Suzuki WagonR+ RB310 Service Manual
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Suzuki WagonR+ RB310 Service Manual

Suzuki WagonR+ RB310 Service Manual

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Summary of Contents for Suzuki WagonR+ RB310

  • Page 1 SERVICE MANUAL SUPPLEMENTARY SERVICE MANUAL WIRING DIAGRAM MANUAL...
  • Page 2 VIN TABLE MANUAL LIST Model A: The VIN within the range shown in the table are categorized as “model A” HOW TO APPLICABLE TSMMMA53S00100001 TSMMMA53S00180000 Model B: The VIN within the range shown in the table are categorized as “model B” TSMMMA93S00100001 TSMMMA93S00180000 Model C:...
  • Page 3 MANUAL LIST Manual Manual Part Name Language Manual Part Number Group 99500-83E00-01E 99500-83E00-01G RB413 Service Manual 99500-83E00-01F 99500-83E00-01D 99500U83E10-01E 99500U83E10-01G RB310 Service Manual 99500U83E10-01F 99500U83E10-01D 99501U83E00-01E RB413 99501U83E00-01G Supplementary Service Manual (4WD) 99501U83E00-01F 99501U83E10-01E 99501U83E10-01G RB310/413 Supplementary Service Manual 99501U83E10-01F 99501U83E10-01D 99501U83E20-01E 99501U83E20-01G...
  • Page 4 MANUAL LIST HOW TO FIND APPLICABLE MANUALS VIN TABLE 1. Identify the model category which contains the VIN of the vehicle under repair. Refer to the “VIN TABLE” 2. Refer to the corresponding service manuals in the Applicable Manual Group column. The numbers shown in the column show manual group in the “MANUAL LIST”.
  • Page 5 Therefore, please note that the actual vehicle being serviced may differ from the manual. MAGYAR SUZUKI CORPORATION reserves the right to make changes at any time without notice. Please note that this manual contains references to equipment that may not be marketed in all countries.
  • Page 6 Foreword...
  • Page 7 Zeitpunkt der Drucklegung zur Verfügung standen. Die Erläuterungen der vorliegenden Anleitung basieren auf den technischen Daten des Standardmodells oder Basismodells. Sie weichen daher zuweilen von den tatsächlichen Gegebenheiten des zu wartenden Fahrzeugs ab. MAGYAR SUZUKI CORPORATION behält sich das Recht zu Veränderungen ohne Ankündigung vor.
  • Page 8 Vorwort...
  • Page 9 Par conséquent, noter que le véhi- cule soumis à entretien peut être différent du manuel. MAGYAR SUZUKI CORPORATION se réserve le droit de procéder sans préavis et à tout moment à des changements.
  • Page 10 Avant-propos...
  • Page 11 Dit betekent dat het voertuig waaraan gewerkt wordt enigszins kan verschillen van de beschrijvingen in het handboek. MAGYAR SUZUKI CORPORA- TION behoudt zich het recht voor om zonder voorafgaande kennisgeving te allen tijde wijzigingen aan te bren- gen.
  • Page 12 Voorwoord...
  • Page 13 Table of Contents Table of Contents Precautions........... 8A-0-1 System circuit diagram ........8A-6-1 General information........8A-1-1 A-1 Cranking system.........8A-6-1 8A-0 A-2 Charging system ........8A-6-2 How to read connector layout diagram ..8A-1-1 A-3 Cooling system (G10 / M13A) ....8A-6-3 How to read connector codes and terminal A-3 Cooling system (DSL) ......8A-6-4 nos.
  • Page 14 Table of Contents E-1 Heater and air conditioner G-1 Radio..........8A-6-62 (G10 / M13A)...........8A-6-54 G-2 Cigarette lighter........ 8A-6-63 E-1 Heater and air conditioner (DSL)..8A-6-55 G-3 Clock..........8A-6-64 Connector list..........8A-7-1 F-1 Anti-lock brake system......8A-6-56 F-2 Air-bag control system ......8A-6-58 Glossary ............8A-8-1 F-3 Power steering........8A-6-60...
  • Page 15 Inhaltsverzeichnis Inhaltsverzeichnis Vorsichtsmaßregeln........8A-0-2 Zusatzsicherungskasten (DSL)....8A-5-8 Allgemeines Informationen ......8A-1-1 Systemschaltdiagramm........8A-6-1 8A-0 A-1 Kurbelsystem........8A-6-1 Bezeichnungen des A-2 Ladesystem ........8A-6-2 Steckverbindungsplans .......8A-1-1 A-3 Kühlsystem (G10 / M13A) ....8A-6-3 Ablesen der Steckverbindungscodes und A-3 Kühlsystem (DSL) ......8A-6-4 Klemmennummern........8A-1-2 A-4 Zündanlage (G10) ......8A-6-5 8A-1 Ermittlung des Massepunkts .......8A-1-4 A-4 Zündanlage (M13A)......8A-6-6...
  • Page 16 Inhaltsverzeichnis E-1 Heizung und klimaanlage G-1 Radio ..........8A-6-62 (G10 / M13A) ..........8A-6-54 G-2 Zigarettenanzünder......8A-6-63 E-1 Heizung und klimaanlage (DSL)..8A-6-55 G-3 Uhr ........... 8A-6-64 Liste der stecker ...........8A-7-1 F-1 Antiblockiersystem......8A-6-56 F-2 Airbag-steuersystem......8A-6-58 Fachbegriffe ..........8A-8-1 F-3 Servolenkung........8A-6-60...
  • Page 17 Tables des matières Tables des matières Précautions........... 8A-0-3 Schéma du circuit d’alimentation (DSL)..8A-5-2 Informations générales........ 8A-1-1 Fusibles et pièces protégées ....8A-5-3 Boîte à fusibles principale ......8A-5-3 Comment lire le schéma de disposition des 8A-0 Boîte à fusibles de circuit individuel ..8A-5-5 connecteurs..........8A-1-1 Boîte à...
  • Page 18 Tables des matières D-10 Antibrouillard arrière.......8A-6-53 F-3 Direction assistée ......8A-6-60 E-1 Chauffage et climatisation G-1 Radio ..........8A-6-62 (G10 / M13A) ..........8A-6-54 G-2 Allume-cigares ......... 8A-6-63 E-1 Chauffage et climatisation (DSL)..8A-6-55 G-3 Horloge ..........8A-6-64 F-1 Système d’antiblocage Liste des connecteurs........8A-7-1 des freins ..........8A-6-56 Glossaire ............8A-8-1 F-2 Système de commande...
  • Page 19 Inhoudsopgave Inhoudsopgave Individuele circuitzekeringenkast ....8A-5-5 Voorzorgsmaatregelen ........ 8A-0-4 Hulpzekeringenkast (DSL) ......8A-5-8 Algemene informatie........8A-1-1 8A-0 Elektrisch schema ........8A-6-1 Lezen van een stekkerschema ....8A-1-1 A-1 Startsysteem ........8A-6-1 Lezen van stekkercodes en A-2 Laadsysteem ........8A-6-2 aansluitingnummers ........8A-1-2 A-3 Koelsysteem (G10 / M13A) ....8A-6-3 Lezen van een massapunt ......8A-1-4 A-3 Koelsysteem (DSL) ......8A-6-4 8A-1...
  • Page 20 Inhoudsopgave E-1 Verwarming en airconditioning F-3 Stuurbekrachtiging ......8A-6-60 (G10 / M13A) ..........8A-6-54 G-1 Radio ..........8A-6-62 E-1 Verwarming en airconditioning G-2 Sigarettenaansteker......8A-6-63 (DSL)............8A-6-55 G-3 Klok..........8A-6-64 F-1 Antiblokkeersysteem ......8A-6-56 Lijst van stekkers ......... 8A-7-1 F-2 Airbagregelsysteem......8A-6-58 Verklarende woordenlijst......8A-8-1...
  • Page 21 Service on or around the air bag system / Seat belt pretensioner system components or their wiring must be performed only by an authorized SUZUKI dealer. Observe all the warnings in the service man- ual and disable the systems before servicing on or around the components and the wiring of the sys- tems.
  • Page 22 Wartungsarbeiten an Komponenten oder Verdrahtung des Airbag-Systems bzw. Gurtstrammersy- stems oder in dessen Bereich dürfen nur von einem autorisierten SUZUKI-Fachhändler ausgeführt werden. Bitte beachten Sie jegliche Warnungshinweise in den Werkstatt-Handbüchern, und deaktivie- ren Sie die Systeme, bevor Sie mit irgendwelchen Arbeiten an den Systemkomponenten oder deren Verdrahtung beginnen.
  • Page 23 à prétendeur ou de leur câblage doivent être exclusivement effectuées par un concession- naire SUZUKI agréé. Bien se conformer à tous les avertissements donnés dans le manuel d’entretien et mettre les systèmes hors service avant de procéder aux opérations d’entretien sur ou autour des composants et du câblage des systèmes.
  • Page 24 (Voor voertuigen uitgerust met het SRS-airbagsysteem en/of het veiligheidsgordelspannersysteem) Onderhoud aan of rondom de onderdelen of bedrading van het airbagsysteem/veiligheidsgordelspan- nersysteem mag uitsluitend door een officiële SUZUKI-dealer worden uitgevoerd. Volg alle waarschu- wingen in het werkplaatshandboek op en schakel de systemen uit alvorens onderhoud aan of rondom de onderdelen of bedrading van de systemen uit te voeren.
  • Page 25 8A-1-1 General information Allgemeine Informationen Informations générales Algemene informatie How to read connector layout diagram Bezeichnungen des Steckverbindungsplans Comment lire le schéma de disposition des connecteurs Lezen van een stekkerschema 8A-1 L26 (TO O01) Connector code Steckverbindungscode Code connecteur Stekkercode L 36 [A-1] [A-2]...
  • Page 26 8A-1-2 How to read connector codes and terminal nos. Ablesen der Steckverbindungscodes und Klemmennummern. Comment lire les codes connecteur et identifier les n° des contacts. Lezen van stekkercodes en aansluitingnummers Connector code / Terminal No. / Terminal layout Steckverbindungscode / Klemmennummer / Klemmenbelegung Code connecteur / N°...
  • Page 27 8A-1-3 Terminals in one connector (Broken line) (B15) / Terminals in different connectors (B14, B16) Klemmen eines Steckers (gestrichelte Linie) (B15) / Klemmen anderer Stecker (B14, B16) Contacts dans un connecteur (pointillé) (B15) / Contacts dans des connecteurs différents (B14, B16) Aansluitingen in één stekker (stippellijn) (B15) / Aansluitingen in verschillende stekkers (B14, B16) Joint connector (J/C) Verbindungsstecker (J/C)
  • Page 28 8A-1-4 Connector location, shape and terminal No. Der Position, Form und Klemmennummer des Steckers L’emplacement, la forme ou le n° de contact d’un connecteur. Plaats van stekker, vorm en aansluitingnr. Section 8A-6 (Translation [*A]) (“SYSTEM CIRCUIT DIAGRAM”) -Connector code and terminal No. Section 8A-7 (Translation [*C])

  • Page 29: Fuse Number

    8A-1-5 How to read power supply diagram Erklärung eines stromversorgungsdiagramm Légende des schémas du circuit d’alimentation Lezen van een voedingsschema Section 8A-5 (“POWER SUPPLY DIAGRAM”) Abschnitt 8A-5 (“STROMVERSORGUNGSDIAGRAMM”) Section 8A-5 (“SCHÉMA DU CIRCUIT D'ALIMENTATION”) Hoofdstuk 8A-5 (“VOEDINGSSCHEMA”) Fuse number Sicherungsnummer N˚de fusible Zekeringnummer Battery...
  • Page 30 8A-1-6 How to read system circuit diagram Erklärung eines systemschaltdiagramms Légende des schémas des circuits électriques Lezen van een elektrisch schema The circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of the diagram (ground (earth)) as if giving an image of water flow.
  • Page 31 8A-1-7 [A] Fuse No. Sicherungsnummer N° de fusible Zekeringnr. Circuit jumping page / direc- Drahtüberbrückungsseite / Page de saute des fils / direc- Verwijzingspagina/-richting tion Richtung tion Circuit jumping point / direc- Drahtüberbrückungspunkt / Point de saute des fils / direc- Verwijzingspunt/-richting tion Richtung...
  • Page 32 8A-1-8 Symbols and marks Symbole und markierungen Symboles et repères Symbolen en merktekens Battery Batterie Ground (Earth) Masse Batterie Accu Masse Massa fuse Sicherung Coil, Solenoid Spule, Magnet Fusible zekering Bobine, Solénoïde Spoel, solenoïde Heater Heizung Bulb Birne Chauffage Verwarming Ampoule Gloeilamp Cigarette lighter...
  • Page 33 8A-1-9 Ignition switch Zundschalter Keyless entry Schlüsselloser Ein- stieg Contacteur d´allu- Contactslot Ouverture sans clé Afstandsbediening mage voor de portieren Immobilizer system Wegfahrsperrensy- Combination meter Kombinationsinstru- stem ment Système immobilisa- Startblokkeersysteem Compteur mixte Combinatiemeter teur Lighting switch Lichtschalter Headlight leveling Scheinwerfer-Höhen- einstellung Commutateur de feu...
  • Page 34 8A-1-10 Side air-bag (R) Seiten Air-bag (R) Side air-bag (L) Seiten Air-bag (L) Airbag latéral (D) Zij-airbag (R) Airbag latéral (G) Zij-airbag (L) Power steering Servolenkung Glow plug Glühkerze Direction assistée Stuurbekrachtiging Bougie de prechauff- Gloeibougie Abbreviations Abkürzungen Abréviations Afkortingen Abbreviation Full term Bedeutung...
  • Page 35 8A-1-11 Joint connector Verbindungsstecker onnecteur commun Knooppuntstekker Left Links Gauche Links Light emitting diode Leuchtdiode Diode à lueurs Licht uitstralende diode Left hand drive vehicle Fahrzeug mit Linkslenkung Véhicule à conduite à Voertuig met links stuur droite Tief Laag Manifold absolute pressure Absoluter Druck im Aus- Pression absolue du col- Absolute spruitstukdruk puffkrümmer...
  • Page 36 8A-1-12 Wire / connector color symbols Symbole der Kabel und Steckerfarben Symboles des codes couleur câbles / connecteurs Kleurcodes voor draden/stekkers Couleur câbles / connec- Symbol Wire / Connector Color Kabel und Steckerfarben Kleur van draad/stekker teurs Black Schwarz Noir Zwart Blue Blau...
  • Page 37 8A-3-1 Connector layout diagram Stecker-layout-diagramm Schéma de dispositiondes blocs raccord de câblage Stekkerschema Engine compartment Motorraum Compartiment moteur Motorruimte A: Battery harness A: Batterie-KabelbFaum A: Faisceau de câbles de la batterie A: Accubedradingsbundel C: Engine harness C: Motor-Kabelbaum C: Faisceau de câbles du moteur C: Motorbedradingsbundel 8A-3 (TO E26) C01...
  • Page 38 8A-3-2 M13A (TO E40) (TO E41) (TO E26) 4 31 (TO E26) Connective Aansluit No./Color position Anschlussposition Position de connexion positie Engine harness Motor-Kabelbaum Faisceau de câbles du Motorbedradingsbundel moteur C01/N Main fuse Hauptsicherung Fusible principal Hoofdzekering C02/N Main fuse Hauptsicherung Fusible principal Hoofdzekering...
  • Page 39 8A-3-3 Connective Aansluit No./Color position Anschlussposition Position de connexion positie Engine harness Motor-Kabelbaum Faisceau de câbles du Motorbedradingsbundel moteur C05/- Starting motor Anlasser Moteur de depart Startmotor C06/BLK Starting motor Anlasser Moteur de depart Startmotor (G10 / M13A) C06/- (DSL) C07/GRY Generator Lichtmaschine...
  • Page 40 8A-3-4 B: A/C harness B: Klimaanlagen-Kabelbaum B: Faisceau de câbles d’A/C B: A/C-bedradingsbundel G: Instrument panel harness G: Instrumententafel-Kabelbaum G: Faisceau de câbles du panneau des instruments G: Instrumentenpaneelbedradingsbundel RHD (G10 / M13A) (TO E46) (TO E47) (TO E02) LHD (G10 / M13A) (TO E47) (TO E46) (TO E02)
  • Page 41 8A-3-5 LHD (DSL) G91 (Option) (TO E47) (TO E46) G89 (Option) 25 26 G90 (Option) G95 (Option) (TO D27) Connective Aansluit No./Color position Anschlussposition Position de connexion positie A/C harness Klimaanlagen-Kabel- Faisceau de câbles d’A/C A/C-bedradingsbundel baum Main harness (To E02) Haupt-Kabelbaum (ZUM Faisceau de câbles prin- Hoofdbedradingsbundel...
  • Page 42 8A-3-6 D: Injector harness (G10) D:Einspritzventil-Kabelbaum (G10) D:Faisceau de câbles de l’injecteur (G10) D: Verstuiverbedradingsbundel (G10) (TO E40) (TO E41) No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Injector harness Einspritzventil- Faisceau de câbles de Verstuiverbedradingsbun- Kabelbaum l’injecteur Main harness (To E41) Haupt-Kabelbaum (ZUM Faisceau de câbles prin- Hoofdbedradingsbundel...
  • Page 43 8A-3-7 D: Injector harness (DSL) D:Einspritzventil-Kabelbaum (DSL) D:Faisceau de câbles de l’injecteur (DSL) D: Verstuiverbedradingsbundel (DSL) (TO E71) (TO G87) No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Injector harness Einspritzventil- Faisceau de câbles de Verstuiverbedradingsbun- Kabelbaum l’injecteur Injector harness (To G87) Einspritzventil-Kabel- Faisceau de câbles de Verstuiverbedradingsbun- baum (ZUM G87)
  • Page 44 8A-3-8 E: Main harness (G10) E: Haupt-Kabelbaum (G10) E: Faisceau de câbles principal (G10) E: Hoofdbedradingsbundel (G10) (TO G41) (TO B01) (TO G42) 10 11 E62-2 E62-1 (TO C03) (TO D02) (TO D01) (TO G41) (TO G42) 10 11 E62-2 (TO B01) E62-1 (TO C03)
  • Page 45 8A-3-9 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Main harness Haupt-Kabelbaum Faisceau de câbles prin- Hoofdbedradingsbundel cipal E01/BLK Horn Hupe Avertisseur sonore Claxon A/C harness (To B01) Klimaanlagen-kabel- Faisceau de câbles d’A/C A/C-bedradingsbundel E02/N baum (ZUM B01) (AU B01) (naar B01) Front turn signal light (R) Frontblinkleuchte (R) Clignotant avant (D)
  • Page 46 8A-3-10 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Radiator fan control relay Kühlergebläsesteuerre- Relais de commande de Stuurrelais van radiateur- E53/BLK lais ventilateur de radiateur ventilator Horn relay Hupenrelais Relais d’avertisseur Claxonrelais E54/BLK sonore E55/BLK ISC relay ISC-relais Relais d’ISC ISC-relais E56/BLK Main relay...
  • Page 47 8A-3-11 E: Main harness (M13A) E: Haupt-Kabelbaum (M13A) E: Faisceau de câbles principal (M13A) E: Hoofdbedradingsbundel (M13A) (TO C03) (TO G41) E49 E50 (TO C14) (TO C13) (TO G42) 10 11 (A/T) (A/T) (M/T) (A/T)
  • Page 48 8A-3-12 (TO C14) (TO C03) (TO G42) (TO G41) (TO C13) 10 11 (M/T) (A/T) (A/T) (A/T) No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Main harness Haupt-Kabelbaum Faisceau de câbles prin- Hoofdbedradingsbundel cipal E01/BLK Horn Hupe Avertisseur Claxon Front turn signal light (R) Frontblinkleuchte (R) Clignotant avant (D) Richtingaanwijzer voor E03/BLK...
  • Page 49 8A-3-13 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Headlight beam leveling Scheinwerferstrahlnivel- Commande de reglage Actuator van koplamp- E34/BLK actuator (L) lierstellglied (L) du faisceau de phare (G) hoogteverstelling (L) E35/BLK Headlight (L) Scheinwerf-erlicht (L) Phare (G) Koplamp (L) E36/BLK Front position light (L) Vordere parkleuc-hte (L)
  • Page 50 8A-3-14 E: Main harness (DSL) E: Haupt-Kabelbaum (DSL) E: Faisceau de câbles principal (DSL) E: Hoofdbedradingsbundel (DSL) (TO G42) (TO C03) (TO G41) 10 11 (TO D46) No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Main harness Haupt-Kabelbaum Faisceau de câbles prin- Hoofdbedradingsbundel cipal E01/BLK...
  • Page 51 8A-3-15 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Main harness Haupt-Kabelbaum Faisceau de câbles prin- Hoofdbedradingsbundel cipal Headlight beam leveling Scheinwerferstrahlnivel- Commande de reglage Actuator van koplamp- E34/BLK actuator (L) lierstellglied (L) du faisceau de phare (G) hoogteverstelling (L) E35/BLK Headlight (L) Scheinwerf-erlicht (L)
  • Page 52 8A-3-16 Instrument panel Armaturenbrett Panmeau d’instruments Instrumentenpaneel E: Main harness E: Haupt-Kabelbaum E: Faisceau de câbles principal E: Hoofdbedradingsbundel RHD (G10 / M13A) E12 (A/T) E13 (A/T) E61 (G10) E78 (M13A) E79 (M13A) E16 (TO G56) (TO L23) (TO G57) LHD (G10 / M13A) E12 (A/T) E13 (A/T)
  • Page 53 8A-3-17 LHD (DSL) (TO G56) (TO G57) (TO L23) Connective Aansluit No./Color position Anschlussposition Position de connexion positie Main harness Haupt-Kabelbaum Faisceau de câbles prin- Hoofdbedradingsbundel cipal E12/N(A/T) E13/N(A/T) Instrument panel harness Armaturenbrett-kabel- Faisceau de fils électri- Instrumentenpaneelbe- E16/N (To G56) baum (ZUM G56) ques de planche de bord dradingsbundel (naar...
  • Page 54 8A-3-18 G: Instrument panel harness G: Instrumententafel-Kabelbaum G: Faisceau de câbles du panneau des instruments G: Instrumentenpaneelbedradingsbundel RHD (G10 / M13A) G52 (G10) G52-2 14 15 G52-1 (M13A) (A/T) (TO E17) G01-1 G01-2 (TO J09) (TO J10) (TO J01) (TO E16) (TO J02) 16 17 12 13...
  • Page 55 8A-3-19 LHD (M13A) 14 15 G25 G65 G30 G31 G29 G33 G32 G52-2 (A/T) G52-1 G61 (With DRL) G62 (With DRL) G01-2 G01-1 (TO J09) (TO J01) (TO J10) (TO J02) 16 17 12 13 (TO E17) (TO L26) (TO L31) (TO E16) No./Color Connective position...
  • Page 56 8A-3-20 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Instrument panel harness Instrumententafel- Faisceau de câbles du Instrumentenpaneelbe- Kabelbaum panneau des instruments dradingsbundel Front fog light switch Nebelscheinwerferschal- Interrupteur d’anti- Voormistlichtschakelaar G12/BLK brouillard avant Rear fog light switch Schalter für hecknebel- Interrupteur d’anti- Achtermistlichtschake- G13/GRN...
  • Page 57 8A-3-21 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Instrument panel harness Instrumententafel- Faisceau de câbles du Instrumentenpaneelbe- Kabelbaum panneau des instruments dradingsbundel Driver inflator Gasgenerator (Fahrer- Gazogène côté conduc- Opblaaseenheid bestuur- G65/BLK seite) teur dersairbag Passenger inflator Gasgenerator (Beifahrer- Gazogène côté...
  • Page 58 8A-3-22 Roof, rear Dach, heck Toit, Arrière Dak, achter K:Roof wire, Rear roof wire, High mounted stop light wire, Rear wiper wire, Rear defogger wire K: Dachleitung, Hinterer dachdraht,Kabel für oberes bremslicht, Draht für heckscheibenwischer, Heckscheibenbeheizungsdraht K: Fil de toit, Câble de toit arrière, Fil de feu stop en position èlevèe, Câble d’essuie-glace arrière, Achterruitverwarmingskabe K: Dakdraad, achterdakdraad, draad van hooggemonteerd remlicht, achterruitwisserdraad, achterruitverwarmingsdraad O: Rearend door harness O: Hecktür-Kabelbaum...
  • Page 59 8A-3-23 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Rearend door harness Hecktür-Kabelbaum Faisceau de câbles de Kofferdekselbedradings- hayon arrière bundel Floor harness (To L03) Boden-Kabelbaum (ZUM Faisceau de câbles de Vloerbedradingsbundel O01/N L03) plancher (AU L03) (naar L03) Floor harness (To L02) Boden-Kabelbaum (ZUM Faisceau de câbles de Vloerbedradingsbundel...
  • Page 60 8A-3-24 J: Front door wire, Rear door wire J: Fronttürkabel, Hecktürkable J: Fil de portière avant, Fil de portière arrière J: Voorportierdraad, achterportierdraad J19 J03 With power window Without power window (TO G05) (TO G06) (TO L15) (TO G55) (TO L20) (TO G54) With power window Without power window...
  • Page 61 8A-3-25 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Front door wire (Driver Fronttüraabel (Fahrer- Fil de portièr avant (Côté Voorportierdraad side) seite) conducteur) (bestuurderszijde) Instrument panel harness Armaturenbrett-kabel- Faisceau de fils électri- Instrumentenpaneelbe- J01/N (To G05) baum (ZUM G05) ques de planche de bord dradingsbundel (naar (AU G05)
  • Page 62 8A-3-26 Floor Boden Plancher Vloer L: Floor harness L: Boden-Kabelbaum L: Faisceau de câbles de plancher L: Vloerbedradingsbundel (TO K03) (TO O01) (TO O02) (TO J17) (TO G07) (TO G08) (TO J15) (TO R01) (A/T) (TO E18) (TO K01) (TO K03) (TO O01) (TO O02) (TO R01)
  • Page 63 8A-3-27 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Floor harness Boden-Kabelbaum Faisceau de câbles de Vloerbedradingsbundel plancher Rear combination light Heckkombinations Feu combiné arrière (D) Combinatielicht achter L01/N leuchte (R) Rearend door harness Hecktür-Kabelbaum Faisceau de câbles de Kofferdekselbedradings- L02/N (To O02) (ZUM O02)
  • Page 64 8A-3-28 G: Instrument panel harness G: Instrumententafel-Kabelbaum G: Faisceau de câbles du panneau des instruments G: Instrumentenpaneelbedradingsbundel Q: Pretensioner wire Q: Gurtstrafferkabel Q: Fil de prétendeur Q: Gordelvoorspannerdraad...
  • Page 65 8A-3-29 No./Color Connective position Anschlussposition Position de connexion Aansluitpositie Instrument panel harness Armaturenbrett- Faisceau de fils Instrumentenpaneelbe- kabelbaum électriques de planche dradingsbundel de bord G66/YEL A/B SDM Pretensioner (Driver Pretensionneur (Fahrer- Vorspanner (Côté con- Gordelvoorspanner G67/YEL side) seite) ducteur) (bestuurderszijde) Side air-bag sensor Seiten-Airbag-Sensor Capteur d’airbag latéral...
  • Page 66 8A-3-30 Memo Notizen Note Memo...
  • Page 67 8A-4-1 Ground (earth) point (G10 / M13A) Massepunkt (G10 / M13A) Points de masse (G10 / M13A) Massapunt (G10 / M13A) 18 19 22 24 8A-4 Right side shown Driver side Passenger side LHD shown M13A...
  • Page 68 8A-4-2 Ground (earth) point (DSL) Massepunkt (DSL) Points de masse (DSL) Massapunt (DSL) 18 19 22 24 Right side shown Driver side Passenger side LHD shown...
  • Page 69 8A-5-1 Power supply diagram Stromversorgungsdiagramm Schéma du circuit d’alimentation Voedingsschema Power supply diagram (G10 / M13A) Stromversorgungsdiagramm (G10 / M13A Schéma du circuit d’alimentation (G10 / M13A) Voedingsschema (G10 / M13A) Main fuse box M13A WHT/BLK WHT/BLU BLK/RED Starting motor BLU/YEL "A-1"...
  • Page 70 8A-5-2 Power supply diagram (DSL) StromversorgungsdiagrammÅiDSL) Schéma du circuit d’alimentation (DSL) Voedingsschema (DSL) Main fuse box 100A WHT/BLK WHT/BLU BLK/RED Starting motor BLU/YEL "A-1" Supplementary Generator fuse box "A-2" Individual circuit fuse (In main fuse box) WHT/RED BLK/YEL LT GRN/RED WHT/BLU GRN/WHT Option...
  • Page 71 8A-5-3 Fuses and the protected parts Sicherungen und geschützte teile Fusibles et pièces protégées Zekeringen en beschermde onderdelen Main fuse box Hauptsicherungskasten Boîte à fusibles principale Hoofdzekeringenkast Control relay relay #1 G10 / M13A Relay "B-7" "A-3" "A-5" H/L.R H/L.L USE THE DESINGNATED FUSES AND RELAYS ONLY LAMP BATT ABS RDTR...
  • Page 72 8A-5-4 Fuse Sicherung Protected circuit Schutzschaltung Circuit protege Beschermd circuit Fusible Zekering Radiator fan control relay Kühlergebläsesteuerre- Relais de commande de Stuurrelais 1 van radia- lais #1 ventilateur de radiateur #1 teurventilator Radiator fan control relay Kühlergebläsesteuerre- Relais de commande de Stuurrelais 2 van radia- #2 (DSL) lais #2 (DSL)
  • Page 73 8A-5-5 Individual circuit fuse box Einzelschaltkreissicherungskasten Boîte à fusibles de circuit individuel Individuele circuitzekeringenkast REAR STOP DOME REAR DOOR HAZARD TAIL CIGAR RADIO DEFG LOCK USE THE DESIGNATED FUSE ONLY FUSE PULLER POWER WINDOW TURN WIPER METER HEATER COIL BACK WASHER Diesel Fuse...
  • Page 74 8A-5-6 Fuse Sicherung Protected circuit Schutzschaltung Circuit protege Beschermd circuit Fusible Zekering Power mirror switch Spiegelschalter Interrupteur de rétrovi- Schakelaar van elek- seurs trisch verstelbare spiegel Radio A/B SDM AIR BAG A/C switch Klimaanlagen-schalter Relais de chauffage A/C-schakelaar Air flow meter (DSL) Lufimassenmesser (DSL) Debitmetre d’air (DSL) Luchtstroommeter (DSL) A/T relay (M13A)
  • Page 75 8A-5-7 Fuse Sicherung Protected circuit Schutzschaltung Circuit protege Beschermd circuit Fusible Zekering Headlight beam leveling Scheinwerferstrahl-nivel- Commande de réglage du Actuator van koplamp- actuator (L) lierstellglied (L) faisceau de phare (G) hoogteverstelling (L) Back-up light switch Rückfahrleuchtenschalter Interrupteur de feux de Achteruitrijlichtschakelaar marche arrière Door lock controller...
  • Page 76 8A-5-8 Supplementary fuse box (DSL) Zusatzsicherungskasten (DSL) Boîte à fusibles supplémentaires (DSL) Hulpzekeringenkast (DSL) Fuse Sicherung Protected circuit Schutzschaltung Circuit protege Beschermd circuit Fusible Zekering Fuel heating relay Kraftstoffheizungsrelais Relais de chauffage du Brandstofverwarmingsre- carburant lais Glow controller Flammwächter Régulateur de préchauf- Voorgloeiregeleenheid fage PTC heater relay #1...
  • Page 77 8A-6-1 System circuit diagram Systemschaltdiagramm Schéma des circuits électriques Elektrisch schema A-1 Cranking system A-1 Kurbelsystem A-1 Systène de démarrage A-1 Startsysteem LOCK D M13A BLK/YEL BLK/YEL 8A-6 BLK/RED BLK/YEL Transaxle range sensor BLK/YEL BLK/YEL BLK/YEL "A-5" BLK/YEL Starting motor...
  • Page 78 8A-6-2 A-2 Charging system A-2 Ladesystem A-2 Système de charge A-2 Laadsysteem M13A only Individual METER G10 / M13A Main fuse box BATT circuit fuse box COIL B 100A BLK/RED BLK/WHT WHT/RED BLK/WHT WHT/RED J/C #4 BLK/WHT BLK/WHT WHT/RED IC regulator Generator...
  • Page 79 8A-6-3 A-3 Cooling system (G10 / M13A) A-3 Kühlsystem (G10 / M13A) A-3 Système de refroidissement (G10 / M13A) A-3 Koelsysteem (G10 / M13A) Main fuse box RDTR BLK/YEL BLK/YEL BLK/YEL BLU/YEL Main relay BLK/RED control relay #1 BLU/RED BLU/BLK BLU/RED BLU/RED "A-5"...
  • Page 80 8A-6-4 A-3 Cooling system (DSL) A-3 Kühlsystem (DSL) A-3 Système de refroidissement (DSL) A-3 Koelsysteem (DSL) Main fuse box RDTR BLU/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLU/YEL BLU/YEL BLK/YEL Control Control Control relay #3 relay #2 relay #1 BLU/RED BLU/ORN LT GRN LT GRN LT GRN "A-5"...
  • Page 81 8A-6-5 A-4 Ignition system (G10) A-4 Zündanlage (G10) A-4 Système d’allumage (G10) A-4 Ontstekingssysteem (G10) Individual circuit fuse box COIL BLK/WHT "A-5" BLK/WHT YEL/BLU "A-5" BLK/WHT BLK/WHT BLK/WHT BLK/WHT Igniter RED/BLU RED/BLU IG COIL RED/BLU Distributor Noise suppressor BLK/YEL BLK/YEL Cont M "F-3"...
  • Page 82 8A-6-6 A-4 Ignition system (M13A) A-4 Zündanlage (M13A) A-4 Système d’allumage (M13A) A-4 Ontstekingssysteem (M13A) Individual COIL circuit fuse box BLK/WHT BLK/WHT "A-5" J/C #4 RED/BLU YEL/BLU BLK/WHT BLK/WHT YEL/BLU BLK/WHT RED/BLU BLK/WHT IG COIL #1 IG COIL #2 BLK/YEL BLK/YEL BLK/YEL...
  • Page 83 8A-6-7 Memo Notizen Note Memo...
  • Page 84 8A-6-8 A-5 Engine & A/C control System (G10) A-5 Motor-und klimaanlagen-steuerystem (G10) A-5 Moteur & systeme de commande du climatiseur (G10) A-5 Motor- en A/C-regelsysteem (G10) (1/4) E40 D02 Main fuse Individual BLK/RED circuit fuse box COIL BLK/RED BLK/RED BLK/YEL BLK/WHT EVAP Canister...
  • Page 85 8A-6-9 (2/4) DOME Individual RADIO circuit fuse box E62-1 WHT/BLU PTC heater relay Control BLK/RED relay "A-3 " RED/WHT RED/WHT BLK/RED BLK/RED WHT/BLK RED/WHT WHT/BLU PTC heater RED/WHT J/C #3 BLU/RED BRN/WHT BLK/WHT BLK/WHT BLU/RED BRN/WHT Heated Heated oxygen oxygen sensor #2 sensor #1 CMP sensor...
  • Page 86 8A-6-10 (3/4) Tail light relay Relay "D-2" "B-3" RED/YEL BLK/YEL RED/YEL BLK/YEL BLK/YEL BLK/RED Dual pressure switch Diode #4 "E-1" IAC relay RED/WHT BLU/RED GRN/WHT LT GRN/RED RED/WHT GRN/RED BLK/YEL GRN/RED BRN/WHT WHT/GRN LT GRN GRN/RED LT GRN/RED BLK/YEL YEL/RED EVAP thermistor WHT/GRN...
  • Page 87 8A-6-11 (4/4) (Tacho) Brake light switch (Check engine) "C-1" "C-3" "D-7" ImbCM Compressor relay "E-1" "A-7" BRN/YEL WHT/BLK GRN/WHT PPL/WHT PNK/BLU YEL/GRN YEL/BLU Igniter Blower fan & ECT sensor "C-1" "A-4 " switch "E-1"...
  • Page 88 8A-6-12 A-5 Engine & A/C control System (M13A) A-5 Motor-und klimaanlagen-steuerystem (M13A) A-5 Moteur & systeme de commande du climatiseur (M13A) A-5 Motor- en A/C-regelsysteem (M13A) (1/4) Individual Main fuse box COIL circuit fuse box BLK/YEL E41 C13 BLK/WHT BLK/RED BLK/RED BLK/RED BLK/YEL...
  • Page 89 8A-6-13 (2/4) BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED Air flow meter (In IAT sensor) valve BLU/ORN BLU/WHT BLU/YEL BLU/RED BLK/RED BLU/WHT BLU/YEL BLU/RED BLU/ORN GRN/YEL LT GRN LT GRN/RED YEL/GRN WHT/GRN GRN/RED LT GRN YEL/GRN GRN/RED WHT/GRN...
  • Page 90 8A-6-14 (3/4) Individual DOME circuit fuse box RADIO BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED WHT/BLU Control (TEMP) relay #1 "C-1" "A-3" Vehicle sensor sensor speed sensor WHT/GRN J/C #5 J/C #5 WHT/GRN WHT/BLU "A-6" RED/BLU BRN/YEL BLK/YEL YEL/BLU BLK/YEL IG COIL #1 IG COIL #2 "A-4"...
  • Page 91 8A-6-15 (4/4) Transaxle range sensor "A-1" Brake light Compressor Cont M Tail light relay switch relay (Immobi) (Speed) (Check engine) (Tacho) "E-1" "D-7" "C-3" "D-3" "C-3" "C-1" "C-1" "F-3" BRN/YEL RED/YEL Cont M GRN/WHT PPL/WHT BRN/YEL "F-3" Dual ImbCM pressure BRN/YEL switch RED/YEL...
  • Page 92 8A-6-16 A-5 Engine & A/C control System (DSL) A-5 Motor-und klimaanlagen-steuerystem (DSL) A-5 Moteur & systeme de commande du climatiseur (DSL) A-5 Motor- en A/C-regelsysteem (DSL) (1/4) Individual Main fuse box circuit fuse box BLK/YEL BLK/YEL BLK/YEL Main relay BLK/WHT BLK/YEL E46 G42 BLK/RED...
  • Page 93 8A-6-17 (2/4) Option Supplementary Individual circuit DOME fuse box fuse box RADIO WHT/BLU BLK/WHT E47 G41 BLK/WHT BLK/WHT BLK/WHT BLK/WHT BLK/WHT BLK/WHT BLU/WHT Fuel heating relay ImbCM Compressor Switch relay "A-7" "E-1" BLK/YEL BLU/ORN GRN/ORN Cont.M "E-1" BLK/YEL BLU/ORN BLK/YEL BLK/YEL BRN/WHT PNK/BLK...
  • Page 94 8A-6-18 (3/4) Individual Supplementary A Early DSL only STOP COIL circuit fuse box fuse box BLK/WHT GRN/RED Diesel engine control circuit G87 D27 BLK/WHT BLK/WHT BLK/WHT BLK/WHT BLK/WHT BLRK/WHT GRN/RED GRN/RED Air flow meter Clutch Brake light switch switch (Oil level) (Oil level) (Check engine) "C-3"...
  • Page 95 8A-6-19 (4/4) With ABS Front wheel speed sensor (R) Without ABS COIL E16 G56 E16 G56 BLK/WHT ORN/BLU WHT/BLU BLK/WHT (SERVICE VEHICLE SOON) (GLOW) (TACHO) (TEMP) Speed sensor relay "C-3" "C-3" "C-1" "C-1" GRY/RED GRN/YEL BRN/YEL WHT/GRN Cont M Control Control Control relay #1...
  • Page 96 8A-6-20 A-6 A/T control system A-6 A/T-steuersystem A-6 Système de commande A/T A-6 A/T-regelsysteem (1/2) TURN Individual BACK circuit fuse box Transaxle range sensor L23 E18 BLU/YEL GRN/RED GRN/BLK Back-up light "D-8" BLU/BLK J/C #5 BLU/BLK A/T shift switch lever Input sensor...
  • Page 97 8A-6-21 (2/2) Individual DOME circuit fuse box COIL RADIO Vehicle speed BLK/WHT WHT/BLU (O/D OFF) sensor "C-3" "A-5" WHT/BLU BLU/YEL WHT/BLU G52-2 A/T relay WHT/BLU PNK/BLU BLU/YEL J/C #5 WHT/RED WHT/BLU WHT/RED J/C #5 WHT/RED BRN/YEL WHT/RED LT GRN/RED WHT/BLU BLK/YEL BLU/RED WHT/RED...
  • Page 98 8A-6-22 A-7 Immobilizer system A-7 Wegfahrsperrensystem A-7 Système immobilisateur A-7 Startblokkeersysteem M13A Individual DOME METER circuit fuse box STOP COIL RADIO BLK/WHT BLK/RED PPL/WHT GRN/RED WHT/BLU ImbCM WHT/BLK WHT/RED J/C #2 WHT/BLK WHT/RED "A-5"...
  • Page 99 8A-6-23 B-1 Windshield wiper and washer B-1 Frontschweibnwischer und waschanlage B-1 Essuie-glace et lave-glace de pare-brise B-1 Voorruitwisser en -sproeier Individual WIPER circuit fuse box WASHER YEL/BLU YEL/BLU YEL/BLU BLU/ORN GRN Washer Switch Intermittent timer Wiper BLK/ORN BLU/BLK BLU/RED BLU/WHT BLU/BLK YEL/BLU BLU/RED...
  • Page 100 8A-6-24 B-2 Rear wiper and washer B-2 Heckschweibenwischer und waschanlage B-2 Essuie-Glace et lave-glace arrière B-2 Achterruitwisser en -sproeier Individual WIPER circuit fuse box WASHER YEL/BLU Switch YEL/BLU Washer BLK/ORN YEL/BLU BLU/BLK J/C #1 YEL/BLU BLK/ORN YEL/BLU BLU/BLK...
  • Page 101 8A-6-25 B-3 Rear defogger B-3 Heckscheibenentfeuchter B-3 Désembueur arrière B-3 Achterruitverwarming REAR Individual HEATER DEFG circuit fuse box BLU/YEL BLK/RED G01-1 Relay BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL Diode #4 BLK/YEL "A-5" Blower fan & Switch...
  • Page 102 8A-6-26 B-4 Power window B-4 Elektrische fensterheber B-4 Vitre électrique B-4 Elektrische ruitbediening Individual POWER circuit fuse box WINDOW WHT/BLU GRN/BLK WHT/BLU RED/BLU RED/BLU GRN/BLK RED/BLU WHT/BLU GRN/BLK WHT/BLU Sub switch Main switch DOWN DOWN Front Front...
  • Page 103 8A-6-27 Memo Notizen Note Memo...
  • Page 104 8A-6-28 B-5 Power door lock B-5 Elektrische türverriegelung B-5 Verrouillage centralisé des portes B-5 Centrale portiervergrendeling (1/2) RHD with power window Individual TURN DOOR LHD with power window circuit fuse box BACK LOCK Without power window YEL/BLK WHT/GRN IF EQPD controller controller WHT/RED...
  • Page 105 8A-6-29 (2/2) IF EQPD controller controller RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK Lock Lock RED/BLK dead dead lock lock Unlock Unlock Front Front RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK Lock Lock dead dead lock lock Unlock Unlock Lock Rear (L) Rear (R) Rear end...
  • Page 106 8A-6-30 B-6 Power mirror B-6 Elektrisch verstellbarer Spiegel B-6 Rétroviseur électrique B-6 Elektrisch verstelbare spiegel Individual circuit fuse box YEL/BLK YEL/BLK Switch DOWN WHT/GRN GRY/RED GRY/BLU WHT/GRN GRY/RED GRY/BLU GRY/RED GRY/BLU LT GRN/RED LT GRN/BLK LT GRN/BLK LT GRN/RED WHT/GRN WHT/GRN WHT/GRN WHT/GRN...
  • Page 107 8A-6-31 B-7 Horn B-7 Hupe B-7 Avertisseur sonore B-7 Claxon G10 / M13A HORN Main fuse box GRN/WHT GRN/WHT GRN/WHT Horn relay BLU/ORN BLU/ORN Horn Horn Horn switch (In driver inflator) J/C #2...
  • Page 108 8A-6-32 C-1 Combination meter (Meter) (G10) C-1 Kombinationsinstrument (Meter) (G10) C-1 Compteur mixte (Compteur) (G10) C-1 Combinatiemeter (meter) (G10) DOME Individual METER RADIO circuit fuse box COIL Tail light relay BLK/WHT "D-3" RED/YEL BLK/RED WHT/BLU BLK/WHT J/C #1 RED/YEL Warning buzzer Speedometer circuit WHT/GRN...
  • Page 109 8A-6-33 C-1 Combination meter (Meter) (M13A / DSL) C-1 Kombinationsinstrument (Meter) (M13A / DSL) C-1 Compteur mixte (Compteur) (M13A / DSL) C-1 Combinatiemeter (meter) (M13A / DSL) Individual DOME METER circuit fuse box RADIO DSL (Option) Tail light relay "D-3" RED/YEL WHT/BLU BLK/RED...
  • Page 110 8A-6-34 C-2 Combination meter (Indicator) C-2 Kombinationsinstrument (Anzeigelampe) C-2 Compteur mixte (Témoin indicateur) C-2 Combinatiemeter (indicator) Main fuse box H/L,L Turn signal switch WHT/BLU (In turn & dimmer switch) "D-6" GRN/YEL WHT/BLU GRN/RED Dimmer & passing switch "D-1" J/C #2...
  • Page 111 8A-6-35 Memo Notizen Note Memo...
  • Page 112 8A-6-36 C-3 Combination meter (Warning light) C-3 Kombinationsinstrument (Wrnleuchte) C-3 Compteur mixte (Témoins d’avertissement) C-3 Combinatiemeter (waarschuwingslampje) (1/2) M13A Early DSL only PPL/WHT GRY/RED GRN/YEL YEL/BLK With DRL PPL/WHT PPL/WHT BLU/YEL YEL/BLK DRL controller ImbCM "A-5" "D-1" YEL/BLK "A-5" "A-7" Cont M YEL/BLK "A-6"...
  • Page 113 8A-6-37 (2/2) Individual METER M13A circuit fuse box DSL (Option) BLK/RED YEL/BLK IF EQPD Warning buzzer ABS / EBD circuit WHT/RED BLU/BLK YEL/GRN GRY/RED BLK/ORN WHT/RED YEL/GRN WHT/RED YEL/GRN BLU/BLK BLK/ORN WHT/RED GRY/RED Generator Cont M Cont.M "A-2" Brake fluid level switch "F-1"...
  • Page 114 8A-6-38 D-1 Headlight system (Without DRL system) D-1 Scheinwerferanlage (Ohne DRL-system) D-1 Système des phares (Sans le système DRL) D-1 Koplampsysteem (zonder DRL-systeem) DSL (Option) Main fuse box H/L.L H/L.R WHT/RED WHT/BLU Headlight (L) Headlight (R) WHT/BLU RED/WHT RED/WHT WHT/BLU RED/WHT RED/WHT RED/WHT...
  • Page 115 8A-6-39 Memo Notizen Note Memo...
  • Page 116 8A-6-40 D-1 Headlight system (With DRL system) D-1 Scheinwerferanlage (Mit DRL-system) D-1 Système des phares (Avec le système DRL) D-1 Koplampsysteem (met DRL-systeem) (1/2) DSL (Option) Main fuse box H/L.L H/L.R WHT/BLU WHT/RED Headlight (R) Headlight (L) WHT/BLU RED/WHT WHT/BLU RED/WHT RED/WHT GRN/RED...
  • Page 117 8A-6-41 (2/2) TAIL HEATER Main fuse box RED/GRN RED/GRN RED/GRN G01-2 Tail light relay GRN/RED RED/BLU BLU/YEL RED/GRN (OIL) "C-3" YEL/BLK WHT/RED RED/WHT DRL controller RED/YEL "D-3" Tail lamp system...
  • Page 118 8A-6-42 D-2 Position,tail and license plate light D-2 Begrenzungs-,heck-und kennzeichenleuchte D-2 Feux de gabart,arriére et de plaque d’immatriculation D-2 Parkeerlicht, achterlicht en kentekenplaatverlichting Without DRL Individual TAIL With DRL circuit fuse box RED/GRN RED/GRN RED/GRN RED/GRN RED/GRN RED/GRN RED/GRN G01-2 G01-2 Tail light relay Tail light relay...
  • Page 119 8A-6-43 Memo Notizen Note Memo...
  • Page 120 8A-6-44 D-3 Illumination light D-3 Beleuchtungslampe D-3 Dispositif d’éclairage D-3 Verlichting (1/2) Individual TURN TAIL circuit fuse box BACK Without DRL With DRL RED/GRN RED/GRN RED/GRN G01-2 Tail light relay GRN/RED RED/YEL Lighting switch Tail Head RED/YEL RED/YEL J/C #1 RED/YEL RED/YEL RED/WHT...
  • Page 121 8A-6-45 (2/2) Without DRL With DRL LHD (A/T) RED/GRN RED/GRN RED/GRN RHD (A/T) G01-2 Tail light relay RED/BLU GRN/RED DRL controller RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL Switch "A-5" J/C #4 "D-9" RED/YEL J/C #1 RED/YEL RED/WHT RED/YEL shift ILL RED/YEL Blower fan &...
  • Page 122 8A-6-46 D-4 Interior light (Without power door lock system) D-4 Innenbeleuchtung (Ohne zentralverriegelung) D-4 Plafonterior (Sans système de verrouillage de portière motorisé) D-4 Interieurverlichting (zonder centrale portiervergrendeling) DOME TURN Individual RADIO BACK circuit fuse box WHT/BLU WHT/BLU WHT/BLU WHT/BLU Lighting switch WHT/BLU WHT/BLU Interior light...
  • Page 123 8A-6-47 D-4 Interior light (With power door lock system) D-4 Innenbeleuchtung (Mit zentralverriegelung) D-4 Plafonterior (Avec système de verrouillage de portière motorisé) D-4 Interieurverlichting (met centrale portiervergrendeling) DOME TURN Individual RADIO BACK circuit fuse box WHT/BLU WHT/BLU WHT/BLU WHT/BLU Lighting switch WHT/BLU WHT/BLU Interior light...
  • Page 124 8A-6-48 D-5 Headlight beam leveling system D-5 Scheinwerfer-nivelliersystem D-5 Système de réglage des faisceaux de phares D-5 Koplamphoogteverstellingssysteem Individual TURN BACK circuit fuse box Tail light relay "D-3" Actuator (R) Actuator (L) RED/YEL GRN/BLK GRN/BLK GRN/BLK J/C #1 RED/WHT GRN/BLK Switch...
  • Page 125 8A-6-49 D-6 Turn signal and hazard warning light D-6 Blinklicht und warnleuchte D-6 Feux clignotants et feux de détresse D-6 Richtingaanwijzers en alarmknipperlicht Individual TURN circuit fuse box HAZARD BACK Turn signal switch (In dimmer & passing switch) controller "B-5" switch GRN/YEL GRN/YEL...
  • Page 126 8A-6-50 D-7 Brake light D-7 Bremsleuchte D-7 Feux stop D-7 Remlicht High mounted stop light (door-mounted) Individual STOP High mounted stop light (spoiler built-in) circuit fuse box C DSL GRN/RED GRN/RED GRN/RED Brake light switch GRN/WHT GRN/BLK GRN/WHT GRN/WHT "A-5" "A-5"...
  • Page 127 8A-6-51 D-8 Back-up light D-8 Rückfahrleuchte D-8 Feux de marche arrière D-8 Achteruitrijlicht TURN Individual BACK circuit fuse box Back-up light switch Transaxle range sensor Back up light (In rear combination light)
  • Page 128 8A-6-52 D-9 Front fog light D-9 Vordere nebelleuchten D-9 Antibrouillard avant D-9 Voormistlicht Tail light relay "D-3" Main fuse box J/C #1 RED/WHT RED/YEL Switch PPL/WHT PPL/WHT LT GRN/RED E47 G41 PPL/WHT PPL/WHT PPL/WHT Relay LT GRN J/C #1 Controller "D-10"...
  • Page 129 8A-6-53 D-10 Rear fog light D-10 Hecknebelleuchte D-10 Antibrouillard arrière D-10 Achtermistlicht Tail light relay "D-3" Individual REAR circuit fuse box RED/WHT J/C #1 RED/WHT BRN/YEL Switch Dimmer Switch & passing switch "D-1" "D-9" RED/BLU PPL/WHT Controller BRN/YEL BRN/YEL BRN/YEL J/C #1 BRN/YEL...
  • Page 130 8A-6-54 E-1 Heater and air conditioner (G10 / M13A) E-1 Heizung und klimaanlage (G10 / M13A) E-1 Chauffage et climatisation (G10 / M13A) E-1 Verwarming en airconditioning (G10 / M13A) RHD (G10) Individual LHD (G10) HEATER circuit fuse box COIL M13A BLU/YEL BLU/WHT...
  • Page 131 8A-6-55 E-1 Heater and air conditioner (DSL) E-1 Heizung und klimaanlage (DSL) E-1 Chauffage et climatisation (DSL) E-1 Verwarming en airconditioning (DSL) Option Option Individual Individual Individual Individual Supplementary Supplementary REAR REAR HEATER HEATER circuit circuit circuit circuit fuse box fuse box COIL COIL...
  • Page 132 8A-6-56 F-1 Anti-lock brake system F-1 Antiblockiersystem F-1 Système d’antiblocage des freins F-1 Antiblokkeersysteem (1/2) Individual DOME METER Main fuse box circuit fuse box RADIO WHT/BLU BLK/RED WHT/BLK WHT/RED ABS / EBD circuit J/C #2 WHT/BLK WHT/BLK WHT/BLK WHT/RED BLU/BLK Brake light switch WHT/RED "D-7"...
  • Page 133 8A-6-57 (2/2) Front wheel speed Front wheel speed Rear wheel speed Rear wheel speed sensor (L) sensor (R) sensor (R) sensor (L) BLK/RED WHT/BLU ORN/BLU BLK/RED Cont M PPL/WHT Diagnosis connector "A-5"...
  • Page 134 8A-6-58 F-2 Air-bag control system F-2 Airbag-steuersystem F-2 Système de commande des airbags F-2 Airbagregelsysteem (1/2) DOME RADIO Individual circuit fuse box WHT/BLU BLU/RED WHT/RED J/C #2 WHT/RED GRN/RED YEL/RED LT GRN Contact coil 12 16...
  • Page 135 8A-6-59 (2/2) Individual METER circuit fuse box BLK/RED Connection detection pin IF EQPD GRN/YEL WHT/RED RED/BLK GRN/WHT GRN/ORN GRN/BLK RED/YEL WHT/GRN sensor sensor...
  • Page 136 8A-6-60 F-3 Power steering F-3 Servolenkung F-3 Direction assistée F-3 Stuurbekrachtigingssysteem (1/2) Main fuse box Individual DOME METER circuit fuse box RADIO COIL M13A BLK/RED BLK/RED WHT/BLU BLK/WHT BLK/RED BLK/RED Cont M WHT/RED J/C #2 WHT/BLU WHT/RED "A-5" Vehicle speed sensor "A-5"...
  • Page 137 8A-6-61 (2/2) Noise suppressor M13A "A-4" "A-5" BRN/YEL BRN/YEL BRN/YEL Cont M C2 C3 C4 B1 B2 B3 B4 Torque sensor Motor & clutch...
  • Page 138 8A-6-62 G-1 Radio G-1 Radio G-1 Radio G-1 Radio DOME Individual RADIO circuit fuse box WHT/BLU YEL/BLK Tail light relay YEL/BLK "D-3" RED/YEL Antenna YEL/BLK Antenna J/C #1 RED/YEL Radio LT GRN/BLK GRY/RED LT GRN GRY/BLU LT GRN/BLK GRY/RED BLU/BLK BLK/WHT BLK/RED LT GRN...
  • Page 139 8A-6-63 G-2 Cigarette lighter G-2 Zigarettenanzünder G-2 Allume-cigares G-2 Sigarettenaansteker Individual circuit fuse box CIGAR YEL/BLK BLU/BLK Tail light relay Cigarette lighter "D-2" YEL/BLK RED/YEL J/C #1 Accessory socket RED/YEL Ashtray ILL J/C #1...
  • Page 140 8A-6-64 G-3 Clock G-3 Uhr G-3 Horloge G-3 Klok Individual DOME circuit fuse box RADIO Without DRL WHT/BLU YEL/BLK Tail light relay "D-3" RED/YEL J/C #1 RED/YEL Clock J/C #1...

