Suzuki SX4 Service Manual
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Suzuki SX4 Service Manual

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Table of Contents

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Download this manual See also: Owner's Manual
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING
CAUTION
,
!
!
lighted by these signal words.
WARNING
!
Indicates a potential hazard that could result in death or injury.
CAUTION
!
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING
!
This service manual is intended for authorized Suzuki dealers and qualified service technicians only.
Inexperienced technicians or technicians without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.
WARNING
!
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under
"General Description" in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-
vice Precautions" under "On-Vehicle Service" in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
• Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking
process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
The circle with a slash in this manual means "Don't do this" or "Don't let this happen".
IMPORTANT
and NOTE have special meanings. Pay special attention to the messages high-

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Do you have a question about the SX4 and is the answer not in the manual?

Questions and answers

paul murphy
March 19, 2025

My heater stopped working the blower **** is good, control unit ?

0
1 comments:
Mr. Anderson
March 19, 2025

Possible issues with the heater in a Suzuki SX4 if the blower is working but the heater is not include:

1. Incorrect Temperature Output
- Temperature control cable broken or bent (non-A/C and manual A/C) → Check the temperature control cable.
- Temperature selector faulty (non-A/C and manual A/C) → Check the temperature selector.
- Incorrect installation of the temperature control cable (non-A/C and manual A/C) → Check and adjust the position as necessary.
- Temperature control door assembly broken → Repair the temperature control door assembly.
- Air ducts clogged → Repair air ducts.
- Heater core leaked or clogged → Replace the heater core.
- Heater hoses leaked or clogged → Replace heater hoses.
- Thermostat faulty → Check the thermostat.
- Temperature control actuator faulty (auto A/C) → Check the temperature control actuator.
- HVAC control module faulty (auto A/C) → Check the HVAC control module.
- Wiring or grounding faulty (auto A/C) → Repair as necessary.

2. Other Possible Causes
- Air flow control cable broken or bent → Check the air flow control cable.

Checking and addressing these components should help identify and resolve the heater issue.

This answer is automatically generated

0
Adetunji Ismail
March 4, 2025

I have an issue of crank but not starting When I scan it brought this codeU0100 Which means no communication thou crank sensor wire was cut off but it was fix back What could be wrong and what could be the solution,

User image 67c6e55d91ac0
0
1 comments:
Mr. Anderson
May 14, 2025

A Suzuki SX4 that cranks but does not start with a U0100 code (Lost Communication with ECM/PCM) after the crank sensor wire was repaired could have the following issues:

1. Faulty Engine Swap: The engine may not be compatible or not properly installed, as noted in the context that the problem started after an engine replacement.

2. Crankshaft Sensor Issues: Even after repairing the crank sensor wire, the sensor itself could be faulty or not sending a proper signal.

3. ECU Communication Problem (U0100): This indicates a loss of communication with the ECU, possibly due to wiring faults, poor ground connections, or a damaged ECU.

4. Starter Motor Issues: Although the engine cranks, if the starter motor is weak or has voltage issues (as noted with 11.5V), it may not spin the engine fast enough for it to start.

In summary, the likely causes are improper engine installation, crank sensor signal issues, ECU communication failure, or weak starter motor performance.

This answer is automatically generated

0
Gawthorpe
February 27, 2025

Adjust throttle motor

0
1 comments:
Mr. Anderson
February 27, 2025

The idle speed on a Suzuki SX4 should be controlled by the Idle Air Control Valve (IACV) rather than adjusting the idle screw on the throttle body, as the screw is factory set. Before using compressed air in the idle-air-bypass passages, the IACV should be removed to prevent damage to its delicate mechanism. If there is an issue with idle speed, checking the IACV function and referring to the SX4 service manual is recommended.

This answer is automatically generated

1
Germaine Nieves
June 24, 2025

Por donde se saca el selenoide tcc

User image 685adbccd2e68
0
michael c robertson
June 4, 2025

Dash indicator light reset procedure.

0
Ali salah
May 30, 2025

اريد طريقه تركيب ووزن الترس الحديد الخاص بحساس الكرنك

User image 683a3154f034c
0
Arbaj khan
May 21, 2025

alto me B1141 foult code aa rha hai

0
mel coon
May 16, 2025

we bought the car & had no issues besides the filler neck. we changed it & then later on down the road we jumped another car with the suzuki sx4 & after doing it blew the alternator, got new alternator & now if we don't turn headlights on BEFORE you start the car you can hear some pump in the trunk area going on & off. Or you can pull up on the emergency brake one click & it will stop. if you turn off the headlights after it's running the noise will come back. it did NOT do this until we jumped another vehicle, that is what blew the alternator. we have a brand new one in the car now. any ideas of why it's doing this? it seems electrical but we don't know where to begin.

0
ادیک ابرامی
April 21, 2025

دلایل بالا رفتن مصرف بنزین در مدل اتومات

User image 6806728aea58c
0
jack wrona
March 6, 2025

increasing revs when changing gears

-1
1 comments:
Mr. Anderson
March 6, 2025

The Suzuki SX4 may have increasing revs when changing gears due to its drive-by-wire system and the difference in final drive ratios between the manual (4.41) and automatic (2.81) transmissions. This difference causes high cruising RPMs in the manual version and sluggishness in the automatic. Additionally, if the revs climb while going uphill, it may be due to the transmission downshifting or kicking out of overdrive. Other possible causes include low transmission fluid, abuse, or a faulty transmission design.

This answer is automatically generated

0

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Summary of Contents for Suzuki SX4

  • 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 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. 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

    TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Steering ............... 6-i General Information ..........0A-1 Precautions .............. 6-1 Maintenance and Lubrication ......... 0B-1 Steering General Diagnosis ........6A-1 Steering Wheel and Column ........6B-1 Engine .................
  • Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Air Bag Warning ..........00-10 Air Bag System Service Warning ...... 00-10 Precautions............00-1 Fastener Caution..........00-11 Precautions for Vehicles Equipped with a Suspension Caution .......... 00-11 Supplemental Restraint (Air Bag) System ..00-1 Wheels and Tires Caution.........

  • Page 8: Precautions

    • If the air bag system and another vehicle the tester may deploy the air bag or activate system both need repair, SUZUKI the pretensioner. recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 9 Precautions: 00-2 Servicing and Handling • After an air bag (inflator) module has been deployed, the surface of the air bag may WARNING contain a powdery residue. This powder consists primarily of cornstarch (used to Many of service procedures require lubricate the bag as it inflates) and by- disconnection of “A/B”...
  • Page 10 00-3 Precautions: • Even when the accident was light enough not to WARNING cause air bags to activate, be sure to inspect system parts and other related parts according to instructions • For handling and storage of a SDM, select under “Repair and Inspection Required after Accident a place where the ambient temperature in Section 8B”.

  • Page 11: General Precautions

    Precautions: 00-4 General Precautions • Be sure to observe following instructions S7RW0A0000002 when handling service materials such as The WARNING and CAUTION describe some general fuel, oil, fluid, coolant, grease, sealant, precautions that you should observe when servicing a thread lock cement, etc. Otherwise, your vehicle.
  • Page 12 When use of a certain type of lubricant, bond or reconnecting the battery, connect the positive cable sealant is specified, be sure to use the specified type. first and then the negative cable, and replace the terminal cover. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I2RH01010027-01 I2RH01010030-01...

  • Page 13: Warning For Wheel (With Tire) Removal

    Precautions: 00-6 • Be sure to use special tools when instructed. Special tool (A): 09917–98221 (B): 09916–58210 I2RH01010034-01 • Use care not to expose connectors and electrical parts to water which will be a cause of a trouble. I2RH01010031-01 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly.

  • Page 14: Precautions In Servicing 4Wd Model

    00-7 Precautions: Precautions in Servicing 4WD Model • When testing with 2-wheel brake tester, be S7RW0A0000004 sure to observe the following instructions. CAUTION Otherwise, drivetrain damage and personal injury may result. • Never perform any of the following [A], [B] –...

