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Suzuki Liana RH418 Supplementary Service Manual

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WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING
CAUTION
,
!
!
lighted 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 technicians only.
Inexperienced technicians or technicians 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 technician and may render the vehicle unsafe for the driver
and passengers.
WARNING
!
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under
"General Description" in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-
vice Precautions" under "On-Vehicle Service" in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
• Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking
process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
The circle with a slash in this manual means "Don't do this" or "Don't let this happen".
IMPORTANT
and NOTE have special meanings. Pay special attention to the messages high-

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Summary of Contents for Suzuki Liana RH418

  • Page 1 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.
  • Page 2 And for any section, item or description not found in this supplement, 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 as specified in each description.
  • Page 3 TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-* Transmission / Transaxle .......... 5-i Precautions .............

  • Page 5: General Information

    Table of Contents 0- i Section 0 General Information CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. General Information ........ 0A-1 PCV Valve Inspection .........
  • Page 6 0A-1 General Information: General Information General Description Transmission Identification Number S3RH0B0101008 The automatic transmission identification number is located on transmission case. I3RH01010004-01...

  • Page 7: Maintenance And Lubrication

    Maintenance and Lubrication: 0B-1 Maintenance and Lubrication Repair Instructions Automatic Transaxle Fluid Inspection Automatic Transaxle Fluid Cooler Hose S3RH0B0206030 Inspection 1) Inspect transaxle case for evidence of fluid leakage. S3RH0B0206032 Check automatic transaxle fluid cooler hose for fluid Repair leaky point, if any. leakage, cracks, damage and deterioration.
  • Page 8 0B-2 Maintenance and Lubrication: Transfer Oil (4WD A/T) and Rear Differential Oil (4WD) Inspection S3RH0B0206033 1) Check transfer case or differential for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove level plug of transfer or differential and check oil level.
  • Page 9 Table of Contents 1- i Section 1 Engine CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........1-1 MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Precautions.............
  • Page 10 1-ii Table of Contents Radiator Fan Control System Check....1A-99 Crankshaft Position (CKP) Sensor and Its Radiator Fan Control Circuit Check ....1A-101 Circuit Inspection..........1C-* Power Steering Pressure (PSP) Switch Signal Vehicle Speed Sensor (VSS) and Its Circuit Circuit Check..........1A-104 Inspection............
  • Page 11 Table of Contents 1-iii Pistons, Piston Rings and Connecting Rods Engine Cooling System Inspection and Components............1D-45 Cleaning .............1F-* Pistons, Piston Rings and Connecting Rods Cooling System Flush and Refill ......1F-* Removal and Installation.........1D-46 Cooling Water Pipes or Hoses Removal and Pistons, Piston Rings, Connecting Rods and Installation ............1F-* Cylinders Disassembly and Assembly ....1D-47...
  • Page 12 1-iv Table of Contents Fuel Tank Inlet Valve Inspection ......1G-* Diagnostic Information and Procedures ....1I-* Fuel Pump On-Vehicle Inspection....... 1G-* Cranking System Symptom Diagnosis ....1I-* Fuel Pump Assembly Components..... 1G-* Cranking System Test...........1I-* Fuel Pump Assembly Removal and Repair Instructions ..........1I-* Installation ............
  • Page 13 Precautions: Precautions Precautions Precautions for Engine S3RH0B1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00 in related manual”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 1A”. Precautions on Fuel System Service Refer to “Precautions on Fuel System Service in Section 1G in related manual”.
  • Page 14 • Diagnostic information stored in ECM memory can be • When raising or supporting engine for any reason, do cleared as well as checked by using SUZUKI scan not use a jack under oil pan. Due to small clearance tool. Before using scan tool, read its Operator’s...
  • Page 15 ECM is shut off for specified time or it is cleared by of “On-Board Diagnostic System Description” and each SUZUKI scan tool.) item in “Precautions in Diagnosing Trouble” and execute ECM also indicates trouble area in memory by means diagnosis according to “Engine and Emission Control...
  • Page 16 Air bag SDM. (1) lights and remains ON as long as the SUZUKI serial data line (6) is used for SUZUKI scan tool trouble exists but it turns OFF when the to communicate with immobilizer control module.
  • Page 17 Engine General Information and Diagnosis: 1A-4 Air Intake System Description S3RH0B1101005 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air control valve (4) and intake manifold (5). The air (by the amount corresponding to manifold absolute pressure (6) 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.
  • Page 18 1A-5 Engine General Information and Diagnosis: Engine and Emission Control System Flow Diagram I3RH0B110001-01...
  • Page 19 Engine General Information and Diagnosis: 1A-6 ECM Input / Output Circuit Diagram C41-9 BLU/YEL C41-11 BLK/RED C41-21 BLU/WHT BLU/RED C41-31 YEL/BLK C41-23 C41-8 BLU/GRN BLK/ORN GRY/RED C41-22 C41-6 GRN/RED GRY/BLU C41-16 BLK/RED C41-4 BLU/BLK LT GRN/RED C41-26 G04-12 C41-13 G04-21 BLK/YEL LT GRN C41-14...
  • Page 20 1A-7 Engine General Information and Diagnosis: 1. CKP sensor 21. A/C compressor relay 41. Ignition coil assembly (for No.1 and No.4 spark plugs) 2. CMP sensor 22. A/C compressor magnet clutch 42. Ignition coil assembly (for No.2 and No.3 spark plugs) 3.
  • Page 21 PPL/WHT Throttle opening signal for for TCM (A/T) TCM (A/T) GRY/RED D-range ID-up signal (A/T) — — PPL/YEL Malfunction indicator lamp — — Data link connector (SUZUKI PNK/GRN Monitor output serial data line) YEL/GRN Engine coolant temp. signal for meter...
  • Page 22 1A-9 Engine General Information and Diagnosis: Engine and Emission Control Input / Output Table S3RH0B1101007 ELECTRIC CONTROL DEVICE OUTPUT INPUT DIAGNOSIS SWITCH BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH POWER STEERING PRESSURE SWITCH LIGHTING SWITCH REAR DEFOGGER SWITCH BLOWER SWITCH A/C SWITCH (IF EQUIPPED) A/C EVAP INLET / OUTLET AIR TEMP .
  • Page 23 Engine General Information and Diagnosis: 1A-10 Schematic and Routing Diagram Engine and Emission Control System Diagram S3RH0B1102001 I3RH0B110003-01 1. Air cleaner 16. CMP sensor 29-2. Test switch terminal 2. EVAP canister purge valve 17. CKP sensor 29-3. Duty output terminal...
  • Page 24 1A-11 Engine General Information and Diagnosis: 3. IAT sensor 18. VSS 30. Stop lamp 4. TP sensor 19. Power steering pressure switch (if equipped) 31. Stop lamp switch 5. IAC valve 20. Radiator fan 32. ECM 6. MAP sensor 21. Malfunction indicator lamp in combination meter 33.
  • Page 25 Engine General Information and Diagnosis: 1A-12 Component Location Electronic Control System Components Location S3RH0B1103001 I3RH0B110004-01 INFORMATION SENSORS CONTROL DEVICES OTHERS 1. MAP sensor a: Fuel injector A: ECM 2. TP sensor b: EVAP canister purge valve B: Main relay 3. IAT sensor c: Fuel pump relay C: EVAP canister 4.
  • Page 26 1A-13 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine and Emission Control System Check S3RH0B1104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
  • Page 27 Engine General Information and Diagnosis: 1A-14 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.
  • Page 28 Diagnosis” and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer complaint analysis, trouble symptom confirmation and/or I3RH0A110008-01 basic engine check) and repair or replace faulty parts, if any. DTC Check S3RH0B1104003 Using SUZUKI Scan Tool 1) Prepare SUZUKI scan tool.
  • Page 29 Using Scan Tool write it down. Refer to scan tool operator’s manual for further details. 1) Connect SUZUKI scan tool to data link connector in If communication between scan tool and ECM is not the same manner as when making this connection possible, check if scan tool is communicable by for DTC check.
  • Page 30 1A-17 Engine General Information and Diagnosis: DTC Table S3RH0B1104005 Detecting condition DTC No. Detecting item (DTC will set when detecting:) P0011 Camshaft position-Timing over- Actual valve of advanced valve timing does not reach (No.32) advanced or system performance target value, or valve timing is advanced although 1 driving cycle P0012 Camshaft position-Timing over-...
  • Page 31 Engine General Information and Diagnosis: 1A-18 Fail-Safe Table S3RH0B1104006 When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC No.
  • Page 32 1A-19 Engine General Information and Diagnosis: Scan Tool Data S3RH0B1104007 As the data values 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.
  • Page 33 Engine General Information and Diagnosis: 1A-20 Normal condition / Scan tool data Vehicle condition reference values VVT (CAMSHAFT At specified idle speed after warning up 0 – 3° POSITION) GAP (TARGET- ACTUAL POSITION) Throttle valve fully closed 0.5 – 1.0 V TP SENSOR VOLT Ignition switch ON / (THROTTLE POSITION...
  • Page 34 1A-21 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values Blower motor switch and A/C switch turned ON / ECT over 110 °C, 230 °F A/C COND FAN (if equipped Engine running with A/C) Blower motor switch and/or A/C switch turned OFF A/C PRESSURE SW (if...
  • Page 35 Engine General Information and Diagnosis: 1A-22 VVT (CAMSHAFT POSITION) GAP [TARGET-ACTUAL ELECTRIC LOAD (ON/OFF) POSITION] (°) ON: Headlight, small light or rear window defogger ON It is calculated using the formula: target valve timing signal inputted. advance – actual valve timing advance. OFF: Above electric loads all turned OFF.
  • Page 36 1A-23 Engine General Information and Diagnosis: Visual Inspection S3RH0B1104008 Visually check the following parts and systems. Inspection item Referring section • Engine oil – level, leakage “Engine Oil and Filter Change in Section 0B in related manual” • Engine coolant – level, leakage “Engine Coolant Change in Section 0B in related manual”...
  • Page 37 4) Check engine idle speed with scan tool. I2RH01110005-01 Is it 610 – 710 r/min. (650 – 750 r/min. for A/T vehicle)? Do you have SUZUKI scan tool? Go to Step 8. Go to Step 7. Check ignition timing as follows: Go to “Engine Symptom...
  • Page 38 Check ignition timing as follows: Go to “Engine Symptom Check ignition control Diagnosis”. related parts referring to 1) Select “MISC” mode on SUZUKI scan tool and fix “Ignition Timing ignition timing to initial one. Inspection in Section 1H in related manual”.
  • Page 39 Engine General Information and Diagnosis: 1A-26 Step Action 13 Check ignition spark as follows: Go to Step 14. Go to “Ignition System Symptom Diagnosis in 1) Disconnect injector couplers. Section 1H in related 2) Remove spark plugs and connect them to high tension manual”.
  • Page 40 1A-27 Engine General Information and Diagnosis: Engine Symptom Diagnosis S3RH0B1104010 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection” and “Engine Basic Inspection”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug “Spark Plug Inspection in Section 1H in related...
  • Page 41 Engine General Information and Diagnosis: 1A-28 Condition Possible cause Correction / Reference Item Engine noise – Valve Improper valve lash “Camshaft, Tappet and shim Inspection in noise Section 1D” Worn valve stem and guide “Valves and Valve Guides Inspection in NOTE Section 1D”...
  • Page 42 1A-29 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection in Section 1F in related manual” Poor water pump performance “Water Pump Inspection in Section 1F in related manual” Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning in Section 1F in related manual”...
  • Page 43 Engine General Information and Diagnosis: 1A-30 Condition Possible cause Correction / Reference Item Poor gasoline mileage Leaks or loose connection of high- “High-Tension Cord Inspection in Section 1H in tension cord related manual” Faulty spark plug (improper gap, heavy “Spark Plug Inspection in Section 1H in related deposits and burned electrodes, etc.) manual”...
  • Page 44 1A-31 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Excessive engine oil Sticky piston ring “Cylinders, Pistons and Piston Rings consumption – Oil Inspection in Section 1D” entering combustion Worn piston and cylinder “Cylinders, Pistons and Piston Rings chamber Inspection in Section 1D”...
  • Page 45 Engine General Information and Diagnosis: 1A-32 Condition Possible cause Correction / Reference Item Surge – Engine power Leaky or loosely connected high-tension “High-Tension Cord Inspection in Section 1H in variation under steady cord related manual” throttle or cruise. Feels Faulty spark plug (excess carbon “Spark Plug Inspection in Section 1H in related like vehicle speeds up deposits, improper gap, and burned...
  • Page 46 1A-33 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection in Section 1H in related manual” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including Igniter) Inspection in Section 1H in related manual” Leaks, loose connection or “High-Tension Cord Inspection in Section 1H in disconnection of high-tension cord...
  • Page 47 Engine General Information and Diagnosis: 1A-34 Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection in Section 1H in related engine fails to idle manual” Leaky or disconnected high-tension cord “High-Tension Cord Inspection in Section 1H in related manual”...
  • Page 48 1A-35 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection in Section 1H in related (HC) emission or carbon manual” monoxide (CO) Leaky or disconnected high-tension cord “High-Tension Cord Inspection in Section 1H in related manual”...
  • Page 49 Engine General Information and Diagnosis: 1A-36 Malfunction Indicator Lamp Does Not Come ON at Ignition Switch ON (But Engine at Stop) S3RH0B1104011 Wiring Diagram C41-27 PPL/WHT BLK/WHT G04-23 G04-15 PNK/BLK BLK/YEL BRN/WHT G04-10 G03-17 PNK/GRN BLK/RED BLK/RED G04-6 G03-7 PPL/YEL BLK/RED G04-5 C41 (31P)
  • Page 50 1A-37 Engine General Information and Diagnosis: Troubleshooting Step Action MIL power supply check Go to Step 4. Go to Step 2. 1) Turn ignition switch to ON position. Do other warning lights come ON? METER fuse check Go to Step 3. Replace “METER”...
  • Page 51 Engine General Information and Diagnosis: 1A-38 Malfunction Indicator Lamp Remains ON after Engine Starts S3RH0B1104012 Wiring Diagram C41-27 PPL/WHT BLK/WHT G04-23 G04-15 PNK/BLK BLK/YEL BRN/WHT G04-10 G03-17 PNK/GRN BLK/RED BLK/RED G04-6 G03-7 PPL/YEL BLK/RED G04-5 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110012-01...