  • Page 141: Connector List

    8A-7-1 Connector list Liste der stecker Liste des connecteurs Lijst van stekkers B01 (TO E02) B01 (TO E02) C03 (TO E26) C03 (TO E26) G10, DSL M13A 8A-7 G10, M13A G10, M13A G10, DSL M13A C13 (TO E41) 9 10 11 12 13 14 15 16 C14 (TO E40) 12 11 10 9...
  • Page 142 8A-7-2 1 2 3 1 2 3 D01 (TO E41) D02 (TO E40) 9 10 11 12 12 11 10 9 13 14 15 16 16 15 14 13 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30...
  • Page 143 8A-7-3 5 4 3 2 1 D46 (TO E71) 1 2 3 4 5 6 E02 (TO B01) E02 (TO B01) E16 (TO G56) 10 9 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 14 13 12 11 18 19...
  • Page 144 8A-7-4 E17 (TO G57) E18 (TO L23) 9 10 9 10 11 12 5 6 7 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 15 16 17 18 19 20 9 10 11 12 13 7 8 9 13 14 15 16...
  • Page 145 8A-7-5 E46 (TO G42) E46 (TO G42) E47 (TO G41) 9 10 11 12 13 14 15 16 G10, M13A E62-1 E62-2 1 2 3 3 4 5 IF EQPD E71 (TO D46) 3 2 1 6 5 4 6 7 8...
  • Page 146 8A-7-6 G01-1 G01-2 G05 (TO J01) 1 2 3 5 6 7 8 9 10 12 13 14 15 16 17 18 8 7 6 5 3 4 5 G06 (TO J02) G07 (TO L26) G08 (TO L31) 9 10 1 2 3 4 5 6 7 8 3 4 5 6 11 12...
  • Page 147 8A-7-7 3 4 5 G10,DSL G52-1 G52-2 G54 (TO J09) G55 (TO J10) 1 2 3 6 5 4 3 3 4 5 G56 (TO E16) G57 (TO E17) G61 (IF EQPD) 9 10 6 5 4 11 12 13 14 15 16 17 18 19 20 G62 (IF EQPD) 1 2 3 4 5 6 7 8...
  • Page 148 8A-7-8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 33 34 35 36 37 38 39 40 41 42 43 44 48 49 50 31 32 46 47 53 54 55 56 57 58 59 60 61 62 63 64 65 66 68 69...
  • Page 149 8A-7-9 L02 (TO O02) L03 (TO O01) 3 2 1 L15 (TO J17) L13 (TO R01) 1 2 3 L20 (TO J15) 1 2 3 L23 (TO E18) L25 (TO K01) L26 (TO G07) 10 9 10 9 3 2 1 14 13 12 11 14 13...
  • Page 150 8A-7-10 O01 (TO L03) O02 (TO L02) O03 (TO O08) O05 (TO O10) 1 2 3 1 2 3 O08 (TO O03) O10 (TO O05) 1 2 3 R01 (TO L13)
  • Page 151 8A-8-1 Glossary Fachbegriffe Glossaire Verklarende woordenlijst English Deutsch Français Nederlands A/C amplifier Klimaanlagenverstärker Amplificateur d’A/C A/C-versterker A/C mode actuator Klimaanlage-Betriebsart-Stell- Actuateur de mode A/C A/C-standactuator element A/C Pressure sensor Klimaanlagendrucksensor Capteur de pression d’A/C A/C-druksensor A/C & Rear defogger switch Klimaanlagen- und Heckschei- Commande d’A/C et désem- A/C- en achterruitverwar-...
  • Page 152 8A-8-2 English Deutsch Français Nederlands Front intermittent timer relay Vorderes Intervallwischer- Relais de minuterie essuie- Intervaltimerrelais voor Timerrelais glace intermittent avant Fuel heating relay Kraftstoffheizungsrelais Relais de chauffage du carbu- Brandstofverwarmingsrelais rant Fuel level gauge Kraftstoffstandgeber Jauge de niveau de carburant Brandstofpeilmeter Fuel pressure sensor Kraftstoffdrucksensor...
  • Page 153 8A-8-3 English Deutsch Français Nederlands Photo diode Photodiode Photo-diode Fotodiode Photo transistor Phototransistor Photo-transistor Fototransistor Piezoelectric element Piezoelement Elément piézoélectrique Piëzo-elektrisch element Position light Positionsleuchte Feu de position Parkeerlicht Pressure regulator Druckregler Régulateur de pression Drukregelaar Pressure switch Druckschalter Contacteur de pression Drukschakelaar Rear intermittent timer relay Hinteres Intervallwischer-...
  • Page 154 8A-8-4 Memo Notizen Note Memo...
  • Page 155 Prepared by 1st Ed. January, 2004 146F...
  • Page 156 And used as the main subject of descrip- tion is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. MAGYAR SUZUKI SYSTEM CIRCUIT DIAGRAM 8A-7 CORPORATION reserves the right to make changes at any time without notice.
  • Page 157 Fahrzeugs ab. Das Recht zu LISTE DER STECKER 8A-8 Veränderungen, auch unangemeldet, behalten wir uns vor. Die MAGYAR SUZUKI CORPORATION behält sich das Recht auf Änderungen jederzeit und ohne vorherige Ankündigung vor. Für Inspektions- und Wartungsarbeiten an elektrischen Bauteilen ist als zusätzliche Hilfe auch das folgende Bezugsmaterial erhältlich.
  • Page 158 SCHÉMA DES SYSTÈMES ÉLECTRIQUES 8A-7 noter que les illustrations peuvent présenter des différences par rapport aux véhicules en question. MAGYAR SUZUKI CORPORATION se réserve le droit de procéder à des modifications sans préavis. LISTE DES BLOCS RACCORD 8A-8 Pour les travaux d'entretien et de réparation des DE CÂBLAGE...
  • Page 159 In de beschrijvingen wordt het voertuigmodel met de SYSTEEMCIRCUITDIAGRAM 8A-7 standaard specificaties gebruikt. Daarom kunnen sommige afbeeldingen afwijken van het voertuig waaraan u moet werken. MAGYAR SUZUKI COR- PORATION behoudt zich het recht voor op enig tijdstip zonder voorafgaande kennisgeving LIJST VAN AANSLUITINGEN 8A-8 wijzigingen aan te brengen.
  • Page 160 HOW TO USE THIS MANUAL 8A-1-1 SECTION 8A-1 8A-1 HOW TO USE THIS MANUAL CONTENTS · Manual Contents and Description ...................... 8A-1-2 · Applicability ............................8A-1-2 · Cautions in Servicing ......................... 8A-1-3 · Symbols and Marks..........................8A-1-6 · Abbreviations ............................8A-1-7 ·...
  • Page 161 8A-1-2 HOW TO USE THIS MANUAL MANUAL CONTENTS AND DESCRIPTION This manual consists of diagrams showing the harness routing, connector layout, installation positions of single unit parts (fuse, relay, control unit), ground points, power circuit, system circuit and list of connectors. SECTION DESCRIPTION Arrangement of connectors used in this vehicle is shown in relation with the wiring...
  • Page 162 HOW TO USE THIS MANUAL 8A-1-3 CAUTIONS IN SERVICING When performing works related to electric systems, observe fol- lowing cautions for the purpose of protection of electrical parts and prevention of a fire from occurrence. · When removing the battery from the vehicle or disconnecting the cable from the battery terminals for inspection or service works on the electric systems, always confirm first that the ignition switch and all the other switches have been turned...
  • Page 163 8A-1-4 HOW TO USE THIS MANUAL · When installing the wiring harness, fix it with clamps so that no slack is left. · When installing vehicle parts, be careful so that the wiring harness is not interfered with or caught by any other part. ·...
  • Page 164 Service on or around Air Bag System Components or Wiring must be performed only by an autho- rized Suzuki dealer. Please observe all the warnings described in "On Vehicle Service section", the Air Bag System Component and Wiring Location View in the service manual mentioned in FORE- WORD of this manual before performing service on or around Air Bag System Components or Wiring.
  • Page 165 8A-1-6 HOW TO USE THIS MANUAL SYMBOLS AND MARKS In the diagrams of this manual, each equipments are represented by the symbols and marks as shown below. Battery Ground Normal Fuse Slow blow fuse Circuit breaker Coil, Solenoid Heater Bulb Cigarette lighter Motor Pump...
  • Page 166 HOW TO USE THIS MANUAL 8A-1-7 ABBREVIATIONS Listed below are the abbreviations as used in this manual and their full terms. Abbreviation Full term Abbreviation Full term 2 wheel drive vehicles Indicator 4 WD 4 wheel drive vehicles Intermittent Air conditioning Joint connector Automatic transmission LH (D)
  • Page 167 8A-1-8 HOW TO USE THIS MANUAL HOW TO READ CONNECTOR LAYOUT DIAGRAM When necessary to know the location of an electrical part or an intermediate connector, it is easily possible to retrieve it by this diagram. First consult “SYSTEM CIRCUIT DIAGRAM” section or connector table at the right hand pages of this section for the questioned connector code.
  • Page 168 HOW TO USE THIS MANUAL 8A-1-9 INDICATION OF CONNECTORS AND HOW TO READ THEM The connectors are indicated as shown below in "SYSTEM CIRCUIT DIAGRAM" section. For the shape and pin arrangement of each connector used in this manual, refer to "LIST OF CONNECTORS" section. Described below are how they are indicated and how to read them.
  • Page 169 8A-1-10 HOW TO USE THIS MANUAL 3. · Wiring of this vehicle uses joint connectors (J/C) which divide one wire into several different wires or combine several different wires into one wire. · The joint connector is illustrated below. How to Read Connector Codes and Pin Nos. (How to Use Manual) : It is possible to retrieve the location and shape of each connector from the connector code indicated in "SYSTEM CIRCUIT DIAGRAM"...
  • Page 170 HOW TO USE THIS MANUAL 8A-1-11 HOW TO READ INSTALLATION POSITION OF SINGLE UNIT PARTS The diagram in "INSTALLATION POSITION OF SINGLE UNIT PARTS" section shows installation positions of fuse, relays and control units used in this vehicle. They are illustrated as shown below. ENGINE ROOM (RIGHT HAND STEERING VEHICLE) MOTORRAUM (FAHRZEUG MIT RECHTSLENKUNG) COMPARTIMENT MOTEUR (VEHICULE A CONDUITE A DROITE)
  • Page 171 8A-1-12 HOW TO USE THIS MANUAL HOW TO READ GROUND POINT Ground point means the position where the negative harness among wiring harnesses is grounded. The diagram in "GROUND POINT" section shows such ground points. In "SYSTEM CIRCUIT DIAGRAM" section, there are many ground marks followed by black circles with numerical figures in them ( ) which mean that the end of the harness with such black circle is grounded to some part of the vehicle.
  • Page 172 HOW TO USE THIS MANUAL 8A-1-13 HOW TO READ POWER SUPPLY DIAGRAM Power Supply Diagram shows the circuit from the positive terminal of the battery to each fuse in the box and where each fuse is connected (each system circuit name). In addition, the electric load value of each fuse is indicated.
  • Page 173 8A-1-14 HOW TO USE THIS MANUAL HOW TO READ SYSTEM CIRCUIT DIAGRAM The circuit diagram of each system shows the electric circuit from the main fuse, fuse box or the ignition switch (at the top in the diagram) to the ground (at the bottom) so that the circuit can be followed easily when performing inspection and service work.
  • Page 174 HOW TO USE THIS MANUAL 8A-1-15 FUSE BOX Symbol mark Wire color Symbol marks are used for better legibility. This indicates the color of For more information, refer the wire. to item "SYMBOLS AND MARKS" in "HOW TO USE THIS SECTION". SOLENOID MAIN RELAY...
  • Page 175 8A-1-16 HOW TO USE THIS MANUAL HOW TO READ LIST OF CONNECTORS "LIST OF CONNECTORS" section is provided to help identification when looking for the connector in question out of similar ones as well as for retrieval for positions of pins in the connector when checking continuity between pins, etc.
  • Page 176 VERWENDUNG DIESER ANLEITUNG 8A-1-17 ABSCHNITT 8A-1 8A-1 VERWENDUNG DIESER ANLEITUNG INHALT · Inhalt und Beschreibung ........................8A-1-18 · Anwendbarkeit ..........................8A-1-18 · Vorsichtsmaßregeln für die Wartung ....................8A-1-19 · Symbole und Markierungen ......................8A-1-22 · Abkürzungen ............................ 8A-1-23 · Farbcodierungssymbole der Anschlußdrähte ................... 8A-1-23 ·...
  • Page 177 8A-1-18 VERWENDUNG DIESER ANLEITUNG INHALT UND BESCHREIBUNG Diese Anleitung besteht aus Diagrammen, welche die Kabelbaumführung, das Layout der Stecker, die Einbaupositionen der unabhängigen Einheiten (Sicherung, Relais, Steuergerät), die Massepunkte, den Stromlaufplan, die Systemkreisläufe und eine Liste der Stecker zeigen. ABSCHNITT BESCHREIBUNG Die Anordnung der in diesem Fahrzeug verwendeten Stecker ist im Zusammenhang Stecker-Layout-...
  • Page 178 VERWENDUNG DIESER ANLEITUNG 8A-1-19 VORSICHTSMASSREGELN FÜR DIE WARTUNG Bei Wartungsarbeiten mit Bezug auf die elektrische Anlage sind zum Schutz der Fahrzeugelektrik und zur Verhütung von Bränden die folgenden Sicherheitshinweise zu beachten. · Vor dem Ausbau der Batterie oder Trennen der Anschlußkabel von den Batteriepolen für Inspektions- oder Wartungsarbeiten am elektrischen System stets darauf achten, die Zündung auszuschalten und alle sonstigen Schalter auf OFF zu stellen,...
  • Page 179 8A-1-20 VERWENDUNG DIESER ANLEITUNG · Kabel beim Verlegen mit Kabelklemmen befestigen, so daß keine lockeren oder durchhängenden Kabelabschnitte vorhanden sind. NEIN! · Beim Einbauen von Fahrzeugteilen darauf achten, daß das Kabel hierdurch nicht behindert oder durch Einbauteile abgeklemmt wird. NEIN! ·...
  • Page 180 Dieses Fahrzeug ist mit einem zusätzlichen Airbag-Rückhaltesystem ausgerüstet. Wartungen an den und rund um die Komponenten des Airbagsystems oder an der Verdrahtung dürfen nur von einem autorisierten SUZUKI-Vertragshändler ausgeführt werden. Bitte beachten Sie alle in dem Abschnitt "Wartungsarbeiten am Fahrzeug", sowie in den Ansichten der Komponenten und der Verdrahtung des Airbagsystems in der im VORWORT dieser Anleitung erwähnten Wartungsanleitung aufgeführten...
  • Page 181 8A-1-22 VERWENDUNG DIESER ANLEITUNG SYMBOLE UND MARKIERUNGEN In den Plänen dieses Handbuchs ist jedes Bauteil durch ein Symbol dargestellt oder wie unten gezeigt markiert. Batterie Masse Normale Sicherung Träge Sicherung Unterbrecher Spule, Magnet Heizung Birne Zigarettenanzünder Motor Pumpe Hupe Lautsprecher Summer Gong Kondensator...
  • Page 182 VERWENDUNG DIESER ANLEITUNG 8A-1-23 ABKÜRZUNGEN Die nachstehende Tabelle zeigt die in dieser Anleitung verwendeten Abkürzungen und deren Bedeutung. Abkürzung Bedeutung Abkürzung Bedeutung Fahrzeuge mit Zweiradantrieb Indikator Fahrzeuge mit Allradantrieb Unterbrochen Klimaanlage Verbundstecker Automatikgetriebe LH(D) Fahrzeug mit Linkslenkung Zubehör Tief Kurbelwellenposition Schaltgetriebe Nockenwellenposition Absoluter Druck im Auspuffkrümmer...
  • Page 183 8A-1-24 VERWENDUNG DIESER ANLEITUNG WIE DAS STECKER-LAYOUT-DIAGRAMM ZU LESEN IST Wenn Sie die Position eines elektrischen Teils oder eines Zwischensteckers kennen müssen, können Sie diese einfach dem vorliegenden Diagramm entnehmen. Sehen Sie zuerst in dem “SYSTEMSCHALTDIAGRAMM” für den Steckercode des fraglichen Steckers nach, und suchen sie danach den gleichen Code in diesem Abschnitt auf.
  • Page 184 VERWENDUNG DIESER ANLEITUNG 8A-1-25 ANSCHLUSSMARKIERUNGEN UND IDENTIFIZIERUNG Die Stecker sind bezeichnet, wie es im nachfolgenden Abschnitt “SYSTEMSCHALDIAGRAMM” dargestellt ist. Für die Form und Stiftbelegung jedes in dieser Anleitung verwendeten Steckers, siehe den Abschnitt “LISTE DER STECKER”.Nachfolgend ist beschrieben, wie diese Stecker bezeichnet sind und wie diese Bezeichnungen gelesen werden können.
  • Page 185 8A-1-26 VERWENDUNG DIESER ANLEITUNG 3. · Die Verdrahtung dieses Fahrzeuges verwendet Verbindungsstecker (J/C), die einen Draht in mehrere Drähte unterteile bzw. mehrere unterschiedliche Drähte in einen Draht kombinieren. · Ein Verbindungsstecker ist nachfolgend dargestellt. Ablesen des Steckercodes und der Stift-Nr. (Verwendung dieser Anleitung): Anhand des in dem Abschnitt “SYSTEMSCHALTDIAGRAMM”...
  • Page 186 VERWENDUNG DIESER ANLEITUNG 8A-1-27 ERKLÄRUNG DER EINBAUPOSITIONEN VON EINZELEINHEITS- TEILEN Das Diagramm im Abschnitt "EINBAUPOSITION DER EINZELNEN TEILE DER EINHEIT" zeigt die Einbaupositionen für Sicherungen, Relais und Steuereinheiten in diesem Fahrzeug. Die Positionen sind wie unten dargestellt. Um den Massepunkt (Einbauposition) festzustellen, siehe Abschnitt “MASSEPUNKT”. ENGINE ROOM (RIGHT HAND STEERING VEHICLE) MOTORRAUM (FAHRZEUG MIT RECHTSLENKUNG) COMPARTIMENT MOTEUR (VEHICULE A CONDUITE A DROITE)
  • Page 187 8A-1-28 VERWENDUNG DIESER ANLEITUNG ERKLÄRUNG EINES MASSEPUNKTS Massepunkt bedeutet die Stelle, wo die negative Leitung der Verdrahtung geerdet ist. Das Diagramm "MASSEPUNKT" zeigt solche Erdungspunkte. Im Abschnitt "SYSTEMSCHALTDIAGRAMM" gibt es viele Erdungsmarkierungen, gefolgt von schwarzen Kreisen mit Ziffern darin ( ), die bedeuten, daß das Ende des Kabels mit einem derartigen schwarzen Kreis an einem Teil des Fahrzeugs geerdet ist.
  • Page 188 VERWENDUNG DIESER ANLEITUNG 8A-1-29 ERKLÄRUNG EINES STROMVERSORGUNGSDIAGRAMMS Der Abschnitt "BETRIEBSSTROMDIAGRAMM" zeigt die Schaltung von der positive Klemme der Batterie zu jeder Sicherung im Sicherungskasten und zeigt, wo jede Sicherung angeschlossen ist (alle Namen der Systemschaltungen). Außerdem wird die elektrische Last jeder Sicherung angezeigt. Da jedes “SYSTEMSCHALTDIAGRAMM”...
  • Page 189 8A-1-30 VERWENDUNG DIESER ANLEITUNG ERKLÄRUNG EINES SYSTEMSCHALTDIAGRAMM Das Systemschaltdiagramm jedes Systems zeigt die elektrische Schaltung von der Hauptsicherung, vom Sicherungskasten oder vom Zündschalter (oben im Schaltplan) bis zur Erdung (am Boden), so daß sich die Schaltung bei der Wartung oder Inspektion leicht verfolgen läßt. Weitere Informationen über Stecker, Massepunkt und Sicherungen finden Sie durch Querverweise mit dem “SYSTEMSCHALTDIAGRAMM”...
  • Page 190 VERWENDUNG DIESER ANLEITUNG 8A-1-31 Symbolmarkierung 15A 20A Symbolmarkierungen dienen Drahtfarbe der besseren Lesbarkeit. Weitere Information siehe Dieser Code kennzeichnet OMBINATION “SYMBOLE UND die Farbe des Drahtes. ETER MARKIERUNGEN” in (REED) “VERWENDUNG DIESES ABSCHNITTS”. SOLENOID MAIN RELAY Gleiche Markierung Zeigt an, daß der Zwischenstecker identisch ist.
  • Page 191 8A-1-32 VERWENDUNG DIESER ANLEITUNG WIE DIE LISTE DER STECKER ZU LESEN IST Der Abschnitt “LISTE DER STECKER” hilft bei der Identifikation, wenn Sie nach einem fraglichen Stecker unter mehreren ähnlichen Stecker suchen; weiterhin hilft dieser Abschnitt bei der Feststellung der Stiftpositionen in einem Stecker, wenn auf Stromdurchgang zwischen Stiften usw.
  • Page 192 ORGANISATION DE CE MANUEL 8A-1-33 SECTION 8A-1 8A-1 ORGANISATION DE CE MANUEL TABLE DES MATIÈRES · Contenu et description du manuel ....................8A-1-34 · Détails des applications ........................8A-1-34 · Précautions ............................8A-1-35 · Symboles et repères ........................8A-1-38 · Abréviations ............................8A-1-39 ·...
  • Page 193 8A-1-34 ORGANISATION DE CE MANUEL CONTENU ET DESCRIPTION DU MANUEL Ce manuel se compose de schémas représentant l’acheminement des faisceaux de fils électriques, la disposition des blocs raccord de câblage, les positions d’implantation des pièces indépendantes (fusible, relais, dispositif de commande), les points de mise à la masse, le circuit d’alimentation, le circuit de système et la liste des blocs raccord de câblage.
  • Page 194 ORGANISATION DE CE MANUEL 8A-1-35 PRÉCAUTIONS Afin de prévenir toute détérioration des circuits électriques et tout risque d'incendie, prendre les précautions suivantes lors de travaux sur les circuits électriques. · Avant d'enlever la batterie du véhicule ou de débrancher le câble des bornes de la batterie et d'effectuer des travaux d'entretien ou de réparation sur les circuits électriques, toujours s'assurer que le contacteur d'allumage et tous les autres...
  • Page 195 8A-1-36 ORGANISATION DE CE MANUEL · Fixer les faisceaux électriques avec des brides de sorte qu'ils soient bien tendus. NON! · Lors de l'installation des pièces du véhicule, veiller à ce qu'aucun faisceau électrique ne gêne ou soit pris par une autre pièce.
  • Page 196 à sac gonflable ou du câblage doivent être exécutés par un concessionnaire Suzuki autorisé. Veuillez vous conformer à toutes les mises en garde décrites dans la rubrique intitulée "Section entretien exécuté sur le véhicule", consulter les schémas des organes du système à...
  • Page 197 8A-1-38 ORGANISATION DE CE MANUEL SYMBOLES ET REPÈRES Dans ce manuel, chaque appareil est représenté par les symboles et les repères suivants. Batterie Masse Fusible ordinaire Fusible à fusion lente Disjoncteur Bobine, Solénoïde Chauffage Ampoule Allume-cigares Moteur Pompe Avertisseur sonore Haut-parleur Vibreur Signal musical...
  • Page 198 ORGANISATION DE CE MANUEL 8A-1-39 ABRÉVIATIONS Les abréviations utilisées dans ce manuel et les termes complets correspondants sont indiqués ci-dessous. Abréviation Terme complet Abréviation Terme complet Véhicules deux roues motrices Indicateur Véhicules quatre roues motrices Intermittent Climatisation Connecteur joint Boîte à vitesses automatique LH (D) Véhicule à...
  • Page 199 8A-1-40 ORGANISATION DE CE MANUEL COMMENT INTERPRÉTER LE SCHÉMA DE DISPOSITION DES BLOCS RACCORD DE CÂBLAGE Quand il est nécessaire de connaître l’emplacement d’un organe électrique ou d’un bloc raccord de câblage intermédiaire, il est très facile d’obtenir le renseignement à l’aide de ce schéma. Consulter tout d’abord la section intitulée “SCHÉMA DE CIRCUIT DE SYSTÈME”...
  • Page 200 ORGANISATION DE CE MANUEL 8A-1-41 INDICATION ET LÉGENDE DES CONNECTEURS Les blocs raccord de câblage sont indiqués comme représenté dans la section intitulée “SCHÉMA DE CIRCUIT DE SYSTÈME”. En ce qui concerne la forme et la disposition des broches de chaque bloc raccord de câblage utilisé...
  • Page 201 8A-1-42 ORGANISATION DE CE MANUEL 3. · Le câblage de ce véhicule fait usage de blocs raccord de jonction (J/C) qui permettent de diviser un fil en plusieurs fils différents ou en plusieurs fils différents combinés dans un même câble. ·...
  • Page 202 ORGANISATION DE CE MANUEL 8A-1-43 LÉGENDE DES POSITIONS D'INSTALLATION DES PIECES INDIVIDUELLES Le schéma dans la section "POSITIONS D'INSTALLATION DES PIECES INDIVIDUELLES" indique les positions d'installation des fusibles, relais et blocs de commande utilisés dans ce véhicule.Elles sont illustrées de la façon suivante.
  • Page 203 8A-1-44 ORGANISATION DE CE MANUEL LÉGENDE DES POINTS MASSE Le point de masse signifie la position où le faisceau négatif des faisceaux de câblage est mis à la masse. Le schéma dans la section "POINT MASSE" indique les divers points de masse. Dans la section "SCHÉMA DES CIRCUITS DU SYSTÈME", de nombreux repères de masse sont suivis de cercles noirs contenant des nombres ( ).
  • Page 204 ORGANISATION DE CE MANUEL 8A-1-45 LÉGENDE DES SCHÉMAS DU CIRCUIT D'ALIMENTATION La section Schéma du Circuit D'alimentation indique le circuit à partir de la borne positive de la BATTERIE jusqu'à chaque fusible dans le boîtier à fusibles et où chaque fusible est raccordé (nom de circuit de chaque système).
  • Page 205 8A-1-46 ORGANISATION DE CE MANUEL LÉGENDE DES SCHÉMAS DES CIRCUITS ÉLECTRIQUES Le schéma du circuit électrique de chaque système montre le circuit à partir du fusible principal, du boîtier à fusibles ou du contacteur d'allumage (haut du schéma) jusqu'à la masse (bas du schéma) de sorte qu'il sera aisé de suivre tout le circuit lors des travaux d'entretien ou de réparation.
  • Page 206 ORGANISATION DE CE MANUEL 8A-1-47 FUSE BOX Symbole repère Des symboles repères sont Code de couleur utilisés pour améliorer la compréhension. Pour de Indique la couleur du câble plus amples informations, OMBINATION se reporter à “SYMBOLES ETER ET REPÈRES” dans (REED) “COMMENT UTILISER CETTE SECTION”.
  • Page 207 8A-1-48 ORGANISATION DE CE MANUEL COMMENT INTERPRÉTER LA LISTE DES BLOCS RACCORD DE CÂBLAGE La section intitulée “LISTE DES BLOCS RACCORD DE CÂBLAGE” a été compilée à des fins d’assistance à l’identification lorsque le bloc raccord de câblage en question est recherché parmi des blocs raccord de câblage similaires ainsi que pour retrouver l’implantation des broches du bloc raccord de câblage quand il s’agit de vérifier la continuité...

