Suzuki SQ416 Service Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Automobile
  5. Canvas SQ416
  6. Service manual

Suzuki SQ416 Service Manual

Hide thumbs Also See for SQ416:
Table of Contents

Advertisement

Quick Links

See also: Service Manual , Owner's Manual
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for authorized
SUZUKI dealers and qualified service me-
chanics only. Inexperienced mechanics or
mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the me-
chanic and may render the vehicle unsafe for
the driver and passengers.
WARNING:
For vehicles equipped with a Supplemental
Restraint (Air Bag) System:
D Service on and around the air bag system
components or wiring must be performed
only by an authorized SUZUKI dealer.
Refer to "Air Bag System Components and
Wiring Location View" under "General De-
scription" in air bag system section in order
to confirm whether you are performing ser-
vice on or near the air bag system compo-
nents or wiring. Please observe all WARN-
INGS and "Service Precautions" under "On-
Vehicle Service" in air bag system section
before performing service on or around the
air bag system components or wiring. Fail-
ure to follow WARNINGS could result in
unintentional activation of the system or
could render the system inoperative. Either
of these two conditions may result in severe
injury.
D If the air bag system and another vehicle
system both need repair, SUZUKI recom-
mends that the air bag system be repaired
first, to help avoid unintended air bag sys-
tem activation.
D Do not modify the steering wheel, instru-
ment panel or any other air bag system com-
ponent (on or around air bag system compo-
nents or wiring). Modifications can adverse-
ly affect air bag system performance and
lead to injury.
D If the vehicle will be exposed to tempera-
tures over 93_C (200_F) (for example, during
a paint baking process), remove the air bag
system components (air bag (inflator) mod-
ule, sensing and diagnostic module (SDM),
seat belt pretensioner (if equipped) before-
hand to avoid component damage or unin-
tended activation.

Advertisement

Table of Contents
loading

Related Manuals for Suzuki SQ416

Summary of Contents for Suzuki SQ416

  • Page 1 D Service on and around the air bag system cial meanings. Pay special attention to the messages components or wiring must be performed highlighted by these signal words. only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and WARNING: Wiring Location View” under “General De- Indicates a potential hazard that could result scription”...
  • Page 2 And for any section, item or description not found in this supplement, refer to the related manuals mentioned in the next page. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
  • Page 3 RELATED MANUAL MANUAL NAME MANUAL NO. APPLICABILITY SQ416/SQ420/SQ625 99501-65D01-xxx This manual is the base manual for Transmission, Unit Repair Manual Transfer and Differentials (Front and Rear) of this supplementary service manual. SQ416/SQ420/SQ625 99512-65D11-015 Applicable model mentioned in FOREWORD Wiring Diagram Manual of this supplementary service manual.
  • Page 4 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION ENGINE GENERAL INFORMATION General Information General Information and Diagnosis (G16/J20) Maintenance and Lubrication General Information and HEATING AND AIR Diagnosis (H25) CONDITIONING Engine Mechanical (G16) Heater and Ventilation Engine Mechanical (H25) Air Conditioning Engine Mechanical (J20) STEERING, SUSPENSION, Engine Cooling...
  • Page 5 GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION NOTE For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in FOREWORD of this manual. CONTENTS Abbreviations and Symbols May Be Used in This Manual .

  • Page 6: Brakes

    0A-2 GENERAL INFORMATION Abbreviations and Symbols May Be Used in This Manual ABBREVIATIONS Anti-lock Brake System EFE Heater Early Fuel Evaporation Heater ATDC After Top Dead Center (Positive Temperature Coefficient, American Petroleum Institute PTC Heater) Automatic Transmission Fluid E EPS Electronic Power Steering Automatic Locking Retractor EVAP...

  • Page 7: General Information 0A

    GENERAL INFORMATION 0A-3 Park/Neutral Position Power Steering PSP Switch Power Steering Pressure Switch (P/S Pressure Switch) Powertrain Control Module Positive Crankcase Ventilation R RH Right Hand Society of Automotive Engineers Sensing and Diagnostic Module (Air bag controller, Air bag control module) Sequential Multiport Fuel Injection SOHC...
  • Page 8 0A-4 GENERAL INFORMATION SYMBOLS SYMBOL DEFINITION SYMBOL DEFINITION Tightening torque Apply SUZUKI BOND NO. 1216 99000-31160 Apply oil (engine, transmission, Apply SILICONE SEALANT transfer, differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND automatic transmission fluid) 366E 99000-31090...

  • Page 9: Table Of Contents

    REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: D For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual. D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense.

  • Page 10: Note

    3E-2 REAR SUSPENSION ON-VEHICLE SERVICE SHOCK ABSORBER The shock absorber is non-adjustable, non-refillable, and cannot be disassembled. The only service the shock absorber requires is replacement when it has lost its resistance, is damaged, or leaking fluid. REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack to prevent it from lowering.

  • Page 11: Lower Rod

    REAR SUSPENSION 3E-3 LOWER ROD REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack. 1. Axle housing 2. Floor jack 3) Remove lower rod front mount bolt. 1. Lower rod 2. Front mount bolt 4) Remove lower rod rear mount bolt.

