Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 3 And for any section, item or description not found in this supplement, refer to the related manual below. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
Page 4 Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
Page 5 TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-i Transmission / Transaxle .......... 5-i Precautions ............
Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........00-1 Precautions for Installing Mobile Communication Equipment ........00-* Precautions............
Page 8 00-1 Precautions: Precautions Precautions Brakes Caution and Note S5JB0E0000014 Precaution for Vehicle Equipped with ESP® CAUTION System S5JB0E0000020 All brake fasteners are important attaching • When testing with any of the following equipments parts in that they could affect the (when vehicle is tested by rotating wheels (tires) performance of vital parts and systems, and/ under vehicle stop), be sure to deactivate ESP®...
Page 9 Table of Contents 0- i Section 0 General Information CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. General Information ........ 0A-1 Crankcase Ventilation Hoses and Connections Inspection (Vehicle without General Description ..........0A-1...
Page 10 0A-1 General Information: General Information General Description Abbreviations S5JB0E0101001 FWD: Front Wheel Drive 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center ABS: Anti-lock Brake System GEN: Generator AC: Alternating Current GND: Ground A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HC: Hydrocarbons A/F: Air Fuel Mixture Ratio HO2S: Heated Oxygen Sensor...
Page 11 General Information: 0A-2 SFI: Sequential Multiport Fuel Injection SOHC: Single Over Head Camshaft TBI: Throttle Body Fuel Injection (Single-Point Fuel Injection, SPI) TCC: Torque Converter Clutch TCM: Transmission Control Module (A/T Controller, A/T Control Module) TPMS: Tire Pressure Monitoring System TP Sensor: Throttle Position Sensor TVV: Thermal Vacuum Valve (Thermal Vacuum Switching Valve, TVSV, Bimetal Vacuum Switching...
Page 12 0A-3 General Information:...
Page 13 Table of Contents 1- i Section 1 Engine CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........1-* Visual Inspection ..........1A-* Engine Basic Inspection........
Page 14 1-ii Table of Contents DTC P0625 / P0626: Generator Field DTC P0123: Throttle Position Sensor (Main) Circuit High ..........1A-* Terminal Circuit Low / High ....... 1A-* DTC P0131 / P0132 / P0134: O2 Sensor DTC P0660: Intake Manifold Tuning Valve (HO2S) Circuit Low Voltage / High Voltage Control Circuit / Open (For J20 Engine)....
Page 15 Table of Contents 1-iii Aux. Emission Control Devices ....1B-* Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Diagnostic Information and Procedures.... 1B-* Inspection............1C-* EGR System Inspection ........1B-* Mass Air Flow (MAF) and Intake Air Repair Instructions ..........1B-* Temperature (IAT) Sensor Removal and EVAP Canister Purge Inspection ......1B-* Installation ............
Page 16 1-iv Table of Contents Timing Chain Cover Components ....... 1D-* Valves and Cylinder Head Removal and Installation ............1D-* Timing Chain Cover Removal and Valves and Cylinder Head Disassembly Installation ............1D-* and Assembly ........... 1D-* Timing Chain Cover Cleaning and Valves and Valve Guides Inspection....
Page 17 Table of Contents 1-v Radiator Removal and Installation .......1F-* Oil Pan and Oil Pump Strainer Cleaning....1E-* Oil Pump Components .........1E-* Water Pump Removal and Installation (For Oil Pump Removal and Installation ......1E-* M16 Engine Model) ..........1F-* Oil Pump Disassembly and Reassembly .....1E-* Water Pump Removal and Installation (For Oil Pump Inspection ..........1E-* J20 Engine Model) ..........1F-*...
Page 18 1-vi Table of Contents Charging System ........1J-* General Description ..........1H-* Ignition System Construction ......1H-* General Description ..........1J-* Schematic and Routing Diagram......1H-* Battery Description ..........1J-* Ignition System Wiring Circuit Diagram....1H-* Generator Description .......... 1J-* Component Location ........... 1H-* Diagnostic Information and Procedures .....1J-* Ignition System Components Location....
Page 19 – Resistance value of all relays and actuators is as • Diagnostic information stored in ECM memory can be specified respectively. cleared as well as checked by using SUZUKI scan – MAP sensor, electric load current sensor (for J20 tool or OBD generic scan tool (Vehicle without engine), A/C refrigerant pressure sensor (if diagnosis connector).
Page 20 • It is possible to communicate by using not only including the following parts when the ignition switch is SUZUKI scan tool (2) but also OBD generic scan tool. ON and the engine is running, and indicates the result by (Diagnostic information can be accessed by using a turning on or flashing malfunction indicator lamp (1).
Page 21 SUZUKI scan tool (2).) In addition, DTC can be read by not only using SUZUKI scan tool but also displayed on odometer (5) of the combination meter. (i.e. when diagnosis switch terminal (3) is grounded with a service wire (4) and ignition switch is turned ON.) For further detail of the...
Page 22 1A-4 Engine General Information and Diagnosis: Freeze Frame Data (Vehicle Not Equipped with Diagnosis Connector) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”.
Page 23 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 (in ECM), BCM (Body electrical Control...
Page 24 1A-6 Engine General Information and Diagnosis: CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a twisted pair of two communication lines for the high-speed data transmission. As one of its characteristics, multiple control modules can communicate simultaneously.
Page 25 Engine General Information and Diagnosis: 1A-7 ECM Reception Data ABS hydraulic unit/control module control module Receives data of ECM assmbly (for vehicle (for vehicle (for A/T model) without ESP with ESP Torque reduction request Slip control signal Transmission malfunction indication on Transmission emissions related malfunction active Transmission gear selector...
Page 26 1A-8 Engine General Information and Diagnosis: Engine and Emission Control System Flow Diagram I5JB0D110003-01...
Page 27 Engine General Information and Diagnosis: 1A-9 ECM Input / Output Circuit Diagram For J20 engine BLU/ORN BLU/BLK E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 C37-44 BLU/RED BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41 WHT/RED C37-52 BLK/YEL C37-1 C37-51...
Page 28 1A-10 Engine General Information and Diagnosis: 1. Accelerator pedal position (APP) sensor 27. Stop lamp switch 53. “CPRSR” fuse assembly 2. Shield wire 28. Stop lamp 54. Ignition coil assembly (for No.1 spark plug) 3. CMP sensor 29. DLC 55. Ignition coil assembly (for No.2 spark plug) 30.
Page 29 Engine General Information and Diagnosis: 1A-11 For M16 engine BLU/ORN BLU/BLK E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 C37-44 BLU/RED BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41 WHT/RED C37-52 C37-1 C37-51 WHT/BLU BLK/YEL C37-2 PNK/BLK PNK/GRN C37-16 PNK/BLU...
Page 30 1A-12 Engine General Information and Diagnosis: 1. Accelerator pedal position (APP) sensor 24. DLC 47. A/C compressor (if equipped with A/C) assembly 2. Shield wire 25. To BCM and ABS / ESP® control module 48. “CPRSR” fuse 3. CMP sensor 26.
Page 31 Engine General Information and Diagnosis: 1A-13 Terminal Wire color Circuit Terminal Wire color Circuit Electric load current sensor — — signal (for J20 engine) CO adjusting resistor signal (if Throttle position sensor (sub) GRN/WHT equipped) signal Oxygen signal of heated Ground for throttle position oxygen sensor-2 sensor...
Page 32 1A-14 Engine General Information and Diagnosis: Terminal Wire color Circuit Terminal Wire color Circuit 12 V serial communication line PPL/WHT — — of data link connector Cruise control main switch BLK/WHT signal (if equipped with cruise — — control system) Clutch pedal position switch signal (if equipped with cruise —...
Page 33 Engine General Information and Diagnosis: 1A-15 Engine and Emission Control Input / Output Table S5JB0E1101012 ELECTRIC CONTROL DEVICE OUTPUT INPUT For detecting fuel level FUEL LEVEL SENSOR BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR (if equipped with A/C) BLOWER SWITCH A/C SWITCH (if equipped with A/C) A/C EVAP OUTLET AIR TEMP.
Page 34 1A-16 Engine General Information and Diagnosis: Schematic and Routing Diagram Engine and Emission Control System Diagram S5JB0E1102001 I5JB0A110015-04...
Page 35 Engine General Information and Diagnosis: 1A-17 1. Air cleaner 18. Radiator cooling fan motor 35. Immobilizer coil antenna (if equipped) 2. EVAP canister purge valve 19. Combination meter 36. Main relay 3. MAF and IAT sensor 20. BCM 37. Wheel speed sensor (VSS) 4.
Page 36 1A-18 Engine General Information and Diagnosis: Information sensors Control devices Others 1. MAF and IAT sensor a: Fuel injector A: ECM 2. Electric throttle body assembly (built-in b: EVAP canister purge valve B: Combination meter throttle position sensor and throttle actuator) 3.
Page 37 Engine General Information and Diagnosis: 1A-19 Information sensors Control devices Others 1. MAF and IAT sensor a: Fuel injector A: ECM 2. Electric throttle body assembly (built-in b: EVAP canister purge valve B: Combination meter throttle position sensor and throttle actuator) 3.
Page 38 1A-20 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) HO2S-2 circuit voltage is lower than specification for more HO2S heater control circuit low 2 driving than specified time continuously even though control duty *P0037 (Sensor-2) cycles...
Page 39 Engine General Information and Diagnosis: 1A-21 Detecting condition DTC No. Detecting item (DTC will set when detecting:) O2 sensor (HO2S) circuit no Output voltage of HO2S-2 is more than specification after 2 driving *P0140 activity detected (Sensor-2) warming up engine. cycles Total fuel trim is larger than specification for specified time 2 driving...
Page 40 1A-22 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) 1 driving *P0607 Control module performance Data programming error. cycle Starter signal is low voltage even though engine is started 2 driving Starter relay circuit low *P0616 with vehicle at stop.
Page 41 Engine General Information and Diagnosis: 1A-23 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Pedal position sensor (main) Output voltage of pedal position sensor (main) is higher 1 driving *P2123 circuit high input than specification. cycle Pedal position sensor (sub) Output voltage of pedal position sensor (sub) is lower 1 driving *P2127...
Page 42 1A-24 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting) *P0705 Transmission range sensor circuit malfunction (PRNDL input) *P0707 Transmission range sensor circuit low *P0712 Transmission fluid temperature sensor circuit low *P0713 Transmission fluid temperature sensor circuit high *P0717 Input / Turbine speed sensor circuit no signal *P0722 Output speed sensor circuit no signal *P0741 Torque converter clutch circuit performance or stuck off...
Page 43 Engine General Information and Diagnosis: 1A-25 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S5JB0E1104011 Wiring Diagram E23-4 WHT/RED WHT/RED E23-19 WHT/BLU WHT/BLU G28-13 G28-15 PPL/RED BLK/YEL BLK/WHT E23-29 C37-15 BLK/ORN C37-30 BLK/ORN...
Page 44 1A-26 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: in related manual”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action MIL power supply check...
Page 45 Engine General Information and Diagnosis: 1A-27 Step Action Combination meter circuit check Substitute a known- “BLK” wire is open or good combination meter high resistance circuit. 1) Turn ignition switch to OFF position. and recheck. If MIL still 2) Measure resistance between “G28-15” terminal of remains OFF, substitute combination meter connector and vehicle body ground.
Page 46 1A-28 Engine General Information and Diagnosis: DTC P0500: Vehicle Speed Sensor (VSS) Malfunction S5JB0E1104051 Wiring Diagram WHT/RED WHT/RED E23-4 E23-19 WHT/BLU WHT/BLU YEL/BLK LT GRN LT GRN/BLK 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110060-03 1.
Page 47 Engine General Information and Diagnosis: 1A-29 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: in related manual”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 48 1A-30 Engine General Information and Diagnosis: 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 49 Engine General Information and Diagnosis: 1A-31 DTC P1674: CAN Communication (Bus Off Error) S5JB0E1104064 Wiring Diagram WHT/RED E23-4 WHT/BLU E23-19 G31-4 G31-2 G31-1 G31-3 E53-46 E03-8 WHT/BLU E53-42 E03-10 WHT/RED E91-22 E53-13 E03-12 E91-23 E53-44 E03-6 G45-9 E92-17 E92-7 G45-10 G44-19 G28-10 G44-18...
Page 50 1A-32 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Transmission error that is inconsistent between • ECM transmission data and transmission monitor (CAN bus • BCM monitor) data is detected more than 7 times continuously. •...
Page 51 Engine General Information and Diagnosis: 1A-33 Step Action ECM, TCM (for A/T model), BCM, ABS / ESP® control Go to Step 4. Intermittent trouble. module, 4WD control module (if equipped), combination Check for intermittent meter, keyless start control module (if equipped) and referring to “Intermittent steering angle sensor (for vehicle with ESP®) and Poor Connection...
Page 52 1A-34 Engine General Information and Diagnosis: Step Action DTC check in ECM Go to Step 10. CAN communication circuit wire between 1) Disconnect connector from keyless start control module keyless start control (if equipped) with ignition switch turned OFF. module and CAN circuit 2) Check ECM for DTC.
Page 53 Engine General Information and Diagnosis: 1A-35 Step Action 14 CAN communication circuit check Go to Step 15. Repair or replace defective CAN 1) Disconnect connectors from all control modules (ECM, communication circuit. TCM (if equipped), BCM, ABS or ESP® control module, 4WD control module (if equipped), keyless start control module (if equipped), combination meter, steering angle sensor (if equipped)) with ignition switch turned OFF.
Page 54 1A-36 Engine General Information and Diagnosis: Step Action DTC check Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Check ECM, TCM (for A/T model), ABS / ESP® control module, 4WD control module (if equipped), keyless start control module (if equipped) and BCM for DTC.
Page 55 Engine General Information and Diagnosis: 1A-37 Step Action DTC check in ECM Go to Step 10. CAN communication circuit wire between 1) Connect connectors to ECM and TCM with ignition BCM and CAN circuit switch turned OFF. junction connector is 2) Disconnect connectors from BCM with ignition switch open or high resistance.
Page 56 1A-38 Engine General Information and Diagnosis: Step Action 13 DTC check Go to Step 14. CAN communication circuit wire between 1) Disconnect connector from steering angle sensor steering angle sensor (vehicle with ESP®) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.
Page 57 Engine General Information and Diagnosis: 1A-39 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: in related manual”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
Page 58 1A-40 Engine General Information and Diagnosis: Step Action ABS or ESP® control module check CAN communication Substitute a known- circuit wire between good ABS or ESP® 1) Measure resistance at following connector terminals. BCM and ECM control module and • Between “WHT/BLU” terminal and “WHT” terminal of connector is open or recheck.
Page 59 Engine General Information and Diagnosis: 1A-41 Step Action 12 DTC check Go to Step 13. CAN communication circuit wire between 1) Disconnect connector from 4WD control module (if 4WD control module equipped) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.
Page 60 1A-42 Engine General Information and Diagnosis: Step Action 17 Combination meter operation check Substitute a known- Check BCM power and good ECM and recheck. ground circuits, If 1) Check combination meter operation for seat belt warning circuits are OK, lamp by fastening and unfastening driver side seat belt substitute a known- with ignition switch turned ON.
Page 61 Engine General Information and Diagnosis: 1A-43 Step Action ECM and ABS / ESP® control module connector check Go to Step 5. Intermittent trouble. Check for intermittent 1) Check for proper connection at each ECM and ABS / referring to “Intermittent ESP®...
Page 62 1A-44 Engine General Information and Diagnosis: Step Action DTC check in ECM Go to Step 8. CAN communication circuit wire between 1) Connect connectors to ABS or ESP® control module BCM and CAN circuit and ECM with ignition switch turned OFF. junction connector is 2) Disconnect connector from BCM with ignition switch open or high resistance.
Page 63 Engine General Information and Diagnosis: 1A-45 Step Action 13 DTC check in ECM Go to Step 12. CAN communication circuit wire between 1) Disconnect connector from 4WD control module (if 4WD control module equipped) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.
Page 64 1A-46 Engine General Information and Diagnosis: Inspection of ECM and Its Circuits S5JB0E1104080 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
Page 65 Engine General Information and Diagnosis: 1A-47 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ 10 – 14 V Output signal is active low (“Reference C37-1 Fuel injector No.1 Engine running at idle pulse.
Page 66 1A-48 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 0.5 – 1.0 V Ignition switch turned ON. Run engine at 2000 rpm, Electric load 1.3 – 1.7 V headlight switch turned current sensor C37-9 — signal (for J20 Run engine at 2000 rpm, engine)
Page 67 Engine General Information and Diagnosis: 1A-49 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ Output signal is active low PNK/ 10 – 14 V C37-16 Fuel injector No.3 Engine running at idle pulse.
Page 68 1A-50 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON, 3.3 – 3.8 V ECT at 0 °C, 32 °F. Engine coolant PPL/ Ignition switch turned ON, C37-24 temp. (ECT) 1.38 – 1.72 V —...
Page 69 Engine General Information and Diagnosis: 1A-51 Terminal Wire Circuit Normal voltage Condition Remarks color 2.6 – 2.8 V A/F sensor signal Engine running at idle C37-37 (“Reference — (–) after warmed up engine. waveform No.18: ”) 3.0 – 3.2 V A/F sensor signal Engine running at idle C37-38...