  • Page 15: Precautions For Installing Mobile Communication Equipment

    Precautions: 00-8 Precautions for Installing Mobile Precautions for Electrical Circuit Service S7RW0A0000008 Communication Equipment • When replacing a fuse, make sure to use a fuse of the S7RW0A0000006 When installing mobile communication equipment such specified capacity. Use of a fuse with a larger capacity as CB (Citizens-Band)-radio or cellular-telephone, be will cause a damage to the electrical parts and a fire.
  • Page 16 00-9 Precautions: • When connecting connectors, also hold connectors • Be careful not to touch the electrical terminals of parts and put them together until they lock securely (a click which use microcomputers (e.g. electronic control unit is heard). like as ECM, PCM, P/S controller, etc.). The static electricity from your body can damage these parts.

  • Page 17: Air Bag Warning

    Never connect probe where male terminal is only by an authorized SUZUKI dealer. Refer supposed to fit. to “Air Bag System Components, Wiring and Connectors Location in Section 8B” in...

  • Page 18: Fastener Caution

    00-11 Precautions: Fastener Caution ABS Caution S7RW0A0000011 S7RW0A0000015 CAUTION • When ABS control module is removed / installed, do not use impact wrenches which generate shock or When fasteners are removed, always reinstall impact to avoid damaging sensors in ABS control them at the same location from which they module.

  • Page 19: Repair Instructions

    Precautions: 00-12 Repair Instructions Electrical Circuit Inspection Procedure 4) Using continuity check or voltage check the following S7RW0A0006001 procedure, check the wire harness for open circuit While there are various electrical circuit inspection and poor connection with its terminals. Locate methods, described here is a general method to check abnormality, if any.
  • Page 20 00-13 Precautions: Voltage Check Short Circuit Check (Wire Harness to Ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect negative (–) cable at battery. check can be used as circuit check. 2) Disconnect connectors at both ends of the circuit to 1) With all connectors connected and voltage applied to be checked.

  • Page 21: Intermittent And Poor Connection Inspection

    Precautions: 00-14 Intermittent and Poor Connection Inspection • Poor terminal-to-wire connection. S7RW0A0006002 Check each wire harness in problem circuits for poor Most intermittent are caused by faulty electrical connection by shaking it by hand lightly. If any connections or wiring, although a sticking relay or abnormal condition is found, repair or replace.
  • Page 22 00-15 Precautions:...

  • Page 23: Maintenance And Lubrication

    Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Fuel Evaporative Emission Control System Inspection............0B-7 General Description ..........0A-1 Brake Discs and Pads (Front) Inspection....0B-7 Abbreviations ............0A-1 Brake Drums and Shoes (Rear) Inspection ..0B-7 Symbols .............. 0A-2 Brake Hoses and Pipes Inspection .....0B-8 Wire Color Symbols ..........

  • Page 24: Electronic Stability Program

    0A-1 General Information: General Information General Information General Description Abbreviations S7RW0A0101001 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center GEN: Generator ABS: Anti-lock Brake System GND: Ground AC: Alternating Current GPS: Global Positioning System A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HVAC: Heating, Ventilating and Air Conditioning A/F: Air Fuel Mixture Ratio HC: Hydrocarbons...

  • Page 25: Differential

    WU-TWC: Warm Up Three Way Catalytic Converter Symbols S7RW0A0101002 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO. 1216B 99000-31230 Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E...
  • Page 26 0A-3 General Information: There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “GRN”). The dual-colored wire uses two color symbols (i.e. “GRN/YEL”). The first symbol represents the base color of the wire (“GRN”...
  • Page 27 General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.

  • Page 28: Rear Suspension

    0A-5 General Information: Vehicle Lifting Points S7RW0A0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.

  • Page 29: Vehicle Identification Number

    General Information: 0A-6 Vehicle Identification Number In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against engine front mounting S7RW0A0101006 The number is punched on the front dash panel in member (1) or rear jacking bracket (2). engine room and it is also attached on the left side of instrument panel depending on the vehicle specification.
  • Page 30 0A-7 General Information: Component Location Warning, Caution and Information Labels Location S7RW0A0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.

  • Page 31: General Information

    General Information: 0A-8 I7RW0A010001-01 1. Air bag label on driver air bag (inflator) module 7. Pretensioner label on seat belt retractor 2. Air bag label on contact coil assembly 8. Side/Curtain air bag label on pillar (both right and left sides) (if equipped) 3.

  • Page 32: Maintenance Schedule Under Normal Driving

    0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S7RW0A0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S7RW0A0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
  • Page 33 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Miles (x 1,000) Months Inspect at first 15,000 km (9,000 miles Brake lever and cable (damage, stroke, operation) (I: only Chassis and body Clutch pedal (travel) Clutch fluid (leakage, level) (I: — —...
  • Page 34 0B-3 Maintenance and Lubrication: Severe Maintenance Maintenance Maintenance interval condition code operation Every 15,000 km (9,000 miles) or 12 months – B C D – – – – Accessory drive belt Every 45,000 km (27,000 miles) or 36 months Every 7,500 km A –...
  • Page 35 Maintenance and Lubrication: 0B-4 Accessory Drive Belt Replacement Before draining engine oil, check engine for oil leakage. S7RW0A0206002 If any evidence of leakage is found, make sure to correct Water Pump and Generator Drive Belt defective part before proceeding to the following work. Replace belt with new one referring to “Water Pump / 1) Drain engine oil by removing drain plug.
  • Page 36 0B-5 Maintenance and Lubrication: 4) Screw new filter on oil filter stand by hand until the Engine oil specification filter O-ring contacts mounting surface. Oil pan capacity: About 3.7 liters (7.8 / 6.5 US / lmp pt.) CAUTION Oil filter capacity: About 0.2 liter (0.4 / 0.3 US / To tighten oil filter properly, it is important to lmp pt.) accurately identify the position at which filter...
  • Page 37 Maintenance and Lubrication: 0B-6 Exhaust System Inspection S7RW0A0206006 WARNING To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance, or the vehicle is raised for other service, check exhaust system as follows: I2RH01140007-01...

  • Page 38: Inspection

    0B-7 Maintenance and Lubrication: Fuel Tank Inspection Brake Discs and Pads (Front) Inspection S7RW0A0206012 S7RW0A0206015 Check fuel tank damage, cracks, fuel leakage, corrosion 1) Remove wheel and caliper but don’t disconnect and tank bolts looseness. brake hose from caliper. If a problem is found, repair or replace. 2) Check front disc brake pads and discs for excessive wear, damage and deflection.

  • Page 39: Brake Hoses And Pipes Inspection

    Maintenance and Lubrication: 0B-8 Brake Hoses and Pipes Inspection 2) Check tooth tip of each notch for damage or wear. If S7RW0A0206017 any damage or wear is found, replace parking lever. Perform this inspection where these is enough light and 3) Check parking brake lever for proper operation and use a mirror as necessary.

  • Page 40: Tires Inspection

    0B-9 Maintenance and Lubrication: Tires Inspection Suspension System Inspection S7RW0A0206021 S7RW0A0206024 1) Check tires for uneven or excessive wear, or • Inspect front struts and rear shock absorbers for evidence of oil leakage, dents or any other damage on damage. If defective, replace. Refer to “Irregular and/or Premature Wear sleeves;...

  • Page 41: Drive Shaft (Axle) Boots Inspection

    Maintenance and Lubrication: 0B-10 Propeller Shaft (4WD) Inspection 2) Check bolts and nuts for tightness and retighten them as necessary. Repair or replace defective S7RW0A0206027 1) Check propeller shaft connecting bolts for parts, if any. looseness. If looseness is found, tighten to specified 3) Check steering linkage for looseness and damage.

  • Page 42: Transfer Oil Inspection (4Wd)

    0B-11 Maintenance and Lubrication: Transfer Oil Inspection (4WD) HVAC Air Filter (If Equipped) Replacement S7RW0A0206033 S7RW0A0206039 Check transfer oil for leakage, contamination and level Replace HVAC air filter with new one referring to “HVAC referring to “Transfer Oil Level Check in Section 3C”. Air Filter Removal and Installation (If Equipped) in Section 7A”.

  • Page 43: Specifications

    Maintenance and Lubrication: 0B-12 Clutch (for Manual Transaxle) Steering Check for the following. • Check to ensure that steering wheel is free from • Clutch is completely released when depressing clutch instability, or abnormally heavy feeling. pedal, • Check that the vehicle does not wander or pull to one •...