  • Page 12: Lateral Rod

    3E-4 REAR SUSPENSION LATERAL ROD REMOVAL 1) Hoist vehicle. 2) Remove lateral rod mounting bolts. 3) Remove lateral rod. 1. Bolt 2. Washer 3. Lateral rod INSTALLATION 1) Install lateral rod to rear axle, and vehicle body. 2) Lower hoist. 3) Tighten lateral rod mounting bolts to specified torque.
  • Page 13 REAR SUSPENSION 3E-5 5) Clean mating surfaces of axle housing and differential carrier and apply sealant to housing side. “A”: Sealant 99000-31110 “A” 1. Axle housing 6) Install differential carrier assembly to axle housing and tighten carrier nuts to specified torque. Tightening Torque (a): 55 N m (5.5 kg-m, 40.0 lb-ft)
  • Page 14 3E-6 REAR SUSPENSION 14) Clean mating surface of axle housing (right & left) and brake back plate, then apply sealant as shown. “A”: Sealant 99000-31110 “A” 1. Axle housing 15) Apply grease to axle shaft inner oil seal lip as shown. “A”: Grease 99000-25010 1.
  • Page 15 REAR SUSPENSION 3E-7 19) Connect brake pipes to wheel cylinders (right & left) and tighten brake pipe flare nuts to specified torque. Tightening Torque (g): 16 N m (1.6 kg-m, 11.5 lb-ft) 20) Install brake drum (right & left). For details, refer to SECTION 5C “BRAKE DRUM INSTALLATION”.

  • Page 16: Tightening Torque Specifications

    3E-8 REAR SUSPENSION 27) Tighten right and left lower/upper rod nuts lateral rod mount bolt and shock absorber nuts to specified torque. NOTE: When tightening these nuts, be sure that vehicle is off hoist and in non loaded condition. Tightening Torque (i): 100 N m (10.0 kg-m, 72.0 lb-ft) (m): 85 N...
  • Page 17 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.

  • Page 18: Engine General Information And Diagnosis (G16 / J20 Engines)

    6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) ENGINE DIAGNOSIS Engine Diagnostic Flow Table INSPECTION OF PCM (ECM) AND ITS CIRCUITS PCM (ECM) and its circuits can be checked at PCM (ECM) wiring couplers by measuring voltage and resistance. CAUTION: PCM/ECM cannot be checked by itself.
  • Page 19 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) 6-3 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Power source for CO adjusting 4.75 – 5.25 V Ignition switch ON resistor (if equipped) Power source for back up 10 – 14 V Ignition switch ON and OFF 10 –...
  • Page 20 6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION ——— —— ——— Heated oxygen sensor-2 While engine running at 2000 r / min. 0.01 – 0.95 V (if equipped) for 3 min. or longer after warming up. ———...
  • Page 21 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) 6-5 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ground for HO2S-1 shield wire —— ——— Power source for TP sensor 4 75 4.75 – 5.25 V 5 25 V Ignition switch ON Ignition switch ON Power source for MAP sensor Power source 10 –...
  • Page 22 6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION A / T output speed sensor (–) About 2.5 V Ignition switch ON A / T output speed sensor (+) About 2.5 V Ignition switch ON 24-25 ———...
  • Page 23 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) 6-7 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Deflects between Ignition switch ON, Rear right tire Vehicle speed sensor 0 – 1 V and over 4 V turned slowly with rear left tire locked Deflects between Camshaft position sensor (+) Ignition switch ON, crankshaft turned slowly...
  • Page 24 6-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) Resistance Check 1) Disconnect couplers from ECM/PCM with ignition switch OFF. CAUTION: Never touch terminals of ECM/PCM itself or connect voltmeter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected couplers as listed in the following table.
  • Page 25 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) 6-9 TABLE B-1 FUEL PUMP CIRCUIT INSPECTION WIRING DIAGRAM 1. Main relay 2. Fuel pump relay 3. Main fuse 4. To ignition switch 5. Fuel pump 6. Fuse box NOTE: See page 6-7 for the applicable model. INSPECTION STEP ACTION...
  • Page 26 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.

  • Page 27: Engine General Information And Diagnosis (H25 Engine) 6

    6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) ENGINE DIAGNOSIS DIAGNOSTIC TROUBLE CODE (DTC) TABLE (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with (DTC will set when detecting:) monitor monitor connector connector P0100 Sensor output too low (No.34) Mass air flow circuit 1 driving 1 driving malfunction...
  • Page 28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-3 (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with (DTC will set when detecting:) monitor monitor connector connector Response time of HO2S-1 output voltage HO2S circuit slow response 2 driving P0153 between rich and lean is longer than (Bank 2 –...
  • Page 29 6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) (vehicle (vehicle DETECTING CONDITION DETECTING ITEM without with (DTC will set when detecting:) monitor monitor connector connector Exhaust gas recirculation 2 driving P0400 Excessive or insufficient EGR flow. flow malfunction detected cycles applicable Output waveforms of HO2S-1 and HO2S-2 are similar.

  • Page 30: Engine General Information And

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-5 DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) P0705 Transmission range circuit (No.72) malfunction P0715 Input/turbine speed sensor (No.76) circuit malfunction P0720 A/T VSS signal circuit malfunction (No.75) Torque converter clutch circuit P0741 performance or stuck off P0743...