  • Page 208: Table Of Contents

    GEBRUIK VAN DEZE HANDLEIDING 8A-1-49 DEEL 8A-1 8A-1 GEBRUIK VAN DEZE HANDLEIDING INHOUD · Inhoud en beschrijving van deze handleiding .................. 8A-1-50 · Van toepassing zijnde modellen ....................... 8A-1-50 · Wees voorzichtig wanneer u onderhoud pleegt ................8A-1-51 · Symbolen en tekens......................... 8A-1-54 ·...

  • Page 209: Inhoud En Beschrijving Van Deze Handleiding

    8A-1-50 GEBRUIK VAN DEZE HANDLEIDING INHOUD EN BESCHRIJVING VAN DEZE HANDLEIDING Deze handleiding bevat diagrammen voor het leiden van de bundels, plaats van aansluitingen, installatieplaats van enkele onderdelen (zekering, relais, regeleenheid), aardepunten, spanningcircuit, systeemcircuit, lijst van aansluitingen en algehele bedrading. DEEL BESCHRIJVING Rangschikking van stekkers en aansluitingen gebruikt in dit voertuig wordt getoond...

  • Page 210: Wees Voorzichtig Wanneer Uonderhoud Pleegt

    GEBRUIK VAN DEZE HANDLEIDING 8A-1-51 WEES VOORZICHTIG WANNEER U ONDERHOUD PLEEGT Wanneer u werk gaat uitvoeren dat te maken heeft met de elektrische systemen, dient u de volgende voorzorgen in acht te nemen om de elektrische onderdelen te beschermen en brand te voorkomen.
  • Page 211 8A-1-52 GEBRUIK VAN DEZE HANDLEIDING · Wanneer u de bedradingsbundel gaat installeren, dient u deze vast te zutten met klemmen zodat hij nergens los hangt. NEE! · Wanneer u onderdelen van het voertuig gaat installeren, moet u voorzichtig zijn dat u de bedradingsbundel niet hindert of door enig onderdeel afklemt.
  • Page 212 Airbag-systeem mag alleen worden uitgevoerd door een erkende Suzuki dealer. Neemt u alstublieft alle waarschuwingen in acht die zijn beschreven in de sectie “Over onderhoud aan het voertuig”, en de Air Bag System Component en bedrading...

  • Page 213: Symbolen En Tekens

    8A-1-54 GEBRUIK VAN DEZE HANDLEIDING SYMBOLEN EN TEKENS In de diagrammen in deze handleiding worden de gebruikte onderdelen voorgesteld door de hieronder vermelde symbolen en tekens. Accu Aarde Normale zekering Langzame zekering Stroomonderbreker Spoel, Solenoïde Verwarming Lamp Sigarettenaansteker Motor Pomp Claxon Luidspreker Zoemer...

  • Page 214: Afkortingen

    GEBRUIK VAN DEZE HANDLEIDING 8A-1-55 AFKORTINGEN Zie de volgende lijst voor de in deze handleiding gebruikte afkortingen en hun betekenis. Afkorting Betekenis Afkorting Betekenis auto’s met 2-wielaandrijving Indicator auto’s met 4-wielaandrijving Met tussenpozen airconditioning Verbindingsaansluiting Automatische transmissie LH (D) Stuur links (voertuig) Accessoire Laag Krukaspositie...

  • Page 215: Hoe Stekker-Layout Diagrammen Gelezen Moeten Worden (Deel 8A-3)

    8A-1-56 GEBRUIK VAN DEZE HANDLEIDING HOE STEKKER-LAYOUT DIAGRAMMEN GELEZEN MOETEN WORDEN Wanneer u de plaats van een elektrisch onderdeel of een tussenstekker moet opzoeken, kunt u deze gemakkelijk terugvinden met behulp van dit diagram. Kijk eerst in de sectie “SYSTEEMCIRCUITDIAGRAM” of in de stekkertabel op de bladzijden aan de rechterkant van deze sectie voor de gezochte stekkercode.

  • Page 216: Hoe Stekkers Worden Aangegeven En Hoe Deze Gelezen Moeten Worden

    GEBRUIK VAN DEZE HANDLEIDING 8A-1-57 HOE STEKKERS WORDEN AANGEGEVEN EN HOE DEZE GELEZEN MOETEN WORDEN De stekkers worden zoals hieronder afgebeeld aangeduid in de sectie “SYSTEEMCIRCUITDIAGRAM”. Voor de vorm en de penposities van de diverse stekkers die in deze handleiding gebruikt worden, dient u de "LIJST VAN AANSLUITINGEN"...
  • Page 217 8A-1-58 GEBRUIK VAN DEZE HANDLEIDING 3. · De bedrading van dit voertuig maakt gebruik van varbindingsstukken die een enkele draad in verschillende draden kunnen splitsen of verschillende draden kunnen samenvoegen tot een draad. · Een dergelijk verbindingsstuk ziet u hieronder afgebeeld. Hoe u stekkercodes en pen-nummers moet aflezen (Hoe u de handleiding moet gebruiken): Het is mogelijk om de plaats en vorm van elke stekker terug te vinden via de stekkercode zoals die staat aangegeven in de sectie “SYSTEEMCIRCUITDIAGRAM”...

  • Page 218: Hoe Installatieposities Van Eenheidsonderdelen Gelezen Moeten Worden (Deel 8A-4)

    GEBRUIK VAN DEZE HANDLEIDING 8A-1-59 HOE INSTALLATIEPOSITIES VAN EENHEIDSONDERDELEN GELEZEN MOETEN WORDEN Het diagram in de secctie “INSTALLATIEPOSITIES VAN EENHEIDSONDERDELEN” laat de installatieposities zien van zekeringen, relais en bedieningseenheden zoals die in dit voertuig gebruikt worden. Deze worden aangegeven zoals hieronder staat afgebeeld. ENGINE ROOM (RIGHT HAND STEERING VEHICLE) MOTORRAUM (FAHRZEUG MIT RECHTSLENKUNG) COMPARTIMENT MOTEUR (VEHICULE A CONDUITE A DROITE)

  • Page 219: Hoe De Aardingspunten Gelezen Moeten Worden (Deel 8A-5)

    8A-1-60 GEBRUIK VAN DEZE HANDLEIDING HOE DE AARDINGSPUNTEN GELEZEN MOETEN WORDEN Een aardingspunt is een plek waar de negatieve draad van de bedradingsbundel geaard wordt. Het diagram in de sectie “AARDEPUNT” laat dergelijke aardingspunten zien. In de sectie “SYSTEEMCIRCUITDIAGRAM” staan vele aardingstekens gevolgd door zwarte cirkels met nummers ( ), hetgeen betekent dat het uiteinde van de bedradingsbundel met een dergelijk zwart cirkeltje ergens aan een onderdeel van het voertuig geaard is.
  • Page 220 GEBRUIK VAN DEZE HANDLEIDING 8A-1-61 HOE EEN STROOMVOORZIENINGSDIAGRAM GELEZEN MOETN WORDEN Het stroomvoorzieningsdiagram laat de schakelingen zien vanaf de positieve aansluiting van de accu naar elke zekering in de zekeringenkast en waar elke zekering is aangesloten (elke systeemschakeling-naam). Bovendien staat de elektrische belastingswaarde van elke zekering aangegeven. Aangezien elk “SYSTEEMCIRCUIT-DIAGRAM”...

  • Page 221: Hoe Een Systeemschakelingsdiagram Gelezen Moet Worden (Deel 8A-7)

    8A-1-62 GEBRUIK VAN DEZE HANDLEIDING HOE EEN SYSTEEMSCHAKELINGSDIAGRAM GELEZEN MOET WORDEN Het schakelingsdiagram van elk systeem laat de elektrische schakeling zien vanaf de hoofdzekering, de ze- keringenkast of de contactschakelaar (bovenaan het diagram) naar de aarding (onderaan), zodat de schakeling gemakkelijk gevolgd kan worden wanneer u inspectie en onderhoudswerkzaamheden uit gaat voeren.
  • Page 222 GEBRUIK VAN DEZE HANDLEIDING 8A-1-63 ZEKERING Symboolteken 15A 20A Symbooltekens worden gebruikt om de Draadkleur leesbaarheid te verbeteren. Raadpleeg het onderdeel Dit geeft de kleur van “SYMBOLEN EN TEKENS” de draad aan. onder “GEBRUIK VAN MBINATIEMETER DEZE HANDLEIDING” voor (REED) meer informatie.

  • Page 223: Hoe De Lijst Van Stekkers En Aansluitingen Gelezen Moet Worden (Deel 8A-8)

    8A-1-64 GEBRUIK VAN DEZE HANDLEIDING HOE DE LIJST VAN STEKKERS EN AANSLUITINGEN GELEZEN MOET WORDEN De sectie “LIJST VAN AANSLUITINGEN” is bedoeld om te helpen bij de identificatie wanneer u naar een bepaalde stekker aan het zoeken bent tussen vergelijkbare stekkers, en ook wanneer u de posities van pennen moet opzoeken in de stekker wanneer u de stroomdoorvoer tussen bepaalde pennen moet controleren enz.
  • Page 224 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-1 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM SECTION 8A-3 ABSCHNITT 8A-3 SECTION 8A-3 DEEL 8A-3 CONNECTOR LAYOUT DIAGRAM ANSCHLUSSSCHALTPLAN 8A-3 SCHÉMA DE DISPOSITION DES CONNECTEURS STEKKER LAYOUT DIAGRAM CONTENTS INHALT TABLE DES MATIÈRES INHOUD •...
  • Page 225 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-2 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ENGINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK A: BATTERY CABLE C: ENGINE HARNESS A: BATTERIEKABEL C: MOTORKABELBAUM A: CÂBLE DE BATTERIE C: FAISCEAU DE MOTEUR A: ACCUKABEL C: BEDRADINGSBUNDEL MOTOR (E26) ENGINE HARNESS...
  • Page 226 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-3 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 227 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-4 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ENGINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK B: A/C HARNESS G: INSTRUMENT PANEL HARNESS B: KLIMAANLAGEN-KABELBAUM G: INSTRUMENTENTAFEL-KABELBAUM B: FAISCEAU C/A G: FAISCEAU DE TABLEAU DE BORD B: BEDRADINGSBUNDEL AIR-CONDITIONER G: BEDRADINGSBUNDEL INSTRUMENTENPANEEL RECHTS (E46)
  • Page 228 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-5 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 229 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-6 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ENGINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK D: INJECTOR HARNESS D: EINSPRITZVORRICHTUNG-KABELBAUM D: FAISCEAU DE FILS ÉLECTRIQUES D’INJECTEUR D: BEDRADINGSBUNDEL INJECTOR 1.0L (E41) (E40) INJECTOR HARNESS EINSPRITZVORRICHTUNG-KABELBAUM FAISCEAU DE FLS ÉLECTRIQUES D'INJECTOR BEDRADINGSBUNDEL INJECTOR...
  • Page 230 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-7 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 231 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-8 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ENGINE ROOM (1.0L) MOTORRAUM (1,0L) COMPARTIMENT MOTEUR (1,0L) MOTORBAK (1,0L) E: MAIN HARNESS E: HAUPTKABELBAUM E: FAISCEAU PRINCIPAL E: HOOFDBEDRADINGSBUNDEL RECHTS CONDUITE À DROITE (G41) (B01) MET STUUR RECHTS (G42)
  • Page 232 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-9 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. CONNECTEUR NO. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] STEKKER NR.
  • Page 233 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-10 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ENGINE ROOM (1.0L) MOTORRAUM (1,0L) COMPARTIMENT MOTEUR (1,0L) MOTORBAK (1,0L) E: MAIN HARNESS E: HAUPTKABELBAUM E: FAISCEAU PRINCIPAL E: HOOFDBEDRADINGSBUNDEL RECHTS (G41) CONDUITE À DROITE (B01) MET STUUR RECHTS (G42)
  • Page 234 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-11 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 235 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-12 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ENGINE ROOM (1.3L) MOTORRAUM (1,3L) COMPARTIMENT MOTEUR (1,3L) MOTORBAK (1,3L) E: MAIN HARNESS E: HAUPTKABELBAUM E: FAISCEAU PRINCIPAL E: HOOFDBEDRADINGSBUNDEL RECHTS E49 E50 CONDUITE À DROITE (G41) (B01) MET STUUR RECHTS...
  • Page 236 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-13 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 237 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-14 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ENGINE ROOM (1.3L) MOTORRAUM (1,3L) COMPARTIMENT MOTEUR (1,3L) MOTORBAK (1,3L) E: MAIN HARNESS E: HAUPTKABELBAUM E: FAISCEAU PRINCIPAL E: HOOFDBEDRADINGSBUNDEL RECHTS E49 E50 CONDUITE À DROITE (G41) (B01) MET STUUR RECHTS...
  • Page 238 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-15 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. CONNECTEUR NO. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] STEKKER NR.
  • Page 239 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-16 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM INSTRUMENT PANEL INSTRUMENTENTAFEL TABLEAU DE BORD INSTRUMENTENPANEEL E: MAIN HARNESS E: HAUPTKABELBAUM E: FAISCEAU PRINCIPAL E: HOOFDBEDRADINGSBUNDEL RECHTS CONDUITE À DROITE MET STUUR RECHTS (TYPE 1) (G56) (L23) (G57)
  • Page 240 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-17 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. CONNECTEUR NO. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] STEKKER NR.
  • Page 241 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-18 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM INSTRUMENT PANEL INSTRUMENTENTAFEL TABLEAU DE BORD INSTRUMENTENPANEEL G: INSTRUMENT PANEL HARNESS G: INSTRUMENTENTAFEL-KABELBAUM G: FAISCEAU DE TABLEAU DE BORD G: HOOFDBEDRADINGSBUNDEL INSTRUMENT PANEL HARNESS INSTRUMENTENTAFEL-KABELBAUM FAISCEAU DE TABLEAU DE BORD RECHTS HOOFDBEDRADINGSBUNDEL...
  • Page 242 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-19 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. CONNECTEUR NO. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] STEKKER NR.
  • Page 243 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-20 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM INSTRUMENT PANEL INSTRUMENTENTAFEL TABLEAU DE BORD INSTRUMENTENPANEEL G: INSTRUMENT PANEL HARNESS G: INSTRUMENTENTAFEL-KABELBAUM G: FAISCEAU DE TABLEAU DE BORD G: HOOFDBEDRADINGSBUNDEL INSTRUMENT PANEL HARNESS INSTRUMENTENTAFEL-KABELBAUM RECHTS FAISCEAU DE TABLEAU DE BORD HOOFDBEDRADINGSBUNDEL...
  • Page 244 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-21 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. CONNECTEUR NO. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] STEKKER NR.
  • Page 245 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-22 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM INSTRUMENT PANEL & FLOOR (TYPE 1) INSTRUMENTENTAFEL & BODEN (TYP 1) TABLEAU DE BORD & PLANCHER (TYPE 1) INSTRUMENTENPANEEL & VLOER (TIPO 1) Q: AIR BAG HARNESS Q: AIRBAG-KABELBAUM Q: FAISCEAU DE COUSSIN D’AIR Q: BEDRADINGSBUNDEL AIR-BAG...
  • Page 246 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-23 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 247 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-24 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM INSTRUMENT PANEL & FLOOR (TYPE 2,3) INSTRUMENTENTAFEL & BODEN (TYP 2,3) TABLEAU DE BORD & PLANCHER (TYPE 2,3) INSTRUMENTENPANEEL & VLOER (TIPO 2,3) G: INSTRUMENT PANEL HARNESS Q: AIR BAG HARNESS G: INSTRUMENTENTAFEL-KABELBAUM Q: AIRBAG-KABELBAUM...
  • Page 248 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-25 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. CONNECTEUR NO. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] STEKKER NR.
  • Page 249 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-26 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM ROOF, REAR DACH, HECK TOIT, ARRIÈRE DAK, ACHTERKANT K: ROOF WIRE, REAR ROOF WIRE N:REAR DEFOGGER WIRE K: DACHDRAHT, HINTERER DACHDRAHT N: HECKSCHEIBENBEHEIZUNGSDRAHT K: CÂBLE DE TOIT, CÂBLE DE TOIT ARRIÈRE N: CÂBLE DE DÉSEMBUEUR ARRIÈRE K: DAKKABEL, ACHTERSTE DAKKABEL N: ACHTERRUITVERWARMINGSKABEL...
  • Page 250 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-27 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 251 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-28 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM DOOR TÜR PORTE PORTIER J: DOOR HARNESS J: TÜRKABELBAUM J: FAISCEAU DE PORTE J: PORTIERKABELBUNDEL FRONT DOOR HARNESS (DRIVER SIDE) VORDER-KABELBAUM (FAHRERSEITE) FAISCEAU DE FILS LECTRIQUES DES (EXCEPT TYPE 3) PORTES AVANT (CÔTÉ...
  • Page 252 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-29 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. CONNECTEUR NO. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] STEKKER NR.
  • Page 253 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-30 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM FLOOR BODEN PLANCHER VLOER L: FLOOR HARNESS L: BODENKABELBAUM L: FAISCEAU DE PLANCHER L: BEDRADINGSBUNDEL VLOER RECHTS (O01) (O02) CONDUITE À DROITE (K03) MET STUUR RECHTS (J17) (G07) (G08)
  • Page 254 CONNECTOR LAYOUT DIAGRAM / ANSCHLUSSSCHALTPLAN 8A-3-31 SCHÉMA DE DISPOSITION DES CONNECTEURS / STEKKER LAYOUT DIAGRAM CONNECTOR No. MATING COMPONENT [MATING CONNECTOR] / ZUSAMMENPASSENDE KOMPONENTE [ZUSAMMENPASSENDER ANSCHLUSS] ANSCHLUSS-NR. COMPOSANT DE CONNEXION [CONNECTEUR DE CONNEXION] / BIJPASSEND ONDERDEEL [BIJPASSEND STEKKER] CONNECTEUR NO. STEKKER NR.
  • Page 255 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-1 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN SECTION 8A-4 ABSCHNITT 8A-4 SECTION 8A-4 DEEL 8A-4 INSTALLATION POSITIONS OF SINGLE UNIT PARTS EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN 8A-4 CONTENTS...
  • Page 256 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-2 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN ENGINE ROOM (RIGHT HAND STEERING VEHICLE) MOTORRAUM (FAHRZEUG MIT RECHTSLENKUNG) COMPARTIMENT MOTEUR (VEHICULE A CONDUITE A DROITE) MOTORBAK (VOERTUIG MET RECHTS STUUR) RADIATOR FAN CONTROL (TYPE 1) HORN RELAY [E54]...
  • Page 257 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-3 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN ENGINE ROOM (LEFT HAND STEERING VEHICLE) MOTORRAUM (FAHRZEUG MIT LINKSLENKUNG) COMPARTIMENT MOTEUR (VEHICULE A CONDUITE A GAUCHE) MOTORBAK (VOERTUIG MET LINKS STUUR) RADIATOR FAN CONTROL (TYPE 1) HORN RELAY [E54]...
  • Page 258 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-4 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN ENGINE ROOM (1.0L) MOTORRAUM (1,0L) COMPARTIMENT MOTEUR (1,0L) MOTORBAK (1,0L) NOISE SUPPRESSOR [G58] EFE HEATER RELAY #1 [E62-1] EFE HEATER RELAY #2 [E62-2] STÖRFUNKEN- CHAUFFE-EFE-RELAIS #1 CHAUFFE-EFE-RELAIS #2...
  • Page 259 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-5 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN MEMO NOTIZEN NOTE MEMO...
  • Page 260 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-6 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN INSTRUMENT PANEL (RIGHT HAND STEERING VEHICLE) INSTRUMENTENTAFEL (FAHRZEUG MIT RECHTSLENKUNG) TABLEAU DE BORD (VEHICULE A CONDUITE A DROITE) INSTRUMENTENPANEEL (VOERTUIG MET RECHTS STUUR) INTERMITTENT TIMER [G51] REAR WINDOW DEFOGGER RELAY TAIL LIGHT RELAY [G01-2]...
  • Page 261 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-7 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN INSTRUMENT PANEL (LEFT HAND STEERING VEHICLE) INSTRUMENTENTAFEL (FAHRZEUG MIT LINKSLENKUNG) TABLEAU DE BORD (VEHICULE A CONDUITE A GAUCHE) INSTRUMENTENPANEEL (VOERTUIG MET LINKS STUUR) INTERMITTENT DOOR LOCK DRL CONTROLLER...
  • Page 262 INSTALLATION POSITIONS OF SINGLE UNIT PARTS / EINBAUPOSITIONEN VON EINZELEINHRIT-TEILEN 8A-4-8 PASITIONS D’INSTALLATION DES PIECES INDIVIDUELLES / INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN FLOOR BODEN PLANCHER VLOER RECHTS RECHTS CONDUITE À DROITE CONDUITE À DROITE MET STUUR RECHTS MET STUUR RECHTS DIODE #5 [L27] DIODE #4 [L28] DIODE #5 DIODE #4...
  • Page 263 GROUND POINT / MASSEPUNKT 8A-5-1 POINTS DE MASSE / AARDEPUNT SECTION 8A-5 ABSCHNITT 8A-5 SECTION 8A-5 DEEL 8A-5 GROUND POINT MASSEPUNKT POINTS DE MASSE AARDEPUNT CONTENTS INHALT TABLE DES MATIÈRES INHOUD 8A-5 · ENGINE ROOM ..........................8A-5-2 · INSTRUMENT PANEL ........................8A-5-3 ·...
  • Page 264 GROUND POINT / MASSEPUNKT 8A-5-2 POINTS DE MASSE / AARDEPUNT ENGINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK 1.3L ONLY 1.0L ONLY NUR 1,3L NUR 1,0L 1,3L UNIQUEMENT 1,0L UNIQUEMENT ALLEEN 1,3L ALLEEN 1,0L...
  • Page 265 GROUND POINT / MASSEPUNKT 8A-5-3 POINTS DE MASSE / AARDEPUNT INSTRUMENT PANEL INSTRUMENTENTAFEL TABLEAU DE BORD INSTRUMENTENPANEEL RECHTS CONDUITE À DROITE MET STUUR RECHTS LINKS CONDUITE À GAUCHE MET STUUR LINKS...
  • Page 266 GROUND POINT / MASSEPUNKT 8A-5-4 POINTS DE MASSE / AARDEPUNT FLOOR BODEN PLANCHER VLOER...
  • Page 267 GROUND POINT / MASSEPUNKT 8A-5-5 POINTS DE MASSE / AARDEPUNT REAR TÜR PORTE ACHTERKANT...
  • Page 268 POWER SUPPLY DIAGRAM / STROMVERSORGUNGSDIAGRAMM 8A-6-1 SCHÉMA DU CIRCUIT D’ALIMENTATION / SPANNINGSTOEVOER-DIAGRAM SECTION 8A-6 ABSCHNITT 8A-6 SECTION 8A-6 DEEL 8A-6 POWER SUPPLY DIAGRAM STROMVERSORGUNGSDIAGRAMM SCHÉMA DU CIRCUIT D’ALIMENTATION SPANNINGSTOEVOER-DIAGRAM CONTENTS INHALT TABLE DES MATIÈRES INHOUD − POWER SUPPLY DIAGRAM (TYPE 1,2) ................. 8A-6-2 −...
  • Page 269 POWER SUPPLY DIAGRAM / STROMVERSORGUNGSDIAGRAMM 8A-6-2 SCHÉMA DU CIRCUIT D’ALIMENTATION / SPANNINGSTOEVOER-DIAGRAM POWER SUPPLY DIAGRAM (TYPE 1,2) STROMVERSORGUNGSDIAGRAMM (TYP 1,2) SCHÉMA DU CIRCUIT D’ALIMENTATION (TYPE 1,2) SPANNINGSTOEVOER-DIAGRAM (TIPO 1,2) RECHTS MAIN FUSE CONDUITE A DROITE HAUPTSICHERUNG MET STUUR RECHTS FUSIBLE PRINCIPAL HOOFDZEKERING LINKS CONDUITE A GAUCHE...
  • Page 270 POWER SUPPLY DIAGRAM / STROMVERSORGUNGSDIAGRAMM 8A-6-3 SCHÉMA DU CIRCUIT D’ALIMENTATION / SPANNINGSTOEVOER-DIAGRAM W HT G01-2 G01-2 TAIL LIGHT RELAY HECKLEUCHTENRELAIS TAIL LIGHT RELAY RELAIS DE FEU ARRIÈRE DRL CONTROLLER HECKLEUCHTENRELAIS ACHTERLICHTRELAIS DRL-REGLER RELAIS DE FEU ARRIÈRE REGULATEUR DE DRL ACHTERLICHTRELAIS DRL REGELAAR YEL/RED GRN/RED...
  • Page 271 POWER SUPPLY DIAGRAM / STROMVERSORGUNGSDIAGRAMM 8A-6-4 SCHÉMA DU CIRCUIT D’ALIMENTATION / SPANNINGSTOEVOER-DIAGRAM POWER SUPPLY DIAGRAM (TYPE 3) STROMVERSORGUNGSDIAGRAMM (TYP 3) SCHÉMA DU CIRCUIT D’ALIMENTATION (TYPE 3) SPANNINGSTOEVOER-DIAGRAM (TIPO 3) RECHTS MAIN FUSE CONDUITE A DROITE HAUPTSICHERUNG MET STUUR RECHTS FUSIBLE PRINCIPAL HOOFDZEKERING LINKS CONDUITE A GAUCHE...
  • Page 272 POWER SUPPLY DIAGRAM / STROMVERSORGUNGSDIAGRAMM 8A-6-5 SCHÉMA DU CIRCUIT D’ALIMENTATION / SPANNINGSTOEVOER-DIAGRAM MAIN FUSE / FUSE / RELAY BOX HAUPTSICHERUNG / SICHERUNG / RELAISKASTEN FUSIBLE PRINCIPAL / FUSIBLE / BOÎTIER DE RELAIS HOOFDZEKERING / ZEKERING / RELAIS WHT/RED BLK/YEL GRN/WHT WHT/BLU LT GRN/RED <IF EQUIPPED>...
  • Page 273 POWER SUPPLY DIAGRAM / STROMVERSORGUNGSDIAGRAMM 8A-6-6 SCHÉMA DU CIRCUIT D’ALIMENTATION / SPANNINGSTOEVOER-DIAGRAM MAIN FUSE / FUSE / RELAY HAUPTSICHERUNG / SICHERUNG / RELAIS FUSIBLE PRINCIPAL / FUSIBLE / RELAIS FUSIBLE PRINCIPAL / FUSIBLE / RELE RADIATOR FAN CONTROL RELAY KÜHLERGEBLÄSE-STEUERRELAIS RELAIS DE COMMANDE DE VENTILATEUR DE RADIATEUR HORN RELAY STUURRELAIS RADIATEURVENTILATOR...
  • Page 274 POWER SUPPLY DIAGRAM / STROMVERSORGUNGSDIAGRAMM 8A-6-7 SCHÉMA DU CIRCUIT D’ALIMENTATION / SPANNINGSTOEVOER-DIAGRAM FUSE (TYPE 3) SICHERUNG (TYP 3) FUSIBLE (TYPE 3) ZEKERING (TIPO 3) NOTE: The number at each fuse corresponds to that of Power Supply Disgram (8A-6-2,3) or System Circuit Diagram (8A-7). HINWEIS: Die Nummer jeder Sicherung entspricht der jeweiligen Nummer auf dem Stromversorgungsdiagramm (8A-6-2,3) oder Systemschaltdiagramm (8A-7).
  • Page 275 SYSTEM CIRCUIT DIAGRAM 8A-7-1 SECTION 8A-7 SYSTEM CIRCUIT DIAGRAM CONTENTS SYSTEM No. : SYSTEM PAGE No. : CRANKING SYSTEM ......................8A-7-5 : CRANKING SYSTEM ....................... 8A-7-5 : CHARGING SYSTEM ......................8A-7-6 : CHARGING SYSTEM ....................... 8A-7-6 : COOLING SYSTEM ......................8A-7-7 : COOLING SYSTEM .........................
  • Page 276 SYSTEMSCHALTDIAGRAMM 8A-7-2 ABSCHNITT 8A-7 SYSTEMSCHALTDIAGRAMM INHALT SYSTEM-NR. : SYSTEM Seite -NR. : KURBELSYSTEM ....................... 8A-7-5 : KURBELSYSTEM ........................8A-7-5 : LADESYSTEM ........................8A-7-6 : LADESYSTEM .......................... 8A-7-6 : KÜHLSYSTEM ........................8A-7-7 : KÜHLSYSTEM ......................... 8A-7-7 : ZÜNDSYSTEM ........................8A-7-8 : ZÜNDSYSTEM ......................... 8A-7-8 : MOTORSTEURESYSTEM .....................
  • Page 277 SCHÉMA DES CIRCUITS ÉLECTRIQUES 8A-7-3 SECTION 8A-7 SCHÉMA DES CIRCUITS ÉLECTRIQUES TABLES DES MATIÈRES SYSTÈME NO. : SYSTÈME PAGE NO. : SYSTÈME DE DÉMARRAGE ..................... 8A-7-5 : SYSTÈME DE DÉMARRAGE ....................8A-7-5 : SISTEMA DE CARGA ......................8A-7-6 : SISTEMA DE CARGA ......................8A-7-6 : SYSTEME DE REFROIDISSEMENT ..................
  • Page 278 SYSTEEMCIRCUITDIAGRAM 8A-7-4 DEEL 8A-7 SYSTEEMCIRCUITDIAGRAM INHOUD SYSTEEM NR. : SYSTEEM BLADZIJDE NR. : STARTSYSTEEM ........................ 8A-7-5 : STARTSYSTEEM ........................8A-7-5 : LAADSTROOMSYSTEEM ....................8A-7-6 : LAADSTROOMSYSTEEM ....................... 8A-7-6 : KOELSYSTEEM ........................8A-7-7 : KOELSYSTEEM ........................8A-7-7 : ONTSTEKINGSSYSTEEM ....................8A-7-8 : ONTSTEKINGSSYSTEEM......................
  • Page 279 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-5 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-1:CRANKING SYSTEM A-1:KURBELSYSTEM A-1:SYSTÈME DE DÉMARRAGE A-1:STARTSYSTEEM (SEE "POWER SUPPLY DIAGRAM") MAIN FUSE (SIEHE "STROMVERSORGUNGSDIAGRAMM") HAUPTSICHERUNG (VOIR "SCHÉMA DU CIRCUIT D'ALIMENTATION") FUSIBLE PRINCIPAL (ZIE "SPANNINGSTOEVOER-DIAGRAM") HOOFDZEKERING WHT/BLU LOCK MAIN SWITCH HAUPTSCHALTER COMMUTATEUR PRINCIPAL...
  • Page 280 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-6 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-2:CHARGING SYSTEM A-2:LADESYSTEM A-2:SYSTÈME DE CHARGE A-2:LAADSTROOMSYSTEEM 1.3L CIRCUIT FUSE MAIN FUSE SCHALTKREISSICHERUNG HAUPTSICHERUNG 1.0L BATT FUSIBLE DE CIRCUIT FUSIBLE PRINCIPAL COIL CIRCUITZEKERING HOOFDZEKERING BLK/WHT BLK/WHT BLK/WHT BLK/WHT COMBINATION COMBINATION METER...
  • Page 281 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-7 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-3:COOLING SYSTEM A-3:KÜHLSYSTEM A-3:SYSTEME DE REFROIDISSEMENT A-3:KOELSYSTEEM CIRCUIT FUSE MAIN FUSE SCHALTKREISSICHERUNG HAUPTSICHERUNG RDTR FUSIBLE DE CIRCUIT FUSIBLE PRINCIPAL CIRCUITZEKERING HOOFDZEKERING BLK/YEL BLK/YEL BLK/YEL MAIN RELAY BLU/YEL HAUPTRELAIS RELAIS PRINCIPAL HOOFDRELAIS BLK/RED...
  • Page 282 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-8 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-4:IGNITION SYSTEM (1.0L) A-4:ZÜNDSYSTEM (1,0L) A-4:SYSTÈM D'ALLUMAGE (1,0L) A-4:ONTSTEKINGSSYSTEEM (1,0L) CIRCUIT FUSE SCHALTKREISSICHERUNG COIL FUSIBLE DE CIRCUIT CIRCUITZEKERING BLK/WHT ENGINE CONTROL MODULE (SEE "A-5") MOTORSTEUERMODUL (SIEHE "A-5") MODULE DE COMMANDE DU MOTEUR (VOIR "A-5") MOTORREGELAPPARAAT (ZIE "A-5") BLK/WHT ENGINE CONTROL MODULE (SEE "A-5")
  • Page 283 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-9 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-4:IGNITION SYSTEM (1.3L) A-4:ZÜNDSYSTEM (1,3L) A-4:SYSTÈM D'ALLUMAGE (1,3L) A-4:ONTSTEKINGSSYSTEEM (1,3L) CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT COIL CIRCUITZEKERING BLK/WHT ENGINE CONTROL MODULE (SEE "A-5") MOTORSTEUERMODUL (SIEHE "A-5") MODULE DE COMMANDE DU MOTEUR (VOIR "A-5") MOTORREGELAPPARAAT (ZIE "A-5") BLK/WHT YEL/BLU...
  • Page 284 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-10 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-5:ENGINE CONTROL SYSTEM (1.0L) 1 of 2 A-5:MOTORSTEUESYSTEM 1 (1,0L) von 2 A-5:SYSTÈM DE COMMANDE DU MOTOR (1,0L) 1 de 2 A-5:MOTORREGELSYSTEEM (1,0L) 1 op 2 E40 D02 CIRCUIT FUSE SCHALTKREISSICHERUNG COIL...
  • Page 285 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-11 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM CIRCUIT FUSE SCHALTKREISSICHERUNG DOME FUSIBLE DE CIRCUIT RADIO CIRCUITZEKERING E62-1 WHT/BLU RADIATOR FAN CONTROL RELAY EFE HEATER RELAY #1 (SEE "A-3") CHAUFFE-EFE-RELAIS #1 KÜHLERLÜFTERRELAIS (SIEHE "A-3") RELAIS DE EFE HEIZUNG #1 BLK/RED RELAIS DE COMMANDE DE VENTILATEUR EFE VERWARMING RELAIS #1...
  • Page 286 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-12 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-5:ENGINE CONTROL SYSTEM (1.0L) 2 of 2 A-5:MOTORSTEUESYSTEM (1,0L) 2 von 2 A-5:SYSTÈM DE COMMANDE DU MOTOR (1,0L) 2 de 2 A-5:MOTORREGELSYSTEEM (1,0L) 2 op 2 <LHD ONLY> LICENSE PLATE LIGHT (SEE "D-3") REAR WINDOW DEFOGGER ZULASSUNGSSCHILDBELEUCHTUNG...
  • Page 287 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-13 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM COMBINATION METER (SEE "C-1") KOMBINATIONSINSTRUMENT (SIEHE "C-1") COMPTEUR MIXTE (VOIR "C-1") COMBINATIEMETER (ZIE "C-1") CHECK EFE HEATER RELAY #2 ENGINE TACHO (SEE "F-1") IMMOBILIZER CONTROL CHAUFFE-EFE-RELAIS #2 MODULE (SEE "A-7") (SIEHE "F-1") WEGFAHRSPERRE RELAIS DE EFE HEIZUNG #2...
  • Page 288 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-14 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-5:ENGINE CONTROL SYSTEM (1.3L) 1 of 2 A-5:MOTORSTEUESYSTEM (1,3L) 1 von 2 A-5:SYSTÈM DE COMMANDE DU MOTOR (1,3L) 1 de 2 A-5:MOTORREGELSYSTEEM (1,3L) 1 op 2 CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT COIL...
  • Page 289 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-15 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM COMBINATION METER (SEE "C-1") KOMBINATIONSINSTRUMENT (SIEHE "C-1") COMPTEUR MIXTE (VOIR "C-1") COMBINATIEMETER (ZIE "C-1") CHECK BLK/RED BLK/RED BLK/RED ENGINE TACHO BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED IAC VALVE IAC-VENTIL VALVE IAC IAC VALVE INJECTOR...
  • Page 290 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-16 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-5:ENGINE CONTROL SYSTEM (1.3L) 2 of 2 A-5:MOTORSTEUESYSTEM (1,3L) 2 von 2 A-5:SYSTÈM DE COMMANDE DU MOTOR (1,3L) 2 de 2 A-5:MOTORREGELSYSTEEM (1,3L) 2 op 2 CIRCUIT FUSE DOME SCHALTKREISSICHERUNG RADIO...
  • Page 291 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-17 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM REAR WINDOW DEFOGGER (SEE "B-3") HECKSCHEIBENHEIZUNG (SIEHE "B-3") DÉSEMBUEUR DE LUNETTE ARRIÈRE (VOIR "B-3") ACHTERRUITVERWARMING (ZIE "B-3") LICENSE PLATE LIGHT (SEE "D-3") REAR WINDOW DEFOGGER RELAY (SEE "B-3") ZULASSUNGSSCHILDBELEUCHTUNG (SIEHE "D-3") HECKSCHEIBENHEIZUNGS- ÉCLAIRAGE DE PLAQUE MINÉRALOGIQUE (VOIR "D-3")
  • Page 292 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-18 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-6:A/T CONTROL SYSTEM (1.3L) A-6:A/T STEUERSYSTEM (1,3L) A-6:SYSTÈM DE COMMANDE A/T (1,3L) A-6:A/T REGELSYSTEEM (1,3L) CIRCUIT FUSE TURN SCHALTKREISSICHERUNG STOP BACK FUSIBLE DE CIRCUIT J/C #1 CIRCUITZEKERING CIRCUIT FUSE 21 (SEE "F-6") SCHALTKREISSICHERUNG 21 (SIEHE "F-6") FUSIBLE DE CIRCUIT 21 (VOIR "F-6") CIRCUITZEKERING 21 (ZIE "F-6")
  • Page 293 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-19 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT COIL CIRCUITZEKERING COMBINATION METER (SEE "C-1") BLK/WHT KOMBINATIONSINSTRUMENT (SIEHE "C-1") COMPTEUR MIXTE (VOIR "C-1") COMBINATIEMETER (ZIE "C-1") O/D OFF A/C COMPRESSOR KLIMAANLAGEN-KOMPRESSOR COMPRESSEUR A/C A/C COMPRESSOR BLK/WHT...
  • Page 294 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-20 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM A-7:IMMOBILIZER CONTROL SYSTEM A-7:WEGFAHRSPERRE-STEUERSYSTEM A-7:SYSTÈME DE COMMANDE DE L’IMMOBILISATEUR A-7:CONTACTSLOT-BEVEILIGING REGELSYSTEEM CIRCUIT FUSE SCHALTKREISSICHERUNG DOME DOME STOP 15A FUSIBLE DE CIRCUIT COIL RADIO RADIO CIRCUITZEKERING BLK/WHT WHT/BLU GRN/RED WHT/BLU WHT/BLU WHT/BLU...
  • Page 295 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-21 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-1:WINDSHIELD WIPER AND WASHER B-1:FRONTSCHEIBENWISCHER UND WASCHANLAGE B-1:ESSUIE-GLACE ET LAVE-GLACE DE PARE-BRISE B-1:WINDSCHUTZSCHEIBENWISCHER UND WASCHER CIRCUIT FUSE WIPER SCHALTKREISSICHERUNG WASHER FUSIBLE DE CIRCUIT CIRCUITZEKERING YEL/BLU YEL/BLU WIPER & WASHER SWITCH WISCHER U.
  • Page 296 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-22 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-2:REAR WIPER AND WASHER B-2:HECKSCHEIBENWISCHER UND WASCHANLAGE B-2:ESSUIE-GLACE ET LAVE-GLACE ARRIÈRE B-2:ACHTERRUITWISSER EN-SPROEIER CIRCUIT FUSE WIPER SCHALTKREISSICHERUNG WASHER FUSIBLE DE CIRCUIT CIRCUITZEKERING YEL/BLU WIPER & WASHER SWITCH WISCHER U. WASCHERSCHALTER CONTACTEUR DE L'ESSUIE-GLACE ET LAVE-GLACE WISSER- EN SPROEIERSCHAKELAAR...
  • Page 297 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-23 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-3:REAR WINDOW DEFOGGER B-3:HECKSCHEIBENENTFEUCHTER B-3:DÉSEMBUEUR DE FENÊTRE ARRIÈRE B-3:ACHTERRUITVERWARMING 1.3L / LHD-1.0L CIRCUIT FUSE REAR HEATER RHD-1.0L SCHALTKREISSICHERUNG DEFG FUSIBLE DE CIRCUIT CIRCUITZEKERING BLU/YEL BLK/RED G01-1 ENGINE CONTROL MODULE (SEE "A-5") REAR WINDOW DEFOGGER RELAY MOTORSTEUERMODUL (SIEHE "A-5") HECKSCHEIBENHEIZUNGSRELAIS...
  • Page 298 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-24 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-4:POWER WINDOW B-4:AUTOMATISCHER FENSTERHEBER B-4:LÈVE-VITRES ÉLECTRIQUES B-4:ELEKTRISCH BEDIENDE RUIT CIRCUIT FUSE POWER SCHALTKREISSICHERUNG WINDOW FUSIBLE DE CIRCUIT CIRCUITZEKERING WHT/BLU GRN/BLK WHT/BLU RED/BLU POWER WINDOW SUB SWITCH (PASSENGER SIDE) FENSTERHEBER- NEBENSCHALTER (BEIFAHRERSEITE)
  • Page 299 SYSTEM CIRCUIT DIAGRAM / SYSTEM-SCHALTDIAGRAMM 8A-7-25 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM MEMO NOTIZEN NOTE MEMO...
  • Page 300 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-26 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-5:POWER DOOR LOCK SYSTEM (TYPE 1) B-5:ZENTRALVERRIEGELUNG (TYP 1) B-5:SYSTÈME DE VERROUILLAGE DE PORTIÈRE MOTORISÉ (TYPE 1) B-5:CENTRALE PORTIERVERGRENDELING (TIPO 1) CIRCUIT FUSE RHD WITH POWER WINDOW SCHALTKREISSICHERUNG TURN RECHTSLENKUNG MIT DOOR...
  • Page 301 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-27 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM DOOR LOCK CONTROLLER STEUEREINHEIT FÜR TÜRVERRIEGELUNG COMMANDE DE VERROUILLAGE DES PORTES PORTIERVERGRENDELING-REGELEENHEID RED/BLK BLU RED/BLK RED/BLK RED/BLK RED/BLK BLU RED/BLK RED/BLK GRN FRONT DOOR LOCK MOTOR LOCK LOCK VORDERTÜR-SPERRMOTOR RED/BLK BLU DEAD...
  • Page 302 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-28 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-6:POWER DOOR MIRROR CONTROL SYSTEM B-6:TÜRSPIEGELVERSTELLUNG B-6:SYSTÈME DE COMMANDE RÉTROV ISEUR DE PORIÈRE MOTORISÉ B-6:ELEKTRISCH BEDIENDE BUITENSPIEGELSYSTEEM CIRCUIT FUSE RECHTS SCHALTKREISSICHERUNG CONDUITE A DROITE FUSIBLE DE CIRCUIT MET STUUR RECHTS CIRCUITZEKERING LINKS CONDUITE A GAUCHE...
  • Page 303 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-29 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-7:HORN B-7:HUPE B-7:AVERTISSEUR SONORE B-7:CLAXON CIRCUIT FUSE HORN SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING GRN/WHT GRN/WHT GRN/WHT HORN RELAY HUPENRELAIS RELAIS D'AVERTISSEUR SONORE CLAXIONRELAIS BLU/ORN (TYPE 2) (TYPE 1) HORN HUPE AVERTISSEUR...
  • Page 304 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-30 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM B-8:POWER DOOR LOCK SYSTEM (TYPE 2,3) B-8:ZENTRALVERRIEGELUNG (TYP 2,3) B-8:SYSTÈME DE VERROUILLAGE DE PORTIÈRE MOTORISÉ (TYPE 2,3) B-8:CENTRALE PORTIERVERGRENDELING (TIPO 2,3)
  • Page 305 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-31 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM TYPE 2 TYP 2 TYPE 2 TIPO2 TYPE 3 TYP 3 TYPE 3 TIPO 3 <IF EQUIPPED> DOOR LOCK CONTROLLER KEYLESS CONTROLLER STEUEREINHEIT FÜR TÜRVERRIEGELUNG SCHL SSELLOSER CONTROL-LER COMMANDE DE VERROUILLAGE DES PORTES COMMANDE SANS CLAVETTES PORTIERVERGRENDELING-REGELEENHEID...
  • Page 306 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-32 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM C-1:COMBINATION METER (1.0L) 1 of 2 C-1:KOMBINATIONSINSTRUMENT (1,0L) 1 von 2 C-1:COMPTEUR MIXTE (1,0L) 1 de 2 C-1:COMBINATIEMETER (1,0L) 1 op 2 TYPE1,2 CIRCUIT FUSE TYPE3 DOME SCHALTKREISSICHERUNG METER COIL COIL...
  • Page 307 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-33 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM TURN SIGNAL SWITCH (IN TURN & DIMMER SWITCH) (SEE "D-5") BLINKERSCHALTER (IM BLINK- & ABBLENDSCHALTER) (SIEHE "D-5") CIRCUIT FUSE CONTACTEUR DE CLIGNOTANT (DANS LE CONTACTEUR DE SCHALTKREISSICHERUNG CLIGNOTANT ET INVERSEUR) (VOIR "D-5") H/L.L FUSIBLE DE CIRCUIT RICHTINGAANWIJZERSCHAKELAAR (IN RICHTINGAANWIJZER- EN...
  • Page 308 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-34 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM C-1:COMBINATION METER (1.3L) 1 of 2 C-1:KOMBINATIONSINSTRUMENT (1,3L) 1 von 2 C-1:COMPTEUR MIXTE (1,3L) 1 de 2 C-1:COMBINATIEMETER (1,3L) 1 op 2 TYPE 1,2 CIRCUIT FUSE SCHALTKREISSICHERUNG TYPE 3 DOME METER FUSIBLE DE CIRCUIT...
  • Page 309 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-35 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM CIRCUIT FUSE SCHALTKREISSICHERUNG H/L.L FUSIBLE DE CIRCUIT CIRCUITZEKERING TURN SIGNAL SWITCH (IN TURN & DIMMER SWITCH) (SEE "D-5") BLINKERSCHALTER (IM BLINK- & ABBLENDSCHALTER) (SIEHE "D-5") CONTACTEUR DE CLIGNOTANT (DANS LE CONTACTEUR DE CLIGNOTANT ET INVERSEUR) (VOIR "D-5") WHT/BLU RICHTINGAANWIJZERSCHAKELAAR (IN RICHTINGAANWIJZER- EN...
  • Page 310 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-36 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM C-1:COMBINATION METER (1.0L & 1.3L) 2 of 2 C-1:KOMBINATIONSINSTRUMENT (1,0L U. 1,3L) 2 von 2 C-1:COMPTEUR MIXTE (1,0L ET 1,3L) 2 de 2 C-1:COMBINATIEMETER (1,0L EN 1,3L) 2 op 2 CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT...
  • Page 311 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-37 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-1:HEADLIGHT (IF NOT EQUIPPED WITH DRL SYSTEM) D-1:SCHEINWERFER (BEI AUSSTATTUNG OHNE DRL-SYSTEM) D-1:PHARE (SI PAS ÉQUIPÉ DU SYSTÈME DRL) D-1:KOPLAMP (INDIEN NIET UITGERUST MET DRL SYSTEEM) CIRCUIT FUSE SCHALTKREISSICHERUNG H/L.L H/L.R...
  • Page 312 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-38 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-2:HEADLIGHT (IF EQUIPPED WITH DRL SYSTEM) D-2:SCHEINWERFER (BEI AUSSTATTUNG MIT DRL-SYSTEM) D-2:PHARE (SI ÉQUIPÉ DU SYSTÈME DRL) D-2:KOPLAMP (INDIEN UITGERUST MET DRL SYSTEEM) CIRCUIT FUSE SCHALTKREISSICHERUNG H/L.L H/L.R FUSIBLE DE CIRCUIT CIRCUITZEKERING WHT/RED...
  • Page 313 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-39 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM CIRCUIT FUSE SCHALTKREISSICHERUNG HEATER FUSIBLE DE CIRCUIT CIRCUITZEKERING BLU/YEL WHT/RED RED/WHT DRL CONTROLLER DRL-REGLER REGULATEUR DE DRL YEL/BLK DRL REGELAAR YEL/RED YEL/BLK (TO "D-3" SYSTEM) (ZU SYSTEMSCHALTDIAGRAMM "D-3") YEL/BLK (VERS SYSTÈME DE "D-3") (NAAR "D-3"...
  • Page 314 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-40 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-3:POSITION, TAIL AND LICENSE PLATE LIGHT (TYPE 1,2) D-3:PARKLEUCHTEN, HECKLEUCHTEN UND NUMMERNSCHILDLEU-CHTEN (TYP 1,2) D-3:FEUX DE POSITION, ARRIÈRE ET DE PLAQUE D’IMMATRICULATION (TYPE 1,2) D-3:POSITIELICHT, ACHTERLICHT EN KENTEKEKENPLAATVERLICHING (TIPO 1,2) 1.3L / LHD-1.0L WITHOUT DRL WITH DRL...
  • Page 315 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-41 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM MEMO NOTIZEN NOTE MEMO...
  • Page 316 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-42 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-3:POSITION, TAIL AND LICENSE PLATE LIGHT (TYPE 3) D-3:PARKLEUCHTEN, HECKLEUCHTEN UND NUMMERNSCHILDLEU-CHTEN (TYP 3) D-3:FEUX DE POSITION, ARRIÈRE ET DE PLAQUE D’IMMATRICULATION (TYPE 3) D-3:POSITIELICHT, ACHTERLICHT EN KENTEKEKENPLAATVERLICHING (TIPO 3) CIRCUIT FUSE TAIL SCHALTKREISSICHERUNG...
  • Page 317 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-43 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-4:INTERIOR LIGHT (WITHOUT POWER DOOR LOCK SYSTEM) D-4:INNENLEUCHTE (OHNE ZENTRALVERRIEGELUNG) D-4:PLAFONNIER (SANS SYSTÈME DE VERROUILLAGE DE PORTIÈRE MOTORISÉ) D-4:INTERIEURVERLICHTING (ZONDER CENTRALE PORTIERVERGRENDELING ) CIRCUIT FUSE DOME TURN SCHALTKREISSICHERUNG ILLUMI RADIO BACK...
  • Page 318 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-44 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-5:INTERIOR LIGHT (WITH POWER DOOR LOCK SYSTEM) D-5:INNENLEUCHTE (MIT ZENTRALVERRIEGELUNG) D-5:PLAFONNIER (AVEC SYSTÈME DE VERROUILLAGE DE PORTIÈRE MOTORISÉ) D-5:INTERIEURVERLICHTING (MET CENTRALE PORTIERVERGRENDELING ) CIRCUIT FUSE DOME TURN ILLUMI SCHALTKREISSICHERUNG RADIO BACK...
  • Page 319 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-45 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-6:TURN SIGNAL AND HAZARD WARNING LIGHT D-6:BLINKLICHT UND WARNLEUCHTE D-6:FEUX CLIGNOTANTS ET FEUX DE DÉTRESSE D-6:RICHTINGAANWIJZER-EN ALARMKNIPPERLICHT CIRCUIT FUSE SCHALTKREISSICHERUNG TURN HAZARD FUSIBLE DE CIRCUIT BACK CIRCUITZEKERING COMBINATION METER (SEE "C-1") <IF EQUIPPED>...
  • Page 320 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-46 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-7:BRAKE LIGHT D-7:BREMSLEUCHTE D-7:FEUX STOP D-7:REMLICHT CIRCUIT FUSE SCHALTKREISSICHERUNG STOP FOR SEPARATE UNIT TYPE HIGH MOUNTED STOP LIGHT FUSIBLE DE CIRCUIT FÜR SEPARATE, HOCH MOUNTIERTE BREMSLEUCHTE CIRCUITZEKERING POUR FEUX STOP Á IMOLANTATION HAUTE DE TYPE Á ÉlÉMENT SÉPARÉ VOOR APARATE EENHEID TYPE HOOG GEMONTEERD REMLICHT FOR SPOILER BUILT-IN HIGH MOUNTED STOP LIGHT FÜR IN SPOILER EINGEBAUTE, HOCH MOUNTIERTE BREMSLEUCHTE...
  • Page 321 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-47 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-8:BACK-UP LIGHT D-8:RÜCKFAHRLEUCHTE D-8:FEUX DE MARCHE ARRIÈRE D-8:ACHTERUITRJLICHT TURN CIRCUIT FUSE BACK SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING <MT> <AT> BACK-UP LIGHT SWITCH RÜCKFAHRLEU- CHTENSCHALTER TRANSMISSION INTERRUPTEUR RANGE SENSOR DE FEUX DE GETRIEBEBEREICH- MARCHE ARRIÈRE...
  • Page 322 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-48 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-9:HEADLIGHT LEVELING D-9:SCHEINWERFER-NIVELLIERUNG D-9:REGLAGE DES PHARES D-9:KOPLAMPSTRAAL-AFSTEL (TYPE 3) CIRCUIT FUSE (SEE "F-6") CIRCUIT FUSE TURN SCHALTKREISSICHERUNG SCHALTKREISSICHERUNG (SIEHE "F-6") BACK FUSIBLE DE CIRCUIT FUSIBLE DE CIRCUIT CIRCUITZEKERING (VOIR "F-6") CIRCUITZEKERING (ZIE "F-6")
  • Page 323 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-49 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-10:FRONT FOG LIGHT (IF EQUIPPED) D-10:N0EBELSCHEINWERFER (BEI AUSSTATTUNG) D-10:ANTIBROUILLARD AVANT (SI ÉQUIPÉ) D-10:VOORMISTLAMP (INDIEN UITGERUST) CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT (SEE "F-6") CIRCUITZEKERING (SIEHE "F-6") (VOIR "F-6") (ZIE "F-6") LT GRN/RED RED/YEL...
  • Page 324 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-50 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM D-11:REAR FOG LIGHT D-11:NEBELSCHLUSSLEUCHTE D-11:ANTIBROUILLARD ARRIERE D-11:MISTACHTERLICHT CIRCUIT FUSE RHD-1.3L SCHALTKREISSICHERUNG REAR FUSIBLE DE CIRCUIT (SEE "F-6") TYPE 1,2 CIRCUITZEKERING (SIEHE "F-6") (VOIR "F-6") TYPE 3 (ZIE "F-6") (TYPE 1) (TYPE 2,3) YEL/RED...
  • Page 325 SYSTEM CIRCUIT DIAGRAM / SYSTEM-SCHALTDIAGRAMM 8A-7-51 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM MEMO NOTIZEN NOTE MEMO...
  • Page 326 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-52 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-1:HEATER AND AIR CONDITIONER (1.0L) F-1:HEIZUNG UND KLIMAANLAGE (1,0L) F-1:CHAUFFAGE ET CLIMATISATION (1,0L) F-1:VERWARMING EN AIR CONDITIONING (1,0L) CIRCUIT FUSE HEATER SCHALTKREISSICHERUNG TAIL ILLUMI FUSIBLE DE CIRCUIT CIRCUITZEKERING BLU/YEL RED/GRN RED/YEL...
  • Page 327 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-53 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM CIRCUIT FUSE RECHTS SCHALTKREISSICHERUNG CONDUITE A DROITE COIL FUSIBLE DE CIRCUIT MET STUUR RECHTS CIRCUITZEKERING LINKS CONDUITE A GAUCHE MET STUUR LINKS BLU/YEL TYPE 1,2 BLK/WHT BLU/WHT TYPE 3 RADIATOR FAN CONTROL RELAY (SEE "A-3") KÜHLERGEBLÄSE-STEUERRELAIS (SIEHE "A-3") BLU/YEL...
  • Page 328 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-54 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-1:HEATER AND AIR CONDITIONER (1.3L) F-1:HEIZUNG UND KLIMAANLAGE (1,3L) F-1:CHAUFFAGE ET CLIMATISATION (1,3L) F-1:VERWARMING EN AIR CONDITIONING (1,3L) CIRCUIT FUSE HEATER SCHALTKREISSICHERUNG ILLUMI TAIL FUSIBLE DE CIRCUIT CIRCUITZEKERING BLU/YEL RED/YEL RED/GRN...
  • Page 329 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-55 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM CIRCUIT FUSE RECHTS SCHALTKREISSICHERUNG CONDUITE A DROITE COIL FUSIBLE DE CIRCUIT MET STUUR RECHTS CIRCUITZEKERING LINKS CONDUITE A GAUCHE MET STUUR LINKS TYPE 1,2 TYPE 3 BLK/WHT A/C SWITCH KLIMAANLAGEN- SCHALTER COMMUTATEUR A/C...
  • Page 330 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-56 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-2:RADIO F-2:RADIO F-2:RADIO F-2:RADIO CIRCUIT FUSE SCHALTKREISSICHERUNG RADIO FUSIBLE DE CIRCUIT DOME FUSIBLE DEL CIRCUITO WHT/BLU YEL/BLK (SEE “F-6”) (SIEHE “F-6”) (VOIR “F-6”) (ZIE “F-6”) ANTENNA ANTENNE ANTENNE ANTENNE YEL/BLK RED/YEL...
  • Page 331 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-57 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-3:CIGAR LIGHTER / ACCESSORY SOCKET / ASH TRAY ILLUMINATION F-3:ZIGARETTENANZÜNDER / ZUBEHÖRANSCHLUSS / ASCHENBECHERBELEUCHTUNG F-3:ALLUME-CIGARES / PRISE D’ACCESSOIRES / ÉCLAIRAGE DU CENDRIER F-3:SIGARETTEAANSTEKER / ACCESOIRE-STROOMAANSLUITING / ASBAKVERLICHTING CIRCUIT FUSE SCHALTKREISSICHERUNG CIGAR FUSIBLE DE CIRCUIT...
  • Page 332 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-58 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-4:POWER STEERING F-4:SERVOLENKUNG F-4:DIRECTION ASSISTEE F-4:STUURBEKRACHTIGING CIRCUIT FUSE SCHALTKREISSICHERUNG MAIN FUSE FUSIBLE DE CIRCUIT HAUPTSICHERUNG DOME CIRCUITZEKERING FUSIBLE PRINCIPAL COIL RADIO 1.3L HOOFDZEKERING 1.0L (TYPE 1) (TYPE 2,3) COMBINATION BLK/WHT METER...
  • Page 333 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-59 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-5:CLOCK F-5:UHR F-5:HORLOGE F-5:KLOK WITH DRL WITHOUT DRL MIT DRL OHNE DRL CIRCUIT FUSE AVEC DRL SANS DRL SCHALTKREISSICHERUNG DOME MET DRL FUSIBLE DE CIRCUIT ZONDER DRL RADIO CIRCUITZEKERING (TYPE 2,3 : RHD) J / C #1...
  • Page 334 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-60 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-6:ILLUMINATION LIGHT (1.0L) F-6:BELEUCHTUNG (1,0L) F-6:FEUX D’ÉCLAIRAGE (1,0L) F-6:VERLICHTINGSLAMP (1,0L) (TYPE 3) (TYPE 1,2) CIRCUIT FUSE CIRCUIT FUSE TURN TURN SCHALTKREISSICHERUNG SCHALTKREISSICHERUNG TAIL FUSIBLE DE CIRCUIT BACK BACK FUSIBLE DE CIRCUIT CIRCUITZEKERING CIRCUITZEKERING...
  • Page 335 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-61 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM F-6:ILLUMINATION LIGHT (1.3L) F-6:BELEUCHTUNG (1,3L) F-6:FEUX D’ÉCLAIRAGE (1,3L) F-6:VERLICHTINGSLAMP (1,3L) (TYPE 3) (TYPE 1,2) CIRCUIT FUSE CIRCUIT FUSE TURN TURN SCHALTKREISSICHERUNG SCHALTKREISSICHERUNG TAIL FUSIBLE DE CIRCUIT BACK BACK FUSIBLE DE CIRCUIT CIRCUITZEKERING CIRCUITZEKERING...
  • Page 336 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-62 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM G-1:ANTI-LOCK BRAKE SYSTEM (TYPE 1,2) G-1:ANTIBLOCKIERBREMSSYSTEM (TYP 1,2) G-1:SYSTÈME D’ANTIBLOCAGE (TYPE 1,2) G-1:ANTIBLOKKEERSYSTEEM (TIPO 1,2) DOME STOP COIL RADIO CIRCUIT FUSE GRN/RED MAIN FUSE BRAKE LIGHT SCHALTKREISSICHERUNG SWITCH HAUPTSICHERUNG BLK/WHT FUSIBLE DE CIRCUIT...
  • Page 337 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-63 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM G-2:AIR BAG CONTROL SYSTEM (TYPE 1,2) G-2:AIRBAG-STEUERUNG (TYP 1,2) G-2:SYSTEME DE COMMANDE DES COUSSINS D’AIR (TYPE 1,2) G-2:AIRBAG-REGELSYSTEEM (TIPO 1,2) CIRCUIT FUSE DOME SCHALTKREISSICHERUNG RADIO COIL FUSIBLE DE CIRCUIT CIRCUITZEKERING WHT/BLE BLK/WHT...
  • Page 338 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-64 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM G-3:AIR BAG CONTROL SYSTEM (TYPE 2,3) G-3:AIRBAG-STEUERUNG (TYP 2,3) G-3:SYSTEME DE COMMANDE DES COUSSINS D’AIR (TYPE 2,3) G-3:AIRBAG-REGELSYSTEEM (TIPO 2,3) CIRCUIT FUSE DOME SCHALTKREISSICHERUNG RADIO FUSIBLE DE CIRCUIT CIRCUITZEKERING WHT/BLE WHT/RED...
  • Page 339 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-65 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM CIRCUIT FUSE SCHALTKREISSICHERUNG COIL FUSIBLE DE CIRCUIT CIRCUITZEKERING BLK/WHT COMBINATION METER KOMBINATIONSINSTRUMENT COMPTEUR MIXTE COMBINATIEMETER CONNECTION DETECTION PIN ANSCHLUSSER- KENNUNGSSTIFT BROCHE DE DÉTECTION DE CONNEXION VERBINDINGSDETECTIEPEN AIR BAG CONTROL MODULE AIRBAG-STEUERMODUL <IF EQUIPPED>...
  • Page 340 SYSTEM CIRCUIT DIAGRAM / SYSTEMSCHALTDIAGRAMM 8A-7-66 SCHÉMA DES CIRCUITS ÉLECTRIQUES / SYSTEEMCIRCUITDIAGRAM G-4:ANTI-LOCK BRAKE SYSTEM (TYPE 3) G-4:ANTIBLOCKIERBREMSSYSTEM (TYP 3) G-4:SYSTÈME D’ANTIBLOCAGE (TYPE 3) G-4:ANTIBLOKKEERSYSTEEM (TIPO 3) DOME STOP COIL RADIO CIRCUIT FUSE GRN/RED MAIN FUSE BRAKE LIGHT SCHALTKREISSICHERUNG HAUPTSICHERUNG SWITCH BLK/WHT FUSIBLE DE CIRCUIT...
  • Page 341 LIST OF CONNECTORS / LISTE DER STECKVERBINDER 8A-8-1 LISTE DES CONNECTEURS / LIJST VAN AANSLUITINGEN SECTION 8A-8 ABSCHNITT 8A-8 SECTION 8A-8 DEEL 8A-8 LIST OF CONNECTORS LISTE DER STECKVERBINDER LISTE DES CONNECTEURS LIJST VAN AANSLUITINGEN CONTENTS INHALT TABLE DES MATIÈRES INHOUD ·...
  • Page 342 LIST OF CONNECTORS / LISTE DER STECKVERBINDER 8A-8-2 LISTE DES CONNECTEURS / LIJST VAN AANSLUITINGEN LIST OF CONNECTORS LISTE DER STECKVERBINDER NOTE : The illustration below shows the harness side connectors, but not the component side connectors. HINWEIS : Die nachstehende Abbildung zeigt die Steckverbinder der Kabelbaumseite, aber nicht die Steckverbinder auf der Komponentenseite. LISTE DES CONNECTEURS REMARQUE : L’illustration ci-dessous montre les connecteurs du faisceau de câbles, mais pas les connecteurs des composants.
  • Page 343 LIST OF CONNECTORS / LISTE DER STECKVERBINDER 8A-8-3 LISTE DES CONNECTEURS / LIJST VAN AANSLUITINGEN NOTE : The illustration below shows the harness side connectors, but not the component side connectors. HINWEIS : Die nachstehende Abbildung zeigt die Steckverbinder der Kabelbaumseite, aber nicht die Steckverbinder auf der Komponentenseite. REMARQUE : L’illustration ci-dessous montre les connecteurs du faisceau de câbles, mais pas les connecteurs des composants.
  • Page 344 LIST OF CONNECTORS / LISTE DER STECKVERBINDER 8A-8-4 LISTE DES CONNECTEURS / LIJST VAN AANSLUITINGEN NOTE : The illustration below shows the harness side connectors, but not the component side connectors. HINWEIS : Die nachstehende Abbildung zeigt die Steckverbinder der Kabelbaumseite, aber nicht die Steckverbinder auf der Komponentenseite. REMARQUE : L’illustration ci-dessous montre les connecteurs du faisceau de câbles, mais pas les connecteurs des composants.
  • Page 345 LIST OF CONNECTORS / LISTE DER STECKVERBINDER 8A-8-5 LISTE DES CONNECTEURS / LIJST VAN AANSLUITINGEN NOTE : The illustration below shows the harness side connectors, but not the component side connectors. HINWEIS : Die nachstehende Abbildung zeigt die Steckverbinder der Kabelbaumseite, aber nicht die Steckverbinder auf der Komponentenseite. REMARQUE : L’illustration ci-dessous montre les connecteurs du faisceau de câbles, mais pas les connecteurs des composants.
  • Page 346 LIST OF CONNECTORS / LISTE DER STECKVERBINDER 8A-8-6 LISTE DES CONNECTEURS / LIJST VAN AANSLUITINGEN NOTE : The illustration below shows the harness side connectors, but not the component side connectors. HINWEIS : Die nachstehende Abbildung zeigt die Steckverbinder der Kabelbaumseite, aber nicht die Steckverbinder auf der Komponentenseite. REMARQUE : L’illustration ci-dessous montre les connecteurs du faisceau de câbles, mais pas les connecteurs des composants.
  • Page 347 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 348 When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
  • Page 350 Table of Contents GENERAL INFORMATION ENGINE General Information Engine and Emission Control System (G10 Engine) Maintenance and Lubrication HEATING AND AIR CONDITIONING Engine and Emission Control System (M13 Engine) Heater and Ventilation Air Conditioning (Optional) Engine and Emission Control System STEERING, SUSPENSION, WHEELS (Z13DT Engine) * AND TIRES...
  • Page 352 GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS How to Use This Manual.........0A-2 Intermittent and Poor Connection ....0A-17 Precautions............0A-3 Identification Information......0A-19 Precaution for Vehicles Equipped with a Vehicle Identification Number ..... 0A-19 Supplemental Restraint (Air Bag) System..0A-3 Engine Identification Number...... 0A-19 Diagnosis...........0A-4 Transmission Identification Number....

