKR6E-11/*IFR5J11

NOTE:

Under –25°C (–13°F), it is highly recommended to use the spark plugs with an asterisk (*) for better engine starting performance.

INSTALLATION

1) Install spark plug (3) and tighten them to specified torque.


Spark plug (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

2) Install ignition coil assembly (2) securely.

3) Tighten ignition coil bolt (1), and then connect ignition coil coupler.

4) Install ignition coil cover.


CMP Sensor

CAUTION:

Disassembly is prohibited. If anything faulty is found, replace as an assembly unit.

REMOVAL

1) Disconnect CMP sensor coupler (2).

2) Remove A/T fluid level gauge and filler tube.

3) Remove CMP sensor (1) by removing bolt (3).

2

1

3

INSTALLATION

NOTE:

After installing CMP sensor, adjust ignition timing. (Refer to “IGNITION TIMING CHECK AND ADJUSTMENT” in this section).

1) Install a new O-ring (2) with engine oil applied to CMP sensor (1).

1

2


2) Install CMP sensor to camshaft.

Fit the dog of CMP sensor coupling into the slots of camshaft, when installing. The dogs of CMP sensor coupling are offset. Therefore, if the dogs can not be fitted into the slots, turn the CMP sensor shaft by 180 degree and try again.

1. CMP sensor

2. CMP sensor coupling

3. Camshaft

A : Slot offset

(a)

2

3) Tighten CMP sensor bolt (3).


CMP sensor bolt (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)

4) Connect CMP sensor coupler (2) to CMP sensor (1).

1

3, (a)

5) Install A/T fluid level gauge and filler tube.


A/T filler tube bolt (a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)


Noise Suppressor

REMOVAL

1) Disconnect coupler of noise suppressor (1).

2) Remove noise suppressor (1) from harness (2).

INSPECTION

Using ohmmeter, check to be sure that capacitor (condenser) in noise suppressor is not conductive.

If check result is not satisfactory, replace noise suppressor.

INSTALLATION

For installation, reverse removal procedure.

Special Tool


09930-76420 09931-76011

Timing light (Dry cell type) Tech 1A kit (SUZUKI scan tool) (See NOTE “A”.)

09931-76030


Tech 1A


Tech 1A

Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.)

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 adapter, 8. Self-test adapter

“B”: This kit includes the following items and substitutes for the Tech 1A kit.

1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,

6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector, 11. Storage case, 12. Power supply


CHARGING SYSTEM 6H-1

SECTION 6H

CHARGING SYSTEM

WARNING:



“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 of these two conditions may result in severe injury.



NOTE:


CONTENTS

General Description ....................................... 6H-2

Generator ..................................................... 6H-2

Unit Repair Overhaul ..................................... 6H-3

Generator Assembly .................................... 6H-3

Inspection ................................................. 6H-3

Specifications................................................. 6H-6

Battery.......................................................... 6H-6

Generator..................................................... 6H-6

Tightening Torque Specification .................. 6H-6

6H

6H-2 CHARGING SYSTEM

Generator


B : Generator output (Battery terminal)

D : Dummy terminal

E : Ground

F : Field coil terminal

IG : Ignition terminal

WIRING CIRCUIT

L : Lamp terminal

1. Pulley

2. Pulley nut

3. Rotor fan

4. Stator coil

5. Stator core

6. Field coil

7. Rectifier

8. Brush

9. Regulator

10. Rear end frame

11. Drive end frame

1. Generator with regulator assembly

2. I.C. regulator

3. Stator coil

4. Diode

5. Field coil (rotor coil)

6. Charge indicator light

7. Main switch

8. Battery

Generator Assembly

Unit Repair Overhaul


1. Pulley nut

2. Pulley

3. Drive end bearing

4. Stator

5. Stud bolt

6. Driver end bearing

7. Bearing retainer

8. Rotor

9. End housing bearing

10. Bearing cover

11. Wave washer

12. Rear end frame

13. Seal plate

14. Rectifier

15. Insulator

16. Regulator

17. Brush

18. Brush holder

19. Brush holder cover

20. Rear end cover

21. Terminal plate

Inspection

Rotor

• Using ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor.

Standard resistance between slip rings of rotor

: 1.6 – 2.0 Ω


• Using ohmmeter, check that there is no continuity between slip ring and rotor. If there is continuity, replace rotor.

• Check slip rings for roughness or scoring. If rough or scored, replace rotor.

Using a vernier caliper, measure the slip ring diameter.

If the diameter is less than minimum, replace the rotor.

Standard diameter of slip ring

: 14.2 – 14.4 mm (0.557 – 0.567 in.)

Minimum diameter of slip ring

: 12.8 mm (0.504 in.)

Stator

• Using ohmmeter, check all leads for continuity. If there is no continuity, replace stator.

• Using ohmmeter, check that there is no continuity between coil leads and stator core. If there is continuity, replace stator.


Brush and brush holder

Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush.

Exposed brush length “a”

Standard : 10.5 mm (0.413 in.)

Limit : 1.5 mm (0.059 in.)

Rectifier

• Positive Rectifier a) Using an ohmmeter, connect one tester probe to the “B” terminal (1) and the other to each rectifier terminal (2).

b) Reverse the polarity of the tester probes and repeat step a).

c) Check that one shows continuity and the other shows no continuity. If there is continuity, replace the rectifier.

• Negative Rectifier a) Using an ohmmeter, connect one tester probe to each negative terminal (1) and the other to each rectifier terminal (2).

b) Reverse the polarity of the tester probes and repeat step a).

c) Check that one shows continuity and the other shows no continuity. If there is continuity, replace the rectifier.


Battery

Battery type

Rated capacity AH/5HR, 12 Volts

Electrolyte L (US/Imp.pt)

Electrolyte S.G.

Generator

Type

Rated voltage

Nominal output

Permissible max. speed

No-load speed

Setting voltage

Permissible ambient temperature

Polarity

Rotation

Specifications

55D23L

48

75D23L

52

95D26L

66

3.9 (8.24/6.86) 3.9 (8.24/6.86) 4.0 (8.53/7.04)

1.28 when fully charged at 20°C (68°F)

105 A type

12 V

105 A

18000 r/min.

1150 r/min (rpm)

14.2 to 14.8 V

–30 to 90 °C (–22 to 194 °F)

Negative ground

Clockwise viewed from pulley side

Fastening part

Body ground bolt

Generator mounting bolts and nut

“B” terminal inner nut

“B” terminal outer nut

Generator pulley nut

Rear end frame nuts

Rear end cover nuts

Stator stud bolts

Drive end bearing plate screws

Rectifier screws

Regulator and brush holder screws

Terminal plate bolt


N•m

8

23

3.6

8

111

4.5

4.5

9.8

3.0

3.0

2.0

3.9


0.8

2.3

0.37

0.8

11.2

0.45

0.45

1.0

0.30

0.30

0.20

0.39

lb-ft

6.0

16.5

3.0

6.0

81.5

3.5

3.5

7.0

2.2

2.2

1.5

3.0

EXHAUST SYSTEM 6K-1

SECTION 6K

EXHAUST SYSTEM

CAUTION:

Be sure to use UNLEADED FUEL for the catalytic converter equipped vehicle. Use of LEADED FUEL will affect performance of the catalytic converter adversely to a great extent.

NOTE:

• For the descriptions (items) not found in this section, refer to the same section of service manual mentioned in the FOREWORD of this manual.

CONTENTS

On-Vehicle Service..........................................6K-2 Components.................................................. 6K-2

6K

6K-2 EXHAUST SYSTEM


Components

TYPE WITH WELD BOLT AT MUFFLER FRONT FLANGE

1-1 Exhaust manifold (without WU-TWC)

1-2 Exhaust manifold (with WU-TWC)

4. Heated oxygen sensor-1 (if equipped)

5. Exhaust pipe gasket

7. Exhaust pipe bolt

8. Muffler

2. Seal ring 6-1 Exhaust No.2 pipe (without WU-TWC) 8-1. Weld bolt

3-1 Exhaust No.1 pipe (without WU-TWC) 6-2 Exhaust No.2 pipe (with WU-TWC) 9. Muffler mounting

3-2 Exhaust No.1 pipe (with WU-TWC) 6-3 Exhaust No.2 pipe (without TWC) 10. Heated oxygen sensor-2

(if equipped)

11. Muffler tail pipe

12. Muffler gasket

13. No.1 Exhaust pipe stiffener

Tightening Torque

Do not reuse

TYPE WITHOUT WELD BOLT AT MUFFLER FRONT FLANGE

EXHAUST SYSTEM 6K-3

1-1 Exhaust manifold (without WU-TWC)

1-2 Exhaust manifold (with WU-TWC)

2. Seal ring

3-1 Exhaust No.1 pipe (without WU-TWC)

3-2 Exhaust No.1 pipe (with WU-TWC)

4. Heated oxygen sensor-1 (if equipped)

5. Exhaust pipe gasket

7. Exhaust pipe bolt

8. Muffler

6-1 Exhaust No.2 pipe (without WU-TWC) 9. Muffler mounting

6-2 Exhaust No.2 pipe (with WU-TWC)

6-3 Exhaust No.2 pipe (without TWC)

10. Heated oxygen sensor-2

(if equipped)

11. Muffler tail pipe

12. Muffler gasket

13. No.1 Exhaust pipe stiffener

Tightening Torque

Do not reuse

6K-4 EXHAUST SYSTEM

MANUAL TRANSMISSION 7A1-1

SECTION 7A1

MANUAL TRANSMISSION

NOTE:


7A1

CONTENTS

Unit Repair .....................................................7A1-1

Unit Repair

NOTE:

This manual transmission (for H27 engine) is not equipped with C-ring of countershaft rear bearing.

Therefore it is not necessary to disassemble or reassemble this C-ring from or to countershaft rear bearing. For the descriptions (items) other than mentioned above, refer to the same section of “UNIT

REPAIR MANUAL” mentioned in the FOREWORD of this manual.

7A1-2 MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION (4 A/T) 7B1-1

SECTION 7B1

AUTOMATIC TRANSMISSION (4 A/T)

WARNING:






NOTE:


7B1

General Description ......................................7B1-3

Electronic Shift Control System...................7B1-4

Automatic gear shift diagram...................7B1-5

Diagnosis .......................................................7B1-7

On-Board Diagnostic System

(Vehicle without monitor connector) ............7B1-7

On-Board Diagnostic System

(Vehicle with monitor connector) .................7B1-8

Precaution in Diagnosing Trouble ...............7B1-9

Automatic Transmission Diagnostic Flow

Table .........................................................7B1-10

Malfunction Indicator Lamp (MIL) Check... 7B1-13

“O/D OFF” Lamp Check ............................ 7B1-13

“POWER” Lamp Check .............................7B1-13

Diagnostic Trouble Code (DTC) Check.....7B1-13

Diagnostic Trouble Code Clearance ......... 7B1-13

Diagnostic Trouble Code Table.................7B1-14

Fail Safe Table ..........................................7B1-14

Visual Inspection .......................................7B1-14

A/T Basic Check........................................ 7B1-14

Trouble Diagnosis Table 1 ........................7B1-15



Scan Tool Data .........................................7B1-17

Inspection of PCM and Its Circuit ..............7B1-17

CONTENTS

Wire Harness and Connectors .................. 7B1-17

Table A-1 : No TCC Lock-Up Occurs........ 7B1-18

Table A-2 : No Gear Shift to O/D .............. 7B1-20

Table B-1 : “O/D OFF” Light Circuit Check

(“O/D OFF” Light Doesn’t Light at Ignition

Switch ON But Engine Starts Up) ............. 7B1-22

Table B-2 : “O/D OFF” Light Circuit Check

(“O/D OFF” Light Comes ON Steadily) ..... 7B1-23

Table B-3 : “POWER” Light Circuit Check

(“POWER” Light Doesn’t Light at Ignition

Switch ON But Engine Starts Up) ............. 7B1-24

Table B-4 : “POWER” Light Circuit Check

(“POWER” Light Comes ON Steadily) ...... 7B1-25

DTC P0705 (DTC NO.72) - Transmission

Range Sensor (Switch) Circuit Malfunction7B1-26

DTC P0715 (DTC NO.76) - Input/Turbine

Speed Sensor Circuit Malfunction............. 7B1-29

DTC P0720 (DTC NO.75) Output Speed

Sensor Circuit Malfunction ........................ 7B1-32

DTC P0743 (DTC NO.65/66) -

TCC (Lock-Up) Solenoid Electrical ........... 7B1-34

DTC P0753 (DTC NO.61/62)

Shift Solenoid-A (#1) Electrical

DTC P0758 (DTC NO.63/64)

Shift Solenoid-B (#2) Electrical ................. 7B1-36

7B1-2 AUTOMATIC TRANSMISSION (4 A/T)

Stall Test ................................................... 7B1-38

Line Pressure Test.................................... 7B1-39

Road Test ................................................. 7B1-40

Manual Road Test..................................... 7B1-41

Time Lag Test ........................................... 7B1-41

Engine Brake Test .................................... 7B1-42

“P” Range Test.......................................... 7B1-42

On-Vehicle Service ..................................... 7B1-43

Maintenance Service ................................ 7B1-43

Fluid level .............................................. 7B1-43

Fluid change.......................................... 7B1-44

A/T Throttle Cable ..................................... 7B1-45

Solenoid Valves (Shift Solenoid Valves and TCC Solenoid Valve) ......................... 7B1-45

MANUAL SELECTOR ASSEMBLY .......... 7B1-46

SELECT CABLE ....................................... 7B1-48

Unit Repair .................................................. 7B1-49

Sub-Assembly Repair ............................... 7B1-49

Overdrive (case side)............................ 7B1-49

Forward clutch ...................................... 7B1-50

Front upper valve body ......................... 7B1-54

Unit Assembly........................................... 7B1-59

Tightening Torque Specification............... 7B1-60

Special Tool ................................................ 7B1-61


Torque converter

Type

Item

Stall torque ratio

Oil pump Type

Drive system

Gear change device

Type

Shift position

Gear ratio

1st

(low gear)

2nd

(second gear)

3rd

(top gear)

4th

(overdrive gear)

Reverse

(reverse gear

Control elements


Specifications

3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism)

2.0

Trochoid type oil pump

Engine driven

Forward 4-step, reverse 1-step planetary gear type

“P” range Gear in neutral, output shaft fixed, engine start

“R” range

“N” range

“D” range

(O/D ON)

“D” range

(O/D OFF)

“2” range

“L” range

Reverse

Gear in neutral, engine start

Forward 1st

↔ 2nd ↔ 3rd ↔ 4th (O/D) automatic gear change

Forward 1st ↔ 2nd ↔ 3rd automatic gear change

(Normal mode) Forward 1st ↔ 2nd ← 3rd automatic gear change

(Power mode) Forward 2nd ← 3rd automatic gear change and fixed at 2nd gear

Forward 1st

← 2nd ← 3rd reduction, and fixed at

1st gear

2.826

1.493

1.000

0.689

2.703

Transfer

Wet type multi-disc clutch ... 3 sets

Wet type multi-disc brake ... 4 sets

One-way clutch ... 3 sets

Hi : 1.000

Lo : 1.816 (4WD model only)

5.125

Final gear reduction ratio (Differential)

Lubrication Lubrication system

Cooling Cooling system

Fluid used

Force feed system by oil pump

Radiator assisted cooling (water-cooled)

An equivalent of DEXRON



III


Electronic Shift Control System

2

B+

BLU/YEL C51-1-14

5V

5V 5V

B+

3

4

YEL/GRN

YEL/BLU

GRY/YEL

C51-1-12

C51-1-13

C51-3-26

GRY/YEL C51-3-12

GRY/RED

RED/GRN

ORN/BLU

C51-3-13

C51-3-9

C51-3-2

5V

5V

5V

GRY/YEL C51-3-24

1

5

BB+

GRN/WHT E61-34

6

7

8

BLU/YEL

BLU/GRN

WHT

ORN

C51-1-11

C51-1-10

C51-1-21

C51-1-20

C51-1-23

C51-1-22

5V

5V

17 16 15

9

10

11

12

IG1

P

R

N

D

2

L

ORN/GRN

RED

ORN/BLU

YEL/GRN

GRN/ORN

GRN/BLU

C51-1-7

C51-1-6

C51-1-19

C51-1-18

C51-1-28

C51-1-27

12V 12V 12V

GRN

GRN/RED

GRN/YEL

C51-1-2

C51-1-1

C51-1-8

12V

12V

12V

E61-7

E61-20

E61-21

E61-33

E61-31

C51-1-26

PPL/YEL

WHT/BLK

GRY/BLU

YEL/RED

ORN/BLU

ORN/WHT

20

18

19

22

13

BB+

14

PPL/RED

PNK/BLU

GRY

E61-13

E61-35

E61-4

12V

12V

5V 12V

C51-3-20

E61-2

E61-9

C51-3-4

C51-3-15

C51-3-6

C51-3-17

C51-2-7

BLK/WHT

WHT

BLU

BLU/BLK

BLU/BLK

BLK/GRN

BLK/ORN

BLK/GRN

21

23

24

E61 C51-3 C51-1 C51-2

8 7

6 5

23 22

21 20 19

4

18 17 16 15 14 13

3 2

12 11 10

35 34 33 32 31 30 29 28 27 26 25

1

9

24

6 5

4

17 16

15 14

26 25 24

13 12

23 22

11 10 9 8 7

21

3

20

2

19

1

18

7 6 5 4 3

19 18 17 16 15 14 13 12 11 10

2 1

9 8

28 27 26 25 24 23 22 21 20

7 6 5 4 3

20 19 18 17 16 15 14 13 12 11 10

2 1

9 8

30 29 28 27 26 25 24 23 22 21

1. PCM (ECM)

2. VSS

3. CMP sensor

4. TP sensor

5. ECT sensor

6. Stop lamp switch

7. Input shaft speed sensor

8. Output shaft speed sensor

9. Transmission range sensor

10. Shift solenoid-A

11. Shift solenoid-B

12. TCC solenoid


14. Cruise control module

15. “POWER” lamp

16. “O/D OFF” lamp

17. MIL (“SERVICE ENGINE SOON” lamp)

18. O/D off switch

19. P/N change switch

20. 4WD low switch

21. Main relay

22. Ignition switch

23. Battery

24. PCM (ECM) connector terminal (viewed from harness side)


Automatic gear shift diagram

Automatic shift schedule as a result of shift control is shown below. In case that select lever is shifted to L at a higher than 55 km/h or 34 mile/h speed, 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that. No up shift is available in L.

The same as, the select lever is shifted to 2 at a higher than 105 km/h (65 mile/h) speed, 3rd gear is operated and then down shifts to 2nd at a speed lower than that.

[POWER MODE]

Throttle opening

Full throttle km/h (mile/h)

Closed throttle km/h (mile/h)

1 → 2

46

(29)

16

(10)

2 → 3

93

(58)

30

(19)

3 → 4

160

Shift

4 → 3

150

(100) (94)

45

(28)

38

(16)

3 → 2

83

(52)

24

(11)

2 → 1

36

(23)

7

(4)

GEAR SHIFT DIAGRAM [A] AND TCC LOCK-UP DIAGRAM [B]


[NORMAL MODE]

Throttle opening

Full throttle km/h (mile/h)

Closed throttle km/h (mile/h)

1

→ 2

46

(29)

11

(7)

2

→ 3

93

(58)

27

(17)

GEAR SHIFT DIAGRAM [A] AND TCC LOCK-UP DIAGRAM [B]

3

→ 4

160

Shift

4

→ 3

150

(100)

40

(25)

(94)

35

(22)

3

→ 2

83

(52)

21

(13)

2

→ 1

36

(23)

7

(4)


Diagnosis

This vehicle is equipped with an electronic transmission control system, which control the automatic shift up and shift down timing, TCC operation, etc. suitably to vehicle driving conditions.

PCM (ECM) has an On-Board Diagnosis system which detects a malfunction in this system and abnormality of those parts that influence the engine exhaust emission.

When diagnosing a trouble in the transmission including this system, be sure to have full understanding of the outline of “ON-BOARD DIAGNOSTIC SYSTEM” and each item in “PRECAUTION IN DIAGNOSING TROUBLE” and execute diagnosis according to “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE” to obtain correct result smoothly.

On-Board Diagnostic System (Vehicle without monitor connector)

For automatic transmission control system, PCM (ECM) has following functions. Refer to Section 6-1 for details.

• When the ignition switch is turned ON with the engine at a stop, malfunction indicator lamp (MIL) (1) turns ON to check the bulb of the MIL.

• When PCM detects a malfunction in A/T control system

(and/or a malfunction which gives an adverse effect to vehicle emission) while the engine is running, it makes the malfunction indicator lamp in the meter cluster of the instrument panel turn ON and stores the malfunction area.

(If it detects that continuously 3 driving cycles are normal after detecting a malfunction, however, it makes MIL (1) turn

OFF although DTC stored in its memory will remain.)

• It is possible to communicate through DLC (3) by using not only SUZUKI scan tool (2). (Diagnostic information can be accessed by using a scan tool (2).)

2 DRIVING CYCLE DETECTION LOGIC

Refer to Section 6-1 for details.

PENDING DTC


FREEZE FRAME DATA



On-Board Diagnostic System (Vehicle with monitor connector)

For automatic transmission control system, PCM (ECM) has following functions. Refer to Section 6/6-1 for details.

• When the ignition switch is turned ON with the engine at a stop, malfunction indicator lamp (MIL) turns ON to check the bulb of the MIL.

• When PCM detects a trouble in electronic shift control system, it stores its trouble code 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 PCM is shut off for 30 seconds or longer.)

• It is possible to communicate through DLC by using not only

SUZUKI scan tool (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)

• ECM also indicates trouble area in memory by means of flashing of malfunction indicator lamp (1) at the time of inspection. (i.e. when diagnosis switch terminal (3) is connected to ground terminal (4) with a service wire (5) and ignition switch is turned ON.)


Precaution in Diagnosing Trouble

• Don’t disconnect couplers from PCM (ECM), battery cable from battery, PCM ground wire harness from engine or main fuse before checking the diagnosis information (DTC, freeze frame data, etc.) stored in PCM memory. Such disconnection will clear memorized information in PCM memory.

• Using SUZUKI scan tool or also generic scan tool for vehicle without monitor connector, the diagnostic information stored in PCM memory can be checked and cleared as well. Before its use, be sure to read Operator’s (Instruction) Manual supplied with it carefully to have good understanding of its functions and usage.

• Priorities for diagnosing troubles

If two or more diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which was detected earliest in the order and follow the instruction in that table.

If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.

– Diagnostic trouble codes (DTCs) other than DTC P0171/

P0172/P0174/P0175 (Fuel system too lean/too rich), DTC

P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire detected) and DTC P0400 (EGR flow malfunction)

– DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too rich) and DTC P0400 (EGR flow malfunction)

– DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306

(Misfire detected)

• Be sure to read “PRECAUTIONS FOR ELECTRICAL CIR-

CUIT SERVICE” in Section 0A before inspection and observe what is written there.

• PCM replacement

When substituting a known-good PCM, check for following conditions.

Neglecting this check may result in damage to a good PCM.

– All relays and actuators have resistance of specified value.

– MAF sensor, MDP sensor, TP sensor and fuel tank pressure sensor are in good condition. Also, the power circuit of these sensors is not shorted to the ground.


Automatic Transmission 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 next page.

Was customer complaint analysis performed according to instruction?

2 Diagnostic Trouble Code (DTC) and Freeze

Frame Data Check, Record and Clearance

1) Check for DTC (including pending DTC)

Is there any DTC(s)?

3 Visual Inspection

1) Perform visual inspection referring to the next page.


4 Visual Inspection

1) Perform visual inspection referring to the next page.


5 Trouble Symptom Confirmation

1) Confirm trouble symptom referring to the next page.