  • Page 31: Voltage Check

    6-1-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) ECM (PCM) SUBSTITUTION When substituting a known-good ECM (PCM), check for following conditions. Neglecting this check may cause damage to known- good ECM (PCM). – Resistance value of all relays, actuators is as specified respec- tively.
  • Page 32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-7 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION For 3 sec. after ignition switch ON or while engine 0 – 2.5 V running. Fuel pump relay E61 1 E61-1 (TYPE B only: See NOTE.) After 3 sec. from ignition switch ON with engine 10 –...
  • Page 33 6-1-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION E61-21, 22 ——— ——— ——— 0 – 1 V Ignition switch ON Immobilizer indicator lamp (vehicle without monitor connector) 10 – 14 V Engine running E61-23 E61-23 Duty output terminal (vehicle with 0 –...
  • Page 34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-9 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Deflects between C51-3-9 Camshaft position sensor (POS) Ignition switch ON, crankshaft turned slowly. 0 – 1 V and 4 – 6 V Deflects between C51-3-10 Camshaft position sensor (REF) Ignition switch ON, camshaft turned slowly.
  • Page 35 6-1-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C51-1-6 Shift solenoid A (A / T VEHICLE) 10 – 14 V Ignition switch ON 10 – 14 V Ignition switch ON, Transfer lever: N or 2H range C51 1 7 C51-1-7 4WD lamp (if equipped)
  • Page 36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-11 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C51-2-14 IAC valve (stepper motor coil 2) ——— ——— C51-2-15 IAC valve (stepper motor coil 1) ——— ——— EGR valve (stepper motor coil 4) C51-2-16 0 – 1 V (if equipped) Ignition switch ON Ignition switch ON...

  • Page 37: Resistance Check

    6-1-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) RESISTANCE CHECK 1) Disconnect ECM couplers (1) from ECM with ignition switch OFF. CAUTION: Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Check resistance between each pair of terminals of discon- nected couplers as listed in following table.
  • Page 38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-13 STANDARD TERMINAL CIRCUIT CONDITION RESISTANCE C51-1-1 – Body ground Shift solenoid-B 11 – 15 Ω C51-1-2 – Body ground TCC solenoid — C51-1-6 – Body ground Shift solenoid-A A/T input speed 560 – 680 Ω C51-1-8 –...
  • Page 39 6-1-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P0325 (DTC No.43) KNOCK SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1. Knock sensor DTC DETECTING CONDITION TROUBLE AREA D Knock sensor output voltage: 3.98 V or more D “W” circuit open or shorted to ground D Knock sensor output voltage: 0.90 V or less D Knock sensor malfunction D ECM malfunction...
  • Page 40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-15 Fig. 1 for Step 3 Fig. 2 for Step 3 1. Knock sensor 2. Knock sensor connector...
  • Page 41 6-1-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION (DTC No.24) WIRING DIAGRAM 1. Vehicle speed sensor 2. Main relay 3. Speedometer 4. Cruise control module TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) CIRCUIT DESCRIPTION Refer to “ENGINE AND EMISSION CONTROL”...
  • Page 42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-17 WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during to avoid occurrence of an accident. D Road test, should be carried out with 2 person, a driver and tester, on a level road. D Intake air temperature: between –14_C and 70_C (6.8_F and 158_F) D Atmospheric pressure: higher than 560 mmHg (Altitude: lower than 2790 m (9150 ft)) (1) With ignition switch OFF, connect scan tool.
  • Page 43 6-1-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) STEP ACTION Speedometer Circuit check: Substitute a known- Go to Step 7. (1) With ignition switch OFF, disconnect G11 coupler good combination from combination meter. meter and recheck. (2) With ignition switch ON leaving engine OFF, check voltage between C20-1 and C20-2 terminal of VSS coupler.
  • Page 44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) 6-1-19 TABLE B-1 FUEL PUMP CIRCUIT CHECK WIRING DIAGRAM 20 (TYPE A: See NOTE.) 1 (TYPE B: See NOTE.) 1. Fuel pump 2. Fuel pump relay 3. Main relay TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER VIEWED FROM HARNESS SIDE NOTE: See page 6-7 for the applicable model.
  • Page 45 6-1-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE) TROUBLESHOOTING STEP ACTION Fuel Pump Operation check: Fuel pump circuit Go to Step 2. (1) Remove fuel filler cap. is in good condition. (2) Turn On ignition switch. Is fuel pump operation sound heard for 3 sec. after ignition switch ON? Fuel Pump Circuit check: Go to Step 3.
  • Page 46 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 47 6A2-2 ENGINE MECHANICAL (H25 ENGINE) UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Release fuel pressure in fuel feed line. Refer to Section 6. 2) Disconnect negative cable at battery. 3) Remove engine hood. 4) Drain engine oil. 5) Drain coolant. 6) Remove radiator, radiator fan shroud, cooling fan and radiator reservoir.
  • Page 48 ENGINE MECHANICAL (H25 ENGINE) 6A2-3 16) Disconnect following hoses at the location shown in figure: D Fuel feed hose from fuel feed pipe D Fuel return hose from fuel return pipe 17) Remove EVAP canister. 1. Fuel feed hose FRONT 2.
  • Page 49 6A2-4 ENGINE MECHANICAL (H25 ENGINE) 32) Install lifting device. 33) Disconnect engine side mounting brackets to engine mount- ings. 1. Engine side mount bracket 34) Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine. 35) Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assembly.
  • Page 50 ENGINE MECHANICAL (H25 ENGINE) 6A2-5 MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 2. Lower crankcase 3. Crankshaft 4. Main bearing 5. Thrust bearing 6. Rear oil seal 7. Flywheel (M / T) Drive plate (A / T) 8. Water pump 9.
  • Page 51 6A2-6 ENGINE MECHANICAL (H25 ENGINE) INSPECTION Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play 2, (a) Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed.
  • Page 52 ENGINE MECHANICAL (H25 ENGINE) 6A2-7 Main Bearings General information D Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. D Upper half of bearing has oil groove as shown in figure. Install this 1.
  • Page 54 ENGINE MECHANICAL (H25 ENGINE) 6A2-9 2) Next, check crankcase (bearing cap) bore diameter without bearing. On lower surface of lower crankcase 4 alphabets are stamped as shown in figure. Three kinds of alphabets (A, B and C) represent following cap No.
  • Page 55 6A2-10 ENGINE MECHANICAL (H25 ENGINE) 4) From number stamped on crank webs at its center and alpha- bets stamped on crankcase lower side, determine new standard bearing to be installed to journal, by referring to table shown be- low. For example, if number stamped on crank webs is “1” and alpha- bet stamped on crankcase is “B”, install a new standard bearing painted in “Black”...
  • Page 56 ENGINE MECHANICAL (H25 ENGINE) 6A2-11 D If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter: 64.738 – 64.756 mm (2.5487 – 2.5494 in.) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
  • Page 57 6A2-12 ENGINE MECHANICAL (H25 ENGINE) Cylinder Block Distortion of gasketed surface D Using straightedge and thickness gauge, check gasketed sur- face for distortion and, if flatness exceeds its limit, correct it. Flatness Limit: 0.06 mm (0.0024 in.) Honing or reboring cylinders 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
  • Page 58 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 59 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) GENERAL DESCRIPTION ELECTRONIC CONTROL SYSTEM...
  • Page 60 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) 6E1-3 6-1. Fuel injector No.1 -24. Starter magnetic switch 2. Fuel injector No.2 -25. Vehicle speed sensor 3. Fuel injector No.3 26. Combination meter -4. Fuel injector No.4 26-1. Fuel level sensor -5.
  • Page 61 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINES) TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) CIRCUIT CIRCUIT CIRCUIT TERMINAL TERMINAL TERMINAL A / T output speed sensor (–) Ground for MAF sensor Power source for CO adjusting resistor A / T output speed sensor (+) Ground...
  • Page 62 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 63 6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) GENERAL DESCRIPTION The engine and emission control system has 4 major Electronic control system includes ECM (PCM), vari- sub-systems: air intake system, fuel delivery system, ous sensors and controlled devices. electronic control system and emission control sys- Emission control system includes EGR, EVAP and tem.
  • Page 64 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-3...
  • Page 65 6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE)
  • Page 66 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-5 ELECTRONIC CONTROL SYSTEM D Idle air control system The electronic control system consists of 1) various D Fuel pump control system sensors which detect the state of engine and driving D Evaporative emission control system conditions, 2) ECM (PCM) which controls various de- D Ignition control system vices according to the signals from the sensors and...
  • Page 67 6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE)
  • Page 68 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-7 TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) C51-3 C51-1 C51-2...