  • Page 353: How To Use This Manual

    0A-2 GENERAL INFORMATION How to Use This Manual 1) There is a “Table of Contents” on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a “Contents” on the first page of each section, where the main items in that section are listed.

  • Page 354: Precautions

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

  • Page 355: Diagnosis

    0A-4 GENERAL INFORMATION Diagnosis • When troubleshooting air bag system, be sure to follow “Diagnosis” in Section 10B. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. • Never use electrical test equipment other than that specified in this manual.

  • Page 356: Servicing And Handling

    GENERAL INFORMATION 0A-5 Servicing and handling WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger and side Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise.
  • Page 357 0A-6 GENERAL INFORMATION WARNING: • For handling and storage of a SDM, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise. • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM.

  • Page 358: General Precautions

    GENERAL INFORMATION 0A-7 • WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to fol- low the instructions. • After vehicle is completely repaired, perform “Air Bag Diagnostic System Check” in Section 10B. General Precautions The WARNING and CAUTION below describe some general precautions that you should observe when servic- ing a vehicle.
  • Page 359 0A-8 GENERAL INFORMATION • When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. •...
  • Page 360 GENERAL INFORMATION 0A-9 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly. • After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks.

  • Page 361: Precaution For Can Communication System

    0A-10 GENERAL INFORMATION • Always be careful not to handle electrical parts (com- puter, relay, etc.) in a rough manner or drop them. Precaution for CAN Communication System • The loose (1) in the wire harnesses twist of the CAN lines except around the connector (3) should be within 100 mm (3.9 in.) Refer to the wiring diagram for the CAN line discrim- ination.

  • Page 362: Precaution For Installing Mobile Communication Equipment

    GENERAL INFORMATION 0A-11 Precaution for Installing Mobile Communication Equipment When installing mobile communication equipment such as CB (Citizens-Band) -radio or cellular-tele- phone, be sure to observe the following precautions. Failure to follow cautions may adversely affect electronic control system. • Keep the antenna as far away as possible from the vehicle’s electronic control unit. •...

  • Page 363: Precautions For Electrical Circuit Service

    0A-12 GENERAL INFORMATION Precautions for Electrical Circuit Service • When replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire. •...
  • Page 364 GENERAL INFORMATION 0A-13 • When installing the wiring harness, fix it with clamps so that no slack is left. • When installing vehicle parts, be careful so that the wir- ing harness is not interfered with or caught by any other part.
  • Page 365 0A-14 GENERAL INFORMATION • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe (2) from the wire harness side (backside) of the connector (1). • When connecting meter probe (2) from terminal side of coupler (1) because it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its female terminal open for connection.

  • Page 366: Electrical Circuit Inspection Procedure

    GENERAL INFORMATION 0A-15 Electrical Circuit Inspection Procedure While there are various electrical circuit inspection methods, described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. Open circuit check Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully.

  • Page 367: Continuity Check

    0A-16 GENERAL INFORMATION Continuity check 1) Measure resistance between connector terminals at both ends of the circuit being checked (between A-1 and C-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals A-1 and C-1.

  • Page 368: Short Circuit Check (Wire Harness To Ground)

    GENERAL INFORMATION 0A-17 Short circuit check (wire harness to ground) 1) Disconnect negative (–) cable at battery. 2) Disconnect connectors at both ends of the circuit to be checked. NOTE: If the circuit to be checked is connected to other parts (1), disconnect all connectors of those parts.
  • Page 369 0A-18 GENERAL INFORMATION • Improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal. If contact tension is not enough, reform it to increase contact tension or replace. 1.

  • Page 370: Identification Information

    GENERAL INFORMATION 0A-19 Identification Information Vehicle Identification Number The number is punched on front dash panel in engine room and it is also on the left side of instrument panel depending on the vehi- cle specification. Engine Identification Number The number is punched on cylinder block. 1.

  • Page 371: Warning, Caution And Information Labels

    0A-20 GENERAL INFORMATION Warning, Caution and Information Labels The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. 1.

  • Page 372: Vehicle Lifting Points

    GENERAL INFORMATION 0A-21 Vehicle Lifting Points WARNING: • Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.

  • Page 373: When Using Floor Jack

    0A-22 GENERAL INFORMATION When using floor jack WARNING: If the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands.

  • Page 374: Abbreviations And Symbols May Be Used In This Manual

    GENERAL INFORMATION 0A-23 Abbreviations and Symbols May be Used in This Manual Abbreviations Anti-lock Brake System EFE Heater Early Fuel Evaporation Heater (Positive Temperature Coeffi- ATDC After Top Dead Center cient, PTC Heater) American Petroleum Institute Automatic Transmission Fluid Electronic Power Steering Automatic Locking Retractor EVAP Evaporative Emission...
  • Page 375 0A-24 GENERAL INFORMATION PSP Switch Power Steering Pressure Switch (P/S Pressure Switch) Powertrain Control Module Positive Crankcase Ventilation R RH Right Hand Society of Automotive Engineers Sensing and Diagnostic Module (Air bag controller, Air bag control module) Sequential Multiport Fuel Injection SOHC Single Over Head Camshaft Start of Injection...

  • Page 376: Symbols

    GENERAL INFORMATION 0A-25 Symbols SYMBOL DEFINITION SYMBOL DEFINITION Tightening torque Apply SEALANT 1216B 99000-31230 Apply oil (engine, transmission, trans- Apply SILICONE SEALANT fer, differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E automatic transmission fluid) 99000-31090 Apply GREASE A 99000-25010 Apply GREASE C 99000-25030 Apply THREAD LOCK 1322 99000-32110...

  • Page 377: Fastener Information

    0A-26 GENERAL INFORMATION Fastener Information Metric Fasteners Information Most of the fasteners used for this vehicle are JIS-defined and ISO-defined metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diame- ter, thread pitch and strength. CAUTION: Even when the nominal diameter (1) of thread is the same, the thread pitch (2) or the width across flats (3)

  • Page 378: Fastener Strength Identification

    GENERAL INFORMATION 0A-27 Fastener Strength Identification Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark strength identification on the nut face.
  • Page 379 0A-28 GENERAL INFORMATION Tightening torque chart: Thread Diameter (Nominal Diameter) (mm) A equivalent of 4T strength N·m fastener kg-m 0.15 0.30 0.55 10.5 lb-ft 21.0 32.5 47.0 76.0 116.0 A equivalent of 6.8 strength N·m fastener without flange kg-m 0.24 0.47 0.84 12.5 19.3 lb-ft 14.5 30.5 58.0 90.5 139.5 202.5...
  • Page 380 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View and Connec- tors” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 381 0B-2 MAINTENANCE AND LUBRICATION Brake Drums and Shoes (Rear) Automatic Transmission Fluid Inspection............ 0B-19 Replacement..........0B-24 Brake Hoses and Pipes Inspection ..... 0B-19 Automatic Transmission Fluid Cooler Hose Brake Fluid Replacement......0B-19 Inspection ........... 0B-24 Brake Lever and Cable Inspection....0B-19 Transfer Oil (4WD) and Rear Differential Clutch Inspection ........

  • Page 382: Maintenance Schedule

    MAINTENANCE AND LUBRICATION 0B-3 Maintenance Schedule Maintenance Schedule Under Normal Driving Conditions NOTE: • This interval should be judged by odometer reading or months, whichever comes first. • This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively.
  • Page 383 0B-4 MAINTENANCE AND LUBRICATION Z13DT Engine Model: Km (x 1,000) Interval Miles (x 1,000) Months ENGINE Engine accessary drive belt – – – Replace every 150,000 km (90,000 miles) or 120 months Engine oil and With a synthetic engine oil of oil grade: ACEA Replace every 20,000 km (12,000 miles) or oil filter B3, and oil viscosity: SAE 0W-30, 0W-40, 5W-...
  • Page 384 MAINTENANCE AND LUBRICATION 0B-5 G10/M13/Z13DT Engine Models: Km (x 1,000) Interval Miles (x 1,000) Months BRAKE Brake discs and pads (thickness, wear, damage) Brake drums and shoes (wear, damage) – – – Brake hoses and pipes (leakage, damage, clamp) – –...

  • Page 385: Maintenance Recommended Under Severe Driving Conditions

    0B-6 MAINTENANCE AND LUBRICATION Maintenance Recommended Under Severe Driving Conditions If the vehicle is usually used under the conditions corresponding to any severe condition code given below, IT IS RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the following table.
  • Page 386 MAINTENANCE AND LUBRICATION 0B-7 NOTE: • “I”: Inspect and correct or replace if necessary • “R”: Replace or change • 1: Inspect more frequently if the vehicle is used under dusty conditions. ✱ • 2: Clean or replace more frequently if the air from the ventilator decreases. ✱...

  • Page 387: Maintenance Service

    0B-8 MAINTENANCE AND LUBRICATION Maintenance Service Drive Belt Inspection (M13 Engine) WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Water pump and generator drive belt inspection 1) Disconnect negative (–) cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness.

  • Page 388: Drive Belt Inspection (G10 Engine)

    MAINTENANCE AND LUBRICATION 0B-9 Drive Belt Inspection (G10 Engine) WARNING: Disconnect negative cable at battery before checking and replacing belt. A/C compressor drive belt inspection (If equipped) 1) Hoist vehicle and remove engine under cover of right side from vehicle body. 2) Inspect belt for wear, deterioration and tension.

  • Page 389: Engine Accessary Drive Belt Inspection (Z13Dt Engine)

    0B-10 MAINTENANCE AND LUBRICATION Engine Accessary Drive Belt Inspection (Z13DT Engine) WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Water pump and generator drive belt inspection Inspect belt for cracks, cuts, deformation, wear, tension and cleanliness referring to “Water Pump and Generator Drive Belt Inspection”...

  • Page 390: (M13 Engine)

    MAINTENANCE AND LUBRICATION 0B-11 Engine Oil and Oil Filter Replacement (G10/ M13 Engines) WARNING: • New and used engine oil can be hazardous. Be sure to read “WARNING” in General Precaution in Section 0A and observe what in written there. •...
  • Page 391 0B-12 MAINTENANCE AND LUBRICATION 5) Tighten the filter (1) 3/4 turn from the point of contact with the mounting surface using an oil filter wrench (2). Tightening torque Oil filter (b): 14 N·m (1.4 kg-m, 10.5 lb-ft) (for reference) 6) Replenish oil until oil level is brought to FULL level mark on dipstick.

  • Page 392: Engine Oil And Oil Filter Replacement (Z13Dt Engine)

    MAINTENANCE AND LUBRICATION 0B-13 Engine Oil and Oil Filter Replacement (Z13DT Engine) WARNING: • New and used engine oil can be hazardous. Be sure to read “WARNING” in General Precaution in Section 0A and observe what in written there. • Step 1) – 6) outlined below must be performed with ENGINE NOT RUNNING.
  • Page 393 0B-14 MAINTENANCE AND LUBRICATION 4) Install oil filter element. a) Replace seal ring (1) of oil filter housing cover (3) with new one and apply engine oil to seal ring. b) Install new oil filter element (2) to cover. c) Install oil filter housing cover with element. Tightening torque Oil filter housing cover (a): 25 N·m (2.5 kg-m) 18.5 lb-ft 5) Replenish oil until oil level is brought to FULL level mark on...

  • Page 394: Engine Coolant Replacement

    MAINTENANCE AND LUBRICATION 0B-15 Engine Coolant Replacement WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scald- ing fluid and steam can be blown out under pressure if cap is taken off too soon. CAUTION: When changing engine coolant, use mixture of 50% spec- ified water and 50% ANTIFREEZE/ANTICORROSION...

  • Page 395: Distributor Cap And Rotor Inspection (G10 Engine)

    0B-16 MAINTENANCE AND LUBRICATION Distributor Cap and Rotor Inspection (G10 Engine) • Check distributor cap and rubber caps for cracks. • Clean dusty and stained parts using a dry, soft cloth. • Check center electrode and terminals for wear. • Check rotor for cracks and its electrode for wear. Repair or replace any component which is found to be in malcondition.

  • Page 396: Air Cleaner Filter Replacement (Z13Dt Engine)

    MAINTENANCE AND LUBRICATION 0B-17 3) Check that filter is not excessively dirty, damaged or oily, clean filter with compressed air from air outlet side of filter. 4) Install air cleaner filter and clamp upper case securely. Air Cleaner Filter Replacement (Z13DT Engine) Replace air cleaner filter with new one according to steps 1), 2) and 4) of inspection procedure.

  • Page 397: Fuel Tank Inspection

    0B-18 MAINTENANCE AND LUBRICATION Fuel Tank Inspection Check fuel tank damage, cracks, fuel leakage, corrosion and tank bolts looseness. If a problem is found, repair or replace. PCV Valve Inspection Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog.

  • Page 398: Brake Drums And Shoes (Rear) Inspection

    MAINTENANCE AND LUBRICATION 0B-19 Brake Drums and Shoes (Rear) Inspection 1) Remove wheel and brake drum. 2) Check rear brake drums and brake linings for excessive wear and damage, while wheels and drums are removed. At the same time, check wheel cylinders for leaks. Replace these parts as necessary.

  • Page 399: Clutch Inspection

    0B-20 MAINTENANCE AND LUBRICATION 2) Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever. 3) Check parking brake lever for proper operation and stroke, and adjust it if necessary. For checking and adjusting procedures, refer to “Parking Brake Inspection and Adjustment”...

  • Page 400: Wheel Discs Inspection

    MAINTENANCE AND LUBRICATION 0B-21 2) Check inflating pressure of each tire and adjust pressure to specification as necessary. NOTE: • Tire inflation pressure should be checked when tires are cool. • Specified tire inflation pressure should be found on tire placard or in owner’s manual which came with the vehicle.

  • Page 401: Steering System Inspection

    0B-22 MAINTENANCE AND LUBRICATION • Check front suspension arm ball joint stud dust seals for leakage, detachment, tear or any other damage. Replace defective boot, if any. Steering System Inspection 1) Check steering wheel for play and rattle, holding vehicle straight on ground.

  • Page 402: Drive Shaft (Axle) Boots Inspection

    MAINTENANCE AND LUBRICATION 0B-23 Drive Shaft (Axle) Boots Inspection Check drive shaft boots (wheel side and differential side) for leaks, detachment, tear or other damage. Replace boot as necessary. Propeller Shafts (4WD) Inspection 1) Check propeller shaft connecting bolts for looseness. If looseness is found, tighten to specified torque.

  • Page 403: Automatic Transmission Fluid Level Inspection

    0B-24 MAINTENANCE AND LUBRICATION Automatic Transmission Fluid Level Inspec- tion 1) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) Make sure that vehicle is placed level for fluid level check. 3) Pull out dipstick and check fluid level. For fluid level checking procedure, refer to “Fluid Level Check at Normal Operating (Hot) Temperature (Hot Check)”...

  • Page 404: Transfer Oil (4Wd) And Rear Differential Oil (4Wd) Inspection

    MAINTENANCE AND LUBRICATION 0B-25 Transfer Oil (4WD) and Rear Differential Oil (4WD) Inspection 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 405: All Latches, Hinges And Locks Inspection

    0B-26 MAINTENANCE AND LUBRICATION All Latches, Hinges and Locks Inspection Doors Check that each door of front, rear and back doors opens and closes smoothly and locks securely when closed. If any malfunction is found, lubricate hinge and latch or repair door lock system.

  • Page 406: Final Inspection

    MAINTENANCE AND LUBRICATION 0B-27 Final Inspection WARNING: When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to prevent any accident. SEATS Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front seat back allows it to be locked at any angle.
  • Page 407 0B-28 MAINTENANCE AND LUBRICATION FOOT BRAKE Check the followings: • that brake pedal has proper travel, • that brake works properly, • that it is free from noise, • that vehicle does not pull to one side when brake is applied. •...
  • Page 408 MAINTENANCE AND LUBRICATION 0B-29 Recommended Fluids and Lubricants SG, SH, SJ or SL grade (Refer to “Engine Oil and Oil Filter Replacement Engine oil (G10/M13 engines) for G10/M13 engines” in this section for engine oil viscosity.) Refer to “Engine Oil and Oil Filter Replacement (Z13DT Engine)” in this Engine oil (Z13DT engine) section for engine oil grade and viscosity.
  • Page 409 0B-30 MAINTENANCE AND LUBRICATION...
  • Page 410 • 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.