Page 70 1A-52 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V or 4 – 5 V Ignition switch turned ON. — *4 – 5 V Sensor signal is pulse. ↑↓ Pulse frequency which WHT/ CKP sensor signal 0 –...
Page 71 Engine General Information and Diagnosis: 1A-53 Terminal Wire Circuit Normal voltage Condition Remarks color *0 – 0.6 V ↑↓ Output signal is active Oil control valve 10 – 14 V BRN/ At the moment of ignition high pulse. Duty ratio C37-60 output (for M16 (“Reference...
Page 72 1A-54 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color For 2 sec. from the time ignition switch is turned 0 – 2.5 V ON or while engine is WHT/ Fuel pump relay running. E23-15 — output On and after 2 sec.
Page 73 Engine General Information and Diagnosis: 1A-55 Terminal Wire Circuit Normal voltage Condition Remarks color E23-40 — — — — — E23-41 — — — — — E23-42 — — — — — E23-43 — — — — — E23-44 — —...
Page 74 1A-56 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color BLU/ Throttle actuator E23-50 0 – 1 V Ignition switch turned ON. — control relay output Ground for BLU/ accelerator pedal E23-51 Below 0.3 V Ignition switch turned ON. —...
Page 75 Engine General Information and Diagnosis: 1A-57 Reference waveform No.1 Reference waveform No.3 Fuel injector signal (1) with engine idling No.2 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-2” to “C37-58” terminal terminal CH2: “C37-2” to “C37-58” Oscilloscope CH1: 20 V/DIV Oscilloscope...
Page 76 1A-58 Engine General Information and Diagnosis: Reference waveform No.5 Reference waveform No.7 Generator field coil monitor signal (1) at engine idling Heated oxygen sensor-2 signal (1) with engine idling Measurement CH1: “C37-8” to “C37-58” Measurement CH1: “C37-11” to “C37-57” terminal CH2: “C37-28”...
Page 77 Engine General Information and Diagnosis: 1A-59 Reference waveform No.9 Reference waveform No.11 EVAP canister purge valve signal No.4 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-13” to “C37-58” terminal terminal CH2: “C37-17” to “C37-58” Oscilloscope CH1: 10 V/DIV Oscilloscope...
Page 78 1A-60 Engine General Information and Diagnosis: Reference waveform No.12 Reference waveform No.13 Ignition coil signal (1) with engine idling Ignition coil No.4 signal (2) with engine idling (for J20 engine) Measurement CH1: “C37-20” to “C37-58” terminal Measurement CH1: “C37-52” to “C37-58” Oscilloscope CH1: 2 V/DIV terminal...
Page 79 Engine General Information and Diagnosis: 1A-61 Reference waveform No.15 Reference waveform No.16 • Ignition coil No.2 signal (1) with engine idling (for J20 • Ignition coil No.1 signal (1) with engine idling (for J20 engine) engine) • Ignition coil No.2 and No.3 signal (2) with engine idling •...
Page 80 1A-62 Engine General Information and Diagnosis: Reference waveform No.17 Reference waveform No.19 Mass air flow sensor signal (1) with engine racing Intake manifold tuning vacuum solenoid valve signal with engine racing (for J20 engine) Measurement CH1: “C37-26” to “C37-27” terminal CH2: “C37-54”...
Page 81 Engine General Information and Diagnosis: 1A-63 Reference waveform No.20 Reference waveform No.21 CMP sensor signal with engine idling CMP sensor signal with engine idling CH1: “C37-52” to “C37-58” CH1: “C37-52” to “C37-58” Measurement Measurement CH2: “C37-51” to “C37-36” (for J20 CH2: “C37-51”...
Page 82 1A-64 Engine General Information and Diagnosis: Reference waveform No.22 Reference waveform No.23 Throttle actuator output signal with ignition switch turned Throttle actuator output signal with ignition switch turned Measurement CH1: “C37-45” to “C37-58” Measurement CH1: “C37-45” to “C37-58” terminal CH2: “C37-44” to “C37-58” terminal CH2: “C37-44”...
Page 83 Engine General Information and Diagnosis: 1A-65 Reference waveform No.25 Reference waveform No.27 Manifold absolute pressure sensor signal (1) with engine Knock sensor signal at engine speed 4000 r/min. racing Measurement CH1: “C37-56” to “C37-58” Measurement CH1: “C37-55” to “C37-57” terminal terminal CH2: “C37-54”...
Page 84 1A-66 Engine General Information and Diagnosis: Reference waveform No.29 Reference waveform No.31 Oil control valve signal with engine racing (for M16 Ignition coil signal and fuel injector signal with engine engine) cranking Measurement CH1: “C37-52” to “C37-58” CH1: “C37-60” to “C37-59” terminal Measurement CH2: “C37-21”...
Page 85 Engine General Information and Diagnosis: 1A-67 Resistance Check 1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C in related manual”. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Connect special tool to ECM connectors securely.
Page 86 1A-68 Engine General Information and Diagnosis: A/C System Circuits Check S5JB0E1104085 Wiring Diagram WHT/BLU WHT/RED PNK/GRN YEL/RED WHT/BLK WHT/RED E23-4 BLK/RED WHT/BLU E23-19 *RED WHT/RED YEL/GRN YEL/GRN E23-49 RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 BLU/BLK RED/YEL E23-48 YEL/GRN C37-14 GRY/RED GRY/BLK C37-12...
Page 87 Engine General Information and Diagnosis: 1A-69 Step Action Reception data check from BCM Go to applicable DTC Go to Step 2. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch. 3) Check DTC for reception data from BCM. Is there DTC P1678? DTC check of HVAC control module Go to applicable DTC...
Page 88 1A-70 Engine General Information and Diagnosis: Step Action A/C compressor control system check A/C system is in good Go to Step 12. condition. Is A/C compressor started when A/C and blower speed selector switch are turned ON with engine running? 12 A/C compressor relay circuit check Go to Step 13.
Page 89 Engine General Information and Diagnosis: 1A-71 Electric Load Signal Circuit Check S5JB0E1104086 Wiring Diagram WHT/RED E23-4 WHT/BLU E23-19 C37-7 BLU/ORN E03-8 WHT/BLU WHT/RED E03-10 G31-1 E03-12 E03-6 G31-3 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110104-02...
Page 90 1A-72 Engine General Information and Diagnosis: Step Action Electric load signal circuit check Electric load signal Check defective signal circuit is in good circuit. 1) Start engine and select “DATA LIST” mode on scan tool. condition 2) Check electric load signal under following conditions respectively.
Page 91 Table of Contents 2- i Section 2 Suspension CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........2-* Front Stabilizer Bar, Bushing and/or Joint Check ..............2B-20 Precautions..............
Page 92 2-ii Table of Contents Wheels and Tires ........2D-* Rear Suspension frame / Bushing Disassembly and Assembly ......2C-* General Description ..........2D-* Rear Suspension Frame, Bushing and Pad Tires Description ..........2D-* Check ..............2C-* Wheels Description ..........2D-* Rear Wheel Hub Assembly and Rear Irregular and/or Premature Wear Suspension Knuckle Components ....
Page 93 Front Suspension: 2B-1 Front Suspension General Description Front Suspension Construction S5JB0E2201001 I5JB0A220001-03 1. Front strut assembly 7. Tie-rod : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft) 2. Stabilizer bar 8. Stabilizer bar joint : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) 3. Steering knuckle : 135 N⋅m (13.5 kgf-m, 98.0 lb-ft) : 43 N⋅m (4.3 kgf-m, 31.0 lb-ft) 4.
Page 94 2B-2 Front Suspension: Front Wheel Alignment Construction • Check for loose of ball joints. Check tie-rod ends; if S5JB0E2201002 excessive looseness is noted, it must be corrected Among factors for front wheel alignment, only toe setting before adjusting. can be adjusted. Camber and caster are not adjustable. •...
Page 95 Front Suspension: 2B-3 Adjustment Steering Angle Check and Adjustment When tie-rod or tie-rod end was replaced, check toe and 1) Loosen right and left tie-rod end lock nuts (1) first. then also steering angle with turning radius gauge (1). 2) Rotate right and left tie-rods (2) by the same amount If steering angle is not correct, check whether right and to align toe to specification.
Page 96 2B-4 Front Suspension: Front Strut Assembly Components S5JB0E2206002 I5JB0A220004-01 1. Strut assembly 7. Strut support 13. Stabilizer joint 2. Coil spring 8. Strut support nut 14. Strut dust cover 3. Bump stopper 9. Strut nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 4.
Page 97 Front Suspension: 2B-5 Front Strut Assembly Removal and Installation 6) Remove strut bracket bolts and nuts (4). S5JB0E2206003 Removal NOTE When servicing component parts of strut assembly, remove strut rod cap and then loosen strut nut a little before removing strut assembly.
Page 98 2B-6 Front Suspension: Installation Install strut assembly by reversing removal procedure, noting the following instructions. • Insert bolts in such direction as shown in figure. • Tighten all fasteners to specified torque. Tightening torque Strut bracket nut (a): 135 N·m (13.5 kgf-m, 98.0 lb- Brake hose mounting bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft) Stabilizer joint nut (d): 60 N·m (6.0 kgf-m, 43.5 lb-...
Page 99 Front Suspension: 2B-7 Front Strut Assembly Disassembly and Assembly For assembly, reverse disassembly procedure, noting Assembly S5JB0E2206004 the following instructions. 1) Compress coil spring with special tool (A) until total Disassembly length becomes about 310 mm (12.2 in.) as shown. 1) Attach special tool (A) to coil spring as shown.
Page 100 2B-8 Front Suspension: 4) Pull strut rod as far up as possible and use care not Front Strut Assembly Check S5JB0E2206005 to allow it to retract into strut. • Inspect strut for oil leakage, damage or deformation. 5) Attach coil spring seat to coil spring upper seat and If defect is found, replace strut as an assembly unit, then install strut dust cover firmly.
Page 101 Front Suspension: 2B-9 Front Wheel Hub Assembly and Steering Knuckle Components S5JB0E2206006 CAUTION Never disassemble front wheel hub assembly. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. I5JB0A220012-01 1. Front wheel hub assembly 4.
Page 102 I5JB0A220014-01 section to avoid the encoder malfunction. 6) Remove wheel hub housing bolts (3), and then remove wheel hub assembly (1) and dust cover (2). “A”: Grease 99000–25010 (SUZUKI Super Grease A) 2, "A" I5JB0A220015-01 7) Remove hub bolts (1) with copper hammer or...
Page 103 Front Suspension: 2B-11 5) Install brake disk and brake caliper. Steering Knuckle Removal and Installation S5JB0E2206008 6) Tighten caliper carrier bolt to specified torque. Removal Tightening torque Caliper carrier bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft) 1) Hoist vehicle and remove wheel. 2) Remove Front wheel hub assembly referring to 7) Depress foot brake pedal and hold it there.
Page 104 2B-12 Front Suspension: 8) Disconnect ball joint from steering knuckle (2) with 5) Install ABS wheel speed sensor (2) (if ABS puller and then remove steering knuckle (2). equipped) and tighten front wheel speed sensor bolt (3). Tightening torque Front wheel speed sensor bolt (b): 10 N·m (1.0 kgf-m, 7.5 lb-ft) 3,(b) I5JB0A220024-01...
Page 105 Front Suspension: 2B-13 Front Wheel Hub, Disc, Nut and Bearing Check Suspension Control Arm Removal and S5JB0E2206009 Installation • Inspect each wheel disc for dents, distortion and S5JB0E2206010 Removal cracks. A disc in badly damaged condition must be replaced. 1) Remove steering knuckle from suspension control arm referring to “Steering Knuckle Removal and •...
Page 106 2B-14 Front Suspension: Suspension Control Arm / Bushing Assembly Disassembly and Assembly CAUTION S5JB0E2206011 Apply grease (included in the repair kit) to Disassembly ball joint and inside of ball stud boot when 1) Remove rubber stopper (1). the ball stud boot is replaced. 2) Cut rubber (2) of flange of suspension control arm front bushing.
Page 107 Front Suspension: 2B-15 Suspension Control Arm Joint Check S5JB0E2206014 • Check smooth rotation of ball stud. • Check damages of ball stud. • Check damages of dust cover. NOTE Suspension control arm and arm joint cannot be separated. If there is any damage to either parts, control arm I4RS0B220023-01 assembly must be replaced as a complete unit.
Page 108 2B-16 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or 7) Disconnect front height sensor connector (1) (if equipped with head light auto leveling system) and Bushings Removal and Installation S5JB0E2206016 then detach clip (2). Removal 1) Hoist vehicle and remove wheels (right & left). 2) Remove engine under cover.
Page 109 Front Suspension: 2B-17 11) Remove front propeller shaft referring to “Propeller 15) Remove engine front body side mounting nuts (1). Shaft Removal and Installation: in Section 3D in 16) Remove suspension frame mounting bolts (2), and related manual”. then lower suspension frame (3) with stabilizer bar, 12) Fix radiator (2) to body with rope (1) to avoid the P/S gear box assembly and front differential radiator (2) fall off when front suspension frame...
Page 110 2B-18 Front Suspension: 18) Remove stabilizer bar (1) and bushing (2) from 4) Install P/S gear box assembly (1) and front suspension frame (3). differential assembly (2) referring to “P/S Gear Case Assembly Removal and Installation: in Section 6C in related manual”...
Page 111 Front Suspension: 2B-19 6) Tighten suspension frame mounting bolts (1) and 8) Install hood referring to “Hood Removal and engine front body side mounting nuts (2) to specified Installation: in Section 9J in related manual”. torque. 9) Install front propeller shaft referring to “Propeller Shaft Removal and Installation: in Section 3D in CAUTION related manual”.
Page 112 2B-20 Front Suspension: Front Suspension Frame Check 14) Connect front fender lining clip (1) (if equipped with S5JB0E2206017 head light auto leveling system). Inspect for cracks, deformation or damage. If defective, replace. I5JB0A220056-01 I5JB0A220042-01 15) Install stabilizer joints (1), and tighten nuts to Front Stabilizer Bar, Bushing and/or Joint specified torque.
Page 113 Front Suspension: 2B-21 Stabilizer Joint 1) Check for smooth rotation. 2) Check damages of ball stud. 3) Check damages of dust cover. NOTE Stabilizer joint (1) cannot be disassembled. If there is any damage to either parts, stabilizer joint assembly must be replaced as a complete unit. I4RH01220007-01 Front Suspension Fasteners Check S5JB0E2206019...
Page 114 2B-22 Front Suspension: Special Tools and Equipment Recommended Service Material S5JB0E2208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Special Tool S5JB0E2208002 09900–00411 09900–00414 Hexagon bit socket Hexagon bit (6 mm) 09913–75821 09941–56510 Bearing installer attachment Socket wrench (19 mm) 09943–25010...
Page 115 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........3-* Repair Instructions ..........
Page 116 3-ii Table of Contents Repair Instructions ..........3C-55 Function of 4WD Control System Component ............3C-6 Transfer Oil Level Check........3C-55 4WD Control System Operation......3C-6 Transfer Oil Change..........3C-55 4WD Control System Wiring Circuit Diagram..3C-11 Transfer Oil Seal Removal and Installation ..3C-56 Terminal Arrangement of 4WD Control Transfer Switch Removal and Installation ..3C-57 Module ............3C-12 Transfer Switch Inspection........3C-57...
Page 117 Table of Contents 3-iii Propeller Shafts ........3D-* Propeller Shaft Removal and Installation .... 3D-* Propeller Shaft Disassembly and Assembly ..3D-* Precautions............3D-* Propeller Shaft Inspection ........3D-* Propeller Shaft Caution ........3D-* Specifications ............3D-* General Description ..........3D-* Tightening Torque Specifications......
Page 118 3) Pour specified oil into transfer up to lever plug hole if memory can be cleared as well as checked by using front propeller shaft is removed. SUZUKI scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 119 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-2 General Description Transfer Description S5JB0E3311001 The aluminum transfer case directly connected to the back of the transmission contains input gear, counter gear, rear output shaft, front output shaft, center differential, drive chain and their accompanying gears, hubs, sleeves, fork, etc. The center differential is installed in the transfer.
Page 120 3C-3 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Shift Control System Components S5JB0E3311002 I5JB0A332001-01 1. Transfer switch 4. N indicator 7. Center differential lock switch 2. Differential lock indicator 5. 4WD control module 8. 4L/N switch 3. 4L indicator 6.
Page 121 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-4 4WD Control System Description S5JB0E3311003 Transfer Shift Control The 4WD control module controls the transfer shift actuator based on the signal from the transfer switch so that the transfer is shifted to the selected position (4H, 4H-lock, N or 4L-lock). (Shifting to the N position requires that the switch to “...
Page 122 3C-5 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Operation Condition Indicator Buzzer • Ignition switch is OFF. — • Transfer is at 4H/N position. • Within 2 seconds after ignition switch is turn ON (checking indicator operation). — • Transfer is at 4H-lock/4L-lock position. Flashes at 0.25 Sounds at 1 seconds for 3...