  • Page 69: C51-2-14 Iac Valve (Stepper Motor Coil

    6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 1. Fuel injector No.1 CIRCUIT CIRCUIT TERMINAL TERMINAL 2. Fuel injector No.2 E61-1 Fuel pump relay (TYPE B only: See NOTE) C51-3-18 Knock sensor (if equipped) 3. Fuel injector No.3 E61-2 —— C51-3-19 ——...
  • Page 70 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) 6E2-9 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE Input Function Output Main relay control Main relay Fuel pump control Fuel pump relay f f f f Injection control Injectors f f f f f f f f f f f f f f f Idle air control...
  • Page 71 6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (H25 ENGINE) ON-VEHICLE SERVICE ELECTRONIC CONTROL SYSTEM KNOCK SENSOR Inspection Check knock sensor (1) referring to DTC P0325 (No.43) Flow Table. If malfunction is found, replace. Removal and Installation Refer to Section 6A2.
  • Page 72 AUTOMATIC TRANSMISSION (4 A / T) 7B1-1 SECTION 7B1 AUTOMATIC TRANSMISSION (4 A/T) NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in FOREWORD of this manual. CONTENTS ON-VEHICLE SERVICE .

  • Page 73: On-Vehicle Service

    7B1-2 AUTOMATIC TRANSMISSION (4 A / T) ON-VEHICLE SERVICE MANUAL SELECTOR ASSEMBLY Type-1 Type-2 1. Manual lever assembly 2. Select indicator 1. Manual selector assembly 8. Knob button assembly (Select lever assembly) 9. Shift lock solenoid rod 3. Illumination lamp 2.
  • Page 74 AUTOMATIC TRANSMISSION (4 A / T) 7B1-3 (For Type-2) 1) Disconnect negative (–) cable at battery. 2) Remove console box. 3) Disconnect connector for illumination lamp, shift lock solenoid (if equipped) and overdrive OFF switch. 4) Remove selector assembly mounting bolts. 5) Disconnect selector cable from manual selector assembly ex- panding selector cable clip.
  • Page 75 7B1-4 AUTOMATIC TRANSMISSION (4 A / T) (For Type-2) Reverse removal procedure to install manual selector assembly noting the following instructions. D Make sure that selector cable clip hold selector cable on manual selector assembly securely. D Tighten manual selector assembly mounting bolts as specified torque.