  • Page 52 1A-39 Engine General Information and Diagnosis: MIL Flashes at Ignition Switch ON S3RH0B1104013 Wiring Diagram C41-27 PPL/WHT BLK/WHT G04-23 G04-15 PNK/BLK BLK/YEL BRN/WHT G04-10 G03-17 PNK/GRN BLK/RED BLK/RED G04-6 G03-7 PPL/YEL BLK/RED G04-5 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110012-01 1.
  • Page 53 Engine General Information and Diagnosis: 1A-40 MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Terminal S3RH0B1104014 Wiring Diagram C41-27 PPL/WHT BLK/WHT G04-23 G04-15 PNK/BLK BLK/YEL BRN/WHT G04-10 G03-17 PNK/GRN BLK/RED BLK/RED G04-6 G03-7 PPL/YEL BLK/RED G04-5 C41 (31P) G04 (24P)
  • Page 54 1A-41 Engine General Information and Diagnosis: MIL Does Not Light at Ignition Switch ON and Engine Does Not Start Through It Is Cranked Up S3RH0B1104015 Wiring Diagram G04-23 BLK/WHT BLK/ORN C41-1 BLK/YEL BRN/WHT G04-10 C41-2 BLK/RED G04-6 C41-3 BLK/RED G04-5 C41 (31P) G04 (24P) G03 (17P)
  • Page 55 Engine General Information and Diagnosis: 1A-42 Troubleshooting Step Action Fuse check Go to Step 2. Replace fuse and check for short in circuits 1) Check for fuse blow at “IG” fuse and “FI” fuse (1). connected to this fuse. I2RH01110053-01 Are fuses in good condition? Main relay circuit check Go to Step 3.
  • Page 56 1A-43 Engine General Information and Diagnosis: Step Action Main relay circuit check Go to Step 6. Go to Step 8. 1) Turn ignition switch to OFF position. 2) Install main relay to main fuse box. 3) Measure voltage between “G04-10” wire terminal of ECM connector and body ground.
  • Page 57 Engine General Information and Diagnosis: 1A-44 DTC P0011 (No. 32) / P0012 (No. 32): Camshaft Position-Timing Over-Advanced or System Performance / Timing Over-Retarded S3RH0B1104055 Wiring Diagram G04-12 C41-1 BLK/ORN BLK/YEL G04-21 C41-2 C41-3 [A]: C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0B110005-01...
  • Page 58 1D”. temperature. If OK, go to Step 5. 3) Select menu to DATA LIST. 4) Check that the VVT GAP displayed on SUZUKI scan tool is 0 – 5°. Is it OK? Camshaft position control signal check Substitute a known- Go to Step 5.
  • Page 59 Engine General Information and Diagnosis: 1A-46 Step Action Check oil control valve Replace camshaft Replace oil control timing sprocket. valve. 1) Check oil control valve referring to “Oil Control Valve Inspection in Section 1C”. Is it in good condition? NOTE Upon completion of inspection and repair work, perform “DTC Confirmation Procedure”...
  • Page 60 1A-47 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) Clear DTC, start engine and keep it at idle for 1 min. 2) Select “DTC” mode on scan tool and check DTC. DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2.
  • Page 61 Engine General Information and Diagnosis: 1A-48 DTC P0110 (No. 18): Intake Air Temp. (IAT) Circuit Malfunction S3RH0B1104017 Wiring Diagram LT GRN/BLK C41-15 C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110024-01 1. From other sensors DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause •...
  • Page 62 1A-49 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check IAT sensor and its circuit Go to Step 3. Intermittent trouble.
  • Page 63 Engine General Information and Diagnosis: 1A-50 DTC P0115 (No. 19): Engine Coolant Temp. (ECT) Circuit Malfunction S3RH0B1104018 Wiring Diagram C41-14 LT GRN C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110025-01 1. From other sensors DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause •...
  • Page 64 1A-51 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check ECT sensor and its circuit Go to Step 3. Intermittent trouble.
  • Page 65 Engine General Information and Diagnosis: 1A-52 DTC P0120 (No. 13): Throttle Position Circuit Malfunction S3RH0B1104019 Wiring Diagram C41-22 GRY/RED C41-16 GRY/BLU C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110026-01 1. To MAP sensor and CO adjust resistor (if equipped) 2.
  • Page 66 1A-53 Engine General Information and Diagnosis: Step Action Check TP sensor and its circuit Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch OFF and Check for intermittent then turn ignition switch ON. referring to “Intermittent and Poor Connection 2) Check throttle valve opening percentage displayed on Inspection in Section 00...
  • Page 67 Engine General Information and Diagnosis: 1A-54 DTC P0130 (No. 14): Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1) S3RH0B1104021 Wiring Diagram C41-13 C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110015-01 1. From other sensors DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause •...
  • Page 68 1A-55 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Is there DTC(s) other than HO2S-1 (DTC P0130)? Go to applicable DTC Go to Step 3.
  • Page 69 Engine General Information and Diagnosis: 1A-56 DTC P0135 (No. 14): Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1) S3RH0B1104024 Wiring Diagram BLK/WHT PNK/BLK C41-7 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110016-01 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause DTC will set when one of the following conditions is met.
  • Page 70 1A-57 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check heater for operation Intermittent trouble. Go to Step 3. 1) Check voltage at terminal “C41-7”.
  • Page 71 Engine General Information and Diagnosis: 1A-58 DTC P0325 (No. 17): Knock Sensor Circuit Malfunction S3RH0B1104029 Wiring Diagram C41-25 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110019-01 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause •...
  • Page 72 1A-59 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check knock sensor signal Intermittent trouble or Go to Step 3. faulty ECM.
  • Page 73 Engine General Information and Diagnosis: 1A-60 DTC P0335 (No. 23): Crankshaft Position (CKP) Sensor Circuit Malfunction S3RH0B1104030 Wiring Diagram I2RH0B110046-01 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause No CKP sensor signal for 2 sec. at engine cranking. •...
  • Page 74 1A-61 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check CKP sensor and connector for proper installation Go to Step 3. Correct.
  • Page 75 Engine General Information and Diagnosis: 1A-62 Step Action Check CKP sensor for operation Go to Step 7. Replace CKP sensor. 1) Remove CKP sensor from cylinder block. 2) Remove metal particles on end face of CKP sensor, if any. 3) Connect each connector to ECM and CKP sensor. 4) Turn ignition switch ON.
  • Page 76 1A-63 Engine General Information and Diagnosis: DTC P0340 (No. 15): Camshaft Position (CMP) Sensor Circuit Malfunction S3RH0B1104031 Wiring Diagram BLK/RED C41-11 BLK/ORN C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110051-01 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause No CMP sensor signal during engine running (CKP sensor •...
  • Page 77 Engine General Information and Diagnosis: 1A-64 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check CMP sensor and connector for proper installation Go to Step 3. Correct.
  • Page 78 1A-65 Engine General Information and Diagnosis: Step Action Check CMP sensor for operation Go to Step 7. Replace CMP sensor. 1) Remove CMP sensor from timing chain cover. 2) Remove metal particles on end face of CMP sensor, if any. 3) Connect each connector to ECM and CMP sensor.
  • Page 79 Engine General Information and Diagnosis: 1A-66 DTC P0500 (No. 16): Vehicle Speed Sensor (VSS) Malfunction S3RH0B1104036 Wiring Diagram BLK/RED G04-24 BLK/ORN 3, +B BLK/RED G04 -24 BLK/ORN C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110024-01 [A]: M/T vehicle 2.
  • Page 80 1A-67 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Is vehicle equipped A/T? Go to Step 10. Go to Step 3. Does speedometer indicate vehicle speed? Go to Step 4.
  • Page 81 Engine General Information and Diagnosis: 1A-68 Step Action Check VSS signal circuit Go to Step 8. “PPL” wire open or short. Poor connection 1) Measure voltage from terminal “a” of VSS connector to of ECM connector ground. terminal. If OK, substitute a known-good ECM and recheck.
  • Page 82 1A-69 Engine General Information and Diagnosis: Step Action 12 Check vehicle speed signal circuit Go to Step 13. Go to Step 15. 1) Turn ignition switch OFF position. 2) Disconnect connector from TCM. 3) Turn ignition switch to ON position, without running engine.
  • Page 83 Engine General Information and Diagnosis: 1A-70 DTC P0601: Internal Control Module Memory Check Sum Error S3RH0B1104038 System Description Internal control module is installed in ECM. DTC Detecting Condition and trouble Area DTC detecting condition Possible cause Data write error or check sum error DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.
  • Page 84 1A-71 Engine General Information and Diagnosis: DTC P1915 (No. 33): Oil Control Valve Circuit S3RH0B1104056 Wiring Diagram G04-12 C41-1 BLK/ORN BLK/YEL G04-21 C41-2 C41-3 [A]: C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0B110007-01 [A]: Oil flow 2. ECM 4.
  • Page 85 Engine General Information and Diagnosis: 1A-72 Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check” in this section. Check oil control valve circuit Go to Step 3. Go to Step 5.
  • Page 86 1A-73 Engine General Information and Diagnosis: Voltage Check 1) Remove ECM (1) from vehicle body referring to “Engine Control Module (ECM) Removal and Installation in Section 1C in related manual”. 2) Check voltage and/or pulse signal at each terminal of couplers (2) connected, using voltmeter (3) and oscilloscope (4).
  • Page 87 Engine General Information and Diagnosis: 1A-74 Terminal No. Circuit Normal Voltage Condition C41-1 Ground Below 0.3 V Ignition switch turned ON C41-2 Ground Below 0.3 V Ignition switch turned ON C41-3 Ground Below 0.3 V Ignition switch turned ON 10 – 14 V Ignition switch turned ON with engine stop *0 –...
  • Page 88 1A-75 Engine General Information and Diagnosis: Terminal No. Circuit Normal Voltage Condition C41-18 — — — 0 – 1 V Ignition switch turned ON *0 – 0.6 V ↑↓ Engine running. C41-19 Ignition coil No.2 4 – 6 V (Output signal is active high pulse. Pulse (Reference waveform frequency varies depending on engine speed.) No.6)
  • Page 89 Engine General Information and Diagnosis: 1A-76 Terminal No. Circuit Normal Voltage Condition G04-5 Power source 10 – 14 V Ignition switch ON G04-6 Power source 10 – 14 V Ignition switch ON A/C refrigerant pressure below 1500 kPa, 15 kg/ 0 –...
  • Page 90 10 – 14 V When engine running Data link connector G03-8 4 – 6 V Ignition switch ON (SUZUKI serial data line) *0 – 1 V Ignition switch turned ON. ↑↓ (Output signal is active low duty pulse. Duty ratio Engine coolant temp.
  • Page 91 Engine General Information and Diagnosis: 1A-78 1. Reference waveform No.1 3. Reference waveform No.3 Oil control valve signal at ignition switch ON Heated oxygen sensor-1 signal at engine idling Measurement CH1: G04-12 to G04-21 Measurement CH1: C41-13 to C41-10 terminal terminal CH2: C41-7 to C41-1 Oscilloscope setting CH1: 5 V/DIV...
  • Page 92 1A-79 Engine General Information and Diagnosis: 5. Reference waveform No.5 7. Reference waveform No.7 IAC valve signal Ignition coil No.1 and No.4 signal at engine idling Measurement CH1: C41-6 to C41-1 Measurement CH1: C41-11 to C41-1 terminal terminal CH2: C41-20 to C41-1 Oscilloscope setting CH1: 5 V/DIV Oscilloscope setting CH1: 2 V/DIV, CH2: 2 V/DIV TIME: 4 ms/DIV...
  • Page 93 Engine General Information and Diagnosis: 1A-80 9. Reference waveform No.9 11. Reference waveform No.11 No.4 fuel injector signal at engine idling No.2 fuel injector signal at engine idling Measurement CH1: C41-11 to C41-1 Measurement CH1: C41-11 to C41-1 terminal CH2: C41-8 to C41-1 terminal CH2: C41-21 to C41-1 Oscilloscope setting CH1: 5 V/DIV, CH2: 20 V/DIV...
  • Page 94 1A-81 Engine General Information and Diagnosis: 13. Reference waveform No.13 15. Reference waveform No.15 Knock sensor signal at engine speed 4000 r/min. CMP sensor signal at engine idling Measurement CH1: C41-25 to C41-1 Measurement CH1: C41-11 to C41-1 terminal terminal CH2: C41-23 to C41-1 Oscilloscope setting CH1: 1 V/DIV Oscilloscope setting CH1: 2 V/DIV, CH2: 2 V/DIV...
  • Page 95 Engine General Information and Diagnosis: 1A-82 17. Reference waveform No.17 19. Reference waveform No.19 Manifold absolute pressure sensor signal at engine Tachometer (Ignition pulse) signal at engine idling racing Measurement CH1: C41-11 to C41-1 Measurement CH1: C41-26 to C41-10 terminal CH2: G03-1 to C41-1 terminal CH2: C41-16 to C41-10...
  • Page 96 1A-83 Engine General Information and Diagnosis: 21. Reference waveform No.21 23. Reference waveform No.23 Engine coolant temperature signal at engine idling Ignition coil signal and fuel injector signal at engine cranking Measurement CH1: C41-14 to C41-10 terminal CH2: G03-9 to C41-1 Measurement CH1: C41-20 to C41-1 Oscilloscope setting CH1: 500 mV/DIV, CH2: 5 V/DIV...
  • Page 97 Engine General Information and Diagnosis: 1A-84 Resistance Check 1) Disconnect ECM couplers (1) from ECM with ignition switch OFF. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Check resistance between each pair of terminals of disconnected couplers as listed in the following table. CAUTION •...
  • Page 98 1A-85 Engine General Information and Diagnosis: Fuel Injector Circuit Check S3RH0B1104045 Wiring Diagram C41-9 BLU/YEL BLK/RED BLU/WHT C41-21 BLU/RED C41-31 BLU/GRN C41-8 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110078-01 1. No.1 injector 3. No.3 injector 2. No.2 injector 4.
  • Page 99 Engine General Information and Diagnosis: 1A-86 Fuel Pump and Its Circuit Check S3RH0B1104046 Wiring Diagram C41-24 BLK/RED BLK/RED C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110079-01 1. Fuel pump relay 2. Fuel pump Troubleshooting CAUTION Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ECM, wire harness, etc.