6 Rechecking and Record of DTC/Freeze Frame

Data

1) Recheck for DTC and freeze frame data referring to “DTC Check” in this section.


7 Rechecking and Record of DTC/Freeze Frame

Data

1) Recheck for DTC and freeze frame data referring to “DTC Check” in this section.


8 Automatic Transmission Basic Inspection and

Trouble Diagnosis Table

1) Check and repair according to “A/T Basic

Check” and “Trouble Diagnosis Table” in this section.


9 Troubleshooting for DTC

1) Check and repair according to applicable

DTC diag. flow Table.


10 Check for Intermittent Problems

1) Check for intermittent problems referring to the next page.


Yes

Go to Step 2.

Print DTC and freeze frame data or write them down and clear them by referring to “DTC CLEAR-

ANCE” in this section

Go to Step 3.


Go to Step 11.

Go to Step 6.

Go to Step 9.

Go to Step 9.

Go to Step 11.

Repair or replace malfunction part(s).

Go to Step 11.

No

Perform customer complaint analysis.

Go to Step 4.

Go to Step 5.

Go to Step 8.

Go to Step 7.

Go to Step 8.

Go to Step 10.


Go to Step 11.

Go to Step 11.

Step Action

11 Final Confirmation Test

1) Clear DTC if any.

2) Perform final confirmation test referring to the next page.

Is there any problem symptom, DTC or abnormal condition?

Yes

Go to Step 6.


No

End.

STEP 1. CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as described by the customer.

For this purpose, use of such a inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.

STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK, RECORD AND

CLEARANCE

First, referring to DTC check section, check DTC (including pending DTC). If DTC exists, print or write down

DTC and freeze frame data and then clear them by referring to DTC clearance section. DTC indicates malfunction in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and normal condition has been restored. In order to know that, check symptom in question according to

Step 5 and then recheck DTC according to Step 6.

Diagnosing a trouble based on the DTC in this step only or failure to clear the DTC in this step may result in an faulty diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unnecessary.

STEP 3 and STEP 4. VISUAL INSPECTION

As a preliminary step, be sure to perform visual check of the items that support proper function of the A/T and engine referring to Visual Inspection section.

STEP 5. TROUBLE SYMPTOM CONFIRMATION

Check trouble symptoms based on information obtained in Step 1 “CUSTOMER COMPLAINT ANALYSIS” and

Step 2 “DTC/FREEZE FRAME DATA CHECK”.

Also, recheck DTC according to “DTC CONFIRMATION PROCEDURE” described in each “DTC FLOW

TABLE”.

STEP 6 and STEP 7. RECHECKING AND RECORD OF DTC/FREEZE FRAME DATA

Refer to “DTC CHECK” in this section for checking procedure.

STEP 8. A/T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE

Perform A/T basic check according to the “A/T Basic Check Flow Table” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referring to “TROUBLE DIAGNO-

SIS TABLE” and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer complaint analysis, trouble symptom confirmation and/or A/T basic check) and repair or replace faulty parts, if any.

STEP 9. DIAGNOSTIC TROUBLE CODE FLOW TABLE

Based on the DTC indicated in Step 6 and 7 and referring to “DIAGNOSTIC TROUBLE CODE FLOW TABLE” in this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, PCM or other part and repair or replace faulty parts.


STEP 10. CHECK FOR INTERMITTENT PROBLEM


“INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in Step 2.

STEP 11. FINAL CONFIRMATION TEST

Confirm that the problem symptom has gone and the A/T is free from any abnormal conditions.

If what has been repaired is related to the malfunction DTC, clear the DTC once, set conditions under which

DTC was detected and A/T and/or vehicle was repaired and confirm that no DTC is indicated.

CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)

NOTE:

The above form is a standard sample. It should be modified according to conditions characteristic of each market.


Malfunction Indicator Lamp (MIL) Check

Refer to the same item in Section 6-1 for checking procedure.

“O/D OFF” Lamp Check

1) Check that O/D off switch button is at OFF position (pushed).


3) Check that “O/D OFF” lamp lights for about 2 – 4 sec. and then goes OFF.

If anything faulty is found, advance “DIAGNOSTIC FLOW

TABLE B-1 or B-2 “O/D OFF” LAMP CIRCUIT CHECK”.

“POWER” Lamp Check

1) Check that Power/Normal change switch button is at Normal position.


3) Check that “POWER” lamp lights for about 2 – 4 sec. and then goes OFF.

If anything faulty is found, advance “DIAGNOSTIC FLOW

TABLE B-3 or B-4 “POWER” LAMP CIRCUIT CHECK”.

Diagnostic Trouble Code (DTC) Check

Refer to the same item in Section 6-1 for checking procedure.

Diagnostic Trouble Code Clearance

Refer to the same item in Section 6-1 for clearance procedure.


Diagnostic Trouble Code Table

Refer to the same item in Section 6-1.

Fail Safe Table

Refer to the same item in Section 6-1.

Visual Inspection

Visually check following parts and systems.

INSPECTION ITEM

• A/T fluid - - - - - level, leakage, color

• A/T fluid hoses - - - - - disconnection, looseness, deterioration

• Throttle (accelerator) cable - - - - - play, installation

• A/T throttle cable - - - - - play, installation

REFERRING SECTION

SECTION 0B

SECTION 7B1

SECTION 6E2

SECTION 7B1

• A/T select cable - - - - - installation, operation

• Engine oil - - - - - level, leakage

• Engine coolant - - - - - level, leakage

• Battery - - - - - fluid level, corrosion of terminal

SECTION 7B1

SECTION 0B

SECTION 0B

• Connectors of electric wire harness - - - - - disconnection, friction Section 6-1 or 7B1

• Fuses - - - - - burning SECTION 8

• Parts - - - - - installation, damage

• bolt - - - - - looseness

• Other parts that can be checked visually

• Also check following items at engine start, if possible.

– “O/D OFF” lamp - - - - - Operation

– “POWER” lamp - - - - - Operation

– Malfunction indicator lamp (“SERVICE ENGINE SOON” lamp) - -

- - - Operation

– Charge warning lamp - - - - - Operation

– Engine oil pressure warning lamp - - - - - Operation

SECTION 7B1

SECTION 7B1

Section 6-1

SECTION 6H

SECTION 8C (SECTION 6A2 for pressure check)

– Engine coolant temp. meter - - - - - Operation

– Other parts that can be checked visually

A/T Basic Check

This inspection is important for troubleshooting when PCM (ECM) has detected no DTC and no abnormality has been noted in visual inspection. Follow flow table carefully.

Step

1

Action

Was “AUTOMATIC TRANSMISSION DIAGNOSTIC

FLOW TABLE” performed?

Yes

Go to Step 2.

2 Perform “MANUAL ROAD TEST” in this section.

Is it OK?

3 Proceed to “TROUBLE DIAGNOSIS TABLE 1” in this section.

Is trouble identified?

Go to Step 3.

Repair or replace defective parts.

No

Go to “AUTOMATIC

TRANSMISSION DIAG-

NOSTIC FLOW TABLE”.

Go to Step 4.

Go to Step 5.


Step Action

4 Perform stall test, time rag test, line pressure test, engine brake test and “P” range test referring to

“STALL TEST”, “LINE PRESSURE TEST”, “ENGINE

BRAKE TEST” and ““P” RANGE TEST” in this section.

Are the test results satisfactory?

5 Proceed to “TROUBLE DIAGNOSIS TABLE 2” in this section.

Is trouble identified?

Yes

Go to Step 5.

Repair or replace defective parts.

Proceed to “TROUBLE

DIAGNOSIS TABLE 3” in this section.

No

Proceed to “TROUBLE

DIAGNOSIS TABLE 3” in this section.

Trouble Diagnosis Table 1


TCC does not operate Brake pedal (stop lamp) switch or its circuit faulty (H25 engine only)

4WD low switch or its circuit faulty

Gear does not change to 4th

Engine coolant temp. sensor or its circuit faulty

Cruise control signal circuit faulty (if equipped)

O/D off switch or its circuit faulty

4WD low switch or its circuit faulty

Engine coolant temp. sensor or its circuit faulty

Cruise control signal circuit faulty (if equipped)

Correction

Refer to “DIAGNOSTIC FLOW

TABLE A-1” in this section.

Refer to “DIAGNOSTIC FLOW

TABLE A-2” in this section.


TRANSMISSION FLUID

Condition

Low fluid pressure

High fluid pressure

Possible Cause

Clogged oil pump strainer

Malfunction of pressure regulator valve

Pressure regulator valve

RUNNING CONDITION

Unable to run in all range

Condition

Poor 1st speed running or excessive slippage in “D” or “2”

Possible Cause

Regulator valve stick

Clogged oil strainer

Seized or broken planetary gear

Faulty manual valve

Faulty 1–2 shift valve

Correction

Wash strainer.

Overhaul valve body.

Overhaul valve body.

Correction

Replace.

Wash strainer.

Repair or replace.

Replace.

Replace.


GEAR SHIFT

Condition

Poor 1–2 shift, excessive slippage


Poor start or surging in “D” range

Poor 3-4 shift, excessive slippage

Excessive shock on

1–2 shift


2–3 shift


3–4 shift

Non operate lock-up system

Possible Cause

Regulator valve sticking

1–2 shift valve sticking

Shift solenoid valve-B sticking

Intermediate coast modulator valve sticking


Shift solenoid valve-A sticking



Shift solenoid valve-B sticking


Faulty accumulator, second brake piston


Faulty accumulator, direct clutch piston


TCC (Lock-up) control valve sticking

Solenoid valve No.2 (TCC solenoid valve) sticking

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Correction


TRANSMISSION FLUID

Condition

Low fluid pressure

Possible Cause

Leakage from oil pressure circuit Overhaul.

Correction

RUNNING CONDITION

Unable to run in all range

Condition

Poor 1st speed running or excessive slippage in “D” or “2”

Unable to run or excessive slippage in

“L” range

Unable to run or excessive slippage in

“R” range

Possible Cause

Wear in oil pump

Seizure in oil pump

Fluid pressure leakage to over drive clutch due to wear of oil pump bushing

Faulty in torque converter

Fluid pressure leakage from forward clutch due to wear or breakage of O/D case seal ring

Overdrive clutch slipping

Fluid pressure leakage of forward clutch due to wear or breakage of O/D case seal ring

Reverse brake disc slipping

Broken brake piston O-ring

Fluid pressure leakage to direct clutch due to wear or breakage of center support seal ring

Worn direct clutch

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Correction


GEAR SHIFT

Condition



Poor start or surging in “D” range


Poor start or juddering in “R” range

Possible Cause

Fluid pressure leakage to overdrive clutch due to wear or breakage of O/D case seal ring

Faulty second brake

Broken O-ring of second brake piston

Faulty second coast brake (in “2” range)

Fluid pressure leakage to overdrive clutch due to wear or breakage of O/D case seal ring

Worn direct clutch bushing

Direct clutch slipping

Foreign material caught in direct clutch piston check ball

Fluid pressure leakage of forward clutch due to wear or breakage of O/D case seal ring

Malfunction of forward clutch

Faulty overdrive brake

Faulty overdrive clutch

Fluid pressure leakage of direct clutch due to wear or breakage of oil center support seal ring

Worn direct clutch

Faulty one-way clutch

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.


1– 2 shift

Non operate lock-up system

Faulty torque converter Replace.

Correction

ABNORMAL NOISE

Condition

Abnormal noise in “P” or “N” range

Worn oil pump

Possible Cause

Replace.

Correction

Scan Tool Data


Inspection of PCM and Its Circuit


Wire Harness and Connectors



Table A-1 : No TCC Lock-Up Occurs


PCM turns TCC solenoid OFF under any of the following conditions.

• Brake pedal switch : ON

• 4WD LOW switch : ON

• Cruise control module : TCC OFF command signal is output (if equipped).

• ECT : ECT < 30 °C (86 °F)

TROUBLESHOOTING

WARNING:

• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during testing to avoid occurrence of an accident.

• Road test should be carried out with 2 person, a driver and tester, on a level road.

Step Action

1 Was “AUTOMATIC TRANSMISSION DIAG-

NOSTIC FLOW TABLE” performed?

Yes

Go to Step 2.

2 ECT check :


2) Check ECT using scan tool.

Is ECT more than 30 °C (86 °F)?

3 Perform running test under the following conditions and check voltage between C51-1-8 terminal of PCM coupler and ground.

• Normal mode in “D” range.

• Transfer “2H” position.

• Cruise control is not operated (if equipped).

• Brake pedal released.

• Drive vehicle with TCC ON condition referring to “TCC LOCK-UP DIAGRAM” in this section.

Is it battery voltage?

4 Brake switch signal inspection :

With ignition switch ON, check voltage between

E61-34 terminal of PCM coupler terminal and ground.

Go to Step 3.

Faulty TCC solenoid valve, its circuit or transmission.

Go to Step 5.

Brake switch specification

Brake pedal released : 0 V

Brake pedal depressed : Battery voltage

Is the result as specified?

No

Go to “AUTOMATIC

TRANSMISSION DIAG-

NOSTIC FLOW TABLE” in this section.

Faulty ECT sensor, its circuit or engine cooling system.

If OK, substitute a knowngood PCM and recheck.

Go to Step 4.

Faulty brake pedal switch or its circuit.



Step Action

5 “4WD LOW” switch signal inspection :


C51-1-26 terminal of PCM coupler and ground.

Yes

Go to Step 6.

“4WD LOW” switch specification

Transfer gear position “4L” or “N” : 0 V

Transfer gear position “4H” or “2H” :

Battery voltage

No

Faulty “4WD LOW” switch or its circuit.


6


Is vehicle equipped with cruise control system? Go to Step 7.

7 Cruise control signal inspection :


E61-35 terminal of PCM coupler and ground.



PCM and recheck.

Substitute a know-good

PCM and recheck.

Faulty cruise control module or its circuit.



Table A-2 : No Gear Shift to O/D


PCM does not shift to O/D gear under any of the following conditions.

• O/D off switch : ON

• 4WD LOW switch : ON

• Cruise control module : O/D OFF command signal is output (if equipped).

• ECT : ECT < 30 °C (86 °F)

TROUBLESHOOTING

WARNING:

• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during testing to avoid occurrence of an accident.

• Road test should be carried out with 2 person, a driver and tester, on a level road.

Step Action

1 Was “AUTOMATIC TRANSMISSION DIAG-

NOSTIC FLOW TABLE” performed?

2 ECT check :


2) Check ECT using scan tool.

Is ECT more than 30 °C (86 °F)?

3 Perform running test under the following conditions and check voltage between C51-1-2 terminal of PCM coupler and ground, C51-1-1 terminal of PCM coupler and ground.

• O/D off switch OFF (“O/D OFF” lamp OFF).

• Normal mode in “D” range.

• Transfer “2H” position.

• Cruise control is not operated (if equipped).

• Drive vehicle with 4th gear condition referring to “Gear shift diagram” in this section.

Is each voltage about 0 V?

4 O/D off switch signal inspection :



“O/D” cut switch specification

“O/D” cut switch OFF : Battery voltage

“O/D” cut switch ON : 0 V

Yes

Go to Step 2.

Go to Step 3.

Faulty shift solenoid valve, its circuit or transmission

Go to Step 5.

No

Go to “AUTOMATIC

TRANSMISSION DIAG-

NOSTIC FLOW TABLE” in this section.

Faulty ECT sensor, its circuit or engine cooling system.


“GRN” wire or “GRN/

RED” wire shorted to power circuit.

If OK, go to Step 4.

Faulty O/D off switch or its circuit.




Step Action

5 “4WD LOW” switch signal inspection :


C51-1-26 terminal of PCM coupler and ground.

Yes

Go to Step 6.

“4WD LOW” switch specification

Transfer gear position “4L” or “N” : 0 V

Transfer gear position “4H” or “2H” :

Battery voltage

No

Faulty “4WD LOW” switch or its circuit.


6


Is vehicle equipped with cruise control system? Go to Step 7.

7 Cruise control signal inspection :





PCM and recheck.


PCM and recheck.

Faulty cruise control module or its circuit.



Table B-1 : “O/D OFF” Light Circuit Check (“O/D OFF” Light Doesn’t Light at

Ignition Switch ON But Engine Starts Up)

WIRING DIAGRAM

1. PCM

2. Fuse

3. O/D off switch

TROUBLESHOOTING


5. J/C

6. J/C

Step Action

1 “O/D OFF” light circuit check:

1) With ignition switch OFF, disconnect couplers from PCM.

2) Using service wire, connect E61-20 terminal of disconnected PCM coupler and ground.

Does “O/D OFF” light turn ON at ignition switch

ON?

Yes

Poor E61-20 terminal connection.

If OK, substitute a knowgood PCM and recheck.

No

Bulb burned out or faulty

“WHT/BLK”, “BLK/WHT” wire.


Table B-2 : “O/D OFF” Light Circuit Check (“O/D OFF” Light Comes ON

Steadily)

WIRING DIAGRAM

Refer to “TABLE B-1” in this section.

TROUBLESHOOTING

Step Action

1 Check O/D off switch status.

Press O/D off switch button (1).

Does “O/D OFF” lamp come ON steadily?

2 Check lamp circuit for short.

1) Turn ignition switch OFF and disconnect

PCM connectors.


Does “O/D OFF” lamp come ON steadily?

3 Check O/D off switch circuit.

1) Check resistance between terminal E61-33 of disconnected PCM connector and body ground with O/D off switch button (1) released.


4 Check O/D off switch for operation.


2) Disconnect O/D off switch connector.

3) Check continuity between switch terminals under each condition below.

Yes

Go to Step 2.

“WHT/BLK” circuit shorted to ground.

Go to Step 4.

“YEL/RED” circuit shorted to ground.

No

System is OK.

Go to Step 3.

Check PCM ground circuit for open.

If ground circuit is OK, substitute a known-good

PCM and recheck.

Replace O/D off switch.

O/D switch operation

With O/D off switch button (1) released :

No continuity

With O/D off switch button (1) pressed :

Continuity


[A] for Step 1/[B] for Step 4


Table B-3 : “POWER” Light Circuit Check (“POWER” Light Doesn’t Light at

Ignition Switch ON But Engine Starts Up)

WIRING DIAGRAM

1. PCM

2. Fuse

3. O/D off switch

TROUBLESHOOTING


5. J/C

Step Action

1 “POWER” light circuit check :

1) With ignition switch OFF, disconnect couplers from PCM.

2) Using service wire, connect E61-21 terminal of disconnected PCM coupler and ground.

Does “POWER” light turn ON at ignition switch

ON?

Yes

Poor E61-21 terminal connection.


No

Bulb burned out or faulty

“GRY/BLU”, “BLK/WHT” wire.


Table B-4 : “POWER” Light Circuit Check (“POWER” Light Comes ON

Steadily)

WIRING DIAGRAM

Refer to “TABLE B-3” in this section.

TROUBLESHOOTING

Step Action

1 Check Power/Normal change switch position.

Is switch button at Normal position?

Yes

Go to Step 2.

No

Set Power/Normal change switch at Normal position.

Go to Step 3.

2 Check lamp circuit for short.

1) Turn ignition switch OFF and disconnect PCM connectors.


Does “POWER” lamp come ON steadily?

3 Check Power/Normal change switch circuit.

1) Check resistance between terminal E61-31 of disconnected PCM connector and body ground with

P/N change switch OFF.


“GRY/BLU” circuit shorted to ground.

Go to Step 4.

Check PCM ground circuit for open.

If ground circuit is OK, substitute a knowngood PCM and recheck.

Replace Power/Normal change switch.

4 Check Power/Normal change switch for operation.

1) Remove Power/Normal change switch.

2) Check continuity between switch terminals “4” and

“5” under each condition below.

Normal position: No continuity

Power position: Continuity.


“ORN/BLU” circuit shorted to ground.

[A] for Step 1/[B] for Step 4


DTC P0705 (DTC NO.72) - Transmission Range Sensor (Switch) Circuit Malfunction

WIRING DIAGRAM

1. PCM

2. Fuse

3. J/C

4. Transmission range sensor (switch)



• Transmission range switch signal (P, R, N, D, 2 or L) is not inputted for 25 sec, at 60 km/h (38 mile/h) or higher vehicle speed.

or

• Multiple signals are inputted simultaneously for 25 sec.


TROUBLE AREA

• Transmission range sensor (switch) maladjusted.

• Transmission range sensor (switch) or its circuit malfunction.

• PCM



WARNING:



1) Connect scan tool to DLC with ignition switch OFF, if available.

2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and start engine.

3) Shift A/T selector lever to each of L, 2, D, N, R and P ranges for 30 seconds each.

4) Increase vehicle speed to about 70 km/h (45 mile/h) in D range.

5) Keep driving above vehicle speed for 30 seconds.

6) Release accelerator pedal, decrease vehicle speed and stop vehicle.

7) Check DTC and/or pending DTC.

TROUBLESHOOTING

Step Action

1 Was “A/T DIAGNOSTIC FLOW TABLE” in this section performed?

2 Do you have SUZUKI scan tool?

3 Check Transmission range switch (sensor) circuit for operation.

Check by using SUZUKI scan tool :

1) Connect SUZUKI scan tool to DLC with ignition switch OFF.

2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 2 or L) on display when shifting select lever to each range.

Is applicable range indicated?

Are check results satisfactory?

4 Check Transmission range switch (sensor) circuit for operation.

Check by not using SUZUKI scan tool :


2) Check voltage at terminals C51-1-6, C51-1-7,

C51-1-18, C51-1-19, C51-1-27 and C51-1-28 respectively with select lever shifted to each range.

Taking terminal C51-1-28 as an example, is battery voltage indicated only when select lever is shifted to

“2” range and 0 V for other ranges as shown in figure?

Check voltage at other terminals likewise, referring to figure.


5 Check select cable for adjustment referring to

“SELECT CABLE ADJUSTMENT” in this section.

Is it adjusted correctly?

Yes

Go to Step 2.

Go to Step 3.


Check for intermittent referring to “INTER-

MITTENT AND POOR

CONNECTION” in

Section 0A.


Check for intermittent referring to “INTER-

MITTENT AND POOR

CONNECTION” in

Section 0A.

Go to Step 6.

No

Go to “A/T DIAGNOS-

TIC FLOW TABLE” in this section.

Go to Step 4.

Go to Step 5.

Go to Step 5.

Adjust.


Step Action

6 Check transmission range switch for installation position.

1) Shift select lever to “N” range.

2) Check that “N” reference line on switch and center line on shaft are aligned.

Are they aligned?

7 Check transmission range switch (sensor) referring to

“TRANSMISSION RANGE SWITCH” in this section.


Yes

Go to Step 7.

“YEL”, “ORN/GRN”,

“RED”, “ORN/BLU”,

“YEL/GRN”, “GRN/

ORN” or “GRN/BLU” circuit open or short.

If wires and connections are OK, substitute a known-good

PCM and recheck.

Adjust.

No

Replace Transmission range switch.

Fig. for Step 2.

Select lever position P

R

N

D

2

L

Terminal

C51-1-7 C51-1-6 C51-1-19 C51-1-18 C51-1-28 C51-1-27

B + V 0 V 0 V 0 V 0 V 0 V

0 V

0 V

B + V

0 V

0 V

B + V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

B + V

0 V

0 V

0 V

B + V

0 V

0 V

0 V

B + V


DTC P0715 (DTC NO.76) - Input/Turbine Speed Sensor Circuit Malfunction

WIRING DIAGRAM

1. PCM

2. Input shaft speed sensor



Input speed sensor detected speed is lower than specification while vehicle running under all of the following conditions :

• at higher than 10 km/h (7 mile/h) with 1st gear in D range for 1 sec. or more.

• at higher than 20 km/h (13 mile/h) with 2nd gear in

D range for 2 sec. or more.

• at higher than 30 km/h (20 mile/h) with 3rd gear in D range for 2 sec. or more.