Page 123 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-6 Function of 4WD Control System Component S5JB0E3311004 Part Name Function Detects transfer shift position combining center differential lock 4L/N switch switch. Center differential lock switch Detects transfer shift position combining 4L/N switch. Transfer switch Shifts transfer shift position.
Page 124 3C-7 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 4H (4WD High) Position The driving force from the transmission is transmitted to the transfer input gear. As the center LSD case and transfer input gear are engaged via the reduction shift sleeve at this time, the driving force transmitted from the transfer input gear to the rear output shaft rotates them at the same speed.
Page 125 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-8 4H-lock (4WD High Center Differential Lock) Position When 4H-lock position is selected from 4H position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “A”. The shift cam shifts the differential lock shift fork in the arrow direction “B”, and the differential lock clutch sleeve also moves in the arrow direction “B”.
Page 126 3C-9 Transfer: Motor-Shift Type (Transfer with Shift Actuator) N (Neutral) Position When N position is selected from 4H position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “A”. The shift cam shifts the High / Low shift fork in the arrow direction “B”, and the reduction shift sleeve moves in the arrow direction “B”.
Page 127 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-10 4L-lock (4WD Low Center Differential Lock) Position When 4L-lock position is selected from 4H-lock position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “A”. The shift cam shifts the High/Low shift fork in the arrow direction “B”, and the reduction shift sleeve moves in the arrow direction “B”.
Page 128 3C-11 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 4WD Control System Wiring Circuit Diagram S5JB0E3311006 E91-18 LT GRN G59-2 C54-1 E91-2 E91-19 BLU/BLK G59-3 C54-4 E91-3 E91-20 BLU/ORN G59-4 C54-2 E91-25 C54-3 E91-26 RED/BLK C54-5 BLK/YEL E91-24 PNK/WHT E91-13 E91-14 RED/GRN BLK/ORN E91-7...
Page 129 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-12 Terminal Arrangement of 4WD Control Module S5JB0E3311007 I4JA01332038-01 [A]: Connector “E91” viewed from harness side Terminal Circuit Terminal Circuit E91-1 Ground E91-18 Transfer switch 1 E91-2 Transfer actuator motor 1 E91-19 Transfer switch 2 E91-3 Transfer actuator motor 2 E91-20...
Page 130 • DTC can be checked by either one of the following ways. – DTC can be checked by using SUZUKI scan tool (4) connected to DLC (5). – If equipped with diagnosis connector, DTC can be displayed on digital display odometer by shorting diagnosis connector (6).
Page 131 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-14 CAN Communication System Description S5JB0E3311010 Refer to “CAN Communication System Description: in Section 1A”. 4WD Control Module Transmission Data Combination Meter Buzzer on reques Lock indication status Low indication status Transmit DATA control Neutral Indication Status module...
Page 132 3C-15 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step Action Visual inspection Repair or replace Go to Step 8. malfunction part. Go to 1) Perform visual inspection. Step 11. Is there any faulty condition? Trouble symptom confirmation Go to Step 6. Go to Step 7.
Page 133 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-16 Detail of 4WD Control System Check Step 1: Customer complaint analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 134 3C-17 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step 3 and 4. Visual inspection 4WD Control System Operation Inspection S5JB0E3314003 As a preliminary step, be sure to perform visual check of NOTE the items that support proper function of the 4WD control system referring to “Visual Inspection: Motor-Shift Type •...
Page 135 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-18 e) Check that 4L indicator blink, and then e) Check that differential lock indicator blinks, and differential lock indicator and 4L indicator comes then not comes ON. ON steady. 5) Inspect shift operation from 4H to N as follows. 3) Inspect shift operation from 4L-lock to 4H-lock as a) Stop vehicle completely with engine running.
Page 136 I5JB0A332012-01 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between SUZUKI scan tool and...
Page 137 1) Turn ignition switch to OFF position. the following cases. Be careful not to clear 2) Connect SUZUKI scan tool to data link connector them before keeping their record. (DLC) (1) located on underside of instrument panel.
Page 138 3C-21 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Detecting condition DTC No. Detecting item position (DTC will set when detecting) indicators Though actuator position switch is “4L-lock” C1228 4L/N switch circuit short position, the OFF signal is not input from the 4L/ N switch.
Page 139 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-22 Scan Tool Data S5JB0E3314009 Normal Condition / Scan Tool Data Vehicle Condition Reference Value Vehicle speed At vehicle stop 0 km/h, 0 mph Transfer shifted to 4H position Transfer being shifted between 4H-lock and 4H position 4H-lock –...
Page 140 3C-23 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Mode switch 3 (Transfer switch) (ON / OFF): ABS active (ON / OFF): ON: Transfer switch to 4H-lock or 4L-lock position. This parameter indicates ABS status detected by OFF: Transfer switch to 4H or N position. 4WD control module.
Page 141 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-24 Condition Possible cause Correction / Reference Item Gear slipping out of mesh Worn control cover shift shaft Check control cover shift shaft referring to “Transfer Assembly Inspection: Motor-Shift Type (Transfer with Shift Actuator)”. Worn shift fork or sleeve Check shift fork or sleeve referring to “Transfer Assembly Inspection: Motor-Shift Type...
Page 142 3C-25 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops S5JB0E3314012 Wiring Diagram G28-15 PPL/RED BLK/YEL G28-13 WHT/GRN G28-10 E91-22 G28-8 E91-23 2221201918 1615141312 I5JB0A332015-03 [A]: 4WD control module connector “E91” (viewed from harness side) 4.
Page 143 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-26 Troubleshooting Step Action Transfer position indicator power supply check Go to Step 2. Go to Step 3. 1) Turn ignition switch to ON position. Do other indicators come ON? Check DTC Go to applicable DTC Substitute a known- diag.
Page 144 3C-27 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Position Indicator Remains ON Steady at Ignition Switch ON S5JB0E3314013 Wiring Diagram G28-15 PPL/RED BLK/YEL G28-13 WHT/GRN G28-10 E91-22 G28-8 E91-23 2221201918 1615141312 I5JB0A332015-03 [A]: 4WD control module connector “E91” (viewed from harness side) 4.
Page 145 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-28 DTC C1213: Transfer Switch Circuit Open S5JB0E3314014 Wiring Diagram E91-18 LT GRN G59-2 E91-19 BLU/BLK G59-3 G59-4 E91-20 BLU/ORN I5JB0A332016-01 [A]: 4WD control module connector “E91” (viewed from harness side) 1. 4WD control module [B]: Transfer switch connector “G59”...
Page 146 3C-29 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step Action Transfer switch check Substitute a known- Replace transfer switch. good 4WD control 1) Check transfer switch referring to “Transfer Switch module and recheck. Inspection: Motor-Shift Type (Transfer with Shift Actuator)”. Is switch in good condition? Wire harness check Substitute a known-...
Page 147 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-30 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Transfer switch combination different from specification is • Transfer switch detected for more than 0.5 seconds. • Transfer switch circuit • 4WD control module DTC Confirmation Procedure 1) Clear DTC using scan tool.
Page 148 3C-31 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open S5JB0E3314016 Wiring Diagram C54-1 E91-2 C54-4 E91-3 C54-2 E91-25 C54-3 E91-26 RED/BLK...
Page 149 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-32 Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Transfer shift actuator motor position switch circuit Go to Step 3.
Page 150 3C-33 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short S5JB0E3314017 Wiring Diagram C54-1 E91-2 C54-4 E91-3 C54-2 E91-25 C54-3 E91-26 RED/BLK...
Page 151 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-34 Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Transfer shift actuator motor position switch circuit Go to Step 3.
Page 152 3C-35 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC C1227: 4L/N Switch Circuit Open S5JB0E3314018 Wiring Diagram PNK/WHT E91-13 E91-14 RED/GRN I5JB0A332018-01 [A]: 4WD control module connector “E91” (viewed from harness side) 3. 4L/N switch 1. 4WD control module 4. Center differential lock switch 2.
Page 153 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-36 Step Action 4L/N switch check Substitute a known- Replace 4L/N switch. good 4WD control 1) Check 4L/N switch referring to “Transfer Assembly module and recheck. Inspection: Motor-Shift Type (Transfer with Shift Actuator)”. Is switch in good condition? Wire harness check Substitute a known-...
Page 154 3C-37 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. 4L/N switch circuit check Go to Step 3. Go to Step 4.
Page 155 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-38 DTC C1230: Transfer Actuator Circuit Malfunction S5JB0E3314020 Wiring Diagram C54-1 E91-2 E91-3 C54-4 C54-2 E91-25 C54-3 E91-26 RED/BLK C54-5 BLK/YEL E91-24 I5JB0A332017-01 [A]: 4WD control module connector “E91” (viewed from harness side) 2.
Page 156 3C-39 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Transfer shift actuator circuit check Go to Step 3. Go to Step 4.
Page 157 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-40 DTC C1237: Center Differential Lock Switch Circuit Open S5JB0E3314021 Wiring Diagram PNK/WHT E91-13 E91-14 RED/GRN I5JB0A332018-01 [A]: 4WD control module connector “E91” (viewed from harness side) 3. 4L/N switch 1. 4WD control module 4.
Page 158 3C-41 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Center differential lock switch circuit check Go to Step 3.
Page 159 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-42 DTC C1238: Center Differential Lock Switch Circuit Short S5JB0E3314022 Wiring Diagram PNK/WHT E91-13 E91-14 RED/GRN I5JB0A332018-01 [A]: 4WD control module connector “E91” (viewed from harness side) 3. 4L/N switch 1. 4WD control module 4.
Page 160 3C-43 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Select transfer switch to “4L-lock” position and keep its position for 1 min. 3) Check DTC. Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2.
Page 161 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-44 DTC C1240: 4WD Control Module Power Supply Circuit Malfunction S5JB0E3314023 Wiring Diagram E91-12 BLK/WHT E91-11 E91-1 E91-10 I5JB0A332019-01 [A]: 4WD control module connector “E91” (viewed from harness side) 4. “4WD” fuse 1. 4WD control module 5.
Page 162 3C-45 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. 4WD control module power circuit check Poor “E91-11”...
Page 163 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-46 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area CPP switch signal is input when vehicle speed is 30 km/h (19 • CPP switch mph). • CPP switch circuit • 4WD control module DTC Confirmation Procedure 1) Clear DTC using scan tool.
Page 164 3C-47 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC U1073: Control Module Communication Bus Off S5JB0E3314026 Wiring Diagram G31-2 G31-4 G31-1 G31-3 WHT/RED E23-4 WHT/BLU E23-19 E91-22 E91-23 E03-8 WHT/BLU E53-46 E03-10 WHT/RED E53-42 E92-17 E03-12 E53-13 E92-7 E03-6 E53-44 G44-19 G28-10 G44-18...
Page 165 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-48 [A]: Keyless start control module connector (if equipped) (viewed from harness side) 1. BCM [B]: ECM connector (viewed from harness side) 2. 4WD control module [C]: TCM connector (for A/T model) (viewed from harness side) 3.
Page 166 3C-49 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Control module connector check Go to Step 3. Intermittent trouble.
Page 167 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-50 DTC U1100: Lost Communication with ECM S5JB0E3314027 Wiring Diagram Refer to “DTC U1073: Control Module Communication Bus Off: Motor-Shift Type (Transfer with Shift Actuator)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ECM is detected for •...
Page 168 3C-51 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC U1101: Lost Communication with TCM S5JB0E3314028 Wiring Diagram Refer to “DTC U1073: Control Module Communication Bus Off: Motor-Shift Type (Transfer with Shift Actuator)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for TCM is detected for •...
Page 169 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-52 DTC U1121: Lost Communication with ABS / Electronic Stability Program Hydraulic Unit / Control Module S5JB0E3314029 Wiring Diagram Refer to “DTC U1073: Control Module Communication Bus Off: Motor-Shift Type (Transfer with Shift Actuator)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 170 3C-53 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Inspection of 4WD Control Module and Its Circuits S5JB0E3314030 4WD control module and its circuits can be checked at coupler connected to 4WD control module by measuring voltage, pulse signal. CAUTION 4WD control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to 4WD control module with couplers disconnected from it.
Page 171 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-54 Terminal Wire Normal Circuit Condition Number Color Voltage Ignition switch turned to ON position and transfer shift actuator being rotated 4H-lock → 4H → N direction or 10 – 14 V Transfer actuator 4H-lock →...
Page 172 3) Apply sealant to thread of level / filler plug, and then Whenever vehicle is hoisted for any other tighten it to specified torque. service work than oil change, also be sure to “A”: Sealant 99000–31260 (SUZUKI Bond check for oil leakage. No.1217G) 3) Remove oil filler plug (2).
Page 173 7) Apply sealant to thread of level / filler plug, and then Transfer Oil Seal Removal and Installation S5JB0E3316003 tighten it to specified torque. Removal “A”: Sealant 99000–31260 (SUZUKI Bond 1) Lift up vehicle and drain transfer oil. No.1217G) 2) Remove front propeller shaft and/or rear propeller Tightening torque shaft referring to “Propeller Shaft Removal and...
Page 174 1) Install new oil seal using special tool and plastic Check continuity between following terminals when hammer, and then apply grease to oil seal lip. transfer switch (1) operated at each position. : Grease 99000–25010 (SUZUKI Super Grease Switch position Terminal 1 – 2 N (3) 1 –...
Page 175 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-58 Installation 8) Support engine rear mounting member (1) with Reverse removal procedure for installation noting the transmission jack (2). following. 9) Remove engine rear mounting bolts (3), and then • Connect 4WD control module connectors securely. slant the transmission with transfer.
Page 176 3C-59 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Assembly Components S5JB0E3316008 1217G 1217G 1217G 1322 1217G I5JB0A331009-06...
Page 177 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-60 1. Front oil seal No.1 20. Washer 39. Oil strainer bolt : Apply grease 99000-25010 to oil seal lip. 2. Front case bolt 21. Shim 40. Oil pump outer rotor 3. Front case 22.
Page 178 3C-61 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 6) Remove front case (1) using plastic hammer. 9) Remove needle bearings (1) from center case (2) using special tools, if necessary. Special tool (A): 09913–76010 (B): 09925–98210 I5JB0A331014-01 7) Remove rear case bolts (1) and clamp (2) and then separate center case (3) using special tool.
Page 179 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-62 13) Remove differential lock clutch sleeve (1) from rear 17) Remove rear oil seal (1) from rear case (2) using flat output shaft (2). end rod or the like, if necessary. I5JB0A331026-01 I5JB0A331022-01 18) Remove needle bearing (1) from rear case (2) using 14) Remove front drive sprocket bush (1) from rear...
Page 180 Input gear plate bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft) Reassembly 1) Install new front oil seal No.2 to front case (1) using 1, (a) special tool, and then apply grease to oil seal lip. : Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–85210 I5JB0A331035-03 I5JB0A331033-01...
Page 181 5) Install new rear oil seal (1) to rear case (2) using special tool as shown in figure, and then apply grease to oil seal lip. “A”: Grease 99000–25010 (SUZUKI Super Grease A) Distance between case and oil seal “a”...
Page 182 Distance between case and oil seal “a” : 3.5 – 4.5 mm (0.138 – 0.177 in.) “A”: Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–70123...
Page 183 (0.047 in.) in diameter, mate front case (3) with “a” center case and then tighten bolts (2) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) 4, “A” Tightening torque Rear case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Page 184 1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolts (3) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Oil pump cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 “A”...
Page 185 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-68 Transfer Assembly Inspection • Measure the width of groove part of differential lock S5JB0E3316010 clutch sleeve (1). • Check needle bearing and bearing contacting surface If measured value is out of specification, replace for damage.
Page 186 3C-69 Transfer: Motor-Shift Type (Transfer with Shift Actuator) • Connect terminal “1” of transfer actuator (3) to the • Operate the motor, and measure the resistance positive of battery (4) and terminal “2” to the negative, between following terminals of transfer actuator when and confirm cam (2) rotates in the direction of A.
Page 187 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-70 Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components S5JB0E3316011 I5JB0A331061-02 1. Snap ring 6. Counter gear 2. Bearing 7. Front output shaft 3. Input gear plate : Do not reuse.
Page 188 3C-71 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3) Remove bearing (1) from input gear (2) using 3) Install snap rings (1) to input gear (2). bearing puller (3) and press (4), and then remove input gear plate. I5JB0A331066-01 I5JB0A331064-01 4) Install bearing (1) and snap ring (2).
Page 189 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-72 Reassembly 2) Remove bearing (1) from front output shaft (2) using bearing puller (3) and press (4). 1) Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
Page 190 3C-73 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Rear Output Shaft Assembly Disassembly and Reassembly Reassembly 1) Clean all components thoroughly, inspect them for S5JB0E3316015 any abnormality and replace with new ones as necessary. Disassembly 2) To ensure lubrication of rear output shaft (1), air blow 1) Remove snap ring (1) from rear output shaft (2).
Page 191 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A in related manual”. Special Tools and Equipment Recommended Service Material S5JB0E3318001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 192 Bearing installer 09928–36510 09940–54910 Transfer cap Front fork oil seal install driver SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loop back adapter, 7.