  • Page 100 1A-87 Engine General Information and Diagnosis: Step Action Check fuel pump for operation Go to Step 3. “PNK”, “BLK” or “BLK/ RED” circuit open or 1) Remove fuel pump relay from relay box with ignition fuel pump malfunction. switch turned OFF. 2) Check for proper connection to fuel pump relay at each terminals.
  • Page 101 Engine General Information and Diagnosis: 1A-88 Fuel Pressure Check S3RH0B1104047 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I2RH0B110082-01 1. Injector 3. Fuel pressure regulator 2. Delivery pipe 4. Fuel pump Troubleshooting Step Action Check fuel pressure Go to Step 2. Go to Step 5.
  • Page 102 1A-89 Engine General Information and Diagnosis: Step Action With fuel pump operated and fuel return hose blocked by Faulty fuel pressure Shortage of fuel or fuel pinching it, is fuel pressure applied? regulator. pump or its circuit malfunction (refer to “Fuel Pump and Its Circuit Check”).
  • Page 103 (closed throttle position) system, PCV valve and and ECT sensor for EVAP canister purge performance. control system. If sensors are OK, substitute a known- good ECM. Is SUZUKI scan tool available? Go to Step 10. Go to Step 11.
  • Page 104 10 Check PNP signal (“D” range signal) Go to Step 12. Repair or replace. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check PNP signal (“P/N” and “D” range) on display when shifting selector lever to each range.
  • Page 105 Circuit is in good Go to Step 4. condition. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF, set parking brake and block drive wheels. 2) Warm up engine to normal operating temperature. 3) Clear DTC and select “MISC TEST” mode on SUZUKI scan tool.
  • Page 106 1A-93 Engine General Information and Diagnosis: Step Action Check wire harness for open and short Replace IAC valve and Repair or replace. recheck. 1) Turn ignition switch OFF. 2) Disconnect IAC valve coupler. 3) Check for proper connection to IAC valve at each terminals.
  • Page 107 Engine General Information and Diagnosis: 1A-94 Troubleshooting 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”...
  • Page 108 1A-95 Engine General Information and Diagnosis: Step Action Check A/C condenser fan control relay and its circuit Go to Step 5. “BLU/YEL” wire open or short. Poor “G04-9” 1) Check voltage at terminal “G04-9” under each condition terminal connection. given as follows. If wire and connection Voltage at terminal “G04-9”...
  • Page 109 Engine General Information and Diagnosis: 1A-96 Step Action Check A/C condenser fan “RED/BLU” or “BLK” Replace A/C condenser circuit open. fan motor. 1) Turn ignition switch OFF. 2) Disconnect A/C condenser fan motor connector (1). 3) Check for proper connection to motor at “RED/BLU” and “BLK”...
  • Page 110 1A-97 Engine General Information and Diagnosis: Step Action Check A/C compressor control relay Go to Step 10. Replace A/C compressor control 1) Turn ignition switch OFF and remove A/C compressor relay. control relay (1). 2) Check for proper connection to relay at terminals “c” and “d”.
  • Page 111 Check electric load signal circuit Electric load signal “YEL/BLK” and/or “BLU/ circuit is in good BLK” circuit open or 1) Connect SUZUKI scan tool to DLC with ignition switch condition. short, electric load OFF. diodes malfunction or 2) Start engine and select “DATA LIST” mode on scan tool.
  • Page 112 1A-99 Engine General Information and Diagnosis: Step Action Check electric load signal circuit Electric load signal “YEL/BLK” and/or “BLU/ circuit is in good BLK” circuit open or 1) Turn ignition switch ON. condition. short, electric load 2) Check voltage at each terminals “G04-17” and “G03-10” diodes malfunction or of ECM connector connected, under above each each electric load circuit...
  • Page 113 Engine General Information and Diagnosis: 1A-100 Troubleshooting Step Action Is there DTC(s) ECT sensor circuit (DTC P0115)? Go to corresponding Go to Step 2. DTC flow. Check low speed radiator fan control circuit Go to Step 3. Perform from Step 1 to Step 6 in “Radiator Fan 1) Connect scan tool to DLC with ignition switch OFF.
  • Page 114 1A-101 Engine General Information and Diagnosis: Step Action Check radiator fan control No.3 Go to Step 11. “BLU” wire is open circuit or high resistance 1) Connect radiator fan control relay No.3 to relay box with in circuit. ignition switch turn OFF. 2) Run engine until ECT is over 102 °C, 216 °F.
  • Page 115 Engine General Information and Diagnosis: 1A-102 Step Action Check wire circuit Go to Step 2. “BLK/WHT” and/or “BLU/WHT” wire open 1) Disconnect radiator fan control relay No.1 (1) from relay circuit. box with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between each engine ground to “BLK/WHT”...
  • Page 116 1A-103 Engine General Information and Diagnosis: Step Action Check radiator fan control relay No.1 “BRN” wire open circuit. Replace relay. 1) Check radiator fan control relay No.1, referring to “Radiator Fan Relay No.1, No.2 and No.3 Inspection in Section 1C in related manual”. Is result in good condition? Check radiator fan control No.1 Go to Step 7.
  • Page 117 Engine General Information and Diagnosis: 1A-104 Step Action Check wire circuit Go to Step 12. “GRN/RED” wire shorted to power supply 1) Turn ON ignition switch. circuit. 2) Check voltage between “G04-3” terminal wire and vehicle body ground. Is voltage 0 V? 12 Check radiator fan control relay No.2 and No.3 “GRN/RED”...
  • Page 118 PSP switch signal circuit check Signal circuit is in good Go to Step 4. condition. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Start engine and select “DATA LIST” mode on scan tool. 3) Check power steering pressure switch.
  • Page 119 Engine General Information and Diagnosis: 1A-106 Generator Control Signal Circuit Check S3RH0B1104054 Wiring Diagram RED/BLU C41-12 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110090-01 1. Generator Circuit Description ECM sends signal (0 – 1 V) to generator terminal C to suspend charging during vehicle take off or fast acceleration. Troubleshooting Step Action...
  • Page 120 Before starting engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. 1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF, if it is available. Special tool...
  • Page 121 When without using SUZUKI scan tool: NOTE IAC duty can be checked not only using SUZUKI scan tool but also using diagnosis connector. Set tachometer. ii) Using service wire (2), ground “Diag. switch terminal” (4) in diagnosis connector (3) and connect duty meter (1) between “Duty output terminal”...
  • Page 122 This tool is included in fuel pressure gauge set (09912- pressure gauge set (09912- 58413). 58413). 09912–58490 SUZUKI scan tool 3-way joint & hose — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
  • Page 123 Aux. Emission Control Devices: 1B-1 Aux. Emission Control Devices Repair Instructions Vacuum Passage Inspection S3RH0B1206005 Start engine and run it at idle speed. Disconnect vacuum hose (1) from EVAP canister purge valve (2). With finger placed against hose disconnected, check that vacuum is applied. If it is not applied, clean vacuum passage by blowing compressed air.
  • Page 124 1C-1 Engine Electrical Devices: Engine Electrical Devices Repair Instructions Idle Air Control (IAC) Valve Removal and Idle Air Control (IAC) Valve Inspection S3RH0B1306002 Installation 1) Connect each connector to IAC valve (1), TP sensor S3RH0B1306001 Removal and IAT sensor. 1) Remove throttle body from intake manifold referring 2) Check that rotary valve (2) of lAC valve opens and to “Throttle Body Removal and Installation in Section closes once and then stops in about 60 ms as soon...
  • Page 125 Engine Electrical Devices: 1C-2 Oil Control Valve Removal and Installation 2) Check resistance between terminals of oil control S3RH0B1306020 valve. Removal Resistance of oil control valve Remove oil gallery pipe No.1 (1) and oil control valve (2) 6.7 – 7.7 Ω at 20 °C (68 °F) from timing chain cover (3).
  • Page 126 1C-3 Engine Electrical Devices: Oxygen Sensor Heater Inspection Camshaft Position (CMP) Sensor Removal and S3RH0B1306012 Installation 1) Disconnect sensor connector. S3RH0B1306013 Removal 2) Using ohmmeter, measure resistance between 1) Disconnect negative cable at battery. terminals “V ” and “GND” of sensor connector. If found faulty, replace oxygen sensor.
  • Page 127 Engine Mechanical: 1D-1 Engine Mechanical General Description Engine Construction Description S3RH0B1401001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration consisting of 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
  • Page 128 1D-2 Engine Mechanical: Variable Valve Timing (VVT) System Description S3RH0B1401002 System Description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high.
  • Page 129 Engine Mechanical: 1D-3 Oil control valve Timing advancing The oil control valve switches and adjusts the hydraulic When the duty ratio of the signal output from the ECM is pressure applied to the cam timing sprocket by moving heavy, the spool valve (4) of the oil control valve moves the spool valve (1) according to the duty pulse signals to the left (opposite direction against the coil (5)).
  • Page 130 1D-4 Engine Mechanical: Timing retarding When the duty ratio of the signal output from the ECM is light, the spool valve of the oil control valve moves to the right (head for the coil). By this spool valve movement, the pressurized oil is led into the chambers for timing retarding and the oil in the chambers for timing advancing is drained.
  • Page 131 Engine Mechanical: 1D-5 Diagnostic Information and Procedures Compression Check 8) Install special tool (Compression gauge) into spark S3RH0B1404001 plug hole. Check compression pressure on all 4 cylinders as Special tool follows: (A): 09915–64512 1) Warm up engine to normal operating temperature. (B): 09915–64530 2) Stop engine after warming up.
  • Page 132 1D-6 Engine Mechanical: 11) Carry out Steps 8) through 10) on each cylinder to 2) Stop engine and turn off the all electric switches. obtain 4 readings. 3) Remove engine cover (1). 12) After checking, install spark plugs and ignition coil assembles (1) with high-tension cord (2).
  • Page 133 Engine Mechanical: 1D-7 Valve Lash (Clearance) Inspection If valve lash is out of specification, record valve lash and S3RH0B1404003 adjust it to specification by replacing shim. 1) Remove negative cable at battery. Valve clearance specification 2) Remove cylinder head cover referring to “Cylinder When cold (Coolant When hot (Coolant Head Cover Removal and Installation”.
  • Page 134 1D-8 Engine Mechanical: Replacement of Shim c) Hold down the tappet so as not to contact the shim by installing special tool on camshaft 1) Close the valve whose shim (2) is to be replaced by housing with housing bolt (1) tighten housing turning crankshaft, then turn tappet (3) till its cut bolts to specified torque.
  • Page 135 Engine Mechanical: 1D-9 5) Using a micrometer (2), measure the thickness of 7) Install new shim facing shim No. side with tappet. the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table. Shim thickness specification Intake side: A = B + C –...
  • Page 136 1D-10 Engine Mechanical: Repair Instructions Air Cleaner Element Removal and Installation Accelerator Cable Adjustment S3RH0B1406001 S3RH0B1406003 Removal With accelerator pedal depressed fully, check clearance between throttle lever (1) and lever stopper (2) (throttle 1) Disconnect air cleaner outlet No.1 hose (1) from air body) which should be within the following specification.
  • Page 137 Engine Mechanical: 1D-11 Throttle Body Components Throttle Body Removal and Installation S3RH0B1406004 S3RH0B1406006 Removal 1) Disconnect negative cable at battery. 2) Drain cooling system referring to “Cooling System Flush and Refill in Section 1F in related manual”. 3) Disconnect accelerator cable (1) from throttle valve lever.
  • Page 138 1D-12 Engine Mechanical: Throttle Body Disassembly and Assembly Installation S3RH0B1406007 1) Clean mating surfaces and install throttle body gasket to intake manifold. Disassembly Use new gasket. Remove TP sensor and IAC valve from throttle body. NOTE While disassembling and assembling throttle body, use special care not to deform levers on throttle valve shaft or cause damage to any other parts.
  • Page 139 Engine Mechanical: 1D-13 Throttle Body and Intake Manifold Components S3RH0B1406009 I3RH0B140015-01 1. Intake manifold 7. EVAP canister purge valve 13. Intake manifold mounting bolt (short) 19. Cushion 2. Intake manifold gasket 8. TP sensor 14. Intake manifold mounting bolt (long) 20.
  • Page 140 1D-14 Engine Mechanical: Throttle Body and Intake Manifold Removal and 7) Disconnect the following hoses: Installation • Brake booster hose (1) from intake manifold S3RH0B1406010 • PCV hose (2) from PCV valve Removal • Canister purge hose (3) from EVAP canister purge valve 1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G in related manual”.
  • Page 141 Engine Mechanical: 1D-15 Cylinder Head Cover Removal and Installation Installation Reverse removal procedure for installation noting the S3RH0B1406011 Removal followings. 1) Disconnect negative cable at battery. • Use new intake manifold gasket and EGR pipe gasket 2) Remove engine cover (1). (if equipped).
  • Page 142 1D-16 Engine Mechanical: Installation 3) Install cylinder head cover to cylinder head. 1) Install new spark plug hole gaskets (1) and new NOTE cylinder head cover gasket (2) to cylinder head cover When installing cylinder head cover, use care (3) as shown in the figure. so that cylinder head cover gasket or spark plug hole gaskets will not get out of place or fall off.
  • Page 143 Engine Mechanical: 1D-17 Engine Mountings Components S3RH0B1406012 I3RH0B140017-01 [A]: A/T model 3. Engine left mounting 7. Engine front torque bush [B]: M/T model 4. Engine left mounting bracket No.1 8. Mounting member 1. Engine right mounting 5. Engine left mounting bracket No.2 9.
  • Page 144 1D-18 Engine Mechanical: Engine Assembly Removal and Installation 12) Remove fuse box from its bracket. S3RH0B1406013 13) Disconnect the following cables. Removal • Accelerator cable 1) Relieve fuel pressure according to “Fuel Pressure • Gear select control cable (For M/T vehicle) Relief Procedure in Section 1G in related manual”.
  • Page 145 Engine Mechanical: 1D-19 14) Disconnect the following hoses: 21) Remove engine left mounting bolts (1) and engine right mounting bracket nuts (2). Brake booster hose (1) Heater inlet and outlet hoses from intake manifold from each pipe Canister purge hose (2) Radiator inlet and outlet from EVAP canister hoses from each pipe...