TROUBLE AREA

Input speed sensor and its circuit

PCM



WARNING:




2) Clear DTC, pending DTC and freeze frame data by using scan tool.

3) Start engine and turn O/D cut switch ON.

4) Shift select lever to D range and start vehicle.

5) Keep vehicle speed at higher than 10 km/h (7 mile/h) with 1st gear in D range for 2 sec. or more.

6) Increase vehicle speed and keep it at higher than 20 km/h (13 mile/h) with 2nd gear in D range for 2 sec. or more.

7) Increase vehicle speed and keep it at higher than 30 km/h (20 mile/h) with 3rd gear in D range for 2 sec. or more.

8) Stop vehicle.


TROUBLESHOOTING

Step

1 section performed?

Action

Was “A/T DIAGNOSTIC FLOW TABLE” in this

Yes

Go to Step 2.

No

Go to “A/T DIAGNOSTIC


Go to Step 3.

2 Input shaft speed sensor circuit check :

1) Remove PCM cover.

2) With ignition switch OFF, disconnect PCM connectors.

3) Check for proper connection to input shaft speed sensor at C51-1-10 and C51-1-11 terminals.

4) If OK, check resistance of sensor circuit.

Go to Step 4.

Input shaft speed sensor resistance :

Resistance between C51-1-10 and C51-1-11

530 – 650

Ω

Resistance between C51-1-10/C51-1-11 and ground :

1 M Ω


3 Input shaft speed sensor check :

1) With ignition switch OFF, disconnect input shaft speed sensor connector.

2) Check for proper connection to input shaft speed sensor at each terminals.

3) If OK, then check resistance of input shaft speed sensor.

Are measured values as specified in Step 2?

“BLU/GRN” or “BLU/YEL” wire open or shorted to ground.

Replace input shaft speed sensor.

Step Action

4 Check visually input speed sensor and overdrive clutch drum for the followings.

• No damage




REFERENCE


Yes

Intermittent trouble or faulty PCM.


TENT AND POOR CON-


No


Connect oscilloscope between C51-1-11 (+) and C51-1-10 (–) of

PCM connector connected to PCM and check input speed sensor signal.

[A] : Oscilloscope waveforms at specified idle speed in “p” range


DTC P0720 (DTC NO.75) Output Speed Sensor Circuit Malfunction

WIRING DIAGRAM

1. PCM

2. Output shaft speed sensor



• With 4WD LOW switch OFF, no output shaft speed sensor signal is inputted while vehicle speed sensor signal are inputted, or

• With 4WD LOW switch OFF, no output shaft speed sensor signal is inputted while engine running at higher than specified engine speed with “D” range.


TROUBLE AREA

• Output speed sensor or its circuit

• PCM


WARNING:




2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool.

3) Start engine and shift transfer lever to “2H” or “4H” range.

4) Drive vehicle at 40 km/h (25 mile/h) or more for longer than 10 sec. (or higher than 3500 r/min engine speed with “D” range for longer than 10 sec.)

5) Stop vehicle and check DTC and/or pending DTC.


TROUBLESHOOTING

Step Action

1 Was “A/T DIAGNOSTIC FLOW TABLE” in this section performed?

Yes

Go to Step 2.

No



Go to Step 3.

2 Output shaft speed sensor circuit check :

1) Remove PCM cover.

2) With ignition switch OFF, disconnect PCM connectors.

3) Check for proper connection to output speed sensor at C51-1-22 and C51-1-23 terminals.

4) If OK, check resistance of sensor circuit.

Go to Step 4.

Resistance between C51-1-22 and C51-1-23 :

387 – 473 Ω (at 20 °C (68 °F))

Resistance between C51-1-22/C51-1-23 and ground :

1 M Ω or more


3 Output shaft speed sensor check :

1) With ignition switch OFF, disconnect output shaft speed sensor connector.

2) Check for proper connection to output shaft speed sensor at each terminals.

3) If OK, then check resistance of output shaft speed sensor.

Are measured values as specified in Step 2?

4 Check visually output shaft speed sensor and sensor rotor for the followings.

• No damage




“ORN” or “WHT” wire open or shorted to ground.



TENT AND POOR CON-


Replace output shaft speed sensor.


REFERENCE

Connect oscilloscope between C51-1-23 (+) and C51-1-22 (–) of

PCM connector connected to PCM and check output speed sensor signal.

[A] : Oscilloscope waveforms at about 40 km/h (25 mile/h)


DTC P0743 (DTC NO.65/66) - TCC (Lock-Up) Solenoid Electrical

WIRING DIAGRAM

1. PCM

2. Shift solenoid-A

3. Shift solenoid-B

4. TCC solenoid



Voltage at terminal C51-1-8 of PCM is high while TCC solenoid OFF is commanded or low while TCC solenoid ON is commanded.

TROUBLE AREA

• TCC (lock-up) solenoid valve

• TCC (lock-up) solenoid valve circuit

• PCM



WARNING:





3) Start engine, warm it up to normal operating temperature and shift transfer lever to “2H” or “4H” range.

4) Shift selector lever in D range and keep it there for 10 seconds.

5) Increase vehicle speed to about 80 km/h (50 mile/h) in 4th gear and in D range.

6) Keep driving at above speed for 20 seconds.



TROUBLESHOOTING

Step


Action


Yes

Go to Step 2.

2 Check TCC solenoid circuit for short.


PCM connectors.

2) Check for proper connection to PCM at terminal C51-1-8.

3) If OK, then turn ignition switch ON and measure voltage between terminal C51-1-8 of disconnected PCM connector and ground.

Is it about 0 V?

3 Check TCC solenoid circuit for open or short.


2) Measure resistance between terminal C51-

1-8 of disconnected PCM connector and ground.

Is it 11 – 15

Ω (at 20 °C (68 °F))?

Go to Step 3.



TENT AND POOR CON-


No



“GRN/YEL” circuit shorted to power circuit.

“GRN/YEL” circuit open or shorted to ground.

If wire and connections are OK, replace TCC solenoid.


DTC P0753 (DTC NO.61/62) Shift Solenoid-A (#1) Electrical

DTC P0758 (DTC NO.63/64) Shift Solenoid-B (#2) Electrical

WIRING DIAGRAM

1. PCM

2. Shift solenoid-A

3. Shift solenoid-B

4. TCC solenoid



DTC P0753 (DTC NO.61/62):

Voltage detected at C51-1-2 terminal is specified voltage or lower when shift solenoid valve-A is ON or specified voltage or higher when it is OFF.

DTC P0758 (DTC NO.63/64):

Voltage detected at C51-1-1 terminal is specified voltage or lower when shift solenoid valve-B is ON or specified voltage or higher when it is OFF.

TROUBLE AREA

• Shift solenoid valve-A

• Shift solenoid valve-A circuit

• PCM

• Shift solenoid valve-B

• Shift solenoid valve-B circuit

• PCM



WARNING:





3) Start engine and shift transfer lever to “2H” or “4H” range.

4) Shift selector lever in D range and keep it for 10 seconds.

5) Drive vehicle about 30 km/h (20 mile/h) with 2nd gear in “D” range for 10 seconds.

6) Increase vehicle speed to about 80 km/h (50 mile/h) with 4th gear in D range and keep it for 10 seconds.



TROUBLESHOOTING

Step


Action


Yes

Go to Step 2.

2 Check shift solenoid circuit for short.


PCM connectors.

2) Check for proper connection to PCM at terminals C51-1-2 or C51-1-1.

3) If OK, then turn ignition switch ON and measure voltage between terminal C51-1-2 or

C51-1-1 of disconnected PCM connector and ground.

Is it about 0 V?

3 Check shift solenoid circuit for open or short.


2) Measure resistance between terminal C51-

1-2 or C51-1-1 of disconnected PCM connector and ground.

Is it 11 – 15

Ω (at 20 °C (68 °F))?

Go to Step 3.



TENT AND POOR CON-


No



“GRN” or “GRN/RED“ circuit shorted to power circuit.

“GRN” or “GRN/RED“ circuit open or shorted to ground.

If wire and connections are OK, replace malfunction shift solenoid.


Stall Test

This test is to check overall performance of automatic transmission and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature and its level is between FULL and LOW marks.

CAUTION:

• Do not run engine at stall more than 5 seconds continuously, for fluid temperature may rise excessively high.

• After performing stall test, be sure to leave engine running at idle for longer than 30 seconds before another stall test.

1) Apply parking brake and block wheels.

2) Install tachometer.

3) Start engine with select lever shifted to “P”.

4) Depress brake pedal fully.

5) Shift select lever to “D” and depress accelerator pedal fully while watching tachometer. Read engine rpm quickly when it has become constant (stall speed).

6) Release accelerator pedal immediately after stall speed is checked.

7) In the same way, check stall speed in “R” range.

8) Stall speed should be within the following specification.

Stall speed :

2,460 – 2,760 r/min.

TROUBLESHOOTING

Condition

Lower than standard level

Higher than standard level in “D” range

Higher than standard level in “R” range

Possible cause

• Faulty engine output

• Defective torque converter

• Slippery O/D clutch

• Slippery forward clutch

• Malfunctioning O/D one-way clutch

• Malfunctioning one-way clutch No. 2

• Low line pressure

• Slippery direct clutch

• Slippery reverse brake

• Low fluid pressure

• Slippery O/D clutch

• Defective O/D one-way clutch


Line Pressure Test

Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following conditions.

• Automatic fluid is at normal operating temperature (70 to 80

° C/158 – 176 °F).

• Fluid is filled to proper level (between FULL HOT and LOW

HOT on dipstick).

1) Apply parking brake securely and place checks against wheels.

2) Attach oil pressure gauge to fluid pressure check hole (1) in transmission case.

Special tool

(A) : 09925-37811-001

CAUTION:

After attaching oil pressure gauge, check that not fluid leakage exists.

3) Depress foot brake fully, run engine at idle and stall.

4) Check fluid pressure in “D” or “R” range within the following specification.

CAUTION:

Do not continue running engine at stall speed longer than 5 seconds.

Line pressure :

Idle speed

Stall speed

“D” range

4.1 – 4.6 kg/cm

2

58 – 65 psi

12.0 – 13.5 kg/cm

2

171 – 192 psi

“R” range

5.4 – 6.0 kg/cm

2

77 – 85 psi

14.6 – 17.1 kg/cm

2

208 – 243 psi

5) If check result is OK, disconnect special tool, then tighten transmission case plug to specified torque.


Transmission case plug : 17 N·m (1.7 kg-m, 12.0 lb-ft)


TROUBLESHOOTING

Condition

Line pressure higher than standard level in each range

Line pressure lower than standard level in each range

Line pressure lower than standard level only in

“D” range

Line pressure lower than standard level only in

“R” range

Possible cause

• Malfunctioning regulator valve

• Malfunctioning throttle valve

• Maladjusted A/T throttle cable

• Defective O/D clutch

• Defective oil pump

• Malfunctioning throttle valve

• Malfunctioning regulator value

• Maladjusted A/T throttle cable

• Fluid leakage from forward clutch


• Leakage from “D” range fluid pressure circuit

• Fluid leakage from direct clutch


• Fluid leakage from reverse brake

• Fluid leakage from “R” range fluid circuit

Road Test

This test is to check if upshift and downshift take place at specified speed while actually driving vehicle on a level road.

WARNING:

• Carry out test in very little traffic area to prevent an accident.

• Test requires 2 persons, a driver and a tester.

1) Warm up engine.

2) With engine running at idle, shift select lever “D”.

3) Accelerate vehicle speed by depressing accelerator pedal gradually.

4) While driving in “D” range, check if gear shift occurs properly as shown in “GEAR SHIFT DIAGRAM” in this section.

TROUBLESHOOTING

Condition

When 1

→ 2 upshift fails to occur

When 2 → 3 upshift fails to occur

When 3 → O/D upshift fails to occur

When gear shift point is incorrect

Possible cause

1–2 shift valve stuck



• Maladjusted throttle cable

• Defective shift solenoid valve -A or -B

• 1–2, 2–3 or 3–4 shift valve not operating properly


Manual Road Test

This test check the gear being used in “L”, “2” or “D” range when driven with unoperated gear shift control system. Test drive vehicle on a level road.

NOTE:

Before this test, check diagnostic trouble code (DTC).

1) Disconnect shift solenoid coupler (1) valves on transmission.

WARNING:

To avoid the danger of being burned, do not touch the hot exhaust system when disconnecting shift solenoid coupler (1).

2) With select lever in “P”, start engine and warm it up.

3) With select lever in “L” range, start vehicle and accelerate to

20 km/h (12.5 mile/h). Check in this state that 1st gear is being used.

4) At 20 km/h (12.5 mile/h), shift select lever to “2” range and accelerate to 40 km/h (25 mile/h). Check in this state that 3rd gear is being used.

5) At 40 km/h (25 mile/h), shift select lever to “D” range and check that O/D gear is used when speed is higher than 40 km/h (25 mile/h).

6) After above checks, stop vehicle then engine, and connect shift solenoids coupler (1) with ignition switch OFF.

WARNING:

To avoid the danger of being burned, do not touch the hot exhaust system when connecting shift solenoid coupler

(1).

7) Clear DTC with scan tool.

Time Lag Test

This test is to check conditions of clutch, reverse brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt.

1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.

2) Start engine.

3) With stop watch ready, shift select lever from “N” to “D” range and measure time from that moment till shock is felt.

4) Similarly measure time lag by shifting select lever from “N“ to “R” range.

Specification for time lag :

“N”

→

Less than 1.2 sec.

“N”

→

Less than 1.5 sec.


NOTE:

• When repeating this test, be sure to wait at least minute after select lever is shifted back to “N” range.

• Engine should be warmed up fully for this test.

TROUBLESHOOTING

Condition

When “N” → “D” time lag exceeds specification

When “N” → “R” time lag exceeds specification

Possible cause


• Worn forward clutch


• Worn direct clutch

• Worn reverse brake

Engine Brake Test

WARNING:

Before test, make sure that there is no vehicle behind so as to prevent rear-end collision.

1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake operates.

2) In the same way as in step 1, check engine brake for operation when select lever is shifted down to “L” range.

3) If engine brake fails to operate in above tests, possible causes for such failure are as follows. Check each part which is suspected to be the cause.

TROUBLESHOOTING

Condition

Fails to operate when shifted down to “2” range

Fails to operate when shifted down to “L” range

Possible cause

Second coast brake defective

Reverse brake defective

“P” Range Test

1) Stop vehicle on a slope, shift select lever to “P” range and at the same time apply parking brake.

2) After stopping engine, depress brake pedal and release paring brake.

3) Then, release brake pedal gradually and check that vehicle remains stationary.

4) Depress brake pedal and shift select lever to “N” range.

5) Then, release brake pedal gradually and check that vehicle moves.

WARNING:

Before test, check to make sure no one is around vehicle or down on a slope and keep watchful for safety during test.



Maintenance Service

Fluid level

LEVEL CHECK AT NORMAL OPERATING TEMPERATURE

1) Stop vehicle and place it level.

2) Apply parking brake and place chocks against wheels.

3) With selector at P position, start engine.

4) Warm up engine till fluid temperature reaches normal operating temperature (70 – 80 °C (158 – 176 °F)). As a guide to check fluid temperature, warm up engine till engine coolant temperature meter indicated around 1 unit above “C” point.

5) Keep engine idling and shift selector slowly to “L” and back to “P” position.

[A] : Shift the select lever with its button pushed in.

[B] : Shift the select lever without pushing its button.

6) With engine idling, pull out dipstick, wipe it off with a clean cloth and put it back into place.

7) Pull out dipstick again and check fluid level indicated on it.

Fluid level should be between FULL HOT and LOW HOT. if it is below LOW HOT, add an equivalent of DEXRON

®

-III up to

FULL HOT.

Fluid specification :

An equivalent of DEXRON

®

-III

NOTE:

• DO NOT RACE ENGINE while checking fluid level, even after the engine start.

• DO NOT OVERFILL. Overfilling can causes foaming and loss of fluid through breather. Then slippage and transmission failure can result.

• Bringing the level from LOW HOT to FULL HOT requires 0.3 liters (0.64/0.53 US/lmp.pt).

• If vehicle was driven under high load such as pulling a trailer, fluid level should be checked about half an hour after it is stopped.


LEVEL CHECK AT ROOM TEMPERATURE

The fluid level check at room temperature (20 – 30 °C (68 – 86

°F)) performed after repair or fluid change before test driving is just preparation for level check of normal operating temperature.

The checking procedure itself is the same as that described previously. If the fluid level is between FULL COLD and LOW COLD, proceed to test drive. And when the fluid temperature has reached the normal operating temperature, check fluid level again and adjust it as necessary.

Fluid change

1) Lift up vehicle.

2) With engine is cool, remove drain plug (1) from oil pan and drain A/T fluid.

3) Install drain plug (1).


A/T fluid drain plug (a) :

23 N·m (2.3 kg-m, 17.0 lb-ft)

4) Lower vehicle and fill proper amount of an equivalent of

DEXRON

®

-III.

5) Check fluid level referring to “LEVEL CHECK NORMAL

OPERATING TEMPERATURE” of “FLUID LEVEL” in this section.

Fluid specification :

An equivalent of DEXRON

®

-III

Fluid capacity

When draining from drain plug hole:

2.5 liters (5.28/4.40 US/lmp.pt.)

When overhauling:

6.8 liters (14.37/11.97 US/lmp.pt.)


A/T Throttle Cable

ADJUSTMENT

1) Pull inner cable (3) by force of 2 N (0.2 kg, 0.45 lb) or less to be no slack of inner cable with A/T throttle cable (1) curved as shown in the figure.

2) Fix stopper (2) to inner cable (3) with clearance “c”.

A/T throttle cable adjusting position (clearance “c”) :

0.8 – 1.5 mm (0.03 – 0.06 in.)

3) Warm up engine and transmission to normal operating temperature.

4) Make sure that accelerator cable is adjusted as specified.

5) With throttle valve closed, check clearance “c”, which should be within the following specification, of A/T throttle cable (1).

If it is out of specification, adjust it by turning cable adjusting nut (2).

A/T throttle cable adjusting position (clearance “c”) :

0.8 – 1.5 mm (0.03 – 0.06 in.)

6) Tighten lock nut (3) securely.

Solenoid Valves (Shift Solenoid Valves and

TCC Solenoid Valve)

INSPECTION

With PCM couplers disconnected and using service wire as shown in the figure, check each solenoid valve for clicking sound.

Shift solenoid valve - A (#1)

Shift solenoid valve - B (#2)

TCC (Lock-up) solenoid valve

C51-1-2

C51-1-1

C51-1-8


MANUAL SELECTOR ASSEMBLY

1. Manual lever assembly

2. Select indicator assembly

3. Illumination assembly

4. Bulb filter

5. Bulb

6. knob assembly

7. Shift lock solenoid (if equipped)

8. Manual selector assembly mounting bolt

Tightening torque

REMOVAL



3) Disconnect connector for illumination lamp, shift lock solenoid (if equipped) and overdrive OFF switch (if equipped).

4) Remove selector assembly mounting bolts.

5) Disconnect selector cable (1) from manual selector assembly (2) expanding selector cable clip (3).

INSTALLATION

Reverse removal procedure to install manual selector assembly noting the following instructions.

• Make sure that selector cable clip (3) hold selector cable (1) on manual selector assembly (2) securely.

• Tighten manual selector assembly mounting bolts as specified torque.

Tightening Torque

Manual selector assembly mounting bolts :

18 N·m (1.8 kg-m, 13.5 lb-ft)

• Connect interlock cable end to cam referring to step 2) to 8) of “Interlock cable installation” of the service manual mentioned in FOREWORD of this manual, if necessary.

• Confirm that brake (key) interlock system operates properly

(if equipped).


INSPECTION

• Check select lever for smooth and clear-cut movement and position indicator for correct indication.

For operation of select lever, refer to left figure.


SELECT CABLE

1. Selector lever assembly

2. Selector lever assembly mounting bolt

3. Selector cable

4. Cable bracket

5. Cable bracket mounting bolt

6. Washer 11. Transmission range switch assembly

7. Clip 12. Transmission range switch mounting bolt

8. Manual select lever nut (transmission range switch side) 13. Manual select lever nut (selector cable side)

9. Lock washer

10. Manual select lever

14. Selector cable clip

Tightening Torque

2

4

3

1, (a)

ADJUSTMENT

1) Loosen manual shift lever (select cable side) nut (1).

2) Shift select lever to “N” range.

3) Align center line (2) on manual valve shaft (3) to “N” reference line (4) as shown.

4) Tighten manual shift lever nut (selector cable side) (1) as specified torque.


Manual shift lever nut (a) :

23 N·m (2.3 kg-m, 17.0 lb-ft)

5) After select cable was installed, check for the following.

• Push vehicle with selector lever shifted to “P” range.

Vehicle should not move.

• Vehicle can not be driven in “N” range.

• Vehicle can be driven in “D”, “2” and “L” ranges.

• Vehicle can be backed in “R” range.


Unit Repair

NOTE:

The service procedure to be described in this item is the same as that of H25 engine model except the following description.

Refer to the same section of the Unit Repair Manual mentioned in FOREWORD of this manual for the description not found in this item.

Sub-Assembly Repair

Overdrive (case side)

DISASSEMBLY

1) Measure clearance between retaining ring (1) and brake backing plate (2) with thickness gauge.

If it is not within standard range, replace brake disc or brake plate.

Clearance between retaining ring and brake backing plate

Standard :

0.40 – 0.90 mm (0.016 – 0.035 in.)

2) Remove retaining ring (1), brake backing plate (2), brake disc (3), brake plate (4), cushion brake plate (5) in that order.

Then remove planetary ring gear, thrust bearing race and thrust rear bearing.

3) Remove retaining ring (1), retainer (2) and piston return spring (3).


4) Blow air into fluid hole in O/D case (2) and remove brake piston (1).

5) Remove brake piston inner ring and brake piston outer ring from brake piston.

6) Unsnap seal ring (1).

7) Remove 2 seal rings (1).

NOTE:

Be careful not to open seal ring more than necessary.

Forward clutch

1. Input shaft

2. Piston

3. Return spring

4. O-ring

5. Retaining ring

6. Bearing race

7. Bearing

8. Clutch plate

9. Clutch disc

10. Froward clutch hub

11. Direct clutch input hub


DISASSEMBLY

1) After removing retaining ring (1), remove direct clutch input hub (2) and forward clutch hub (3).

2) Remove bearing race and thrust bearing.

1. Thrust bearing No. 2

2. Thrust forward clutch bearing

3. Thrust rear race

3) Install direct clutch input hub (1) and retaining ring (2).

4) Install forward clutch (2) to O/D case (1). Apply 4 – 8 kg/cm

2 air pressure into fluid hole at the right of cut in O/D case and measure movement of forward clutch piston.

If measured value is not within standard range, use either

1.8 mm (0.071 in.) or 2.0 mm (0.079 in.) clutch disc to adjust it to standard value.

Standard forward clutch piston movement :

1.40 – 1.70 mm (0.056 – 0.067 in.)


5) Remove retaining ring (1) and then remove direct clutch input hub.

6) Remove retaining ring and then remove all clutch discs.

7) Using special tool and hydraulic press, compress forward clutch piston return spring and remove retaining return spring.

Special tool

(A) : 09926-98310

CAUTION:

Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

8) Remove forward clutch piston return spring.

9) Install forward clutch to O/D case. Blow low pressure air into fluid hole at the right of cut in O/D case to remove forward clutch piston.


DIRECT CLUTCH

DISASSEMBLY

1) Install direct clutch assembly (1) to center support (2) and with 4 – 8 kg/cm

2

air pressure applied to second fluid hole from the left, measure stroke of direct clutch piston as shown in figure.