  • Page 44: Special Tools And Equipment

    0B-13 Maintenance and Lubrication: Special Tools and Equipment Recommended Fluids and Lubricants S7RW0A0208001 Engine oil SG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine oil viscosity.) Engine coolant “Antifreeze/Anticorrosion coolant” (Ethylene glycol base coolant) Brake fluid Refer to reservoir cap of brake master cylinder.
  • Page 45 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC Clearance ..........1A-26 Troubleshooting for Communication Error Precautions............. 1-1 with Scan Tool Using CAN......1A-26 Precautions for Engine.......... 1-1 DTC Table............1A-32 Engine General Information and Fail-Safe Table..........1A-36 Scan Tool Data ..........1A-38 Diagnosis ..........
  • Page 46 1-ii Table of Contents DTC P0118: Engine Coolant Temperature DTC P0617: Starter Relay Circuit High ...1A-141 Circuit High .............1A-84 DTC P1510: ECM Back-Up Power Supply DTC P0122: Throttle Position Sensor (Main) Malfunction............1A-143 Circuit Low ............1A-87 DTC P2101: Throttle Actuator Control Motor DTC P0123: Throttle Position Sensor (Main) Circuit Range / Performance......1A-144 DTC P2102: Throttle Actuator Control Motor...
  • Page 47 Table of Contents 1-iii Vacuum Hose Inspection ........1B-3 Camshaft Position Control (VVT Variable EVAP Canister Purge Valve Inspection ....1B-3 Valve Timing) System Description ....1D-3 EVAP Canister Inspection........1B-4 Diagnostic Information and Procedures ....1D-5 EGR Valve Removal and Installation (If Compression Check..........1D-5 Equipped)............
  • Page 48 1-iv Table of Contents Main Bearings, Crankshaft and Cylinder Radiator Cooling Fan Disassembly and Block Removal and Installation .......1D-59 Reassembly ............1F-9 Crankshaft Inspection ........1D-62 Radiator On-Vehicle Inspection and Cleaning ..1F-9 Main Bearings Inspection........1D-64 Radiator Removal and Installation ...... 1F-9 Sensor Plate Inspection ........1D-68 Water Pump / Generator Drive Belt Tension Rear Oil Seal Inspection ........1D-68...
  • Page 49 Table of Contents 1-v Ignition System Wiring Circuit Diagram....1H-2 Charging System ........1J-1 Component Location ...........1H-3 General Description ..........1J-1 Ignition System Components Location ....1H-3 Battery Description..........1J-1 Diagnostic Information and Procedures....1H-4 Generator Description ......... 1J-2 Ignition System Symptom Diagnosis....1H-4 Diagnostic Information and Procedures .... 1J-3 Reference Waveform of Ignition System.....1H-4 Battery Inspection ..........

  • Page 50: Precautions

    1-1 Precautions: Precautions Engine Precautions Precautions for Engine S7RW0A1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 1A”. Precautions of ECM Circuit Inspection Refer to “Precautions of ECM Circuit Inspection in Section 1A”.

  • Page 51: Engine General Information And Diagnosis

    ECM memory. Such disconnection will erase memorized information in ECM memory. • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan IYSQ01110001-01 tool or CAN communication OBD generic scan tool. Before using scan tool, read its Operator’s...

  • Page 52: Precautions For Dtc Troubleshooting

    • Before performed trouble shooting, be sure to read the scan tool used. the “Precautions of ECM Circuit Inspection”. – SUZUKI scan tool displays DTC detected by ECM. • When measuring circuit voltage, resistance and/or – CAN communication OBD generic scan tool...

  • Page 53: Precaution On Can Troubleshooting

    Engine General Information and Diagnosis: 1A-3 Precaution on CAN Troubleshooting S7RW0A1100007 CAN schematic and routing diagram : [C] : [D] : [E] I7RW0A110001-03 [A]: Non-Taiwan model [C]: CAN high line (RED) [E]: K-line [B]: Taiwan model [D]: CAN low line (WHT)
  • Page 54 CAN has a trouble, it is possible to communicate between scan tool and these control modules. Bus check with SUZUKI scan tool SUZUKI scan tool (SUZUKI-SDT) efficiently diagnoses a CAN bus malfunction by “Communication Bus Check” and “Communication Malfunction DTC” under “Bus check”.

  • Page 55: General Description

    Engine General Information and Diagnosis: 1A-5 General Description Statement on Cleanliness and Care Engine Diagnosis General Description S7RW0A1101001 S7RW0A1101002 An automobile engine is a combination of many NOTE machined, honed, polished and lapped surfaces with There are two types of OBD system tolerances that are measured in the thousands of an depending on the vehicle specification.
  • Page 56 1 driving cycle of the DTC which is • It is possible to communicate via DLC (3) by using not detected in the 2 driving cycle detection logic. only SUZUKI scan tool (2) but also CAN communication OBD generic scan tool. (Diagnostic Freeze Frame Data information can be accessed by using a scan tool.)
  • Page 57 • Heated oxygen sensor-2 erased unless the power to ECM is shut off for • ECT sensor specified time or it is cleared by SUZUKI scan tool • TP sensor (SUZUKI-SDT) (2).) For further detail of the checking / clearing procedure, •...

  • Page 58: Data Link Connector (Dlc) Description

    OBD CAN Hi line (6) and Low line (3) (CAN line of ISO 15765-4) are used for SUZUKI scan tool (SUZUKI-SDT) (7) or CAN communication OBD generic scan tool to communicate with ECM (included in immobilizer control) and TCM (Transmission Control Module) (for A/T model).

  • Page 59: Can Communication System Description

    Engine General Information and Diagnosis: 1A-9 CAN Communication System Description S7RW0A1101006 ECM (1), ABS / ESP® control module (2), BCM (3), combination meter (4), keyless start control module (if equipped with keyless start control system) (5), 4WD control module (for 4WD model) (6), steering angle sensor (ESP® model) (8), yaw rate / G sensor (ESP®...
  • Page 60 1A-10 Engine General Information and Diagnosis: ECM Transmission Data Keyless start Combination ESP® control 4WD control control meter module module module Driving cycle active Warm up cycle active Throttle position signal A/C compressor clutch signal A/C refrigerant pressure signal Fuel consumption signal Fuel level signal Odometer signal Engine coolant temperature signal...

  • Page 61: Air Intake System Description

    Engine General Information and Diagnosis: 1A-11 Air Intake System Description S7RW0A1101007 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “Electric Throttle Body System Description”.), and intake manifold (4). The air (by the amount corresponding to throttle valve (5) opening and engine speed) is filtered by the air cleaner, distributed by the intake, and finally drawn into each combustion chamber.

  • Page 62: Electronic Control System Description

    1A-12 Engine General Information and Diagnosis: Operation Description ECM (5) detects opening (depressed extent of pedal) of the accelerator pedal based on signal voltage of the APP sensor (1) and using that data and engine operation condition, it calculates the optimum throttle valve opening. On the other hand, it detects the throttle valve opening based on the signal voltage of the throttle position sensor (3) included in the throttle body (2) and compares it with the above calculated optimum throttle valve opening.

  • Page 63: Engine And Emission Control Input / Output Table

    Engine General Information and Diagnosis: 1A-13 Engine and Emission Control Input / Output Table S7RW0A1101010 ELECTRIC CONTROL DEVICE OUTPUT INPUT BAROMETRIC PRESSURE SENSOR BRAKE LIGHT 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 64: Schematic And Routing Diagram

    1A-14 Engine General Information and Diagnosis: Schematic and Routing Diagram ECM Input / Output Circuit Diagram S7RW0A1102003 E01-35 E01-45 E01-37 E01-32 E01-52 C01-45 E01-34 C01-44 E01-36 C01-43 E01-51 C01-54 E01-50 C01-40 C01-42 RED/YEL C01-20 C01-41 C01-1 BLU/YEL C01-2 BLU/WHT C01-21 BLK/ORN C01-16 BLU/RED...
  • Page 65 Engine General Information and Diagnosis: 1A-15 4. CMP sensor 28. Electric throttle body assembly 52. To ABS / ESP® control module 5. CKP sensor 29. Throttle actuator 53. “STOP” fuse 6. HO2S-1 30. TP sensor 54. Main relay 7. HO2S-2 (if equipped) 31.
  • Page 66 1A-16 Engine General Information and Diagnosis: Connector: C01 Terminal Wire color Circuit Terminal Wire color Circuit BLU/YEL Fuel injector No.1 output — — BLU/WHT Fuel injector No.2 output — — EGR valve (stepper motor coil 2) GRN/ORN — — output EGR valve (stepper motor coil 1) GRN/RED —...
  • Page 67 Engine General Information and Diagnosis: 1A-17 Connector: E01 Terminal Wire color Circuit Terminal Wire color Circuit BLK/RED Main power supply Ground for ECM Power source for ECM internal Power supply of throttle WHT/RED memory actuator drive circuit. CAN communication line (active high signal) to ABS / ESP®...