Page 193 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-76 Non-Shift Type (Transfer without Shift Actuator) Precautions Transfer Warning S5JB0E3320001 Refer to “Transfer Warning: Motor-Shift Type (Transfer with Shift Actuator)”. General Description Transfer Construction S5JB0E3321001 The aluminum transfer case directly connected to the back of the transmission contains the input gear, rear output shaft, front output shaft and drive chain.
Page 194 3C-77 Transfer: Non-Shift Type (Transfer without Shift Actuator) Diagnostic Information and Procedures Transfer Symptom Diagnosis S5JB0E3324001 Before attempting to repair the transfer or related components for any reason other than mechanical failure, the condition and possible causes should be identified. When any of these conditions occur, the following inspections should be made before disassembling the transfer.
Page 195 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-78 Repair Instructions Transfer Oil Change S5JB0E3326001 Refer to “Transfer Oil Change: Motor-Shift Type (Transfer with Shift Actuator)”. The point which is different from the motor-shift type (transfer with shift actuator) is described. Transfer oil capacity (Reference) : 1.6 liters (3.4/2.8 US/lmp.pt) Transfer Oil Level Check...
Page 196 3C-79 Transfer: Non-Shift Type (Transfer without Shift Actuator) Transfer Assembly Components S5JB0E3326005 1217G 1217G 1217G 1217G I5JB0A331084-05...
Page 197 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-80 1. Front oil seal No.1 17. Differential lock clutch sleeve 33. Oil drain plug : Apply grease 99000-25010 to oil seal lip. : Apply sealant 99000-31260 to plug thread. 2. Front case bolt 18.
Page 198 3C-81 Transfer: Non-Shift Type (Transfer without Shift Actuator) 5) Remove rear case bolts (1), and then separate 8) Remove needle bearing (1), snap ring (2), washer center case (2) using special tool. (3) and shim(s) (4) from rear output shaft (5). Special tool (A): 09912–34510 I5JB0A331089-01...
Page 199 I5JB0A331025-01 special tool, and then apply grease to oil seal lip. 15) Remove rear oil seal (1) from rear case (2) using flat : Grease 99000–25010 (SUZUKI Super Grease A) end rod or the like, if necessary. Special tool (A): 09913–85210...
Page 200 Distance between case and oil seal “a” : 3.5 – 4.5 mm (0.138 – 0.177 in.) “A”: Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–70123...
Page 201 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-84 9) Install differential lock clutch sleeve (1) to rear 13) Select shim (1) as follows. output shaft (2) as shown in figure. a) Install shim, washer (2) and used snap ring (3) into rear output shaft (4).
Page 202 Distance between case and oil seal “a” center case and then tighten bolts (2) to specified : 3.5 – 4.5 mm (0.138 – 0.177 in.) torque. “A”: Grease 99000–25010 (SUZUKI Super “A”: Sealant 99000–31260 (SUZUKI Bond Grease A) No.1217G) Special tool Tightening torque (A): 09913–70123...
Page 203 (3) to which thread lock cement has been applied and differential lock shift lever case dowel bolts (4) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) “B”: Thread lock cement 99000–32110 (Thread Lock Cement Super 1322) Tightening torque Differential lock shift lever case bolt (a): 23 N·m...
Page 204 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A in related manual”. Special Tools and Equipment Recommended Service Material S5JB0E3328001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 205 Table of Contents 4- i Section 4 Brakes CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........4-1 Front Brakes ..........4B-1 Precautions.............
Page 206 4-ii Table of Contents DTC U1100: Lost Communication with Parking Brake Lever Removal and Installation ............4D-* ECM (Reception Error)........4E-32 Parking Brake Cable Removal and Repair Instructions ..........4E-33 Installation ............4D-* Hydraulic Unit Operation Check ......4E-33 Specifications............4D-* ABS (ESP®) Hydraulic Unit / Control Tightening Torque Specifications......
Page 207 Table of Contents 4-iii DTC C1075 / 1076 / 1077 / 1078: Steering DTC Check ............4F-12 DTC Table............4F-13 Angle Sensor / Master Cylinder Pressure DTC Clearance ..........4F-16 Sensor / Longitudinal G Sensor / Lateral G Fail-Safe Table..........4F-17 Sensor in Yaw Rate / G Sensor Scan Tool Data ..........
Page 208 4-iv Table of Contents Specifications............. 4F-52 Special Tools and Equipment ......4F-52 Tightening Torque Specifications...... 4F-52 Special Tool ............4F-52...
Page 209 Precautions: Precautions Precautions Precautions for Brakes S5JB0E4000001 Suspension Caution Refer to “Suspension Caution: in Section 00 in related manual”. Wheels and Tires Caution Refer to “Wheels and Tires Caution: in Section 00 in related manual”. Brake Caution Refer to “Brakes Caution and Note: in Section 00”. General Precautions Refer to “General Precautions: in Section 00 in related manual”.
Page 210 4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis General Description Brakes Construction S5JB0E4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder (2) to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder.
Page 211 Brake Control System and Diagnosis: 4A-2 Front Brake Hose / Pipe Construction S5JB0E4101002 I5JB0A410002-03 [A]: For LH steering vehicle 4. From ABS hydraulic unit to left front brake 9. Master cylinder fixing nut [B]: For RH steering vehicle 5. ABS (ESP®) hydraulic unit / control module 10.
Page 212 4A-3 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brakes Symptom Diagnosis S5JB0E4104002 Condition Possible cause Correction / Reference Item Not enough braking force Brake fluid leakage from brake lines Locate leaking point and repair. Brake disc or pads stained with fluid Clean or replace.
Page 213 Brake Control System and Diagnosis: 4A-4 Condition Possible cause Correction / Reference Item Pedal pulsation Damaged or loose wheel bearings Replace wheel bearings. (Pedal pulsates when Distorted steering knuckle or rear axle Replace knuckle or rear axle shaft. depressed for braking) shafts Excessive disc lateral runout Check per instructions.
Page 214 4A-5 Brake Control System and Diagnosis: Repair Instructions Front Brake Hose / Pipe Removal and Removal Installation 1) Raise and support vehicle properly. Remove tire and S5JB0E4106011 wheel. CAUTION 2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Do not allow brake fluid to get on painted 3) Drain brake fluid in reservoir.
Page 215 Brake Control System and Diagnosis: 4A-6 3) Take out fluid with syringe or such. 2) Install reservoir (1) and drive in reservoir connector pin (2) by using special tool (A). till both of its ends at 4) Disconnect clutch reservoir hose (1) from reservoir the right and left of reservoir becomes the same (2) for M/T vehicle.
Page 216 4A-7 Brake Control System and Diagnosis: Removal 6) Loosen master cylinder fixing nuts (1) and then remove master cylinder (2) with reservoir (3) from 1) Disconnect reservoir lead wire at coupler (1). brake booster (4). I5JB0A410016-02 I5JB0A410018-02 2) Clean outside of master cylinder and take out fluid with syringe or such.
Page 217 Brake Control System and Diagnosis: 4A-8 4) Connect brake pipes to master cylinder and tighten Master Cylinder Assembly Inspection S5JB0E4106016 brake pipe flare nuts (1) to specified torque. • Check master cylinder for corrosion and smooth Tightening torque operation. Brake pipe flare nut for M10 (a): 16 N·m (1.6 kgf- •...
Page 218 4A-9 Brake Control System and Diagnosis: Brake Booster Components S5JB0E4106017 NOTE The difference between RH steering vehicle and LH steering vehicle booster components is the location of vacuum hose. I5JB0D410001-01 1. Brake master cylinder assembly 5. Clevis pin lock nut 9.
Page 219 Brake Control System and Diagnosis: 4A-10 Brake Booster Removal and Installation Installation S5JB0E4106018 NOTE Removal • Check length of push rod clevis (2). Refer 1) Disconnect brake pipes from ABS (ESP®) hydraulic to “Booster Push Rod Clevis Adjustment: unit / control module assembly if equipped. in related manual”.
Page 220 4A-11 Brake Control System and Diagnosis: Specifications Tightening Torque Specifications S5JB0E4107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Brake pipe flare nut for M10 12.0 Brake pipe flare nut for M12 14.0 Master cylinder fixing nut 13.0 Booster attaching nut NOTE The specified tightening torque is also described in the following.
Page 221 Front Brakes: 4B-1 Front Brakes Repair Instructions Installation Front Disc Brake Pad Removal and Installation 1) Install pad spring (1) and pads (2). S5JB0E4206003 NOTE Removal Install brake pad with wear indicator (5) to 1) Hoist vehicle and remove front wheel. vehicle center side on right wheel brake.
Page 222 4B-2 Front Brakes: 3) Install wheel and lower vehicle. 3) Install brake flexible hose as shown and tighten flexible hose joint bolt (1) to specified torque. 4) Tighten wheel nuts to specified torque. Tightening torque Tightening torque Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m, Wheel nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) 17.0 lb-ft) 5) Upon completion of installation, perform brake test.
Page 223 Front Brakes: 4B-3 3) Remove disc by using 8 mm bolts (1) (2 pcs). Installation 1) Install disc to wheel hub. 2) Install caliper assembly to steering knuckle. 3) Tighten caliper carrier bolts (1) to specification. Tightening torque Caliper carrier bolt (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft) 1,(a) IYSQ01420025-01...
Page 224 (2) until it locks. module memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 225 ABS: 4E-2 General Description ABS Description Self-Diagnosis Description S5JB0E4501001 S5JB0E4501004 ABS is controlled by ABS control module or by ESP® ABS (ESP®) control module diagnoses conditions of the control module (if equipped). system component parts (whether or not there is any ABS activation and control with ESP®...
Page 226 4E-3 ABS: CAN Communication System Description S5JB0E4501003 Refer to “CAN Communication System Description: in Section 1A” for CAN communication system description. ABS communicates control data with each control module as follows. ABS Transmission Data 4WD control module Combination Meter (if equipped) Torque up request Wheel speed signal (front right) Wheel speed signal (front left)
Page 227 ABS: 4E-4 Schematic and Routing Diagram ABS Schematic S5JB0E4502001 INPUT OUTPUT ABS (ESP®) control module Hydraulic unit Wheel speed sensor (LF) Pump motor Wheel speed sensor (LR) Pump motor driver (transistor) Wheel speed sensor (RF) Solenoid valve power supply driver (transistor) Wheel speed sensor (RR) LF inlet solenoid valve LF outlet solenoid valve...
Page 228 4E-5 ABS: 5. Solenoid valve driver (transistor) 14. Wheel speed sensor (Right-front) 23. Yaw rate / G sensor assembly 6. Pump motor driver (transistor) 15. Wheel speed sensor (Left-front) 7. Solenoid valve 16. Wheel speed sensor (Right-rear) ABS Wiring Circuit Diagram S5JB0E4502002 The figure shows for vehicle without ESP®.
Page 229 ABS: 4E-6 4. Junction block assembly 16. Right-front wheel speed sensor 28. Brake fluid level switch 5. Combination meter 17. Left-front wheel speed sensor 29. Parking brake switch 6. ABS warning lamp 18. Data link connector 30. Junction connector 7. EBD warning lamp (Brake warning lamp) 19.
Page 230 4E-7 ABS: Component Location ABS Components Location S5JB0E4503001 NOTE As for the difference of RH steering vehicle and LH steering vehicle, the location of the combination meter, data link connector, stop lamp switch and the brake master cylinder assembly only changes. I6JB01450004-01 1.
Page 231 ABS: 4E-8 Diagnostic Information and Procedures ABS Check S5JB0E4504001 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”. 3) Perform “DTC check, record and clearance: ”...
Page 232 4E-9 ABS: Customer questionnaire (Example) I2RH01450014-01 Problem symptom confirmation Check if what the customer claimed in “Customer Questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check: ”...
Page 233 ABS: 4E-10 Step 3: DTC Check Recheck DTC referring to “DTC Check: ”. Step 4: ABS Check According to ABS Check for the DTC confirmation in Step 3, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator assembly or other part and repair or replace faulty parts. Step 5: Brakes Diagnosis Check the parts or system suspected as a possible cause referring to “Brakes Symptom Diagnosis: in Section 4A”...
Page 234 3) Turn ignition switch to ON position. C1042 failure 4) Read DTC according to instructions displayed on Inlet solenoid valve circuit SUZUKI scan tool and print it or write it down. Refer C1045 failure to SUZUKI scan tool operator’s manual for further Outlet solenoid valve circuit details.
Page 235 0 km/h, 0.0 MPH Vehicle stop Speed scan tool. LR Wheel 0 km/h, 0.0 MPH Vehicle stop 1) Connect SUZUKI scan tool to data link connector in Speed the same manner as when making this connection Brake pedal for DTC check.
Page 236 4E-13 ABS: ABS Warning Lamp Does Not Come ON at Ignition Switch ON S5JB0E4504008 Wiring Diagram WHT/BLU E53-32 WHT/BLU E03-1 WHT/RED E53-1 WHT/RED E03-14 E53-35 WHT/GRN BLK/YEL GRN/ORN GRN/ORN E03-7 PPL/RED E53-13 E03-12 E53-44 E03-6 E53-16 E03-13 E53-47 E03-26 I6JB01450005-01 [A]: With ESP®...
Page 237 ABS: 4E-14 Troubleshooting Step Action 1) Turn ignition switch to ON position. Go to Step 2. Go to Step 3. Do other warning lamps come ON? 1) Connect scan tool to DLC with ignition switch turned Go to “DTC U1073: Substitute a known- OFF.
Page 238 4E-15 ABS: Troubleshooting Step Action 1) Perform diagnostic trouble code check. Go to applicable DTC Go to Step 2. diag. flow. Is there any DTC(s)? Are main fuses for ABS pump motor and ABS solenoid in Go to Step 3. Replace fuse and check good condition? circuit for short to...
Page 239 ABS: 4E-16 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady S5JB0E4504011 Wiring Diagram WHT/BLU E53-32 WHT/BLU E03-1 WHT/RED E53-1 WHT/RED E03-14 E53-35 WHT/GRN BLK/YEL GRN/ORN GRN/ORN E03-7 PPL/RED E53-13 E03-12 E53-44 E03-6 E53-16 E03-13 E53-47 E03-26 RED/BLK RED/BLK I6JB01450006-02 [A]: With ESP®...
Page 240 4E-17 ABS: Troubleshooting Step Action 1) Make sure that: Go to Step 2. Release parking brake completely and/or • Parking brake is completely released. replenish brake fluid. • Brake fluid level is upper than the minimum level. Are the check results OK? 1) Turn ignition switch to ON position.
Page 241 ABS: 4E-18 Inspection Step Action 1) Turn ignition switch to ON position. Go to Step 2. Go to Step 6. Does ABS warning lamp come ON? 1) Turn ignition switch to OFF position. Go to Step 3. Replace fuse and check for short.
Page 242 4E-19 ABS: Step Action 1) Turn ignition switch to OFF position. Substitute a known- Repair high resistance good ABS hydraulic unit or open in “PPL/WHT” 2) Check proper connection at “E03-5” (“PPL/WHT” wire) / control module and wire circuit for anti lock terminal for serial data circuit.
Page 243 ABS: 4E-20 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure S5JB0E4504014 Wiring Diagram BLK/YEL GRN/ORN E53-35 GRN/ORN E03-7 E53-14 E03-22 BLU/BLK BLU/BLK E53-15 E03-21...
Page 244 4E-21 ABS: DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check: ”. 1) Turn ignition switch OFF. Go to Step 3. ABS wheel speed sensor circuit shorted to 2) Disconnect ABS (ESP®) control module connector. power.
Page 245 ABS: 4E-22 Step Action Refer to “Front Wheel Speed Sensor On-Vehicle Inspection: Substitute a known- Replace sensor and ” and/or “Rear Wheel Speed Sensor On-Vehicle Inspection: good ABS (ESP®) recheck. ”, check output voltage or waveform. hydraulic unit / control module assembly and Is specified voltage and/or waveform obtained? recheck.
Page 246 4E-23 ABS: DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet Solenoid Circuit Failure, Outlet Solenoid Circuit Failure, Master Cylinder Cut Solenoid Circuit Failure, Low Pressure Solenoid Circuit Failure S5JB0E4504022 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit Failure...
Page 247 ABS: 4E-24 [A]: With ESP® 1. Battery 5. Solenoid valve [B]: Without ESP® 2. Main fuse box 6. Solenoid valve power supply driver (transistor) [C]: ESP® control module connector (viewed from terminal 3. ESP® hydraulic unit / control module 7. Solenoid valve driver side) assembly [D]: ABS control module connector (viewed from terminal...
Page 248 4E-25 ABS: DTC Detecting Condition The ABS (ESP®) control module monitors the power source voltage at terminal “E03-14” (or “E53-1”). When the power source voltage becomes extremely high or low while vehicle is running at more than 20 km/h (13 MPH), this DTC will be set.
Page 249 ABS: 4E-26 DTC C1061: Pump Motor and/or Motor Driver Circuit S5JB0E4504017 Wiring Diagram WHT/BLU E53-32 WHT/BLU E03-1 E53-16 E03-13 E53-47 E03-26 I6JB01450010-01 [A]: With ESP® 1. Battery 5. ESP® hydraulic unit / control module assembly [B]: Without ESP® 2. Main fuse box 6.