  • Page 76: Select Cable

    AUTOMATIC TRANSMISSION (4 A / T) 7B1-5 SELECT CABLE [Type-1] [Type-2] 1. Selector lever assembly 9. Lock washer 1. Select lever assembly 10. Manual select lever 2. Selector lever assembly 10. Manual select lever 2. Bolt 11. Lock washer mounting bolt 11.
  • Page 77 7B1-6 AUTOMATIC TRANSMISSION (4 A / T) 3) Turn nut A by hand till it contacts manual select cable joint. Then tighten nut B with wrench. 4) After select cable was installed, check for the following. D Push vehicle with select lever shifted to “P”. Vehicle should not move.
  • Page 78 AUTOMATIC TRANSMISSION (4 A / T) 7B1-7 FRONT UPPER VALVE BODY 1. Front upper valve boy 2. Cut valve retainer 3. Cut back plug 4. Cut back valve 5. Spring 6. Front valve end cover 7. Secondary regulator valve 8. Secondary regulator spring 9.
  • Page 79 7B1-8 AUTOMATIC TRANSMISSION (4 A / T) ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points. D Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size. Coil outer diameter and free length of each valve spring Name of spring Outer diameter...
  • Page 80 AUTOMATIC TRANSMISSION (4 A / T) 7B1-9 LOWER VALVE BODY 1. Lower valve body 9. TCC (Lock-up) control sleeve 2. Spring 10. TCC (Lock-up) control valve 3. Pressure relief valve ball 11. Pin 4. Pressure relief valve retainer 12. Retainer 5.
  • Page 81 7B1-10 AUTOMATIC TRANSMISSION (4 A / T) DISASSEMBLY 1) Remove bypass valve (1), bypass valve spring, check ball valve damping spring, valve body ball (2) and ball valve spring. 3. Check ball 4. Primary regulator valve sleeve retainer 5. Locating pin 2) Remove lower valve body plate (1) and lower valve body plate gasket.
  • Page 82 AUTOMATIC TRANSMISSION (4 A / T) 7B1-11 7) Pressing TCC (lock-up) control sleeve with finger and using magnet (1), remove locating pin and then remove TCC (lock-up) control sleeve, TCC (lock-up) control valve and TCC (lock-up) control valve spring. 8) Check which step of primary regulator valve sleeve (1) (how many steps down from its tip) contacts primary regulator valve sleeve retainer (2).
  • Page 83 7B1-12 AUTOMATIC TRANSMISSION (4 A / T) ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points. D Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size. Coil outer diameter and free length of each valve spring : Name of spring Outer diameter...
  • Page 84 AUTOMATIC TRANSMISSION (4 A / T) 7B1-13 D Tighten TCC (lock-up) solenoid valve bolt to specified torque. Tightening torque TCC solenoid valve bolt: 5.5 N m (0.55 kg-m, 4.0 lb-ft) 1. Solenoid valve No.2 (TCC solenoid valve) 2. O-ring D Tighten pressure relief valve bolt to specified torque. Tightening torque Pressure relief valve bolt: 5.5 N...