  • Page 146 1D-20 Engine Mechanical: Installation 10) Install suspension frame (1) with stabilizer bar and suspension control arms referring to “Front 1) Install clutch cover and clutch disk referring to Suspension Frame Removal and Installation in “Clutch Cover, Clutch Disc and Flywheel Removal Section 2B in related manual”.
  • Page 147 Engine Mechanical: 1D-21 21) Refill transaxle with transaxle oil referring to “Manual 18) Check to ensure that all removed parts are back in place. Transaxle Oil Change in Section 5B in related Reinstall any necessary parts which have not been manual”...
  • Page 148 1D-22 Engine Mechanical: Timing Chain Cover Removal and Installation 4) Remove cylinder head cover and oil pan referring to S3RH0B1406015 “Cylinder Head Cover Removal and Installation” and “Oil Pan and Oil Pump Strainer Removal and Removal Installation in Section 1E”. 5) Remove P/S pump bracket (if equipped).
  • Page 149 Engine Mechanical: 1D-23 Installation 5) Apply sealant “A” to mating surface between cylinder and cylinder head, and apply sealant “B” to mating 1) Install oil seal (1) to timing chain cover, if removed. surface of timing chain cover as shown in the figure. NOTE “A”: Sealant 99000–31140 When installing new oil seal (1), press fit to...
  • Page 150 1D-24 Engine Mechanical: 8) Install cap (3) to timing chain cover (1). 15) Install crankshaft pulley (1). Tighten bolt (2) to Tighten bolts to specified torque. specified torque. To lock crankshaft pulley, use special tool with it as shown in the figure. Tightening torque Cap bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft) Special tool...
  • Page 151 Engine Mechanical: 1D-25 Oil gallery pipe Oil control valve Inspect strainer (1) and mating surface (2) of oil control Inspect oil gallery pipes No.1 (1), No.2 (2) and No.3 (3). valve. Replace if crack, deformation or clog exists. Clean oil control valve. I3RH0B140030-01 I3RH0B140029-01 Timing Chain and Chain Tensioner Components...
  • Page 152 1D-26 Engine Mechanical: Timing Chain and Chain Tensioner Removal Installation and Installation CAUTION S3RH0B1406018 After timing chain is removed, never turn Removal crankshaft and camshafts independently 1) Remove timing chain cover referring to “Timing more than such an extent (“a”, “b”) as shown Chain Cover Removal and Installation”.
  • Page 153 Engine Mechanical: 1D-27 6) Apply engine oil to sliding surface of chain tensioner 3) Install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft (1) and install chain tensioner and spacer. timing sprocket as shown in the figure. Tighten tensioner bolt to specified torque.
  • Page 154 1D-28 Engine Mechanical: 8) Screw in plunger (1) by turning timing chain 10) Apply engine oil to timing chain and then turn tensioner adjuster (2) in arrow direction and install a crankshaft clockwise by 2 revolutions and check that retainer (3) (wire) to hold plunger in place. match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is in match with notch (4)
  • Page 155 Engine Mechanical: 1D-29 Timing Chain and Chain Tensioner Inspection Crankshaft Timing Sprocket S3RH0B1406019 Check teeth of sprocket for wear or damage. Timing Chain No.1 Guide Check shoe (1) for wear or damage. I2RH0B140070-01 Timing Chain Check timing chain for wear or damage. I2RH0B140068-01 Timing Chain Tensioner Check shoe (1) for wear or damage.
  • Page 156 1D-30 Engine Mechanical: Camshaft, Tappet and Shim Components S3RH0B1406020 I3RH0B140037-01 1. Intake camshaft 5. Shim 9. Camshaft bearing : Shim No. on it faces tappet side. : Install a bearing half with some holes to upper side of intake camshaft No.1 bearing. 2.
  • Page 157 Engine Mechanical: 1D-31 4) Loosen camshaft housing bolts in such order as Installation indicated in the figure and remove them. 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to cylinder head. NOTE When installing shim, make sure to direct shim No.
  • Page 158 1D-32 Engine Mechanical: 4) Apply engine oil to sliding surface of each camshaft 7) After applying engine oil to housing bolts, tighten and camshaft journal then install them as shown in them temporarily first. Then tighten them by the figure. following numerical order in the figure.
  • Page 159 Engine Mechanical: 1D-33 Camshaft, Tappet and shim Inspection Camshaft Runout S3RH0B1406022 Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. Intake Cam Timing Sprocket Assembly If measured runout exceeds the specified limit, replace Fit intake cam timing sprocket assembly to camshaft (2) camshaft.
  • Page 160 1D-34 Engine Mechanical: 6) Tighten camshaft housing bolts in such order as If measured camshaft journal clearance exceeds indicated in the figure a little at a time till they are limit, measure journal (housing) bore and outside tightened to specified torque. diameter of camshaft journal.
  • Page 161 Engine Mechanical: 1D-35 Wear of Tappet and Shim Measure cylinder head bore and tappet outside diameter Check tappet and shim for pitting, scratches or damage. to determine cylinder head-to-tappet clearance. If If any malcondition is found, replace. clearance exceeds limit, replace tappet or cylinder head. Cylinder head to tappet clearance Standard: 0.025 –...
  • Page 162 1D-36 Engine Mechanical: Valves and Cylinder Head Components S3RH0B1406023 I3RH0B140044-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt for M8 : Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified procedure. 2. Valve spring retainer 8. Valve guide : Tightening torque 3.
  • Page 163 Engine Mechanical: 1D-37 Valves and Cylinder Head Removal and 9) Check all around cylinder head for any other parts required to be removed or disconnected and remove Installation or disconnect whatever necessary. S3RH0B1406024 10) Remove exhaust manifold, if necessary referring to Removal “Exhaust Manifold Removal and Installation in 1) Remove engine assembly from vehicle referring to...
  • Page 164 1D-38 Engine Mechanical: 5) Install cylinder head to cylinder block. Cylinder head bolt diameter measurement Apply engine oil to cylinder head bolts and tighten points them gradually as follows. “a”: 83.5 mm (3.29 in.) “b”: 115 mm (4.53 in.) a) Tighten cylinder head bolts (“1” – “10”) to 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) according to numerical Cylinder head bolt diameter difference order as shown by using a 12 corner socket...
  • Page 165 Engine Mechanical: 1D-39 Valves and Cylinder Head Disassembly and 3) Release special tool, and remove spring retainer and valve spring. Assembly S3RH0B1406025 4) Remove valve from combustion chamber side. 5) Remove valve stem seal (1) from valve guide, and Disassembly then valve spring seat (2).
  • Page 166 1D-40 Engine Mechanical: Assembly 3) Ream valve guide bore with special tool (5.5 mm reamer). After reaming, clean bore. 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as Special tool to remove burrs and make it truly round.
  • Page 167 Engine Mechanical: 1D-41 6) Install valve to valve guide. Special tool Before installing valve to valve guide, apply engine (A): 09916–14510 oil to stem seal, valve guide bore, and valve stem. (B): 09916–14910 (C): 09916–84511 I2RH0B140099-01 7) Install valve spring and spring retainer. I2RH0B140101-01 Each valve spring has top end (large-pitch end (1)) 9) Install intake manifold, injectors and exhaust...
  • Page 168 1D-42 Engine Mechanical: If bore gauge is not available, check end deflection of • Inspect valve stem end face for pitting and wear. If valve stem with a dial gauge instead. pitting or wear is found there, valve stem end may be Move stem end in directions (1) and (2) to measure end resurfaced, but not so much as to grind off its deflection.
  • Page 169 Engine Mechanical: 1D-43 • Seating contact width: c. Valve lapping: Create contact pattern on each valve in the usual Lap valve on seat in two steps, first with coarse manner, i.e., by giving uniform coat of marking size lapping compound applied to face and the compound to valve seat and by rotatingly tapping seat second with fine-size compound, each time using with valve head.
  • Page 170 1D-44 Engine Mechanical: • Check cylinder head for cracks on intake and exhaust • Distortion of manifold seating faces: ports, combustion chambers, and head surface. Using Check seating faces of cylinder head for manifolds, a straightedge and thickness gauge, check flatness of using a straightedge and thickness gauge, in order to gasketed surface at a total of 6 locations.
  • Page 171 Engine Mechanical: 1D-45 Pistons, Piston Rings and Connecting Rods • Spring squareness: Use a square and surface plate to check each spring Components for squareness in terms of clearance between end of S3RH0B1406029 valve spring and square. Valve springs found to exhibit a larger clearance than limit must be replaced.
  • Page 172 1D-46 Engine Mechanical: Pistons, Piston Rings and Connecting Rods 2) Install guide hoses (1) over connecting rod bolts. These guide hoses protect crank pin and threads of Removal and Installation rod bolt from damage during installation of S3RH0B1406030 connecting rod and piston assembly. Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
  • Page 173 Engine Mechanical: 1D-47 5) Install bearing cap (1) as follows • Force piston pin out. a) Point arrow mark (2) on cap to crankshaft pulley side. Tighten connecting rod bearing cap nut to specified procedure as follows. Tighten all cap nuts to 15 N⋅m (1.5 kgf-m, 11.0 lb-ft).
  • Page 174 1D-48 Engine Mechanical: Cylinders, Pistons and Piston Rings Inspection 2) Install piston rings to piston: S3RH0B1406032 • As indicated in the figure, 1st and 2nd rings have “T” mark respectively. When installing these piston Cylinder rings to piston, direct marked side of each ring •...
  • Page 175 Engine Mechanical: 1D-49 Pistons • Ring groove clearance: Before checking, piston grooves must be clean, dry • Inspect piston for faults, cracks or damage. and free of carbon deposits. Damaged or faulty piston should be replaced. Fit new piston ring (1) into piston groove, and •...
  • Page 176 1D-50 Engine Mechanical: Piston Rings Piston pin clearance in small end To measure end gap, insert piston ring (1) into cylinder Connecting rod small end: 0.003 – 0.014 mm bore and then measure the gap by using thickness (0.00012 – 0.00055 in.) gauge (2).
  • Page 177 Engine Mechanical: 1D-51 • Connecting rod alignment: Mount connecting rod on aligner to check it for bow and twist. If limit is exceeded, replace it. Connecting rod alignment Limit on bow: 0.05 mm (0.0020 in.) Limit on twist: 0.10 mm (0.0039 in.) I4RH01140053-01 Crank Pin and Connecting Rod Bearings Inspection...
  • Page 178 1D-52 Engine Mechanical: Connecting Rod Bearing General Information 4) Install rod bearing cap (1) to connecting rod. Service connecting rod bearings are available in When installing cap, be sure to point arrow mark (2) standard size and 0.25 mm (0.0098 in.) undersize on cap to crankshaft pulley side as shown in the bearing.
  • Page 179 Engine Mechanical: 1D-53 Selection of Connecting Rod Bearings 2) Next, check crankshaft pin diameter. On crank web No.3, four alphabets are stamped as shown in figure. NOTE Three kinds of alphabet (“A”, “B” and “C”) represent the following crankshaft pin diameter respectively. •...
  • Page 180 1D-54 Engine Mechanical: 3) There are five kinds of standard bearings differing in 4) From number stamped on connecting rod and its cap thickness. To distinguish them, they are painted in and alphabets stamped on crank web No.3, the following colors at the position as indicated in determine new standard bearing to be installed to figure.
  • Page 181 Engine Mechanical: 1D-55 Main Bearings, Crankshaft and Cylinder Block Components S3RH0B1406035 I3RH0B140048-01 [A]: Sealant application amount 7. Crankshaft timing sprocket key 16. Rear oil seal housing mounting bolt “a”: 3 mm (0.12 in.) 8. Crankshaft 17. Main bearing mounting No.2 bolt : Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified procedure.
  • Page 182 1D-56 Engine Mechanical: “b”: 2 mm (0.08 in.) 9. Thrust bearing 18. Main bearing mounting No.1 bolt : Make sure main bearing mounting No.1 bolt deformation when reuse it due to plastic deformation tightening referring to “Main Bearings Inspection”. : Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) and 60°...
  • Page 183 Engine Mechanical: 1D-57 Installation 2) Install main bearings to cylinder block. Upper half of bearing (1), has an oil groove (2). CAUTION Install it to cylinder block (3), and the other half without oil groove to bearing cap. • Use new bearing cap No.1 bolts. If they are Make sure that two halves are painted in the same reused, check thread diameters of bearing color.
  • Page 184 1D-58 Engine Mechanical: d) Tighten bolts (11) – (20) to 25 N⋅m (2.5 kgf-m, 8) Install rear oil seal housing (1) and tighten bolts to 18.0 lb-ft) according to numerical order as specified torque by using special tool. shown. Special tool Tightening torque (A): 09911–97720 Crankshaft bearing cap No.1 bolt (1) –...

  • Page 185: Crankshaft Inspection

    Engine Mechanical: 1D-59 10) Install pistons and connecting rods. Refer to Thrust Play “Pistons, Piston Rings and Connecting Rods Measure this play with crankshaft set in cylinder block in Removal and Installation”. the normal manner, that is with thrust bearing (1) and journal bearing caps installed.
  • Page 186 1D-60 Engine Mechanical: Main Bearings Inspection Use a dial gauge to read displacement in axial (thrust) direction of crankshaft. S3RH0B1406038 If its limit is exceeded, replace thrust bearing with new General Information standard one or oversize one to obtain standard thrust •...
  • Page 187 Engine Mechanical: 1D-61 4) Tighten bearing cap No.1 bolts (1) – (10) and No.2 5) Remove bearing caps, and measure gauging plastic bolts (11) – (20) gradually as follows. (2) width at its widest point using scale (1) on gauging plastic envelop. If clearance exceeds its a) Tighten bolts (1) –...
  • Page 188 1D-62 Engine Mechanical: Selection of Main Bearings 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five Standard bearing alphabets are stamped as shown in the figure. If bearing is in malcondition, or bearing clearance is out Three kinds of alphabets (“A”, “B”...
  • Page 189 Engine Mechanical: 1D-63 3) There are 5 kinds of standard bearings differing in 5) Measure main bearing clearance with newly thickness. To distinguish them, they are painted in selected standard bearing referring to “Main Bearing the following colors at the position as indicated in the Clearance”...
  • Page 190 1D-64 Engine Mechanical: • If necessary, regrind crankshaft journal and select Bearing Cap Bolt undersize bearing to use with it as follows. Measure each thread diameter bearing cap No.1 bolts (1) at “A” and “B” by using a micrometer (2). a.