Page 250 4E-27 ABS: DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure S5JB0E4504018 Wiring Diagram WHT/GRN BLK/YEL GRN/ORN E53-35 GRN/ORN E03-7 WHT/RED E53-1 WHT/RED E03-14 I6JB01450011-02 [A]: With ESP® 2. Main fuse box 7. Power control unit [B]: Without ESP® 3. Ignition switch 8.
Page 251 ABS: 4E-28 Step Action Check main fuse for ABS solenoid and its terminal. Go to Step 4. Replace fuse and check for short circuit to Is it in good condition? ground. 1) Turn ignition switch to OFF position. Substitute a known- “WHT/BLU”...
Page 252 4E-29 ABS: DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check: ”. Clear all DTCs and check DTC. Go to Step 3. Could be a temporary malfunction of the ABS Is it DTC C1071? (ESP®) control module.
Page 253 ABS: 4E-30 DTC U1073: Control Module Communication Bus Off S5JB0E4504020 Wiring Diagram E53-13 E03-12 E91-22 E53-44 E03-6 E91-23 E53-42 WHT/RED E03-10 WHT/RED E53-46 WHT/BLU E03-8 WHT/BLU G44-19 E23-19 WHT/BLU G44-18 E23-4 WHT/RED G28-10 E92-17 G28-8 E92-7 G31-1 G45-9 G31-3 G45-10 G31-4 G31-2 3938...
Page 254 4E-31 ABS: DTC Detecting Condition Transmission error that is inconsistent between transmission data and transmission monitor (CAN bus monitor) data is detected more than 7 times continuously. DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check: ”. 1) Check connection of connectors of all control modules Go to Step 3.
Page 255 ABS: 4E-32 DTC U1100: Lost Communication with ECM (Reception Error) S5JB0E4504021 Wiring Diagram Refer to “DTC U1073: Control Module Communication Bus Off: ”. DTC Detecting Condition Reception error of communication data for ECM is detected more than specified time continuously. DTC Troubleshooting Step Action...
Page 256 Step on brake pedal (1) and then select testing 2) Check that battery voltage is 11 V or higher. wheel by SUZUKI scan tool and the wheel (2) should be turned by another person’s hand. At this 3) Lift up vehicle.
Page 257 ABS: 4E-34 ABS (ESP®) Hydraulic Unit / Control Module Assembly Removal and Installation S5JB0E4506004 CAUTION Never disassemble ABS (ESP®) hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS (ESP®) hydraulic unit / control module assembly.
Page 258 4E-35 ABS: Removal 6) Remove ABS (ESP®) hydraulic unit / control module with bracket from vehicle by removing bracket bolt 1) Disconnect negative (–) cable from battery. and two bracket nuts. 2) Remove ECM referring to “Engine Control Module 7) Remove bolt and pull out ABS (ESP®) hydraulic unit (ECM) Removal and Installation: in Section 1C in / control module assembly (1) from bracket (3) using related manual”.
Page 259 ABS: 4E-36 2) Connect ABS (ESP®) control module connector and Front Wheel Speed Sensor On-Vehicle lock it as shown in figure. Inspection S5JB0E4506005 Output Voltage Inspection 1) Disconnect negative (–) cable from battery. 2) Hoist vehicle a little. 3) Disconnect wheel speed sensor connector. 4) Disconnect wheel speed grommet from vehicle body.
Page 260 4E-37 ABS: 7) Measure voltage at resistance with wheel rotation Front Wheel Speed Sensor Removal and and confirm voltage alternately changes between Installation high and low voltages. S5JB0E4506006 If voltage does not change with wheel rotation, check Removal sensor, mating encoder and their installation 1) Disconnect negative (–) cable from battery.
Page 261 ABS: 4E-38 3) Check that there is no clearance between sensor Rear Wheel Speed Sensor Removal and and knuckle. Installation S5JB0E4506009 Removal 1) Disconnect negative (–) cable from battery. 2) Disconnect rear wheel speed sensor coupler (1). 3) Hoist vehicle and remove wheel. 4) Remove harness clamp (4) and clamp bolts (2).
Page 262 4E-39 ABS: • Check that there is no clearance between sensor and brake back plate. I5JB0A450034-01 Front Wheel Encoder Removal and Installation S5JB0E4506012 CAUTION Front wheel encoder is included in front wheel hub assembly. If front wheel encoder needs to replaced, replace it as a front wheel hub assembly.
Page 263 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A in related manual”. Special Tools and Equipment Special Tool S5JB0E4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 264 Therefore, be sure to read “Precautions for Installing SUZUKI scan tool. Before using scan tool, read its Mobile Communication Equipment: in Section 00 in Operator’s (Instruction) Manual carefully to have good related manual”...
Page 265 There are two ways to stop the ESP® function completely as described bellow. • Connect the SUZUKI scan tool, set to the “MISC. TEST” mode to stop the ESP® function. Refer to SUZUKI scan tool operator's manual for further details.
Page 266 4F-3 Electronic Stability Program: • When no abnormality is detected (the system is in good condition), ABS warning lamp, EBD warning lamp, ESP® warning lamp, SLIP indicator lamp and ESP® OFF lamp turn OFF after 2 seconds. • When an abnormality in the system is detected, some of ABS warning lamp, EBD warning lamp (brake warning lamp), ESP®...
Page 267 Electronic Stability Program: 4F-4 Warning lamp / Indicator lamp Condition and operation ESP® OFF lamp • If ESP® OFF switch is turned “ON”, the ESP® OFF lamp light up. When it is “ON”, TCS and stability control system functions are controlled not to work. However, when the speed is over 30 km/h (18.5 mph), ESP®...
Page 268 4F-5 Electronic Stability Program: CAN Communication System For Electronic Stability Program Description S5JB0E4601005 There is CAN communication system only for ESP® control module (1) and yaw rate / G sensor assembly (2). This CAN communication system is independent from other control modules. I6JB01460006-01 ESP®...
Page 269 Electronic Stability Program: 4F-6 Schematic and Routing Diagram Electronic Stability Program Schematic S5JB0E4602001 INPUT OUTPUT ESP® hydraulic unit/control module assembly Hydraulic unit Master cylinder pressure sensor ESP® control module Pump motor driver Pump motor (transistor) Solenoid valve power supply driver (transistor) Battery Voltage Ignition Voltage LF inlet solenoid valve...
Page 270 4F-7 Electronic Stability Program: Electronic Stability Program Wiring Circuit Diagram S5JB0E4602002 WHT/BLU WHT/RED WHT/GRN BLK/YEL GRN/ORN E53-35 G45-3 E53-10 G45-1 GRN/ORN G45-9 G45-2 PPL/RED E53-7 BLU/WHT G45-10 E53-16 E53-47 G28-8 G28-10 WHT/RED WHT/BLU E53-1 E53-32 G31-1 E53-13 E53-44 G31-3 RED/BLK G31-7 RED/BLK G31-8...
Page 271 Electronic Stability Program: 4F-8 5. Steering angle sensor 19. BCM 33. ESP® OFF switch 6. CAN driver 20. Brake fluid level switch 34. Power control unit 7. Combination meter 21. Parking brake switch 35. Internal memory 8. SLIP indicator lamp 22.
Page 272 4F-9 Electronic Stability Program: Component Location Electronic Stability Program Component Location S5JB0E4603001 I6JB01460010-03 1. ESP® warning lamp 7. ESP® OFF switch 13. Yaw rate / G sensor assembly 2. EBD warning lamp (brake warning lamp) 8. Rear wheel speed sensor 14.
Page 273 Electronic Stability Program: 4F-10 Diagnostic Information and Procedures Electronic Stability Program Check S5JB0E4604001 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”.
Page 274 4F-11 Electronic Stability Program: Customer questionnaire (Example) I6JB01460011-02 Problem symptom confirmation If symptom in “Customer Questionnaire” is found or reproduced in the vehicle, confirm the symptom is problem or not. (This step should be done with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check: in Section 4E”, “ABS Warning Lamp Check: in Section 4E”...
Page 275 Warning Lamp Does Not Come ON at Ignition Switch S5JB0E4604004 ON: ” or “ESP® Warning Lamp Comes ON Steady: ”. 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (1). Special tool (A): SUZUKI scan tool...
Page 276 4) Read DTC according to instructions displayed on If SUZUKI scan tool can not communicate SUZUKI scan tool and print it or write it down. Refer ESP® control module, perform “Serial Data to SUZUKI scan tool operator’s manual for further Link Circuit Check: ”.
Page 277 Electronic Stability Program: 4F-14 ESP® (displayed Detecting condition (DTC will be Diagnostic Items warning warning warning on SUZUKI set when detecting) lamp lamp lamp scan tool) ESP® OFF switch circuit Mechanical switch failure, failure in — — — C1027 failure switch wiring is shorted to ground.
Page 278 4F-15 Electronic Stability Program: ESP® (displayed Detecting condition (DTC will be Diagnostic Items warning warning warning on SUZUKI set when detecting) lamp lamp lamp scan tool) ESP® (ABS) control ESP® (ABS) control module internal C1071 module internal defect defect is detected.
Page 279 After repair or replace malfunction part(s), clear all DTCs by performing the following procedure or using SUZUKI scan tool. 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check.
Page 280 4F-17 Electronic Stability Program: Fail-Safe Table S5JB0E4604023 When any of the following DTC(s) is detected, ESP® system is in fail-safe mode per its DTC and ABS, EBD and/or TCS / stability functions are deactivated until the resolution is applied. Fail-safe operation DTC No.
Page 281 Electronic Stability Program: 4F-18 Fail-safe operation DTC No. TCS / Fail-safe condition resolutive stability C1041 C1042 C1043 C1044 C1045 C1046 When ESP® control module detects the system as normal, after ignition switch turned OFF to ON. C1051 C1052 C1053 C1054 C1055 C1056 C1050...
Page 282 4F-19 Electronic Stability Program: Fail-safe operation DTC No. TCS / Fail-safe condition resolutive stability C1090 C1091 C1092 C1093 U1073 When ESP® control module detects the system as normal, after ignition switch turned OFF to ON. U1100 U1101 U1126 U1139 U1140 NOTE •...
Page 283 Electronic Stability Program: 4F-20 Scan Tool Data S5JB0E4604024 The parameter data below are values measured with the scan tool when the normally operating vehicle is under the following conditions. When taking measurements for comparison by using the scan tool, be sure to check that the vehicle is under the following conditions.
Page 284 4F-21 Electronic Stability Program: ESP® Warning Lamp Does Not Come ON at Ignition Switch ON S5JB0E4604008 Wiring Diagram WHT/BLU E53-32 WHT/RED E53-1 E53-35 WHT/GRN BLK/YEL GRN/ORN PPL/RED E53-13 E53-44 E53-16 E53-47 I6JB01460013-01 [A]: ESP® control module connector (viewed from terminal side) 4.
Page 285 Electronic Stability Program: 4F-22 Step Action 1) Remove combination meter with ignition switch turned Go to Step 6. Repair power supply OFF. circuit for combination meter. 2) Check for proper connection to “PPL/RED” and “BLK” wire of combination meter connector. 3) If OK, turn ON ignition switch and measure voltage at “PPL/RED”...
Page 286 4F-23 Electronic Stability Program: Step Action 1) Check CAN communication circuit between combination Substitute a known- Repair or replace. meter and ESP® control module referring to “DTC good combination meter U1073: Control Module Communication Bus Off: ”. and recheck. If ABS warning lamp remains Is CAN communication circuit in good condition? ON, substitute a known-...
Page 287 Electronic Stability Program: 4F-24 Step Action 1) Turn ignition switch to OFF position. Go to Step 5. “WHT/RED” and/or “WHT/BLU” wire circuit 2) Check for proper connection to ESP® control module open. connector at terminals “E53-1” and “E53-32”. 3) If OK then turn ignition switch to ON position and measure voltage between each terminal of “E53-1”, “E53-32”...
Page 288 4F-25 Electronic Stability Program: DTC C1015 / C1017 / C1023: Longitudinal G Sensor / Lateral G Sensor / Yaw Rate Sensor in Yaw Rate / G Sensor Assembly Failure S5JB0E4604025 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area C1015: •...
Page 289 Electronic Stability Program: 4F-26 [A]: ESP® control module connector (viewed from terminal side) 3. Junction block assembly 7. CAN driver [B]: ECM connector (viewed from harness side) 4. Stop lamp switch 8. ESP® hydraulic unit control module assembly 1. Battery 5.
Page 290 4F-27 Electronic Stability Program: DTC C1018: Brake Fluid Level Switch Failure S5JB0E4604027 Wiring Diagram G31-1 E53-13 G31-3 E53-44 G31-7 RED/BLK 18 17 13 12 39 38 28 27 24 23 I6JB01460017-02 [A]: ESP® control module connector (viewed from terminal side) 2.
Page 291 Electronic Stability Program: 4F-28 Step Action Check brake fluid level switch circuit Go to Step 6. “BLKL/RED” wire circuit is shorted to ground. 1) Disconnect BCM connector. 2) Check for proper connection to BCM connector at “G31- 7” terminal. 3) If OK, then check resistance between “G31-7” terminal and vehicle body ground.
Page 292 4F-29 Electronic Stability Program: Step Action Check sensor calibration Go to Step 4. Steering angle sensor calibration was 1) Calibrate steering angle sensor referring to “Sensor incompleted. Calibration: ”. 2) Clear all DTC(s) and check DTC for ESP®. Is DTC C1024 still detected? Check steering angle sensor Substitute a known- Replace steering angle...
Page 293 Electronic Stability Program: 4F-30 Step Action Check ESP® OFF switch Go to Step 4. Replace ESP® OFF switch. 1) Turn ignition switch to OFF position. 2) Remove ESP® OFF switch referring to “ESP® OFF Switch Removal and Installation: ”. 3) Check for proper connection at each terminal of ESP® OFF switch.
Page 294 4F-31 Electronic Stability Program: DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure S5JB0E4604032 Wiring Diagram WHT/BLU E53-32 WHT/RED E53-1 BLK/YEL E53-35 WHT/GRN L39-2 E53-29 L39-1 E53-25 L39-3 PNK/WHT E53-37 L39-5 PNK/GRN E53-31 E53-16 E53-47 I6JB01460019-03 [A]: ESP® control module connector (viewed from terminal side) 2.
Page 295 Electronic Stability Program: 4F-32 Step Action Check yaw rate / G sensor assembly power supply Substitute a known- Go to Step 5. circuit good yaw rate / G sensor assembly and 1) Measure voltage between connector terminal “L39-3” recheck. and “L39-5” with ignition switch turned ON. Is it 10 –...
Page 296 4F-33 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2 Go to “Electronic Stability Program Check: ”. Check steering angle sensor power supply circuit Go to Step 3. Replace fuse and check for short circuit to 1) Check circuit fuses for steering angle sensor and its ground.
Page 297 Electronic Stability Program: 4F-34 Step Action Check ESP® control module Substitute a known- Steering angle sensor good ESP® hydraulic was malfunction. 1) Turn ignition switch to OFF position. unit / control module 2) Substitute a known-good steering angle sensor. assembly and recheck. 3) Calibrate steering angle sensors referring to “Sensor Calibration: ”.
Page 298 4F-35 Electronic Stability Program: DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet Solenoid Circuit Failure, Outlet Solenoid Circuit Failure, Master Cylinder Cut Solenoid Circuit Failure, Low Pressure Solenoid Circuit Failure S5JB0E4604015 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid...
Page 299 Electronic Stability Program: 4F-36 Step Action Check back up light switch circuit Go to Step 4. “RED” wire circuit is shorted to power circuit. 1) Turn ignition switch to OFF position. 2) Disconnect ESP® control module connector. 3) Check for proper connection to ESP® control module connector terminal at “E53-10”.
Page 300 4F-37 Electronic Stability Program: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area CAN line communication error in ESP® control module • CAN communication circuit (for yaw rate / G sensor and yaw rate / G sensor assembly is detected. assembly) •...
Page 301 Electronic Stability Program: 4F-38 DTC Detecting Condition Trouble Area C1078: • Yaw rate / G sensor assembly Lateral G sensor in yaw rate / G sensor assembly • Lateral G sensor calibration is incompleted calibration is incompleted. • ESP® control module DTC Troubleshooting Step Action...
Page 302 4F-39 Electronic Stability Program: DTC C1091 / 1092 / 1093: ECM / TCM / 4WD Control Module Data in CAN Line Failure S5JB0E4604041 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area C1091: • Engine control system ECM sent invalid signal to ESP® control module. •...
Page 303 Electronic Stability Program: 4F-40 DTC U1101: Lost Communication with TCM (Reception Error) S5JB0E4604042 Wiring Diagram E53-13 E91-22 E53-44 E91-23 E53-42 WHT/RED E53-46 WHT/BLU G44-19 E23-19 WHT/BLU G44-18 E23-4 WHT/RED G28-10 E92-17 G28-8 E92-7 G45-9 G31-1 G45-10 G31-3 G31-4 G31-2 34 33 32 31 30 29 24 23 16 15 14 13 12 11 10 9...
Page 304 4F-41 Electronic Stability Program: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area TCM message data is missing from CAN communication. • CAN communication circuit (for A/T model) • TCM • ESP® control module DTC Troubleshooting Step Action Was “Electronic Stability Program Check”...