  • Page 85: Unit Assembly

    7B1-14 AUTOMATIC TRANSMISSION (4 A / T) UNIT ASSEMBLY 1) After applying A/T fluid to new O-rings, install them to reverse brake piston (3), reaction sleeve (2) and secondary reverse pis- ton (1). 2) Install reverse brake piston assembly and brake piston return spring to transmission case, using care not to damage O-ring.
  • Page 86 AUTOMATIC TRANSMISSION (4 A / T) 7B1-15 5) Install brake applying tube (1) so that its lug fits in a in transmis- sion case. After installation, check that 4 lugs (3) along the un- derside of brake applying tube fit inside of reverse brake piston and leaf spring (2) is installed properly.
  • Page 87 7B1-16 AUTOMATIC TRANSMISSION (4 A / T) 9) Using screwdriver with vinyl tape or the like wound at its tip, install retaining reaction plate ring (1). After installation, check that ring is in groove securely. 10) After confirming that lugs of all brake plates and brake discs are in grooves securely, hold retaining direct clutch ring (1) of plan- etary sun gear, install center support assembly by aligning fluid holes (2) in center support and transmission case.
  • Page 88 AUTOMATIC TRANSMISSION (4 A / T) 7B1-17 14) Install forward clutch assembly by putting all lugs of direct clutch disc hub together and matching them with groove cut in direct clutch input hub, and at the same time aligning splines in forward clutch hub with inner shaft.
  • Page 89 7B1-18 AUTOMATIC TRANSMISSION (4 A / T) 19) When clutch disc or plate has been replaced, check height dif- ference between O/D case and O/D clutch cylinder by mea- suring it as shown in the figure. Standard height difference “a” between O/D case and O/D clutch cylinder: About 3.5 mm (0.138 in.) NOTE:...
  • Page 90 AUTOMATIC TRANSMISSION (4 A / T) 7B1-19 23) Apply 2 – 4 kg/cm air pressure into fluid holes in the figure as numbered and check operation sound of each part. (1) O/D clutch (2) O/D brake (3) Forward clutch (4) Direct clutch (5) B1 brake (Second coast brake) (6) B2 brake (Second brake) (7) Reverse brake...
  • Page 91 7B1-20 AUTOMATIC TRANSMISSION (4 A / T) 29) Align hole in manual shift shaft with that in manual shift lever and drive in new manual shift lever pin (1). 30) Align hole in sleeve cover with dent in manual shift lever and caulk securely with pin punch (1).
  • Page 92 AUTOMATIC TRANSMISSION (4 A / T) 7B1-21 33) Apply A/T fluid to new O-ring and spring and install them to ac- cumulator piston and install accumulator piston to transmis- sion case. 4. Upper spring 5. Coil outer diameter Accumulator piston and spring specification (G16 engine): Used for Piston outer diameter “a”...
  • Page 93 7B1-22 AUTOMATIC TRANSMISSION (4 A / T) 34) Lift valve body a little and install nipple of throttle cable to throttle valve cam. 35) After confirming that accumulator piston is pushed all the way down, match pin of manual shift lever with groove in manual valve.
  • Page 94 AUTOMATIC TRANSMISSION (4 A / T) 7B1-23 38) Lubricate new O-ring with A/T fluid and attach it to grommet of solenoid wire harness. Then connect solenoid wire harness to transmission case and fix it with solenoid wire harness clamp. Connect each connector to solenoid. And install new gasket and brake applying cover.
  • Page 95 7B1-24 AUTOMATIC TRANSMISSION (4 A / T) 43) For J20 and H25 engines, perform the following procedures. [J20 and H25 engines] a) Clean mating surface of transmission case (1) and adapter case (2) and apply sealant “A” to adapter case (2). “A”...
  • Page 96 AUTOMATIC TRANSMISSION (4 A / T) 7B1-25 47) Confirm that torque converter is fully fitted in transmission. Confirmation can be done by measuring dimension between end surface of housing case (2) and drive plate installation seat. Standard dimension between end surface of case housing and drive plate installation seat “a”: For G16 engine: 21.5 mm (0.85 in.) For J20 engine: 17.3 mm (0.68 in.)
  • Page 97 DIFFERENTIAL (FRONT) 7E-1 SECTION 7E DIFFERENTIAL (FRONT) NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in FOREWORD of this manual. CONTENTS ON-VEHICLE SERVICE ..............7E-2 REMOVAL AND INSTALLATION .
  • Page 98 7E-2 DIFFERENTIAL (FRONT) ON-VEHICLE SERVICE REMOVAL AND INSTALLATION Differential Mountings REAR MOUNTING (For front differential carrier) Solid Type 1) Lift up vehicle and remove mounting assembly by removing 2 bolts and nuts from differential carrier side and 2 bolts from cross member side.
  • Page 99 DIFFERENTIAL (FRONT) 7E-3 DISMOUNTING 1) Lift up vehicle and drain oil. 2) Disconnect air hose and breather hose from differential housing. 3) Before removing propeller shaft, give match marks on joint flange and propeller shaft as shown. 4) Remove propeller shaft flange by removing its 4 bolts and sus- pend it with cord or the like.
  • Page 100 7E-4 DIFFERENTIAL (FRONT) 9) With differential housing assembly held with transmission jack, remove mounting bolts on right end of housing. 1. Mounting bracket bolt 2. Mounting bracket R 3. Differential housing 10) Using 2 large screwdrivers as levers, pull out right side drive shaft joint from differential and dismount housing assembly from vehicle.
  • Page 101 DIFFERENTIAL (FRONT) 7E-5 REMOUNTING For remounting, reverse dismounting procedure and use following tightening torque. Tightening torque Front drive shaft flange bolts (a): 50 N m (5.0 kg-m, 36.5 lb-ft) Propeller shaft flange bolts (a): 50 N m (5.0 kg-m, 36.5 lb-ft) Front mounting bracket bolts (a): 50 N m (5.0 kg-m, 36.5 lb-ft)
  • Page 102 7E-6 DIFFERENTIAL (FRONT) UNIT REPAIR Refer to the same section of “UNIT REPAIR MANUAL” mentioned in “FOREWORD” of this manual. TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening part Fastening art kg-m lb-ft Differential oil level/filler plug 17.0 Differential oil drain plug 17.0 Front mounting bolts 61.5...
  • Page 103 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 104 8C-2 INSTRUMENTATION / DRIVER INFORMATION GENERAL DESCRIPTION COMBINATION METER CHECK ENGINE BRAKE 1. Tachometer 11. AIR BAG warning light (if equipped) 2. Speedometer 12. O / D OFF light (A / T vehicle only) 3. Fuel level meter 13. Fasten seat belt light (if equipped) 4.
  • Page 105 INSTRUMENTATION / DRIVER INFORMATION 8C-3 or ABS or CHECK ENGINE EBD circuit ABS circuit NOTE: Terminal arrangement of coupler viewed from harness side. Coupler A Coupler B Coupler C Coupler A Coupler B Coupler C 1. To cruise control module Gr / Bl 1.
  • Page 106 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 107 8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS GENERAL DESCRIPTION REAR WIPER AND WASHER (IF EQUIPPED) Rear Wiper Assembly Rear Wiper and Washer Switch (For vehicle without cruise control system) Rear Wiper Intermittent Relay (For vehicle without cruise control system) Rear Wiper and Washer Switch (For vehicle with cruise control system)
  • Page 108 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-3 ON-VEHICLE SERVICE REAR WINDOW WIPER AND WASHER (FOR VEHICLE WITH CRUISE CONTROL SYSTEM) INSPECTION Rear Wiper and Washer Switch 1) Disconnect negative (–) cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Use a circuit tester to check the continuity at each switch posi- tion.
  • Page 109 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.