  • Page 68: Engine And Emission Control System Flow Diagram

    1A-18 Engine General Information and Diagnosis: Engine and Emission Control System Flow Diagram S7RW0A1102002 I7RW0A110008-02...

  • Page 69: Engine And Emission Control System Diagram

    Engine General Information and Diagnosis: 1A-19 Engine and Emission Control System Diagram S7RW0A1102001 I5RW0C110009-02...
  • Page 70 1A-20 Engine General Information and Diagnosis: 1. Air cleaner 17. Radiator cooling fan 33. A/C switch (A/C model) 2. EVAP canister purge valve 18. A/C condenser cooling fan 34. A/C evaporator outlet air temp. sensor (manual A/C model) 3. MAF and IAT sensor 19.

  • Page 71: Component Location

    Engine General Information and Diagnosis: 1A-21 Component Location Electronic Control System Components Location S7RW0A1103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0D110016-03 Information sensors Control devices Others 1.

  • Page 72: Diagnostic Information And Procedures

    1A-22 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine and Emission Control System Check S7RW0A1104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
  • Page 73 Engine General Information and Diagnosis: 1A-23 Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test”. Is there any problem symptom, DTC or abnormal condition?
  • Page 74 1A-24 Engine General Information and Diagnosis: Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.

  • Page 75: Malfunction Indicator Lamp (Mil) Check

    Engine General Information and Diagnosis: 1A-25 Step 2: DTC / Freeze Frame Data Check, Record and Step 11: Final Confirmation Test Clearance Confirm that the problem symptom has gone and the First, check DTC (including pending DTC), referring to engine is free from any abnormal conditions. If what has “DTC Check”.

  • Page 76: Dtc Clearance

    Board Diagnostic (OBD) System”. – TCM – Keyless start control module 1) Connect SUZUKI scan tool or CAN communication OBD generic scan tool to data link connector in the – ESP® control module same manner as when making this connection for –...
  • Page 77 Engine General Information and Diagnosis: 1A-27 Wiring Diagram L34-3 C06-17 L34-2 C06-7 WHT C01-13 G26-22 RED C01-12 G26-23 E01-3 E01-18 G241-9 G241-6 G241-7 G241-10 E08-12 E08-1 G241-8 E08-2 G241-11 E08-13 G33-9 E04-2 G33-10 E04-1 G04-4 G04-2 G04-3 G16-19 G04-1 G16-18 G26-22 C06-17 G26-23...
  • Page 78 1A-28 Engine General Information and Diagnosis: 14 13 12 11 10 9 8 7 24 23 18 17 3938 32 31 3938 32 31 5453 5453 47 46 47 46 18 17 13 12 39 38 33 32 31 30 29 28 27 24 23 18 17...
  • Page 79 Engine General Information and Diagnosis: 1A-29 Troubleshooting Step Action Scan tool check Go to Step 2. Scan tool faulty. Refer to its operator’s manual. 1) Disconnect scan tool from DLC with ignition switch turned OFF. 2) Check for proper connection to all terminals of scan tool connector.
  • Page 80 1A-30 Engine General Information and Diagnosis: Step Action CAN line check between DLC and BCM Go to Step 6. Repair CAN line. 1) Turn ignition switch to OFF position. 2) Disconnect BCM connector from BCM. 3) Check for proper connection to all terminals of BCM connector.
  • Page 81 Engine General Information and Diagnosis: 1A-31 Step Action CAN line check Go to Step 8. Repair CAN line. 1) Turn ignition switch to OFF position. 2) Disconnect connectors of all control module / sensor communicated by CAN. 3) Check all the following CAN lines for open, short to power circuit, short to ground circuit, short to other CAN line and high resistance.

  • Page 82: Dtc Table

    1A-32 Engine General Information and Diagnosis: DTC Table S7RW0A1104006 NOTE • There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”. • For non-Euro-OBD model, some of DTC No. with delta ( ) mark in the following table can not be detected by ECM depending on vehicle specification.
  • Page 83 Engine General Information and Diagnosis: 1A-33 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Engine coolant temperature circuit 1 driving *P0117 Circuit voltage of ECT sensor is less than specification. cycle Engine coolant temperature circuit 1 driving *P0118 Circuit voltage of ECT sensor is more than specification.
  • Page 84 1A-34 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Catalyst system efficiency below 2 driving Output waveforms of HO2S-1 and HO2S-2 are similar. *P0420 threshold cycles Evaporative emission system purge Monitor signal of EVAP canister purge valve is different 2 driving *P0443 control valve circuit...
  • Page 85 Engine General Information and Diagnosis: 1A-35 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Difference between the opening angle based on Pedal position sensor (main / sub) accelerator pedal position sensor (main) and the opening 1 driving *P2138 voltage correlation angle based on accelerator pedal position sensor (sub) is...

  • Page 86: Fail-Safe Table

    1A-36 Engine General Information and Diagnosis: For Vehicle Equipped with A/T NOTE There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”. When using CAN communication OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also the following DTC(s) is displayed on CAN communication OBD generic scan tool simultaneously.
  • Page 87 Engine General Information and Diagnosis: 1A-37 DTC No. Detected item Fail-safe operation • ECM turns off throttle actuator control relay and throttle valve is fixed at the opening of about 7° from its completely closed position (default P0122 Throttle position sensor (main) circuit low opening).

  • Page 88: Scan Tool Data

    1A-38 Engine General Information and Diagnosis: Scan Tool Data S7RW0A1104009 As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
  • Page 89 Engine General Information and Diagnosis: 1A-39 Normal condition / Scan tool data Vehicle condition reference values SHORT FT B1 At specified idle speed after warming up –20 – +20% (SHORT TERM FUEL TRIM) LONG FT B1 At specified idle speed after warming up –20 –...
  • Page 90 1A-40 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values Engine coolant temp.: lower RADIATOR FAN than 97.5 °C (207.5 °F) (RADIATOR COOLING FAN Ignition switch ON Engine coolant temp.: 100 CONTROL RELAY) °C (212 °F) Blower motor switch and A/C A/C COND FAN switch turned ON/ECT over...
  • Page 91 Engine General Information and Diagnosis: 1A-41 Scan Tool Data Definitions FUEL SYSTEM B1 (FUEL SYSTEM STATUS) Air/fuel ratio feedback loop status displayed as one of COOLANT TEMP (ENGINE COOLANT TEMPERATURE, °C, °F) the followings. OPEN: Open-loop has not yet satisfied conditions to go It is detected by engine coolant temp.
  • Page 92 1A-42 Engine General Information and Diagnosis: A/C COND FAN (A/C CONDENSER COOLING FAN CANIST PRG DUTY (EVAP CANISTER PURGE FLOW DUTY, %) CONTROL RELAY, ON/OFF) This parameter indicates valve ON (valve open) time ON: Command for A/C condenser cooling fan control rate within a certain set cycle of EVAP canister purge relay operation being output.

  • Page 93: Visual Inspection

    Engine General Information and Diagnosis: 1A-43 INJ PULSE WIDTH (FUEL INJECTION PULSE WIDTH, THROTTLE MOTOR RELAY (ON/OFF) ON: Throttle actuator (motor) control activated by ECM. msec.) OF: Throttle actuator (motor) control stopped by ECM. This parameter indicates time of the injector drive (valve opening) pulse which is output from ECM (but injector VEHICLE SPEED (km/h, mph) drive time of NO.1 cylinder for multiport fuel injection).
  • Page 94 1A-44 Engine General Information and Diagnosis: Step Action Check keyless start control system malfunction Go to Step 5. Keyless start control system malfunction. 1) Check keyless start control system referring to “Keyless Start System Operation Inspection in Section 10E”. Is check result satisfactory? Is engine cranked? Go to Step 6.