  • Page 191 Engine Mechanical: 1D-65 Rear Oil Seal Inspection Cylinder Block Inspection S3RH0B1406040 S3RH0B1406042 Carefully inspect oil seal (1) for wear or damage. Distortion of Gasketed Surface If its lip is worn or damaged, replace it. • Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It.
  • Page 192 1D-66 Engine Mechanical: Specifications Tightening Torque Specifications S3RH0B1407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Engine cover bolt Tighten 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified procedure Camshaft housing bolt for tightening of special tool Camshaft housing bolt Intake manifold bolt and nut 18.0 Cylinder head cover bolt...
  • Page 193 For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A in related manual”. Special Tools and Equipment Recommended Service Material S3RH0B1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1215 P/No.: 99000–31110 SUZUKI Bond No.1207B P/No.: 99000–31140...
  • Page 194 1D-68 Engine Mechanical: 09916–14910 09916–34542 Valve spring compressor Reamer handle attachment 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67021 Valve guide installer handle Tappet holder 09916–77310 09916–84511...

  • Page 195: Engine Lubrication System

    Engine Lubrication System: 1E-1 Engine Lubrication System General Description Engine Lubrication Description passages drilled in the crankshaft, and then injected S3RH0B1501001 from the big end of connecting rod to lubricate piston, The oil pump is of a trochoid type, and mounted on the rings and cylinder wall.
  • Page 196 1E-2 Engine Lubrication System: Repair Instructions Oil Pan and Oil Pump Strainer Components S3RH0B1506001 I3RH0B150002-01 [A]: Sealant application amount 3. O-ring 8. Oil pan nut : Tighten 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) by the specified procedure. “a”: 3 mm (0.12 in.) 4.
  • Page 197 Engine Lubrication System: 1E-3 8) Remove oil pump strainer (1) from cylinder block. 3) Install oil pan to cylinder block. a) Fit upper oil pan to cylinder block. b) Tighten oil pan bolts and nuts temporarily by hand. c) Tighten oil pan bolts and nuts to specified torque by numerical order as shown in figure.
  • Page 198 1E-4 Engine Lubrication System: Oil Pump Components S3RH0B1506004 I3RH0B150004-01 1. Rotor plate 6. Rotor plate bolt : Tightening torque 2. O-ring 7. Relief valve : Do not reuse. 3. Outer rotor 8. Spring : Apply thin coat of engine oil to sliding surface of each parts.
  • Page 199 Engine Lubrication System: 1E-5 Assembly 5) Install rotor plate and tighten all bolts to specified torque. After installing plate, check to be sure that 1) Wash, clean and then dry all disassembled parts. rotors turn smoothly by hand (0.3 N⋅m (0.03 kgf-m, 2) Apply thin coat of engine oil to inner and outer rotors, 0.25 lb-ft) torque or below).
  • Page 200 For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A in related manual”. Special Tools and Equipment Recommended Service Material S3RH0B1508001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.

  • Page 201: Fuel System

    Fuel System: 1G-1 Fuel System Repair Instructions Fuel Pipe Removal and Installation 4) Disconnect brake pipe from pipe joint. S3RH0B1706005 5) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they WARNING were.
  • Page 202 1G-2 Fuel System: Fuel Injector Removal and Installation Installation S3RH0B1706007 Reverse removal procedure for installation noting the following. WARNING • Replace injector O-ring (1) with new one using care Before servicing fuel system, be sure to not to damage it. observe “Precautions on Fuel System •...
  • Page 203 “MISC TEST” mode on SUZUKI scan Use special care to prevent sparking when tool. connecting and disconnecting test lead to iii) Turn fuel pump ON by using SUZUKI scan and from battery. tool. 1) Install injector (3) and fuel pressure regulator (4) to Special tool special tool (injector checking tool).
  • Page 204 4) Remove fuel pressure regulator from fuel delivery pipe. 5) Disconnect fuel return hose (3) from pressure regulator. I2RH0B170012-01 I2RH0B170014-01 [A]: When using SUZUKI scan tool 3. Battery [B]: When not using SUZUKI scan tool 4. Keep as far apart as possible...
  • Page 205 Fuel System: 1G-5 Fuel Tank Removal and Installation Installation For installation, reverse removal procedure and note the S3RH0B1706012 WARNING following precautions. • Use new O-ring (1). Before servicing fuel system, be sure to • Apply thin coat of gasoline to O-ring to facilitate observe “Precautions on Fuel System installation.
  • Page 206 1G-6 Fuel System: 8) Disconnect fuel filler hose (1) and breather hose (2) WARNING from filler neck (3). A small amount of fuel may be released after CAUTION the fuel hose is disconnected. In order to reduce the chance of personal injury, cover Never disconnect fuel filler hose (1) from fuel the hose and pipe to be disconnected with a tank inlet.
  • Page 207 Fuel System: 1G-7 Installation 5) Connect fuel feed pipe (1), fuel return pipe (3) and purge pipe (2) to each pipe as shown in the figure 1) If parts have been removed from fuel tank, install and clamp them securely. them before installing fuel tank to vehicle.
  • Page 208 1G-8 Fuel System: Specifications Tightening Torque Specifications S3RH0B1707001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Fuel delivery pipe bolt 18.0 Fuel pressure regulator bolt Fuel tank bolt 36.5 Fuel filler hose clamp 0.15 Fuel pump assembly bolt NOTE The specified tightening torque is also described in the following. “Fuel System Components in related manual”...
  • Page 209 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Drive Shaft / Axle ........3A-1 Front Drive Shaft Assembly Removal and Installation ............3A-2 General Description ..........
  • Page 210 3A-1 Drive Shaft / Axle: Drive Shaft / Axle Repair Instructions Front Drive Shaft Components S3RH0B3106001 I3RH0B311009-02 [A]: Tripod joint type 10. Damper...
  • Page 211 Drive Shaft / Axle: 3A-2 [B]: DOJ type 11. Center shaft side joint (RH of M/T model) : Apply light black grease included in spare part to joint. [C]: Center shaft (M/T model) 12. Wheel side joint : Apply black grease included in spare part to joint. [D]: Center shaft (A/T model) 13.
  • Page 212 3A-3 Drive Shaft / Axle: 10) Disconnect front suspension control arm ball stud (1) Install drive shaft assembly by reversing removal from steering knuckle (2) after removing ball stud procedure and noting the following points. bolt (3) and nut. • Do not reuse drive shaft nut (2). •...
  • Page 213 Drive Shaft / Axle: 3A-4 Front Drive Shaft Disassembly and Assembly 4) Remove differential side boot small band, and then S3RH0B3106004 pull out differential side boot from shaft. 5) Remove damper band, and then pull out damper Disassembly through shaft. 6) Remove wheel side boot big band (1) using flat end For tripod joint type rod or the like.
  • Page 214 3A-5 Drive Shaft / Axle: 2) Slide boot (1) toward the center of shaft and remove 5) Remove differential side boot small band, and then snap ring (2) from outer race, and then take shaft out pull out differential side boot from shaft. of outer race (3).
  • Page 215 Drive Shaft / Axle: 3A-6 2) Remove O-ring from center shaft. (for M/T model) 3) Remove oil seals from center bearing support, if equipped. 4) Remove circlip (1) using special tool. Special tool (A): 09900-06108 I3RH0A311005-01 5) Remove center bearing from center bearing support. Assembly For tripod joint type Judging from abnormality noted before disassembly and...
  • Page 216 3A-7 Drive Shaft / Axle: 4) Fasten wheel side boot small band using special 8) Confirm that wheel side boot is not stretched and tool. contracted, and then fasten boot big band (1) securely using special tool. NOTE Special tool •...
  • Page 217 Drive Shaft / Axle: 3A-8 12) Apply grease to inside of tripod joint housing (1), CAUTION joint it with tripod joint and fit boot (2) to tripod joint • Bend each boot band against forward housing. After fitting boot, insert screwdriver into rotation.
  • Page 218 3A-9 Drive Shaft / Axle: 3) Set new differential side small band and new differential side boot on shaft temporarily. 4) Drive in the cage (1) using a pipe (2). CAUTION Install cage directing smaller outside diameter side to wheel side. Drive shaft joint cage installing pipe diameter “a”: 23.0 mm (0.906 in.) or more “b”: 32.0 mm (1.260 in.) or less...
  • Page 219 Drive Shaft / Axle: 3A-10 6) Apply grease to entire surface of cage. Use specified 9) When fixing boot (1) to joint housing (2) with grease in tube included in spare parts. differential side big band (3), adjust so that measurements become as indicated in the following.
  • Page 220 3A-11 Drive Shaft / Axle: For center shaft • Install oil seals (1, 2) to center bearing support (4) in Install center shaft by reversing the removal procedure proper direction and specified position as shown using and noting the following points. special tool.
  • Page 221 For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A in related manual”. Special Tools and Equipment Recommended Service Material S3RH0B3108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 NOTE Required service material is also described in the following.
  • Page 222 3A-13 Drive Shaft / Axle:...
  • Page 223 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........5-1 DTC P0705 (No.34): Transmission Range Sensor Circuit Malfunction (PRNDL Input)..5A-35 Precautions.............
  • Page 224 5-ii Table of Contents Input Shaft Speed Sensor Removal and Transaxle Case Removal and Installation..5A-122 Installation ............5A-70 Automatic Transaxle Unit Assembly ....5A-122 Input Shaft Speed Sensor Inspection....5A-70 Specifications ...........5A-132 Transmission Fluid Temperature Sensor Tightening Torque Specifications....5A-132 Inspection............5A-70 Special Tools and Equipment ......5A-133 “O/D OFF”...
  • Page 225 Table of Contents 5-iii Clutch ............5C-* Clutch Operating Cylinder Removal and Installation ............5C-* General Description ..........5C-* Clutch Operating Cylinder Components....5C-* Clutch Construction..........5C-* Clutch Operating Cylinder Disassembly and Diagnostic Information and Procedures.... 5C-* Reassembly ............5C-* Clutch System Symptom Diagnosis ....5C-* Clutch Operating Cylinder Inspection....
  • Page 226 5-1 Precautions: Precautions Precautions Precautions on Transmission / Transaxle S3RH0B5000001 Air Bag Warning Refer to “Air Bag Warning in Section 00 in related manual”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 5A”. Precautions for Disassembly and Reassembly Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
  • Page 227 TCM and/or ECM memory. • Apply ATF to sliding or rotating parts before • Using SUZUKI scan tool the diagnostic information reassembly. stored in TCM memory can be checked and cleared • A new friction plates should be soaked in ATF at least as well.
  • Page 228 5A-2 Automatic Transmission/Transaxle: General Description A/T Description S3RH0B5101001 This automatic transaxle is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up mechanism. The gear shift device consists of 2 sets of planetary gear units, 4 disc type clutches, a disc type brake, a band type brake and 2 one-way clutches.
  • Page 229 Automatic Transmission/Transaxle: 5A-3 I2RH01510002-01 1. Torque converter clutch (TCC) 9. One-way clutch No.0 17. Parking lock gear 2. 2nd and 4th brake band 10. Forward clutch 18. Counter driven gear (Reduction gear) 3. Reverse clutch 11. Coast clutch 19. Oil pump 4.
  • Page 230 5A-4 Automatic Transmission/Transaxle: Specifications Item Specifications Type 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism) Torque converter Stall torque ratio 1.90 – 2.05 Type Internal gear type oil pump Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type “P”...
  • Page 231 Automatic Transmission/Transaxle: 5A-5 4. Overdrive clutch 10. Front large planetary pinion gear 16. Input shaft 5. Rear planetary ring gear 11. Planetary sun gear 17. Reverse clutch 6. Rear planetary pinion gear 12. Planetary carrier 18. 2nd and 4th brake Functions Part name Function...
  • Page 232 “O/D OFF” lamp (1) and stores malfunction DTC in its memory. • It is possible to communicate with TCM through data link connector (DLC) (2) by using SUZUKI scan tool (3). Diagnostic information can be checked and erased by using scan tool.
  • Page 233 Automatic Transmission/Transaxle: 5A-7 Schematic and Routing Diagram Transmission Control Module (TCM) Wiring Diagram S3RH0B5102001 The TCM is an electronic circuit component that controls gear shift and idle-up according to the signal from each sensor. It is a microcomputer of an IC, transistor, diode, etc. It is installed at the right side of the steering column. G07-28 GRY/RED G03-6...
  • Page 234 5A-8 Automatic Transmission/Transaxle: Operation of Shift Solenoid Valves and TCC Solenoid Valve RANGE GEAR Neutral — (O/D) (> 7 km/h) (≤ 7 km/h) Shift solenoid × × × (—) valve-A (NO. 1) Shift solenoid × × × × × × SOLENOIDS (—) valve-B (NO.
  • Page 235 Automatic Transmission/Transaxle: 5A-9 Automatic Gear Shift Diagram S3RH0B5102003 Automatic shift schedule as a result of shift control is shown in the following. In case that selector lever is shifted to L at a higher than 55 km/h (34 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower than that.
  • Page 236 5A-10 Automatic Transmission/Transaxle: Component Location Electronic Shift Control System Components Location S3RH0B5103001 I3RH0B510003-01 1. Engine 15. TCC solenoid valve H: Brake signal 2. Transaxle 16. Transmission fluid temperature sensor (A/T fluid I: Shift indicator, “O/D OFF” lamp and DTC signal temp.
  • Page 237 Automatic Transmission/Transaxle: 5A-11 Diagnostic Information and Procedures A/T System Check S3RH0B5104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC check, record and clearance Print DTC or write it...
  • Page 238 5A-12 Automatic Transmission/Transaxle: 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.
  • Page 239 Automatic Transmission/Transaxle: 5A-13 NOTE The form is a standard sample. It should be modified according to conditions characteristic of each market. Step 2. DTC Check, Record and Clearance First, referring to “DTC Check”, check DTC. If DTC exists, print or write down DTC and then clear malfunction DTC(s) by referring to “DTC Clearance”.
  • Page 240 • Confirmation available table of automatic transaxle related DTC is shown in the following. DTC in TCM Code type I Code type II × SUZUKI scan tool × Not using scan tool (Displaying on odometer) : Available (DTC can be confirmed) ×: Not available (DTC can not be confirmed)
  • Page 241 Automatic Transmission/Transaxle: 5A-15 • A: Driving cycles when “O/D OFF” light flashing and storing DTC in TCM memory. • *1: “O/D OFF” lamp does not flash although DTC is detected and stored in TCM memory. DTC No. Detecting condition Detecting item Type I Type II (DTC will set when detecting:)
  • Page 242 I3RH0A510010-01 3) Turn ignition switch ON. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between scan tool and TCM is not possible, check if scan tool is communicable by connecting it to TCM in another vehicle.