  • Page 110: General Description

    8E-2 CRUISE CONTROL SYSTEM GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8. SYMBOLS AND MARKS Refer to Section 8A. ABBREVIATIONS Refer to Section 8A. WIRING COLOR SYMBOLS Refer to Section 8. JOINT CONNECTOR Refer to Section 8. FUSE BOX AND RELAY Refer to Section 8A.

  • Page 111: Cruise Control System

    CRUISE CONTROL SYSTEM 8E-3 CRUISE CONTROL SYSTEM The cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.g., on a highway. It allows the driver to drive his vehicle at a constant speed of 40 km/h (25 mile/h) or higher without depressing the accelerator pedal (constant cruising).

  • Page 112: Components And Functions

    8E-4 CRUISE CONTROL SYSTEM COMPONENTS AND FUNCTIONS Component Function Cruise control actuator Cruise control module: assembly with control Executes centralized control by means of a microcomputer over all functions module including setting a constant speed, resuming it, setting coast, limiting minimum speed and cancelling cruise control.

  • Page 113: Cancel Conditions

    CRUISE CONTROL SYSTEM 8E-5 Component Function PCM – Overdrive and TCC When the throttle opening for the vehicle speed exceeds the specified value off command signal output during cruise control, the cruise control module sends this signal to PCM. PCM uses this signal as one of signals to control 4-A/T.
  • Page 114 8E-6 CRUISE CONTROL SYSTEM Condition Possible Cause Correction Vehicle speed can not Actuator cable play maladjusted or Refer to “CRUISE CABLE PLAY be set. actuator cable faulty INSPECTION AND ADJUSTMENT” in this section. Main switch, “COAST/SET”, “RESUME/ Refer to “CRUISE MAIN SWITCH, ACCEL”...

  • Page 115: Note On System Circuit Inspection

    CRUISE CONTROL SYSTEM 8E-7 Condition Possible Cause Correction “RESUME/ACCEL” Main switch, “COAST/SET”, “RESUME/ Refer to “CRUISE MAIN SWITCH, switch fails to resume ACCEL” and “CANCEL” switch circuits COAT/SET, RESUME/ACCEL AND preset vehicle speed faulty CANCEL SWITCHES CIRCUITS after cruise control is CHECK”...

  • Page 116: Cruise Main Switch Indicator Lamp Circuit Check

    8E-8 CRUISE CONTROL SYSTEM CRUISE MAIN SWITCH INDICATOR LAMP CIRCUIT CHECK Step Action Check Circuit for Short. “Lg/W” circuit is Go to Step 2. 1) Disconnect connector from cruise control module with shorted to ignition switch OFF. ground. 2) Turn ignition switch ON. Does cruise main switch indicator lamp turn ON? Check Circuit for Open Lamp circuit is...

  • Page 117: Cruise" Indicator Lamp Circuit Check

    CRUISE CONTROL SYSTEM 8E-9 “CRUISE” INDICATOR LAMP CIRCUIT CHECK Step Action Check Circuit for Short. “G/Y” circuit is Go to Step 2. 1) Disconnect connector from cruise control module with shorted to ignition switch OFF. ground. 2) Turn ignition switch ON. Does “CRUISE”...

  • Page 118: Cruise Main Switch, Coast/Set, Resume/Accel And Cancel Switches Circuits Check

    8E-10 CRUISE CONTROL SYSTEM CRUISE MAIN SWITCH, COAST/SET, RESUME/ACCEL AND CANCEL SWITCHES CIRCUITS CHECK Step Action Switch Circuit Check Switch circuit is Go to Step 2. 1) Disconnect connector from cruise control module with ignition switch OFF. 2) Check for proper connection to cruise control module at terminal E132-8.

  • Page 119: Vss Circuit Check

    CRUISE CONTROL SYSTEM 8E-11 VSS CIRCUIT CHECK Step Action Vehicle Speed Sensor Circuit Check VSS circuit is “Bl/Y” circuit is 1) Disconnect connector from cruise control module with open. ignition switch OFF. 2) Check for proper connection to cruise control module at terminal E132-1.

  • Page 120: Stop Lamp Switch

    8E-12 CRUISE CONTROL SYSTEM STOP LAMP SWITCH (WITH PEDAL POSITION SWITCH) CIRCUITS CHECK Step Action Stop Lamp Switch (With Pedal Position Switch) Circuits Check Stop lamp switch Go to Step 2. 1) Disconnect connector from cruise control module with (with pedal ignition switch OFF.