  • Page 95: Engine Symptom Diagnosis

    Engine General Information and Diagnosis: 1A-45 Engine Symptom Diagnosis S7RW0A1104012 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection” and “Engine Basic Inspection”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug “Spark Plug Inspection in Section 1H”...
  • Page 96 1A-46 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noise – Valve Improper valve lash “Camshaft, Tappet and Shim Inspection in noise Section 1D” Worn valve stem and guide “Valves and Valve Guides Inspection in NOTE Section 1D”...
  • Page 97 Engine General Information and Diagnosis: 1A-47 Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection in Section 1F” Poor water pump performance “Water Pump Inspection in Section 1F” Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning in Section 1F”...
  • Page 98 1A-48 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Excessive engine oil Sticky piston ring “Cylinders, Pistons and Piston Rings consumption – Oil Inspection in Section 1D” entering combustion Worn piston and cylinder “Cylinders, Pistons and Piston Rings chamber Inspection in Section 1D”...
  • Page 99 Engine General Information and Diagnosis: 1A-49 Condition Possible cause Correction / Reference Item Excessive detonation – Faulty spark plug “Spark Plug Inspection in Section 1H” Engine makes Loose connection of high-tension cord “High-Tension Cord Removal and Installation continuously sharp in Section 1H” metallic knocks that Engine overheating Condition “Engine overheating”...
  • Page 100 1A-50 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection in Section 1H” engine fails to idle Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation in Section 1H”...
  • Page 101 Engine General Information and Diagnosis: 1A-51 Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection in Section 1H” (HC) emission or carbon Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation monoxide (CO) in Section 1H”...

  • Page 102: Malfunction Indicator Lamp Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)

    1A-52 Engine General Information and Diagnosis: Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S7RW0A1104013 Wiring Diagram C01-13 C01-12 E01-3 E01-18 RED/BLK BLK/ORN G241-31 G241-16 BLK/YEL BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30...
  • Page 103 Engine General Information and Diagnosis: 1A-53 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • 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 104: Malfunction Indicator Lamp Remains On After Engine Starts

    1A-54 Engine General Information and Diagnosis: Malfunction Indicator Lamp Remains ON after Engine Starts S7RW0A1104014 Wiring Diagram Refer to “Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)”. Circuit Description When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point).

  • Page 105: Dtc P0010: Camshaft Position Actuator Circuit (For Engine With Vvt System)

    Engine General Information and Diagnosis: 1A-55 DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system) S7RW0A1104015 System and Wiring Diagram GRN/RED C01-60 C01-58 BLK/ORN C01-59 GRN/WHT C01-15 C01-30 E01-31 [A]: 39 38 32 31 39 38 32 31 54 53 47 46 54 53...
  • Page 106 1A-56 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 107: Dtc P0011 / P0012: Camshaft Position - Timing Over-Advanced Or System Performance / Retarded (For Engine With Vvt System)

    Engine General Information and Diagnosis: 1A-57 Step Action Oil control valve check Substitute a known- Faulty oil control valve. Check oil control valve referring to “Oil Control Valve good ECM and recheck. Inspection (For Engine with VVT) in Section 1D”. Is resistance within specified value? DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for engine with VVT system)
  • Page 108 Installation in Section temperature. 1D”. If OK, go to Step 5. 3) Select menu to “Data List”. 4) Check that “VVT GAP” displayed on SUZUKI scan tool is 0 – 3°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.

  • Page 109: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1)

    Engine General Information and Diagnosis: 1A-59 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) S7RW0A1104017 Wiring Diagram BLK/WHT E01-29 BLK/WHT BLK/RED C01-46 C01-10 C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110020-01...
  • Page 110 1A-60 Engine General Information and Diagnosis: Step Action HO2S-1 heater power circuit check Go to Step 3. “BLK/WHT” wire is open circuit or shorted to 1) Disconnect connector from HO2S-1 with ignition switch ground circuit. turned OFF. 2) Check for proper connection to HO2S-1 at “BLK/WHT” and “BLK/RED”...

  • Page 111: Dtc P0037 / P0038: Ho2S Heater Control Circuit Low / High (Sensor-2)

    Engine General Information and Diagnosis: 1A-61 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) S7RW0A1104018 Wiring Diagram BLK/WHT E01-29 BLK/WHT RED/BLU C01-47 C01-11 C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110021-01...
  • Page 112 1A-62 Engine General Information and Diagnosis: Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. HO2S-2 heater power circuit check Go to Step 3. “BLK/WHT” wire is open circuit or shorted to 1) Disconnect connector from HO2S-2 with ignition switch ground circuit.

  • Page 113: Dtc P0101: Mass Air Flow Circuit Range / Performance

    Engine General Information and Diagnosis: 1A-63 DTC P0101: Mass Air Flow Circuit Range / Performance S7RW0A1104019 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED E01-16 BLK/RED GRN/BLK C01-26 C01-27 BLK/YEL C01-25 GRY/BLU GRY/BLU...
  • Page 114 1A-64 Engine General Information and Diagnosis: NOTE Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temperature at engine start: –10 °C (14°F) to 80 °C (176 °F) • Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F) •...
  • Page 115 Engine General Information and Diagnosis: 1A-65 Step Action MAF sensor power supply voltage check Go to Step 6. “BLK/RED” wire is open circuit. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “BLK/RED”...

  • Page 116: Dtc P0102: Mass Air Flow Circuit Low Input

    1A-66 Engine General Information and Diagnosis: DTC P0102: Mass Air Flow Circuit Low Input S7RW0A1104020 Wiring Diagram Refer to “DTC P0101: Mass Air Flow Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of MAF sensor output is less than specified value for specified time •...

  • Page 117: Dtc P0103: Mass Air Flow Circuit High Input

    Engine General Information and Diagnosis: 1A-67 Step Action MAF sensor signal circuit check Go to Step 7. “GRN/BLK” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure voltage between “GRN/BLK” wire terminal of MAF and IAT sensor connector and engine ground with ignition switch turned ON.
  • Page 118 1A-68 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 119: Dtc P0106: Manifold Absolute Pressure Range / Performance

    Engine General Information and Diagnosis: 1A-69 DTC P0106: Manifold Absolute Pressure Range / Performance S7RW0A1104022 Wiring Diagram GRY/RED GRY/RED C01-14 RED/BLK C01-53 C01-58 BLK/ORN GRY/BLU GRY/BLU C01-55 C01-15 C01-30 E01-31 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...

  • Page 120: Dtc P0107: Manifold Absolute Pressure Circuit Low Input

    1A-70 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
  • Page 121 Engine General Information and Diagnosis: 1A-71 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 122: Dtc P0108: Manifold Absolute Pressure Circuit High Input

    1A-72 Engine General Information and Diagnosis: Step Action MAP sensor output signal check Substitute a known- Faulty MAP sensor. good ECM and recheck. 1) Check MAP sensor according to “Manifold Absolute Pressure (MAP) Sensor Inspection (If Equipped) in Section 1C”. Is it in good condition? DTC P0108: Manifold Absolute Pressure Circuit High Input S7RW0A1104024...
  • Page 123 Engine General Information and Diagnosis: 1A-73 Step Action MAP sensor power supply voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from MAP sensor with ignition switch turned OFF. 2) Check for proper connection of MAP sensor at “GRY/ RED”, “RED/BLK”...

  • Page 124: Dtc P0111: Intake Air Temperature Circuit Range / Performance

    1A-74 Engine General Information and Diagnosis: Step Action MAP sensor output signal check Substitute a known- Faulty MAP sensor. good ECM and recheck. 1) Check MAP sensor according to “Manifold Absolute Pressure (MAP) Sensor Inspection (If Equipped) in Section 1C”. Is it in good condition? DTC P0111: Intake Air Temperature Circuit Range / Performance S7RW0A1104025...
  • Page 125 Engine General Information and Diagnosis: 1A-75 5) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.

  • Page 126: Dtc P0112: Intake Air Temperature Sensor Circuit Low

    1A-76 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 6. “BLK/YEL” wire is shorted to ground or 1) Disconnect connectors from ECM with ignition switch other circuit. turned OFF. If wire is OK, substitute 2) Measure resistance between “BLK/YEL” wire terminal of a known-good ECM and MAF and IAT sensor connector and vehicle body recheck.
  • Page 127 Engine General Information and Diagnosis: 1A-77 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and run it for 10 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to...