If it is not within standard range, use 3.55 mm, 3.75 mm or

4.0 mm (0.140 in., 0.147 in. or 0.157 in.) clutch backing plate to adjust it to standard stroke.

Standard direct clutch piston stroke :

0.90 – 1.30 mm (0.035 – 0.051 in.)

2) Remove direct clutch assembly from center support and then remove retaining ring.

3) Remove clutch backing plate (1) and then remove clutch disc (3) and clutch plate (2).

4) Using special tool and hydraulic press (1), compress direct clutch piston return spring (3) and remove retaining return spring ring (2).

Special tool

(A) : 09926-98310

CAUTION:

Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

5) Remove direct clutch piston return spring.


6) Install direct clutch cylinder to center support.

Remove direct clutch piston by blowing air into the second hole from the left as shown in the figure. Also, remove direct clutch inner piston by blowing air into hole at the extreme right. And then remove O-rings from pistons.

Front upper valve body

ASSEMBLY

Assemble each component by reversing disassembly procedure and noting the following points.

• Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size.

Coil outer diameter and free length of each valve spring

Name of spring

Secondary regulator valve spring

Cut back valve spring

Throttle valve secondary spring

Throttle valve primary spring

Outer diameter

17.43 mm

(0.681 in.)

6.85 mm

(0.259 in.)

8.56 mm

(0.337 in.)

10.90 mm

(0.429 in.)

Free length

71.27 mm

(2.806 in.)

23.0 mm

(0.906 in.)

18.86 mm

(0.743 in.)

39.55 mm

(1.557 in.)

• Install as many throttle valve compensating rings as written down when disassembled.

• Tighten throttle cam bolt (1) to specified torque.


Throttle cam bolt (a) : 7.5 N·m (0.75 kg-m, 5.5 lb-ft)

• Tighten pressure relief valve bolts (1) to specified torque.


Pressure relief valve bolt (b) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)

LOWER VALVE BODY


1. Lower valve body

2. Spring

3. Pressure relief valve ball

4. Pressure relief valve retainer

5. Lower valve body plate

6. Lower valve body gasket

7. TCC (Lock-up) control valve plate

8. TCC (Lock-up) control valve gasket

9. TCC (Lock-up) control sleeve

10. TCC (Lock-up) control valve

11. Pin

12. Retainer

13. Primary regulator valve sleeve

14. Primary regulator valve plunger

15. Primary regulator valve

16. Spacer


DISASSEMBLY

1) Remove bypass valve (1), bypass valve spring, check ball valve damping spring, valve body ball (2) and ball valve spring.

3. Check ball

4. Primary regulator valve sleeve retainer

5. Locating pin

2) Remove lower valve body plate (1) and lower valve body plate gasket.

3) Remove TCC (lock-up) control valve plate (2) and TCC

(lock-up) control valve gasket.

4) With pressure relief valve retainer (1) pressed with finger, remove pressure relief valve bolt and then remove pressure relief valve retainer (1), pressure relief valve spring and pressure relief valve ball.

5) Remove TCC (lock-up) solenoid valve (1) and Then remove

O-ring (2) from TCC solenoid valve (1).


6) After removing shift solenoid valve (A & B) (1), remove solenoid valve gasket, low coast modulator valve spring (2), inter coast modulator valve spring (3) and 2 intermediate coast modulator valves (4).

7) Pressing TCC (lock-up) control sleeve with finger and using magnet (1), remove locating pin and then remove TCC (lockup) control sleeve, TCC (lock-up) control valve and TCC

(lock-up) control valve spring.

8) Check which step of primary regulator valve sleeve (1) (how many steps down from its tip) contacts primary regulator valve sleeve retainer (2).

9) Pressing primary regulator valve sleeve (1) with finger and using magnet, remove primary regulator valve sleeve retainer and then remove primary regulator valve sleeve (1), spacer (2), primary regulator valve plunger (3), primary regulator valve spring (4) and primary regulator valve (5).


ASSEMBLY

Assemble each component by reversing disassembly procedure and noting the following points.

• Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size.

Coil outer diameter and free length of each valve spring :

Name of spring

Pressure relief valve spring

TCC (Lock-up) control valve spring

Valve damping spring

Low coast modulator valve spring

Inter coast modulator valve spring

Ball valve spring

Bypass valve spring

Primary regulator valve spring

Outer diameter

13.14 mm (0.517 in.)

11.40 mm (0.449 in.)

4.95 mm (0.195 in.)

10.00 mm (0.394 in.)

9.04 mm (0.356 in.)

(G16 and J20 engines)

10.00 mm (0.394 in.)

(H25 and H27 engine)

10.5 mm (0.413 in.)

13.82 mm (0.544 in.)

17.02 mm (0.670 in.)

Free length

32.14 mm (1.265 in.)

32.60 mm (1.283 in.)

20.00 mm (0.787 in.)

42.35 mm (1.667 in.)

27.26 mm (1.073 in.)

(G16 and J20 engines)

25.60 mm (1.008 in.)

(H25 and H27 engine)

13.7 mm (0.539 in.)

28.90 mm (1.138 in.)

50.28 mm (1.980 in.)

• Install primary regulator valve sleeve so that its tip is positioned as it was before disassembly.

• Use new TCC (lock-up) control valve gasket, solenoid gasket and lower valve body plate gasket.

• Tighten shift solenoid valve bolt to specified torque.


Shift solenoid valve bolt : 10 N·m (1.0 kg-m, 7.5 lb-ft)

1. Solenoid valve No. 1 (Shift solenoid valve)

2. Low coast modulator valve spring

3. Inter coast modulator valve spring

4. Intermediate coast modulator valve

5. Low coast modulator valve


• Tighten TCC (lock-up) solenoid valve bolt to specified torque.


TCC solenoid valve bolt :

5.5 N·m (0.55 kg-m, 4.0 lb-ft)

1. Solenoid valve No. 2 (TCC solenoid valve)

2. O-ring

• Tighten pressure relief valve bolt to specified torque.


Pressure relief valve bolt :

5.5 N·m (0.55 kg-m, 4.0 lb-ft)

• Tighten lower valve body plate (1), TCC (lock-up) control valve plate (2) flange bolt to specified torque.


Lower valve body and TCC control valve Plate bolts :

5.5 N·m (0.55 kg-m, 4.0 lb-ft)

Unit Assembly

1) Apply A/T fluid to new O-ring and spring and install them to accumulator piston and install accumulator piston to transmission case.

4. Upper spring


Accumulator piston and spring specification :

Used for

Direct clutch accumulator (2)

Forward clutch accumulator (1)

Second brake accumulator (3)

Piston outer diameter “a”

31.80 – 31.85 mm

(1.252 – 1.254 in.)

31.80 – 31.85 mm

(1.252 – 1.254 in.)

34.80 – 34.85 mm

(1.370 – 1.372 in.)

Spring free length “b”

Upper spring

Lower spring

Upper spring

Lower spring

Upper spring

Lower spring

43.56 mm (1.715 in.)

30.00 mm (1.181 in.)

57.18 mm (2.251 in.)

30.50 mm (1.201 in.)

56.16 mm (2.211 in.)

18.5 mm (0.728 in.)


Fastening part

Automatic transmission fluid drain plug

Transfer oil level/filler and drain plugs

Transmission case plug

Manual select lever nut

Manual select cable nut

Manual selector assembly bolts

Transmission to engine bolts and nuts

Engine rear mounting bolts

Engine rear mounting member bolts

Universal joint flange bolts and nuts

Torque converter mounting bolts

Adapter case or extension case bolts

Transmission range switch lock bolt

Oil pipe union bolts

Drive plate bolts

Interlock cable clamp screw

Interlock cable outer mounting nut

50

65

42

5.5

35

78

2.2

13

N•m

23

23

17

13

7

18

85

50


2.3

2.3

1.7

1.3

0.7

1.8

8.5

5.0

lb-ft

17.0

17.0

12.5

9.5

5.5

13.5

61.5

36.5

5.0

6.5

4.2

0.55

3.5

7.8

0.22

1.3

36.5

47.0

30.0

4.0

22.5

56.5

1.5

9.5

Special Tool


09925-37811-001

Oil pressure gauge

09931-76030


Tech 1A


Tech 1A

09931-76011

Tech 1A kit (SUZUKI scan tool) (See NOTE “A”.)

09940-53111

Bearing installer Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.)

NOTE:

• “A”: This kit includes the following items and substitutes for the Tech 2 kit.

1. Storage case, 2. Operator’s manual, 3. Suzuki scan tool, 4. DLC cable, 5. Test lead/probe,

6. Power source cable, 7. DLC cable adapter, 8. Self-test adapter

• “B”: This kit includes the following items and substitutes for the Tech 1A kit.

1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector,

11. Storage case, 12. Power supply


CLUTCH 7C1-1

SECTION 7C1

CLUTCH

NOTE:

The clutch of this model is the same as that of H25 engine in the construction and operation.

Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for service procedure.

7C1

7C1-2 CLUTCH

DIFFERENTIAL (FRONT) 7E-1

SECTION 7E

DIFFERENTIAL (FRONT)

NOTE:


7E

CONTENTS

General Description ........................................7E-2

4WD Control System.....................................7E-2

System circuit ............................................7E-2

Diagnosis .........................................................7E-3

Differential Assembly Diagnosis Table..........7E-3

4WD Control System Diagnostic Flow Table 7E-3

Notes on system circuit inspection ............7E-3

Flow table ..................................................7E-4

4WD Control System Circuit Inspection ........7E-5

Voltage check............................................7E-5

4WD Control System Inspection ................... 7E-6

On-Vehicle Service ......................................... 7E-7

Differential Mountings ................................... 7E-7

Rear Mounting for Front Differential Carrier.. 7E-8

Front Differential Assembly ........................... 7E-9

Unit Repair..................................................... 7E-11

Tightening Torque Specification ................. 7E-11

Special Tool................................................... 7E-11

7E-2 DIFFERENTIAL (FRONT)

4WD Control System

System circuit


1. 4WD switch

2. Air pump assembly

3. Pump motor

4. Release valve

5. Pressure switch

6. Transfer

7. Front differential

8. Air hose and pipe

9. 4WD indicator lamp


11. ECM or PCM


Diagnosis

Differential Assembly Diagnosis Table

Condition

Gear noise

Bearing noise

Oil leakage

2WD/4WD switching error

Possible Cause

Deteriorated or water mixed lubricant

Inadequate or insufficient lubricant

Maladjusted backlash between bevel pinion and gear

Improper tooth contact in the mesh between bevel pinion and gear

Loose bevel gear securing bolts

Correction

Repair and replenish.


Adjust.

Adjust or replace.

Damaged side gear(s) or side pinion(s)

(Constant noise) Deteriorated or water mixed lubricant

(Constant noise) Inadequate or insufficientlubricant

Replace or retighten.

Replace.



(Noise while coasting) Damaged bearing(s) of bevel pinion Replace.

(Noise while turning) Damaged differential side bearing(s) Replace.

or axle bearing(s)

Worn or damaged oil seal

Excessive oil

Replace.

Adjust oil level.

Loose differential carrier bolts

Defective actuator

Abnormality in 4WD control system


Replace.

Inspect referring to “4WD

CONTROL SYSTEM DIAG-

NOSTIC FLOW TABLE”.

4WD Control System Diagnostic Flow Table

Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and there is no air leakage from air hoses and the actuator. Refer to “4WD CONTROL SYSTEM INSPECTION” in this section for air leakage.

Notes on system 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 “GENERAL DESCRIPTION” in this section.

• For terminal arrangement, refer to “4WD CONTROL CIRCUIT INSPECTION” in this section.


Flow table

Step Action

1 Turn ON ignition switch (but engine at stop) and check malfunction indicator lamp.

Does lamp light up?

2 Check 4WD switch circuit.

Turn ignition switch ON and check that voltage between terminal C51-3-7 and terminal C51-3-17

(ground) is as follows.

• When transfer shift lever is in N or 2H : 10 – 14 V

• When transfer shift lever is in 4L or 4H : 0 – 1 V

Is the check result satisfactory?

3 Check power supply.


2) Check voltage between C51-1-9 and C51-3-17

(ground). The check results should be as follows.

• When transfer shift lever is in N or 2H : 0 – 1 V



4 Check air pump assembly circuit.

1) Check for proper connection to air pump assembly at all terminals.


3) Check voltage between C51-3-18 and C51-3-17

(ground). The check result should be as follows.

• When transfer shift lever is in 2H or N : 0 – 1 V

• When transfer shift lever is in 4L or 4H (more than

4 seconds after shifted to 4L or 4H) : 10 – 14 V


5 Check 4WD indicator lamp circuit.


2) Check voltage between E61-19 and C51-3-17

(ground). The check result should be as follows.

• When transfer shift lever is in 2H or N : 10 – 14 V



Yes

Go to step 2.

Go to step 3.

Go to step 4.

Go to step 5.

4WD control system is in good condition.

No

A trouble has occurred at some place. Repair it referring to

MALFUNCTION INDI-

CATOR LAMP

(“CHECK ENGINE”

LAMP) CHECK in

DIAGNOSIS of Section 6.

Check 4WD switch

(refer to Section 7A),

“BLK/ORN” and “BLK” circuits of 4WD switch.


(PCM) and recheck.

Check “RED” circuit. If it is OK, substitute a known-good ECM

(PCM) and recheck.

Check air pump assembly referring to

“ON-VEHICLE SER-

VICE”, and then

“PNK” circuit.


(PCM) and recheck.

Check “ORN/BLK” circuit (including indicator lamp and combination meter).


(PCM) and recheck.


4WD Control System Circuit Inspection

Voltage check

Check for input or output voltage (voltage between each circuit and body ground) of ECM (PCM) with ECM

(PCM) connector connected and ignition switch turned ON.

TER-

MINAL

E61-19

CIRCUIT

4WD Indicator lamp

WIRE

COLOR

ORN/

BLK

C51-1-9

Air pump assembly

(Pump motor and release valve)

C51-3-7 4WD switch

C51-3-17 Ground

RED

BLK/

ORN

BLK/

ORN

C51-3-18

Air pump assembly

(pressure switch)

PNK

NORMAL

VOLTAGE

10 –14 V

0 – 1 V

0 – 1 V

10 – 14 V

10 – 14 V

0 – 1 V

0 – 1 V

0 – 1 V

10 – 14 V

CONDITION

Transfer shift lever : 2H or N

4 seconds after transfer shift lever shifted to 4H or 4L




Transfer shift lever : 4H or 4L

–



1. ECM (PCM) connector terminal arrangement ; viewed from harness side


4WD Control System Inspection

1) Install special tool to air hose connecting between air pump assembly and differential (actuator) as shown in figure.

Tighten adjusting screw (2) of special tool as far as it stops.

Close air check side opening by using fuel hose (1) as blind plug.

Special tool

(A) : 09918-18110

SUZUKI GENUINE PARTS

(B) : 09367-04002

NOTE:

Use care not to bend any part of hose.

2) Turn ON ignition switch and shift transfer lever from 2H to 4H range.

3) Check that motor starts running (a sound can be heard) within 1 second and it stops when gauge of special tool indicates specified pressure value.

Check also for air leakage.

Air pressure specification

(for 4WD control system inspection) :

30.0 – 45.0 kPa (0.30 – 0.45 kg/cm

2

, 4.25 - 6.40 psi)

4) Check that pressure value indicated on gauge of special tool drops as soon as transfer lever is shifted to 2H position.

5) Start motor by shifting transfer lever to 4H position again.

Loosen adjusting screw (2) to lower pressure value on gauge. Motor should start to run again and stop in about 4 seconds.

6) With the adjusting screw (2) of special tool loosened, shift transfer shift lever to N or 2H position and then 4L or 4H position.

Pump motor should stop about 10 seconds after motor starts to run.

3. pipe (to air pump assembly)

4. Hose (to differential carrier)

5. Differential housing



Differential Mountings


1) Lift up vehicle and turn steering wheel all way to the right.

2) Separate front mounting bracket R (2) from differential housing (3) by removing bolts (1) from its lower part.

3) Remove front mounting bracket R (2) by removing mounting front bolt (4) from its upper part.

4) Remove front mounting bracket L (3) from differential housing (1) by removing upper and lower fastening bolts (2, 4).

5) Check conditions of each bush. If it is damaged or deteriorated, drive it out with special tools and press for replacement.

Special tool

(A) : 09951-26010

(B) : 09951-16080


3

1, (a)

2, (b)

6) Position slit in each bush (2) as shown when press-fitting it.

Bush instillation position (angle “A”) :

45

°

(slit alignment)

1. Front mounting bracket L

3. Front mounting bracket R

7) Position each bush to bracket as shown in the figure

Bush installation position (length “a”) :

3.0 mm (0.12 in.)

1. Front mounting bracket R

2. Front mounting bracket L

8) Tighten differential front mounting and bracket bolt to specified torque for reinstallation.


Front mounting bolt (a) :

85 N·m (8.5 kg-m, 61.5 lb-ft)

Front mounting bracket bolt (b) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

Rear Mounting for Front Differential Carrier


1) Lift up vehicle and remove rear mounting bracket (3) by removing rear mounting bolt (1) and rear mounting bracket bolts (2).

2) Check mounting rubber for damage or deterioration and replace as necessary.

3) Tighten rear mounting bolts (1) and rear mounting bracket bolts (2) to specified torque for reinstallation.


Rear mounting bolt (a) :

85 N·m (8.5 kg-m, 61.5 lb-ft)

Rear mounting bracket bolts (b) :

50 N·m (5.0 kg-m, 36.5 lb-ft)


Front Differential Assembly

DISMOUNTING

1) Lift up vehicle and drain oil.

2) Disconnect air hose and breather hose from differential housing.

3) Before removing propeller shaft, give match marks (1) on joint flange and propeller shaft as shown in the figure.

4) Remove propeller shaft flange by removing its 4 bolts and suspend it with cord or the like.

NOTE:

If pull out propeller shaft, transfer oil must be drained before pulling out.

5) Remove bolts (1) for left mounting bracket and bolts and nuts (2) for drive shaft flange to set left side of differential free.

3

1

5

2

4

6) Remove bolts (1, 2) and rear mounting bracket (3).

7) Remove bolts (4) and rear mounting bracket No.2 (5).

8) With differential housing assembly held with transmission jack, remove front mounting bracket (2) bolts (1) on right end of housing (3).


(b)

(a)

(b)

9) Using 2 large screwdrivers (4) as levers, pull out right side drive shaft joint (1) from differential (2) and dismount housing assembly from vehicle.

CAUTION:

During above work, use care not to cause damage to drive shaft boot.

REMOUNTING

For remounting, reverse dismounting procedure and use the following tightening torque.


Front drive shaft flange bolts (a) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

Propeller shaft flange bolts (a) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

Front mounting bracket bolts (a) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

Rear mounting bracket bolts(a) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

Rear mounting bolt (b) :

85 N·m (8.5 kg-m, 61.5 lb-ft)

Rear mounting bracket No.2 bolts (b) :

85 N·m (8.5 kg-m, 61.5 lb-ft)

After tightening all fasteners properly, fill hypoid gear oil as specified and check tightening of plugs with specification.


Unit Repair

Refer to the same section of “UNIT REPAIR MANUAL” mentioned in “FOREWORD” of this manual.

Fastening part

Front mounting bolts

Front mounting bracket bolts

Front drive shaft flange bolts

Propeller shaft flange bolts

Rear mounting bolt

Rear mounting bracket bolts

Rear mounting bracket No.2 bolts


N•m

85

50

50

50

85

50

85


8.5

5.0

5.0

5.0

8.5

5.0

8.5

lb-ft

61.5

36.5

36.5

36.5

61.5

36.5

61.5

Special Tool

09918-18110

Air pressure regulator

09951-16080

Bearing installer

09951-26010

Bush remover plate


DIFFERENTIAL (REAR) 7F-1

SECTION 7F

DIFFERENTIAL (REAR)

General Description ........................................ 7F-2

Diagnosis ......................................................... 7F-2

Diagnosis Table ............................................ 7F-2

On-Vehicle Service.......................................... 7F-3

Precaution for Maintenance Service ............. 7F-4

Differential Gear Oil Change ......................... 7F-4

Rear Differential Assembly............................ 7F-5

Dismounting .............................................. 7F-5

Remounting ............................................... 7F-5

Unit Repair ....................................................... 7F-6

CONTENTS

Disassembling Unit ....................................... 7F-6

Component Inspection .................................. 7F-9

Sub-Assembly Adjustment and Reassembly 7F-9

Differential carrier.................................... 7F-10

Differential case ...................................... 7F-10

Differential side bearing .......................... 7F-12

Drive bevel pinion.................................... 7F-13

Assembling Unit .......................................... 7F-17

Tightening Torque Specification ................. 7F-20

Required Service Material ............................ 7F-20

Special Tool................................................... 7F-21

7F

7F-2 DIFFERENTIAL (REAR)


The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle. It is set in the conventional type axle housing.

The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.

Diagnosis

Diagnosis Table

Condition

Gear noise

Bearing noise

Oil leakage

Possible Cause

Deteriorated or water mixed lubricant

Inadequate or insufficient lubricant

Maladjusted backlash between drive bevel pinion and gear

Improper tooth contact in the mesh between drive bevel pinion and gear

Loose drive bevel gear securing bolts

Damaged differential gear(s) or differential pinion(s)

(Constant noise) Deteriorated or water mixed lubricant

(Constant noise) Inadequate or insufficient lubricant

(Noise while coasting) Damaged bearing(s) of drive bevel pinion

(Noise while turning) Damaged differential side bearing(s) or axle bearing(s)

Clogged breather plug

Worn or damaged oil seal

Excessive oil

Correction



Adjust as prescribed.

Adjust or replace.


Replace.



Replace.

Replace.

Clean.

Replace.

Adjust oil level.



1. Universal joint flange

2. Hypoid gear set

3. Bevel pinion spacer

Apply thread lock cement

99000-32110 referring to

“DIFFERENTIAL CASE” in this section.

4. Shim

5. Rear bearing

6. Front bearing

7. Oil seal :

Apply grease 99000-25010 to oil seal lip.

8. Flange nut :

After tightening nut so as rotation torque of bevel pinion shaft to be in specified value, caulk nut securely.

9. Differential carrier assembly

10. Differential pinion

11. Differential gear

12. Pinion shaft No.1

13. Differential left case

14. Differential right case

15. Thrust washer

16. Differential side bearing

17. Bearing adjuster

18. Lock plate

19. Pinion shaft No.2

20. Pinion joint

21. Spring washer

22. Washer

23. Bevel gear bolt :

Apply thread lock cement 99000-32110 to thread part of bolt.

24. Bolt

25. Bolt

26. Bolt

27. Differential case screw :

Apply thread lock cement 99000-32110 to thread part of bolt.

Do not reuse.

Tightening torque

Apply differential oil.


Precaution for Maintenance Service

• When having driven through water, check immediately if water has entered (if so, oil is cloudy). Water mixed oil must be changed at once.

• Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage and status of breather hoses.

Differential Gear Oil Change

NOTE:

• Hypoid gear oil must be used for differential.

• It is highly recommended to use SAE 80W-90 viscosity.

1) Before oil change or inspection, be sure to stop engine and lift up vehicle horizontally.

2) Check oil level and existence of leakage. If leakage is found, correct its cause.

3) Drain old oil and pour proper amount of gear oil as specified

(roughly up to level hole).

4) Torque drain plug (3) and level/filler plugs (2) to specification.

“A” : Sealant 99000-31110


Differential oil level/filler plug (a) :

50 N·m (5.0 kg-m, 36.5 lb-ft)

Differential oil drain plug (b) :

28 N·m (2.8 kg-m, 20.5 lb-ft)

Hypoid gear oil :

API GL-5, SAE 75W-85, 80W-90 or 90

Oil capacity :

2.5 liters (5.3/4.4 US/Imp. pt.)