Page 305 Electronic Stability Program: 4F-42 DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error) S5JB0E4604043 Wiring Diagram Refer to “DTC U1101: Lost Communication with TCM (Reception Error): ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Steering angle sensor message data is missing from CAN •...
Page 306 4F-43 Electronic Stability Program: DTC U1139: Lost Communication with 4WD Control Module (Reception Error) S5JB0E4604044 Wiring Diagram Refer to “DTC U1101: Lost Communication with TCM (Reception Error): ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area 4WD control module message data is missing from CAN •...
Page 307 Electronic Stability Program: 4F-44 Step Action DTC check for ESP® Check ESP® control Check applicable module power and control module power 1) Connect connectors of disconnected control modules ground circuit. If circuits and ground circuit. If communicating by means of CAN. are OK, substitute a circuit is OK, substitute 2) Disconnect each connector.
Page 308 Sensor Calibration (Using SUZUKI Scan Tool) S5JB0E4606001 1) Set steering wheel in straight-ahead position. Refer to “Hydraulic Unit Operation Check: in Section 2) Connect SUZUKI scan tool to data link connector 4E”. (DLC) (1) with ignition switch OFF. Sensor Calibration...
Page 309 Inspection 5) Select menu “SENSOR CALIBRATION” under S5JB0E4606005 Refer to “Front Wheel Speed Sensor On-Vehicle “MISC. TEST” mode of SUZUKI scan tool and Inspection: in Section 4E”. calibrate sensor. Refer to scan tool operator's manual for further derails. Front Wheel Speed Sensor Removal and...
Page 310 , 1422 psi), check “Master Cyl Press” under “DATA LIST” of SUZUKI scan tool. Inspection S5JB0E4606016 If pressure displayed on SUZUKI scan tool is out of 1) Calibrate yaw rate / G sensor assembly referring to specification, replace ESP® hydraulic unit / control “Sensor Calibration: ”.
Page 311 2) Park and level the vehicle with parking brake and fix “a” wheels with chokes. 3) Check yaw rate / G sensor assembly installation condition. 4) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool “a”...
Page 312 4F-49 Electronic Stability Program: 5) Turn ignition switch to ON position and select menu Yaw Rate Inspection “DATA LIST” mode of SUZUKI scan tool. Refer to 1) Calibrate yaw rate / G sensor assembly referring to scan tool operator's manual for further derails.
Page 313 CAUTION • When yaw rate / G sensor assembly is replaced, ESP® control module needs zero calibration. Perform zero calibration by SUZUKI scan tool referring to “Sensor Calibration: ”. • Regarding yaw rate / G sensor assembly removal/installation, confirm specified torque and never use impact wrench to avoid damage.
Page 314 If calibration is incompleted, calibrate sensor S5JB0E4606021 Refer to “Steering Angle Sensor Removal and referring to “Sensor Calibration: ”. Installation: in Section 6B”. 1) Connect SUZUKI scan tool to data link connector Steering Angle Sensor Inspection (DLC) (1) with ignition switch OFF. S5JB0E4606022 Special tool •...
Page 315 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A in related manual”. Special Tools and Equipment Special Tool S5JB0E4608001 09956–02311 SUZUKI scan tool Brake pressure gauge — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 316 4F-53 Electronic Stability Program:...
Page 317 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........5-* Line Pressure Test ..........
Page 318 5-ii Table of Contents Solenoid Valves (Shift Solenoid-A, Shift DTC P0974 / P0977 Shift Solenoid “A” Control Circuit High / Shift Solenoid “B” Solenoid-B, TCC Pressure Control Control Circuit High ........... 5A-* Solenoid and Pressure Control Solenoid DTC P1702 Internal Control Module Inspection............
Page 319 Table of Contents 5-iii Specifications ............5B-* Gear Shift Lever Front Case Assembly Components............5B-* Tightening Torque Specifications......5B-* Gear Shift Shaft and Fork Components ....5B-* Special Tools and Equipment ......5B-* Input Shaft Assembly, Output Shaft Recommended Service Material ......5B-* Assembly and Countershaft Assembly Special Tool ............
Page 320 DTCs are outputted, all DTCs are outputted diagnostic information stored in TCM memory can be repeatedly. cleared as well as checked by using SUZUKI scan tool or OBD generic scan tool. Before using scan tool, • Be sure to read “Precautions for Electrical Circuit read its Operator’s (Instruction) Manual carefully to...
Page 321 Automatic Transmission/Transaxle: 5A-2 General Description Automatic Transmission Description S5JB0E5101001 This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up mechanism.
Page 322 One-way clutch ... 3 sets Transfer (4WD model only) Hi: 1.000 Lo: 1.970 Final gear reduction ratio 5.125 Lubrication Lubrication system Forced feed system by oil pump Cooling Cooling system Radiator assisted cooling (water-cooled) Fluid used SUZUKI ATF 3317 or Mobil ATF 3309...
Page 323 Automatic Transmission/Transaxle: 5A-4 CAN Communication System Description S5JB0E5101004 Refer to “CAN Communication System Description: in Section 1A” for CAN communication system description. TCM communicates control data with each control module as follows. TCM Transmission Data Combination 4WD control Meter module (if equipped) Torque reduction request Slip control signal Transmission malfunction...
Page 324 5A-5 Automatic Transmission/Transaxle: Electronic Shift Control Input / Output Table S5JB0E5101005 OUTPUT INPUT -Accelerator pedal position -Torque red. request -Coolant temperature -Slip control signal (*1) Gear shift control -Engine torque -Shift position signal -Engine speed -A/C ON/OFF 4th gear inhibit control -Brake light switch -Vehicle speed -Cruise control signal...
Page 325 Automatic Transmission/Transaxle: 5A-6 CONTROL INPUT / OUTPUT Accelerator effective position Throttle position Coolant temperature Engine torque Engine speed A/C ON/OFF Brake light switch Vehicle speed Cruise control signal (if equipped with cruise control system) P/N mode switch "3" position switch Input shaft speed sensor Output shaft speed sensor ATF temperature sensor...
Page 326 5A-7 Automatic Transmission/Transaxle: Electronic Shift Control System Wiring Diagram E93-5 E93-14 2.5V YEL/BLK E92-11 E93-6 E92-12 E93-16 2.5V E92-16 E92-15 GRN/RED GRN/YEL E92-5 E92-3 PPL/WHT E92-4 YEL/RED E92-7 E92-2 BRN/RED E92-17 E93-12 PNK/BLK E93-23 PPL/WHT E92-24 YEL/RED E92-20 YEL/BLK E92-10 E92-6 BLK/WHT E93-20...
Page 327 Automatic Transmission/Transaxle: 5A-8 Schematic and Routing Diagram Automatic Gear Shift Table S5JB0E5102001 Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D position. Normal Mode 1. Shift Point in D position and normal mode Vehicle speed km/h Throttle opening (%) Shift...
Page 328 5A-9 Automatic Transmission/Transaxle: Power Mode 1. Shift Point in D position and power mode Vehicle speed km/h Throttle opening (%) Shift (mph) Remark 1st → 2nd 50 – 55 (31 – 34) 2nd → 3rd 99 – 104 (62 – 65) 3rd →...
Page 329 Automatic Transmission/Transaxle: 5A-10 NOTE *1: For vehicle not equipped with engine diagnosis connector model (Except RH steering vehicle not equipped with rear fog light model) The gear change is done at the shift point different from the above while any of the following control functions is working.
Page 330 5A-11 Automatic Transmission/Transaxle: Component Location Electronic Shift Control System Components Location S5JB0E5103001 I5JB0A510014-02...
Page 331 Automatic Transmission/Transaxle: 5A-12 1. Engine 6. Transmission warning light (vehicle is 11. 4L/N low switch (if equipped) 16. Shift solenoid valve-B equipped with engine diagnosis connector) 2. Transmission 7. MIL (vehicle is not equipped with engine 12. Pressure control solenoid valve 17.
Page 332 Confirmation available table of automatic transmission related DTC is shown below. Vehicle is not equipped with engine Vehicle is equipped with engine diagnosis connector diagnosis connector SUZUKI scan tool Generic scan tool Not using scan tool (if equipped with A/T monitor connector) : Available-DTC can be confirmed...
Page 333 Automatic Transmission/Transaxle: 5A-14 Detecting condition (DTC will set when Detecting item detecting) P097 Shift Solenoid “A” Control Circuit Voltage of shift solenoid terminal is high although 1driving 1driving High TCM is commanding shift solenoid to turn OFF. cycle cycle P097 Shift Solenoid “B”...
Page 334 5A-15 Automatic Transmission/Transaxle: Trouble Area Fail Safe Operation Transmission Range Sensor Circuit Low • Range is assumed to be “D” range. • Slip controlled lock-up function is inhibited to operate. • Reverse control is inhibited. • Cruise control function is inhibited to operate. (if equipped with cruise control system) •...
Page 335 Automatic Transmission/Transaxle: 5A-16 Trouble Area Fail Safe Operation CAN Invalid Data- TCM In case of throttle position signal malfunction: • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be •...
Page 336 5A-17 Automatic Transmission/Transaxle: Scan Tool Data S5JB0E5104009 As the data values given in the following table are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference value. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 337 Automatic Transmission/Transaxle: 5A-18 Scan Tool Data Vehicle Condition Normal Condition / Reference Values Trans Range Ignition switch ON Select lever is in “P” position Select lever is in “R” position Select lever is in “N” position Select lever is in “D” position Select lever is in “3”...
Page 338 5A-19 Automatic Transmission/Transaxle: Engine Speed (RPM): Engine speed computed by Shift Sol B Con / MON (ON, OFF): COM-ON: ON signal on CAN communication line fed from ECM. command being outputted to shift solenoid-B. Coolant Temp (°C): Engine coolant temperature COM-OFF: OFF command not being outputted to detected by signal on CAN communication line fed shift solenoid-B.
Page 339 Automatic Transmission/Transaxle: 5A-20 No Gear Shift to 4th Gear S5JB0E5104020 System Description TCM does not shift to 4th gear under any of the following condition. • “3” position switch signal is inputted. • 4L/N switch (if equipped) is turned ON. (4L or N mode) •...
Page 340 5A-21 Automatic Transmission/Transaxle: No Lock-Up Occurs S5JB0E5104021 System Description TCM turns TCC pressure control solenoid OFF under any of the following conditions. • Engine coolant temperature is lower than 60 °C (140 °F). • 4L/N switch (if equipped) is turned ON. (4L or N mode) •...
Page 341 Automatic Transmission/Transaxle: 5A-22 DTC P1774: CAN Communication Bus Off S5JB0E5104041 Wiring Diagram WHT/RED E23-4 WHT/BLU E23-19 G31-4 G31-2 G31-1 G31-3 E53-46 E03-8 WHT/BLU E53-42 E03-10 WHT/RED E91-22 E53-13 E03-12 E91-23 E53-44 E03-6 G28-10 E92-17 E92-7 G28-8 G44-19 G44-18 RED G45-9 G45-10 34 33 32 30 29...
Page 342 5A-23 Automatic Transmission/Transaxle: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Transmission error that is inconsistent between transmission data • ECM and transmission monitor (CAN bus monitor) data is detected more • TCM than 7 times continuously. •...
Page 343 Automatic Transmission/Transaxle: 5A-24 Step Action DTC check Disconnect connectors Check power and of control modules other ground circuit of control 1) Turn ignition switch to OFF position. than the one whose module disconnected in 2) Connect connectors of disconnected control modules connector is Step3).
Page 344 5A-25 Automatic Transmission/Transaxle: DTC Troubleshooting NOTE Upon completion of inspection and repair work, perform “DTC Confirmation Procedure: ” and confirm that the trouble has been corrected. Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: in related manual”.
Page 345 C1026, C1031, C1032, C1035 and/or C1036 in ABS/ESP control module? Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: in related manual”. Do you have SUZUKI scan tool? Go to Step 4. Go to Step 5.
Page 346 Action 4L switch and its circuit check Intermittent trouble or Go to Step 6. faulty TCM. Check for 1) Connect SUZUKI scan tool to DLC with ignition switch intermittent trouble OFF. referring to “Intermittent 2) Turn ignition switch ON. and Poor Connection 3) Select “DATA LIST”...
Page 347 Go to Step 5. 4L switch and its circuit check Intermittent trouble or Go to Step 6. faulty TCM. Check for 1) Connect SUZUKI scan tool to DLC with ignition switch intermittent trouble OFF. referring to “Intermittent 2) Turn ignition switch ON.
Page 348 5A-29 Automatic Transmission/Transaxle: Inspection of TCM and Its Circuits S5JB0E5104049 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance. CAUTION TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it.
Page 349 Automatic Transmission/Transaxle: 5A-30 Connector “E92” Standard Terminal Wire color Circuit Condition voltage BLK/ORN Ground 0 – 1 V Ignition switch ON Pressure control BRN/RED 0.6 – 1.0 V Ignition switch ON solenoid valve (–) TCC pressure control PPL/WHT 0.6 – 1.0 V Ignition switch ON solenoid valve (–) *0 –...
Page 350 5A-31 Automatic Transmission/Transaxle: Connector “E93” Standard Terminal Wire color Circuit Condition voltage 8 – 14 V Ignition switch ON, selector lever at “R” range Transmission range Ignition switch ON, selector lever at other than “R” sensor (“R” range) 0 – 1 V range —...
Page 351 Automatic Transmission/Transaxle: 5A-32 Reference Waveform No. 1 Reference Waveform No. 3 Pressure control solenoid valve signal at engine idling. CAN communication line (High & Low) signal at engine idling. Measurement CH1: “E92-4” to “E92-1” terminal Measurement CH1: “E92-7” to “E92-1” Oscilloscope CH1: 5 V/DIV terminal...
Page 352 5A-33 Automatic Transmission/Transaxle: Reference Waveform No. 5 Input shaft speed sensor signal at engine speed 3000 rpm. Measurement CH1: “E93-6” to “E92-1” terminal Oscilloscope CH1: 2 V/DIV setting TIME: 10 ms/DIV • After warmed up to normal operating temperature Measurement condition •...
Page 353 Automatic Transmission/Transaxle: 5A-34 Repair Instructions Automatic Transmission Unit Components S5JB0E5106027 I5JB0D510006-01 [A]: View A 8. Drive plate cover 16. Oil filler tube bolt 24. Engine earth cable bolt 1. Torque converter mounting bolt No.1 9. Engine to transmission bolt 17. Oil filler tube : 65 N⋅m (6.5 kgf-m, 47.0 : After tightening torque converter lb-ft)
Page 354 5A-35 Automatic Transmission/Transaxle: Automatic Transmission Unit Assembly 3) Measure free length of reverse brake piston return S5JB0E5106052 spring. CAUTION Standard free length of reverse brake piston return spring When replacing pressure control solenoid 16.84 mm (0.663 in.) valve and/or TCC pressure control solenoid valve, it is strictly required to replace it 4) Install reverse brake piston assembly and brake together with valve body assembly as a set.
Page 355 Automatic Transmission/Transaxle: 5A-36 6) Install thrust bearing (1) and thrust bearing race (2) 9) Remove reverse brake reaction plate of planetary after lubricating them with grease. gear assembly and align lugs of reverse brake plate, reverse brake disc and reverse brake backing plate. NOTE Install planetary gear assembly to transmission case Make sure that thrust bearing output shaft...
Page 356 5A-37 Automatic Transmission/Transaxle: 13) After confirming that lugs of all brake plates and brake discs are in grooves securely, hold retaining ring (1) of planetary sun gear, install center support assembly by aligning bolt holes (2) in center support and transmission case. NOTE Unless retaining ring of planetary sun gear is held, brake valve gets off center support and...
Page 357 Automatic Transmission/Transaxle: 5A-38 15) Install direct clutch assembly by aligning splines in 18) When clutch disc and plate have been replaced, direct clutch cylinder with planetary sun gear. check height difference between forward clutch input shaft and transmission case (1) by measuring as NOTE shown in the figure.
Page 358 5A-39 Automatic Transmission/Transaxle: 21) Apply grease to thrust washers (1) and install them 23) Apply A/T fluid to new housing O-ring and install it to to O/D planetary gear (2) and planetary ring gear (3), O/D case. Then install converter housing (1) and and then install O/D input shaft assembly to O/D tighten housing bolt to specified torque.
Page 359 Automatic Transmission/Transaxle: 5A-40 26) Apply 2 – 4 kg/cm air pressure into fluid holes in the 29) Check that inner shaft runs smoothly. figure as numbered and check operation sound of 30) Apply grease to lip of new oil lip seal and drive in oil each part.
Page 360 5A-41 Automatic Transmission/Transaxle: 35) Install parking lock pawl (2), parking pawl pin (1) and 38) Apply A/T fluid to new O-ring and spring and install parking pawl spring (3). them to accumulator piston and install accumulator piston to transmission case. Accumulator spring specification Accumulator spring Accumulator...
Page 361 Automatic Transmission/Transaxle: 5A-42 40) Fix valve body (1) by using bolts with each nominal 43) Connect solenoid coupler to each solenoid. length as indicated in the figure and tightening to 44) Install oil strainer (1) to valve body assembly. specified torque. Tightening torque Tightening torque Oil strainer bolt (a): 5.5 N·m (0.55 kgf-m, 4.0 lb-...