  • Page 128: Dtc P0113: Intake Air Temperature Sensor Circuit High

    1A-78 Engine General Information and Diagnosis: Step Action IAT short circuit check Go to Step 6. “BLK/YEL” wire is shorted to other circuit. 1) Turn ON ignition switch. If wire is OK, substitute 2) Measure voltage between “BLK/YEL” wire terminal of a known-good ECM and MAF and IAT sensor connector and vehicle body recheck.
  • Page 129 Engine General Information and Diagnosis: 1A-79 Step Action IAT sensor voltage check Go to Step 7. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “BLK/YEL”...

  • Page 130: Dtc P0116: Engine Coolant Temperature Circuit Range / Performance

    1A-80 Engine General Information and Diagnosis: Step Action Ground circuit check “GRY/BLU” wire is open Faulty ECM ground circuit or high resistance circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors circuit. Poor “C01-55” substitute a known- connected.
  • Page 131 Engine General Information and Diagnosis: 1A-81 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
  • Page 132 1A-82 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Disconnect ECT sensor connector with ignition switch turned OFF. 2) Check for proper connection to ECT sensor connector at “GRY/BLU” and “LT GRN” wire terminals. 3) If OK, then with ignition switch ON, measure voltage between “LT GRN”...

  • Page 133: Dtc P0117: Engine Coolant Temperature Circuit Low

    Engine General Information and Diagnosis: 1A-83 Step Action 10 Ground circuit check “GRY/BLU” wire is high Faulty ECM ground resistance circuit. circuit. 1) Remove ECM from its bracket with ECM connectors connected. Poor “C01-55” If circuit is OK, connection. substitute a known- 2) Measure resistance between “C01-55”...

  • Page 134: Dtc P0118: Engine Coolant Temperature Circuit High

    1A-84 Engine General Information and Diagnosis: Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from ECT sensor with ignition switch turned OFF. 2) Check for proper connection to ECT sensor at “LT GRN” and “GRY/BLU”...
  • Page 135 Engine General Information and Diagnosis: 1A-85 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
  • Page 136 1A-86 Engine General Information and Diagnosis: Step Action ECT sensor harness resistance check Go to Step 7. “LT GRN” wire is high resistance circuit. 1) Measure resistance between “C01-24” terminal of ECM connector and “LT GRN” wire terminal of ECT sensor connector with ignition switch turn OFF.

  • Page 137: Dtc P0122: Throttle Position Sensor (Main) Circuit Low

    Engine General Information and Diagnosis: 1A-87 DTC P0122: Throttle Position Sensor (Main) Circuit Low S7RW0A1104031 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 E01-45 E01-32 C01-45 C01-44 C01-43 C01-54 C01-40 C01-42...
  • Page 138 1A-88 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.

  • Page 139: Dtc P0123: Throttle Position Sensor (Main) Circuit High

    Engine General Information and Diagnosis: 1A-89 Step Action Wire harness check Substitute a known- “RED” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “C01-43” terminal of ECM connector and engine ground.
  • Page 140 1A-90 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
  • Page 141 Engine General Information and Diagnosis: 1A-91 Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Measure voltage between “GRN” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned ON. Is voltage 4 –...

  • Page 142: Dtc P0131 / P0132: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-1)

    1A-92 Engine General Information and Diagnosis: DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1) S7RW0A1104033 Wiring Diagram BLK/WHT E01-29 BLK/WHT BLK/RED C01-46 C01-10 C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
  • Page 143 Engine General Information and Diagnosis: 1A-93 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
  • Page 144 1A-94 Engine General Information and Diagnosis: Step Action HO2S-1 ground check Go to Step 5. “ORN” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-1 with ignition switch Poor “C01-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-1 connector at ground.

  • Page 145: Dtc P0133: O2 Sensor (Ho2S) Circuit Slow Response (Sensor-1)

    Engine General Information and Diagnosis: 1A-95 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) S7RW0A1104034 Wiring Diagram Refer to “DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Response time (time to change from lean to rich or from rich to lean) of HO2S-1 output...

  • Page 146: Dtc P0134: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-1)

    1A-96 Engine General Information and Diagnosis: DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1) S7RW0A1104035 Wiring Diagram Refer to “DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S voltage is higher than specified value for 1 min.
  • Page 147 Engine General Information and Diagnosis: 1A-97 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. HO2S-1 output voltage check Intermittent trouble. Go to Step 3. Check for intermittent 1) Connect scan tool to DLC with ignition switch turned referring to “Intermittent OFF.

  • Page 148: Dtc P0137 / P0138: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-2)

    1A-98 Engine General Information and Diagnosis: Step Action Air intake system check Replace HO2S-1 Repair or replace air referring to “Heated intake system. 1) Check air intake system for clog or leak. Oxygen Sensor (HO2S- Is it OK? 1 and HO2S-2) Removal and Installation (If Equipped) in Section 1C”.
  • Page 149 Engine General Information and Diagnosis: 1A-99 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
  • Page 150 1A-100 Engine General Information and Diagnosis: Step Action HO2S-2 ground check Go to Step 5. “ORN” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-2 with ignition switch Poor “C01-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-2 connector at ground.

  • Page 151: Dtc P0140: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-2)

    Engine General Information and Diagnosis: 1A-101 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) S7RW0A1104037 Wiring Diagram Refer to “DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S-2 voltage is higher than specified value after warming up engine...
  • Page 152 1A-102 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 4. “BRN” wire is high resistance circuit or 1) Turn OFF ignition switch. open circuit. Poor “C01- 2) Remove ECM from its bracket with ECM connectors 11”...

  • Page 153: Dtc P0171 / P0172: Fuel System Too Lean / Rich

    Engine General Information and Diagnosis: 1A-103 DTC P0171 / P0172: Fuel System Too Lean / Rich S7RW0A1104038 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0171: • Vacuum leakage Total fuel trim is higher than specified value or short term fuel trim is higher •...
  • Page 154 1A-104 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 155: Dtc P0222: Throttle Position Sensor (Sub) Circuit Low

    Engine General Information and Diagnosis: 1A-105 DTC P0222: Throttle Position Sensor (Sub) Circuit Low S7RW0A1104039 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 E01-45 E01-32 C01-45 C01-44 C01-43 C01-54 C01-40 C01-42...
  • Page 156 1A-106 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.

  • Page 157: Dtc P0223: Throttle Position Sensor (Sub) Circuit High

    Engine General Information and Diagnosis: 1A-107 Step Action Wire harness check Substitute a known- “RED” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “C01-43” terminal of ECM connector and engine ground.
  • Page 158 1A-108 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
  • Page 159 Engine General Information and Diagnosis: 1A-109 Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Measure voltage between “WHT” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned ON. Is voltage 4 –...

  • Page 160: Dtc P0301, P0302, P0303, P0304

    1A-110 Engine General Information and Diagnosis: DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S7RW0A1104041 System Description ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
  • Page 161 Engine General Information and Diagnosis: 1A-111 DTC Troubleshooting NOTE If the vehicle runs under fuel deficient condition (such as a condition in which the fuel pump is unable to draw fuel properly), DTC of misfire may possibly be detected due to fuel pressure drop even though there is no abnormal condition existing in the Engine and Emission System.

  • Page 162: Dtc P0327 / P0328: Knock Sensor Circuit Low / High

    1A-112 Engine General Information and Diagnosis: Step Action Engine mechanical system check Check wire harness and Repair or replace connection of ECM defective part. 1) Check engine mechanical parts or system which can ground, ignition system cause engine rough idle or poor performance. and fuel injector for •...
  • Page 163 Engine General Information and Diagnosis: 1A-113 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 164: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit

    1A-114 Engine General Information and Diagnosis: Step Action Knock sensor circuit for high resistance check Faulty knock sensor. “RED” wire is high resistance circuit. 1) Turn OFF ignition switch, measure resistance between “C01-56” terminal of ECM connector and “RED” wire terminal of knock sensor harness connector.
  • Page 165 Engine General Information and Diagnosis: 1A-115 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 3 – 5 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to...