1. Breather hose


Rear Differential Assembly

Dismounting

1) Lift up vehicle and drain oil from rear differential housing.

2) Remove rear brake drums and pull out right and left rear axle shafts. (Refer to “REAR AXLE SHAFT REMOVAL” of Section

3E.)

3) Before removing propeller shaft, give match marks (1) on joint flange and propeller shaft as shown.

4) Remove propeller shaft by removing its flange bolts and nuts.

5) Remove differential assembly by removing its 8 fastening bolts (1).

Remounting

1) Clean mating surfaces of rear axle and differential assembly and apply sealant to axle side evenly.

“A” : Sealant 99000-31110

2) Install differential assembly to axle and fix it with bolts (1) tightened to specified torque.


Differential carrier bolts (a) :

55 N·m (5.5 kg-m, 40.0 lb-ft)


3

3) Install propeller shaft to joint flange aligning match marks and torque flange nuts to specification. Apply thread lock cement to thread part of bolt if reused.

“A” : Cement 99000-32110


Propeller shaft flange nuts (a) :

60 N·m (6.0 kg-m, 43.5 lb-ft)

4) Install right and left rear axle shafts and drums.

(Refer to “REAR AXLE INSTALLATION” of Section 3E and rear brake drum installation of Section 5.)

5) Install wheels.

6) Fill hypoid gear oil as specified and tighten plug to specification.

7) Lower lift.

1

Unit Repair

Disassembling Unit

1) Hold differential assembly securely and put identification marks on differential side bearing caps (6).

2) Take off differential side bearing lock plates (4) and differential side bearing caps (6) by removing their bolts and then take out bearing adjusters (5), side bearing outer races and drive bevel gear with differential case.

1. Differential carrier

2. Drive bevel gear assembly

3. Differential case

A: Identification mark

3) Remove drive bevel gear (hypoid gear), differential gears, differential pinions and pinion shafts.

a) With aluminum plates (2) placed on vise first, grip differential case with it and remove drive bevel gear (hypoid gear)

(3) by removing its bolts (1).

2


b) Remove differential left case (2) from differential right case

(1).

2

1 c) Remove pinion shafts, differential gears, washers, differential pinions, spring washers, thrust washers.

4) Using special tools, pull out differential side bearings (1).

Special tool

(C) : 09913-85230

(D) : 09913-61510

5) Remove drive bevel pinion (hypoid gear) assembly.

a) Hold universal joint flange with special tool and then remove flange nut by using power wrench (4 - 10 magnification) (2).

Special tool

(E) : 09922-66021

1. Socket wrench


b) Make mating marks (1) on drive bevel pinion and companion flange.

CAUTION:

Don't make mating mark on the coupling surface of the flange.

c) Remove companion flange from drive bevel pinion. Use special tool if it is hard to remove.

Special tool

(F) : 09913-65135 d) Remove drive bevel pinion with rear bearing, shim and spacer from carrier.

If it is hard to remove, screw an used nut into drive bevel pinion and hammer on that nut with a plastic hammer but never directly on drive bevel pinion.

e) Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and press.

1. Drive bevel pinion


6) Using a hammer and brass bar (1), drive out front bearing outer race with bearing (2) and oil seal (3).

7) Drive out rear bearing outer race in the same way as in the step 6).

Component Inspection

• Check companion flange for wear or damage.

• Check bearings for wear or discoloration.

• Check differential carrier for cracks.

• Check drive bevel pinion and drive bevel gear for wear or cracks.

• Check differential gears, pinions and pinion shafts for wear or damage.

• Check differential gear spline for wear or damage.

Sub-Assembly Adjustment and Reassembly

Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc.

after disassembly, prepare replacing parts and proceed to reassembly according to procedures as described below.

CAUTION:

• Drive bevel gear and pinion must be replaced as a set when either replacement becomes necessary.

• When replacing taper roller bearing, replace as inner race & outer race assembly.


Differential carrier

For press-fitting drive bevel pinion bearing outer races, use special tools as shown in the figure.

Special tool

(A) : 09924-74510

(B) : 09926-68310

(C) : 09913-75510


Differential case

1) After applying differential oil to differential gear (4), pinions

(5), pinion shafts (6), thrust washer (2) and spring washer

(1), install them in differential right case (3).

For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.

2

1 a b

2) When installing pinion shaft No.2 (2) (shorter) into differential case and pinion, insert its “a” side into pinion joint (1).

NOTE:

“a” is longer than “b”. (“a” > “b”)

3) Check differential pinion gear (1) for smooth rotation.

1


4) In the same manner as described in Step 1), install thrust washer (2), spring washer (1) and differential gear (4).

3. Differential left case

5. Differential pinion

3

2, (a), “A”

“A”

1

3

2, (a), “A”

1

5) Install differential left case (1) and then tighten screws to specified torque.

“A” : Cement 99000-32110


Differential case screw (a) :

9 N·m (0.9 kg-m, 6.5 lb-ft)

3 Differential right case

6) Clean and degrease mating surface of drive bevel gear

(hypoid gear) (1).

7) Apply thread lock cement to hatched part of drive bevel gear

(1) as shown in the figure.

“A” : Cement 99000-32110

2, (a), “A”

1

8) Put drive bevel gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque.

Use thread lock cement for bolts (2).

CAUTION:

Use of any other bolts than that specified is prohibited.

“A” : Cement 99000-32110


Bevel gear bolts (a) : 105 N·m (10.5 kg-m, 76.0 lb-ft)


1

(A)

9) Install special tool to differential case assembly and check that preload is within specification below. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.

Special tool

(B) : 09928-06510

Side gear preload

: Max. 2.5 N·m (0.25 kg-m, 1.8 lb-ft)

1. Torque wrench

2. Differential case assembly

3. Aluminum plate

4. Vise

Differential side bearing

1) Press-fit side bearing (1) with special tool and press.

Special tool

(A) : 09944-66020

2) Hold bearing press-fitted in Step 1) with holder and press-fit side bearing on the other side.

NOTE:

Be sure to use bearing holder for the purpose of protecting lower bearing.

Special tool

(A) : 09944-66020

(B) : 09951-16060


Drive bevel pinion

To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.

Special tool

(A) : 09900-20606

(B) : 09926-78320

(C) : 09922-75222

(D) : 09922-76570

(E) : 09951-46010

(F) : 09926-78311-002

1. Universal Joint flange (P/No. 27110-60A00)

2. Nut

3. Front bearing


5. Rear bearing

6. Spacer


8. Drive bevel gear

“a”: Pinion dummy height + Attachment height

“b”: Axle dummy radius

“a” + “b” Mounting dummy size 110.00 mm/4.3307 in.

“c”: Measured dimension

“d”: Drive bevel pinion mounting distance 110.00 mm/4.3307 in.

“e”: Shim size for mounting distance adjustment (= “c”)


1) Install special tools with bearings and universal joint flange

(2) to differential carrier (1).

NOTE:

This installation requires no spacer or oil seal.

Special tool

(E) : 09951-46010

(F) : 09926-78311-002

2) Tighten flange nut (1) so that specified bearing preload is obtained.

NOTE:

• Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of differential oil to bearings.

• On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.

Special tool

(C) : 09922-75222

(F) : 09926-78311-002

Pinion bearing preload

: 0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)

Spring measure reading with special tool

: 18N – 34N (1.8 – 3.4 kg, 4.0 – 7.5 lb)

4. Socket with adapter


3) Set dial gauge to mounting dummy and make 0 (zero) adjustment on surface plate.

NOTE:

• When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge.

• With dial gauge set, turn dummy back and force by hand a couple of times and attain accurate 0 (zero) adjustment.

• It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).

Special tool

(A) : 09900-20606

(B): 09926-78320

1. Surface plate

2. Screw

4) Place zero-adjusted mounting dummy and dial gauge set on pinion mounting dummy and take measurement between zero position and extended dial gauge measuring tip.

NOTE:

• Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accurately.

• When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.

• Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer.

Special tool

(A) : 09900-20606

(B) : 09926-78311

(D) : 09922-76570

(F) : 09926-78311-002

5) Obtain adjusting shim thickness by using measured value by dial gauge in previous step.

Necessary shim thickness

“e”

=

Dial gauge measured value “c”


6) Select adjusting shim(s) (2) closest to calculated value from among following available sizes and put it in place and then press-fit rear bearing (1).

Calculated valve

“f” : Closest value to “e” (refer to Step 5).)

Special tool

(G) : 09925-18011

(H) : 09927-66010

Available shim thickness

: 1.12, 1.15, 1.18, 1.21,1.24, 1.27, 1.30 and 0.3 mm

(0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)


7) With new pinion spacer (3) inserted as shown in the figure, install front bearing (5) to differential carrier (4).

NOTE:

• Make sure to use new spacer for reinstallation.

• Apply differential oil to bearings.


2. Rear bearing

8) Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) till it becomes flush with carrier end.

Then apply grease “A” to oil seal lip.

“A” : Grease 99000-25010

Special tool

(I) : 09951-18210


9) While tightening flange nut gradually with special tool and power wrench (4 - 10 magnification) (1), set preload of pinion to specification.

NOTE:

• Before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand.


• Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.

Pinion bearing preload

: 0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)


: 16 – 30 N (1.6 – 3.0 kg, 3.5 – 6.6 lb)

Special tool

(C) : 09922-76560

(J) : 09922-66021

2. Socket wrench


Assembling Unit

1) Place bearing outer races on their respective bearings.

Used left and right outer races are not interchangeable.

2) Install case assembly in carrier.

3) Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.

4) Align match marks (1) on cap and carrier. Screw in 2 side bearing cap bolts 2 or 3 turns and press down bearing cap by hand.

NOTE:

If bearing cap does not fit tightly on carrier, side bearing adjuster is not threaded properly. Reinstall adjuster.

5) Tighten cap bolts (provisional torque).


Bearing cap bolt (Provisional torque) (a) :

15 N·m (1.5 kg-m, 11.0 lb-ft)

6) Tighten both bearing adjusters (2) so as to obtain specified gear backlash and at the same time, obtain preload of side bearing.

NOTE:

• Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.

• As a practical measure the following would be recommended to obtain specified backlash and side bearing preload at the same time.

– Obtain specified backlash by turning both adjusters inward lightly.

– Tighten both adjusters further by one notch at a time.

• Measure at least 4 points on drive bevel gear periphery.

Standard backlash

: 0.13 – 0.18 mm (0.005 – 0.007 in.)

Special tool

(A) : 09930-40120

(B) : 09930-40113

(C) : 09900-20701

1. Bearing cap bolt


7) Measure preload of pinion bearing with spring balance (1) or torque wrench (2) and check composite preload of pinion bearing and side bearing.

NOTE:

• Before taking measurement with spring balance (1) or torque wrench (2), check for smooth rotation by hand.


Composite preload of pinion bearing and side bearing

: 1.1 – 2.0 N·m (11.0 – 20.0 kg-cm, 9.5 – 17.4 lb-in.)


: 19.5 – 35.5 N (1.95 – 3.55 kg, 4.30 – 7.83 lb)

Special tool

(D) : 09922-76560

3. Universal joint flange

4. Socket with adapter

8) Torque bearing cap bolts (2) to specification and install bearing lock plates.


Lock plate bolt (b) : 12 N·m (1.2 kg-m, 9.0 lb-ft)

Bearing cap bolt (c) : 85 N·m (8.5 kg-m, 61.5 lb-ft)

1. Lock plate bolt

9) As final step, check gear tooth contact as follows.

a) After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush or sponge etc.

b) Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact.

c) Bring painted part up and check contact pattern, referring to following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.

NOTE:

Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.

1. Brush

“A”: Paint gear marking compound evenly


TOOTH CONTACT PATTERN

NORMAL

DIAGNOSIS AND REMEDY

HIGH CONTACT

Pinion is positioned too far from the center of drive bevel gear.

4) Increase thickness of pinion height adjusting shim and position pinion closer to gear center.

5) Adjust drive bevel gear backlash to specification.

LOW CONTACT

Pinion is positioned too close to the center of drive bevel gear.

1) Decrease thickness of pinion height adjusting shim and position pinion farther from gear center.

2) Adjust drive bevel gear backlash to specification.

If adjustment is impossible, replace differential carrier.

1) Check seating of bevel gear or differential case.

(Check bevel gear for runout).

2) If adjustment is impossible, replace drive bevel gear & pinion set or differential carrier.

Replace drive bevel gear & pinion set or differential case.


10) Upon completion of gear tooth contact check in Step 9), caulk flange nut (2) with caulking tool (1) and hammer.


Fastening part

Differential oil level/filler plug

Differential oil drain plug

Propeller shaft flange nuts

Differential carrier bolts

Bevel gear bolts

Bearing cap bolts

Lock plate bolts

Differential case screws

N•m

50

28

60

55

105

85

12

9


5.0

2.8

6.0

5.5

10.5

8.5

1.2

0.9

lb-ft

36.5

20.5

43.5

40.0

76.0

61.5

9.0

6.5

Material

Thread lock cement

Lithium grease

Sealant



(Part Number)

THREAD LOCK CEMENT

SUPER 1322

(99000-32110)

Use

• Bevel gear bolts

• Differential case bolts

• Bevel gear mating surface

• Propeller shaft flange bolt

Oil seal lips SUZUKI SUPER GREASE A

(99000-25010)

SUZUKI BOND NO. 1215

(99000-31110)

• Rear differential drain plug

• Mating surface of differential housing

• Mating surface of rear axle housing


Special Tool

09900-20606

Dial gauge

09900-20701

Magnetic stand

09913-61510

Bearing puller

09913-65135

Bearing puller

09922-76570

Attachment

09913-75510

Bearing installer

09913-85230

Bearing removing jig

09922-66021

Flange holder

09922-75222

Preload checking tool

09922-76560

Preload checking tool

09924-74510

Installer attachment

09925-18011

Bearing installer

09926-68310

Bearing installer

09926-78311-002

Pinion mounting dummy

(See NOTE.)

09926-78320

Mounting dummy

09927-66010/J-23082-01

Oil pump aligner


09928-06510

Differential torque checking tool

09930-40113

Rotor holder

09930-40120

Attachment

09944-66020

Bearing installer

09951-16060 09951-18210

Lower arm bush remover Oil seal remover & installer No. 2

NOTE:

This tool is constituent of tools with 09926-78311.

09951-46010

Drive shaft oil seal installer


BODY ELECTRICAL SYSTEM 8-1

SECTION 8

BODY ELECTRICAL SYSTEM

WARNING:






8

7A

6K

7C1

7D

7E

7F

8A

6F1

6F2

6G

6H

6K

NOTE:


8D

8E

9

Wiring System

(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram) .......... Section 8A

Lighting System .............................................................................................................................. Section 8B

Instrumententation and Driver Information .................................................................................. Section 8C

Windows, Mirrors, Security and Locks ......................................................................................... Section 8D

Immobilizer Control System............................................................................................................Section 8F

10

10A

10B

CONTENTS

General Description .......................................... 8-3

8-2 BODY ELECTRICAL SYSTEM


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).

INSTRUMENTATION/DRIVER INFORMATION 8C-1

SECTION 8C

INSTRUMENTATION/DRIVER INFORMATION

WARNING:






8C

NOTE:


General Description ........................................8C-2

Combination Meter ........................................8C-2

On-vehicle Service ..........................................8C-4

Fuel Meter/Fuel Gauge Unit ..........................8C-4

Fuel level sensor (sender gauge)..............8C-4

Engine Coolant Temperature (ECT) Meter and Sensor ....................................................8C-5

CONTENTS

Engine coolant temperature sensor .......... 8C-5

Oil Pressure Light ......................................... 8C-5

Oil pressure switch....................................8C-5

Brake Warning Light .....................................8C-5

Brake fluid level switch..............................8C-5

8C-2 INSTRUMENTATION/DRIVER INFORMATION


Combination Meter

1. Tachometer

2. Speedometer

3. Fuel level meter

8. Multifunction indicator light

9. Turn signal pilot light (RH)

10. AIR BAG warning light

4. Engine coolant temperature meter 11. O/D OFF light (A/T vehicle only)

5. Turn signal pilot light (LH) 12. Fasten seat belt light (if equipped)

6. 4WD indicator

7. ABS warning light

13. High beam light

14. Engine oil pressure warning light

15. Charge warning light

16. Brake fluid level, parking brake and EBD warning light

17. POWER indicator light (A/T vehicle only)

18. CRUISE indicator light

19. Immobilizer warning light (if equipped)

20. Shift position indicator (A/T vehicle, if equipped)


COMBINATION METER INTERNAL CIRCUITS

A-11 A-12 A-3

SPEED

METER

TACHO

METER

FUEL

METER

TEMP.

METER or

CHECK

ENGINE

POWER CRUISE 4WD

A-9 B-13 B-2 B-3 B-4 B-5 BB-6

Air bag circuit or BRAKE

EBD circuit or ABS ABS circuit C-9 C-10

L 2 D N R P

A-13 A-8 B-12 C-2 B-11 B-10 C-8 A-15 A-6 A-1 B-9 A-16 A-14 C-7 C-1 if equipped

A-10 C-3 C-4 C-5 A-7 A-5 B-8 B-1

COMBINATION METER COUPLERS

[A] : Coupler A

1. To Cruise control module (if equipped)

2. Blank


4. Blank

5. To ABS control module (if equipped)

6. To PCM (A/T vehicle only)

7. To ABS control module (if equipped)

8. To VSS

9. To combination switch

10. To air bag SDM

11. To main fuse

12. To fuse box


14. To immobilizer control module

(if equipped)

15. To ECM (PCM for A/T vehicle)

16. To ECM (PCM for A/T vehicle)

[B] : Coupler B

GRY/YEL

–

BLK/WHT

–

BLU/ORN

GRY/BLU

BRN

1. To door switch (drive side)

2. To transmission range switch

(A/T vehicle only, if equipped) L


(A/T vehicle only, if equipped) 2


(A/T vehicle only, if equipped) D


(A/T vehicle only, if equipped) N


(A/T vehicle only, if equipped) P


(A/T vehicle only, if equipped) R

8. To illumination control module BLU/YEL

GRN/RED

BLU

RED

PPL

9. To PCM (A/T vehicle only)

10. To ECT sensor

WHT/BLU 11. To fuel level gauge

WHT 12. To ground


BLK/BLU

GRN/BLU

GRN/ORN

YEL/GRN

ORN/BLU

ORN/GRN

RED

RED/GRN

BLU/WHT

BLU/YEL

GRN/YEL

[C] : Coupler C

1. To ground BLK

2. To ECM (PCM for A/T vehicle) BRN


4. To brake fluid level switch

5. To parking brake switch

6. To seat belt switch

7. To generator

PPL/RED

RED/BLK

PPL

GRY/RED

WHT/RED

8. To engine oil pressure switch YEL/BLK

WHT/BLK 9. To combination switch

YEL/WHT 10. To ignition switch

RED/YEL

BLU/RED

PPL/YEL

ORN/BLK

NOTE:

Terminal arrangement of coupler viewed from harness side.


On-vehicle Service

Fuel Meter/Fuel Gauge Unit

Fuel level sensor (sender gauge)

INSPECTION

Remove fuel pump assembly referring to Section 6C.

Use an ohmmeter to confirm that resistance of sender gauge unit changes with change of float position.

If measured value is out of specification, replace fuel sender gauge.

Fuel level sensor specification :

“a”

“b”

“c”

Float Position

53.6 mm

(2.11 in.)

143.1 mm

(5.63 in.)

256.9 mm

(10.11 in.)

Resistance ( Ω

6 – 8

28 – 36

90 – 100

1. Fuel pump assembly

2. Fuel level gauge (–) terminal

3. Fuel level gauge (+) terminal

4. Float


Engine Coolant Temperature (ECT) Meter and

Sensor

Engine coolant temperature sensor


Refer to “ECT SENSOR” in Section 6E2.

Oil Pressure Light

Oil pressure switch


Refer to “OIL PRESSURE CHECK” in Section 6A2.

Brake Warning Light

Brake fluid level switch

INSPECTION

Use an ohmmeter to check switch for continuity.

If found defective, replace switch (reservoir).

Brake fluid level switch specification

OFF position (float up) : No continuity

ON position (float down) : Continuity


WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-1

SECTION 8D

WINDOWS, MIRRORS, SECURITY AND LOCKS

WARNING:






8D

NOTE:


CONTENTS

General Description ....................................... 8D-2

Rear Wiper and Washer (If Equipped) ......... 8D-2

On-Vehicle Service......................................... 8D-3

Windshield Wipers ....................................... 8D-3

Front wiper and washer............................ 8D-3

Rear Window Wiper and Washer

(For Vehicle with Cruise Control System) .... 8D-4

Rear Wiper and Washer Switch ............... 8D-4

Rear Window Wiper and Washer

(For Vehicle without Cruise Control

System)........................................................ 8D-4

Rear Wiper Intermittent Relay...................... 8D-4

8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS


Rear Wiper and Washer (If Equipped)

WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-3


Windshield Wipers

Front wiper and washer

Wiper motor

• As shown in the figure, use a 12 V battery to connect its (+) terminal to terminal “A”, and its (–) terminal to “Black” lead wire (2).

If motor (1) rotates at a low revolution speed of 45 to 55 rpm, it is proper. For high speed check, connect battery (+) terminal to terminal “B”, and its (–) terminal to “Black” lead wire

(2). If motor rotates at a high revolution speed of 67 to 83 rpm, it is proper.

• Testing automatic stop action.

a) Connect 12 V battery (+) terminal to terminal “A” of wiper motor and (–) terminal to Black lead wire (2) and let the motor turn.

b) Disconnect terminal “A” from battery, and let the motor stop.

c) Connect terminal “A” and “D” with a jumper wire (3), and connect terminal “C” to battery (+) terminal. Observe the motor turns once again then stops at a given position.

d) Repeat a) through c) several times and inspect if the motor stops at the given position every time.

8D-4 WINDOWS, MIRRORS, SECURITY AND LOCKS

Rear Window Wiper and Washer (For Vehicle with Cruise Control System)

INSPECTION

Rear Wiper and Washer Switch


2) Disconnect combination switch lead wire coupler.

3) Use a circuit tester to check the continuity at each switch position. If any continuity is not obtained, replace switch.

1 a b

2 c

Terminal

Switch

OFF

Rear wiper ON

Rear washer ON a d b c d

1. Rear wiper switch 2. Rear washer switch

Rear Window Wiper and Washer (For Vehicle without Cruise Control System)

INSPECTION

Refer to “Rear Wiper and Washer Switch (In Combination Switch)” under “Rear Wiper and Washer (If

Equipped)” in the same section of the Service Manual mentioned in FOREWORD of this manual.

Rear Wiper Intermittent Relay

INSPECTION

Refer to “Rear Wiper Intermittent Relay” under “Rear Wiper and Washer (If Equipped)” in the same section of the Service Manual mentioned in FOREWORD of this manual when service vehicle without cruise control system.