  • Page 243 (4) of monitor connector (color in 1) Turn ignition switch OFF. Blue) (2) 5 times at about 1 second interval within 10 2) Connect SUZUKI scan tool to data link connector seconds, using service wire. (DLC) (1) located on underside of instrument panel 4) Check TCM that no malfunction DTC remains in at driver’s seat side.
  • Page 244 5A-18 Automatic Transmission/Transaxle: Fail Safe Table S3RH0B5104008 This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The following table shows the fail safe function for each fail condition of sensor, solenoid, TCM or its circuit.
  • Page 245 Automatic Transmission/Transaxle: 5A-19 Scan Tool Data S3RH0B5104009 As the data values given in the following table 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.
  • Page 246 5A-20 Automatic Transmission/Transaxle: Normal condition / reference Scan tool data Vehicle condition values Selector lever is in “P” position P/N RANGE Selector lever is in “R” position D RANGE Selector lever is in “N” position P/N RANGE D RANGE SIGNAL Ignition switch ON Selector lever is in “D”...
  • Page 247 Automatic Transmission/Transaxle: 5A-21 BRAKE SWITCH (ON/OFF) PRESS CONT SOL (PRESSURE CONTROL SOLENOID, %) Inputted signal from brake light switch on pedal bracket. Electric current value ratio between electric current value ON: Brake pedal depressed being outputted from TCM to solenoid and maximum OFF: Brake pedal released value can be outputted by TCM.
  • Page 248 5A-22 Automatic Transmission/Transaxle: Road Test S3RH0B5104011 This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a level road. WARNING • Carry out test in very little traffic area to prevent an accident. •...
  • Page 249 Automatic Transmission/Transaxle: 5A-23 Condition Possible cause Correction / Reference Item Gear shift point is Abnormal engine condition Inspect and repair engine. incorrect Malfunction of output shaft speed Inspect. If NG, replace. sensor Malfunction of throttle position sensor Inspect. If NG, replace. TCC (lock-up) function Malfunction of TCC solenoid valve Inspect.
  • Page 250 5A-24 Automatic Transmission/Transaxle: Stall Test S3RH0B5104013 This test is to check overall performance of automatic transaxle and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is between FULL and LOW marks.
  • Page 251 Automatic Transmission/Transaxle: 5A-25 Time Lag Test S3RH0B5104014 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.
  • Page 252 5A-26 Automatic Transmission/Transaxle: Line Pressure Test 4) Depress foot brake fully, run engine at idle and stall S3RH0B5104015 then check fluid pressure in “D” or “R” range. Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure CAUTION line.
  • Page 253 Automatic Transmission/Transaxle: 5A-27 Troubleshooting Condition Possible cause Correction / Reference Item Higher than standard Malfunction of pressure control solenoid Inspect. If NG, replace valve body assembly. level in each range valve (Low line pressure) Malfunction of primary regulator valve Replace valve body assembly. (Low line pressure) Lower than standard level Malfunction of pressure control solenoid...
  • Page 254 5A-28 Automatic Transmission/Transaxle: A/T Symptom Diagnosis S3RH0B5104018 Trouble Diagnosis 1 Electrical repair Condition Possible cause Correction / Reference Item → Poor 1 2 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent. If NG, repair.
  • Page 255 Automatic Transmission/Transaxle: 5A-29 Condition Possible cause Correction / Reference Item Incorrect gear shift point Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Throttle position sensor signal circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
  • Page 256 5A-30 Automatic Transmission/Transaxle: Trouble Diagnosis 2 On-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. → Poor 1 2 shift, Engine abnormal condition Inspect and repair engine. excessive shock or Malfunction of shift solenoid valve-B Inspect.
  • Page 257 Automatic Transmission/Transaxle: 5A-31 Condition Possible cause Correction / Reference Item → Poor 3 O/D shift, Engine abnormal condition Inspect and repair engine. excessive shock or Malfunction of TCC solenoid valve Inspect. If NG, replace. slippage Malfunction of input shaft speed sensor Inspect. If NG, replace. Malfunction of output shaft speed Inspect.
  • Page 258 5A-32 Automatic Transmission/Transaxle: Trouble Diagnosis 3 Off-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty oil pump Inspection. If NG, replace. Seized or broken planetary gear Inspection. If NG, replace. Faulty one-way clutch No.2 Inspection.
  • Page 259 Automatic Transmission/Transaxle: 5A-33 No Gear Shift to O/D S3RH0B5104019 System Description TCM does not shift to O/D gear under any of the following condition. • O/D off switch is turned ON. (“O/D OFF” lamp ON.) • Engine coolant temperature is lower than 50 °C (122 °F) •...
  • Page 260 5A-34 Automatic Transmission/Transaxle: No Lock-Up Occurs S3RH0B5104020 System Description TCM turns TCC solenoid OFF under any of the following conditions. • Engine coolant temperature is lower than 50 °C (122 °F). • TCM detects the following DTCs. P0715 / P0720 / P0743 / P0748 / P0753 / P0758 / P1700 / P1702 Troubleshooting WARNING •...
  • Page 261 Automatic Transmission/Transaxle: 5A-35 DTC P0705 (No.34): Transmission Range Sensor Circuit Malfunction (PRNDL Input) S3RH0B5104022 Wiring Diagram WHT/BLK G07-2 G07-1 RED/BLK WHT/RED G07-9 YEL/RED G07-8 G07-21 G07-20 RED/BLU 21 20 I2RH01510020-01 1. TCM 4. Brake light switch 7. Terminal arrangement of TCM connector (viewed from harness side) 2.
  • Page 262 Go to Step 5. operation. Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection OFF. Inspection in Section 00 in related manual”. 2) Turn ignition switch ON and check transmission range signal (“P”, “R”, “N”, “D”, “2”...
  • Page 263 Automatic Transmission/Transaxle: 5A-37 DTC P0710 (No.36 / No.38): Transmission Fluid Temperature Sensor Circuit Malfunction S3RH0B5104043 Wiring Diagram I3RH01510272-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. Transmission fluid temperature sensor 4. Valve body connector DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area •...
  • Page 264 5A-38 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check transmission fluid temperature sensor circuit for Go to step 3. “BLU/ORN” or “LT GRN” open circuit open. 1) Turn ignition switch OFF. 2) Disconnect TCM connectors from TCM.
  • Page 265 Automatic Transmission/Transaxle: 5A-39 DTC P0715 (No.37): Input / Turbine Speed Sensor Circuit Malfunction S3RH0B5104024 Wiring Diagram G07-5 G07-17 2.5V I2RH01510022-01 1. TCM 2. Input shaft speed sensor 3. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No input shaft speed sensor signal is detected although...
  • Page 266 5A-40 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check input shaft speed sensor circuit Go to Step 4. Go to Step 3. 1) Disconnect TCM connectors with ignition switch OFF. 2) Check for proper connection to input shaft speed sensor at “G07-5”...
  • Page 267 Automatic Transmission/Transaxle: 5A-41 DTC P0720 (No.31): Output Shaft Speed Sensor Circuit Malfunction S3RH0B5104025 Wiring Diagram G07-4 G07-16 2.5V I2RH01510024-01 1. TCM 2. Output shaft speed sensor 3. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No output shaft speed sensor signal is detected although...
  • Page 268 5A-42 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check Output Shaft Speed Sensor Circuit Go to Step 4. Go to Step 3. 1) Disconnect TCM connectors with ignition switch OFF. 2) Check for proper connection to output shaft speed sensor at “G07-4”...
  • Page 269 Automatic Transmission/Transaxle: 5A-43 DTC P0725 (No.35): Engine Speed Input Circuit Malfunction S3RH0B5104026 Wiring Diagram LT GRN/ G04-2 G07-15 I2RH01510025-01 1. TCM 3. To tachometer 5. Terminal arrangement of ECM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition...
  • Page 270 5A-44 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check engine speed input signal circuit for open Go to Step 3. “LT GRN/BLK” circuit open. 1) Turn ignition switch OFF. 2) Disconnect TCM and ECM connectors from TCM and ECM.
  • Page 271 Automatic Transmission/Transaxle: 5A-45 DTC P0743 (No.25 / No.26) Torque Converter Clutch Circuit Electrical S3RH0B5104027 Wiring Diagram BLU/WHT G08-12 I3RH0B510005-01 1. TCC solenoid valve 2. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area •...
  • Page 272 5A-46 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve circuit for IG short Go to Step 3. “BLU/WHT” circuit shorted to power circuit 1) Turn ignition switch ON and measure voltage between or open.
  • Page 273 Automatic Transmission/Transaxle: 5A-47 DTC P0748 (No.41 / No.42): Pressure Control Solenoid-A Electrical S3RH0B5104045 Wiring Diagram G08-11 GRY/RED G08-8 GRY/BLK I3RH01510275-01 1. Pressure control 3. Terminal arrangement of TCM connector solenoid valve (viewed from harness side) 2. TCM DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area •...
  • Page 274 5A-48 Automatic Transmission/Transaxle: Step Action Check pressure control solenoid valve resistance Go to Step 4. Replace pressure control solenoid valve or 1) Turn ignition switch OFF. lead wire. 2) Disconnect valve body harness connector (1) on transaxle (2). 3) Check for proper connection to solenoid at “GRY/RED” and “GRY/BLK”...
  • Page 275 Automatic Transmission/Transaxle: 5A-49 DTC P0753 / P0758 (No.21 / No.22 / No.23 / No.24): Shift Solenoid-A (No.1) Electrical / Shift Solenoid- B (No.2) Electrical S3RH0B5104047 Wiring Diagram G08-4 G08-3 GRN/ORN I3RH01510279-01 1. Shift solenoid valve-A (No.1) 3. TCM 2. Shift solenoid valve-B (No.2) 4.
  • Page 276 5A-50 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check shift solenoid valve circuit for IG short Go to Step 3. “GRY” or “GRN/ORN” circuit shorted to power 1) Turn ignition switch OFF and disconnect TCM circuit.
  • Page 277 Automatic Transmission/Transaxle: 5A-51 DTC P1700 (No.32 / No.33): Throttle Position Signal Input Malfunction S3RH0B5104048 Wiring Diagram G03-14 PPL/WHT G07-6 I3RH0B510018-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 278 5A-52 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Is there DTC related to throttle position sensor (P0120)? Go to DTC P0120 Flow. Go to Step 3. Check throttle position signal circuit for IG short “PPL/WHT”...
  • Page 279 Automatic Transmission/Transaxle: 5A-53 DTC P1705 (No.51): Engine Coolant Temperature Signal Circuit Malfunction S3RH0B5104049 Wiring Diagram GRY/BLK G04 -8 G07-7 I3RH0B510019-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 280 5A-54 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Is there DTC related to engine coolant temperature sensor Go to DTC P0115 Flow. Go to Step 3. (P0115)? Check engine coolant temperature signal circuit for IG “GRY/BLK”...
  • Page 281 Automatic Transmission/Transaxle: 5A-55 DTC P1730 (No.64) Engine Torque Signal Circuit Malfunction S3RH0B5104050 Wiring Diagram G07-23 G04-35 RED/WHT I3RH0B510020-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 282 5A-56 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check engine torque signal circuit for IG short “BRN/YEL” circuit Go to Step 3. shorted to power circuit. 1) Turn ignition switch OFF. 2) Disconnect TCM and ECM connectors from TCM and ECM.
  • Page 283 Automatic Transmission/Transaxle: 5A-57 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of torque reduction signal circuit TCM terminal is low • Torque reduction signal circuit from TCM to ECM although TCM does not require ECM to reduce engine malfunction.
  • Page 284 5A-58 Automatic Transmission/Transaxle: Inspection of TCM and Its Circuits S3RH0B5104038 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage and resistance. CAUTION TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it.
  • Page 285 Automatic Transmission/Transaxle: 5A-59 Standard Terminal Circuit Condition voltage Transmission range sensor (“R” 8 – 14 V Ignition switch ON, selector lever at “R” range range) 0 – 1 V Ignition switch ON, selector lever at other than “R” range Transmission range sensor (“P” 8 –...
  • Page 286 5A-60 Automatic Transmission/Transaxle: Standard Terminal Circuit Condition voltage — — — — — — 3 Shift solenoid valve-B (No.2) 0 – 1 V Ignition switch ON, selector lever at “P” range 4 Shift solenoid valve-A (No.1) 9 – 14 V Ignition switch ON, selector lever at “P”...
  • Page 287 Automatic Transmission/Transaxle: 5A-61 TCM Power and Ground Circuit Check S3RH0B5104039 Wiring Diagram G08-20 BLK/WHT IG11 G08-15 G08-19 I2RH01510018-01 1. TCM 3. Ignition switch 5. Terminal arrangement of TCM connector (viewed from harness side) 2. IG fuse 4. Main fuse Troubleshooting Step Action Check TCM power circuit...
  • Page 288 5A-62 Automatic Transmission/Transaxle: “O/D OFF” Lamp Circuit Check S3RH0B5104040 Wiring Diagram G07-10 RED/YEL GRN/BLK G07-3 I2RH01510016-01 1. TCM 3. O/D off switch 2. Combination meter 4. Terminal arrangement of TCM connector (viewed from harness side) Circuit Description Operation (ON/OFF) of the “O/D OFF” lamp is controlled by transmission control module (TCM) and combination meter.
  • Page 289 Automatic Transmission/Transaxle: 5A-63 Troubleshooting Step Action Does “O/D OFF” lamp light steady? Go to Step 2. Go to Step 4. Check O/D off switch circuit Go to Step 3. Faulty combination meter or TCM. 1) Turn ignition switch OFF and disconnect TCM connectors.
  • Page 290 5A-64 Automatic Transmission/Transaxle: Step Action Does “O/D OFF” lamp blink for 10 seconds and then go out? “RED/YEL” circuit open Go to Step 6. or shorted to ground. If circuit is OK, faulty combination meter or TCM. Inspect combination meter referring to “O/D OFF Indicator Lamp (A/T Vehicle Only) Symptom...