  • Page 121: Transmission Range Switch Circuit Check

    CRUISE CONTROL SYSTEM 8E-13 TRANSMISSION RANGE SWITCH CIRCUIT CHECK Step Action Transmission Range Switch Circuit Check Transmission Go to Step 2. 1) Disconnect connector from cruise control module with range switch ignition switch OFF. circuit is OK. 2) Check for proper connection to cruise control module at terminal E132-9.

  • Page 122: Clutch Pedal Position Switch Circuit Check

    8E-14 CRUISE CONTROL SYSTEM CLUTCH PEDAL POSITION SWITCH CIRCUIT CHECK Step Action Clutch Pedal Position Switch Circuit Check Clutch pedal Go to Step 2. 1) Disconnect connector from cruise control module with position switch ignition switch OFF. circuit is OK. 2) Check for proper connection to cruise control module at terminal E132-9.

  • Page 123: Throttle Valve Opening Signal Circuit Check

    CRUISE CONTROL SYSTEM 8E-15 THROTTLE VALVE OPENING SIGNAL CIRCUIT CHECK Step Action Powertrain Control Module (PCM) Diagnostic Trouble Check and repair Go to Step 2. Code Check TP sensor referring 1) Check PCM for DTC. to Section 6-1. Is there a DTC related to throttle position sensor? Throttle Valve Opening Signal Circuit Check Throttle valve Go to Step 3.

  • Page 124: Overdrive And Tcc Off Command Signal Circuit Check

    8E-16 CRUISE CONTROL SYSTEM OVERDRIVE AND TCC OFF COMMAND SIGNAL CIRCUIT CHECK Step Action Overdrive off Command Signal Circuit Check This signal circuit Check “P/Bl” 1) Disconnect connector from cruise control module with is OK. wire for open and ignition switch OFF. short.

  • Page 125: Cruise Control Module And Its Circuit Inspection

    CRUISE CONTROL SYSTEM 8E-17 CRUISE CONTROL MODULE AND ITS CIRCUIT INSPECTION CAUTION: Cruise control module can not be checked by itself. It is strictly prohibited to connect voltmeter or ohm- meter to cruise control module with coupler disconnected from it. VOLTAGE CHECK Check for input or output voltage of control module (voltage between each circuit and body ground) with cruise control module connector connected.
  • Page 126 8E-18 CRUISE CONTROL SYSTEM RESISTANCE CHECK 1) Disconnect cruise control module connector from cruise control module with ignition switch OFF. CAUTION: Never touch terminals of cruise control module itself or connect voltmeter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected connectors as shown in the following table.

  • Page 127: Cruise Cable Play Inspection And Adjustment

    CRUISE CONTROL SYSTEM 8E-19 CRUISE CABLE PLAY INSPECTION AND ADJUSTMENT INSPECTION AND ADJUSTMENT 1) Remove actuator cap. 2) With actuator lever (1) returned at original position (2) (Where lever does not move clockwise any further), check cruise cable for play. If it is out of specification, adjust it as follows Cruise Cable play “a”: 1 –...

  • Page 128: Coast/Set, Resume/Accel And Cancel Switches

    8E-20 CRUISE CONTROL SYSTEM COAST/SET, RESUME/ACCEL AND CANCEL SWITCHES CAUTION: Never disassemble combination switch assembly. Disas- sembly will spoil its original functions. These switches are built in the combination switch assembly. REMOVAL AND INSTALLATION Refer to “COMBINATION SWITCH” in Section 3C1. INSPECTION 1) Disable air bag system referring to “DISABLING AIR BAG SYS- TEM”...

  • Page 129: Clutch Pedal Position (Cpp) Switch

    CRUISE CONTROL SYSTEM 8E-21 CLUTCH PEDAL POSITION (CPP) SWITCH REMOVAL 1) Disconnect CPP switch connector with ignition switch OFF. 2) Remove CPP switch from pedal bracket. 1. CPP switch for cruise control 2. Stop lamp switch 3. CPP switch for starter (if equipped) INSPECTION Check for resistance between terminals under each condition be- low.

  • Page 130: Stop Lamp Switch (With Pedal Position Switch)

    8E-22 CRUISE CONTROL SYSTEM STOP LAMP SWITCH (WITH PEDAL POSITION SWITCH) INSPECTION 1) Disconnect negative (–) cable at battery. 2) Disconnect stop lamp switch connector and remove stop lamp switch from pedal bracket. 3) Check switch (2 contacts) for resistance under each of the fol- lowing each conditions.

  • Page 131: Cruise Control Actuator Assembly

    CRUISE CONTROL SYSTEM 8E-23 CRUISE CONTROL ACTUATOR ASSEMBLY (WITH CONTROL MODULE) CAUTION: Never disassemble cruise control actuator assembly. Disassembly will spoil its original function. REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disconnect connector from actuator assembly (2) (with control module).

  • Page 132: Cruise Cable

    8E-24 CRUISE CONTROL SYSTEM CRUISE CABLE 1. Actuator cap 2. Actuator assembly 3. Screw 4. Cruise cable 5. Clamp 6. Grommet 7. Clamp at member 8. Accelerator pedal 9. Member REMOVAL 1) Disconnect cruise cable from cruise control arm and accelerator bracket. 2) Remove actuator cap and disconnect cruise cable from actuator.
  • Page 133 Prepared by Overseas Service Department 1st Ed. June, 2001 Printed in Japan Printing: June, 2001...

This manual is also suitable for:

Sq625Sq420

Table of Contents