CRUISE CONTROL SYSTEM 8E-1

SECTION 8E

CRUISE CONTROL SYSTEM

WARNING:






General Description ....................................... 8E-2

Cautions in Servicing ................................... 8E-2

Symbols and Marks...................................... 8E-2

Abbreviations ............................................... 8E-2

Wiring Color Symbols................................... 8E-2

Joint Connector ............................................ 8E-2

Fuse Box and Relay ..................................... 8E-2

Power Supply Diagram ................................ 8E-2

Cruise Control System ................................. 8E-3

Cruise control system circuit .................... 8E-3

Components and functions....................... 8E-4

Cancel Conditions .................................... 8E-5

Diagnosis ........................................................ 8E-5

Diagnosis Table ........................................... 8E-5

Note on System Circuit Inspection ............... 8E-7

Cruise Main Switch Indicator Lamp

Circuit Check ................................................ 8E-8

“Cruise” Indicator Lamp Circuit Check ......... 8E-9

Cruise Main Switch, Coast/Set,

Resume/Accel and Cancel Switches

Circuits Check ............................................ 8E-10

VSS Circuit Check...................................... 8E-11

Stop Lamp Switch (with Pedal Position

Switch) Circuits Check ............................... 8E-12

CONTENTS

9

Transmission Range Switch Circuit Check 8E-13

Clutch Pedal Position Switch Circuit Check 8E-14

Throttle Valve Opening Signal Circuit

Check......................................................... 8E-15

Overdrive and TCC off Command Signal

Circuit Check.............................................. 8E-16

Cruise Control Module Power and Ground

Circuits Check ............................................ 8E-16

Cruise Control Module and Its Circuit

Inspection................................................... 8E-17

Cruise Cable Play Inspection and

Adjustment ................................................. 8E-19

On-Vehicle Service ...................................... 8E-19

Cruise Main Switch .................................... 8E-19

Coast/Set, Resume/Accel and Cancel

Switches..................................................... 8E-20

Vehicle Speed Sensor (VSS) ..................... 8E-20

Transmission Range Switch ...................... 8E-20

Clutch Pedal Position (CPP) Switch .......... 8E-21

Stop Lamp Switch (with Pedal Position

Switch) ....................................................... 8E-22

Cruise Control Actuator Assembly

(with Control Module)................................. 8E-23

Cruise Cable .............................................. 8E-24

10

10A

10B

8A

8B

8C

8D

8B

6F1

6F2

6G

6H

6K

7A

7A1

7B1

7C1

7D

7E

8E

8E-2 CRUISE CONTROL SYSTEM

Cautions in Servicing

Refer to Section 8.

Symbols and Marks

Refer to Section 8A.

Abbreviations


Wiring Color Symbols

Refer to Section 8.

Joint Connector

Refer to Section 8.

Fuse Box and Relay


Power Supply Diagram




Cruise Control System

The cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.g., on a highway. It allows the driver to drive his vehicle at a constant speed of 40 km/h (25 mile/h) or higher without depressing the accelerator pedal (constant cruising). The system also has such functions as to change the vehicle speed without operating the accelerator pedal (but using SET COAST and ACCEL RESUME switches), cancel cruise control (CANCEL switch) and resume the speed in memory automatically after cruise control is cancelled (ACCEL RESUME switch). The system mainly consists of a vehicle speed sensor, an actuator assembly incorporated with control module, cruise main switch, SET COAST switch, ACCEL RESUME switch and CANCEL switch, etc.

1. Cruise main switch

1-1 Cruise main switch indicator lamp

2. “CRUISE” Indicator light

3. SET COAST/ACCEL RESUME/CANCEL switch


5. Cruise control actuator assembly (with control module)

6. PCM / ECM

7. Stop lamp switch (with brake pedal position switch)

8. Clutch pedal position switch (M/T vehicle)

9. Automatic transmission

10. Transmission range switch (Park/Neutral position switch) (A/T vehicle)

Cruise control system circuit



Components and functions

Cruise control actuator assembly with control module

Component

Cruise main switch

SET COAST switch

ACCEL RESUME switch

Function

Cruise control module:

Executes centralized control by means of a microcomputer over all functions including setting a constant speed, resuming it, setting coast, limiting minimum speed and cancelling cruise control.

Cruise control actuator (stepping motor & clutch) :

Actuates accelerator pedal through cruise cable and arm according to a signal from cruise control module to control vehicle speed.

This switch has a momentary contact type button to turn the cruise control system ON and OFF.

When this switch is rotated (ON) and then released (OFF) while vehicle is running at a speed 40 km/h (25 mile/h) or higher, vehicle speed at that OFF moment is stored in memory and it is maintained (constant cruising).

Rotating this switch (ON) continuously during constant cruising keeps slowing down vehicle speed as long as it is ON. When it is released (OFF), vehicle speed at that moment is stored in memory and vehicle starts constant cruising.

When this switch is rotated (ON) during constant cruising, vehicle speed keeps increasing as long as it is ON. When it is released (OFF), vehicle speed at that moment is stored in memory and vehicle starts constant cruising. If vehicle speed is higher than 40 km/h (25 mile/h) after cruise control is cancelled, turning this switch ON momentarily will resume the speed at which vehicle was running before cancellation.

CANCEL switch When this switch is pressed (ON), cruise control (accelerator pedal control) is cancelled.

Vehicle speed sensor (VSS) The vehicle speed sensor (VSS) is mounted on the transfer or transmission.

The VSS converts vehicle speed into pulse signal and send it to the cruise control module.

Stop lamp switch The stop lamp switch has 2 contact points. One contact point closes when the brake pedal is depressed to light the stop lamp and provides a voltage signal to the cruise control module. This signal, when inputted cancels cruise control

(sets the accelerator pedal free).

The other contact point (brake pedal position switch) opens when the brake pedal is depressed, to shut off the power to the magnetic clutch in the actuator, thereby cancelling cruise control (setting the accelerator pedal free).

This switch is installed to cancel cruise control (constant cruising) without fail.

Clutch pedal position switch

(M/T vehicle only)

Transmission range switch

(Park/Neutral position switch)

(A/T vehicle only)

When the clutch pedal is depressed, the clutch pedal position switch closes and provides a ground signal to cruise control module.

The cruise control module cancels cruise control (accelerator pedal control) when this signal is inputted.

When the selector lever is places in either “P” or “N” position, the transmission range switch closes and provides a ground signal to cruise control module. The cruise control module cancels cruise control (accelerator pedal control) when this signal is inputted.

PCM – Throttle opening signal (4 A/T vehicle only)

Throttle opening signal is inputted from PCM.

From this signal, the cruise control module detects the throttle opening and uses it as one of the factors to output the overdrive and TCC OFF command signal to PCM.


Component

PCM – Overdrive and TCC off command signal output

Cruise main switch indicator lamp

“CRUISE” indicator lamp

Function

When the throttle opening for the vehicle speed exceeds the specified value during cruise control, the cruise control module sends this signal to PCM. PCM uses this signal as one of signals to control 4-A/T.

In the state with the ignition switch ON and the cruise control system OFF, pressing this switch once and releasing it will activate the cruise control system and the cruise control module will cause the indicator lamp to light up.

It lights up when cruise control (accelerator pedal control) is functioning.

Cancel Conditions

Constant cruising is cancelled under the following conditions.

• Ignition switch is turned OFF.

• Cruise main switch is turned OFF.

• Vehicle speed has slowed down to lower than minimum operating speed (40 km/h (25 mile/h)).

• *Vehicle speed varies beyond cancel speed range (–15 km/h, –9 mile/h) from preset speed.

• *Brake pedal is depressed. (Stop lamp switch is turned ON).

• *Clutch pedal is depressed (Clutch pedal position switch is turned ON) (For M/T vehicle).

• *Selector lever is shifted to N range (Park/Neutral position switch in transmission range switch is turned ON).

• *CANCEL switch is turned ON.

NOTE:

When constant cruising is cancelled under above any condition with * (asterisk), vehicle speed before cancellation can be resumed by operating ACCEL RESUME switch, provided that vehicle speed is higher than 40 km/h (25 miles/h).

Diagnosis

Diagnosis Table

Condition

Main switch indicator lamp fails to light up or remains ON.

“CRUISE” indicator lamp fails to light up or remains ON.

circuits faulty

Possible Cause

Main switch indicator lamp circuit faulty

Cruise control module power and ground

Actuator assembly faulty

“CRUISE” indicator lamp circuit

Cruise control module power and ground circuits


Correction

Refer to “CRUISE MAIN SWITCH INDI-

CATOR LAMP CIRCUIT CHECK” in this section.

Refer to “CRUISE CONTROL MODULE

POWER AND GROUND CIRCUIT


Replace actuator assembly.

Refer to ““CRUISE” INDICATOR LAMP

CIRCUIT CHECK” in this section.






Condition

Vehicle speed can not be set.

Vehicle set speed is unstable.

Actual vehicle speed deviates above or below set speed.

Acceleration or deceleration by using

“RESUME/ACCEL” or

“COAST/SET” switch is not attained.

Cruise control is not cancelled even when

“CANCEL” switch is operated.

Possible Cause

Actuator cable play maladjusted or actuator cable faulty

Main switch, “COAST/SET”, “RESUME/

ACCEL” and “CANCEL” switch circuits faulty

VSS circuit faulty

Stop lamp switch circuit faulty

Correction

Refer to “CRUISE CABLE PLAY

INSPECTION AND ADJUSTMENT” in this section.

Refer to “CRUISE MAIN SWITCH,

COAT/SET, RESUME/ACCEL AND

CANCEL SWITCHES CIRCUITS


Refer to “VSS CIRCUIT CHECK” in this section.

Refer to “STOP LAMP SWITCH (WITH

PEDAL POSITION SWITCH) CIRCUITS


Transmission range switch circuit (4 A/T model only) faulty

Refer to “TRANSMISSION RANGE

SWITCH CIRCUIT CHECK” in this section.

Clutch pedal position switch circuit faulty Refer to “CLUTCH PEDAL POSITION


Cruise control module power and ground circuits faulty






VSS circuit faulty




Refer to “VSS CIRCUIT CHECK” in this section.

Throttle valve opening signal circuit faulty Refer to “THROTTLE VALVE OPENING

SIGNAL CIRCUIT CHECK” in this sec-

Actuator assembly faulty tion.






SIGNAL CIRCUIT CHECK” in this section.




















Condition

“RESUME/ACCEL” switch fails to resume preset vehicle speed after cruise control is cancelled.

Cruise control is not cancelled even when brake pedal is depressed.

Cruise control is not cancelled even when clutch pedal is depressed.

Cruise control is not cancelled even when selector lever is shifted to “N” position.

4 speed A/T gear shifting is frequent between 3rd and overdrive when driving on uphill road (Hunting).

4 speed A/T is not shifted to overdrive gear even though not on uphill road.



Possible Cause


Correction







Stop lamp switch circuit faulty


Refer to “STOP LAMP SWITCH (WITH

PEDAL POSITION SWITCH) CIRCUITS



Clutch pedal position switch circuit faulty Refer to “CLUTCH PEDAL POSITION

SWITCH CIRCUIT CHECK” in this Section.



Transmission range switch circuit (4 A/T model only) faulty

Refer to “TRANSMISSION RANGE




SIGNAL CIRCUIT CHECK” in this Section.

Overdrive and TCC off command signal circuit faulty

Refer to “OVERDRIVE AND TCC OFF

COMMAND SIGNAL CIRCUIT CHECK” in this section.

Actuator assembly faulty Replace actuator assembly.


SIGNAL CIRCUIT CHECK” in this sec-

Overdrive and TCC off command signal circuit faulty tion.

Refer to “OVERDRIVE AND TCC OFF

COMMAND SIGNAL CIRCUIT CHECK” in this section.

Actuator assembly faulty Replace actuator assembly.

Note on System Circuit Inspection

Refer to “PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A.


Cruise Main Switch Indicator Lamp Circuit Check

Step Action

1 Check Circuit for Short.

3) Disconnect connector from cruise control module with ignition switch OFF.


Does cruise main switch indicator lamp turn ON?

2 Check Circuit for Open

1) Check for proper connection to cruise control module at terminal E132-10.

2) If OK, connect terminal E132-10 to ground.

Does indicator lamp turn ON at ignition switch ON?

3 Lamp Bulb Check

1) Remove cruise main switch from instrument panel.

2) Remove lamp bulb and check it.

Is bulb in good condition?

Fig. for Step 2

Yes

“LT GRN/WHT” circuit is shorted to ground.

No

Go to Step 2.

Lamp circuit is OK. Go to Step 3.

“BLK/WHT” or “LT

GRN/WHT” circuit is open.

Replace bulb.


“Cruise” Indicator Lamp Circuit Check

Step Action

1 Check Circuit for Short.



Does “CRUISE” indicator lamp turn ON?

2 Check Circuit for Open


2) If OK, connect terminal E132-4 to ground.

Does indicator lamp turn ON at ignition switch ON?

3 Lamp Bulb Check

1) Remove combination meter from instrument panel.

2) Remove lamp bulb and check it.

Is bulb in good condition?

Fig. for Step 2

Yes

“GRN/YEL” circuit is shorted to ground.

No

Go to Step 2.

Lamp circuit is OK. Go to Step 3.

“BLK/WHT” or

“GRN/YEL” circuit is open.

Replace bulb.


Cruise Main Switch, Coast/Set, Resume/Accel and Cancel Switches Circuits

Check

Step Action

1 Switch Circuit Check



3) If OK, check resistance between terminal E132-8 and

E132-5 under each condition below.

Switch circuit specification (resistance)

All switches OFF : Infinity

COAST/SET switch rotated (ON) : 200 – 240

Ω

RESUME/ACCEL switch rotated (ON) : 820 – 1000 Ω

CANCEL switch pressed (ON) : About 0

Ω

4) Turn ignition switch ON and check voltage between terminal E132-8 and ground under each condition below.

Switch circuit specification (voltage)

Cruise main switch released (OFF) : 0 V

Cruise main switch pressed (ON) : 10 – 14 V

Are check results in above steps 3) and 4) satisfactory?

2 Cruise Main Switch Check

1) Check cruise main switch for operation referring to “Cruise

Main Switch Inspection” in this section.

Is switch in good condition?

3 COAST/SET, RESUME/ACCEL and CANCEL Switches Check

1) Check COAST/SET, RESUME/ACCEL and CANCEL switches for operation referring to “COAST/SET,

RESUME/ACCEL and CANCEL SWITCHES” in this section.

Are all switches in good condition?

Yes

Switch circuit is

OK.

Go to step 3.

“BLK/YEL” or “LT

GRN” circuit is open or short.

No

Go to Step 2.

Replace.

Replace.

Fig. for Step 1

1. Cruise main switch

2. “RESUME ACCEL” switch

3. “COAST SET” switch

4. “CANCEL” switch


VSS Circuit Check

Step Action

1 Vehicle Speed Sensor Circuit Check



3) If OK, check for continuity between terminals E132-1 and

E59-2, terminals C52-2 and C20-1 referring to “CRUISE

CONTROL SYSTEM” in Section 8A.


Yes No

VSS circuit is OK.

“BLU/YEL” circuit is open.

Fig. for Step 1


Stop Lamp Switch (with Pedal Position Switch) Circuits Check

Step Action

1 Stop Lamp Switch (With Pedal Position Switch) Circuits Check


2) Check for proper connection to cruise control module at terminals E132-2 and E132-6.

3) If OK, turn ignition switch ON.

4) Check Voltage between each terminal and ground under each condition below.

Stop lamp switch circuit specification

Brake pedal released terminal E132-2 : 0 V

Brake pedal released terminal E132-6 : 10 – 14 V

Brake pedal depressed terminal E132-2 : 10 – 14 V

Brake pedal depressed terminal E132-6 : 0 V


2 Stop Lamp Switch Position Check

1) Check stop lamp switch for installation position referring to

“STOP LAMP SWITCH” in Section 5.


3 Stop Lamp Switch (With Pedal Position Switch) Check

1) Disconnect connector from stop lamp switch.

2) Check for proper connection to stop lamp switch at all terminals.

3) If OK, check stop lamp and pedal position switches for operation referring to “STOP LAMP SWITCH” in this section.

Is this switch in good condition?

Yes

Stop lamp switch

(with pedal position switch) circuits are

OK.

Go to Step 3.

No

Go to Step 2.

Adjust.

“YEL/GRN” or

“GRN/WHT” circuit is open or short.

Replace.

Fig. for Step 1


Transmission Range Switch Circuit Check

Step Action

1 Transmission Range Switch Circuit Check



3) If OK, connect ohmmeter between terminal E132-9 and ground.

4) Check for continuity under each condition below.

Transmission range switch circuit specification

Selector lever at “P” or “N” range : Continuity

“R”, “D”, “2” or “L” range : Infinity


2 Transmission Range Switch Check

1) Disconnect transmission range switch connector.

2) Check for proper connection to transmission range switch at disconnected connector terminals.

3) If OK, check transmission range switch for operation referring to “TRANSMISSION RANGE SWITCH” in Section

7B1.


Yes

Transmission range switch circuit is OK.

No

Go to Step 2.

“BLK/RED” or

“BLK/YEL” circuit is open or short.

Adjust or replace.

Fig. for Step 1


Clutch Pedal Position Switch Circuit Check

Step Action

1 Clutch Pedal Position Switch Circuit Check



3) If OK, check for resistance between terminal E132-9 and ground under each condition below.

Clutch pedal position switch circuit specification

Clutch pedal released : Infinity

Clutch pedal depressed : Continuity


2 Clutch Pedal Position Switch Position Check

1) Check clutch pedal position switch for installation position referring to “CLUTCH PEDAL POSITION SWITCH” in this section.


3 Clutch Pedal Position Switch Check

1) Disconnect connector from clutch pedal position switch.

2) Check for proper connection to clutch pedal position switch at all terminals.

3) If OK, check clutch pedal position switch for operation referring to “CLUTCH PEDAL POSITION SWITCH” in this section.

Is this switch in good condition?

Yes

Clutch pedal position switch circuit is

OK.

No

Go to Step 2.

Go to Step 3.

“BLU” or “BLK” circuit is open or short.

Adjust.

Replace.

Fig. for Step 1


Throttle Valve Opening Signal Circuit Check

Step Action

1 Powertrain Control Module (PCM) Diagnostic Trouble Code

Check

1) Check PCM for DTC.

Is there a DTC related to throttle position sensor?

2 Throttle Valve Opening Signal Circuit Check


2) Check voltage between terminal E61-4 of PCM connector connected and ground.

Does voltage vary linearly according to throttle opening?

3 Supply Voltage Check

1) Disconnect connector from PCM with ignition switch OFF.

2) Check for proper connection to PCM at terminal E61-4.

3) If OK, connect “BLU” wire terminal of main relay to ground with service wire.


5) Check voltage between E61-4 of PCM connector and ground.

Is it 10 – 14 V?

Yes

Check and repair

TP sensor referring to Section 6-1.

Throttle valve opening signal circuit is OK.

Check TP sensor and circuits referring to Section 6-1.

If OK, substitute a known-good PCM and recheck.

No

Go to Step 2.

Go to Step 3.

Check “GRY” wire for open and short. If OK, proceed to cruise control module power and ground circuits check.

Fig. for Step 2


Overdrive and TCC off Command Signal Circuit Check

Step Action

1 Overdrive off Command Signal Circuit Check




4) Check voltage between terminal E132-3 and ground.

Is it 10 –14 V?

Fig. for Step 1

Yes

This signal circuit is

OK.

No

Check “PNK/

BLU” wire for open and short.

If OK, substitute a known-good

PCM and recheck.

Cruise Control Module Power and Ground Circuits Check

Step Action

1 Power and Ground Circuits Check


2) Check for proper connection to cruise control module at terminals E132-12 and E132-11.


4) Check voltage between terminals E132-12 and E132-11.

Does voltmeter indicate 10 – 14 V?

Yes

Power and ground circuits are OK.

No

“BLU/BLK” or

“BLK” circuit is open.

Fig. for Step 1


Cruise Control Module and Its Circuit Inspection

CAUTION:

Cruise control module can not be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to cruise control module with coupler disconnected from it.

VOLTAGE CHECK

Check for input or output voltage of control module (voltage between each circuit and body ground) with cruise control module connector connected.

CIRCUIT

Vehicle speed sensor

Stop lamp switch

NORMAL

VOLTAGE

Indicator deflection repeated between

0 – 1 V and 3 – 5 V

0 – 2 V

10 – 14 V

10 – 14 V

CONDITION

Ignition switch ON and cruise main switch ON. Vehicle hoisted and rear left tire turned slowly with rear right tire locked.

Brake pedal released.

Brake pedal depressed.

Ignition switch ON.

Overdrive and TCC off signal

(4 A/T only)

CRUISE indicator light

Ground

Brake pedal position switch

(in stop lamp switch)

Throttle valve opening signal from PCM (4A/T only)

Cruise main switch

CANCEL switch

COAST SET switch

RESUME ACCEL switch

Clutch pedal position switch

(M/T only)

Transmission range switch

(Park/Neutral position switch)

(A/T only)

Cruise main switch indicator lamp

10 – 14 V

–

10 – 14 V

0 V

Ignition switch ON.

–

Ignition switch ON and brake pedal released.

Ignition switch ON and brake pedal depressed.

Ignition switch ON.

Voltage varies as specified by graph in “THROTTLE VALVE OPENING SIG-

NAL CIRCUIT CHECK” in this section.

7 – 9V

3 – 5 V

0 – 1 V

1 – 2 V

2.5 – 4 V

Ignition switch ON and cruise main switch released.

Ignition switch ON and cruise main switch pressed.

Ignition switch ON and CANCEL switch pressed.

Ignition switch ON and COAST SET switch rotated.

Ignition switch ON and RESUME ACCEL switch rotated.

Ignition switch ON and clutch pedal released.

10 – 14 V

0 – 1 V

0 V

10 – 14 V

0 – 1 V

10 – 14 V

Ignition switch ON and clutch pedal depressed fully.

Ignition switch ON and selector lever in “P” or “N” range.

Ignition switch ON and selector lever in “R”, “D”, “2” or

“L” range.

Ignition switch ON.

Ignition switch ON and after input main switch ON signal.


TERMINALS CIRCUIT

E132-11 – body ground Ground

E132-6 – E132-12 Brake pedal position switch (in stop lamp switch)

E132-8 – E132-5 CANCEL switch

E132-9 – E132-11

(M/T)

E132-9 – E132-11

(A/T)

COAST SET switch

RESUME ACCEL switch

Clutch pedal position switch (M/T only)

Transmission range switch (Park/neutral position switch)

(A/T only)

RESISTANCE CHECK

4) Disconnect cruise control module connector from cruise control module with ignition switch OFF.

CAUTION:

Never touch terminals of cruise control module itself or connect voltmeter or ohmmeter.

5) Check resistance between each pair of terminals of disconnected connectors as shown in the following table.

1. Cruise control module connector (E132)

STANDARD

RESISTANCE

Continuity

Continuity

No continuity

No continuity

Continuity

No continuity

200 – 240

Ω

No continuity

820 – 1000

Ω

No continuity

Continuity

Continuity

No continuity

CONDITION

–

Brake pedal released.

Brake pedal depressed.

CANCEL switch OFF (released).

CANCEL switch ON (pressed).

COAST SET switch OFF (released).

COAST SET switch ON (rotated).

RESUME ACCEL switch OFF

(released).

RESUME ACCEL switch ON

(rotated).

Clutch pedal released.

Clutch pedal depressed fully.

Selector lever in “P” or “N” range.

Selector lever in “R”, “D”, “2” or “L” range.


Cruise Cable Play Inspection and Adjustment

INSPECTION AND ADJUSTMENT

1) Remove actuator cap.

2) With actuator lever (1) returned at original position (2)

(Where lever does not move clockwise any further), check cruise cable for play.

If it is out of specification, adjust it as follows

Cruise Cable play “a” :

1 – 2 mm (0.04 – 0.08 in.)

3) Loosen cable lock nut (3).

4) Adjust cable play to specified value by turning adjusting nut

(4).

5) Tighten lock nut (3) securely after adjustment.


Cruise Main Switch

REMOVAL


2) Remove meter cluster hood (1) by removing its mounting screws (2).

3) Remove cruise main switch (3) from instrument panel.

4) Disconnect connector from cruise main switch (3).

1

LOAD

INSPECTION

1) Check for resistance between “IG” and “LOAD” terminals.

If check result is not satisfactory, replace.

Cruise main switch specification

Switch button released : Infinity

Switch button pressed : About 3.9 k Ω

IG

INSTALLATION



Coast/Set, Resume/Accel and Cancel

Switches

CAUTION:

Never disassemble combination switch assembly. Disassembly will spoil its original functions.