  • Page 411: General Description

    1A-2 HEATER AND VENTILATION General Description Major Components and Location NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.
  • Page 412 HEATER AND VENTILATION 1A-3 Z13DT Engine Model 1. Heater unit 7. Foot air 13. Air inlet select door 19. Side ventilation control door 2. Air inlet box 8. Front defroster air 14. Blower motor 20. Supplementary heater (if equipped) 3. Ventilator duct 9.

  • Page 413: On-Board Diagnostic System (Z13Dt Engine Model)

    • The on-board diagnostic system is available only for Z13DT engine model with the supplementary heater system. • The SUZUKI scan tool cannot be used. For Z13DT Engine Model with the supplementary heater system, the on-board diagnostic system is available.

  • Page 414: Diagnosis

    HEATER AND VENTILATION 1A-5 Diagnosis Diagnosis Table NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. Z13DT Engine Model Condition Possible Cause Correction Heater blower doesn’t •...

  • Page 415: Wiring Circuit

    1A-6 HEATER AND VENTILATION Wiring Circuit NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. Z13DT Engine Model BLU/YEL WHT/BLU BLU/BLK BLU/YEL BLK/RED RED/WHT PNK/BLU BLK/YEL RED/YEL BLK/YGL...

  • Page 416: Diagnostic Trouble Code (Dtc) Check (Z13Dt Engine Model)

    HEATER AND VENTILATION 1A-7 Diagnostic Trouble Code (DTC) Check (Z13DT Engine Model) NOTE: • This checking procedure is available only for Z13DT engine model with the supplementary heater system. • If more than two DTCs are detected, only DTC, which has the highest priority, is indicated.

  • Page 417: Diagnostic Trouble Code (Dtc) Table (Z13Dt Engine Model)

    1A-8 HEATER AND VENTILATION Diagnostic Trouble Code (DTC) Table (Z13DT Engine Model) NOTE: • This table is available only for Z13DT engine model with the supplementary heater system. • Refer to “A/C System Wiring Circuit Diagram (Z13DT Engine)” in this section for details of system components, wire colors, and terminal numbers of supplementary heater controller.
  • Page 418 HEATER AND VENTILATION 1A-9 Example (DTC No.2-2) of LED Flashing Pattern (a) (a) (a) (a) (a) (a) [A]: First figure 1. LED ON (a). 0.3 seconds (c). 2.0 seconds [B]: Second figure 2. LED OFF (b). 1.0 seconds...

  • Page 419: On-Vehicle Service

    1A-10 HEATER AND VENTILATION On-Vehicle Service Heater Unit NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. Z13DT Engine Model 1. Heater core 4. Temperature control door assembly 7.
  • Page 420 HEATER AND VENTILATION 1A-11 Removal Z13DT Engine Model 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system refer- ring to “Disabling Air Bag System” in Section 10B. 3) Drain engine coolant and disconnect heater hoses (1) from heater unit.

  • Page 421: Supplementary Heater (If Equipped) (Z13Dt Engine)

    1A-12 HEATER AND VENTILATION Supplementary Heater (if equipped) (Z13DT Engine) Removal 1) Remove heater unit referring to “Heater Unit” in this section. 2) Remove supplementary heater cover and supplementary heater referring to illustration in “Heater Unit” in this section. Installation 1) Install supplementary heater and supplementary heater cover referring to illustration in “Heater Unit”...

  • Page 422: Air Inlet Box

    HEATER AND VENTILATION 1A-13 Air Inlet Box NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. Z13DT Engine Model 1. Air inlet box 4. Grommet 7.
  • Page 423 1A-14 HEATER AND VENTILATION...
  • Page 424 • 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.

  • Page 425: General Description

    1B-2 AIR CONDITIONING (OPTIONAL) General Description Major Components and Location NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.
  • Page 426 AIR CONDITIONING (OPTIONAL) 1B-3 For Z13DT Engine Model 1. Cooling unit 5. Discharge hose 9. Side ventilation air 13. Side defroster air 17. Supplementary heater 2. Compressor 6. Suction hose 10. Center ventilation air 14. Fresh air 3. Condenser assembly 7.

  • Page 427: Diagnosis

    1B-4 AIR CONDITIONING (OPTIONAL) Diagnosis General Diagnosis Table NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. Z13DT Engine Model Condition Possible Cause Correction Cool air does not A/C system inoperative come out (A/C system •...
  • Page 428 AIR CONDITIONING (OPTIONAL) 1B-5 Condition Possible Cause Correction Cool air does not • Insufficient or excessive charge of Check charge of refrigerant. come out or insuffi- refrigerant Check system for leaks. cient cooling (A/C sys- • Condenser clogged Check condenser. tem normal operative) •...

  • Page 429: Wiring Circuit

    1B-6 AIR CONDITIONING (OPTIONAL) Wiring Circuit NOTE: For G10 engine model, refer to the same section of the Service Manual mentioned in the “FORE- WORD” of this service manual. M13 Engine 1. Main fuse box 7. A/C switch 13. A/C evaporator thermistor 2.
  • Page 430 AIR CONDITIONING (OPTIONAL) 1B-7 Z13DT Engine Model BLU/YEL WHT/BLU BLU/BLK BLU/YEL BLK/RED RED/WHT PNK/BLU BLK/YEL BLK/WHT GRN/ORN RED/YEL BLK/WHT BLK/YGL GRN/ORN G88-28 G88-79 BLK/WHT GRN/RED G88-37 LtGRN/RED G88-87 G88-1 BLK/WHT BRW/WHT G88-10 G88-2 WHT/RED D26-52 G88-3 D26-17 WHT/BLU G88-29 G88-76 WHT/RED G92-14 RED/ WHT...
  • Page 431 1B-8 AIR CONDITIONING (OPTIONAL) ECM and Supplementary Heater Controller Terminal Arrangements for Z13DT Engine Model G92A 18 17 16 15 14 13 12 11 16 15 14 13 12 11 [A]: ECM coupler [B]: Supplementary heater controller coupler...

  • Page 432: A/C System Inspection Of Ecm And Its Circuits (M13 Engine Model)

    AIR CONDITIONING (OPTIONAL) 1B-9 A/C System Inspection of ECM and Its cir- cuits (M13 Engine Model) NOTE: For G10 engine model, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. ECM and its circuits can be checked at ECM wiring couplers by measuring voltage.
  • Page 433 1B-10 AIR CONDITIONING (OPTIONAL) a. To “A/C” fuse (10A) in circuit fuse box 1. A/C switch 6. Blower fan switch 11. Main relay b. To “HEATER” fuse (25A) in circuit fuse box 2. Dual pressure switch 7. A/C evaporator thermistor 12.
  • Page 434 AIR CONDITIONING (OPTIONAL) 1B-11 Termi- Wire Circuit Measurement Normal value Condition ground E21-05 BLK/ Power supply Ground to 10 – 14 V Ignition switch ON for engine con- engine (Fig B) trol E23-01 BLK/ ECM ground Ground to –0.3 – 0.3 V Ignition switch ON for power cir- body (Fig A)

  • Page 435: Compressor Drive Belt

    1B-12 AIR CONDITIONING (OPTIONAL) Compressor Drive Belt NOTE: For G10 engine model, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. Inspection M13 Engine Model • Check compressor drive belt (6) for wear and cracks, and replace as required.

  • Page 436: Recovery, Evacuation And Charging

    AIR CONDITIONING (OPTIONAL) 1B-13 Z13DT Engine Model Refer to “Water Pump / Generator Drive Belt Removal and Instal- lation” in Section 6B3. Recovery, Evacuation and Charging Operation Procedure for Charging A/C with Refrigerant NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD”...

  • Page 437: On-Vehicle Service

    1B-14 AIR CONDITIONING (OPTIONAL) On-Vehicle Service NOTE: • When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C system, be sure to observe the following instructions. – When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immediately.

  • Page 438: Procedure After Ecm Replacement (Z13Dt Engine Model)

    AIR CONDITIONING (OPTIONAL) 1B-15 Procedure After ECM Replacement (Z13DT Engine Model) Refer to “Procedure After ECM Replacement” under “ECM Regis- tration” in Section 6E3. A/C Condenser Assembly CAUTION: Be careful not to damage condenser fins. If condenser fin is bent, straighten it by using flat head screwdriver or pair of pliers.
  • Page 439 1B-16 AIR CONDITIONING (OPTIONAL) Installation Z13DT Engine Model Reverse removal sequence to install condenser, noting the follow- ing point. • If replace condenser, pour 15 cc of refrigerating oil to com- pressor suction-side. • Evacuate and charge system according to previously described procedure.

  • Page 440: Receiver / Dryer

    AIR CONDITIONING (OPTIONAL) 1B-17 Receiver / Dryer Removal Z13DT Engine Model 1) Recover refrigerant from refrigeration system by using recov- ery and recycling equipment. NOTE: The amount of removed compressor oil must be mea- sured for replenishing compressor oil. 2) Remove A/C condenser assembly referring to A/C con- denser assembly in this section.

  • Page 441: Cooling Unit (Evaporator)

    1B-18 AIR CONDITIONING (OPTIONAL) Cooling Unit (Evaporator) NOTE: For M13 and G10 engine models, refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual. Z13DT Engine Model 1. Evaporator 3. Evaporator case 5. Drain hose 7.

  • Page 442: Dual Pressure Switch (M13 And G10 Engine Models)

    AIR CONDITIONING (OPTIONAL) 1B-19 6) Loosen suction hose & liquid pipe bolt (4). 7) Loosen cooling unit bolt (1), nut (2) and screw (3) as shown in figure. 8) Remove cooling unit (5). M13 and G10 Engine Models Refer to the same section of the Service Manual mentioned in the “FOREWORD”...

  • Page 443: Pressure Sensor (Z13Dt Engine Model)

    1B-20 AIR CONDITIONING (OPTIONAL) Installation Reverse removal procedure for installation, noting the following points. • Apply compressor oil to dual pressure switch O-ring. • Evacuate and charge system according to previously described procedure. Tightening torque Pressure switch: 11 N·m (1.1 kg-m, 8.0 lb-ft) Inspection Check dual pressure switch (1) for continuity at normal tempera- °...

  • Page 444: A/C Relay (Z13Dt Engine)

    AIR CONDITIONING (OPTIONAL) 1B-21 Inspection 1) Connect manifold gauge to A/C system and operate A/C sys- tem. 2) Check output voltage for pressure sensor (1) between GRY/ BLU and BRN/WHT wire terminals, and then compare mea- sured voltage with specified voltage in graph. If it does not show such characteristic as shown in graph, replace pressure sensor.

  • Page 445: A/C Compressor Relay

    1B-22 AIR CONDITIONING (OPTIONAL) A/C Compressor Relay Inspection 1) Disconnect negative cable at battery. 2) Remove A/C compressor relay (1) from relay box (2). 3) Check resistance between each two terminals as in table below. If check results are as specified, proceed to next operation check.
  • Page 446 AIR CONDITIONING (OPTIONAL) 1B-23 6) Disconnect magnet clutch lead wire and disengage lead wire clamp. 7) Remove compressor drive belt by loosening tension pulley bolt (1) and adjust bolt (2). 8) Disconnect suction and discharge hoses from compressor. NOTE: Cap open fittings immediately to keep moisture out of system.

  • Page 447: Replenishing Compressor Oil

    1B-24 AIR CONDITIONING (OPTIONAL) Installation Reverse removal procedure to install compressor noting the fol- lowing instructions. • If compressor is replaced, pour new compressor oil by refer- ring to “Replenishing Compressor Oil” under “Compressor” in this section. • Evacuate and charge system by referring to “Recovery” in this section.

  • Page 448: Magnet Clutch

    AIR CONDITIONING (OPTIONAL) 1B-25 When Replacing Compressor CAUTION: Be sure to use P/N: 99000-990C5-00A compressor oil or an equivalent compressor oil. Compressor oil is sealed in each new compressor by the amount required for A/C system. Therefore, when using a new compres- sor for replacement, drain oil from it by the amount calculated as follows.

  • Page 449: Relief Valve (Z13Dt Engine Model)

    Inspection By using special tool, check if there is refrigerant leakage. If there is refrigerant leakage, replace the compressor assembly. Special tool (A): 09990–86011 Required Service Material Recommended SUZUKI product Material (Part Number) Compressor oil COMPRESSOR OIL • O-ring (refrigerant oil) P/No.: 99000-990C5-00A...

  • Page 450: Front Wheel Alignment

    FRONT WHEEL ALIGNMENT 3A-1 SECTION 3A FRONT WHEEL ALIGNMENT WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.
  • Page 451 3A-2 FRONT WHEEL ALIGNMENT General Description Front Wheel Alignment Specifications Item Front Wheel Toe (total) 0 ± 1 mm Camber –0 ° 20’ ± 1 ° Caster 3 ° 40’ ± 1 ° Side Slip Limit mm/m 0 – IN 3 mm/m Steering Angle Inside 35 °...
  • Page 452 • Service on and around the air bag system components or wiring must be performed only by an autho-rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 453 3B-2 MANUAL RACK AND PINION On-Vehicle Service Tie Rod End Installation 1) Install tie rod end lock nut (1) and tie rod end (2) to tie rod (3). Align lock nut with mark (4) on tie rod thread. 2) Connect tie rod end to knuckle. Tighten new tie rod end nut (1) to specified torque.
  • Page 454 MANUAL RACK AND PINION 3B-3 Manual Rack and Pinion Assembly (Steering Gear Case) Installation 1) Apply grease to inside of pinion packing and install pinion packing onto pinion. Mount steering gear case (1) to body and tighten gear case mount bolts (2) and nuts (3) to speci- fied torque.
  • Page 455 3B-4 MANUAL RACK AND PINION 7) Reinstall cover (1) removed previously to steering shaft joint. 8) Put back floor mat as it was. 9) Install both wheels and tighten wheel bolts to specified torque. Tightening torque Wheel bolt: 95 N·m (9.5 kg-m, 69.0 lb-ft) 10) Lower hoist.
  • Page 456 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 457 3B1-2 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) General Description Wiring Diagram 1. Main fuse box Speedometer 15. Motor assembly (with clutch incorporated) 2. “EPS” fuse (30 A) 9. “EPS” warning lamp 16. Torque sensor 3. Ignition switch 10. To vehicle speed sensor (VSS) for G10 engine model, 17.
  • Page 458 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-3 Diagnosis “EPS” Warning Lamp Circuit Check Flow Table for M13 Engine Model CAUTION: Be sure to perform “System Check Flow Table” before starting diagnosis according to flow table. Step Action 1) Make sure that battery voltage is about 11 V Go to Step 2.
  • Page 459 3B1-4 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) Table-B “EPS” Warning Lamp Remains ON Step Action Was “System Check Flow Table” performed? Go to Step 2. Go to “System Check Flow Table” in this section. 1) With ignition switch OFF, disconnect 8 pin Go to step 3.
  • Page 460 FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.

  • Page 461: General Description

    3D-2 FRONT SUSPENSION General Description The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehi- cle body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also installed a little lower to the rubber mount.

  • Page 462: Diagnosis

    FRONT SUSPENSION 3D-3 Diagnosis Wheel Disc, Bolt & Bearing Check 1) Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. 2) Check wheel bolts for tightness and retighten them to specifi- cation as necessary.

  • Page 463: On-Vehicle Service

    3D-4 FRONT SUSPENSION On-Vehicle Service Stabilizer Bar and/or Bushings Components 1. Split pin 4. Stabilizer bar bushing 7. Mount bushing 10. Paint mark Tightening torque 2. Castle nut 5. Suspension control arm 8. Mount bush bracket 11. Paint mark (RH side) Do not reuse.

  • Page 464: Strut Assembly

    FRONT SUSPENSION 3D-5 • Install mounting bracket (1) so that its oblong hole side (2) comes to the rear. • Tighten stabilizer bar bracket bolts to specified torque. Tightening torque · Stabilizer bar bracket bolt: 45 N m (4.5 kg-m, 32.5 lb-ft) •...

  • Page 465: Steering Knuckle / Bearing

    3D-6 FRONT SUSPENSION • Install wheel and tighten wheel bolts to specified torque. Tightening torque · Wheel bolt (a) 95 N m (9.5 kg-m, 69.0 lb-ft) • Confirm front end (wheel) alignment, referring to Section 3A. Steering Knuckle / Bearing Components Wheel hub 5.
  • Page 466 FRONT SUSPENSION 3D-7 Removal 1) Hoist vehicle and remove wheel. 2) Uncaulk drive shaft nut (1). 3) Depress foot brake pedal and hold it there. Remove drive shaft nut. 4) Remove caliper carrier bolts. 5) Remove caliper with carrier. NOTE: Hang removed caliper with a wire hook of the like so as to prevent brake hose from bending and twisting exces- sively or being pulled.
  • Page 467 3D-8 FRONT SUSPENSION 9) Remove tie-rod end nut and disconnect tie-rod end (2) from knuckle (1) with puller. CAUTION: • Never reuse tie-rod end nut. • Reused nut will not be locked securely. 10) Remove wheel speed sensor (1) from knuckle (if equipped). 11) Remove strut bracket bolts (1) from strut bracket and then control arm ball stud bolt (2).
  • Page 468 FRONT SUSPENSION 3D-9 2) Remove circlip (1). Special tool (A): 09900-06108 3) Remove wheel bearing using special tool and hydraulic press. Special tool (A): 09913-75810 (for gasoline engine model) (A): 09913-85210 (for diesel engine model) CAUTION: • Never reuse wheel bearing. •...
  • Page 469 3D-10 FRONT SUSPENSION 2) Install circlip (1). Special tool (A): 09900-06108 3) Drive in dust cover (1) so that dimensions “a” and “b” become equal as shown. CAUTION: When drive in dust cover, be careful not to deform it. 4) Caulk with a punch. Installation 1) Using special tools and hydraulic press (1), drive wheel hub (2) into wheel bearing (3) as shown.
  • Page 470 FRONT SUSPENSION 3D-11 • Apply grease lightly to contact part (1) of wheel bearing and drive shaft. “A”: Grease 99000-25050 2) Install knuckle (2) to ball stud (3) on suspension control arm (4) and strut bracket (1). Installing direction of each bolt is as shown.

  • Page 471: Suspension Control Arm / Bushing

    3D-12 FRONT SUSPENSION 6) Install brake disc. 7) Tighten brake disc screws. Tightening torque Brake disc screw (a): 9 Nm (0.9 kg-m, 6.5 lb-ft) 8) Install brake caliper/caliper carrier. 9) Tighten caliper carrier bolts to specified torque. Tightening torque · Brake caliper carrier bolt (b): 95 N m (9.5 kg-m, 69.0 lb-ft) 10) Depress foot brake pedal and hold it there.
  • Page 472 FRONT SUSPENSION 3D-13 7) Remove bushing. Place suspension control arm onto flat surface side of spe- cial tool and push out bushing with special tool and oil hydraulic press as shown. Special tool (A): 09943-77910 Installation 1) Place suspension control arm onto flat surface side of spe- cial tool and install new bushing with special tool and oil hydraulic press as shown.

  • Page 473: Tightening Torque Specifications

    3D-14 FRONT SUSPENSION 3) Install ball stud (2) to knuckle (1). Align ball stud groove with knuckle bolt hole as shown. Then install ball stud bolt from the direction as shown. Tighten control arm ball stud bolt to specified torque. Tightening torque Control arm ball stud bolt ·...

  • Page 474: Required Service Material

    FRONT SUSPENSION 3D-15 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium Grease SUZUKI SUPER GREASE (E) • Wheel bearing (Should be applicable for –40 C° – 130 °C or –40 (99000-25050) °F – 266 °F) Special Tool 09943-17912...
  • Page 475 3D-16 FRONT SUSPENSION...
  • Page 476 REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.

  • Page 477: General Description

    3E-2 REAR SUSPENSION General Description 2WD model 63 N·m(6.3 kg-m) 175 N·m (17.5 kg-m) 63 N·m(6.3 kg-m) 95 N·m(9.5 kg-m) 100 N·m (10.0 kg-m) 50 N·m(5.0 kg-m) 90 N·m(9.0 kg-m) 80 N·m(8.0 kg-m) 80 N·m(8.0 kg-m) 1. Rear coil spring 4.
  • Page 478 REAR SUSPENSION 3E-3 4WD model A: With ABS 4. Rear shock absorber 9. Brake drum 14. Wheel bearing retainer ring or rear wheel sensor ring (if equipped with ABS) B: Without ABS 5. Lateral rod 10. Rear axle shaft 15. Spacer 1.

  • Page 479: Diagnosis

    3E-4 REAR SUSPENSION Diagnosis Wheel Disc, Bolt and Bearing Check • Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. • Check wheel bolts for tightness and, as necessary, retighten to specification. Tightening torque ·...

  • Page 480: On-Vehicle Service

    REAR SUSPENSION 3E-5 On-Vehicle Service 2WD model “A”: Body outside 7. Lateral rod outer washer 14. LSPV bracket 21. Trailing arm rear bolt: (only vehicle with LSPV) Insert from vehicle inside. 1. Rear coil spring 8. Rear axle 15. Brake back plate: 22.
  • Page 481 3E-6 REAR SUSPENSION 4WD model "A" “A”: Body outside 11. Oil seal 22. Brake back plate bolt 1. Rear coil spring 12. Spacer: 23. Bearing retainer ring (without ABS) The tapered side of spacer inner diameter directed toward outside (brake drum side). 2.

  • Page 482: Lateral Rod

    REAR SUSPENSION 3E-7 Lateral Rod Installation 1) Install lateral rod (1) or (2) to rear axle (or axle housing) (3) and vehicle body (4) referring to figure for proper installing direction of bolt (5) and washer (6). Tighten nuts (7) temporarily at this step. NOTE: •...

  • Page 483: Coil Spring

    3E-8 REAR SUSPENSION Coil Spring Installation 1) Install coil springs (1) (right & left) on spring seat (2) of rear axle as shown in figure and then raise rear axle. NOTE: When seating coil spring (1), mate spring end with stepped part (3) of rear axle spring seat as shown.

  • Page 484: Bump Stopper

    REAR SUSPENSION 3E-9 8) Lower hoist and vehicle in non-loaded condition, tighten absorber lower bolt (1) and lateral rod body side nut (2) to specified torque. Tightening torque Rear shock absorber lower bolt (a): 63 N·m (6.3 kg-m, 45.5 lb-ft) Lateral rod nut (body side) (b): 100 N·m (10.0 kg-m, 72.5 lb-ft) 9) If equipped with LSPV, check and adjust LSPV spring refer-...
  • Page 485 3E-10 REAR SUSPENSION 2) Install wheel speed sensor lead wire clamp, if equipped. 3) Install parking brake cable clamp (1). 4) Install shock absorber (1) to rear axle (2). 5) Tighten shock absorber lower bolt (3) temporarily by hand. 6) Remove floor jack from rear axle. 7) Install wheel and tighten wheel bolts to specified torque.

  • Page 486: Rear Axle (For 2Wd Model)

    REAR SUSPENSION 3E-11 Rear Axle (for 2WD Model) Installation Install removed parts in reverse order of removal, noting the fol- lowing points. 1) Place rear axle on floor jack. Then install lateral rod to rear axle and tighten nut temporarily by hand. 2) Install trailing arm rear bolts (1) (right &...
  • Page 487 3E-12 REAR SUSPENSION 7) Install brake back plates (1) and tighten back plate bolts (2) to specified torque. Tightening torque · Brake back plate bolt (a): 23 N m (2.3kg-m, 16.5 lb-ft) 8) Connect wheel speed sensor and lead wire clamps (right & left) (if equipped).

  • Page 488: Wheel Bearing (For 2Wd Model)

    REAR SUSPENSION 3E-13 12) Install brake drums (right & left). For details, refer to steps 3) to 8) of “Brake Drum Installation” in Section 5C. 13) Fill reservoir with brake fluid and bleed brake system. (For bleeding operation, refer to Section 5.) 14) Install wheel and tighten wheel bolts to specified torque.
  • Page 489 3E-14 REAR SUSPENSION 2) Remove circlip (1). Special tool (A): 09900-06108 3) Remove wheel bearing by using special tool and hydraulic press. Special tool (A): 09913-76010 CAUTION: • Never reuse wheel bearing. • Reused bearing should have excessive play. Installation 1) Install new wheel bearing (1) by using special tool and hydraulic press.

  • Page 490: Rear Axle Shaft And Wheel Bearing (For 4Wd Model)

    REAR SUSPENSION 3E-15 Rear Axle Shaft and Wheel Bearing (for 4WD Model) Removal 1) Hoist vehicle and remove rear wheels. 2) Remove brake drum screw and rear brake drum by using 8 mm bolts. For details referring to Section 5C. 1.
  • Page 491 3E-16 REAR SUSPENSION 10) In order to remove the retainer ring (1) from the axle shaft (2), grind (3) with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin. CAUTION: Be careful not to go so far as to grind the shaft. [A]: Without ABS [B]: With ABS 11) Break with a chisel the thin ground retainer ring, and it can...
  • Page 492 REAR SUSPENSION 3E-17 Installation Install removed parts in reverse order of removal, noting the fol- lowing points. 1) Install wheel bearing spacer (1) with the tapered side of its inner diameter directed toward outside, or brake drum side. 2) Press in a new bearing (2) and retainer ring (3) in order by using an hydraulic press (4).
  • Page 493 3E-18 REAR SUSPENSION 6) Install rear axle shaft to rear axle housing and tighten brake back plate bolts to specified torque. NOTE: When installing rear axle shaft, be careful not to cause damage to oil seal lip in axle housing. Tightening torque Brake back plate bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 7) Connect brake pipe to wheel cylinder and tighten brake pipe...

  • Page 494: Rear Axle Housing (For 4Wd Model)

    REAR SUSPENSION 3E-19 Rear Axle Housing (for 4WD Model) Removal 1) Hoist vehicle and remove rear wheels referring to “Wheel Removal and Installation” in Section 3F. 2) Remove rear axle shafts (right & left) referring to Steps 2) – 9) of “Rear Axle Shaft and Wheel Bearing (for 4WD Model)” in this section.
  • Page 495 3E-20 REAR SUSPENSION 11) Loosen trailing arm rear mounting nuts (3) (right & left) from axle housing, but don’t remove bolts. 12) Remove shock absorber lower mounting bolts (1). 13) Lower floor jack until tension of suspension coil spring becomes a little loose and remove trailing arm rear mounting bolts (2) (right &...
  • Page 496 REAR SUSPENSION 3E-21 Installation Install removed parts in reverse order of removal, noting the fol- lowing. 1) Place rear axle housing on floor jack. Then install rear trail- ing arm bolts (1) (right & left) in proper direction as shown. Then tighten nuts (2) temporarily by hand.
  • Page 497 3E-22 REAR SUSPENSION 5) Clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side. “A”: Sealant 99000-31110 6) Install differential carrier assembly to axle housing and tighten carrier bolts to specified torque. Tightening torque Rear differential carrier bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 7) Install propeller shaft to joint flange aligning match marks (2)
  • Page 498 REAR SUSPENSION 3E-23 15) Install rear axle shaft (right & left) to rear axle housing. 16) Tighten brake back plate bolts to specified torque. Tightening torque Brake back plate bolt (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 17) Connect brake pipes (3) to wheel cylinders (1) (right & left) and tighten brake pipe flare nuts (2) to specified torque.

  • Page 499: Tightening Torque Specifications

    3E-24 REAR SUSPENSION 26) Tighten right and left trailing arm nuts (1) and shock absorber lower bolts (2) to specified torque. Tighten lateral rod nuts (3) to specified torque. NOTE: When tightening these bolts and nuts, be sure that vehi- cle is off hoist and in non loaded condition.

  • Page 500: Required Service Material

    REAR SUSPENSION 3E-25 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE (A) • Axle shaft oil seal (99000-25010)···(for 4WD Model) Sealant SUZUKI BOND NO. 1215 • Joint seam of differential carrier and axle housing (99000-31110)···(for 4WD Model)

  • Page 501: Special Tool

    3E-26 REAR SUSPENSION Special Tool 09913-75810 09913-76010 09927-18411 09900-06108 Bearing installer Rear wheel bearing Universal puller Snap ring pliers (for 2WD Model) installer (for 4WD Model) (for 2WD Model) (for 2WD Model) 09942-15511 09943-17912 09921-57810 09913-50121 Sliding hammer Brake drum remover Bearing remover Oil seal remover (for 4WD Model)
  • Page 502 WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: • All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
  • Page 503 3F-2 WHEELS AND TIRES General Description Tires This vehicle is equipped with the following tire. Tire specification 165/60R14 75T ········ Gasoline engine model 165/60R14 79T ····························· Diesel engine model The tire is of tubeless type. The tire is designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressures.
  • Page 504 WHEELS AND TIRES 3F-3 On-Vehicle Service Service Operations Wheel Bolts All models use metric lug wheel bolts. Metric lug bolt size (1): M12 x 1.5 Wheel Removal WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts.
  • Page 505 3F-4 WHEELS AND TIRES Tightening order “A” – “B” – “C” – “D”: Tightening torque · Wheel bolt (a): 95 N m (9.5 kg-m, 69.0 lb-ft) Tightening Torque Specifications Tightening torque Fastening part N•m kg-m lb-ft Wheel bolt 69.0...
  • Page 506 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-1 SECTION 4A FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) CONTENTS General Description........4A-1 Front Drive Shaft Disassembly and Assembly ............. 4A-7 Diagnosis............4A-1 Front Drive Shaft Inspection ...... 4A-16 On-Vehicle Service......... 4A-2 Center Shaft and Center Bearing Support Front Drive Shaft Assembly Construction ..

  • Page 507: On-Vehicle Service

    4A-2 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) On-Vehicle Service Front Drive Shaft Assembly Construction 1. Transaxle 7. Oil filler/level plug 13. Drive shaft washer : Apply sealant 99000-31260 to plug thread 2. Drive shaft assembly 8. Oil drain plug 14. Center bearing support : Apply sealant 99000-31260 to plug thread 3.

  • Page 508: Front Drive Shaft Assembly Removal And Installation

    FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-3 Front Drive Shaft Assembly Removal and Installation Removal CAUTION: To prevent the breakage of boots, be careful not to dam- age the boots when removing drive shaft assembly. 1) Undo caulking (1) and remove drive shaft nut (2). 2) Loosen wheel bolts.
  • Page 509 4A-4 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 9) Pull out drive shaft joint (2) as follows. • For left side of all model and right side of G10 engine model Using tire lever (1), pull out drive shaft joint (2) so as to release snap ring fitting of joint spline at differential side.

  • Page 510: Front Drive Shaft Assembly Inspection

    FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-5 Installation CAUTION: • Be careful not to damage oil seals and boots when installing drive shafts. • Do not hit joint boot with hammer. Inserting joint only by hands is allowed. • Make sure that differential side joint is inserted fully and its snap ring is seated as it was.

  • Page 511: Front Drive Shaft Components

    4A-6 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) Front Drive Shaft Components [A]: Tripod joint type 6. Wheel side joint (Constant velocity ball joint) 14. Circlip : Apply Black grease included in spare part to joint. [B]: DOJ type 7. Boot (Wheel side) 15.

  • Page 512: Front Drive Shaft Disassembly And Assembly

    FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-7 Front Drive Shaft Disassembly and Assembly Disassembly For DOJ type CAUTION: Disassembly of wheel side joint is not allowed. If any abnormality is found, replace it as assembly. 1) Remove differential side boot big band (1) as follows. •...
  • Page 513 4A-8 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) c) Remove cage (1) with retaining ring (2) from housing (3) if necessary. 3) Remove differential side boot small band, and then pull out differential side boot from shaft. 4) Pull out damper through shaft. 5) Remove wheel side boot big band (1) as follows.
  • Page 514 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-9 1) Remove differential side boot big band (1) as follows. • For boot big band without joint Remove boot big band by tapping boot and band with plastic hammer. If it is hard to remove boot big band, cut it using a nipper or a iron saw with care not to damage tripod joint housing.
  • Page 515 4A-10 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 7) Remove wheel side boot big band (1) as follows. • For boot big band without joint Cut boot big band using a iron saw or a nipper with care not to damage wheel side joint housing. •...
  • Page 516 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-11 3) Install new wheel side boot on shaft temporarily. 4) Apply grease in the supplied parts to the inside of joint hous- ing. Grease color: Black Grease amount: Approx. 70 g (2.5 oz) 5) Fit wheel side boot onto grooves of housing and shaft.
  • Page 517 4A-12 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 10) Install damper (1) on left side drive shaft according to dimen- sion specified below. Damper installation position For M/T model with M13 engine “a”: 134 – 140 mm (5.28 – 5.51 in.) For A/T model with M13 engine “a”: 157 –...
  • Page 518 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-13 15) Install boot on joint housing. • For right side When fixing boot (1) to joint housing (2) with differential side boot big band (3), adjust so that measurements become as indicated below. •...
  • Page 519 4A-14 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) For Tripod Joint Type CAUTION: • Do not wash boots in degrease, such as gasoline or kerosene, etc. Washing in degrease causes deteriora- tion of boots. • To ensure full performance of joint as designed, be sure to distinguish two types of grease in spare part and apply the specified amount of grease to each joint.
  • Page 520 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-15 5) Place new wheel side boot small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure. 6) Install wheel side boot small band (1), putting its lower edge against projected end (4) of boot (3) so that clearance “a”...

  • Page 521: Front Drive Shaft Inspection

    4A-16 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 11) Apply grease to inside of joint housing (1), then install hous- ing, joint it with boot and fit boot to joint housing. After fitting boot, insert screwdriver into boot on joint housing side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.

  • Page 522: Center Shaft And Center Bearing Support Disassembly And Assembly (2Wd Model With M13 Engine)

    FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-17 Center Shaft and Center Bearing Support Dis- assembly and Assembly (2WD Model with M13 Engine) Disassembly 1) For M/T model, go to the next step. For A/T model, remove wheel side oil seal and circlip from center bearing support bracket (3).

  • Page 523: Tightening Torque Specification

    4A-18 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) • When installing left oil seal (1) and right oil seal (2) to center bearing support bracket (3) by using special tools, use care so that the oil seals installed in proper direction and position as shown figure.

  • Page 524: Required Service Material

    FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS) 4A-19 RequirPed Service Material Recommended SUZUKI product Material (Part Number) SUZUKI SUPER GREASE A • Oil seal lip Lithium grease (99000-25010) SUZUKI BOND NO. 1217G • Oil drain and filler/level plugs for manual Sealant...
  • Page 525 4A-20 FRONT DRIVE SHAFT (G10/M13 ENGINE MODELS)
  • Page 526 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) 4A3-1 SECTION 4A3 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) CONTENTS General Description........4A3-1 Front Drive Shaft Components ....4A3-5 Front Drive Shaft Disassembly and Diagnosis............4A3-1 Assembly ........... 4A3-6 On-Vehicle Service........4A3-2 Front Drive Shaft Inspection ....4A3-12 Front Drive Shaft Assembly Construction ..

  • Page 527: On-Vehicle Service

    4A3-2 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) On-Vehicle Service Front Drive Shaft Assembly Construction 1. Transaxle 6. Stabilizer mount bracket bolt 11. Drive shaft washer 2. Drive shaft assembly 7. Tie-rod end nut Do not reuse. 3. Tie-rod end 8. Ball stud bolt Tightening torque 4.

  • Page 528: Front Drive Shaft Assembly Removal And Installation

    FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) 4A3-3 Front Drive Shaft Assembly Removal and Installation Removal CAUTION: To prevent the breakage of boots, be careful not to dam- age the boots when removing drive shaft assembly. 1) Undo caulking (1) and remove drive shaft nut (2). 2) Loosen wheel bolts.

  • Page 529: Front Drive Shaft Assembly Inspection

    4A3-4 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) Installation CAUTION: • Be careful not to damage oil seals and boots when installing drive shafts. • Do not hit boot with hammer. Inserting boot only by hands is allowed. • Make sure that differential side joint is inserted fully and its snap ring is seated as it was.

  • Page 530: Front Drive Shaft Components

    FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) 4A3-5 Front Drive Shaft Components [A]: Right side drive shaft assembly 6. Cross groove joint boot small 13. Cross groove joint assembly band : Apply dark brown grease included in spare parts. [B]: Left side drive shaft assembly 7.

  • Page 531: Front Drive Shaft Disassembly And Assembly

    4A3-6 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) Front Drive Shaft Disassembly and Assembly Disassembly For Tripod joint type (right side) CAUTION: • Disassembly of wheel side joint is not allowed. If any abnormality is found, replace it as assembly. • Do not disassemble tripod joint. If any malcondition is found in it, replace it as differential side joint assembly.
  • Page 532 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) 4A3-7 7) Remove wheel side boot big band (1) as follows. For boot big band without joint a) Cut boot big band using a iron saw or a nipper with care not to damage wheel side joint housing. For boot big band with joint a) Remove boot big band by using flat end rod or the like.
  • Page 533 4A3-8 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) b) Clamp drive shaft in soft jawed vise, and then remove cir- clip using special tool and pull out cross groove joint with housing from drive shaft (1) using plastic hammer until cir- clip no longer engages in groove of shaft.
  • Page 534 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) 4A3-9 4) Apply grease in the supplied parts to wheel side joint. Grease color: Dark brown Amount: Approximately 110 g (3.88 oz) 5) Fit wheel side boot onto grooves of housing and shaft. 6) Place new wheel side boot big band onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
  • Page 535 4A3-10 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) 10) Install damper (1) on right side drive shaft according to dimension specified below. Length “a”: 337 – 343 mm (13.28 – 13.50 in.) 11) Set new differential side boot small band and differential side boot (1) on shaft temporarily.
  • Page 536 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) 4A3-11 For Cross groove joint type (left side) 1) Install new wheel side boot on shaft according to step 3) to 9) for Tripod joint Type Drive Shaft Assembly. 2) Install damper (1) on drive shaft according to dimension specified below.

  • Page 537: Front Drive Shaft Inspection

    4A3-12 FRONT DRIVE SHAFT (Z13DT ENGINE MODEL) Front Drive Shaft Inspection Inspection • Check shaft and joint for damage, wear or bend. Replace them as necessary. • Check retaining ring and snap ring for breakage or deforma- tion. Replace as necessary. Tightening Torque Specification Tightening torque Fastening part...
  • Page 538 PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in “FOREWORD” of this manual. CONTENTS On-Vehicle Service..........4B-2 Tightening Torque Specification....4B-6...
  • Page 539 4B-2 PROPELLER SHAFTS On-Vehicle Service [A]: Forward. 4. Propeller shaft No.2 bolt 8. Center support bolt : Apply thread lock 99000-32110 to thread. 1. Propeller shaft No.1 with center support 5. Dynamic damper Tightening torque 2. Viscous coupling with center support 6.
  • Page 540 PROPELLER SHAFTS 4B-3 REMOVAL 1) Hoist vehicle. 2) Before removing propeller shafts, give match marks (1) on propeller shaft No.2 (4) and companion flange (2) of rear dif- ferential as shown. Also give match marks (1) on propeller shaft No.2 yoke (5), dynamic damper (3), viscous coupling with center support (6), yoke (7) of propeller shaft No.1 with center support (8) and transfer output flange (9).
  • Page 541 4B-4 PROPELLER SHAFTS 4) If disassembling propeller shaft assembly is necessary, loosen propeller shaft No.2 bolts (1) and viscous coupling nuts (2) to facilitate subsequent disassembling, but keeping each connection provisionally. 5) Loosen center support bolts (1), then remove propeller shaft No.1 with center support (2), propeller shaft No.2 (3), dynamic damper (5) and viscous coupling with center sup- port (4) all together.
  • Page 542 PROPELLER SHAFTS 4B-5 INSTALLATION Reverse removal procedure to install propeller shafts noting the following points. • When installing propeller shafts, dynamic damper and vis- cous coupling with center support, align the match marks (1). Otherwise, vibration may occur during driving. •...
  • Page 543 4B-6 PROPELLER SHAFTS Tightening Torque Specification Tightening torque Fastening portion N•m kg-m lb-ft Propeller shaft bolt 17.0 Propeller shaft No.2 bolt 17.0 Center support bolt 40.0 Viscous coupling nut 17.0...
  • Page 544 • 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.
  • Page 545 5-2 BRAKES General Description When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis- tons (two in front and four in rear). The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two independent circuits.
  • Page 546 BRAKES 5-3 Check and Adjustment Bleeding Brakes CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. NOTE: For vehicle equipped with ABS, make sure that ignition switch is turned off.
  • Page 547 5-4 BRAKES 3) Depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one-third to one half turn. 4) When fluid pressure in the cylinder is almost depleted, retighten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hydraulic line.
  • Page 548 BRAKES 5-5 Brake Shoe Check Inspection should be carried out on the following points after brake pedal travel “c” (pedal to silencer clearance) check as described on previous page of this section, even when it is more than specification. Amount of brake shoe wear can be checked as follows. 1) Hoist vehicle.
  • Page 549 5-6 BRAKES...
  • Page 550 • 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.
  • Page 551 5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER On-Vehicle Service Rear Brake Hose/Pipe CAUTION: • Do not use lubricated shop air on brake parts as damage to rubber components may result. • If any hydraulic component is removed or brake line disconnected, bleed the brake system. •...
  • Page 552 BRAKES PIPE/HOSE/MASTER CYLINDER 5A-3 26 N·m (2.6 kg-m) View A Detail B View C 20 N·m (2.0 kg-m) 9 N·m (0.9 kg-m) [A]: with ABS vehicle 1. Rear brake hose 4. Top side 7. Right side [B]: without ABS vehi- 2.
  • Page 553 5A-4 BRAKES PIPE/HOSE/MASTER CYLINDER [C]: without ABS vehicle (4WD) 3. Rear brake hose 7. From master cylinder (Secondary) 11. Front side a – g: Clamp 4. To left rear wheel cylinder 8. Top side 12. E–ring (Insert delection) 1. E–ring 5.
  • Page 554 FRONT BRAKE 5B-1 SECTION 5B FRONT BRAKE WARNING: Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by the wheel bolts. Leave a bolt at least not to drop the wheel. Support the wheel and/or tire and then remove the bolt(s) left with the wheel.