Page 362 5A-43 Automatic Transmission/Transaxle: 47) Install adapter case (1) with new adapter gasket to 50) With neutral reference line (1) and cut groove (2) in transmission case and tighten adapter case bolts to switch aligned, tighten lock bolt. specified torque. Tightening torque Tightening torque Transmission range sensor bolt (b): 5.3 N·m ( Adapter case bolt (a): 31 N·m (3.1 kgf-m, 30.0 lb-...
Page 363 Automatic Transmission/Transaxle: 5A-44 Specifications Tightening Torque Specifications S5JB0E5107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Center support bolt 19.0 Torque converter housing bolt 25.5 Torque converter housing bolt 42.0 Oil pump bolt 16.0 Parking pawl bracket bolt 0.74 Valve body bolt Transmission wire connector bolt 11.5 Oil strainer bolt...
Page 364 5A-45 Automatic Transmission/Transaxle:...
Page 365 Table of Contents 6- i Section 6 Steering CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........6-* Steering Lock Assembly (Ignition Switch) Removal and Installation........
Page 366 6-ii Table of Contents P/S Fluid Leakage Check........6C-* Steering Gear Case Mount Bushing P/S System Air Bleeding Procedure ....6C-* Inspection............6C-* P/S Pump and A/C Compressor (If Rack Boot / Tie-Rod Removal and Equipped) Drive Belt Inspection and Installation ............
Page 367 Steering Wheel and Column: 6B-1 Steering Wheel and Column Precautions Service Precautions of Steering Angle Sensor S5JB0E6200004 For service precautions, refer to “Precautions in Sensor Calibration: in Section 4F”. General Description Steering Wheel and Column Construction S5JB0E6201001 This double tube type steering column has the following three important features in addition to the steering function: •...
Page 368 6B-2 Steering Wheel and Column: I6JB01620001-01 1. Steering wheel 9. Steering column lower seal 17. Steering lower shaft assembly upper joint bolt : After tightening all mounting bolts and nuts and all joint bolts and nuts, tighten lower shaft lower joint bolt. 2.
Page 369 Steering Wheel and Column: 6B-3 Repair Instructions Contact Coil Cable Assembly Removal and 5) Disconnect all connectors for contact coil cable assembly. Installation S5JB0E6206003 6) Remove contact coil cable assembly (1) with steering angle sensor (if equipped) from steering CAUTION column.
Page 370 6B-4 Steering Wheel and Column: 3) Connect all connectors that have been removed in Steering Angle Sensor Removal and Installation S5JB0E6206014 “Removal”. 4) Install steering column upper cover (2) and lower Removal cover (3), and then tighten steering column cover 1) Remove steering wheel and contact coil cable screws (1).
Page 371 Steering Wheel and Column: 6B-5 Specifications Tightening Torque Specifications S5JB0E6207001 NOTE The specified tightening torque is also described in the following. “Steering Wheel and Column Construction: ” Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A in related manual”.
Page 372 6B-6 Steering Wheel and Column:...
Page 373 Table of Contents 7- i Section 7 HVAC CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........7-* HVAC Control Module and Its Circuits Inspection (for Vehicle without A/C) ....
Page 374 7-ii Table of Contents DTC B1563: A/C Refrigerant Pressure Schematic and Routing Diagram......7B-2 A/C System Wiring Circuit Diagram ....7B-2 Sensor and/or Its Circuit Malfunction ....7B-* HVAC Control Module and Its Circuits Component Location ........... 7B-* Inspection............7B-* Major Components of A/C System...... 7B-* A/C System Inspection at ECM ......7B-4 A/C Control System Components Location..
Page 375 Table of Contents 7-iii Magnet Clutch Components for M16 Engine Thermal Switch Removal and Installation Model ..............7B-* for M16 Engine Model ........7B-* Magnet Clutch Components for J20 Engine Relief Valve On-Vehicle Inspection for M16 Model ..............7B-* Engine Model ..........7B-10 Magnet Clutch Operating Check for M16 Relief Valve On-Vehicle Inspection For J20 Engine Model .............7B-*...
Page 376 7A-1 Heater and Ventilation: Heater and Ventilation Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S5JB0E7102001 Refer to “A/C System Wiring Circuit Diagram: in Section 7B”.
Page 377 Air Conditioning System: 7B-1 Air Conditioning System General Description Auto A/C Electronic Control Input / Output Table S5JB0E7201003 HVAC control module Temperature selector Data link connector MODE (air flow) selector Blower speed selector Air intake selector A/C refrigerant pressure sensor A/C switch AUTO switch Radiator fan relay...
Page 378 7B-2 Air Conditioning System: Schematic and Routing Diagram A/C System Wiring Circuit Diagram S5JB0E7202001 YEL/GRN *RED WHT/RED RED/GRN YEL/GRN BLU/WHT YEL/GRN BLK/RED G52-8 G52-1 PPL/RED G52-15 RED/BLK G52-16 PPL/GRN G52-2 G52-4 RED/YEL BLU/WHT G52-14 RED/WHT WHT/BLK G52-19 BLK/RED BLU/BLK G52-20 BLU/BLK BLK/RED G52-27...
Page 379 Air Conditioning System: 7B-3 5. To radiator fan relay No.3 21. A/C compressor 37. Indicator lamp, switch, selector 6. Ignition switch 22. Blower motor 38. To wheel speed sensor 7. Small lamp relay 23. Blower motor selector 39. To information display 8.
Page 380 7B-4 Air Conditioning System: DTC B1556: Camshaft Position (CMP) Sensor and/or Its Circuit Malfunction S5JB0E7204027 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HVAC control module receives error code from BCM continuously. • CMP sensor circuit • CMP sensor •...
Page 381 Air Conditioning System: 7B-5 Repair Instructions Operation Procedure for Charging A/C with Refrigerant S5JB0E7206001 WARNING • Your eyes should not be exposed to refrigerant (liquid). Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6 °C (21.2 °F) below freezing point.
Page 382 7B-6 Air Conditioning System: Recovery Evacuation When discharging refrigerant out of A/C system, always CAUTION recover it by using refrigerant recovery and recycling equipment (1). Discharging refrigerant HFC-134a Do not evacuate before recovering (R134a) into atmosphere would cause adverse effect to refrigerant in system.
Page 383 Air Conditioning System: 7B-7 5) Evacuation should be carried out for a total of at Charge least 20 minutes. CAUTION 6) Continue evacuation until low pressure gauge indicates a vacuum less than –100 kPa (–1.0 kg/cm • Because the sight glass is not used for this –760 mmHg, –14.2 psi), and then close both valves A/C system, do not perform an additional (8), (9).
Page 384 7B-8 Air Conditioning System: The initial charging of the A/C system is performed from 5) Start engine and keep engine speed at 1,500 rpm. the high-pressure side with the engine stopped. Then, operate A/C system. And next, this method must be followed by charging from 6) Charge A/C system with refrigerant in vapor state.
Page 385 Air Conditioning System: 7B-9 c) Purge any air existing in center charging hose. Removal of Manifold Gauge Set When using refrigerant container tap valve, use WARNING the following procedure to purge air. Once fully tighten refrigerant container tap High pressure side is under high pressure. valve and then loosen (open) plate nut Therefore, be careful not to get injured slightly.
Page 386 7B-10 Air Conditioning System: There are a number of fittings and places throughout the Relief Valve On-Vehicle Inspection for M16 air conditioning system where a liquid leak detector Engine Model solution may be used to pinpoint refrigerant leaks. S5JB0E7206044 Using special tool, check is there is refrigerant leakage. By merely applying the solution to the area in question If there is refrigerant leakage, replace relief valve (1).
Page 387 Table of Contents 9- i Section 9 Body, Cab and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-1 J: Front and rear door wire / K: Roof wire (RHD, 3dr) ..............9A-* Precautions.............
Page 388 9-ii Table of Contents A-10 4WD Control System Circuit Diagram ..9A-* Precautions for Discharge Headlight B-1 Windshield Wiper and Washer Circuit Service (If Equipped)......... 9B-* Diagram ............9A-* Precautions in Diagnosing Troubles B-2 Rear Wiper and Washer Circuit Diagram ..9A-* (Vehicle Equipped with Auto Leveling B-3 Rear Defogger Circuit Diagram ....
Page 389 Table of Contents 9-iii Headlight Aiming Adjustment with Screen ...9B-* Diagnostic Information and Procedures ....9C-4 Headlight Switch (in Lighting Switch) Speedometer Symptom Diagnosis......9C-4 Removal and Installation........9B-* Tachometer Symptom Diagnosis ......9C-4 Headlight Switch (in Lighting Switch) Engine Coolant Temperature (ECT) Meter Inspection............
Page 390 9-iv Table of Contents Front Speaker Removal and Installation ..... 9C-* Diagnostic Information and Procedures .... 9E-* Rear Speaker Removal and Installation (5 Rear End door Window Defogger Symptom Door Model) ............9C-* Diagnosis ............9E-* Rear Speaker Removal and Installation (3 Power Window Control System Symptom Door Model) ............
Page 391 Table of Contents 9-v Keyless Entry System Operation Inspection ..9F-* Power Sliding (Sun) Roof System Door Lock Function of Keyless Start Description ............9I-* System Symptom Diagnosis (If Equipped) ..9F-* Diagnostic Information and Procedures ....9I-* Repair Instructions ..........9F-* Power Sliding (Sun) Roof System Front Door Lock Assembly Components .....9F-* Symptom Diagnosis ..........9I-* Front Door Lock Assembly Removal and...
Page 392 9-vi Table of Contents Exterior Trim ..........9M-* Roof Rail Removal and Installation (If Equipped)............9M-* Repair Instructions ..........9M-* Splash Guard Removal and Installation (If Roof Drip Molding Removal and Installation Equipped)............9M-* (If Equipped) ............. 9M-*...
Page 393 Precautions: Precautions Precautions Precautions on Body, Cab and Accessories S5JB0E9000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00 in related manual”. Fastener Caution Refer to “Fastener Caution: in Section 00 in related manual”. Precautions for Body Service Refer to “Precautions for Body Service: ”.
Page 394 S5JB0E9204006 NOTE • Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of SUZUKI Scan Tool” under “Scan Tool Data: in Section 10B”.
Page 395 Turn signal / hazard warning relay faulty Check turn signal / hazard warning relay NOTE referring to “Turn Signal and Hazard Warning Relay Inspection: in related manual”. • Use of SUZUKI scan Turn signal light switch faulty Check turn signal light switch referring to “Turn tool makes it easy to...
Page 396 S5JB0E9204013 NOTE • Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of SUZUKI Scan Tool” under “Scan Tool Data: in Section 10B”.
Page 397 Lighting Systems: 9B-4 Repair Instructions With rear fog light switch Headlight Switch (in Lighting Switch) Inspection S5JB0E9206007 Check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Without rear fog light switch and auto-on headlight switch PASS PASS...
Page 398 9B-5 Lighting Systems: With auto-on headlight switch Headlight Relay Inspection S5JB0E9206030 1) Disconnect negative (–) cable at battery. 2) Remove headlight relay from main fuse box. 3) Check that there is no continuity between terminal “3” and “4”. If there is continuity, replace relay. 4) Connect battery positive (+) terminal to terminal “2”...
Page 399 Lighting Systems: 9B-6 Turn Signal Light Switch (in Lighting Switch) Headlight Manual Leveling Switch Inspection (If Inspection Equipped) S5JB0E9206012 S5JB0E9206021 Check for continuity between terminals at each switch Check for continuity between terminals at each switch position. If check result is not as specified, replace position.
Page 400 9C-1 Instrumentation / Driver Info. / Horn: Instrumentation / Driver Info. / Horn General Description CAN Communication System Description S5JB0E9301001 Refer to “CAN Communication System Description: in Section 1A” for CAN communication system description. Combination meter communicates control data with each control module as follows.
Page 401 Instrumentation / Driver Info. / Horn: 9C-2 Combination Meter Reception Data Control Keyless Control Module Start Module Control (A/T (vehicle Control (vehicle Module model) Module equipped (if equipped) equipped (if equipped) with ESP ) with ESP ) Engine revolution speed signal Immobilizer indicator light control signal Vehicle speed signal...
Page 402 9C-3 Instrumentation / Driver Info. / Horn: Schematic and Routing Diagram Combination Meter Circuit Diagram S5JB0E9302001 G28-10 G28-8 G28-22 G28-16 G28-14 G28-13 G28-12 G28-19 G28-20 G28-15 G28-11 I5JB0D930002-01...
Page 403 Instrumentation / Driver Info. / Horn: 9C-4 1. Main fuse 6. Fuel meter 11. CPU 16. Illumination cancel switch (if equipped) 2. METER fuse 7. ECT meter 12. Power supply 17. Combination meter 3. Combination switch 8. ODO-TRIP 13. Interface circuit 18.
Page 404 9C-5 Instrumentation / Driver Info. / Horn: Low Fuel Warning Light Symptom Diagnosis S5JB0E9304005 NOTE Confirm that fuel meter is in good condition before referring to the following possible causes. • When fuel level meter circuit is shorted to ground circuit, fuel level meter indicates empty even if fuel tank does not empty.
Page 405 S5JB0E9304015 NOTE • Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of SUZUKI Scan Tool” under “Scan Tool Data: in Section 10B”.
Page 406 9C-7 Instrumentation / Driver Info. / Horn: Information Display Symptom Diagnosis (If Equipped) S5JB0E9304018 NOTE This thermometer indicates the ambient temperature in back of front bumper member. Under any one of the following listed conditions, however, even when the ambient temperature goes up, the thermometer display does not rise so as to correct the rise of the ambient temperature caused by the radiant heat of the engine.
Page 407 Instrumentation / Driver Info. / Horn: 9C-8 Repair Instructions Ignition Switch Inspection Fuel Level Sensor Removal and Installation S5JB0E9306002 S5JB0E9306004 Main Fuel Level Sensor • Check for continuity between terminals at each switch For removal and installation, refer to “Fuel Pump position.
Page 408 9C-9 Instrumentation / Driver Info. / Horn: Remote Audio Control Switch Inspection S5JB0E9306026 1) Remove driver air bag (inflator) module referring to “a” “b” “Driver Air Bag (Inflator) Module Removal and Installation: in Section 8B in related manual”. 2) Disconnect remote audio control switch connector from contact coil.
Page 409 Wipers / Washers: 9D-1 Wipers / Washers Repair Instructions Intermittent Wiper Relay Circuit Windshield Wiper and Washer Switch 1) Turn the windshield wiper switch to “INT” position. Inspection 2) Connect battery positive (+) terminal to terminal “5” S5JB0E9406009 and its negative (–) terminal to terminal “2”. 3) Connect voltmeter positive lead to terminal “4”...
Page 410 9D-2 Wipers / Washers: 6) Disconnect end of the jumper wire from terminal “5”. Washer Linked Circuit 7) Connect disconnected jumper wire end to terminal 1) Make sure that front wiper switch is at “OFF” “2”, then check that voltage between terminal “4” and position.
Page 411 Wipers / Washers: 9D-3 Rear Wiper and Washer Switch Inspection S5JB0E9406011 Check for continuity between terminals at each switch position. If check result is not as specified, replace switch. 1 2 3 I5JB0D940005-01 [A]: RH steering vehicle without rear fog light [B]: Other than RH steering vehicle without rear fog light...
Page 412 9D-4 Wipers / Washers:...
Page 413 Table of Contents 10- i Section 10 Control systems CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........10-* BCM Self-Diagnosis Function ......
Page 414 10-ii Table of Contents Immobilizer Control System Introduction ..10C-* Schematic and Routing Diagram ......10E-3 Immobilizer Control System Components Keyless Start System Electric Wiring Location ............10C-* Circuit Diagram ..........10E-3 On-Board Diagnostic System Description Diagnostic Information and Procedures ..10E-4 (Self-diagnosis Function) ........ 10C-* Precautions in Diagnosing Troubles ....10E-4 Schematic and Routing Diagram......10C-2 Self-Diagnosis Function ........
Page 415 Cruise Control System: 10A-1 Cruise Control System General Description Cruise Control System Construction S5JB0EA101001 The cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.g., on a highway. It allows the driver to drive his vehicle at a constant speed of 40 km/h (25 mile/h) or higher without depressing the accelerator pedal.
Page 416 10A-2 Cruise Control System: Components and Functions of Cruise Control System S5JB0EA101002 Component Function ECM and electric throttle body ECM executes centralized control over all functions including setting a constant speed, assembly resuming it, setting coast, cancelling cruise control limiting minimum speed. ECM controls electric throttle valve opening to keep actual vehicle speed at set (target) speed.
Page 417 Cruise Control System: 10A-3 Cancel Conditions of Cruise Control System • *Clutch pedal is depressed (Clutch pedal position S5JB0EA101003 switch is turned ON) (For M/T vehicle). Constant cruising is cancelled under the following • *Selector lever is shifted to “P”, “R” or “N” range. conditions.