These switches are built in the combination switch assembly.


Refer to “COMBINATION SWITCH” in Section 3C1.

INSPECTION

1) Disable air bag system referring to “DISABLING AIR BAG

SYSTEM” in Section 10B.

2) Disconnect connector (1) of COAST/SET, RESUME/ACCEL and CANCEL switches.

3) Check for resistance between “SW” and “GND” terminals of disconnected switch connector (1) under each condition below.

If check result is not satisfactory, replace combination switch assembly.

COAST/SET, RESUME/ACCEL and CANSEL switch specification

All switches released (OFF) : Infinity

CANCEL switch pressed (ON) : About 0

Ω

COAST/SET switch rotated (ON) : 200 – 240

Ω

RESUME/ACCEL switch rotated (ON) : 820 – 1000 Ω

Vehicle Speed Sensor (VSS)

INSPECTION

Refer to Section 6E2.

Transmission Range Switch

Refer to Section 7B1 for inspection, removal, installation and adjustment.


Clutch Pedal Position (CPP) Switch

REMOVAL

1) Disconnect CPP switch connector with ignition switch OFF.

2) Remove CPP switch from pedal bracket.

1. CPP switch for cruise control

2. Stop lamp switch

3. CPP switch for starter (if equipped)

INSPECTION

Check for resistance between terminals under each condition below.

If check result is not satisfactory, replace.

CPP switch resistance

When switch shaft is free : Continuity

When switch shaft is pushed : No continuity

1. Push

2. Free

INSTALLATION

1) Install CPP switch to pedal bracket.

2) With clutch pedal released, adjust switch position so that clearance between end of thread and clutch pedal bracket is within specification.

Clearance “a” between end of thread and clutch pedal bracket :

1.5 – 2.0 mm (0.06 – 0.08 in)

3) Tighten lock nut to specified torque.


CPP switch lock nut (a) : 7.5 N·m (0.75 kg-m, 5.5 lb-ft)

4) Connect connector to CPP switch securely.

1. Clutch pedal

2. CPP switch for cruise control

3. Lock nut


Stop Lamp Switch (with Pedal Position

Switch)

INSPECTION


2) Disconnect stop lamp switch connector and remove stop lamp switch from pedal bracket.

3) Check switch (2 contacts) for resistance under each of the following each conditions.

If check result is not satisfactory, replace stop lamp switch.

Stop lamp switch specification

Between terminals “1” and “3” (Contact for stop lamp)

FREE (2) : Continuity, PUSH (1) : No continuity

Between terminals “2” and “4” (Contact for brake pedal position)

FREE (2) : No continuity, PUSH (1) : Continuity

4) Install stop lamp switch and adjust its position referring to

Section 5.


Cruise Control Actuator Assembly (with Control Module)

CAUTION:

Never disassemble cruise control actuator assembly.

Disassembly will spoil its original function.

REMOVAL


2) Disconnect connector from actuator assembly (2) (with control module).

3) Remove actuator cap (1) from actuator assembly (2).

4) Disconnect cruise cable (3) from actuator assembly (2).

5) Remove actuator assembly (2) from vehicle.

INSPECTION

Move actuator lever (1) by hand and check its operation as described below.

1) Actuator lever (1) should not turn clockwise.

2) Actuator lever (1) should turn smoothly by about 1/3 rotation counterclockwise and contact internal stopper.

3) When hand is taken off from actuator lever (1) at the position in 2) above, it should return to its original position (2) by return spring force. If actuator lever (1) does not operate as described above, replace it.

INSTALLATION

Install actuator assembly by reversing removal procedure, noting the following point.

• Adjust cruise cable play to specification referring to “CRUISE

CABLE PLAY INSPECTION AND ADJUSTMENT” in this section.


Cruise Cable

1. Actuator cap

2. Actuator assembly

3. Screw

4. Cruise cable

5. Clamp

6. Grommet

7. Clamp at member

8. Accelerator pedal

9. Member

REMOVAL

1) Disconnect cruise cable from cruise control arm and accelerator bracket.

2) Remove actuator cap and disconnect cruise cable from actuator.

3) Release cable from all clamps.

4) Remove cable from vehicle.

INSTALLATION

Install cruise cable by reversing removal procedure, noting the following points.

• Refer to the figure for proper clamp location and cable routing.

• Adjust cable play to specification referring to “CRUISE CABLE PLAY INSPECTION AND ADJUSTMENT” in this section.

BODY SERVICE 9-1

SECTION 9

BODY SERVICE

WARNING:






• When body servicing, if shock may be applied to air bag system component parts, remove those parts beforehand. (Refer to Section 10B.)

9

NOTE:


• Fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or could result in major repair expense. They must be replaced with one of the same part number of with an equivalent part if replacement becomes necessary.

Do not use a replacement part of lesser quality or substitute a design. Torque values must be used as specified during reassembly to assure proper retention of these parts.

Glass, Windows and Mirror.............................. 9-2

Quarter Window .............................................. 9-2

Body Structure .................................................. 9-3

Under Body Dimensions ................................. 9-3

Body Dimensions ............................................ 9-4

Seat..................................................................... 9-8

Second Seat.................................................... 9-8

Third Seat (If Equipped) .................................. 9-9

Paint and Coatings.......................................... 9-10

CONTENTS

Sealant Application Area............................... 9-10

Undercoating/Anti-corrosion Compound

Application Area............................................ 9-17

Exterior and Interior Trim............................... 9-19

Floor Carpet .................................................. 9-19

Front floor carpet....................................... 9-19

Rear floor carpet (without third seat vehicle)...................................................... 9-20

Head Lining................................................... 9-20

9-2 BODY SERVICE

“A”

4

“c”

“b”

“a” 5

“d”

6

Glass, Windows and Mirror

Quarter Window


Refer to “WINDSHIELD” in this section as removal and installation procedures are basically the same. However, note the followings.

• Before applying primer to glass edge, install molding according to installing position shown in the figure.

• Observe the following precautions when applying adhesive along glass edge.

– Adhesive should be applied evenly especially in height.

– Be careful not to damage primer.

– Press glass against body quickly after adhesive is applied.

Adhesive amount specification (quarter window)

Height “a” : 12 mm (0.47 in.)

Width “b” : 8 mm (0.31 in.)

Width “c” : 16 mm (0.63 in.) for glass front, rear and upper section.

Width “c” : 14 mm (0.55 in.) for glass bottom section.

Position “d” : 177 mm (6.97 in.) for left side glass front section.

Position “d” : 75 mm (2.95 in.) for right side glass front section.

Position “d” : 29 mm (1.15 in.) for glass rear section.

Position “d” : 39 mm (1.54 in.) for glass upper section.

Position “d” : 22 mm (0.87 in.) for glass bottom section.

1. Spacer

2. Glass

3. Molding

4. Adhesive

5. Primer

6. Ceramic print

Under Body Dimensions

Body Structure i j h k l m n o p


a b e f g d h’ g’ c a. Front bumper side installation hole b. 1st mounting installation hole c. Suspension frame front installation hole d. Front strut installation outside hole e. Suspension arm installation rear side hole f. 2nd mounting installation hole g (g’).

φ20 jig hole h (h’). Jig hole

Hole to hole distance : a – g : 1363 mm (53.66 in.) a – g’ : 1574 mm (61.97 in.) b – g : 1291 mm (50.83 in.) b – g’ : 1554 mm (61.18 in.) c – g : 1354 mm (53.31 in.) c – g’ : 1084 mm (42.68 in.) d – f : 1339 mm (52.72 in.) d – g’ : 913 mm (35.94 in.) e – g : 569 mm (22.40 in.) e – g’ : 881 mm (34.68 in.) i. 3rd mounting installation hole j. Lower rod installation hole k. Upper rod installation inside hole l. Lateral rod installation hole m. Rear shock absorber installation hole n. 4th mounting installation hole o. Fuel tank installation rear right side hole p. Fuel tank installation rear left side hole f – g : 200 mm (7.87 in.) f – g’ : 928 mm (36.54 in.) g – h’ : 1488 mm (58.58 in.) g’ – h’ : 1225 mm (48.23 in.) h – i : 181 mm (7.13 in.) h – k : 606 mm (23.86 in.) h – l : 1004 mm (39.53 in.) h – m : 1110 mm (43.70 in.) h – n : 1633 mm (64.29 in.) h – o : 1660 mm (65.35 in.) h – p : 1770 mm (69.68 in.) i – h’ : 1073 mm (42.24 in.) j – h’ : 1029 mm (40.51 in.) k – h’ : 970 mm (38.19 in.) l – h’ : 1353 mm (53.27 in.) m – h’ : 1477 mm (58.15 in.) n – h’ : 1876 mm (73.86 in.) o – h’ : 1781 mm (70.12 in.) p – h’ : 1664 mm (65.51 in.)


Body Dimensions

j’ h’ j j’ h k i’ j i g h c’ d c’ b’ c f e b l b e d c a. Front bumper installation clip hole b (b’). Front bumper installation hole c (c’). Headlight installation hole d (d’). Headlight installation resin nut hole e (e’). Headlight installation bolt hole f (f’). Front fender installation bolt hole

Hole to hole distance : a – g : 276 mm (10.87 in.) a – k : 1000 mm (39.37 in.) b – b’ : 1370 mm (53.94 in.) b – g : 730 mm (28.74 in.) c – c’ : 668 mm (26.30 in.) c – e : 414 mm (16.30 in.) c – g : 406 mm (15.98 in.) c – j : 1029 mm (40.51 in.) c – k : 1000 mm (39.37 in.) d – c’ : 1016 mm (40.00 in.) f g. Center member installation hole h (h’). Fender installation reference hole i (i’). Fender installation hole j (j’). Fender installation reference hole k. Cowl top panel center hole ( φ6) l. Mounting installation hole d – d’ : d – e : d – g : f – f’ : f – h : f – j :

1302 mm (51.26 in.)

189 mm (7.44 in.)

672 mm (26.46 in.) d – k : 968 mm (38.11 in.) e – e’ : 1456 mm (57.32 in.)

1550 mm (61.02 in.)

299 mm (11.77 in.)

811 mm (31.93 in.) g – k : 854 mm (33.62 in.) h – h’ : 1339 mm (52.72 in.) a h – j : 677 mm (26.65 in.) h – j’ : 1504 mm (59.21 in.) h – k : 927 mm (36.50 in.) i – i’ : 1344 mm (52.91 in.) i – j : 391 mm (15.39 in.) i – k : 760 mm (29.92 in.) j – j’ : 1348 mm (53.07 in.) j – k : 676 mm (26.61 in.) l – j : 961 mm (37.83 in.) l – k : 1018 mm (40.08 in.) d’ e’ f’


c b’ b’ a c’ k (k’) m (m’) c e (e’) g (g’) h (h’) b n o f (f’) i (i’) j (j’) d (d’) l (l’) a. Garnish installation clip hole e. Trim installation clip hole f (f’). Scuff installation hole (at rear end) g (g’). Trim installation hole h (h’). Hole in rear door upper hinge in upper part i (i’). Hole in rear door lower hinge in lower part b (b’). Front end of front windshield lower installation section j (j’). Rear scuff installation hole (at front end) c (c’). Front end of front windshield upper installation section k (k’). Trim installation hole d. Hole in front door lower hinge at rear l (l’). Rear door striker lower section installation hole m (m’). Trim installation hole n. Installation hole for front seat front inside o. Installation hole for front seat rear inside

Hole to hole distance : a – c : 982 mm (38.66 in.) b – b’ : 1390 mm (54.72 in.) b – c : 755 mm (29.72 in.) b – c’ : 1406 mm (55.35 in.) c – c’ : 1012 mm (39.84 in.) d – d’ : 1545 mm (60.83 in.) d – n : 800 mm (31.50 in.) e – e’ : 1110 mm (43.70 in.) e – n : 1036 mm (40.79 in.) f – f’ : f – n : g – g’ : g – o : h – h’ : h – o : j – j’ :

1511 mm (59.49 in.)

620 mm (34.41 in.)

1085 mm (42.72 in.)

1099 mm (43.27 in.)

1521 mm (59.88 in.)

901 mm (35.47 in.) i – i’ : 1547 mm (60.91 in.) i – n : 806 mm (31.73 in.)

1511 mm (59.49 in.) j – o : 649 mm (25.55 in.) k – k’ : 1095 mm (43.11 in.) k – o : 1475 mm (58.07 in.) l – l’ : 1513 mm (59.57 in.) l – o : 1273 mm (50.12 in.) m – m’ : 1110 mm (43.70 in.) m – o : 2037 mm (80.20 in.)


h d i c a f j b k g e a. Hole in front door upper hinge at rear b. Hole in front door lower hinge at rear c. Trim installation clip hole d.

φ7 jig hole e. Scuff installation hole (rear end) f. Hole in rear door upper hinge in upper part g. Hole in rear door lower hinge in lower part h. Assistant grip front installation hole i. Trim installation hole j. Door striker lower section installation hole k. Front seat belt installation hole

Hole to hole distance: a – d : 1155 mm (45.47 in.) a – f : 1046 mm (41.18 in.) a – g : 1090 mm (42.91 in.) b – f : 1120 mm (44.09 in.) b – g : c – k : d – e : f – j :

1140 mm (44.88 in.)

1245 mm (49.02 in.)

1174 mm (46.22 in.)

1029 mm (40.51 in.) g – j : 1082 mm (42.60 in.) h – j : 879 mm (34.61 in.) h – k : 1282 mm (50.47 in.) i – k : 1435 mm (56.50 in.)

g’ c f’ b’ b’ a h b b b d f e g f f f’


a. Clip hole in the center of head lining rear installation section b (b’). Innermost end of roof panel installation section c. Installation hole in upper part of back door striker d. Installation hole in uppermost part of upper hinge e. Installation hole in uppermost part of lower hinge f (f’). Innermost end of rear floor tail member installation section g (g’). Installation hole in outer upper section of rear combination right lamp h. Nut hole

Hole to hole distance : a – b’ : 448 mm (17.64 in.) a – f’ : 1054 mm (41.50 in.) a – g’ : 1050 mm (41.34 in.) a – h : 921 mm (36.25 in.) b – b’ : 888 mm (34.96 in.) b – d : 400 mm (15.75 in.) b – e : b – f : b’ – c :

837 mm (32.95 in.)

892 mm (35.12 in.)

650 mm (25.59 in.) b’ – f : 1314 mm (51.73 in.) b’ – h : 996 mm (39.21 in.) c – d : 1245 mm (49.02 in.) c – e : f – f’ : f’ – h : g – g’ : g’ – h :

1293 mm (50.90 in.)

1030 mm (40.55 in.)

512 mm (20.16 in.)

1544 mm (60.79 in.)

806 mm (31.73 in.)


Second Seat

Seat

1. Head restraint

2. Head restraint guide

3. Seat back

4. Tether anchor hook

5. Seat reclining assembly

6. Rod

7. Seat reclining assembly cover

8. Seat cushion

9. Adjuster handle (back side)

10. Seat adjuster

REMOVAL

1) Remove adjuster extension cover.

2) Remove adjuster extension bracket.

3) Remove front and rear adjuster inside covers.

4) Remove adjuster outside covers.

5) Remove second seat mounting bolts.

6) Disassemble and repair seat as necessary.

11. Seat adjuster cover

12. Cover

13. Adjuster extension bracket

14. Adjuster handle (front side)

15. Second seat mounting bolt

16. Rod belt (if equipped)

Tightening torque

INSTALLATION

Reverse removal procedure to install rear seat, noting the following instruction.

• Tighten second seat mounting bolts as specified torque.


Third Seat (If Equipped)

4

5

10 35 N·m (3.5 kg-m)

8

7

1

1

2

3

12

2

6

12

4

5

10 35 N·m (3.5 kg-m)

7

8

9

1. Head restraint

2. Head restraint guide

3. Seat back

4. Seat reclining knob

5. Seat reclining rod

6. Reclining supporter

7. Seat reclining assembly

8. Seat reclining assembly cover

9. Seat cushion

10. Third seat mounting bolt

Tightening torque

REMOVAL

1) Raise the front portion of seat cushion to remove rear seat cushion.

2) Remove 6 mounting bolts to remove seat back.

3) Disassemble and repair seat if necessary.

INSTALLATION

Reverse removal procedure to install rear seat noting the following instruction.

• Tighten third seat mounting bolts as specified torque.


Sealant Application Area

Paint and Coatings

“A” (“B”)

“A”

K

“A” (“B”)

2

“A”

Y

1

“A”

K – K

9

“A”

3

5

7

“A”

4

“A” (“B”)

“A”

H – H

“A”

H

Z

“A”

N

I

N

I K

J

G

J

G

H

“A” (“B”)

10

11

“A” (“B”)

6

J – J

8

“B”

“A” (“B”)

“A” (“B”)

4

1

“A”

6

“A”

I – I

9

“A”

11

VIEW:Y

4

“A”

“C”

12

“A”

T

G – G

VIEW:T N – N

1. Side body inner panel

2. Rear wheel housing outer rear panel

3. Rear wheel housing panel

4. Rear floor panel

5. Tail lower member

6. Center floor panel

7. Front floor panel

8. Center floor member

9. Side sill inner panel

10. Side outer panel

11. Main floor extension panel

12. Rear floor cap

“A” : Apply sealant

“B” : Brush treatment

“C” : Apply sealant between cap and panel

D

D

E

E


“A” (“B”)

“A”

1

“A”

2

3

“A”

“A” (“B”)

4

D – D

1. Cowl top panel

2. Dash panel

3. Cowl front panel

4. Front floor panel

5. Front pillar inner lower panel



2

E – E

5

VIEW:Z


“A” (“B”)

N

C

C

9

L – L

2

1

“A”

3

“A”

7

“A”

1

8

2

“A” (“B”)

A – A

7

N

“A”

2

“A” (“B”)

6

5

4

C – C

“A”

B – B

“A”

1

“A” (“B”)

2

L

L

A

B

“A” (“B”)

1. Rear quarter inner panel

2. Side body outer panel

3. Back pillar outer panel

4. Front pillar inner panel

“A” (“B”)

VIEW:W

W

X

A

B

O

U

V

5. Roof panel

6. Front pillar upper reinforcement

7. Rear wheel housing panel

8. Fuel inlet box

9. Air outlet panel




“A” (“B”)

“A”

“A”

“A” (“B”)

“A”

VIEW:U

QQ

QQ

1

M

VIEW:X

M

4

3

“A”

QQ – QQ

2

1

“A” (“B”)

M – M

“A” (“B”)

“A” (“B”)

“A”

VIEW:V (LH)

“A”

VIEW:V (RH)

1. Side body outer panel

2. Rear wheel housing outer panel

3. Center floor gusset

4. Center floor panel



“A” (“B”)

O


“A”

“C”

VIEW:DD

“D”

“D”

GG – GG

DD

GG

GG

FF

VIEW:FF

BB

“b”

“b”

“A”

CC

“E”

VIEW:EE

“A”

EE

“a”

AA

AA

“C”

“E”

VIEW:CC

VIEW:BB

“A”


“B” : Sealant width (more than 5 mm (0.20 in.) between “a” and “b”)

“C” : Wipe off sealant in this section

“D” : Be free from protrude of sealant outside from this line

“E” : Smooth out sealant with a brush

“C” 15-20 mm

(0.59-0.79 in.)

“A”

“B”

AA – AA


JJ

“A”

LL

“b”

“A”

“C”

“C”

VIEW:LL

“A”

“B”

“A”

VIEW:JJ

KK

“a”

“B”

HH

HH “A”

MM

MM

“a”

“A”

PP

PP

“D”

HH – HH “B”

“A”

VIEW:KK

“B”

NN

NN

“b”

“A”

MM – MM

OO OO

OO – OO

“A”

NN – NN

“A”

“D”

PP – PP


“B” : Smooth out sealant with a brush

“C” : Wipe off sealant in this section

“D” : Sealant width (more than 5 mm (0.20 in.) between “a” and “b”)


“B”


“B” : Smooth out sealant with a brush

“C” : Sealant width C more than 5 mm (0.20 in.)

KK

“A”

KK

“B”

“C”

LL – LL

“A”

LL LL

KK – KK

Undercoating/Anti-corrosion Compound Application Area


“A”

A

A

A – A

“A”

“B”

C

“A”

4

2

3

B – B

B

B

Z

“A”

C

D

D

“A”

“a”

1

“B”

7

6

“A”

5

“b”

D – D

C – C

“a”

VIEW: Z

“B”

“a” : 200 mm (7.87 in.)

“b” : 100 mm (3.94 in.)

“A” : Apply rust proof wax (hot wax 50 µm or more)

“B” : Apply rust proof wax (high viscosity wax 50 µm or more)

1. Side body outer

2. Side sill inner

3. Frame

4. Main floor

5. Side body outer

6. Rear wheel housing

7. Center floor


A

A

Z

“A”

B

B

“A” “A”

3

4

“B”

“A”

A – A

2

C

“A” “B” “A”

VIEW: Z

1

“B”

“B”

“B”

9

“a”

“A”

B – B

“A”

8

“A”

5

1

“b”

7

“B”

“B”

6

C – C

“a” : 30 mm (1.18 in.)

“b” : 100 mm (3.94 in.)

“A” : Apply undercoating (PVC, 400 µm or more)

“B” : Add undercoating (PCV) to cover edges and mating parts

1. Main floor

2. Front fender

3. Front wheel housing

4. Frame

5. Dash panel

6. Extension floor

7. Center floor

8. Rear floor

9. Side sill inner

10. Side sill outer

10

C

Floor Carpet

Exterior and Interior Trim


1. Front floor carpet 2. Dash panel insulation

3

3. Rear floor carpet

Front floor carpet

REMOVAL

1) Remove front and second seats.

2) Remove third seat cushion (if equipped).

3) Remove front and second seat belt lower anchor bolts.

4) Remove dash side trims (1), front side sill scuffs (2), center pillar inner lower trims (3), rear side sill scuffs (4) and rear quarter lower trims (5).

5) Remove parking brake lever cover, console box and console box front extension.

6) Remove front floor carpet.

INSTALLATION

Reverse removal sequence to install front floor carpet noting the following point.

• Tighten seat belt anchor bolts as specified torque referring to

Section 10A.


2

3

Rear floor carpet (without third seat vehicle)

REMOVAL

1) Remove rear luggage mat end garnish (1), rear side sill scuff and rear quarter lower trims (2).

2) Remove luggage hook plate nut (3).

3) Remove rear floor carpet.

INSTALLATION

Reverse removal procedure for installation, noting the following.

1

5

4

3

1

8

7

6

9

2

Head Lining

REMOVAL

1) Remove front side sill scuffs (1), rear side sill scuffs (2), center pillar lower trims (3), center pillar upper trims (4), front pillar upper trims (5) rear luggage mat end garnish (6), rear luggage box (7), rear quarter lower trims (8) and rear quarter upper trims (9).


1

5

1 2

3

4

5

6

3) Remove sliding roof switch and sliding roof trim (if equipped).

4) Remove sun visor assembly (1)

5) Remove map lamp (2), dome lamp (3) and luggage lamp (4).

6) Remove assistant grips (5).

7) Disconnect rear washer hose and roof harness.

8) Remove head lining (6).

NOTE:

For without sunroof model.

Adhesive is used in head lining. Clear adhesive from head lining and roof after removing roof lining.


CAUTION:

Do not remove rear A/C No.2 duct (1) from head lining (2).

If perform this prohibited service, head lining (2) will be broken.

2

4

1 3

2

INSTALLATION

Reverse removal procedure to install head lining noting the following instructions.

• Set roof harness (1) and rear washer hose (2) to head lining

(3) with adhesive tape as shown.

• For without sunroof model

Apply double coated tape (4) to head lining as shown.

1

• Tighten seat belt anchor bolt as specified torque referring to

Section 10A.