  • Page 555: On-Vehicle Service

    5B-2 FRONT BRAKE On-Vehicle Service CAUTION: Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber com- ponents may result. If any component is removed or line disconnected, bleed the brake system. Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners. 1.

  • Page 556: Front Disc Brake Caliper

    FRONT BRAKE 5B-3 2) Install caliper (1) and tighten caliper pin bolts (2) to specifica- tion. NOTE: Make sure that boots (3) are fit into groove securely. Tightening torque Caliper pin bolt (a): 30 N·m (3.0 kg-m, 22.0 lb-ft) 3) Tighten front wheel bolts to specification. Tightening torque Wheel bolt (b): 95 N·m (9.5 kg-m, 69.0 lb-ft) 4) Upon completion of installation, perform brake test.

  • Page 557: Front Brake Disc

    5B-4 FRONT BRAKE 4) Torque wheel bolts to specification. Tightening torque · Wheel bolt (c): 95 N m (9.5 kg-m, 69.0 lb-ft) 5) After completing installation, fill reservoir with brake fluid and bleed brake system. Perform brake test and check each installed part for oil leakage.

  • Page 558: Tightening Torque Specification

    FRONT BRAKE 5B-5 3) Torque caliper carrier bolts (1) to specification. Tightening torque · Caliper carrier bolt (a): 95 N m (9.5 kg-m, 69.0 lb-ft) 4) Torque front wheel bolts to specifications. Tightening torque · Wheel bolt (b): 95 N m (9.5 kg-m, 69.0 lb-ft) 5) Upon completion of installation, perform brake test.
  • Page 559 5B-6 FRONT BRAKE...
  • Page 560 • 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.

  • Page 561: On-Vehicle Service

    5C-2 PARKING AND REAR BRAKE On-Vehicle Service CAUTION: • Replace all components included in repair kits to service this drum brake. Lubricate parts as speci- fied. • If any hydraulic component is removed or brake line disconnected, bleed the brake system. •...
  • Page 562 PARKING AND REAR BRAKE 5C-3 175 N·m (17.5 kg-m) 9 N·m (0.9 kg-m) 1. Brake back plate: 9. Piston assembly 17. Parking brake cable Clean back plate and apply thin coat of Bentonite base brake grease (anti-squeal agent) to six surfaces on which shoe rims rest. 2.

  • Page 563: Parking Brake Cable Component Location

    5C-4 PARKING AND REAR BRAKE Parking Brake Cable Component Location 1. Parking brake lever assembly 4. Parking cable bracket 7. Parking brake cable bolt 2. Equalizer 5. Parking brake cable: 8. Parking brake lever bolt Apply water tight sealant 99000-31090 to plate and cable contact. 3.

  • Page 564: Brake Drum (For 2Wd Model)

    PARKING AND REAR BRAKE 5C-5 Brake Drum (for 2WD Model) Removal 1) Hoist vehicle and remove wheel referring to “Wheel” Removal in Section 3F. 2) Remove spindle cap (1) as shown (by hammering lightly at 3 locations around it so as not to deform or cause damage to seating part of cap).
  • Page 565 5C-6 PARKING AND REAR BRAKE e) Pull brake drum (1) off by hand. If it is hard to remove, use special tools. NOTE: When drum is removed, visually inspect wheel cylinder for brake fluid leakage. Correct leaky point if any. Special tool (A): 09942-15511 (B): 09943-17912...

  • Page 566: Brake Drum Removal And Installation (For 4Wd Model)

    PARKING AND REAR BRAKE 5C-7 3) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil. 4) Install new spindle nut (1). 5) Tighten spindle nut (1) to specified torque. Tightening torque Spindle nut (a): 175 N·m (17.5 kg-m, 126.5 lb-ft) 6) Calk spindle nut (1).
  • Page 567 5C-8 PARKING AND REAR BRAKE 2) Remove brake drum screw (1) and release parking brake lever. 3) Remove brake drum. If brake drum can not be removed easily, increase clearance between brake shoes and drum, referring to step a) – d) in “Brake Drum (for 2WD Model)”.

  • Page 568: Brake Back Plate (For 2Wd Model)

    PARKING AND REAR BRAKE 5C-9 6) Install wheel and tighten wheel bolts to specified torque. Tightening torque Wheel bolt (b): 95 N·m (9.5 kg-m, 69.0 lb-ft) 7) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and perform brake test (foot brake and parking brake).
  • Page 569 5C-10 PARKING AND REAR BRAKE Installation 1) Apply water tight sealant to mating surfaces of brake back plate and rear axle. “A”: Sealant 366E, 99000-31090 NOTE: In case of vehicle equipped with ABS, do not apply seal- ant around hole for wheel speed sensor. 2) Install brake back plate and tighten back plate bolts to speci- fied torque.

  • Page 570: Brake Back Plate (For 4Wd Model)

    69.0 Required Service Material Recommended SUZUKI product Material (Part Number) Water tight SUZUKI SEALING COMPOUND 366E • To apply to mating surfaces of brake back sealant (99000-31090) plate and rear axle • To apply to mating surfaces of brake back...

  • Page 571: Special Tools

    5C-12 PARKING AND REAR BRAKE Special Tools 09942-15511 09943-17912 09913-75520 Sliding hammer Brake drum remover Bearing installer (for 2WD Snap-on Part (Front wheel hub model) NO. B3404B or equivalent remover) 09913-65135 09926-68310 09950-78230 Bearing puller (for 2WD Bearing installer (for 2WD Flare nut wrench (10 –...
  • Page 572 • 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.
  • Page 573 6-2-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0113 Intake Air Temperature DTC P0401 Exhaust Gas Recirculation Sensor Circuit High ........6-2-73 Flow Insufficient Detected......6-2-120 DTC P0117 Engine Coolant DTC P0402 Exhaust Gas Recirculation Temperature Circuit Low......6-2-76 Flow Excessive Detected......6-2-120 DTC P0118 Engine Coolant DTC P0420 Catalyst System Efficiency Temperature Circuit High......

  • Page 574: General Information

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-3 General Information Statement on Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch).

  • Page 575: Precaution

    6-2-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Precaution Precaution on engine service THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELI- ABLE ENGINE PERFORMANCE. • When raising or supporting engine for any reason, do not use a jack under oil pan.

  • Page 576: Fuel Pressure Relief Procedure

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-5 • Fuel or fuel vapor hose connection varies with each type of pipe. When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to the figure Hose Connection.

  • Page 577: Fuel Leakage Check Procedure

    6-2-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 3) Disconnect fuel pump relay (1) from relay box (2). 4) Remove fuel filter cap to release fuel vapor pressure in fuel tank and then reinstall it. 5) Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2-3 times for about 3 seconds each time to dissipate fuel pressure in lines.

  • Page 578: Diagnosis

    ECM memory as freeze frame data. (For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (2) but also OBD generic scan tool. (Diagnostic informa- tion can be accessed by using a scan tool.)
  • Page 579 6-2-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Driving Cycle A “Driving Cycle” consists of engine startup and engine shutoff. 2 Driving Cycle Detection Logic The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC) but the malfunction indicator lamp does not light at this time.
  • Page 580 DLC (1) is in compliance with SAE J1962 in the shape of connec- tor and pin assignment. OBD serial data line (3) (K line of ISO 9141) is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module and ABS control module.

  • Page 581: Precaution In Diagnosing Trouble For Engine

    ECM memory. • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool or OBD generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good under- standing as to what functions are available and how to use it.

  • Page 582: Engine And Emission Control System Check

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-11 Engine and Emission Control System Check Refer to the following items for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to complaint analysis.
  • Page 583 6-2-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Final Confirmation Test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test” in followings. Is there any problem symptom, DTC or abnormal condi- tion? 1.

  • Page 584: Customer Problem Inspection Form (Example)

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-13 Customer Problem Inspection Form (Example) NOTE: The above form is a standard sample. It should be modified according to conditions characteristic of each market.

  • Page 585: Malfunction Indicator Lamp (Mil) Check

    5) After completing the check, turn ignition switch off and dis- connect scan tool from data link connector. Diagnostic Trouble Code (DTC) Clearance 1) Connect OBD generic scan tool or SUZUKI scan tool to data link connector in the same manner as when making this con- nection for DTC check.
  • Page 586 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-15 NOTE: DTC and freeze frame data stored in ECM memory are also cleared in the following cases. Be careful not to clear them before keeping their record. • When power to ECM is cut off (by disconnecting bat- tery cable, removing fuse or disconnecting ECM con- nectors).

  • Page 587: Dtc Table

    6-2-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Table DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) P0010 Camshaft position actuator Actual valve timing fails to become close to target 1 driving circuit advance level of each function although advance control cycle function or retarding control function is at work.
  • Page 588 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-17 DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) P0134 O2 sensor (HO2S) circuit no Output voltage of HO2S–1 fails to go above specifica- 2 driving activity detected (Sensor–1) tion. cycles (or HO2S–1 circuit open or short) P0136 O2 sensor (HO2S) circuit Maximum output voltage of HO2S–2 is lower than speci- 2 driving...
  • Page 589 6-2-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DETECTING ITEM DETECTING CONDITION (DTC will set when detecting:) P1601 CAN communication error Transmitting or receiving error detected to ECM for 1 driving specified time continuously. cycle P1603 TCM trouble code detected When ECM receives a trouble code from TCM, which 1 driving indicates that some problem occurred in sensor circuits...

  • Page 590: Fail-Safe Table

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-19 Fail-Safe Table When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC NO.

  • Page 591: Visual Inspection

    6-2-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Visual Inspection Visually check the following parts and systems. INSPECTION ITEM REFERRING SECTION • Engine oil – level, leakage “Engine Oil and Oil Filter” in Section 0B. • Engine coolant – level, leakage “Engine Coolant”...

  • Page 592: Engine Basic Inspection

    Is it 650 – 750 r/min? Check ignition timing as follows: Go to “Engine Symp- Check ignition control 1) Using SUZUKI scan tool, select “MISC” mode on tom Diagnosis” in this related parts referring SUZUKI scan tool and fix ignition timing to initial section.
  • Page 593 6-2-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check ignition spark as follows: Go to Step 12. Go to “Ignition Spark 1) Disconnect injector couplers. Test” in Section 6F2. 2) Remove spark plugs and connect them to high-ten- sion cords or ignition coils.

  • Page 594: Engine Symptom Diagnosis

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-23 Engine Symptom Diagnosis Perform troubleshooting referring to following table when ECM has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Reference Item Hard Starting Faulty spark plug...
  • Page 595 6-2-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Low oil pressure Improper oil viscosity “Engine Oil and Oil Filter Replacement” in Section 0B. Malfunctioning oil pressure switch “Oil Pressure Switch Inspection” in Sec- tion 8C. Clogged oil strainer “Oil Pan and Oil Pump Strainer”...
  • Page 596 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-25 Condition Possible Cause Reference Item Overheating Inoperative thermostat “Thermostat Inspection” in Section 6B2. Poor water pump performance “Water Pump Inspection” in Section 6B2. Clogged or leaky radiator “Radiator Inspection” in Section 6B2. Improper engine oil grade “Engine Oil and Oil Filter Replacement”...
  • Page 597 6-2-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Excessive engine Blown cylinder head gasket “Valves and Cylinder Head Inspection” oil consumption in Section 6A2. Leaky camshaft oil seals “Camshaft, Tappet and Shim” in Sec- tion 6A2. Sticky piston ring “Pistons, Piston rings, Connecting Rods and Cylinders Inspection”...
  • Page 598 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-27 Condition Possible Cause Reference Item Surge Leaky or loosely connected high-tension cord “High-tension Cords Inspection” in Sec- (Engine power vari- tion 6F2. ation under steady Faulty spark plug (excess carbon deposits, “Spark Plugs Inspection” in Section throttle or cruise.
  • Page 599 6-2-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Engine has no Faulty spark plug “Spark Plugs Inspection” in Section power 6F2. Faulty ignition coil with ignitor “Ignition Coil Assembly (Including Igni- tor) Inspection” in Section 6F2. Leaks, loose connection or disconnection of “High-tension Cords Inspection”...
  • Page 600 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-29 Condition Possible Cause Reference Item Improper engine Faulty spark plug “Spark Plugs Inspection” in Section idling or engine fails 6F2. to idle Leaky or disconnected high-tension cord “High-tension Cords Inspection” in Sec- tion 6F2.
  • Page 601 6-2-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Condition Possible Cause Reference Item Excessive hydrocar- Faulty spark plug “Spark Plugs Inspection” in Section bon (HC) emission 6F2. or carbon monox- Leaky or disconnected high-tension cord “High-tension Cords Inspection” in Sec- ide (CO) tion 6F2.

  • Page 602: Scan Tool Data

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-31 Scan Tool Data As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condi- tion, there may be cases where the checked value does not fall within each specified data range.
  • Page 603 6-2-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) SCAN TOOL DATA VEHICLE CONDITION NORMAL CONDITION/ REFERENCE VALUES At specified idle speed with no load after warm- 1.0 – 4.0 g/s ✱ (MASS AIR FLOW RATE) ing up 0.14 – 0.52 lb/min At 2500 r/min with no load after warming up 4.0 –...
  • Page 604 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-33 SCAN TOOL DATA VEHICLE CONDITION NORMAL CONDITION/ REFERENCE VALUES RADIATOR FAN Ignition switch ON Engine coolant temp.: (RADIATOR FAN CON- Lower than 92.5°C TROL RELAY) (198.5°F) Engine coolant temp.: 97.5°C (208°F) or higher BLOWER FAN Ignition switch ON Blower fan switch: 2nd speed position or more...
  • Page 605 6-2-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) LONG FT B1 (LONG TERM FUEL TRIM, %) Long term fuel trim value represents long term corrections to the air/fuel mixture computation. A value of 0 indi- cates no correction, a value greater than 0 means an enrichment correction, and a value less than 0 means an enrichment correction, and a value less than 0 implies an enleanment correction.
  • Page 606 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-35 IGNITION ADVANCE (IGNITION TIMING ADVANCE FOR NO.1 CYLINDER, °) Ignition timing of NO.1 cylinder is commanded by ECM. The actual ignition timing should be checked by using the timing light. BATTERY VOLTAGE (V) This parameter indicates battery positive voltage inputted from main relay to ECM.

  • Page 607: Inspection Of Ecm And Its Circuits

    6-2-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Inspection of ECM and Its Circuits ECM and its circuits can be checked at ECM wiring couplers by measuring voltage, pulse signal and resistance. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with coupler disconnected from it.
  • Page 608 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-37 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE E23-1 BLK/YEL Ground for ECM Below 0.3 V Ignition switch turned ON E23-2 BLK/YEL Ground for ECM Below 0.3 V Ignition switch turned ON 10 –...
  • Page 609 6-2-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 10 – 14 V Ignition switch is turned ON *0 – 2 V Ignition switch is turned to ST (cranking) EGR valve (stepper ↑↓ position.
  • Page 610 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-39 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE 10 – 14 V Ignition switch turned ON *0 – 2 V Ignition switch is turned to ST (cranking) EGR valve (stepper ↑↓ position. E23-34 GRN/BLK motor coil 2) output...
  • Page 611 6-2-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE *2 – 3 V Ignition switch turned ON (Reference wave- E22-9 Knock sensor signal Engine running at idling with after warm- form No.15 and ing up No.16) Engine running at idling with after warm-...
  • Page 612 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-41 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE E22-21 – – – – E22-22 – – – – E22-23 – – – – E22-24 – – – – E22-25 – – – –...
  • Page 613 6-2-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON, stop lamp not 0 – 1 V Electric load signal for lighted up E21-9 GRN/WHT stop lamp Ignition switch turned ON, stop lamp 10 –...
  • Page 614 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-43 TERMINAL WIRE NORMAL CIRCUIT CONDITION NUMBER COLOR VOLTAGE Ignition switch turned ON, blower fan 10 – 14 V selector selected OFF position or A/C (High input) switch turned OFF or A/C evaporator LT GRN/ A/C request signal (if temp.
  • Page 615 6-2-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 1. Reference waveform No.1 Heated oxygen sensor–2 heater signal at engine idling Measurement CH1: E22-33 to E23-1 terminal CH2: E23-3 to E23-1 Oscilloscope CH1: 500 mV/DIV, CH2: 10 V/DIV setting TIME: 200 ms/DIV Measurement •...
  • Page 616 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-45 4. Reference waveform No.4 IAC valve signal Measurement CH1: E23-8 to E23-1 terminal Oscilloscope CH1: 5 V/DIV setting TIME: 4 ms/DIV Measurement • After warmed up to normal operating condition temperature • Engine at specified idle speed 5.
  • Page 617 6-2-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 7. Reference waveform No.7 Ignition coil No.1 and No.4 signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E23-32 to E23-1 Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 40 ms/DIV Measurement •...
  • Page 618 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-47 10. Reference waveform No.10 Fuel injector signal at engine racing Measurement CH1: E22-10 to E23-1 terminal CH2: E22-6 to E23-1 Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV setting TIME: 1 ms/DIV Measurement •...
  • Page 619 6-2-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 13. Reference waveform No.13 No.2 fuel injector signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E22-6 to E23-1 Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV setting TIME: 40 ms/DIV Measurement •...
  • Page 620 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-49 17. Reference waveform No.17 CMP sensor signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E22-30 to E23-1 Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 20 ms/DIV Measurement •...
  • Page 621 6-2-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 20. Reference waveform No.20 Manifold absolute pressure sensor signal at engine racing Measurement CH1: E22-15 to E22-28 terminal CH2: E22-34 to E22-28 Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 200 ms/DIV Measurement •...
  • Page 622 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-51 23. Reference waveform No.23 Ignition pulse (engine revolution) signal at engine idling Measurement CH1: E22-10 to E23-1 terminal CH2: E21-12 to E23-1 Oscilloscope CH1: 5 V/DIV, CH2: 5 V/DIV setting TIME: 10 ms/DIV Measurement •...
  • Page 623 6-2-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 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 discon- nected couplers as listed in the following table.
  • Page 624 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-53 Component Location INFORMATION SENSORS CONTROL DEVICES OTHERS 1. MAF and IAT sensor a: Fuel injector A: ECM 2. TP sensor b: EVAP canister purge valve B: Combination meter 3. Stop lamp switch c: Fuel pump relay C: EVAP canister 4.

  • Page 625: On" With Ignition Switch On

    6-2-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” with Ignition Switch ON (But Engine Stops) Wiring Diagram BLU/BLK PPL/WHT E21-1 BLK/RED BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL...
  • Page 626 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-55 Step Action MIL Power Supply Check Go to Step 4. “BLU/BLK” wire circuit open or 1) Disconnect ignition switch connector. poor connection. 2) Remove “METER” fuse. 3) Measure resistance between “BLU/BLK” wire terminal of ignition switch connector and “BLU/BLK”...
  • Page 627 6-2-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table A-2 Malfunction Indicator Lamp Circuit Check-lamp Remains “ON” after Engine Starts Wiring Diagram BLU/BLK PPL/WHT E21-1 BLK/RED BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL...
  • Page 628 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-57 Step Action MIL Circuit Check Go to Step 3. “PPL/WHT” wire cir- 1) Turn ignition switch to OFF position. cuit shorted to 2) Remove combination meter referring to “Combination ground. Meter Removal and Installation” in Section8. 3) Disconnect connectors from ECM.
  • Page 629 6-2-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table A-3 ECM Power and Ground Circuit Check-MIL Doesn’t Light with Igni- tion Switch ON and Engine Doesn’t Start Though It Is Cranked Up Wiring Diagram BLU/BLK PPL/WHT E21-1 BLK/RED BLK/WHT E21-28 BLU/BLK E22-1 E23-2...
  • Page 630 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-59 Step Action Main Relay Circuit Check Go to Step 4. Go to Step 8. 1) Turn ignition switch to OFF position. 2) Check for fuse blow at FI fuse (20 A). (See Fig. 1.) 3) If OK, measure voltage between “E23-15”...
  • Page 631 6-2-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Main Relay Check “BLU/BLK” wire Replace main 1) Measure resistance between each two terminals of main open circuit or relay. relay. (See Fig. 3). high resistance cir- Between main relay terminals cuit.
  • Page 632 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-61 DTC P0010 Camshaft Position Actuator Circuit Wiring Diagram BLK/YEL BLK/YEL E22-3 E22-1 BRN/YEL E22-2 E23-2 BLK/YEL E23-1 BLK/YEL [A]: [A]: Oil flow 3. Camshaft timing sprocket 6. Oil pan 1. Oil control valve 4.
  • Page 633 6-2-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Confirmation Procedure 1) Clear DTC. Refer to “DTC Clearance”. 2) Start engine and keep it at idle for 10 seconds. 3) Check DTC. Refer “DTC Check”. Troubleshooting Step Action Was “Engine and Emission Control System Check” per- Go to Step 2.
  • Page 634 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-63 Step Action Check wire circuit. Go to Step 9. “BLK/YEL” wire 1) Disconnect connectors from ECM with ignition switch open or high resis- turned OFF. tance circuit. 2) Measure resistance between “E22-3” terminal of ECM con- nector and “BLK/YEL”...
  • Page 635 2) Start engine and warm up to normal operating tempera- Chain Tensioner ture. Removal and 3) Select menu to DATA LIST. Installation” in 4) Check that the VVT GAP displayed on SUZUKI scan tool is Section 6A1. 0 – 5°. If OK, go to Step Is it OK?
  • Page 636 • Vehicle speed at 80 km/h (50 mile/h). and recheck. • Gear position at 5th or D range. 2) Check that the VVT GAP displayed on SUZUKI scan tool is 0 – 5°. Is it OK? Oil Control Circuit Visual Inspection Go to Step 6.
  • Page 637 6-2-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0102 Mass Air Flow Circuit Low Input Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED E21-5 BLK/RED E22-14 E22-32 E22-17...
  • Page 638 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-67 Troubleshooting Step Action Was “Engine and Emission Control System Check” per- Go to Step 2. Go to “Engine and formed? Emission Control System Check” in this section. MAF Sensor Check. Intermittent trouble. Go to Step 3.
  • Page 639 6-2-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check MAF sensor output signal. Substitute a known- Faulty MAF and IAT 1) Connect connectors to MAF sensor and ECM with good ECM and sensor. ignition switch turned OFF. recheck. 2) Check voltage between “E22-14”...
  • Page 640 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-69 DTC P0103 Mass Air Flow Circuit High Input Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED E21-5 BLK/RED E22-14 E22-32 E22-17...
  • Page 641 6-2-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Check” per- Go to Step 2. Go to “Engine and formed? Emission Control System Check” in this section. MAF sensor check. Intermittent trouble. Go to Step 3.
  • Page 642 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-71 DTC P0112 Intake Air Temperature Sensor Circuit Low Wiring Diagram BLK/RED E22-14 E22-32 LT GRN E22-17 BRN/WHT BRN/WHT E22-28 1. MAF and IAT sensor 3. To other sensor 2. ECM 4. From main relay DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
  • Page 643 6-2-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. IAT sensor and its circuit check. Go to Step 3.

  • Page 644: Dtc P0113 Intake Air Temperature Sensor Circuit High

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-73 DTC P0113 Intake Air Temperature Sensor Circuit High Wiring Diagram BLK/RED E22-14 E22-32 LT GRN E22-17 BRN/WHT BRN/WHT E22-28 1. MAF and IAT sensor 3. To other sensor 2. ECM 4. From main relay DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
  • Page 645 6-2-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action IAT sensor and its circuit check. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch turned OFF. referring to “Intermittent 2) Turn ON ignition switch. and Poor Connection 3) Check intake air temp.
  • Page 646 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-75 Step Action Check ground circuit. Go to Step 9. Go to Step 8. 1) Connect connectors to ECM. 2) Check for proper connection of IAT sensor connector at “BRN/WHT” wire terminal. 3) Measure resistance between “BRN/WHT” wire terminal of IAT sensor connector and body ground.

  • Page 647: Dtc P0117 Engine Coolant Temperature Circuit Low

    6-2-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0117 Engine Coolant Temperature Circuit Low Wiring Diagram YEL/GRN E22-16 E22-28 BRN/WHT BRN/WHT 1. ECT sensor 2. ECM 3. To other sensors DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are •...
  • Page 648 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-77 Step Action Check ECM voltage. Got to Step 6. Go to Step 4. 1) Disconnect connector from ECT sensor with ignition switch turned OFF. 2) Check for proper connection to ECT sensor at “YEL/GRN”...

  • Page 649: Dtc P0118 Engine Coolant Temperature Circuit High

    6-2-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0118 Engine Coolant Temperature Circuit High Wiring Diagram YEL/GRN E22-16 E22-28 BRN/WHT BRN/WHT 1. ECT sensor 2. ECM 3. To other sensors DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are •...
  • Page 650 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-79 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. ECT sensor and its circuit check. Go to Step 3.
  • Page 651 6-2-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check ECT sensor ground circuit. Go to Step 9. Go to Step 8. 1) Connect connectors to ECM. 2) Check for proper connection of ECT sensor connector at “BRN/WHT” wire terminal. 3) Measure resistance between “BRN/WHT”...

  • Page 652: Dtc P0121 Throttle Position Sensor Circuit Range/Performance

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-81 DTC P0121 Throttle Position Sensor Circuit Range/Performance Wiring Diagram E22-8 WHT/GRN WHT/GRN E22-34 E22-28 BRN/WHT BRN/WHT 1. TP sensor 3. To other sensors 2. To MAP sensor 4. ECM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Difference between actual throttle opening (detected from TP...
  • Page 653 Check TP sensor and its circuit. Go to Step 11. Go to Step 3. 1) Turn OFF ignition switch and connect SUZUKI scan tool to DLC. 2) Turn ON ignition switch and check TP sensor output voltage when throttle valve is at idle position and fully opened.
  • Page 654 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-83 Step Action Check wire circuit. Go to Step 6. “WHT/GRN” and/or 1) Disconnect connectors from ECM with ignition “GRY” wire shorted switch turned OFF. to ground circuit. 2) Measure resistance between “WHT/GRN” wire ter- If wire are OK, sub- minal of ECM connector and body ground and stitute a known-...
  • Page 655 6-2-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check MAF sensor and its circuit. Go to Step 12. Repair or replace it. 1) Check MAF sensor and its circuit, referring to “DTC P0102 Mass Air Flow Circuit Low Input” and “DTC P0103 Mass Air Flow Circuit High Input”...

  • Page 656: Dtc P0122 Throttle Position Sensor Circuit Low

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-85 DTC P0122 Throttle Position Sensor Circuit Low Wiring Diagram E22-8 WHT/GRN WHT/GRN E22-34 E22-28 BRN/WHT BRN/WHT 1. TP sensor 2. To MAP sensor 3. To other sensors 4. ECM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are...
  • Page 657 6-2-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check TP sensor and its circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch turned OFF and then turn ON ignition referring to “Intermittent switch.
  • Page 658 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-87 Step Action Check TP sensor. Substitute a known-good Replace TP sensor. 1) Check resistance between terminals of TP ECM and recheck. sensor. See Fig. 2. TP sensor resistance Between 1 and 3: 4.0 – 6.0 k Ω...

  • Page 659: Dtc P0123 Throttle Position Circuit High Input

    6-2-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0123 Throttle Position Circuit High Input Wiring Diagram E22-8 WHT/GRN WHT/GRN E22-34 E22-28 BRN/WHT BRN/WHT 1. TP sensor 3. To other sensors 2. To MAP sensor 4. ECM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are...
  • Page 660 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-89 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check TP sensor and its circuit. Go to Step 3.
  • Page 661 6-2-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check wire circuit. Go to Step 8. “GRY” wire open circuit or 1) Measure resistance between “E22-34” wire high resistance circuit. terminal of ECM connector and “GRY” wire terminal of TP sensor connector with igni- tion switch turned OFF.

  • Page 662: Dtc P0131 O2 Sensor (Ho2S) Circuit Low Voltage (Sensor-1)

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-91 DTC P0131 O2 Sensor (HO2S) Circuit Low Voltage (Sensor-1) DTC P0132 O2 Sensor (HO2S) Circuit High Voltage (Sensor-1) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT E23-4 WHT/BLU BLK/WHT E22-11 BRN/WHT BRN/WHT E22-28 1.
  • Page 663 6-2-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) NOTE: Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PROCEDURE. • Intake air temp.: –7°C, 19.4°F or higher • Engine coolant temp.: 70°C, 158°F or higher •...
  • Page 664 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-93 Step Action Check HO2S–1 sensor ground. Go to Step 6. “BRN/WHT” wire high 1) With ignition switch turned ON, check volt- resistance circuit. age between “BRN/WHT” wire terminal of Poor “E22-28” terminal HO2S–1 sensor connector and engine connection.

  • Page 665: Dtc P0133 O2 Sensor (Ho2S) Circuit Slow Response (Sensor-1)

    6-2-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0133 O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT E23-4 WHT/BLU BLK/WHT E22-11 BRN/WHT BRN/WHT E22-28 1. Relay box 4. Circuit fuse box 7. Heater 10.

  • Page 666: Dtc P0134 O2 Sensor (Ho2S) No Activity Detected (Sensor-1)

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-95 1) Perform step 1) to 6) of DTC P0131/P0132 confirmation procedure. 2) Check if DTC and pending DTC exists by using scan tool. If not, check if oxygen sensor monitoring test has completed by using scan tool.
  • Page 667 6-2-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Maximum HO2S voltage is lower than 0.45 V. • HO2S–1 (2 driving cycle detection logic) • HO2S–1 circuit • Fuel system •...
  • Page 668 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-97 Step Action Check wire circuit. Go to Step 6. “RED” wire high resis- 1) Disconnect connectors from ECM with igni- tance circuit or open cir- tion switch turned OFF. cuit. 2) Remove ECM from vehicle body and con- Poor “E22-11”...

  • Page 669: Dtc P0031 Ho2S Heater Control

    6-2-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0031 HO2S Heater Control Circuit Low (Sensor-1) DTC P0032 HO2S Heater Control Circuit High (Sensor-1) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT BLK/WHT E23-4 WHT/BLU E22-11 BRN/WHT BRN/WHT E22-28 1. Relay box 4.
  • Page 670 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-99 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check HO2S–1 heater power circuit. Go to Step 3.
  • Page 671 6-2-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check HO2S–1 heater power circuit. HO2S–1 heater circuit are “BLK/WHT” and “YEL” 1) Disconnect connector from ECM with igni- wire high resistance cir- tion switch turned OFF. Substitute a known-good cuit.

  • Page 672: Dtc P0136 O2 Sensor (Ho2S) Circuit (Sensor-2)

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-101 DTC P0136 O2 Sensor (HO2S) Circuit (Sensor-2) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT BLK/WHT BLU/RED E23-3 WHT/BLU E22-33 BRN/WHT BRN/WHT E22-28 1. Relay box 3. Ignition switch 5. “IG COIL” fuse 7.
  • Page 673 6-2-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Increase vehicle speed to 60 – 80 km/h (37 – 50 mile/h) at 5th gear or D range. 5) Release accelerator pedal and with engine brake applied, keep vehicle coasting (with fuel cut for 4 sec.
  • Page 674 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-103 Step Action Check wire circuit. Go to Step 7. “BLU” wire high resis- 1) Disconnect connectors from ECM with igni- tance circuit or open cir- tion switch turned OFF. cuit. 2) Remove ECM from vehicle body and con- Poor “E22-33”...

  • Page 675: Dtc P0037 Ho2S Heater Control

    6-2-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0037 HO2S Heater Control Circuit Low (Sensor-2) DTC P0038 HO2S Heater Control Circuit High (Sensor-2) Wiring Diagram BLK/WHT BLK/WHT E21-28 BLU/BLK BLK/WHT E23-3 WHT/BLU BLK/WHT BLU/RED E22-33 BRN/WHT BRN/WHT E22-28 1. Relay box 4.
  • Page 676 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-105 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check HO2S–2 heater power circuit. Go to Step 3.

  • Page 677: Dtc P0171 System Too Lean

    6-2-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check HO2S–2 heater power circuit. HO2S–2 heater circuit are “BLU/RED” wire high 1) Disconnect connectors from ECM with igni- resistance circuit. tion switch turned OFF. Substitute a known-good 2) Connect connector to HO2S–2 with ignition ECM and recheck.
  • Page 678 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-107 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Is there DTC(s) other than “P0171” and “P0172”? Go to applicable DTC Go to Step 3.

  • Page 679: Dtc P0300 Random Misfire Detected

    6-2-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0300 Random Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected SYSTEM DESCRIPTION ECM measure the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
  • Page 680 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-109 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Drive vehicle under freeze frame data condition as noted for 1 min. or more. 4) Stop vehicle and check DTC and pending DTC.

  • Page 681: Dtc P0327 Knock Sensor Circuit Low

    6-2-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Engine mechanical systems check. Check wire harness Repair or replace. Check engine mechanical parts or system which can and connection of cause engine rough idle or poor performance. ECM ground, ignition –...
  • Page 682 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-111 DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool. 3) Start engine and run it for 10 sec.

  • Page 683: Dtc P0335 Crankshaft Position (Ckp) Sensor Circuit

    6-2-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) [A]: Fig. for Step 3 DTC P0335 Crankshaft Position (CKP) Sensor Circuit Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 BLK/YEL E22-35 E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED...
  • Page 684 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-113 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 3 – 5 sec. 4) Check DTC and pending DTC. Troubleshooting Step Action...
  • Page 685 6-2-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check CKP Sensor. Go to Step 8. Replace CKP sensor. 1) Remove CKP sensor referring to “CKP Sensor Removal and Installation” in Section 6E2. 2) Remove metal particles on end face of CKP sensor, if any.
  • Page 686 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-115 [A]: Fig. 1 for Step 3 [B]: Fig. 3 for Step 8 [C]: Fig. 2 for Step 7...

  • Page 687: Dtc P0340 Camshaft Position Sensor Circuit

    6-2-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0340 Camshaft Position Sensor Circuit Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 BLK/YEL E22-35 E23-2 BLK/YEL WHT/BLU E23-1 BLK/YEL BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED E21-5 BLK/RED E22-10 1.
  • Page 688 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-117 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 5 sec. 4) Check DTC and pending DTC. Troubleshooting Step Action...
  • Page 689 6-2-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check CMP Sensor. Go to Step 8. Replace CMP sen- 1) Remove CMP sensor referring to “CMP Sensor sor. Removal and Installation” in Section 6E2. 2) Remove metal particles on end face of CMP sen- sor, if any.
  • Page 690 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-119 [A]: Fig. 1 for Step 3 [B]: Fig. 3 for Step 8 [C]: Fig. 2 for Step 7...

  • Page 691: Dtc P0401 Exhaust Gas Recirculation Flow Insufficient Detected

    6-2-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected System/Wiring Diagram 1. EGR value 4. Sensed information 7. “IG COIL” fuse 10. Main relay 2. Intake manifold 5.
  • Page 692 Go to Step 5. EGR valve operation check. Go to Step 4. Go to Step 10. 1) With ignition switch turned OFF, install SUZUKI scan tool. 2) Check EGR system referring to “EGR System Inspection” in Section 6E2. Is it in good condition?
  • Page 693 6-2-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action MAP sensor check. Intermittent trouble or Repair or replace. 1) Check MAP sensor for performance referring to faulty ECM “MAP Sensor Individual Check” in “DTC P0108” Check for intermittent Diag. Flow Table. referring to “Intermit- Is check result satisfactory? tent and Poor Connec-...

  • Page 694: Dtc P0420 Catalyst System Efficiency Below Threshold

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-123 DTC P0420 Catalyst System Efficiency Below Threshold System/Wiring Diagram E22-11 BRN/WHT BRN/WHT E22-28 E22-33 Circuit Description ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by HO2S–2 (2).
  • Page 695 6-2-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • While vehicle running at constant speed under other than • Exhaust gas leak high load. • Three way catalytic converter malfunction •...

  • Page 696: Dtc P0443 Evaporative Emission System Purge Control Valve Circuit

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-125 DTC P0443 Evaporative Emission System Purge Control Valve Circuit Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED BLK/RED E21-5 RED/BLK E23-13...
  • Page 697 6-2-126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting WARNING: In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas hot water. Step Action Was “Engine and Emission Control System...

  • Page 698: Dtc P0480 Fan 1 (Radiator Cooling Fan) Control Circuit

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-127 DTC P0480 Fan 1 (Radiator Cooling Fan) Control Circuit Wiring Diagram BLK/YEL BLK/YEL BLU/BLK E23-15 E22-1 BLK/RED BLK/RED E21-6 BLK/YEL E23-2 BLK/YEL BLK/RED BLK/RED E21-5 E23-1 BLK/YEL E21-4 BLK/YEL BLU/RED 20A 30A YEL/GRN E22-16 E22-28...
  • Page 699 6-2-128 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Check Relay Circuit Go to Step 3. “BLK/RED”...
  • Page 700 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-129 Step Action Check Relay Circuit Go to Step 8. “BLU” wire in open or high 1) Turn ignition switch to OFF position. resistance circuit. 2) Disconnect connectors from ECM. 3) Remove radiator fan relay from relay box. 4) Check for proper connection to “E21-4”...

  • Page 701: Dtc P0500 Vehicle Speed Sensor (Vss) Malfunction

    6-2-130 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0500 Vehicle Speed Sensor (VSS) Malfunction Wiring Diagram BLK/RED E22-19 1. VSS 3. ECM 2. To main relay 4. To TCM (if equipped) DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area •...
  • Page 702 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-131 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Check vehicle speed signal. Intermittent trouble or Go to Step 3. Is vehicle speed displayed on scan tool in step faulty ECM.
  • Page 703 6-2-132 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check vehicle speed sensor signal. Go to Step 12. Go to Step 10. 1) Remove VSS referring to “Vehicle Speed Sensor (VSS)” in Section 7A2 or “Output Shaft Speed Sensor (VSS)” in Section 7B1. 2) Remove metal particles on end face of VSS, if any.
  • Page 704 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-133 [A]: Fig. 1 for Step 5 [B]: Fig. 2 for Step 9...

  • Page 705: Dtc P0505 Idle Air Control System

    6-2-134 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0505 Idle Air Control System System/Wiring Diagram BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED BLK/RED E21-5 BLK/RED GRN/YEL E23-8 1.
  • Page 706 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-135 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check” in this section. Idle Speed Check Go to Step 3. Go to Step 4.

  • Page 707: Dtc P1500 Starter Signal Circuit Malfunction

    6-2-136 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1500 Starter Signal Circuit Malfunction Wiring Diagram WHT/BLU BLK/YEL BLK/YEL E22-35 BLK/YEL WHT/BLU BLK/YEL BLK/RED BLK/YEL E22-35 BLK/YEL [A]: M/T Vehicle 1. ECM 3. Ignition switch 5. Instrument panel harness/engine harness connector [B]: A/T Vehicle 2.
  • Page 708 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-137 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Signal circuit check Poor “E22-35” connection “BLK/YEL” wire or “BLK/ 1) Disconnect connectors from ECM with igni- or intermittent trouble.

  • Page 709: Dtc P0107 Manifold Absolute Pressure Low Input

    6-2-138 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P0107 Manifold Absolute Pressure Low Input Wiring Diagram E22-8 WHT/GRN WHT/GRN LT GRN/RED E22-15 E23-2 BLK/YEL E23-1 BLK/YEL E22-28 BRN/WHT BRN/WHT 1. Manifold absolute pressure sensor 2. To TP sensor 3. To other sensors 4.
  • Page 710 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-139 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Check MAP sensor and its circuit. Go to Step 3. Intermittent trouble.
  • Page 711 6-2-140 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check MAP sensor signal circuit. Go to Step 11. Go to Step 9. 1) Turn ON ignition switch. 2) Measure voltage between “LT GRN/RED” wire terminal in MAP sensor harness con- nector and engine ground.

  • Page 712: Dtc P0108 Manifold Absolute Pressure High Input

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-141 DTC P0108 Manifold Absolute Pressure High Input Wiring Diagram E22-8 WHT/GRN WHT/GRN LT GRN/RED E22-15 E23-2 BLK/YEL E23-1 BLK/YEL E22-28 BRN/WHT BRN/WHT 1. Manifold absolute pressure sensor 3. To other sensors 2. To TP sensor 4.
  • Page 713 6-2-142 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Check MAP sensor and its circuit. Go to Step 3. Intermittent trouble.

  • Page 714: Dtc P0601 Internal Control Module Memory Check Sum Error

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-143 Step Action Check MAP sensor signal circuit. Go to Step 8. “LT GRN/RED” wire 1) Disconnect connectors from ECM with igni- shorted to power supply tion switch turn OFF. or other circuit. 2) Turn ON ignition switch.

  • Page 715: Dtc P1510 Ecm Back-Up Power Supply Malfunction

    6-2-144 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1510 ECM Back-up Power Supply Malfunction Wiring Diagram WHT/BLU E21-16 1. ECM 2. “DOME RADIO” fuse 3. Relay box Circuit Description Battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ECM, etc.
  • Page 716 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-145 Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Battery voltage supply circuit check Poor “E21-16” connection “DOME RADIO”...

  • Page 717: Dtc P1601 Can Communication Error

    6-2-146 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1601 Can Communication Error Wiring Diagram E13-17 E21-8 E13-7 E21-7 1. ECM 2. TCM DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Transmission or reception error of communication data •...
  • Page 718 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-147 Step Action Circuit Check Go to Step 4. “WHT” wire circuit open or 1) Turn ignition switch to OFF position. high resistance. 2) Disconnect connectors from ECM and TCM. 3) Check for proper connection to “E21-7” ter- minal of ECM connector and “E13-7”...

  • Page 719: Dtc P1603 Tcm Trouble Code Detected

    6-2-148 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC P1603 TCM Trouble Code Detected DTC Detecting Condition When ECM receives a trouble code from TCM, which indicates that some problem occurred in sensor circuits and its calculated values used for operations such as idle speed control, engine power control, and so on by TCM, ECM sets DTC P1603.