  • Page 291 Automatic Transmission/Transaxle: 5A-65 Repair Instructions A/T Fluid Level Check NOTE S3RH0B5106001 Level Check at Normal Operation Temperature • Do not race engine while checking fluid level, even after the engine start. 1) Stop vehicle and place it level. • Do not overfill. Overfilling can cause 2) Apply parking brake and place chocks against foaming and loss of fluid through breather.
  • Page 292 5A-66 Automatic Transmission/Transaxle: Selector Lever Components 5) Lower vehicle and fill proper amount of an equivalent of DEXRON ® -III. S3RH0B5106004 6) Check fluid level referring to “A/T Fluid Level Check”. Automatic transaxle fluid An equivalent of DEXRON ® -III Automatic transaxle fluid capacity 2.5 N·m (0.25 kg-m) When draining from drain plug hole: 2.9 liters...
  • Page 293 Automatic Transmission/Transaxle: 5A-67 Select Cable Components S3RH0B5106006 I3RH0B510008-01 1. Selector lever assembly 6. Clip 2. Select cable 7. Select cable retainer bolt 3. Select cable retainer 8. Manual shift lever pin : Apply lithium grease 99000-25010 to all around pin (0.15 g) 4.
  • Page 294 5A-68 Automatic Transmission/Transaxle: Transmission Range Sensor (Shift Switch) 5) Shift selector lever to “N” position. Inspection and Adjustment 6) Apply grease to selector lever pin and install adjuster S3RH0B5106008 (cable end) to it. Inspection : Grease 99000–25010 1) Disconnect transmission range sensor connector (1).
  • Page 295 Automatic Transmission/Transaxle: 5A-69 5) Check that engine starts in “N” and “P” ranges but it Installation doesn’t start in “D”, “2”, “L” or “R” range. Also, check 1) Apply A/T fluid to output shaft speed sensor O-ring. that back-up lamp turn ON in “R” range. 2) Install output shaft speed sensor (1) to A/T case and tighten bolt to specified torque.
  • Page 296 5A-70 Automatic Transmission/Transaxle: Input Shaft Speed Sensor Removal and Input Shaft Speed Sensor Inspection S3RH0B5106012 Installation 1) Disconnect negative cable at battery. S3RH0B5106011 Removal 2) Disconnect input shaft speed sensor connector (2). 1) Disconnect negative cable at battery. 3) Check resistance between input shaft speed sensor 2) Disconnect input shaft speed sensor connector (2).
  • Page 297 Automatic Transmission/Transaxle: 5A-71 7) Warm up transmission fluid temperature sensor (2). 10) Install transaxle side cover (1). Check resistance between terminals of A/T side NOTE valve body connector. Thus make sure its resistance decrease with the increase of temperature. Apply sealant to 2 bolts (2). After inspection, install transmission fluid temp.
  • Page 298 5A-72 Automatic Transmission/Transaxle: “O/D OFF” Switch Inspection 5) Remove transmission fluid temperature sensor (1) S3RH0B5106014 and sensor harness from clamp. 1) Remove console box. 6) Disconnect solenoid connectors (2). 2) Disconnect O/D off switch connector (1). 3) Check continuity between O/D off switch (2) terminals.
  • Page 299 Automatic Transmission/Transaxle: 5A-73 Installation 4) Install transmission fluid sensor (5) and sensor wire to clamp. 1) Install shift solenoid valve-A (No.1) (1), shift solenoid valve-B (No.2) (2) and TCC solenoid valve (3) in that order. Tightening torque Shift solenoid bolt (a): 7.0 N·m (0.7 kgf-m, 5.0 lb- Valve body bolt (b): 10 N·m (1.0 kgf-m, 7.5 lb-ft) I2RH01510064-01 5) Clean mating surface of A/T side cover and A/T...
  • Page 300 5A-74 Automatic Transmission/Transaxle: 8) Install A/T fluid cooler pipe (1). Operation Check Tightening torque Shift solenoid valve-A (No.1) and -B (No.2) A/T fluid pipe union bolt (color: green) (a): 27 • Check that solenoid valve (1) actuate with click sound N·m (2.7 kgf-m, 19.5 lb-ft) when battery voltage is conducted.
  • Page 301 Automatic Transmission/Transaxle: 5A-75 Pressure Control Solenoid Valve Inspection TCC solenoid valve S3RH0B5106017 • Check that solenoid valve (1) actuate with click sound when battery voltage is conducted. Resistance Check • Apply oiler (2) to solenoid valve (1) and give Measure resistance between pressure control solenoid compression by hands and then check to be sure that valve (1) terminals.
  • Page 302 5A-76 Automatic Transmission/Transaxle: Transmission Control Module (TCM) Removal Not using regulated DC power supply and Installation 1) Connect pressure control solenoid valve (1) to S3RH0B5106018 battery (2) setting the 8 – 10 W bulb (4) on the way CAUTION as shown in the figure. TCM consists of highly precise parts, 2) Check for movement of valve (3) in the direction of therefore when handling it, be careful not to...
  • Page 303 Automatic Transmission/Transaxle: 5A-77 Differential Side Oil Seal Replacement A/T Fluid Cooler Hoses Replacement S3RH0B5106019 S3RH0B5106022 The rubber hoses for the A/T fluid cooler should be 1) Lift up vehicle and drain automatic transaxle fluid. replaced at specified interval. When replacing them, be 2) Remove drive shaft joints from differential gear of sure to note the following.
  • Page 304 5A-78 Automatic Transmission/Transaxle: Automatic Transaxle Unit Components S3RH0B5106023 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 50 N·m (5.0 kg-m) 25 N·m (2.5 kg-m) 85 N·m (8.5 kg-m) 70 N·m (7.0 kg-m) I3RH0B510012-01 1. Lower stiffener 4.
  • Page 305 Automatic Transmission/Transaxle: 5A-79 Automatic Transaxle Unit Dismounting and 6) Remove starting motor. Remounting 7) Remove bolts and nut fastening engine and S3RH0B5106024 transaxle, then detach transaxle from engine. Dismounting NOTE 1) Take down transaxle with engine. For its procedure, When detaching transaxle from engine, move refer to “Engine Assembly Removal and Installation it in parallel with crankshaft and use care so in Section 1D”.
  • Page 306 5A-80 Automatic Transmission/Transaxle: Remounting 4) Install lower stiffener. 1) Make sure that torque converter is installed correctly Tightening torque to transaxle. Lower stiffener bolt: 50 N·m (5.0 kgf-m, 36.5 lb- Refer to “Automatic Transaxle Unit Assembly”. 2) Attach transaxle to engine. 5) Install starter motor.
  • Page 307 Automatic Transmission/Transaxle: 5A-81 Automatic Transaxle Assembly Components S3RH0B5106025 I3RH0B510036-01 1. Torque converter 22. Gasket 43. Manual valve lever 2. A/T fluid drain plug 23. 1st / reverse brake piston 44. Spacer 3. Transaxle housing 24. O-ring 45. Output shaft speed sensor 4.
  • Page 308 5A-82 Automatic Transmission/Transaxle: 5. A/T fluid inlet pipe 26. Snap ring 47. Manual valve lever shaft 6. A/T fluid pipe union bolt (color: green) 27. Breather hose 48. Transmission range sensor 7. Gasket 28. VSS 49. Manual shift lever 8. Oil strainer 29.
  • Page 309 Automatic Transmission/Transaxle: 5A-83 3) Remove fluid cooler pipes (1). 5) Remove fluid level gauge (1), fluid filler tube (2), output shaft speed sensor (3), input shaft speed NOTE sensor (4) and vehicle speed sensor (5) (for Never reuse gaskets (2) after removal. speedometer).
  • Page 310 5A-84 Automatic Transmission/Transaxle: 7) Pull out differential gear assembly. 14) Remove transaxle side cover (1) by removing bolts. 8) Clean and wipe off gasket sealant on mating surface between transaxle housing and transaxle case. 9) Remove three gaskets at transaxle case side. NOTE Never reuse removed gaskets.
  • Page 311 Automatic Transmission/Transaxle: 5A-85 19) Remove valve body connector mounting bolt and b) Plug oil hole (1). remove valve body connector and its harness. c) Measure piston rod stroke while applying and 20) Remove 2 gaskets (1). releasing compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 –...
  • Page 312 5A-86 Automatic Transmission/Transaxle: 27) Apply valve lifter as illustrated and push in brake 31) Disassemble 2nd and 4th brake piston assembly. inner cover. a) Remove brake inner cover (1) and O-rings (2). Special tool NOTE (A): 09916-14510 Never reuse removed O-ring. (B): 09916-48210 28) Remove snap ring by using snap ring pliers (special tool).
  • Page 313 Automatic Transmission/Transaxle: 5A-87 36) Remove 5 gaskets (1). 38) Pull out sun gear assembly. 39) Inspect 1st and reverse brake piston stroke. NOTE a) Set special tools (dial gauge and magnetic Never reuse removed gaskets. stand). Special tool (A): 09900–20607 (B): 09900-20701 b) Measure piston stroke while applying and releasing compressed air (400 –...
  • Page 314 5A-88 Automatic Transmission/Transaxle: 42) Remove retainer ring (1) and 1st and reverse brake 48) Remove countershaft thrust roller bearing (1) with piston return spring (2). race. 43) Remove 1st and reverse brake piston with O-ring Countershaft thrust roller bearing dimension installed while applying and releasing compressed Outside diameter: 66.0 mm (2.60 in.) air (400 –...
  • Page 315 Automatic Transmission/Transaxle: 5A-89 51) Remove snap ring. 53) Remove slotted spring pin (3) using pin punch or the like. 52) Press counter drive gear subassembly (1) using special tool. NOTE Special tool Never reuse removed spacer (2) and slotted (B): 09925-86010 spring pin (3).
  • Page 316 5A-90 Automatic Transmission/Transaxle: Oil Pump Disassembly and Reassembly 2) Install driven gear and drive gear to oil pump body S3RH0B5106028 after applying fluid to gears. 3) Install oil pump cover (1) to oil pump body (2) and Disassembly ® tighten eight torx bolts (3) to specification.
  • Page 317 Automatic Transmission/Transaxle: 5A-91 Oil Pump Inspection 3) Check side clearance of both gears. S3RH0B5106029 Using a straightedge (1) and a feeler gauge, 1) Check body clearance of driven gear (1). measure side clearance between gears and pump Push driven gear (2) to one side of oil pump body body.
  • Page 318 5A-92 Automatic Transmission/Transaxle: Forward Clutch Components S3RH0B5106030 I2RH01510137-01 1. Race 7. Clutch drum thrust washer 13. Forward clutch roller thrust bearing 2. Clutch drum oil seal ring 8. Snap ring 14. Rear cover oil seal ring 3. Snap ring 9. Forward clutch return spring subassembly 15.
  • Page 319 Automatic Transmission/Transaxle: 5A-93 Forward Clutch Disassembly and Reassembly 6) Install forward clutch piston subassembly (1) to S3RH0B5106032 transaxle rear cover (2). 7) Remove forward clutch piston subassembly (3) with Disassembly O-rings installed through oil hole (4) compressed air 1) Remove snap ring (1). (400 –...
  • Page 320 5A-94 Automatic Transmission/Transaxle: Special tool Reassembly (A): 09926-98330 1) Coat new oil seal rings (3, 4) with A/T fluid. 2) Install them to transaxle rear case (2) and forward NOTE clutch drum subassembly (1). • When installing return spring, be careful NOTE so that return spring will not fall or tilt.
  • Page 321 Automatic Transmission/Transaxle: 5A-95 11) Apply A/T fluid to ring gear thrust roller bearing, race NOTE (1) and clutch drum thrust washer (2). • If friction plate lining is exfoliated, Ring gear thrust roller bearing dimension discolored or worn hardly, replace all Outside diameter: 32.5 mm (1.28 in.) friction plates.
  • Page 322 5A-96 Automatic Transmission/Transaxle: Overdrive Clutch and Coast Clutch Components S3RH0B5106034 I2RH01510150-01 1. Overdrive and coast clutch assembly 7. Retaining plate 13. Coast clutch piston 2. Snap ring 8. Friction plate 14. Overdrive clutch piston 3. Retaining plate 9. Separator plate 15.
  • Page 323 Automatic Transmission/Transaxle: 5A-97 Overdrive Clutch and Coast Clutch 3) Measure coast clutch piston stroke while applying and releasing compressed air (400 – 800 kPa, 4 – 8 Disassembly and Reassembly kg-cm , 57 – 113 psi) through oil hole (1) by using S3RH0B5106036 special tools.
  • Page 324 5A-98 Automatic Transmission/Transaxle: 5) Using special tool and hydraulic press (2), compress 10) Remove coast clutch piston (1) with O-rings using overdrive clutch return spring and remove snap ring compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – (1).
  • Page 325 Automatic Transmission/Transaxle: 5A-99 5) Using special tool and hydraulic press (2), compress 8) Install snap ring (1). overdrive clutch return spring and install snap ring NOTE (1). Make sure that opening end of ring is not Special tool aligned with groove section of drum. (A): 09926-98310 NOTE •...
  • Page 326 5A-100 Automatic Transmission/Transaxle: NOTE 12) Install forward clutch assembly and overdrive and coast clutch assembly to transaxle rear cover. • If friction plate lining is exfoliated, 13) Measure overdrive clutch piston stroke again, using discolored or worn hardly, replace all special tools.
  • Page 327 Automatic Transmission/Transaxle: 5A-101 Planetary Gear Components S3RH0B5106038 I2RH01510164-01 1. Snap ring 12. Carrier front thrust roller bearing 23. Rear ring gear flange 2. Front planetary ring gear 13. Carrier front thrust roller bearing race 24. One-way clutch No.0 3. One-way clutch No.1 14.
  • Page 328 5A-102 Automatic Transmission/Transaxle: Planetary Gear Operation Check Planetary Gear Disassembly and Reassembly S3RH0B5106039 S3RH0B5106040 One-way clutches Disassembly 1) Install forward clutch assembly and overdrive / coast Planetary gear assembly clutch assembly to transaxle rear cover. 1) Remove the following parts by removing snap ring 2) Install rear planetary ring gear assembly to overdrive (1).
  • Page 329 Automatic Transmission/Transaxle: 5A-103 4) Remove front ring gear thrust washer (1). 8) Remove front ring gear flange (1) by removing snap ring (2). Front ring gear thrust washer dimension Outside diameter: 85.5 mm (3.67 in.) Inside diameter: 70.0 mm (2.76 in.) Thickness: 2.0 mm (0.08 in.) I2RH01510173-01 9) Remove O-ring (1).