Page 418 10A-4 Cruise Control System: Schematic and Routing Diagram Cruise Control System Wiring Diagram S5JB0EA102001 E23-50 BLU/ORN E23-4 WHT/RED WHT/RED WHT/BLU WHT/BLU E23-19 E23-17 C37-45 BLU/YEL C37-44 BLU/RED E23-56 E23-55 WHT/BLU E23-54 C37-53 ORN/BLU E23-53 C37-54 BLU/GRN E23-52 C37-40 BLU/YEL E23-51 C37-41 BLU/BLK BLK/WHT...
Page 419 Cruise Control System: 10A-5 Diagnostic Information and Procedures Cruise Control System Symptom Diagnosis S5JB0EA104001 NOTE • ECM uses TCM, ABS or ESP® control module and CAN communication to transmit and receive data for cruise control. Therefore, check that no DTC is detected from ECM, TCM, ABS or ESP® control module before performing this Cruise Control System Symptom Diagnosis.
Page 420 10A-6 Cruise Control System: Condition Possible cause Correction / Reference Item Cruise control cannot be CANCEL switch faulty Check CANCEL switch for function referring to cancelled “Cruise Control Switch Inspection: in related manual”. Stop (brake) lamp switch faulty Check stop (brake) lamp switch for function referring to “Stop (Brake) Lamp Switch Inspection: in related manual”.
Page 421 • Diagnostic information stored in BCM memory can be control module (if equipped), keyless start control cleared as well as checked by using SUZUKI scan module (if equipped), steering angle sensor (if tool. Before using scan tool, read its Operator’s...
Page 422 10B-2 Body Electrical Control System: CAN Communication System Description S5JB0EA201002 Refer to “CAN Communication System Description: in Section 1A” for CAN communication system description. BCM communication control data with each control module as follows. BCM Transmission Data Keyless Control Start Module Control (vehicle...
Page 423 Body Electrical Control System: 10B-3 Schematic and Routing Diagram Body Electrical Control System Wiring Circuit Diagram S5JB0EA202001 G30-22 BLU/BLK GRN/RED G30-7 G30-6 G30-19 G31-24 WHT/BLK G31-21 BLK/RED PNK/BLK G30-16 LT GRN/BLK G30-9 G31-17 LT GRN/RED RED/BLU G31-12 G31-25 G31-23 PNK/BLU G31-22 G31-13 GRN/YEL...
Page 424 10B-4 Body Electrical Control System: 1. BCM 22. Navigation 43. Dimmer and passing switch 2. Auto-ON headlight sensor 23. POWER/NORMAL mode switch 44. Horn relay 3. Rear wiper motor 24. Headlight auto leveling control module 45. Horn switch 4. Rear wiper relay 25.
Page 425 Body Electrical Control System: 10B-5 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the figure will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 426 10B-6 Body Electrical Control System: Final Confirmation Test Confirm that the problem symptom has gone and the body electrical control system is free from any abnormal conditions. If what has been repaired is related to the malfunction DTC, check DTC again and confirm that no DTC is indicated.
Page 427 Diagnosis Using Output Test Function of SUZUKI Scan Tool SUZUKI scan tool has the output test function which can force operation of following actuators and relays of the system controlled by BCM. When a malfunction is found in the system controlled by BCM, execute the output test which enables easy judgment whether the malfunction is on the input side or output side of BCM.
Page 428 10B-8 Body Electrical Control System: DTC Table S5JB0EA204004 DTC (indicated DTC (displayed on (displayed on by theft odometer in Detected item Detecting condition SUZUKI scan deterrent light) combination meter) tool) NO DTC 0000 0000 — No DTC detected B1133 1133...
Page 429 Body Electrical Control System: 10B-9 DTC B1141 / DTC B1142 (No. 1141 / No. 1142) Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction S5JB0EA204009 Wiring Diagram WHT/BLK G31-24 BLK/RED G31-21 I5JB0AA20007-01 1. Outside air temperature sensor 3. Outside air temperature sensor connector 2.
Page 430 10B-10 Body Electrical Control System: DTC Troubleshooting Step Action Outside air temperature sensor check Go to Step 2. Replace outside air temperature sensor. 1) Turn ignition switch to OFF position. 2) Disconnect connector from outside air temperature sensor. 3) Check outside air temperature sensor for resistance referring to “Outside Air Temperature Sensor Inspection (If Equipped): in Section 9C in related manual”.
Page 431 Body Electrical Control System: 10B-11 DTC U1073 (No. 1073): Control Module Communication Bus Off S5JB0EA204013 Wiring Diagram G31-4 WHT/RED E23-4 G31-2 WHT/BLU E23-19 G31-1 G31-3 E91-22 E91-23 WHT/BLU E53-46 E03-8 E53-42 E03-10 WHT/RED E92-17 E53-13 E03-12 E92-7 E53-44 E03-6 G44-19 G28-10 G44-18 G28-8...
Page 432 10B-12 Body Electrical Control System: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Transmission error that is inconsistent between transmission data • CAN circuit and transmission monitor (CAN bus monitor) data is detected more • Combination meter than 7 times continuously.
Page 433 Body Electrical Control System: 10B-13 Step Action DTC check of BCM Disconnect connectors Check power and of control modules other ground circuit of control 1) Turn ignition switch to OFF position. than the one whose module disconnect in 2) Connect connectors of disconnected control modules connector is Step 3).
Page 434 10B-14 Body Electrical Control System: Step Action Control module connector check Go to Step 5. Intermittent trouble. Check for intermittent 1) Check connection of connectors of all control modules referring to “Intermittent communicating by means of CAN. and Poor Connection 2) Recheck BCM for DTC.
Page 435 Body Electrical Control System: 10B-15 DTC U1101 (No. 1101): Lost communication with TCM S5JB0EA204015 Wiring Diagram Refer to “DTC U1073 (No. 1073): Control Module Communication Bus Off: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area BCM can not receive CAN data from TCM (A/T •...
Page 436 10B-16 Body Electrical Control System: Step Action DTC check of BCM Disconnect connectors Check power and of control modules other ground circuit of control 1) Turn ignition switch to OFF position. than the one whose module disconnected in 2) Disconnect connector of any one of control module other connector is Step 2).
Page 437 Body Electrical Control System: 10B-17 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module S5JB0EA204016 Wiring Diagram Refer to “DTC U1073 (No. 1073): Control Module Communication Bus Off: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area BCM can not receive data sent by CAN from keyless start •...
Page 438 10B-18 Body Electrical Control System: Step Action DTC check of BCM Disconnect connectors Check power and of control modules other ground circuit of control 1) Disconnect connector of any one of control module other than the one whose module disconnected in than BCM.
Page 439 • DTC stored in ECM memory can be checked as well equipped), Steering angle sensor (if equipped) and as cleared by using SUZUKI scan tool. Before using DLC is established by CAN (Computer Area Network). SUZUKI scan tool, read its operator’s manual (For more detail of CAN communication, refer to “CAN...
Page 440 10C-2 Immobilizer Control System: Schematic and Routing Diagram Immobilizer Control System Wiring Circuit Diagram S5JB0EA302001 NOTE For more details about power supply and ground wire circuits for ECM, BCM, ABS/ESP® control module, keyless start control module and combination meter, refer to “System Circuit Diagram: in Section 9A in related manual”.
Page 441 Immobilizer Control System: 10C-3 Diagnostic Information and Procedures Diagnostic Trouble Code (DTC) Table S5JB0EA304004 NOTE ECM detects diagnostic trouble code (DTC). Immobilizer control module (ICM) does not. Immobilizer DTC No. Detecting Item Detecting Condition Indicator Lamp Transponder code in the transponder built in P1614 Transponder response error the ignition key cannot be read through Flash...
Page 442 10C-4 Immobilizer Control System: DTC P1614: Transponder Response Error S5JB0EA304008 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ” Detecting Condition and Trouble Area Detecting Condition Trouble Area Transponder code in the transponder built in the ignition • Use of the ignition key without the transponder key cannot be read through immobilizer control module •...
Page 443 Immobilizer Control System: 10C-5 Step Action Immobilizer control module (ICM) check Replace ECM with new Replace immobilizer one referring to “Engine control module (ICM) 1) Check immobilizer control module (ICM) referring to Control Module (ECM) with new one referring “Inspection of Immobilizer Control Module (ICM) and Its Removal and to “Immobilizer Control Circuit: in related manual”.
Page 444 10C-6 Immobilizer Control System: Troubleshooting Step Action Diagnostic Trouble Code (DTC) confirmation Go to Step 2. The troubleshooting is completed. 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: in related manual”. 2) Turn the ignition switch to OFF position. 3) Check if any DTC is detected referring to “Diagnostic Trouble Code (DTC) Check: in related manual”.
Page 445 Immobilizer Control System: 10C-7 Step Action Check for short of wire circuits between steering lock Go to Step 9. Make sure of insulation unit and keyless start control module of each wire circuit. 1) Measure resistance at the following connector terminals. •...
Page 446 10C-8 Immobilizer Control System: DTC P1616: Unregistered Keyless Start Control Module (for Vehicle with Keyless Start System) S5JB0EA304010 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ” Circuit Description P1616 is detected when ECM detects different ID codes registered in ECM and keyless control module after turning engine start knob to ON position.
Page 447 Immobilizer Control System: 10C-9 DTC P1618: Keyless Start Control Module CAN Communication Error (for Vehicle with Keyless Start System) S5JB0EA304011 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ” Detecting Condition and Trouble Area Detecting Condition Trouble Area Reception error of communication data for keyless start •...
Page 448 10C-10 Immobilizer Control System: Step Action Check for open and high resistance in CAN Go to Step 5. Repair open or high communication wire circuits between ABS/ESP® resistance in control module and keyless start control module malfunctional wire circuit. 1) Disconnect connector “E03” from ABS control module or “E53”...
Page 449 Immobilizer Control System: 10C-11 Step Action Check for short to power supply wire circuit in CAN Go to Step 8. Repair short to power communication wire circuits supply wire circuit in CAN communication 1) Measure resistance at the following wire terminals with wire circuits.
Page 450 10C-12 Immobilizer Control System: Troubleshooting Step Action Diagnostic Trouble Code (DTC) confirmation Go to Step 2. The troubleshooting is completed. 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: in related manual”. 2) Turn the ignition switch to OFF position. 3) Check if any DTC is detected referring to “Diagnostic Trouble Code (DTC) Check: in related manual”.
Page 451 Immobilizer Control System: 10C-13 Step Action Check for short to ground circuit in communication wire Go to Step 9. Repair short to ground circuit wire circuit in communication wire 1) With immobilizer control module (ICM) connector “G24” circuit. and ECM connector “E23” disconnected, check resistance between “G24-3”...
Page 452 10C-14 Immobilizer Control System: Step Action 14 Immobilizer control module (ICM) check Replace ECM with new Replace immobilizer one referring to “Engine control module (ICM) 1) Check immobilizer control module (ICM) referring to Control Module (ECM) with new one referring “Inspection of Immobilizer Control Module (ICM) and Its Removal and to “Immobilizer Control...
Page 453 Immobilizer Control System: 10C-15 Step Action Registration of the unregistered ignition key with ECM Go to Step 4. The troubleshooting is and Diagnostic Trouble Code (DTC) check completed. 1) Register the transponder code in the transponder in the unregistered ignition key with ECM referring to “Registration of the Ignition Key: in related manual”.
Page 454 10C-16 Immobilizer Control System: DTC P1636: Immobilizer Information Registration Failure S5JB0EA304016 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ” DTC Detecting Condition and Trouble Area Detecting Condition Trouble Area The registration of the immobilizer control system • CAN communication wire circuits faulty information in ECM is failed.
Page 455 Immobilizer Control System: 10C-17 DTC P1638: Immobilizer Information Mismatched S5JB0EA304017 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ” DTC Detecting Condition and Trouble Area Detecting Condition Trouble Area • The immobilizer control system information in ECM and •...
Page 456 10C-18 Immobilizer Control System: Step Action Replacement of BCM Go to Step 6. The troubleshooting is completed. 1) Replace BCM with new one referring to “BCM Removal and Installation: in Section 10B in related manual”. 2) Check ECM for DTC referring to “Diagnostic Trouble Code (DTC) Check: in related manual”.
Page 457 Keyless Start System: 10E-1 Keyless Start System General Description Operation Area of Remote Controller S5JB0EA501005 Shown below are the operation areas of the remote controller for the keyless engine start function and door lock function of the keyless start system. I5JB0AA50004-09 [A]: Door lock function of keyless start system 3.
Page 458 10E-2 Keyless Start System: • The ignition knob switch cannot be turned using the keyless engine start function fails to turn: – The remote controller which has been registered in the keyless start control module and another un-registered one are both carried at the same time –...
Page 459 Keyless Start System: 10E-3 Schematic and Routing Diagram Keyless Start System Electric Wiring Circuit Diagram S5JB0EA502001 WHT/RED WHT/BLU WHT/BLU WHT/RED G44-19 G44-2 WHT/BLU G44-18 ORN/BLU G44-1 WHT/RED G44-24 G44-23 BLK/RED GRY/BLK G44-4 G22-6 GRY/GRN G44-3 G44-20 G22-3 G44-6 GRY/RED G44-29 BRN/YEL G22-7 PNK/BLK...
Page 460 10E-4 Keyless Start System: Diagnostic Information and Procedures Precautions in Diagnosing Troubles DTC Check S5JB0EA504001 S5JB0EA504007 • The keyless start system executes data transmission/ 1) Check to make sure that all doors are closed. reception by means of the radio wave. Therefore, 2) Open driver side door window glass and door.
Page 461 Keyless Start System: 10E-5 6) Read flashing pattern of key indicator lamp which represents DTC as shown in example below and write it down. When more than 2 DTCs are stored in memory, flashing for each DTC is repeated three times starting with the smallest DTC number in increasing order.
Page 462 10E-6 Keyless Start System: Inspection of Keyless Start Control Module and Its Circuits S5JB0EA504013 Keyless start control module and its circuits can be checked at keyless start control module wiring couplers by measuring voltage and resistance. CAUTION Keyless start control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to keyless start control module with coupler disconnected from it.
Page 463 Keyless Start System: 10E-7 Terminal Normal Circuit Condition Number Voltage G44-1 Driver side door antenna (–) *0 – 5 V Refer to “Reference waveform No. 1: ” G44-2 Driver side door antenna (+) G44-3 Rear end door antenna (–) *0 – 5 V Refer to “Reference waveform No.
Page 464 10E-8 Keyless Start System: Terminal Normal Circuit Condition Number Voltage G44-39 — — — G44-40 — — — Reference waveform No. 1 Reference waveform No. 2 Driver, passenger and rear end door antenna request Center antenna signal signals (Request signal (1) transmitted by each door (Request signal (1) transmitted by center antenna when antenna when each door request switch is pushed) each door request switch is pushed)
Page 465 Keyless Start System: 10E-9 Reference waveform No. 3 Reference waveform No. 5 Luggage room antenna signal Steering lock unit signal (Request signal (1) transmitted by luggage room (Signal (1) communicated between keyless start control antenna when each door request switch is pushed) module and steering lock unit when measurement condition described below applies) Measurement...
Page 466 10E-10 Keyless Start System: Reference waveform No. 6 In case the position of passenger side door lock is Driver and passenger side door lock switch signals. changed from the lock to the unlock when the position of (This signal indicates door lock status.) driver and passenger side door is at the lock In case the position of driver and passenger side door Measurement...
Page 467 Keyless Start System: 10E-11 In case the position of driver side door lock is changed In case the position of driver and passenger side door from the lock to the unlock when the position of driver lock is changed from the lock to the unlock. and passenger side door is at the lock.
Page 468 10E-12 Keyless Start System: DTC No. 31: Lost Communication with BCM S5JB0EA504020 Wiring Diagram G31-4 WHT/RED E23-4 G31-2 WHT/BLU E23-19 G31-1 G31-3 E91-22 E91-23 WHT/BLU E53-46 E03-8 E53-42 E03-10 WHT/RED E92-17 E53-13 E03-12 E92-7 E53-44 E03-6 G44-19 G28-10 G44-18 G28-8 G45-9 G45-10 2221201918...
Page 469 Keyless Start System: 10E-13 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Keyless start control module cannot receive data • CAN communication circuit sent by CAN from BCM • Keyless start control module • BCM DTC Confirmation Procedure 1) Clear DTC referring to “DTC Clearance: in related manual”.
Page 470 10E-14 Keyless Start System: Step Action DTC check of keyless start control module Using same method, Check power and disconnect connectors ground circuit of 1) Turn ignition switch to OFF position. of control module other disconnected control 2) Disconnect connector of any one of control module other than keyless start module and recheck.
Page 471 Keyless Start System: 10E-15 DTC No. 33: Control Module Communication Bus Off S5JB0EA504021 Wiring Diagram Refer to “DTC No. 31: Lost Communication with BCM: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Communication is not available with all control •...
Page 472 10E-16 Keyless Start System: Step Action DTC check of keyless start control module Using same method, Check power and disconnect connectors ground circuit of 1) Turn ignition switch to OFF position. of control module other disconnected control 2) Connect connectors of disconnected control modules than keyless start module.
Page 473 Prepared by 1st Ed. Jan., 2006...
Page 474 19 mm 19 mm SUPPLEMENTARY SERVICE MANUAL FOR ESP MODEL 99501-64J00-01E 99501-64J00-01E...

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