  • Page 720: Dtc P2227 Barometric Pressure Circuit Range/Performance

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-149 DTC P2227 Barometric Pressure Circuit Range/Performance DTC P2228 Barometric Pressure Circuit Low DTC P2229 Barometric Pressure Circuit High System Description Barometric pressure sensor is installed in ECM (PCM). DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area DTC P2227:...
  • Page 721 6-2-150 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) DTC Troubleshooting Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Emis- Check” performed? sion Control System Check”. Is DTC P2227 set? Go to Step 3. Substitute a known-good ECM and recheck.
  • Page 722 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-151 Troubleshooting Step Action Check each injector for operating sound at Fuel injector circuit is in Go to Step 2. engine cranking using sound scope. good condition. Do all 4 injector make operating sound? Check fuel injector resistance.
  • Page 723 6-2-152 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-2 Fuel Pump and Its Circuit Check BLU/BLK BLK/WHT BLK/WHT E21-28 BLK/WHT E23-14 WHT/BLU BLK/YEL E21-1 BLK/RED 60A 20A E23-2 BLK/YEL E23-1 BLK/YEL BLK/RED E21-6 BLK/YEL BLK/RED BLK/RED E21-5 E23-15 BLU/BLK BLK/YEL 1.
  • Page 724 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-153 Step Action Check fuel pump relay. Go to Step 5. Faulty relay. 1) Check fuel pump relay, referring to “Main Relay, Fuel Pump Relay and Radiator Fan Relay Inspection” in Section 6E2. Is relay in good condition? Check fuel pump relay drive signal.
  • Page 725 6-2-154 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-3 Fuel Pressure Check 1. Injector 3. Fuel filter and fuel pump B: Hose 2. Delivery pipe A: Gauge C: 3-way joint Troubleshooting NOTE: Before using the following table, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good con- dition.
  • Page 726 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-155 Step Action Fuel Line Check Faulty fuel pressure reg- Repair or replace. 1) Check fuel pipe, fuel hose and joint for damage or ulator. deform. Are they in good condition? Was fuel pressure higher than specification in Step 1? Go to Step 6. Go to Step 7.
  • Page 727 6-2-156 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-4 Idle Air Control System Check BLK/WHT E21-28 BLU/BLK E22-1 E23-2 BLK/YEL E23-1 BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL 60A 20A BLK/RED BLK/RED E21-5 BLK/RED GRN/YEL E23-8 1.
  • Page 728 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-157 Step Action Check A/C (input) signal circuit referring to Step Go to Step 6. Repair or replace A/C sig- 1 of “Table B-5 A/C Signal Circuit Check”, if nal circuit or A/C system. equipped.
  • Page 729 6-2-158 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-5 A/C Signal Circuits Check (Vehicle with A/C) PNK/BLU E21-13 BLU/YEL BLU/BLK BLK/WHT BLK/WHT BLK/WHT GRN/ORN BLU/YEL GRN/ORN LT GRN/RED E21-30 YEL/GRN E21-16 GRN/RED E21-15 BRN/WHT E22-28 E23-11 BLU/WHT BLK/YEL WHT/BLU BLK/YEL BLK/YEL BLU/BLK...
  • Page 730 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-159 Troubleshooting Step Action Check Evaporator Temp. Sensor Go to Step 2. Faulty A/C evaporator 1) Disconnect connectors from ECM with igni- temperature sensor or its tion switch turned OFF. circuit. 2) Check for proper connection to “E21-15” and “E22-28”...
  • Page 731 6-2-160 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Step Action Check A/C Compressor Relay Circuit Go to Step 9. Go to Step 10. 1) Check voltage between “E23-11” wire termi- nal of ECM connector and vehicle body ground under the following condition. While engine running and A/C switch OFF: 10 –...
  • Page 732 Go to Step 2. Go to Step 3. Check electric load signal circuit. Electric load signal circuit “PNK/BLU” and/or 1) Connect SUZUKI scan tool to DLC with ignition is in good condition. “RED/YEL” circuit open switch OFF. or short, electric load 2) Start engine and select “DATA LIST”...
  • Page 733 6-2-162 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Table B-7 Radiator Fan Control System Check BLK/YEL BLK/YEL BLU/BLK E23-15 E22-1 BLK/RED BLK/RED E21-6 BLK/YEL E23-2 BLK/YEL BLK/RED BLK/RED E21-5 E23-1 BLK/YEL E21-4 BLK/YEL BLU/RED 20A 30A YEL/GRN E22-16 E22-28 BRN/WHT 1.
  • Page 734 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) 6-2-163 Step Action Check Radiator Fan Relay Go to Step 6. Replace radiator fan relay. 1) Check radiator fan relay referring to “Main Relay, Fuel Pump Relay and Radiator Fan Relay Inspection” in Section 6E2. Is it in good condition? Radiator Fan Control Circuit Check Go to Step 7.
  • Page 735 6-2-164 ENGINE GENERAL INFORMATION AND DIAGNOSIS (M13 ENGINE) Special Tool Tech 2 kit (SUZUKI scan tool) (See NOTE “C”.) NOTE: “C”: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
  • Page 736 • 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.
  • Page 737 6A2-2 ENGINE MECHANICAL (M13 ENGINE) Timing Chain and Chain Tensioner Pistons, Piston Rings, Connecting Rods Components..........6A2-44 and Cylinders Removal and Installation ... 6A2-68 Timing Chain and Chain Tensioner Pistons, Piston Rings, Connecting Rods Removal and Installation......6A2-44 and Cylinders Disassembly and Timing Chain and Timing Chain Assembly ..........

  • Page 738: General Description

    ENGINE MECHANICAL (M13 ENGINE) 6A2-3 General Description Engine Construction Description The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...

  • Page 739: Engine Lubrication Description

    6A2-4 ENGINE MECHANICAL (M13 ENGINE) Engine Lubrication Description The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into 2 paths in cylinder block. In one path, oil reaches the crankshaft journal bearings.

  • Page 740: Variable Valve Timing (Vvt) System Description

    ENGINE MECHANICAL (M13 ENGINE) 6A2-5 Variable Valve Timing (VVT) System Description 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 gen- eration and lower fuel consumption can be attained in the whole engine speed range from low to high.

  • Page 741: Oil Control Valve

    6A2-6 ENGINE MECHANICAL (M13 ENGINE) Oil control valve The oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ECM. By this operation, the intake valve timing is varied continuously.

  • Page 742: Timing Retarding

    ENGINE MECHANICAL (M13 ENGINE) 6A2-7 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 743: Diagnosis

    6A2-8 ENGINE MECHANICAL (M13 ENGINE) Diagnosis Diagnosis Table Refer to “Engine and Emission Control System Check” in Section 6-2. Compression Check Check compression pressure on all 4 cylinders as follows: 1) Warm up engine to normal operating temperature. 2) Stop engine after warming up. NOTE: After warming up engine, place transaxle gear shift lever in “Neutral”...

  • Page 744: Engine Vacuum Check

    ENGINE MECHANICAL (M13 ENGINE) 6A2-9 NOTE: • For measuring compression pressure, crank engine at least 250 rpm by using fully charged battery. • If measured compression pressure is lower than limit value, check installation condition of special tool. If it is properly installed, possibility is compression pres- sure leakage from where piston ring or valve contact.
  • Page 745 6A2-10 ENGINE MECHANICAL (M13 ENGINE) 3) Remove air cleaner case (1) and resonator (2). 4) Remove PCV hose (1) from PCV valve (2). 5) Connect special tool (Vacuum gauge) to PCV hose (1). Special tool (A): 09915-67311 6) Blind PCV valve (2) using tape (3) or the like. 7) Install air cleaner case and resonator.

  • Page 746: Oil Pressure Check

    ENGINE MECHANICAL (M13 ENGINE) 6A2-11 Oil Pressure Check NOTE: Prior to checking oil pressure, check the following items. • Oil level in oil pan If oil level is low, add oil up to Full level mark (hole) on oil level gauge. •...
  • Page 747 6A2-12 ENGINE MECHANICAL (M13 ENGINE) 6) After warming up, raise engine speed to 4,000 rpm and mea- sure oil pressure. Oil pressure specification More than 270 kPa (2.7 kg/cm , 39.8 psi) at 4,000 rpm 7) Stop engine and remove oil pressure gauge and attachment. 8) Before reinstalling oil pressure switch (2), be sure to wrap its screw threads with sealing tape (1) and tighten switch to specified torque.

  • Page 748: Valve Lash (Clearance) Inspection

    ENGINE MECHANICAL (M13 ENGINE) 6A2-13 Valve Lash (Clearance) Inspection 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation” in this section. 3) Remove right side engine under cover, if necessary. 4) Using 17 mm wrench, turn crankshaft pulley (1) clockwise until cam lobes (2) become perpendicular to shim faces (3) at valves “1”...
  • Page 749 6A2-14 ENGINE MECHANICAL (M13 ENGINE) b) Check housing No. and select special tool corresponding to housing No. referring to the following table. Special tool selection table No. on camshaft Embossed mark housing on special tool I3, I4, I5 IN345 E3, E4, E5 EX345 A: I: Intake side or E: Exhaust side B: Position from timing chain side...
  • Page 750 ENGINE MECHANICAL (M13 ENGINE) 6A2-15 5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by cal- culating the thickness of new shim with the following formula and table. Intake side: A = B + C – 0.200 mm (0.0078 in.) Exhaust side: A = B + C –...

  • Page 751: On-Vehicle Service

    6A2-16 ENGINE MECHANICAL (M13 ENGINE) 8) Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4) and remove special tool. Special tool (A): 09916-67020 or 09916-67021 1. Tappet 2. Camshaft 9) Install camshaft housing (1) and tighten bolts to specified torque.

  • Page 752: Air Cleaner Element Inspection And Cleaning

    ENGINE MECHANICAL (M13 ENGINE) 6A2-17 Air Cleaner Element Inspection and Cleaning • Check air cleaner element for dirt. Replace excessively dirty element. • Blow off dust by compressed air from air outlet side of ele- ment. Knock Sensor Removal and Installation Refer to “Knock Sensor Removal and Installation”...
  • Page 753 6A2-18 ENGINE MECHANICAL (M13 ENGINE) 9) Remove oil level gauge (1). 10) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head cover. 11) Remove cylinder head cover mounting bolts in such order as indicated in figure.
  • Page 754 ENGINE MECHANICAL (M13 ENGINE) 6A2-19 • Timing chain cover (1) and cylinder head (2) mating surface as shown. “A”: Sealant 99000-31250 3) Install cylinder head cover to cylinder head. NOTE: When installing cylinder head cover, use care so that cyl- inder head cover gasket or spark plug hole gaskets will not get out of place or fall off.

  • Page 755: Throttle Body And Intake Manifold Components

    6A2-20 ENGINE MECHANICAL (M13 ENGINE) Throttle Body and Intake Manifold Components 2.5 N·m (0.25 kg-m) 25 N·m (2.5 kg-m) 5 N·m (0.5 kg-m) 25 N·m (2.5 kg-m) 1. Intake manifold 9. Gasket 17. Throttle body mounting bolt 25. To brake booster 2.

  • Page 756: Throttle Body Removal And Installation

    ENGINE MECHANICAL (M13 ENGINE) 6A2-21 Throttle Body Removal and Installation Removal 1) Relieve fuel pressure referring to “Fuel pressure Relief Pro- cedure” in Section 6-2. 2) Disconnect negative cable at battery. 3) Drain coolant by loosening drain plug (1). WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot.

  • Page 757: Intake Manifold Removal And Installation

    6A2-22 ENGINE MECHANICAL (M13 ENGINE) Intake Manifold Removal and Installation Removal 1) Remove throttle body referring to “Throttle Body Removal and Installation” in this section. 2) Disconnect MAP sensor coupler (1). 3) Disconnect the following hoses: • Brake booster hose (2) from cylinder head cover •...

  • Page 758: Exhaust Manifold Components

    ENGINE MECHANICAL (M13 ENGINE) 6A2-23 Exhaust Manifold Components 45 N·m (4.5 kg-m) 50 N·m (5.0 kg-m) 50 N·m (5.0 kg-m) 43 N·m (4.3 kg-m) 45 N·m (4.5 kg-m) 50 N·m (5.0 kg-m) 50 N·m (5.0 kg-m) 1. Exhaust manifold gasket 6.

  • Page 759: Exhaust Manifold Removal And Installation

    6A2-24 ENGINE MECHANICAL (M13 ENGINE) Exhaust Manifold Removal and Installation WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. Removal 1) Disconnect negative cable at battery. 2) Remove front bumper with front grille referring to “Front Bumper and Rear Bumper”...
  • Page 760 ENGINE MECHANICAL (M13 ENGINE) 6A2-25 Installation 1) Install new gasket to cylinder head. 2,(a) 1,(a) Then install exhaust manifold. Tighten manifold bolts (1) and nuts (2) to specified torque. Tightening torque Exhaust manifold bolt and nut (a): 50 N·m (5.0 kg-m, 36.5 lb-ft) NOTE: The figure on the left varies with specification.

  • Page 761: Oil Pan And Oil Pump Strainer Components

    6A2-26 ENGINE MECHANICAL (M13 ENGINE) Oil Pan and Oil Pump Strainer Components [A]: Sealant application amount 3. O-ring 8. Oil pan bolt and nut “a”: 3 mm (0.12 in.) 4. Gasket Tightening torque “b”: 2 mm (0.08 in.) 5. Oil pan drain plug bolt Do not reuse.
  • Page 762 ENGINE MECHANICAL (M13 ENGINE) 6A2-27 6) Remove oil pan and then oil pump strainer (1) from cylinder block. Installation 1) Clean oil pump strainer screen (1). 2) Clean sealing surface on oil pan and cylinder block. Remove oil, old sealant and dust from sealing surface. 3) Apply sealant continuously to oil pan mating surface as shown in figure.
  • Page 763 6A2-28 ENGINE MECHANICAL (M13 ENGINE) 4) Install new O-rings (2) in the position as shown in figure and install oil pump strainer (1). Tighten strainer bolt (3) first and then bracket bolt (4) to specified torque. Tightening torque Oil pump strainer bolt (a): 11 N·m (1.1 kg-m, 8.0 lb-ft) Oil pump strainer bracket bolt (b): 11 N·m (1.1 kg-m, 8.0 lb-ft) 5) After fitting oil pan to cylinder block, run in securing bolts and...

  • Page 764: Engine Mountings Components

    ENGINE MECHANICAL (M13 ENGINE) 6A2-29 Engine Mountings Components 55 N·m (5.5 kg-m) 65 N·m (6.5 kg-m) 25 N·m (2.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m) 55 N·m (5.5 kg-m)

  • Page 765: Unit Repair Overhaul

    6A2-30 ENGINE MECHANICAL (M13 ENGINE) Unit Repair Overhaul Engine Assembly Removal and Installation Removal 1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro- cedure” in Section 6-2. 2) Disconnect negative and positive cables at battery. 3) Remove engine hood after disconnecting windshield washer hose.
  • Page 766 ENGINE MECHANICAL (M13 ENGINE) 6A2-31 14) Disconnect the following electric lead wires: • TP sensor (1) • MAP sensor (2) • ECT sensor (3) • EGR valve (4) • CMP sensor (5) • IAC valve (6) • Ignition coil assembly (7) •...
  • Page 767 6A2-32 ENGINE MECHANICAL (M13 ENGINE) 21) Install lifting device. 22) Remove engine rear mounting bolts (1), engine left mounting bracket nuts (2) and engine right mounting nuts (3). 23) Before removing engine with transaxle from body, recheck to make sure all hoses, electric wires and cables are discon- nected from engine and transaxle.
  • Page 768 ENGINE MECHANICAL (M13 ENGINE) 6A2-33 3) Lift engine with transaxle into engine compartment, but do not remove lifting device. 4) Install engine rear mounting bolts (1), engine left mounting bracket nuts (2) and engine right mounting nuts (3). Tighten these bolts and nuts to specified torque. 1, (a) Tightening torque Engine rear mounting bolt...

  • Page 769: Timing Chain Cover Components

    6A2-34 ENGINE MECHANICAL (M13 ENGINE) Timing Chain Cover Components [A]: Sealant application amount 8. Oil pan mounting bolt and nut 18. Oil control valve “a”: 3 mm (0.12 in.) 9. Cylinder head cover 19. Oil control valve mounting nut : Apply sealant 99000-31250 to the sealing point for timing chain cover mating surface and cylinder head gasket sealing point referring to...

  • Page 770: Timing Chain Cover Removal And Installation

    ENGINE MECHANICAL (M13 ENGINE) 6A2-35 Timing Chain Cover Removal and Installation Removal CAUTION: • Keep working table, tools and hands clean while over- hauling. • Use special care to handle aluminum parts so as not to damage them. • Do not expose removed parts to dust. Keep them always clean.
  • Page 771 6A2-36 ENGINE MECHANICAL (M13 ENGINE) 8) Remove water outlet cap (1) from timing chain cover (2). 9) Remove timing chain cover. 10) Remove oil gallery pipe No.1 (1) and oil control valve (2) from timing chain cover (3). Installation 1) Clean sealing surface on timing chain cover, cylinder block and cylinder head.
  • Page 772 ENGINE MECHANICAL (M13 ENGINE) 6A2-37 5) Apply sealant “A” to mating surface of cylinder and cylinder head and “B” to mating surface of timing chain cover as shown in figure. “A”: Sealant 99000-31140 “B”: Sealant 99000-31250 Sealant amount for timing chain cover Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.) 6) Apply engine oil to oil seal lip, then install timing chain cover...

  • Page 773: Timing Chain Cover Inspection

    6A2-38 ENGINE MECHANICAL (M13 ENGINE) 11) Install water pump pulley. 12) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation” in this section. 13) Install oil pan referring to “Oil Pan and Oil Pump Strainer Removal and Installation” in this section. 14) Install crankshaft pulley (1).

  • Page 774: Oil Control Valve

    ENGINE MECHANICAL (M13 ENGINE) 6A2-39 Oil control valve Inspect strainer (1) and mating surface (2) of oil control valve. Clean oil control valve. Oil gallery pipe Inspect oil gallery pipes No.1 (1), No.2 (2) and No.3 (3). Replace if crack, deformation or clog exists. Oil Pump Components...

  • Page 775: Oil Pump Removal And Installation

    6A2-40 ENGINE MECHANICAL (M13 ENGINE) [A]: Sealant application amount 4. Inner rotor 10. Circlip “a”: 3 mm (0.12 in.) 5. Timing chain cover Tightening torque : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head. : Apply sealant 99000-31250 to mating surface of timing chain cover referring to the figure of Step 4) of “Installation”...
  • Page 776 ENGINE MECHANICAL (M13 ENGINE) 6A2-41 3) Remove relief valve (1), spring (2) and retainer (3) by remov- ing circlip (4). Assembly 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case and plate.

  • Page 777: Oil Pump Inspection

    6A2-42 ENGINE MECHANICAL (M13 ENGINE) Oil Pump Inspection Oil seal • Check oil seal lip for fault or other damage. Replace as nec- essary. NOTE: When installing new oil seal (1), press-fit it to oil pump case (2) by using special tool as shown in the figure. Special tool (A): 09913-75810 Drive in dimension...

  • Page 778: Radial Clearance

    ENGINE MECHANICAL (M13 ENGINE) 6A2-43 Radial clearance Check radial clearance between outer rotor (1) and case (2), using thickness gauge (3). If clearance exceeds its limit, replace oil pump assembly. Limit on radial clearance between outer rotor and case for oil pump : 0.310 mm (0.0122 in.) Side clearance Using straight edge (1) and thickness gauge (2), measure side...

  • Page 779: Timing Chain And Chain Tensioner Components

    6A2-44 ENGINE MECHANICAL (M13 ENGINE) Timing Chain and Chain Tensioner Components 1. Crankshaft timing sprocket 4. Timing chain tensioner 7. Timing chain tensioner bolt : Apply engine oil to sliding surface. 2. Timing chain 5. Timing chain tensioner adjuster assembly 8.
  • Page 780 ENGINE MECHANICAL (M13 ENGINE) 6A2-45 2) By turing crankshaft, align both intake and exhaust camshaft timing sprocket marks (1) with notches (2) of cylinder head respectively and align crank shaft sprocket key (3) with notch of cylinder block (4). 3) Remove timing chain tensioner adjuster assembly (5). 4) Remove timing chain tensioner (6).
  • Page 781 6A2-46 ENGINE MECHANICAL (M13 ENGINE) 3) Install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft timing sprocket as shown in figure. 4) Fit crankshaft timing sprocket to timing chain by aligning gold plate (3) of timing chain and circle mark (4) on crankshaft timing sprocket.
  • Page 782 ENGINE MECHANICAL (M13 ENGINE) 6A2-47 7) Check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with marking of timing chain (2) and match mark on crankshaft timing sprocket (3) are in with marking of timing chain (4). [A]: View A “a”: Approx.

  • Page 783: Timing Chain And Timing Chain Tensioner Inspection

    6A2-48 ENGINE MECHANICAL (M13 ENGINE) 10) Apply engine oil to timing chain and then turn crankshaft clockwise by 2 revolutions and check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is in match with notch (4) on cylinder block as shown in figure.

  • Page 784: Timing Chain

    ENGINE MECHANICAL (M13 ENGINE) 6A2-49 Timing chain • Check timing chain for wear or damage. Timing chain tensioner adjuster • Check that tooth surface (1) are free from damage. Timing chain No.1 guide • Check timing chain No.1 guide (1) for wear or damage.

  • Page 785: Camshaft, Tappet And Shim Components

    6A2-50 ENGINE MECHANICAL (M13 ENGINE) Camshaft, Tappet and Shim Components 1. Intake camshaft 5. Shim 9. Upper 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 786 ENGINE MECHANICAL (M13 ENGINE) 6A2-51 3) With hexagonal section (1) of intake camshaft (2) held sta- tionary with spanner or the like, loosen mounting bolt of intake cam timing sprocket assembly (3) and remove it. “a” CAUTION: Never attempt to loosen mounting bolt with intake cam timing sprocket assembly held stationary.
  • Page 787 6A2-52 ENGINE MECHANICAL (M13 ENGINE) Installation 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to cylinder head. NOTE: When installing shim, make sure to direct shim No. side toward tappet. 2) Install camshaft bearing (1) to cylinder head. CAUTION: Do not apply engine oil to camshaft bearing back.

  • Page 788: Camshaft, Tappet And Shim Inspection

    ENGINE MECHANICAL (M13 ENGINE) 6A2-53 6) Check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install hous- ings as indicated by these marks. A. I: Intake side or E: Exhaust side B.

  • Page 789: Cam Wear

    6A2-54 ENGINE MECHANICAL (M13 ENGINE) Cam wear Using a micrometer, measure cam height “a”. If measured height underruns its limit, replace camshaft. Cam height “a” of camshaft Standard Limit Intake cam 44.929 – 45.089 mm 44.80 mm (1.769 – 1.775 in.) (1.764 in.) Exhaust cam 44.399 –...

  • Page 790: Wear Of Tappet And Shim

    ENGINE MECHANICAL (M13 ENGINE) 6A2-55 7) Remove housing, and using scale (2) on gaging plastic (1) envelop, measure gaging plastic width at its widest point. Camshaft journal clearance Standard Limit Intake side 0.020 – 0.072 mm 0.10 mm No.1 housing (0.0008 –...
  • Page 791 6A2-56 ENGINE MECHANICAL (M13 ENGINE) Measure cylinder head bore and tappet outside diameter to deter- mine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head. Cylinder head to tappet clearance Standard: 0.025 – 0.066 mm (0.0010 – 0.0025 in.) Limit: 0.15 mm (0.0059 in.) Tappet outside diameter [A] Standard: 30.959 –...

  • Page 792: Valves And Cylinder Head Removal And Installation

    ENGINE MECHANICAL (M13 ENGINE) 6A2-57 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2. Valve spring retainer 8. Valve guide Tightening torque 3.
  • Page 793 6A2-58 ENGINE MECHANICAL (M13 ENGINE) Installation 1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface. 2) Install knock pins (1) to cylinder block. 3) Install new cylinder head gasket (2) to cylinder block. “TOP”...
  • Page 794 ENGINE MECHANICAL (M13 ENGINE) 6A2-59 NOTE: If they are reused, check thread diameters of cylinder head bolt (1) for deformation according to the follows and “A” “B” replace them with new ones if thread diameter difference exceeds limit. “a” Measure each thread diameter of cylinder head bolt (1) at “b”...

  • Page 795: Valves And Cylinder Head Disassembly And Assembly

    6A2-60 ENGINE MECHANICAL (M13 ENGINE) Valves and Cylinder Head Disassembly and Assembly Disassembly 1) For ease in servicing cylinder head, remove intake manifold, injectors and exhaust manifold from cylinder head. 2) Using special tools (valve lifter), compress valve spring and then remove valve cotters (1) by using special tool (forceps).
  • Page 796 ENGINE MECHANICAL (M13 ENGINE) 6A2-61 Assembly 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as to remove burrs and make it truly round. Special tool (A): 09916-34542 (B): 09916-37320 2) Install valve guide to cylinder head. Heat cylinder head uniformly to a temperature of 80 to 100 °C (176 to 212 °F) so that head will not be distorted, and drive new valve guide into hole with special tools.
  • Page 797 6A2-62 ENGINE MECHANICAL (M13 ENGINE) 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.

  • Page 798: Valves And Cylinder Head Inspection

    ENGINE MECHANICAL (M13 ENGINE) 6A2-63 9) Install intake manifold referring to “Intake Manifold Removal and Installation” in this section. 10) Install fuel injectors referring to “Fuel Injector Removal and Installation” in Section 6E2. 11) Install exhaust manifold referring to “Exhaust Manifold Removal and Installation”...
  • Page 799 6A2-64 ENGINE MECHANICAL (M13 ENGINE) • Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not too much to grind off its chamber. When it is worn out too much that its chamber is gone, replace valve.

  • Page 800: Cylinder Head

    ENGINE MECHANICAL (M13 ENGINE) 6A2-65 Valve seat repair A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.

  • Page 801: Valve Springs

    6A2-66 ENGINE MECHANICAL (M13 ENGINE) • Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using a straightedge and thickness gauge, check flatness of gasketed surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place abrasive paper on and...

  • Page 802: Pistons, Piston Rings, Connecting Rods And Cylinders Components

    ENGINE MECHANICAL (M13 ENGINE) 6A2-67 Spring squareness Use a square and surface plate to check each spring for square- ness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit given below must be replaced.

  • Page 803: Pistons, Piston Rings, Connecting Rods And Cylinders Removal And Installation

    6A2-68 ENGINE MECHANICAL (M13 ENGINE) Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation” in this section. 2) Remove cylinder head referring to “Valves and Cylinder Head Removal and Installation”.

  • Page 804: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly

    ENGINE MECHANICAL (M13 ENGINE) 6A2-69 4) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft. Using a hammer handle, tap piston head to install piston into bore.
  • Page 805 6A2-70 ENGINE MECHANICAL (M13 ENGINE) b) Force piston pin out. Assembly 1) Decarbonize piston head and ring grooves using a suitable tool. 2) Install piston pin to piston (1) and connecting rod (2): a) After applying engine oil to piston pin and piston pin holes in piston and connecting rod.

  • Page 806: Pistons, Piston Rings, Connecting Rods And Cylinders Inspection

    ENGINE MECHANICAL (M13 ENGINE) 6A2-71 Pistons, Piston Rings, Connecting Rods and Cylinders Inspection Cylinder Visual inspection Inspect cylinder walls for scratches, roughness or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched or ridged, rebore cylinder and use oversize piston. Cylinder bore diameter, taper and out-of-round Using a cylinder gauge (1), measure cylinder bore in thrust and axial directions at two positions (“a”...

  • Page 807: Piston Pin

    6A2-72 ENGINE MECHANICAL (M13 ENGINE) Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance Standard: 0.032 –...

  • Page 808: Piston Rings

    ENGINE MECHANICAL (M13 ENGINE) 6A2-73 Piston pin clearance Check piston pin clearance in small end and piston. Replace con- necting rod and/or piston if its small end is badly worn or dam- aged or if measured clearance exceeds limit. Piston pin clearance in connecting rod small end Standard: 0.003 –...

  • Page 809: Connecting Rod

    6A2-74 ENGINE MECHANICAL (M13 ENGINE) Connecting rod Big-end side clearance Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod. Big-end side clearance Standard: 0.25 –...

  • Page 810: Crank Pin And Connecting Rod Bearings

    ENGINE MECHANICAL (M13 ENGINE) 6A2-75 Crank pin and connecting rod bearings Crank pin diameter Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged or out-of round or taper is out of limit, replace crankshaft or regrind crank pin to undersize and use undersize bearing.
  • Page 811 6A2-76 ENGINE MECHANICAL (M13 ENGINE) 4) Install rod bearing cap (1) to connecting rod. When installing cap, be sure to point arrow mark (2) on cap to crankshaft pulley side, as shown in figure. After applying engine oil to rod bolts and tighten cap nuts (3) gradually as follows.
  • Page 812 ENGINE MECHANICAL (M13 ENGINE) 6A2-77 1) Check stamped numbers on connecting rod and its cap as shown. Three kinds of numbers (“1”, “2” and “3”) represent the fol- lowing connecting rod big end inside diameters. For example, stamped number “1” indicates that correspond- ing connecting rod big end inside diameter is 45.0000 –...
  • Page 813 6A2-78 ENGINE MECHANICAL (M13 ENGINE) 3) There are five kinds of standard bearings differing in thick- ness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing.

  • Page 814: Main Bearings, Crankshaft And Cylinder Block Components

    ENGINE MECHANICAL (M13 ENGINE) 6A2-79 Main Bearings, Crankshaft and Cylinder Block Components...

  • Page 815: Main Bearings, Crankshaft And Cylinder Block Removal And Installation

    6A2-80 ENGINE MECHANICAL (M13 ENGINE) [A]: Sealant application amount 5. Main bearing 15. Flywheel mounting bolt : Upper half of bearing has an oil groove Tightening torque 6. Sensor plate 16. Rear oil seal housing bolt Do not reuse. 7. Crankshaft timing sprocket key 17.
  • Page 816 ENGINE MECHANICAL (M13 ENGINE) 6A2-81 5) Loosen main bearing cap No.1 and No.2 bolts in such order as indicated in figure and remove them. 6) Remove crankshaft from cylinder block. Installation CAUTION: • Use new bearing cap No.1 bolts. They are deformed once they are used because they are plastic deforma- tion tightening bolts.
  • Page 817 6A2-82 ENGINE MECHANICAL (M13 ENGINE) 3) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs. 4) Confirm that dowel pins (3) are installed to intake side of each journal. 5) Install crankshaft to cylinder block.
  • Page 818 ENGINE MECHANICAL (M13 ENGINE) 6A2-83 8) Apply sealant to mating surface of rear oil seal housing (1). “A”: Sealant 99000-31250 Sealant amount for rear oil seal housing Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.) 9) Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool.

  • Page 819: Block Inspection

    6A2-84 ENGINE MECHANICAL (M13 ENGINE) Main Bearings, Crankshaft and Cylinder Block Inspection Main bearing cap No.1 bolt Measure each thread diameter main bearing cap No.1 bolts (1) at “A” “B” “A” on 60mm(2.36in.) from seat side of flange bolt and “B” on 90mm(3.54in.) from seat side of flange bolt by using a micrometer (2).

  • Page 820: Main Bearings

    ENGINE MECHANICAL (M13 ENGINE) 6A2-85 2) Tighten main bearing cap No.1 bolts (1) – (10) and main bearing cap No.2 bolts (11) – (20) gradually as follows. a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft) according to numerical order in figure.
  • Page 821 6A2-86 ENGINE MECHANICAL (M13 ENGINE) • Upper half of bearing (1) has an oil groove (2) as shown in figure. Install this half with oil groove to cylinder block. • Lower half of bearing does not have an oil groove. Visual inspection Check bearings for pitting, scratches, wear or damage.
  • Page 822 ENGINE MECHANICAL (M13 ENGINE) 6A2-87 5) Remove bearing caps and using scale (1) on gaging plastic (2) envelop, measure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
  • Page 823 6A2-88 ENGINE MECHANICAL (M13 ENGINE) 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) or numbers (“1”, “2” and “3”) represent the following cap bore diameters. Stamped alphabets or numbers on cylinder block represent bearing cap bore diameter marked with an arrow in figure respectively.
  • Page 824 ENGINE MECHANICAL (M13 ENGINE) 6A2-89 Specification of new standard crankshaft main bearing size Number stamped on crank web No.2 (Journal diameter) Alphabet A (1) Pink Purple Brown stamped on B (2) Purple Brown Green cylinder block C (3) Brown Green Black (Cap bore dia.) New standard bearing to be...

  • Page 825: Rear Oil Seal

    6A2-90 ENGINE MECHANICAL (M13 ENGINE) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicu- lar to each other in order to check for out-of-round. 3) Using journal diameter measured above and alphabets stamped on cylinder block, select an undersize bearing by referring to table given below.

  • Page 826: Sensor Plate

    ENGINE MECHANICAL (M13 ENGINE) 6A2-91 Sensor plate Check sensor plate for crack or damage. If malcondition is found, replace it. Cylinder block Distortion of gasketed surface Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct it. Cylinder block flatness Limit: 0.03 mm (0.0012 in.) Honing or reboring cylinders...

  • Page 827: Required Service Material

    Required Service Material Recommended SUZUKI product Material (Part Number) Sealant SUZUKI BOND NO. 1207F • To apply to mating surfaces of cylinder block and oil (99000-31250) pan. • To apply to mating surfaces of cylinder block and timing chain cover.
  • Page 828 ENGINE MECHANICAL (M13 ENGINE) 6A2-93 Tightening torque Fastening part N•m kg-m lb-ft Cylinder head bolt for M10 Tighten 20 N·m (2.0 kg-m, 14.5 lb-ft), 40 N·m (4.0 kg-m, 29.0 lb-ft), 60° and 60° by the specified procedure. Bearing cap nut Tighten 15 N·m (1.5 kg-m, 11.0 lb-ft), 45°...

  • Page 829: Special Tool

    6A2-94 ENGINE MECHANICAL (M13 ENGINE) Special Tool 09911-97720 09911-97820 09913-75810 09915-64512 Oil seal guide Oil seal installer Bearing installer Compression gauge 09915-64530 09915-67010 09915-67311 09915-77310 Hose Attachment Vacuum gauge Oil pressure gauge 09915-78211 09916-14510 09916-14521 09916-34542 Oil pressure gauge attach- Valve lifer Valve lifer attachment Reamer handle...
  • Page 830 ENGINE MECHANICAL (M13 ENGINE) 6A2-95 09916-58210 09916-67020 09916-67021 09916-77310 Valve guide installer handle Tappet holder Tappet holder Piston ring compressor See NOTE below 09916-84511 09917-68221 09917-98221 09924-17810 Forceps Camshaft lock holder Valve stem seal installer Flywheel holder 09926-58010 09944-36011 Bearing puller attachment Steering wheel remover NOTE: [A] and [B] tools in the above table are interchangeable.
  • Page 831 6A2-96 ENGINE MECHANICAL (M13 ENGINE)
  • Page 832 ENGINE COOLING (M13 ENGINE) 6B2-1 SECTION 6B2 ENGINE COOLING (M13 ENGINE) CONTENTS General Description........6B2-2 Thermostat Inspection ......6B2-11 Radiator Removal and Installation .... 6B2-12 Cooling System Circulation ......6B2-2 Radiator Inspection ........6B2-13 Coolant............6B2-3 Radiator Cleaning ........6B2-13 Diagnosis............6B2-4 Radiator Cooling Fan Relay Inspection ..6B2-13 Diagnosis Table ..........6B2-4 Radiator Cooling Fan Removal and System Circuit Inspection......6B2-4...

  • Page 833: General Description

    6B2-2 ENGINE COOLING (M13 ENGINE) General Description The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is tube-and-fin type one. Cooling System Circulation While the engine is warmed up (thermostat closed), coolant circulates as follows. 1.

  • Page 834: Coolant

    ENGINE COOLING (M13 ENGINE) 6B2-3 Coolant The coolant recovery system is standard. The coolant in the radiator expands with heat, and the coolant is over- flowed to the reservoir. When the system cools down, the coolant is drawn back into the radiator. The cooling system has been filled with a quality coolant that is a 50/50 mixture of water and ethylene glycol antifreeze.

  • Page 835: Diagnosis

    6B2-4 ENGINE COOLING (M13 ENGINE) Diagnosis Diagnosis Table Condition Possible Cause Correction Engine overheats Loose or broken water pump belt Adjust or replace. (It is in case that radia- Not enough coolant Check coolant level and add as tor fan operates) necessary.

  • Page 836: Maintenance

    ENGINE COOLING (M13 ENGINE) 6B2-5 Maintenance WARNING: • Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir. Coolant should be added only to reservoir as necessary. • As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil.

  • Page 837: Engine Cooling System Inspection And Service

    6B2-6 ENGINE COOLING (M13 ENGINE) Engine Cooling System Inspection and Ser- vice WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pres- sure if cap is taken off too soon.
  • Page 838 ENGINE COOLING (M13 ENGINE) 6B2-7 2) With radiator cap removed, run engine until upper radiator hose is hot (this shows that thermostat is open and coolant is flowing through system). 3) Stop engine and drain coolant from radiator drain plug (1). 4) Close radiator drain plug (1).

  • Page 839: Water Pump/Generator Drive Belt Tension Inspection And Adjustment

    6B2-8 ENGINE COOLING (M13 ENGINE) Water Pump/Generator Drive Belt Tension Inspection and Adjustment WARNING: • Disconnect negative cable at battery before checking and adjusting belt tension. • To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot.

  • Page 840: On-Vehicle Service

    ENGINE COOLING (M13 ENGINE) 6B2-9 On-Vehicle Service WARNING: • Check to make sure that engine coolant temperature is cold before removing any part of cooling system. • Also be sure to disconnect negative cord from battery terminal before removing any part. Cooling System Components 1.

  • Page 841: Cooling System Draining

    6B2-10 ENGINE COOLING (M13 ENGINE) Cooling System Draining 1) Remove radiator cap. 2) Drain coolant from radiator drain plug (1). 3) After draining coolant, be sure to tighten drain plug (1) securely. Cooling System Refill Refer to step 7) to 22) of “Cooling System Flush and Refill” in this section.

  • Page 842: Thermostat Removal And Installation

    ENGINE COOLING (M13 ENGINE) 6B2-11 Thermostat Removal and Installation Removal 1) Drain coolant referring to “Cooling System Draining” in this section. 2) Remove intake manifold referring to “Intake Manifold Removal and Installation” in Section 6A2. 3) Remove generator referring to “Generator Dismounting and Remounting”...

  • Page 843: Radiator Removal And Installation

    6B2-12 ENGINE COOLING (M13 ENGINE) • Check thermostatic movement of wax pellet as follows: a) Immerse thermostat (1) in water, and heat water gradually as shown. b) Check that valve starts to open at specific temperature. Temperature at which valve begins to open : 80 –...

  • Page 844: Radiator Inspection

    ENGINE COOLING (M13 ENGINE) 6B2-13 Radiator Inspection Check radiator for leakage or damage. Straighten bent fins, if any. Radiator Cleaning Clean frontal area of radiator cores. Radiator Cooling Fan Relay Inspection Refer to “Main Relay, Fuel Pump Relay and Radiator Fan Relay” in Section 6E2.

  • Page 845: Radiator Cooling Fan Inspection

    6B2-14 ENGINE COOLING (M13 ENGINE) Radiator Cooling Fan Inspection For M/T vehicle 1) Check continuity between terminals. If there is no continuity, replace radiator fan motor. 2) Connect battery to radiator fan motor coupler as shown in figure, then check that the radiator fan motor operates smoothly.

  • Page 846: Water Pump/Generator Drive Belt Removal And Installation

    ENGINE COOLING (M13 ENGINE) 6B2-15 Water Pump/Generator Drive Belt Removal and Installation Removal 1) Disconnect negative cable at battery. 2) If vehicle equipped with A/C, remove compressor drive belt (4) before removing water pump belt (1). Refer to “Compressor Drive Belt Removal and Installation” in Section 1B.

  • Page 847: Water Pump Removal And Installation

    6B2-16 ENGINE COOLING (M13 ENGINE) Water Pump Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Drain coolant referring to “Cooling System Draining” in this section. 3) Remove water pump/generator drive belt referring to “Water Pump/Generator Drive Belt Removal and Installation” in this section.

  • Page 848: Water Pump Inspection

    (Part Number) Ethylene glycol base Additive to engine cooling system for improving coolant (Anti-freeze/ — cooling efficiency and for protection against Anti-corrosion coolant) rusting. SUZUKI BOND NO. 1207F Water tight sealant To apply to mating surface of water pump (99000-31250)

  • Page 849: Tightening Torque Specification

    6B2-18 ENGINE COOLING (M13 ENGINE) Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft ETC sensor 11.0 Air ventilation bolt 0.45 Thermostat cap bolt Thermostat case bolt 18.0 Generator adjusting bolt 17.0 Generator pivot bolt 36.5 Water pump bolt and Nut 16.0...
  • Page 850 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 851 6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Camshaft position sensor Fuel cut operation inspection....6E2-37 (CMP sensor) and its circuit Radiator fan control system inspection..........6E2-33 inspection..........6E2-38 Camshaft position sensor Mass air flow (MAF) and intake (CMP sensor) removal and air temperature (IAT) sensor installation ..........

  • Page 852: General Description

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-3 General Description Engine and Emission Control System Construction The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, IAC valve and intake manifold.
  • Page 853 6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Engine and Emission Control System Flow Diagram...
  • Page 854 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-5 Engine and Emission Control System Diagram...