  • Page 330 5A-104 Automatic Transmission/Transaxle: 4) Remove on-way clutch No.0 retainer (1) with rear ring gear thrust roller bearing (2) by removing snap ring (3). Rear ring gear thrust roller bearing dimension Outside diameter: 32.5 mm (1.28 in.) Inside diameter: 18.8 mm (0.74 in.) Thickness: 2.7 mm (0.11 in.) I2RH01510172-01 7) Apply A/T fluid to front ring gear thrust roller bearing...
  • Page 331 Automatic Transmission/Transaxle: 5A-105 10) Install one-way clutch No.1 (1) with snap ring (2). Rear planetary ring gear assembly 1) Set one-way clutch No.0 to one-way clutch No.0 outer race and rear planetary ring gear. NOTE Make sure that thinner section “A” of one- way clutch faces toward front side.
  • Page 332 5A-106 Automatic Transmission/Transaxle: Planetary Gear Inspection S3RH0B5106041 Rear Planetary Ring Gear Assembly Visually check the following parts for scratches or discoloration. • Outer surface of one-way clutch No.0 roller (1). • Inner surface of one-way clutch No.0 outer race (2). •...
  • Page 333 Automatic Transmission/Transaxle: 5A-107 Reverse Clutch Preliminary Inspection 4) Install sun gear input flange (thrust washer installed) S3RH0B5106045 with retainer ring. 1) Remove sun gear input flange (1) with thrust washer 5) Mount reverse clutch drum with bearing to oil pump (2) installed by removing retainer ring (3).
  • Page 334 5A-108 Automatic Transmission/Transaxle: Reverse Clutch Disassembly and Reassembly 5) Mount reverse clutch drum with bearing (2) to oil S3RH0B5106046 pump body (3). 6) Remove reverse clutch piston (1) by blowing Disassembly compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 –...
  • Page 335 Automatic Transmission/Transaxle: 5A-109 4) Place reverse clutch return spring onto reverse 9) Measure piston stroke, referring to “Reverse Clutch clutch piston. Preliminary Inspection”. 5) Install snap ring (1), using special tool and hydraulic 10) Remove reverse clutch from oil pump body. press (2).
  • Page 336 5A-110 Automatic Transmission/Transaxle: Reverse Clutch Inspection 17) Install input shaft to reverse clutch drum. S3RH0B5106047 18) Install sun gear input flange (1) with retainer ring (3). 1) Check that sliding surfaces of friction, separator and 19) Apply A/T fluid to thrust washer. cushion plates are not worn or burnt.
  • Page 337 Automatic Transmission/Transaxle: 5A-111 Counter Drive Gear Disassembly and 3) Make sure that ball (1) makes creaking noise when shaking the reverse clutch piston. (i.e., check that Reassembly ball is free.) S3RH0B5106049 4) Check that there is no leakage by applying low- Disassembly pressure air onto ball.
  • Page 338 5A-112 Automatic Transmission/Transaxle: 4) Tighten new lock nut using special tool until starting / 3) Remove angular ball bearing from counter drive gear. rotation torque (bearing preload) will be in specified value shown in the following. NOTE Special tool If inner race of angular ball bearing remains (A): 09927-26010 on counter drive gear (1), remove it using Counter drive gear bearing preload...
  • Page 339 Automatic Transmission/Transaxle: 5A-113 Counter Driven Gear Components S3RH0B5106050 I2RH01510207-01 1. Counter shaft RH thrust roller bearing race 5. Counter shaft driven gear lock nut : Apply automatic transaxle fluid. (for output shaft speed sensor) : After tightening nut to specified tightening torque, stake nut securely.
  • Page 340 5A-114 Automatic Transmission/Transaxle: Counter Driven Gear Disassembly and Reassembly Reassembly 1) Press differential drive pinion (2) to counter driven S3RH0B5106051 gear (1), using hydraulic press (3). Disassembly 1) Clamp counter driven gear (1) with special tool and a vice (2). Special tool (A): 09921-57810 2) Unstake lock section of counter shaft driven gear...
  • Page 341 Automatic Transmission/Transaxle: 5A-115 5) Stake new counter shaft driven gear lock nut (2), 6) Apply A/T fluid to counter shaft LH thrust roller using standard punch in combination with hammer. bearing (1) and race. Counter shaft LH thrust roller bearing dimension NOTE Outside diameter: 66.0 mm (2.60 in.) When staking counter shaft driven gear lock...
  • Page 342 5A-116 Automatic Transmission/Transaxle: Valve Body Assembly Components S3RH0B5106052 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) I2RH01510214-01 1. Valve body assembly 6. Pressure control solenoid valve 11. Transmission fluid temperature sensor clamp 2. Manual valve 7.
  • Page 343 Automatic Transmission/Transaxle: 5A-117 Valve Body Assembly Disassembly and Reassembly S3RH0B5106053 Disassembly 1) Pull out manual valve. 2) Remove solenoid valves by removing bolts. I2RH01510215-01 1. Pressure control solenoid valve 3. Shift solenoid valve-B (No.2) 2. Shift solenoid valve-A (No.1) 4. TCC solenoid valve Reassembly 1) Install solenoid valves to valve body and tighten bolts to specified torque.
  • Page 344 5A-118 Automatic Transmission/Transaxle: Differential Components S3RH0B5106054 I2RH01510217-01 1. Differential gear assembly 5. Differential side bearing outer race : Tightening torque 2. Bolt 6. Differential side bearing shim : Do not reuse. 3. Final gear 7. Oil seal: Apply grease 99000-25030 to oil seal lip.
  • Page 345 Automatic Transmission/Transaxle: 5A-119 Installation 6) Install differential assembly to transaxle case and tighten case bolts to specified torque. Bearing outer race Tightening torque 1) Install bearing outer race and shim by using special Transaxle housing bolt: 30 N·m (3.0 kgf-m, 22.0 tool and hummer.
  • Page 346 5A-120 Automatic Transmission/Transaxle: Differential Inspection Transaxle housing Removal and Installation S3RH0B5106056 S3RH0B5106057 1) Hold differential assembly with soft jawed vice and Removal set special tools as shown. 1) Remove oil seal (4). Special tool (A): 09900–20607 NOTE (B): 09900-20701 Never reuse removed oil seal. 2) Remove oil reservoir plate (1) with three magnets (2) by removing bolts.
  • Page 347 Automatic Transmission/Transaxle: 5A-121 Installation 5) Tighten cylindrical roller bearing retainer (2) with bolt. 1) Apply A/T fluid to counter shaft RH thrust roller bearing (1). Tightening torque Cylindrical roller bearing retainer bolt (a): 13 Counter shaft RH thrust roller bearing dimension N·m (1.3 kgf-m, 9.5 lb-ft) Outside diameter: 46.0 mm (1.81 in.) Inside diameter: 32.5 mm (1.28 in.)
  • Page 348 5A-122 Automatic Transmission/Transaxle: Transaxle Housing Inspection Installation S3RH0B5106058 1) Apply A/T fluid to outer surface of cylindrical roller Check pan for particles. Remove magnets and use them bearing. to collect any chips. 2) Tap cylindrical roller bearing, using special tools. Inspect oil reservoir plate for any chips and particle collected on magnet.
  • Page 349 Automatic Transmission/Transaxle: 5A-123 6) Rotate new spacer approximately 180 degrees. 10) Apply A/T fluid to new O-rings. 7) Stake small hole of new spacer. 11) Place 1st and reverse brake piston (1) with O-rings installed. NOTE Be careful not to damage O-rings during piston installation.
  • Page 350 5A-124 Automatic Transmission/Transaxle: 16) Install special tools on transaxle. b) Install brake inner cover (1) and new O-rings (2). Special tool (A): 09900–20607 (B): 09900-20701 Measure 1st and reverse brake piston stroke by applying and releasing compressed air (400 – 800 kPa, 4 –...
  • Page 351 Automatic Transmission/Transaxle: 5A-125 I2RH01510239-01 I2RH01510241-01 24) Install brake cover (1) to transaxle case with snap 27) Apply A/T fluid to transaxle lubrication tube (1). ring (2), using snap ring pliers. 28) Install transaxle lubrication tube (1). Special tool 29) Tighten clamp with bolt. (A): 09900-06108 Tightening torque Lubrication tube clamp bolt (a): 5.5 N·m (0.55...
  • Page 352 5A-126 Automatic Transmission/Transaxle: 33) Temporarily tighten transaxle housing to transaxle 40) Install forward clutch assembly while rotating. case with 5 – 6 bolts. 34) Stand transaxle up (i.e.: transaxle housing facing down-ward). I2RH01510247-01 41) Check for correct installation of each component parts as follows.
  • Page 353 Automatic Transmission/Transaxle: 5A-127 43) Install five gaskets (1). 49) Apply A/T fluid to counter shaft LH thrust roller bearing (1). NOTE Counter shaft LH thrust roller bearing dimension There is no installation direction for new Outside diameter: 66.0 mm (2.60 in.) gaskets.
  • Page 354 5A-128 Automatic Transmission/Transaxle: 56) Check for correct installation of input shaft as 58) Install oil strainer (1). follows. NOTE Measure the distance “a” by using vernier (1) and straightedge (2). If out of specification, remove input When overhauling automatic transaxle, shaft (3) with reverse clutch assembly and reinstall replace oil strainer.
  • Page 355 Automatic Transmission/Transaxle: 5A-129 65) Apply sealant to thread parts of 2 bolts (1). 70) Tighten valve body assembly (1) with bolts referring to length in the following table. “A”: Sealant 99000–31230 Bolt: Length “L” 66) Install transaxle housing to transaxle case by (1): 20 mm tightening bolts to specified torque.
  • Page 356 5A-130 Automatic Transmission/Transaxle: 73) Wipe off and clean mating surface between case 77) Install the following parts (with new O-rings installed) and side cover. with bolts. 74) Apply sealant to transaxle case by using a nozzle (1) • Valve body connector (1) as shown in figure by such amount that its section is •...
  • Page 357 Automatic Transmission/Transaxle: 5A-131 NOTE 80) Install transmission range sensor assembly. a) Place new rubber plate and new lock washer (3) Make sure to use new gaskets (2). or transmission range sensor (1). b) Tighten transmission range sensor lock nut (4). Tightening torque Transmission range sensor lock nut (a): 7.0 N·m (0.7 kgf-m, 5.0 lb-ft)
  • Page 358 5A-132 Automatic Transmission/Transaxle: Specifications Tightening Torque Specifications S3RH0B5107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft A/T fluid drain plug 29.0 Transmission range sensor bolt 18.0 Output shaft speed sensor bolt 0.55 Input shaft speed sensor bolt 0.55 Transaxle side cover bolt 17.5 A/T fluid pipe union bolt (color: green) 19.5...
  • Page 359 Automatic Transmission/Transaxle: 5A-133 Special Tools and Equipment Recommended Service Material S3RH0B5108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 SUZUKI Super Grease C P/No.: 99000–25030 Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 NOTE Required service material is also described in the following.
  • Page 360 5A-134 Automatic Transmission/Transaxle: 09924–74590 09924–84510–005 Input shaft oil seal installer Bearing installer attachment attachment 09925–06010 09925–37811–001 Bearing puller Oil pressure gauge 09925–86010 09926–68310 Bearing puller attachment Differential bevel pinion bearing installer 09926–96010 09926–98310 Clutch spring compressor Clutch spring compressor 09926–98330 09927–26010 Spring compressor No.
  • Page 361 Bearing & oil seal installer Bearing housing installer 09951–16060 09951–46010 Control arm bush remover Drive shaft oil seal installer SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
  • Page 362 5A-136 Automatic Transmission/Transaxle:...
  • Page 363 Table of Contents 9- i Section 9 Body, Cab and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-* System Circuit Diagram........
  • Page 364 9-ii Table of Contents D-3 Fog Light Circuit Diagram......9A-* Headlight Diode Removal and Installation ..9B-* D-4 Illumination Light Circuit Diagram....9A-* Headlight Diode Inspection ......... 9B-* D-5 Interior Light Circuit Diagram......9A-* Headlight, Clearance Light, Front / Rear Fog D-6 Turn Signal and Hazard Warning Light Light Relays Inspection ........
  • Page 365 Table of Contents 9-iii Engine Coolant Temperature (ECT) Sensor Front Door Glass Removal and Installation ..9E-* Inspection............9C-* Front Door Window Regulator Removal and Brake Fluid Level Switch Inspection ....9C-* Installation ............9E-* Parking Brake Switch Inspection ......9C-* Front Door Window Regulator Inspection ...
  • Page 366 9-iv Table of Contents Power Door Lock Actuator Inspection....9F-* Front Door Assembly Removal and Front Door Lock Assembly Inspection ....9F-* Installation ............9J-* Rear Door Lock Assembly Components ....9F-* Rear Door Assembly Components....... 9J-* Rear Door Lock Assembly Removal and Rear Door Assembly Removal and Installation ............9F-* Installation ............
  • Page 367 Instrumentation / Driver Info. / Horn: 9C-1 Instrumentation / Driver Info. / Horn Schematic and Routing Diagram Combination Meter Circuit Diagram S3RH0B9302001 G20-11 G21-21 G21-16 G21-15 G21-20 G20-4 G20-2 G20-15 G21-14 G20-7 G21-13 G21-17 G20-18 G21-9 G20-6 G20-20 G21-12 G20-8 G20-19 G20-16 G21-11...
  • Page 368 9C-2 Instrumentation / Driver Info. / Horn: Wire Wire Terminal Circuit Terminal Circuit color color G20-1 — — G21-1 — — G20-2 BLK/ORN To engine ground G21-2 — — G20-3 — — G21-3 — — G20-4 RED/YEL To headlight relay G21-4 —...
  • Page 369 Glass / Windows / Mirrors: 9E-1 Glass / Windows / Mirrors Repair Instructions Power Window Main Switch Inspection S3RH0B9506019 Check for continuity between terminals at each switch position. If check result is not as specified, replace switch. I3RH0B950001-01 1. Power window lock switch 4.
  • Page 370 Prepared by 1st Ed. Feb, 2004 2nd Ed. Jul, 2006...
  • Page 371 14 mm SUPPLEMENTARY SERVICE MANUAL 99501-54G30-24E...

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