RESTRAINT SYSTEM 10-1

SECTION 10

RESTRAINT SYSTEM

WARNING:






Seat Belt......................................................................................................................................... Section 10A

Air Bag System.............................................................................................................................. Section 10B

10

CONTENTS

General Description ....................................... 10-2

10-2 RESTRAINT SYSTEM


1. Driver side seat belt with ELR and pretensioner

(if equipped)

2. Front passenger side seat belt with ELR and pretensioner (if equipped)

3. Second rear seat belt (LH) with A-ELR

4. Second rear seat belt (RH) with A-ELR

5. Second rear seat belt (center) without ELR and

A-ELR

6. Third rear seat belt (LH) with A-ELR (if equipped)

7. Third rear seat belt (RH) with A-ELR

(if equipped)

8. Driver side air bag

9. Passenger side air bag

SEAT BELT WITH ELR

The seat belt with Emergency Locking Retractor (ELR) is designed so that it locks immediately (to prevent the webbing from being pulled out of the retractor any further) when any of the following items is detected as exceeding each set value; speed at which the webbing is pulled out of the retractor, acceleration or deceleration of the vehicle speed, and inclination.

SEAT BELT WITH A-ELR

The automatic and emergency locking retractor (A-ELR) works as an Emergency Locking Retractor (ELR) till its webbing is pulled all the way out and then on as an Automatic Locking Retractor (ALR) till it is retracted fully.

ALR :

Automatically locks when the webbing is pulled out from the retractor and allowed to retract even a little.

Then the webbing can not be pulled out any further, unless it is wound all the way back into the retractor, which releases the lock and allows the webbing to be pulled out.

SEAT BELT WITH PRETENSIONER (IF EQUIPPED)

The seat belt with ELR and a pretensioner has a pretensioner mechanism which operates in linkage with the air bag in addition to the above described ELR. The pretensioner takes up the sag of the seat belt in occurrence of a front collision with an impact larger than a certain set value, thereby enhancing restraint performance.

DRIVER AND FRONT PASSENGER SIDE AIR BAGS

The driver and front passenger side air bags are components of the air bag system. In occurrence of a front collision with an impact larger than a certain set value, they are activated by the ignition signal from SDM to supplement protection offered by the driver and front passenger seat belts.

• the driver air bag (inflator) module is deployed from the center of the steering column

• the passenger air bag (inflator) module from the top of the instrument panel in front of the front passenger seat

For more information, refer to Section 10B “Air Bag System”.

SEAT BELT 10A-1

SECTION 10A

SEAT BELT

WARNING:






CAUTION:


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.

10A

On-Vehicle Service....................................... 10A-2

Service Precautions ................................... 10A-2

Service and diagnosis ............................ 10A-2

Disabling air bag system ........................ 10A-2

Enabling air bag system ......................... 10A-2

Handling and storage ............................. 10A-2

CONTENTS

Disposal ................................................. 10A-2

Front Seat Belt ........................................... 10A-3

Second Rear Seat Belt .............................. 10A-6

Third Rear Seat Belt (If Equipped)............. 10A-7

Tightening Torque Specification ................ 10A-8

10A-2 SEAT BELT


Service Precautions

Service and diagnosis

WARNING:

If replacing seat belt is necessary, replace buckle and ELR (or webbing) together as a set. This is for the reason of ensuring locking of tongue plate with buckle. If these parts are replaced individually, such a locking condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and ELR (or webbing) in a set part.

Before servicing or replacing seat belts, refer to following precautionary items.

• Seat belts should be normal relative to strap retractor and buckle portions.

• Keep sharp edges and damaging objects away from belts. Avoid bending or damaging any portion of belt buckle, latch plate and ELR.

• Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)

• When installing a seat belt anchor bolt, start bolt by hand to prevent cross-threading.

• Use only the correct seat belt anchor bolts and screws and tighten to the correct torque value.

• Do not attempt any repairs on retractor mechanisms or retractor covers. Replace defective assemblies with new replacement parts.

• Keep belts dry and clean at all times.

• If there exist any parts in question, replace such parts.

• Replace belts whose webbing is cut or otherwise damaged.

• Do not put anything into trim panel opening which seat belt webbing passes through.

For Seat Belt with Pretensioner

Refer to “SERVICE AND DIAGNOSIS” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B.

WARNING:

When performing service on or around air bag system components or air bag system wiring, disable the air bag system. Refer to “DISABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under

“ON-VEHICLE SERVICE” in Section 10B.

Failure to follow procedures could result in possible air bag activation, personal injury or unneeded air bag system repairs.

Disabling air bag system

Refer to “DISABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in

Section 10B.

Enabling air bag system

Refer to “ENABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in

Section 10B.

Handling and storage

Refer to “HANDLING AND STORAGE” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B.

Disposal

Refer to “DISPOSAL” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B.

SEAT BELT 10A-3

Front Seat Belt

INSPECTION ON VEHICLE

Seat belts with ALR

As to seat belts with ALR (other than driver side seat belt), check them as follows in addition to above check.

• With vehicle at stop, pull seat belt all the way out, let it retract a little and try to pull it. It should not be pulled out, that is, it should be locked where retracted.

• Let seat belt retract to its original state. Next, pull it half way out, let it retract a little and try to pull it again. It should be pulled out smoothly, that is it should not be locked at this time.

WARNING:

• Never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly.

• Be sure to read “SERVICE PRECAUTIONS”, before starting to work and observe every precaution during work. Neglecting them may result in personal injury or unactivation of the seat belt pretensioner, if necessary.

1. Upper anchor

2. Lower anchor

3. Retractor assembly

4. Buckle

5. Retractor assembly upper mounting bolt

: After tightening lower bolt, tightening upper bolt

6. Yellow connector for seat belt pretensioner

(if equipped)

Tightening Torque

[A] Removal

[B] Installation

10A-4 SEAT BELT

REMOVAL

1) Disconnect negative cable at battery.

2) Disable air bag system referring to “DISABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under

“ON-VEHICLE SERVICE” in Section 10B, if necessary.

3) Remove front pillar lower trim.

4) Disconnect Yellow connector for seat belt pretensioner, if necessary.

a) Release locking of lock lever.

b) After unlocking, disconnect to connector.

5) Remove front seat belts from the vehicle.

INSPECTION

WARNING:

Never measure resistance of pretensioner or disassemble it. Otherwise, personal injury may result.

CAUTION:

If seat belt pretensioner (retractor assembly) was dropped from a height of 30 cm (1 ft) or more, it should be replaced.

Seat belts and attaching parts can affect the vital components and systems of a vehicle. Therefore, they should be inspected carefully and replaced with genuine parts only.

Seat belt

• The seat belt webbing or strap should be free from damage.

• Fully extend the seat belt to make sure there are no twists or tears in it.

Retractor assembly

1) Let the seat belt retract fully to confirm its easy retraction.

• The retractor assembly should lock webbing when pulled quickly.

• The retractor assembly should lock webbing even when tilted (approx. 15°) toward the fore and aft or right and left directions.

2) Check retractor assembly with seat belt pretensioner appearance visually for following symptoms and if any one of them is applicable, replace it with a new one as an assembly.

• Pretensioner has activated.

• There is a crack in seat belt pretensioner (retractor assembly).

• Wire harness or connector is damage.

• Seat belt pretensioner (retractor assembly) is damaged or a strong impact (e.g., dropping) was applied to it.

Anchor bolt

• Inspect all seat belt anchor bolts to verify that they are secure.

• All anchor bolts should be secure and torqued to specification.

Belt latch

• Belt latch should be secure when latched.

• Inspect the seat belt buckle, ensuring that it locks and unlocks easily.

• After buckling the seat belt, tug sharply on the belt, checking that the buckle remains locked.

SEAT BELT 10A-5

Seat belt switch

Check driver side seat belt strap switch for continuity by using ohmmeter.

Seat belt strap switch specification

Without inserted buckle tongue to buckle catch:

Terminal “A” and “B” : Continuity

With inserted buckle tongue to buckle catch:

Terminal “A” and “B” : No continuity ( ∞Ω)

1. Buckle tongue

2. Buckle catch

INSTALLATION

Install in reverse order of removal, noting the followings.

• Seat belt anchor bolts should have an unified fine thread (7/16-20 UNF). Under no circumstances should any different sized or metric screw threads be used.

• Connect Yellow connector for seat belt pretensioner securely and fit seat belt pretensioner connector onto front pillar lower panel, if necessary.

a) Connect connector b) Lock connector with lock lever

• Enable air bag system referring to “ENABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in

Section 10B, if necessary.

10A-6 SEAT BELT

Second Rear Seat Belt

WARNING:

Be sure to read “SERVICE PRECAUTIONS” in this section before starting to work and observe every precaution during work.

35 N·m (3.5 kg-m, 25.5 lb-ft)

35 N·m (3.5 kg-m,

25.5 lb-ft)

2

4

4

4

35 N·m (3.5 kg-m, 25.5 lb-ft)

35 N·m (3.5 kg-m, 25.5 lb-ft)

1. Upper anchor

2. Lower anchor


4. Buckle

Tightening Torque

REMOVAL

Refer to the figure above to remove rear seat belts.

INSPECTION

Check second rear seat belt in the same way as when inspecting front seat belt except pretesioner inspection.

(Refer to “FRONT SEAT BELT” in this section.)

INSTALLATION



SEAT BELT 10A-7

Third Rear Seat Belt (If Equipped)

WARNING:

Be sure to read “SERVICE PRECAUTIONS” in this section before starting to work and observe every precaution during work.

35 N·m (3.5 kg-m,

25.5 lb-ft)

35 N·m (3.5 kg-m,

25.5 lb-ft)

4

4

(a)

(a)

35 N·m (3.5 kg-m, 25.5 lb-ft)

1. Upper anchor

2. Lower anchor


4. Buckle

Tightening Torque

REMOVAL

Refer to the figure above to remove rear seat belts.

INSPECTION

Check third rear seat belt in the same way as when inspecting second rear seat belt. (Refer to “SECOND REAR

SEAT BELT” in this section.)

INSTALLATION



10A-8 SEAT BELT


Fastening part

Upper and lower anchor bolt

Retractor assembly bolt

Retractor assembly screw

Buckle bolt

N•m

35

35

5.5

35


3.5

3.5

0.55

3.5

lb-ft

25.5

25.5

4.0

25.5

AIR BAG SYSTEM 10B-1

SECTION 10B

AIR BAG SYSTEM

WARNING:

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

Vehicle Service” in this section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintended 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 disable the air bag system temporarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could result in possible activation of the air bag system, personal injury or otherwise unneeded air bag system repairs.

CAUTION:


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

10B

NOTE:


General Description ......................................10B-3

System Components and Wiring Location

View and Connectors ..................................10B-4

System Wiring Diagram...............................10B-5

Diagnosis .......................................................10B-6

Diagnostic Trouble Code (DTC) ..................10B-6

Use of Special Tool .....................................10B-6

Intermittents and Poor Connections ............10B-8

Air Bag Diagnostic System Check...............10B-9

Air Bag Diagnostic System Check Flow

Table .........................................................10B-10

DTC Check................................................10B-11

DTC Clearance .........................................10B-12

DTC Table .................................................10B-14

Table A - “AIR BAG” Warning Lamp

Comes ON Steady ....................................10B-16

Table B - “AIR BAG” Warning Lamp Does

Not Come ON............................................ 10B-16

Table C - “AIR BAG” Warning Lamp

Flashes......................................................10B-16

CONTENTS

Table D - “AIR BAG” Warning Lamp

Cannot Indicate Flashing Pattern of DTC . 10B-16

Table E - SDM Cannot Communicate through The Serial Data Circuit................. 10B-21

DTC B1015 - Passenger Air Bag Initiator

Circuit Resistance High............................. 10B-23


Circuit Resistance Low ............................. 10B-23


Circuit Short to Ground ............................. 10B-23


Circuit Short to Power Circuit .................... 10B-23

DTC B1021 – Driver Air Bag Initiator







Circuit Short to Power Circuit .................... 10B-28

10B-2 AIR BAG SYSTEM

DTC B1031 – Power Source Voltage

High........................................................... 10B-33

DTC B1032 – Power Source Voltage

Low ........................................................... 10B-33

DTC B1035 – RH Forward Sensor Circuit

Open or Short to Ground .......................... 10B-36

DTC B1036 – RH Forward Sensor Circuit

Short Between Two Wires or Short to

Power Circuit............................................. 10B-36

DTC B1037 – LH Forward Sensor Circuit

Open or Short to Ground .......................... 10B-36

DTC B1038 – LH Forward Sensor Circuit

Short Between Two Wires or Short to

Power Circuit............................................. 10B-36

DTC B1041 – Driver Pretensioner Initiator







Circuit Short to Power Circuit.................... 10B-40

DTC B1045 – Passenger Pretensioner

Initiator Circuit Resistance High................ 10B-40


Initiator Circuit Resistance Low................. 10B-40


Initiator Circuit Short to Ground ................ 10B-40


Initiator Circuit Short to Power Circuit ....... 10B-40

DTC B1051 – Frontal Crash Detected

(System Activation Command Outputted). 10B-46

DTC B1061 – “AIR BAG” Warning Lamp

Circuit Failure............................................ 10B-47

DTC B1071 – Internal SDM Fault ............. 10B-48

DTC B1013 – System Specifications

Different from SDM Specifications............ 10B-48

On-Vehicle Service ..................................... 10B-49

Service Precautions.................................. 10B-49

Service and diagnosis........................... 10B-49

Disabling air bag system....................... 10B-50

Enabling air bag system........................ 10B-50

Handling and storage............................ 10B-51

Repairs and Inspections Required after an Accident ............................................... 10B-56

Accident with deployment/activation - component replacement ....................... 10B-56

Accident with or without deployment/ activation - component inspections....... 10B-57

SDM .......................................................... 10B-60

Forward Sensor ........................................ 10B-62

Seat Belt Pretensioner.............................. 10B-64

Air Bag (Inflator) Module and Seat Belt

Pretensioner Disposal................................ 10B-65

Deployment/Activation Outside Vehicle .... 10B-66

Deployment/Activation Inside Vehicle....... 10B-72

Deployed Air Bag (Inflator) Module and

Activated Seat Belt Pretensioner

Disposal .................................................... 10B-76

Tightening Torque Specification............... 10B-77

Special Tool ................................................ 10B-77



With the air bag system which includes air bags for both the driver’s and passenger’s sides as well as the seat belt pretensioners (if equipped), the sag of the seat belt is taken up (for seat belt with pretensioner), the driver air bag (inflator) module is deployed from the center of the steering column and the passenger air bag

(inflator) module from the top of the instrument panel in front of the front passenger seat in occurrence of a front collision with an impact larger than a certain set value to supplement protection offered by the driver and front passenger seat belts.

1. Driver side air bag

2. Passenger side air bag

3. Seat belt pretensioner (if equipped)

The air bag system is designed to activate only in severe frontal collisions. It is not designed to activate in rear impacts, side impacts, rollovers, or minor frontal collisions, since it would offer no protection in those types of accidents.


System Components and Wiring Location View and Connectors

CONNECTOR “G27” CONNECTOR “Q02”

CONNECTOR “Q05”

CONNECTOR “Q06”

CONNECTOR “Q07”

16 16

CONNECTOR “Q11”

15

7

1

15 5

15

13

12

2

3

14 6

4

10

CONNECTOR “Q12”

9

11

13

CONNECTOR “Q03”

8

10

9

CONNECTOR “Q01”

1. Air bag harness

2. “AIR BAG” fuse box

3. “AIR BAG” monitor coupler

4. DLC

5. Contact coil assembly



8. SDM

9. Seat belt pretensioner (retractor assembly) (if equipped)

10. Pretensioner harness

11. Ground for air bag system

12. Connector “G03”, “E12”

13. Grommet

14. Instrument panel harness

15. Main harness

16. Forward sensor


System Wiring Diagram

1

2

“Q03”

BLU/BLK

BLK/BLU

3

5

BLU/RED

BLK/WHT

17

18

BLU

Q01-4 IG

BLK/WHT

4

BLU

Q01-2 LA

6 L1

L2

8

ORN/GRN

ORN/BLU

YEL/GRN

YEL/BLU

“E12”

7

PPL/RED

ORN/GRN

ORN/BLU

YEL/GRN

YEL/BLU

“G03”

“G27”

9

“Q04”

10

PPL/RED

Q01-20 SDL

ORN/GRN

Q01-19 SL+

ORN/BLU

Q01-18 SL-

YEL/GRN

Q01-13 SR+

YEL/BLU

Q01-14 SR-

“Q02”

PPL

Q01-15 DNS

BLK

Q01-17 GND

“Q01”

11

“Q01”

D+ Q01-10

GRN/RED

DQ01-9

GRN

“Q06”

WHT

GRN

“Q07”

12V

P+ Q01-7

YEL/RED

YEL

PQ01-8

“Q12”

15

5V DP+ Q01-12

PNK

DPQ01-11

WHT

12

14

WHT

GRN

“Q05”

13

BRN

PP+ Q01-5

5V

PPQ01-6

LT GRN

16

“Q11”

[A]

[B]

[C] “Q01” “Q12”,“G03”, “G27”,“E12”

[A]: Shorting bar

[B]: Air bag harness

6. Connection detection pin

7. To ECM, TCM (if equipped) and ABS control module (if equipped)

[C]: Connector

1. From main fuse

2. Ignition switch

3. “IG METER” fuse

8. To data link connector (DLC)

9. “AIR BAG” monitor coupler

10. Ground for air bag system

11. SDM

4. “AIR BAG” warning lamp in combination meter 12. Contact coil assembly

5. “AIR BAG” fuse 13. Driver air bag (inflator) module


15. Driver seat belt pretensioner (if equipped)

16. Passenger seat belt pretensioner (if equipped)

17. LH Forward sensor

18. RH Forward sensor

19. To seat belt switch

TERMINAL ARRANGEMENT OF SDM (VIEWED FROM HARNESS SIDE)

1. CONNECTOR “Q01” (SDM CONNECTOR)

CONNECTOR “Q01” (SDM connector)

TERMINAL

Q01-1

Q01-2

Q01-3

Q01-4

Q01-5

Q01-6

Q01-7

Q01-8

Q01-9

Q01-10

–

“AIR BAG” warning lamp

Ignition switch (power source)

Passenger pretensioner

(if equipped)

Passenger air bag (inflator) module

Driver air bag (inflator) module

CIRCUIT

–

High

Low

High

Low

Low

High

TERMINAL

Q01-11

Q01-12

Q01-13

Q01-14

Q01-15

Q01-16

Q01-17

Q01-18

Q01-19

Q01-20

CIRCUIT

Driver pretensioner

(if equipped)

RH Forward sensor

Diagnosis switch

–

Ground

LH Forward sensor

Data link connector (DLC)

Low

High

High

Low

Low

High


Diagnosis

WARNING:

To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment other than that specified in this manual. Do not use a non-powered probe type tester.

Instructions in this manual must be followed carefully, otherwise personal injury may result.

Diagnostic Trouble Code (DTC)

The AIR BAG DIAGNOSTIC SYSTEM CHECK must always be the starting point of any air bag system diagnosis. The AIR BAG DIAGNOSTIC SYSTEM CHECK checks for proper “AIR BAG” warning lamp operation and checks for air bag diagnostic trouble codes (DTCs) using on-board diagnosis function or SUZUKI scan tool.

Use of Special Tool

WARNING:

To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment other than that specified in this manual. Do not use a non-powered probe type tester.

Instructions in this manual must be followed carefully, otherwise personal injury may result.

You should be familiar with the tools listed in this section under the heading SPECIAL TOOLS. You should be able to measure voltage and resistance. You should be familiar with proper use of a scan tool such as Air Bag

Driver/Passenger Load Tool, Connector Test Adapter Kit and the Digital Multimeter.

Special tool

(A) : 09932-75020 (Connector Test Adapter Kit)

This must be used whenever a diagnostic procedure requests checking or probing a terminal.

Using the appropriate adapter in the special tool will ensure that no damage to the terminal will occur from the multimeter probe, such as spreading or bending.

The adapter will also give an idea of whether contact tension is sufficient, helping to find an open or intermittent open due to poor terminal contact.


Special tool

(B) : 09932-75010 (Air Bag Driver/Passenger Load Tool)

This tool is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag

(inflator) module deployment.

The load tool has three connectors attached to its case which are electrically functional and serve as resistive load substitutions.

No more than two connectors are used at any time.

One of connectors (“STEERING WHEEL”) is used to substitute the load of followings.

• Driver air bag (inflator) module when it is connected at the top of the column to the contact coil assembly.

• Passenger air bag (inflator) module when it is connected to the air bag harness connector for passenger air bag (inflator) module.

• Each of driver and passenger seat belt pretensioners when it is connected to air bag harness connector for driver and passenger seat belt pretensioner (if equipped).

Another connector (“BASE OF COLUMN”) is used to substitute the load of the driver air bag (inflator) module and the contact coil assembly when it is connected at the base of the column to the air bag wire harness.

The third connector (“PASSENGER INFLATOR”) is not used.

By substituting the resistance of the load tool when called for, a determination can be made as to whether an inflator circuit component is causing system malfunction and which component is causing the malfunction.

The load tool should be used only when specifically called for in the diagnostic procedures.

1. Connector for contact coil and driver air bag (inflator) module

(Located near the base of the steering column)

2. Connector for driver, passenger air bag (inflator) module and driver and passenger seat belt pretensioners
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Suzuki SQ416 2001 Owner's Manual

Assistant Bot

WARNING/CAUTION/NOTE

GENERAL INFORMATION

CONTENTS

Precaution for Vehicles Equipped with A Supplemental Restraint

(Air Bag) System

Diagnosis

Servicing and handling

Vehicle Identification Number

Engine Identification Number

Transmission Identification Number

MAINTENANCE AND LUBRICATION

CONTENTS

Maintenance Schedule under Normal Driving Conditions

Maintenance Recommended under Severe Driving Conditions

Engine and Emission Control

Drive belt inspection and replacement

Engine oil and filter replacement

HEATER AND VENTILATION

CONTENTS

Rear Duct

AIR CONDITIONING (OPTIONAL)

CONTENTS

Refrigerant Type

Refrigerant Flow of Air Conditioning System

Major Components And Location

General

Main A/C system (front A/C system)

Rear A/C system

Quickly Checking of Refrigerant Charge (If

Equipped with Sight Glass)

Performance Diagnosis

Performance diagnosis table

Detail diagnosis table (at ambient temperature within 30 - 35 °C (85 - 95 °F))

Wiring Circuit

Inspection of A/C Controller and Its Circuits

Voltage check

Operation Procedure for Charging A/C with Refrigerant

Recovery

Evacuating

Evacuating procedure

Checking system for pressure leaks

Charging

Precaution

Piping

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

Refrigerant recovery

Refrigerant charge

Replenishing compressor oil

Rear A/C Unit (Rear A/C Evaporator)

Rear Expansion Valve

Rear A/C Evaporator Temperature Controller

Refrigerant Pipes and Hoses

Solenoid Valve

Rear Blower Motor Assembly

Rear Blower Motor Relay and Solenoid Valve

Relay

Rear A/C Main Switch

Rear Blower Motor Resistor

Rear Blower Motor Switch

Rear A/C No.1 and No.2 Duct

Rear A/C No.1 duct

Rear A/C No.2 duct

Compressor Assembly

Magnet Clutch

FRONT END ALIGNMENT

CONTENTS

Alignment Service Data (without Load)

Reference Information

POWER STEERING (P/S) SYSTEM

CONTENTS

Power Steering (P/S) Pump

Power Steering Pump Drive Belt

Belt inspection

Belt tension check

Belt tension adjustment

Hydraulic Pressure in P/S Circuit

Hydraulic pressure check

AIR BAG STEERING WHEEL AND COLUMN