  • Page 166: Dtc P0340: Camshaft Position (Cmp) Sensor Circuit

    1A-116 Engine General Information and Diagnosis: Step Action Ground circuit check Go to Step 6. “BLK/ORN” wire is open or high resistance. 1) Turn ignition switch to OFF position. 2) Measure resistance between “BLK/ORN” wire terminal of CKP sensor connector and engine ground. Ω...
  • Page 167 Engine General Information and Diagnosis: 1A-117 System Description The CMP sensor located on the transmission side of cylinder head (VVT model) or timing chain cover (non-VVT model) consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion (VVT model) or exhaust camshaft timing sprocket (non-VVT model)).
  • Page 168 1A-118 Engine General Information and Diagnosis: Step Action Wire harness and connection check Go to Step 7. Go to Step 4. 1) Disconnect connector from CMP sensor. 2) Check for proper connection to CMP sensor at “BLK/ RED”, “RED/YEL” and “BLK/ORN” wire terminals. 3) If OK, turn ON ignition switch and check voltage at “BLK/ RED”, “RED/YEL”...

  • Page 169: Dtc P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected

    Engine General Information and Diagnosis: 1A-119 Step Action CMP sensor check Substitute a known- Replace CMP sensor good ECM and recheck. and/or intake camshaft. 1) Check CMP sensor and signal rotor tooth referring to “Camshaft Position (CMP) Sensor Inspection in Section 1C”.
  • Page 170 1A-120 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0401: • EGR valve Difference in intake manifold absolute pressure between opened EGR valve and closed • EGR passage EGR valve is smaller than specified value. •...
  • Page 171 Go to Step 5. EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch turned OFF, install SUZUKI scan tool to DTC. 2) Check EGR system referring to “EGR System Inspection (If Equipped) in Section 1B”.

  • Page 172: Dtc P0403: Exhaust Gas Recirculation Control Circuit

    1A-122 Engine General Information and Diagnosis: DTC P0403: Exhaust Gas Recirculation Control Circuit S7RW0A1104046 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 GRN/RED C01-4 BLK/RED GRN/ORN C01-3 BLK/RED WHT/RED C01-19 BRN/YEL...
  • Page 173 Engine General Information and Diagnosis: 1A-123 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Description”.

  • Page 174: Dtc P0420: Catalyst System Efficiency Below Threshold

    1A-124 Engine General Information and Diagnosis: DTC P0420: Catalyst System Efficiency below Threshold S7RW0A1104047 System and Wiring Diagram C01-10 C01-57 C01-11 BLU WHT 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110038-01 1.
  • Page 175 Engine General Information and Diagnosis: 1A-125 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...

  • Page 176: Dtc P0443: Evaporative Emission System Purge Control Valve Circuit

    1A-126 Engine General Information and Diagnosis: DTC P0443: Evaporative Emission System Purge Control Valve Circuit S7RW0A1104048 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL E01-16 BLK/RED BLK/RED C01-29 BLU/BLK 39 38 32 31 39 38 32 31...
  • Page 177 Engine General Information and Diagnosis: 1A-127 DTC Troubleshooting WARNING In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas water heater. NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”.

  • Page 178: Dtc P0462 / P0463: Fuel Level Sensor Circuit Low / High

    1A-128 Engine General Information and Diagnosis: DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High S7RW0A1104049 Wiring Diagram 12 V YEL/RED 12 V E01-24 YEL/RED YEL/RED BLK/ORN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110040-01...

  • Page 179: Dtc P0480: Fan 1 (Radiator Cooling Fan) Control Circuit

    Engine General Information and Diagnosis: 1A-129 Step Action Wire harness check Go to Step 4. Repair fuel level sensor signal circuit. 1) Check that fuel level sensor signal circuit (“YEL/RED” wire circuit) is in good condition. Is it in good condition? ECM power and ground circuit check Substitute a known- Repair ECM power and/...
  • Page 180 1A-130 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 181: Dtc P0481: Cooling Fan 2 (A/C Condenser Fan) Control Circuit

    Engine General Information and Diagnosis: 1A-131 Step Action Radiator cooling fan control check Intermittent trouble. Faulty ECM. Check for intermittent 1) Run engine until ECT is over 100 °C, 212 °F. Substitute a known- referring to “Intermittent good ECM and recheck. 2) Measure voltage between vehicle body ground and and Poor Connection “E01-46”...
  • Page 182 1A-132 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up engine to normal operating temperature. 4) Run engine at idle and turn both A/C switch and heater blower switch ON (turn ON air conditioning) for 3 min.
  • Page 183 Engine General Information and Diagnosis: 1A-133 Step Action Check wire circuit Faulty A/C compressor Go to Step 4. control relay. 1) Disconnect A/C compressor control relay (1) from individual circuit fuse box No.1 with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “BLK/WHT”...

  • Page 184: Dtc P0500: Vehicle Speed Sensor (Vss) Malfunction

    1A-134 Engine General Information and Diagnosis: Step Action Check A/C condenser cooling fan control Intermittent trouble. Faulty ECM. Check for intermittent 1) Ignition switch turned OFF. refer to “Intermittent and 2) Remove ECM from vehicle body referring to “Engine Poor Connection Control Module (ECM) Removal and Installation in Inspection in Section Section 1C”...
  • Page 185 Engine General Information and Diagnosis: 1A-135 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Vehicle speed signal is not input while fuel is cut at deceleration • Wheel speed sensor (VSS) (for M/T model) for 4 seconds at 3600 rpm or less. •...

  • Page 186: Dtc P0532: A/C Refrigerant Pressure Sensor Circuit Low

    1A-136 Engine General Information and Diagnosis: Step Action DTC check in TCM Go to “DTC P0722: Substitute a known- Output Speed Sensor good ECM and recheck. 1) Connect scan tool to DLC with ignition switch turned (VSS) Circuit No Signal OFF.
  • Page 187 Engine General Information and Diagnosis: 1A-137 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. A/C refrigerant pressure sensor power supply circuit Go to Step 5. Go to Step 3. check 1) Disconnect connector from A/C refrigerant pressure sensor with ignition switch turned OFF.

  • Page 188: Dtc P0533: A/C Refrigerant Pressure Sensor Circuit High

    1A-138 Engine General Information and Diagnosis: DTC P0533: A/C Refrigerant Pressure Sensor Circuit High S7RW0A1104054 Wiring Diagram Refer to “DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area A/C refrigerant pressure sensor signal voltage is higher than specified •...

  • Page 189: Dtc P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance

    Engine General Information and Diagnosis: 1A-139 Step Action A/C refrigerant pressure sensor signal circuit check “RED/BLU” wire is “RED/BLU” wire is open shorted to power supply or high resistance 1) Disconnect connectors from ECM with ignition switch circuit. circuit. turned OFF. 2) Measure resistance between “RED/BLU”...

  • Page 190: Dtc P0616: Starter Relay Circuit Low

    1A-140 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action DTC recheck Go to Step 2. Intermittent trouble. 1) Clear DTC referring to “DTC Clearance”. Check for intermittent referring to “Intermittent 2) Turn OFF ignition switch.

  • Page 191: Dtc P0617: Starter Relay Circuit High

    Engine General Information and Diagnosis: 1A-141 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Engine starts even though vehicle is at stop and engine starter signal is low voltage. • Engine starter signal circuit (2 driving cycle detection logic) •...
  • Page 192 1A-142 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 193: Dtc P1510: Ecm Back-Up Power Supply Malfunction

    Engine General Information and Diagnosis: 1A-143 DTC P1510: ECM Back-Up Power Supply Malfunction S7RW0A1104058 Wiring Diagram WHT/RED E01-2 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110046-02 1. ECM 2. “DOME” fuse 3.

  • Page 194: Dtc P2101: Throttle Actuator Control Motor Circuit Range / Performance

    1A-144 Engine General Information and Diagnosis: Step Action Battery voltage supply circuit check Poor “E01-2” “DOME” fuse blown, connection or “WHT” or “WHT/RED” 1) Turn OFF ignition switch. intermittent trouble. wire is circuit open or 2) Remove ECM from its bracket with ECM connectors short circuit.
  • Page 195 Engine General Information and Diagnosis: 1A-145 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of throttle actuator output (duty output) is inconsistent with • Throttle actuator circuit throttle actuator control command. • Electric throttle body assembly (1 driving detection logic) •...

  • Page 196: Dtc P2102: Throttle Actuator Control Motor Circuit Low

    1A-146 Engine General Information and Diagnosis: Step Action Throttle actuator circuit check Substitute a known- Replace electric throttle good ECM and recheck. body assembly. 1) Check throttle actuator referring to “Throttle Actuator Performance Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”. Is check result satisfactory? DTC P2102: Throttle Actuator Control Motor Circuit Low S7RW0A1104060...