  • Page 855: Air Intake System Description

    6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 1. Air Cleaner 14. Knock sensor 27. Stop lamp 2. EVAP canister purge valve 15. ECT sensor 28. Stop lamp switch 3. MAF and IAT sensor 16. CMP sensor 29. ECM 4. TP sensor 17.

  • Page 856: Fuel Delivery System Description

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-7 Fuel Delivery System Description The fuel system consists of fuel tank (1), fuel pump (2) (with built-in fuel filter (3) and fuel pressure regulator (4)), delivery pipe (5), injectors (6) and fuel feed line (7). The fuel (8) in the fuel tank (1) is pumped up by the fuel pump (2), sent into delivery pipe (5) and injected by the injectors (6).

  • Page 857: Electronic Control System Description

    6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Electronic Control System Description The electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
  • Page 858 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-9 Electronic Control System Component Location INFORMATION SENSORS CONTROL DEVICES OTHERS 1. MAF and IAT sensor a: Fuel injector A: ECM 2. TP sensor b: EVAP canister purge valve B: Combination meter 3. Stop lamp switch c: Fuel pump relay C: EVAP canister 4.
  • Page 859 6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Engine and Emission Control Input/output Table ELECTRIC CONTROL DEVICE OUTPUT INPUT For detecting fuel level FUEL LEVEL SENSOR BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH LIGHTING SWITCH BLOWER SWITCH A/C SWITCH A/C EVAP OUTLET AIR TEMP.
  • Page 860 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-11 ECM Input/output Circuit Diagram E22-7 BLU/WHT E22-10 E22-6 BLU/YEL BLU/RED E22-5 E22-30 BLU/ORN E22-4 RED/BLK E23-13 E22-14 E22-32 E23-17 GRN/YEL GRN/BLK E23-34 LT GRN E22-17 BLK/RED E23-16 GRN/ORN E23-33 WHT/GRN E22-8 E22-34 E23-8 GRN/YEL BLK/RED...
  • Page 861 6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 1. CKP sensor 20. Immobilizer control module 39. Stop lamp 2. CMP sensor 21. Data link connector 40. Lighting switch 3. VSS 22. Injector No.1 41. Position lamp 4. MAP sensor 23. Injector No.2 42.
  • Page 862 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-13 ECM Terminal Arrangement Table CON- TERMI- CON- TERMI- WIRE COLOR CIRCUIT WIRE COLOR CIRCUIT NECTOR NECTOR BLK/YEL Ground for ECM – – BLK/YEL Ground for ECM – – BLU/RED Heater output of heated oxygen sensor–2 –...
  • Page 863 6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) [A]: Terminal arrangement of ECM coupler (viewed from harness side) NOTE: For abbreviation of wire color, refer to “Abbreviations and Symbols May be Used in This Manual” in Section 0A.

  • Page 864: On-Vehicle Service

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-15 On-Vehicle Service Accelerator cable adjustment With accelerator pedal depressed fully (1), check clearance between throttle lever (2) and lever stopper (3) of throttle body. If measured value is out of specification, adjust it to specification with cable adjusting nut (4).
  • Page 865 6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 1) Connect scan tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool 2) Warm up engine to normal operating temperature. 3) Check engine idle speed and “IAC duty” by using “Data List”...

  • Page 866: Air Intake System

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-17 Air Intake System Throttle body Components 2.5 N·m (0.25 kg-m) 3.5 N·m (0.35 kg-m) 1. Throttle body 4. Gasket 7. TP sensor screws 2. Throttle body gasket 5. Idle air control valve Tightening torque 3.
  • Page 867 6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 5) Disconnect connectors from TP sensor (1) and IAC valve (2). 6) Disconnect engine coolant hoses (3) and breather hose (4) from throttle body. 7) Remove throttle body from intake manifold. 8) 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...

  • Page 868: Throttle Body Cleaning

    A chemical reaction will cause these parts to swell, harden or get distorted. Idle air control (IAC) valve operation check Using Suzuki Scan Tool 1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool 2) Warm up engine to normal operating temperature.

  • Page 869: Installation

    6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Installation 1) Install new gasket (2) to throttle body (1). 2) Install IAC valve (3) to throttle body (1). Tighten IAC valve screws to specified torque. Tightening torque IAC valve screw (a): 3.5 N·m (0.35 kg-m, 2.5 lb-ft) 3) Install throttle body referring to “Throttle Body Removel and Installation”...

  • Page 870: Oil Control Valve Removal And Installation

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-21 Oil control valve removal and installation Removal Remove oil gallery pipe No.1 (1) and oil control valve (2) from tim- ing chain cover (3). Installation 1) Install new O-ring (4) to oil control valve. 2) Install oil control valve to timing chain cover.

  • Page 871: Fuel Delivery System

    6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Fuel Delivery System Fuel pressure inspection WARNING: Be sure to perform work in a well-ventilated area and away from any open flames, or there is a risk of a fire breaking out. 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres- sure Relief Procedure”...

  • Page 872: Fuel Pump With Pressure Regulator On-Vehicle Inspection

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-23 8) After checking fuel pressure, remove fuel pressure gauge. CAUTION: As fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to following pro- cedures. • Place fuel container under joint. •...

  • Page 873: Fuel Pump With Pressure Regulator Removal And Installation

    6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Fuel pump with pressure regulator removal and installation Removal Remove fuel tank from body according to procedure described in “Fuel Tank Removal and Installation” of Section 6C and remove fuel pump from fuel tank. Installation 1) Install fuel pump to its bracket.

  • Page 874: Fuel Injector Removal And Installation

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-25 Fuel injector removal and installation Removal CAUTION: A small amount of fuel may come out after removal of fuel injectors, cover them with shop cloth. 1) Relieve fuel pressure according to procedure described in “Fuel Pressure Relief Procedure”...

  • Page 875: Fuel Injector Inspection

    6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Fuel injector inspection WARNING: As fuel is injected in this inspection, perform in a well ventilated area and away from open flames. Use special care to prevent sparking when connecting and disconnecting test lead to and from battery. 1) Install injector to special tool (injector checking tool).
  • Page 876 ECM, wire harness, etc. iii) Turn ignition switch ON. [A]: When using SUZUKI scan tool [B]: When not using SUZUKI scan tool 7) Apply battery voltage (3) to injector (2) for 15 seconds and measure injected fuel volume with graduated cylinder.

  • Page 877: Electronic Control System

    6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Electronic Control System Engine control module (ECM) removal and installa- tion CAUTION: As ECM consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect battery negative cable at battery. 2) Disable air bag system, refer to “Disabling Air Bag System”...

  • Page 878: Manifold Absolute Pressure Sensor (Map Sensor) Inspection

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-29 Manifold absolute pressure sensor (MAP sensor) inspection 1) Disconnect connector from MAP sensor (1). 2) Remove MAP sensor (1). 3) Arrange 3 new 1.5 V batteries (2) in series (check that total voltage is 4.5 –...

  • Page 879: Throttle Position Sensor (Tp Sensor) On-Vehicle Inspection

    6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Throttle position sensor (TP sensor) on-vehicle inspection 1) Disconnect negative cable at battery. 2) Detach purge valve chamber, and remove air cleaner outlet hose. 3) Disconnect TP sensor connector. 4) Using ohmmeter, check resistance between terminals under each condition given in table below.

  • Page 880: Engine Coolant Temperature Sensor (Ect Sensor) Removal And Installation

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-31 Engine coolant temperature sensor (ECT sensor) removal and installation Removal 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to “Cooling System Draining” in Sec- tion 6B2. WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot.

  • Page 881: Engine Coolant Temperature Sensor (Ect Sensor) Inspection

    6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Engine coolant temperature sensor (ECT sensor) inspection Immerse temperature sensing part of ECT sensor (1) in water (or ice) and measure resistance between terminals while heating water gradually. If measured resistance does not show such characteristic as shown in the graph, replace ECT sensor (1).

  • Page 882: Heated Oxygen Sensor (Ho2S-1 And Ho2S-2) Removal

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-33 Heated oxygen sensor (HO2S-1 and HO2S-2) removal and installation Removal WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative cable at battery.

  • Page 883: Camshaft Position Sensor (Cmp Sensor) Removal And Installation

    6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Camshaft position sensor (CMP sensor) removal and installation Removal 1) Disconnect negative cable at battery. 2) Disconnect connector from camshaft position sensor. 3) Remove camshaft position sensor from cylinder head. Installation 1) Check that O-ring is free from damage. 2) Check that camshaft position sensor and signal rotor teeth are free from any metal particles and damage.

  • Page 884: And Installation

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-35 Crankshaft position sensor (CKP sensor) removal and installation Removal 1) Disconnect negative cable at battery. 2) Remove generator drive belt, loosen pivot bolt (2) and move generator rearward. 3) Disconnect connector from crankshaft position sensor. 4) Remove crankshaft position sensor (1) from cylinder block.

  • Page 885: Vehicle Speed Sensor (Vss) And Its Circuit Inspection

    6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Vehicle speed sensor (VSS) and its circuit inspection 1) Confirm that terminal voltage and ground circuit continuity at VSS connector terminals are in good condition referring to Step 3 to 5 of “DTC P0500 Diag. Flow” in Section 6-2. If not, repair VSS circuit.

  • Page 886: Main Relay, Fuel Pump Relay And Radiator Fan Relay Inspection

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-37 Main relay, fuel pump relay and radiator fan relay inspection 1) Disconnect negative cable at battery. 2) Remove main relay (1), fuel pump relay (2) and radiator fan relay (3) from relay box. 3) Check that there is no continuity between terminal “C”...

  • Page 887: Radiator Fan Control System Inspection

    6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Radiator fan control system inspection System Inspection WARNING: Keep hands, tools, and clothing away from engine cool- ing 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 888: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Removal And Installation

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-39 Mass air flow (MAF) and intake air temperature (IAT) sensor removal and installation CAUTION: • Do not disassemble MAF and IAT sensor. • Do not expose MAF and IAT sensor to any shock. •...

  • Page 889: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Inspection

    6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Mass air flow (MAF) and intake air temperature (IAT) sensor inspection CAUTION: Do not heat up the MAF and IAT sensor more than 100°C (212°F). Otherwise, the MAF and IAT sensor is damaged. •...

  • Page 890: Emission Control System

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-41 Emission Control System EGR system inspection 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turn OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC”...

  • Page 891: Evaporative Emission Control System Inspection

    1) Prepare to operate EVAP canister purge valve as follows. a) When using SUZUKI scan tool: i) Connect SUZUKI scan tool to DLC with ignition switch OFF and disconnect purge valve vacuum hoses from intake manifold and purge valve chamber.
  • Page 892 “A” “B” 2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire. If check result is not described, check vacuum hoses, EVAP canister purge valve, wire harness and connections.
  • Page 893 6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Vacuum Hose Check hoses for connection, leakage, clog and deterioration. Replace as necessary. EVAP Canister Purge Valve 1) With ignition switch OFF, disconnect coupler from canister purge valve. 2) Remove EVAP canister purge valve from air cleaner assem- bly.

  • Page 894: Pcv System Inspection

    ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6E2-45 EVAP Canister WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful. 1) Check outside of EVAP canister visually. 2) Disconnect vacuum hoses from EVAP canister. 3) Check that there should be no restriction of flow through purge pipe (1) and air pipe (2) when air is blown (4) into tank pipe (3).
  • Page 895 6E2-46 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) 6) After checking vacuum, stop engine and remove PCV valve. Shake valve and listen for the rattle of check needle inside the valve. If valve does not the rattle, replace valve. 7) After checking, remove plug and install PCV valve. 8) Install air cleaner assembly securely.

  • Page 896: Special Tool

    09917-47911 09930-88530 Checking tool plate Vacuum pump gauge Injector test lead Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.) NOTE: • “A”: This kit includes the following items. 1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose & clamp, 6.

  • Page 897: Tightening Torque Specification

    6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (M13 ENGINE) Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft TP sensor mounting screw 0.25 IAC valve screw 0.35 ECT sensor 11.5 Heated oxygen sensor 32.5 Camshaft position sensor Knock sensor 16.0 Oil control valve mounting nut Oil gallery pipe No.1 bolt 21.5...
  • Page 898 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.

  • Page 899: Ignition System Construction

    6F2-2 IGNITION SYSTEM (M13 ENGINE) General Description Ignition System Construction The ignition system is an electronic (distributorless) ignition system. Its consists of the parts as described below. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suit- able ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.

  • Page 900: Ignition System Wiring Circuit Diagram

    IGNITION SYSTEM (M13 ENGINE) 6F2-3 Ignition System Wiring Circuit Diagram BLK/WHT RED/BLU E23-31 E23-32 YEL/BLU BLK/WHT E21-28 BLU/BLK BLK/YEL BLK/YEL BLU/BLK E23-15 BLK/RED BLK/RED E21-6 BLK/YEL BLK/RED E21-5 BLK/RED E22-1 WHT/BLU E22-10 E23-2 BLK/YEL 60A 15A E23-1 BLK/YEL E22-30 1. Ignition switch 7.

  • Page 901: Diagnosis

    6F2-4 IGNITION SYSTEM (M13 ENGINE) Diagnosis Ignition System Symptom Diagnosis Condition Possible Cause Correction Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to Loose connection or disconnection of lead wire Connect securely. start (No spark) or high-tension cord(s) Faulty high-tension cord(s) Replace.

  • Page 902: Reference Waveform

    IGNITION SYSTEM (M13 ENGINE) 6F2-5 Reference Waveform Oscilloscope waveforms of CMP sensor and No.1/No.4 ignition trigger signal are as shown in figure when connecting oscillo- scope between terminals E22-10 of ECM connectors connected to ECM and ground, and between terminal E23-32 and ground. Measurement condition for waveform [A] Measurement CH1: E22-10 to E23-1...
  • Page 903 6F2-6 IGNITION SYSTEM (M13 ENGINE) Step Action Electrical Connection Check Go to Step 5. Connect securely. 1) Check ignition coil assemblies and high-tension cords for electrical connection. Are they connected securely? High-tension Cords Check Go to Step 6. Replace high-tension 1) Check high-tension cord for resistance referring to cord(s).

  • Page 904: On-Vehicle Service

    IGNITION SYSTEM (M13 ENGINE) 6F2-7 On-Vehicle Service Ignition Spark Test 1) Remove air cleaner assembly with air intake pipe. 2) Disconnect all injector couplers from injectors. WARNING: Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.

  • Page 905: High-Tension Cords Inspection

    6F2-8 IGNITION SYSTEM (M13 ENGINE) Installation 1) Install No.1 cylinder (2) and No.3 cylinder (3) high-tension cords to spark plugs and ignition coil assemblies (1) while gripping each cap. CAUTION: • Never attempt to use metal conductor high-tension cords as replacing parts. •...

  • Page 906: Spark Plugs Inspection

    IGNITION SYSTEM (M13 ENGINE) 6F2-9 Installation 1) Install spark plugs and torque them to specification. Tightening torque Spark plug: 25 N·m (2.5 kg-m, 18.0 lb-ft) 2) Install ignition coil assemblies referring to “Ignition Coil Assembly (Including Ignitor) Removal and Installation” in this section.

  • Page 907: Ignition Coil Assembly (Including Ignitor) Removal And Installation

    6F2-10 IGNITION SYSTEM (M13 ENGINE) Ignition Coil Assembly (Including Ignitor) Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Remove air cleaner assembly with air intake pipe and cylin- der head upper cover. 3) Disconnect ignition coil coupler. 4) Disconnect high-tension cord (3) from ignition coil assembly (2).

  • Page 908: Crankshaft Position (Ckp) Sensor

    A/T model), and set parking brake. 1) Connect scan tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool 2) Start engine and warm it up to normal operating tempera- ture. 3) Make sure that all of electrical loads except ignition are switched off.
  • Page 909 18.0 Ignition coil bolt Special Tool 09930-76420 Timing light (Dry cell type) Tech 2 kit (SUZUKI scan tool) (See NOTE.) NOTE: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
  • Page 910 CRANKING SYSTEM (0.9 KW REDUCTION TYPE) 6G-1 SECTION 6G CRANKING SYSTEM (0.9 KW REDUCTION TYPE) NOTE: • Starting motor vary depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. •...
  • Page 911 6G-2 CRANKING SYSTEM (0.9 KW REDUCTION TYPE) Specifications Voltage 12 volts Output 0.9 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length 12.3 mm (0.44 in.) Number of pinion teeth Performance Condition Guarantee 90 A maximum No load characteristic 11.0 V 2,800 rpm minimum...
  • Page 912 CHARGING SYSTEM (G10/M13 ENGINES) 6H-1 SECTION 6H CHARGING SYSTEM (G10/M13 ENGINES) NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual. CONTENTS Generator ............6H-2 Removal and installation......6H-3 Diagnosis ............6H-2 Specifications..........6H-3 Undercharged battery........6H-2...
  • Page 913 6H-2 CHARGING SYSTEM (G10/M13 ENGINES) Generator Diagnosis Undercharged battery This condition, as evidenced by slow cranking or indicator clear with red dot can be caused by one or more of the following condi- tions even though indicator lamp may be operating normal. The following procedure also applies to cars with voltmeter and ammeter.
  • Page 914 CHARGING SYSTEM (G10/M13 ENGINES) 6H-3 Load Check 1) Run engine at 2,000 rpm and turn on head light and heater motor. 2) Measure current and if it is less than 20 A repair or replace generator. Unit Repair Overhaul Removal and installation For G10 Engine Refer to “Unit Repair Overhaul”...
  • Page 915 6H-4 CHARGING SYSTEM (G10/M13 ENGINES)
  • Page 916 EXHAUST SYSTEM (M13 ENGINE) 6K2-1 SECTION 6K2 EXHAUST SYSTEM (M13 ENGINE) CONTENTS General Description........6K2-2 Exhaust Manifold Removal and Installation........... 6K2-4 Maintenance ..........6K2-2 Exhaust Manifold Inspection ....... 6K2-4 On-Vehicle Service........6K2-3 Exhaust Pipe Removal and Installation ..6K2-4 Exhaust System Components.....6K2-3 Tightening Torque Specification....6K2-4...
  • Page 917 6K2-2 EXHAUST SYSTEM (M13 ENGINE) General Description The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
  • Page 918 EXHAUST SYSTEM (M13 ENGINE) 6K2-3 On-Vehicle Service Exhaust System Components WARNING: To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. 1.

  • Page 919: Tightening Torque Specification

    6K2-4 EXHAUST SYSTEM (M13 ENGINE) Exhaust Manifold Removal and Installation Removal and installation Refer to “Exhaust Manifold Removal and Installation” in Section 6A2. Exhaust Manifold Inspection Check gasket and seal for deterioration or damage. Replace them as necessary. Exhaust Pipe Removal and Installation Removal and installation For replacement of exhaust pipe, be sure to hoist vehicle and observe “Warning”...

  • Page 920: Manual Transaxle

    • 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.
  • Page 921 7A2-2 MANUAL TRANSAXLE (M13 ENGINE MODEL) General Description Manual Transaxle Construction and Servicing The transaxle provides five forward speeds and one reverse speed by means of three synchronizers and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
  • Page 922 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-3 Transaxle for 2wd Model 1. 5th speed sleeve & hub 8. Reverse idler gear 15. Countershaft 3rd gear 2. Input shaft 5th gear 9. Input shaft 16. Countershaft 2nd gear 3. Input shaft 4th gear 10.
  • Page 923 7A2-4 MANUAL TRANSAXLE (M13 ENGINE MODEL) Transaxle for 4wd Model 1. 5th speed sleeve & hub 7. Reverse gear shaft 13. Countershaft 4th gear 19. Final gear 2. Input shaft 5th gear 8. Reverse idler gear 14. Countershaft 20. Differential case 3.
  • Page 924 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-5 Diagnosis Manual Transaxle Symptom Diagnosis Condition Possible Cause Correction Gears slipping out of Maladjusted gear shift/select control cables Adjust. mesh Worn shift fork shaft Replace. Worn shift fork or synchronizer sleeve Replace. Weak or damaged locating springs Replace.
  • Page 925 7A2-6 MANUAL TRANSAXLE (M13 ENGINE MODEL) On-Vehicle Service CAUTION: Do not reuse circlip, spring pin, E-ring, oil seal, gasket, self locking nut and specified parts. Reuse of it can result in trouble. Manual Transaxle Oil Change 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
  • Page 926 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-7 4) Remove oil seal (1) and install a new one until it becomes flush with case surface using special tool and hammer. NOTE: When installing oil seal, face its spring side inward. Special tool (A): 09913-75510 (2WD and LH of 4WD) (A): 09951-46010 (RH of 4WD) 5) Apply grease to oil seal lip and at the same time check drive...
  • Page 927 7A2-8 MANUAL TRANSAXLE (M13 ENGINE MODEL) Gear Shift Control Lever and Cable Components 1. Gear shift control lever knob 5. Gear select control cable 9. Cable mounting bolt 2. Lever boot holder 6. Gear shift control lever assembly mounting 10. Cable bracket bolt 3.
  • Page 928 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-9 Gear Shift Control Lever and Cable Removal and Installation Removal 1) Remove console box. 2) Disconnect gear shift and select control cables (1) from gear shift control lever assembly (2). a) Disconnect cable end from pivot (7) while pushing cable end bush (4).
  • Page 929 7A2-10 MANUAL TRANSAXLE (M13 ENGINE MODEL) Gear Shift Control Lever and Cable Adjust- ment • Adjustment of shift cable: a) With shift control lever in “NEUTRAL” position, adjust shift cable adjusting nut (3) so that distance “a” between edge of instrument panel (1) and center of shift knob (2) measured as specified value.
  • Page 930 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-11 Vehicle Speed Sensor (VSS) Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Disconnect VSS coupler (1). 3) Remove VSS (2). Installation 1) Apply oil to new O-ring (1) and then install VSS to transaxle. 2) Connect VSS coupler (1).
  • Page 931 7A2-12 MANUAL TRANSAXLE (M13 ENGINE MODEL) Back Up Lamp Switch Removal and Installa- tion Removal 1) Disconnect negative cable at battery. 2) Disconnect back up lamp switch coupler. 3) Remove back up lamp switch (1). 2. Clutch cable 3. Gear shift and select shaft assembly Installation 1) Apply oil to new O-ring (1) and tighten back up lamp switch (2) to specified torque.
  • Page 932 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-13 Unit Repair Overhaul Transaxle Unit Components [A]: Forward 8. Clutch cable 16. Engine rear mounting bolt 1. Engine 9. Backup lamp switch connector 17. Engine rear mounting 2. Transaxle 10. VSS connector 18. Engine rear mounting No.2 bracket bolts 3.
  • Page 933 7A2-14 MANUAL TRANSAXLE (M13 ENGINE MODEL) Transaxle Unit Dismounting and Remounting Dismounting Under hood 1) Disconnect negative cable at battery. 2) Undo wiring harness clamps, disconnect backup lamp switch coupler, VSS coupler and ground cable. 3) Disconnect clutch cable from clutch release lever and bracket.
  • Page 934 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-15 Remounting CAUTION: Care should be taken not to scratch oil seal lip with drive shaft while raising transaxle. Do not hit drive shaft joint with hammer when installing it into differential gear. Reverse dismounting procedure for remounting noting the follow- ing.
  • Page 935 7A2-16 MANUAL TRANSAXLE (M13 ENGINE MODEL) Transaxle Case Components...
  • Page 936 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-17 1. Transaxle right case 11. VSS 2. Transaxle left case 12. Oil gutter bolt : Apply sealant 99000-31260 to mating surface of left case and : Apply thread lock 99000-32110 to all around thread part of bolt. right case.
  • Page 937 7A2-18 MANUAL TRANSAXLE (M13 ENGINE MODEL) Gear Shift and Select Shaft Assembly Removal and Installation Removal 1) Remove gear shift interlock bolt (1) and 5th to reverse inter- lock guide bolt (2) from transaxle case. 2) Remove gear shift and select shaft assembly (3). Installation 1) Apply grease to select lever shaft bush and select lever boss, and install gear shift and select shaft assembly with new...
  • Page 938 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-19 Gear Shift and Select Shaft Disassembly and Assembly 1) Push spring pins out using specified spring pin removers as shown bellow. Special tool (A): 09922-85811 (4.5 mm) (B): 09925-78210 (6.0 mm) (C): 2.8 – 3.0 mm (0.11 – 0.12 in.) Commercially available spring pin remover 2) Inspect component parts for wear, distortion or damage.
  • Page 939 7A2-20 MANUAL TRANSAXLE (M13 ENGINE MODEL) 2) Using special tool, remove circlip (1) and then remove hub plate (2). Special tool (A): 09900-06107 3) Drive out spring pin using special tool and hammer. Special tool (A): 09922-85811 4) Remove gear shift fork (2), sleeve & hub assembly (3), syn- chronizer ring spring, synchronizer ring and 5th gear all together.
  • Page 940 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-21 Assembly 1) Install seat countershaft left bearing outer race (1) to bearing cone, tap cup using special tool and plastic hammer (2). Special tool (A): 09913-84510 2) With putting a shim (2) on bearing outer race (3), place straight edge (1) over it and compress it by hand through straight edge, and then measure clearance “a”...
  • Page 941 7A2-22 MANUAL TRANSAXLE (M13 ENGINE MODEL) CAUTION: Do not reuse left case plate screw (1) and bolts (7). Be sure to use new adhesive pre-coated screw and bolts. Otherwise, screw and bolts may loosen. 4) Place left case plate (2) inserting its end in groove of shift guide shaft (4) and tighten new adhesive pre-coated screw (1) and bolts (7) temporarily with less than specified toque.
  • Page 942 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-23 8) Install needle bearing of separated steel cage type to input shaft, apply oil then install 5th gear (1) and special tool to stop shaft rotation. Special tool (B): 09927-76010 9) Install new countershaft nut (2) and tighten it to specification. Tightening torque Countershaft nut (b): 70 N·m (7.0 kg-m, 51.0 lb-ft) 10) Remove special tool, then caulk countershaft nut (4) at C...
  • Page 943 7A2-24 MANUAL TRANSAXLE (M13 ENGINE MODEL) 15) Clean mating surface of both left case (2) and side cover (1), apply sealant to side cover (1) as shown in figure by such amount that its section is 1.5mm (0.059 in.) in diameter, mate it with left case and then tighten bolts.
  • Page 944 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-25 6) Remove reverse shaft bolt (1) with washer. 7) Remove case bolts (2) from outside and another bolts from clutch housing side. 8) Tapping left case (3) flanges with plastic hammer, remove left case. 9) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3).
  • Page 945 7A2-26 MANUAL TRANSAXLE (M13 ENGINE MODEL) 3) Join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft (3) assemblies all together, then install them into right case (1). CAUTION: Take care not to damage oil seal lip by input shaft, or oil leakage may take place.
  • Page 946 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-27 7) Clean mating surfaces of both right and left cases, apply sealant to right case (2) as shown in figure by such amount that its section is 1.5mm (0.059 in.) in diameter then mate it with left case (1).
  • Page 947 7A2-28 MANUAL TRANSAXLE (M13 ENGINE MODEL) 14) Clean mating surface of guide case. 15) Install fifth gear referring to “Fifth Gear Disassembly and Assembly” in this section. 16) Install gear shift and select shaft assembly referring to “Gear Shift and Select Shaft Assembly Removal and Installation” in this section.
  • Page 948 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-29 Assembly NOTE: Before installation, wash each part and apply specified transaxle oil to sliding faces of bearing and gear. 1) If input shaft oil seal (1) has been removed, install it with its spring side facing upward. Use special tool and hammer for installation and apply grease to oil seal lip.
  • Page 949 7A2-30 MANUAL TRANSAXLE (M13 ENGINE MODEL) Input & Counter Shaft Components...
  • Page 950 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-31 1. Input shaft 18. 5th synchronizer spring 35. Needle bearing (separated steel cage type) 2. Oil seal 19. 5th speed sleeve & hub 36. Countershaft 2nd gear : Apply grease 99000-25010 to oil seal lip 3.
  • Page 951 7A2-32 MANUAL TRANSAXLE (M13 ENGINE MODEL) 4) Using special tool, remove circlip (1). Special tool (A): 09900-06107 5) Drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) from input shaft (1) using puller (4) and press. CAUTION: Make sure to use flat side of puller to avoid causing dam- age to 3rd gear tooth.
  • Page 952 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-33 4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure. NOTE: • No specific direction is assigned to each key but it is assigned as sleeve &...
  • Page 953 7A2-34 MANUAL TRANSAXLE (M13 ENGINE MODEL) 8) Install circlip (1) and confirm that circlip is installed in groove securely. Install needle bearing (2) of steel cage type, apply oil to bearing and then install synchronizer ring (3) and 4th gear (4).
  • Page 954 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-35 4) Using special tool, remove circlip (1). Special tool (A): 09900-06107 5) Apply puller (3) to 1st gear (2) and drive out low speed syn- chronizer sleeve & hub assembly (1) with 1st gear (1) using press.
  • Page 955 7A2-36 MANUAL TRANSAXLE (M13 ENGINE MODEL) 3) Put the synchronizer outer ring (1), inner ring (3) and the cone (2) together and then measure the step difference between the outer ring and the inner ring. And also check each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary.
  • Page 956 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-37 8) Drive in low speed sleeve & hub assembly (1) using special tools and hammer, facing “B” side of sleeve to 1st gear. NOTE: • Support shaft with special tool as shown in figure so that retainer of bearing cone (4) will be free from com- pression.
  • Page 957 7A2-38 MANUAL TRANSAXLE (M13 ENGINE MODEL) 11) Press-fit 4th gear (2) using the same procedure as step 10). 12) Install left bearing cone (1) using special tools and hammer. NOTE: For protection of right bearing cone (3), always support shaft with special tool as illustrated. Special tool (A): 09923-78210 (E): 09925-98221...
  • Page 958 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-39 High Speed and Low Speed Gear Shift Shafts Inspection 1) Using feeler gauge, check clearance between fork (1) and sleeve (2) and replace those parts if it exceeds limit below. NOTE: For correct judgement of parts replacement, carefully inspect contact portion of fork and sleeve.
  • Page 959 7A2-40 MANUAL TRANSAXLE (M13 ENGINE MODEL) Differential Components 1. Differential pinion washer 9. Final gear 2. Differential side pinion gear 10. Final gear bolt : Apply thread lock 99000-32110 to all around thread part of bolt 3. Differential side gear 11.
  • Page 960 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-41 Differential Disassembly and Assembly Disassembly 1) Using special tools, remove right bearing (1) and sensor rotor (2). Special tool (A): 09913-60910 (B): 09925-88210 2) Remove left bearing in the same manner at step 1). 3) Support differential case with soft jawed vise and remove final gear bolts then take out final gear.
  • Page 961 7A2-42 MANUAL TRANSAXLE (M13 ENGINE MODEL) 5) Hold differential assembly with soft jawed vise (3), install final gear (2) as shown in figure and then tighten bolts (1) with thread lock cement applied to specified torque. NOTE: Make sure to install final gear in correct installing direc- tion.
  • Page 962 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-43 • For right side a) Using similar procedure to the above, set dial gauge tip to gear (1) shoulder. b) Move gear up and down by hand and read dial gauge. Special tool (A): 09900-20606 (B): 09900-20701 2) If thrust play is out of specification, select suitable thrust washer from among the following available size, install it and...
  • Page 963 7A2-44 MANUAL TRANSAXLE (M13 ENGINE MODEL) Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Transaxle oil level/filler and drain plugs 15.5 Oil gutter bolt Final gear bolt 65.0 Reverse gear shift lever bolt 17.0 Transaxle case bolt 14.0 Reverse shaft bolt 17.0 Gear shift locating bolt...
  • Page 964 MANUAL TRANSAXLE (M13 ENGINE MODEL) 7A2-45 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Oil seal lip (99000-25010) • Select lever boss • Select lever shaft bush Sealant SUZUKI BOND NO.1217G • Oil drain plug and filler/level plug (99000-31260) •...
  • Page 965 7A2-46 MANUAL TRANSAXLE (M13 ENGINE MODEL) 09923-74510 09923-78210 09924-74510 09925-18011 Bearing remover Bearing installer Installer attachment Bearing installer 09925-68210 09925-78210 09925-88210 09925-98221 Bearing outer race Spring pin remover 6 mm Bearing puller attachment Bearing installer installer (0.24 in.) 09927-76010 09930-30104 09940-53111 09940-54910 Gear holder...
  • Page 966 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View” under “Gen- eral Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 967 7B1-2 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) DTC P0713 Transmission Fluid Select Cable ..........7B1-95 Temperature Sensor Circuit High ..... 7B1-58 Transmission Range Sensor DTC P0717 Input/Turbine Speed (Shift Switch)..........7B1-97 Sensor Circuit Malfunction ......7B1-60 Output Shaft Speed Sensor (VSS) ... 7B1-98 DTC P0722 Output Speed Sensor Input Shaft Speed Sensor......
  • Page 968 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-3 General Description This automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up mechanism.
  • Page 969 7B1-4 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 20 21 22 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23.

  • Page 970: Specifications

    AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-5 Specifications Item Specifications Torque Type 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism) converter Stall torque ratio 1.9 – 2.1 Type Internal involute gear type oil pump (non crescent type) Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type...

  • Page 971: Functions

    7B1-6 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Clutch/Brake/Planetary Gear 1. Input shaft and intermediate shaft 8. Reduction driven gear B1: O/D and 2nd coast brake 2. Reduction drive gear 9. Front sun gear B2: 2nd brake 3. Planet carrier 10. Ring gear B3: 1st and reverse brake 4.
  • Page 972 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-7 Table of Component Operation...
  • Page 973 7B1-8 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Electronic Shift Control System...
  • Page 974 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-9 1. Engine 9. Pressure control solenoid valve 17. Transmission range sensor coupler 2. Transaxle 10. Shift solenoid valve-B (No.2) 18. Solenoid valve coupler 3. “O/D OFF” lamp 11. Shift solenoid valve-A (No.1) 19. Output shaft speed sensor (VSS) 4.

  • Page 975: Transmission Control Module

    7B1-10 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Transmission Control Module (TCM) E12-6 E13-11 E12-16 E13-12 BLU/RED 2.5V E13-16 E12-25 E13-15 BLK/YEL E13-14 WHT/RED E13-5 WHT/BLU E13-7 E13-4 BRN/YEL E13-17 E13-2 LT GRN/RED E12-11 BLU/YEL BLU/RED E12-9 WHT/BLU E13-24 E12-20 IG11 E12-1 E12-8 BLU/YEL WHT/RED...
  • Page 976 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-11 Operation of shift solenoid valves, timing solenoid valve and TCC solenoid valve Valve status Turn power ON Turn power OFF Shift solenoid valve-A (No.1) Close Open Shift solenoid valve-B (No.2) Close Open Timing solenoid Open Close TCC (lock-up) solenoid...
  • Page 977 7B1-12 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Automatic gear shift diagram Automatic shift schedule as a result of shift control is shown below. In case that selector lever is shifted to “L” range at a higher than 44 km/h (27 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower than that.
  • Page 978 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-13 Diagnosis General Description This vehicle is equipped with an electronic transaxle control system, which controls the automatic shift up and shift down timing, TCC operation, etc. suitably to vehicle driving conditions. TCM has an On-Board Diagnosis System which detects a malfunction in this system. When diagnosing a trouble in transaxle including this system, be sure to have full understanding of the outline of “On-Board Diagnostic System”...
  • Page 979 7B1-14 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) On-board Diagnostic System For automatic transaxle control system, TCM has following func- tions. • When ignition switch is turned ON with O/D off switch turned OFF and no malfunction in A/T control system is detected, “O/D OFF”...
  • Page 980 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-15 Precaution in Diagnosing Trouble • Don’t disconnect couplers from TCM, battery cable from battery, TCM ground wire harness from engine or main fuse before checking the diagnosis information stored in TCM memory. Such disconnection will clear memorized information in TCM memory. •...
  • Page 981 7B1-16 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Automatic Transaxle Diagnostic Flow Table Refer to the following items for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer com- 1) Perform customer complaint analysis. plaint analysis. Was customer complaint analysis performed according to instruction? Diagnostic Trouble Code (DTC)/Freeze Frame...
  • Page 982 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-17 Step Action Final Confirmation Test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to the followings. Is there any problem symptom, DTC or abnor- mal condition? 1.
  • Page 983 7B1-18 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 11. Final Confirmation Test Confirm that the problem symptom has gone and the vehicle is free from any abnormal conditions. If what has been repaired is related to the malfunction DTC, clear the DTC once and check to ensure that no malfunction DTC is indicated.
  • Page 984 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-19 Customer Problem Inspection Form (Example) NOTE: The above form is a standard sample. It should be modified according to conditions characteristic of each market.
  • Page 985 7B1-20 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) “O/D OFF” Lamp Check 1) Turn ignition switch ON. 2) Check that “O/D OFF” lamp (1) lights for about 2 sec. and then goes OFF. If anything faulty is found, advance to “Diagnostic Flow Table A-3”...
  • Page 986 After repair or replace malfunction part(s), clear all DTCs by per- forming the following procedure. 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check.
  • Page 987 7B1-22 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Diagnostic Trouble Code (DTC) Table Detecting condition Driving cycle Detecting item (DTC will set when detecting) when MIL lighted Transmission Range Sensor Cir- P0705 Multiple signals are inputted simultaneously. 1driving cycle cuit Malfunction (PRNDL Input) Transmission Range Sensor Cir- P0707 No sensor signal is inputted.
  • Page 988 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-23 Detecting condition Driving cycle Detecting item (DTC will set when detecting) when MIL lighted Voltage of shift solenoid terminal is high Shift Solenoid “B” Control Circuit P0977 although TCM is commanding shift solenoid 1driving cycle High to turn OFF.

  • Page 989: Fail Safe Table

    7B1-24 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Fail Safe Table This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The table below shows the fail safe function for each fail condition of solenoid, solenoid or its circuit. Trouble Area Fail Safe Operation •...
  • Page 990 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-25 Trouble Area Fail Safe Operation • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. • After 15 minutes pass from detecting malfunction, engine coolant temperature is assumed to be 90°C (194°F).

  • Page 991: Visual Inspection

    7B1-26 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Visual Inspection Visually check the following parts and systems. INSPECTION ITEM REFERRING SECTION • A/T fluid ----- level, leakage, color Section 0B • A/T fluid hoses ----- disconnection, looseness, deterioration Section 7B1 • Throttle cable ----- play (under warm engine), installation Section 6E2 •...

  • Page 992: Automatic Transaxle Basic Check

    AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-27 Automatic Transaxle Basic Check This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in visual inspection. Follow the flow table carefully. Step Action Was “Automatic Transaxle Diagnostic Flow Go to Step 2.

  • Page 993: Trouble Diagnosis Table

    7B1-28 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Trouble Diagnosis Table Trouble diagnosis table-1 Electrical Repair Condition Possible Cause Correction Shift solenoid valve-A and/or-B circuit faulty Pressure control solenoid valve circuit faulty → ↔ (Only when N D or 3 O/D shifting) Timing solenoid valve circuit faulty Inspect circuit for open, short and intermit- Output shaft speed sensor (VSS) circuit faulty...
  • Page 994 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-29 Condition Possible Cause Correction Shift solenoid valve-B circuit faulty Pressure control solenoid valve circuit faulty Timing solenoid valve circuit faulty Output shaft speed sensor (VSS) circuit faulty Inspect circuit for open, short and intermit- Input shaft speed sensor circuit faulty tent.
  • Page 995 7B1-30 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Condition Possible Cause Correction Output shaft speed sensor (VSS) circuit faulty Pressure control solenoid valve circuit faulty Inspect circuit for open, short and intermit- tent. If NG, repair. CAN communication circuit faulty Incorrect gear Pressure control solenoid valve circuit faulty shift point Inspect circuit for open, short and intermit-...

  • Page 996: Trouble Diagnosis Table-2

    AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-31 Trouble diagnosis table-2 On-vehicle Repair Condition Possible Cause Correction Unable to run in all Faulty valve body component Replace valve body assembly range Engine abnormal condition Inspect and repair engine Malfunction of shift solenoid valve-A and/or-B Malfunction of output shaft speed sensor (VSS) Malfunction of input shaft speed sensor Malfunction of transmission range sensor...
  • Page 997 7B1-32 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Condition Possible Cause Correction Malfunction of shift solenoid valve-B Malfunction of timing solenoid valve Malfunction of output shaft speed sensor (VSS) Inspect. If NG, replace. Malfunction of input shaft speed sensor Malfunction of O/D off switch →...

  • Page 998: Trouble Diagnosis Table-3

    AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-33 Trouble diagnosis table-3 Off-vehicle Repair Condition Possible Cause Correction Faulty oil pump Seized or broken planetary gear Faulty one-way No.2 clutch Damaged drive plate Inspect. If NG, replace. Unable to run in all range Faulty forward clutch Faulty reverse clutch Faulty 1st and reverse brake...

  • Page 999: Road Test

    7B1-34 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Road Test 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 1000 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-35 Condition Possible Cause Correction Malfunction of shift solenoid valve-B Malfunction of O/D off switch Malfunction of engine coolant temperature sen- Malfunction of output shaft speed sensor (VSS) Malfunction of input shaft speed sensor Inspect. If NG, replace. Malfunction of throttle position sensor →...
  • Page 1001 7B1-36 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) Condition Possible Cause Correction Malfunction of TCC solenoid valve Malfunction of shift solenoid valve-A and/or-B Malfunction of brake light switch Malfunction of engine coolant temperature sen- Malfunction of output shaft speed sensor (VSS) Inspect. If NG, replace. Malfunction of input shaft speed sensor TCC (lock-up) function Malfunction of throttle position sensor...

  • Page 1002: Manual Road Test

    AUTOMATIC TRANSAXLE (M13 ENGINE MODEL) 7B1-37 Manual Road Test This test checks the gears being used in “L”, “2” or “D” range when driven with unoperated gear shift control system. Test drive vehicle on a level road. NOTE: Before this test, check diagnostic trouble code (DTC). 1) With select lever in “P”, start engine and warm it up.

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