  • Page 197: Dtc P2103: Throttle Actuator Control Motor Circuit High

    Engine General Information and Diagnosis: 1A-147 Step Action Throttle actuator control relay circuit check Go to Step 5. “BLK/RED” wire and/or “GRY” wire is open or 1) Remove throttle actuator control relay from individual high resistance. circuit fuse box No.1 with ignition switch turned OFF. 2) Check for proper connection to throttle actuator control relay at “BLK/RED”, “GRY”, “BRN”...

  • Page 198: Dtc P2111: Throttle Actuator Control System - Stuck Open

    1A-148 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 199: Dtc P2119: Throttle Actuator Control Throttle Body Range / Performance

    Engine General Information and Diagnosis: 1A-149 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
  • Page 200 1A-150 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 201: Dtc P2122: Pedal Position Sensor (Main) Circuit Low Input

    Engine General Information and Diagnosis: 1A-151 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input S7RW0A1104064 Wiring Diagram E01-35 E01-37 E01-52 E01-34 E01-36 E01-51 E01-50 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110048-01 1.
  • Page 202 1A-152 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 203: Dtc P2123: Pedal Position Sensor (Main) Circuit High Input

    Engine General Information and Diagnosis: 1A-153 Step Action Wire harness check Substitute a known- “BRN” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “E01-35” terminal of ECM connector and engine ground.
  • Page 204 1A-154 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 205: Dtc P2127: Pedal Position Sensor (Sub) Circuit Low Input

    Engine General Information and Diagnosis: 1A-155 Step Action Wire harness check Go to Step 7. “GRN” wire is shorted to “BRN” wire and/or 1) Disconnect connectors from ECM with ignition switch “RED” wire. turned OFF. 2) Check for proper connection of ECM connector at “E01- 35”, “E01-37”...
  • Page 206 1A-156 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
  • Page 207 Engine General Information and Diagnosis: 1A-157 Step Action ECM voltage check “RED” wire is open or Go to Step 6. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “E01- 34”...

  • Page 208: Dtc P2128: Pedal Position Sensor (Sub) Circuit High Input

    1A-158 Engine General Information and Diagnosis: DTC P2128: Pedal Position Sensor (Sub) Circuit High Input S7RW0A1104067 Wiring Diagram Refer to “DTC P2122: Pedal Position Sensor (Main) Circuit Low Input”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of APP sensor (sub) is higher than specified value.
  • Page 209 Engine General Information and Diagnosis: 1A-159 Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from APP sensor assembly with ignition switch turned OFF. 2) Check for proper connection to APP sensor assembly at “RED”, “YEL”...

  • Page 210: Dtc P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation

    1A-160 Engine General Information and Diagnosis: Step Action Ground circuit check “WHT” wire is open or Faulty ECM ground high resistance circuit. circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors substitute a known- connected. good ECM and recheck.
  • Page 211 Engine General Information and Diagnosis: 1A-161 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the opening angle based on throttle position • Throttle position sensor (main) and (sub) circuit sensor (main) and the opening angle based on throttle position •...
  • Page 212 1A-162 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 5. “RED” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “C01-43” terminal of ECM connector and engine ground.

  • Page 213: Dtc P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation

    Engine General Information and Diagnosis: 1A-163 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation S7RW0A1104069 Wiring Diagram E01-35 E01-37 E01-52 E01-34 E01-36 E01-51 E01-50 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110050-01 1.
  • Page 214 1A-164 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.

  • Page 215: Dtc P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction

    Engine General Information and Diagnosis: 1A-165 Step Action Wire harness check Go to Step 7. “GRN” wire or “YEL” wire is shorted to other 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Check for proper connection of ECM connector at “E01- 37”, “E01-52”, “E01-36”...

  • Page 216: Dtc U0073: Control Module Communication Bus Off

    1A-166 Engine General Information and Diagnosis: DTC Confirmation Procedure DTC P2227: WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...

  • Page 217: Troubleshooting For Can-Dtc

    Before troubleshooting, check to make sure that fuse, battery voltage and generator status are normal. • When performing “Communication Bus Check” using SUZUKI scan tool (SUZUKI-SDT) in each step of this troubleshooting, use the following table to determine whether the control module is in good condition or not.
  • Page 218 1A-168 Engine General Information and Diagnosis: Troubleshooting Step Action DTC Check Go to applicable Go to Step 2. troubleshooting of DTC 1) Turn ignition switch to OFF position. other than CAN-DTC. 2) Connect scan tool to DLC. 3) Check DTC in the following control modules. •...
  • Page 219 Engine General Information and Diagnosis: 1A-169 Step Action CAN line check Go to Step 4. Repair CAN line. 1) Turn ignition switch to OFF position. 2) Disconnect connectors of all control module / sensor communicated by CAN. 3) Check all the following CAN lines for open, short to power circuit, short to ground circuit, short to other CAN line and high resistance.
  • Page 220 1) Turn ignition switch to OFF position. 2) Connect BCM, ECM, ABS / ESP® control module and combination meter connectors. 3) Perform “Communication Bus Check” under “Bus Check” using SUZUKI-SDT with ignition switch turned ® Are all of BCM, ECM, ABS / ESP control module and...
  • Page 221 2) Connect TCM connectors. and Ground Circuit 3) Perform “Communication Bus Check” under “Bus Check in Section 5A”. If Check” using SUZUKI-SDT with ignition switch turned OK, substitute a known- good TCM. ® Are all of BCM, ECM, ABS / ESP...

  • Page 222: Inspection Of Ecm And Its Circuits

    “Step 2” and “Step 3” module. under “DTC C1240: 3) Perform “Communication Bus Check” under “Bus 4WD Control Module Check” on SUZUKI-SDT with ignition switch turned ON. Power Supply Circuit Malfunction in Section ® Are all of BCM, ECM, ABS / ESP control module, 3B”.
  • Page 223 Engine General Information and Diagnosis: 1A-173 I5JB0A110073-01 Viewed from harness side 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110051-01 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON.
  • Page 224 1A-174 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 0.6 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ Output signal is active GRN/ Ignition coil No.2 3 – 5 V high pulse.
  • Page 225 Engine General Information and Diagnosis: 1A-175 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ Output signal is active low BLU/ Fuel injector No.3 10 – 14 V C01-16 Engine running at idle pulse.
  • Page 226 1A-176 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON 0.5 – 1.5 V Mass air flow with engine at stop. GRN/ C01-26 (MAF) sensor 1.5 – 2.0 V When engine running at —...
  • Page 227 Engine General Information and Diagnosis: 1A-177 Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON and accelerator pedal at 0 – 1 V full depressed position after warmed up engine. Output signal is pulse. *0 – 1 V Duty ratio varies Output of throttle ↑↓...
  • Page 228 1A-178 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Oil control valve GRN/ C01-59 ground (for engine Below 1.3 V Ignition switch turned ON. — with VVT system) *0 – 0.6 V ↑↓ Output signal is active Oil control valve 10 –...
  • Page 229 Engine General Information and Diagnosis: 1A-179 Terminal Wire Circuit Normal voltage Condition Remarks color CAN communication line CAN (low) signal is pulse. Pulse communication line *0.5 – 2.5 V Ignition switch turned ON signal displayed with a E01-18 (active low signal) (“Reference with engine at stop.
  • Page 230 1A-180 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON and accelerator pedal at 0.37 – 0.38 V idle position after warmed APP sensor (sub) up engine. E01-36 — signal Ignition switch turned ON 1.70 –...
  • Page 231 Engine General Information and Diagnosis: 1A-181 Terminal Wire Circuit Normal voltage Condition Remarks color Engine running, A/C switch OFF and blower 1.38 – 1.52 V selector at OFF position, A/C refrigerant pressure: 800 kPa (116 psi) Engine running, A/C A/C refrigerant switch ON and blower pressure sensor selector at 1st position or...
  • Page 232 1A-182 Engine General Information and Diagnosis: Reference waveform No.1 Reference waveform No.2 Fuel injector signal (1) with engine idling No.1 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C01-20” to “C01-58” CH1: “C01-2” to “C01-58” terminal terminal CH2: “C01-1” to “C01-58” Oscilloscope CH1: 20 V/DIV Oscilloscope...
  • Page 233 Engine General Information and Diagnosis: 1A-183 Reference waveform No.3 Reference waveform No.4 No.2 fuel injector signal (2) with engine idling EGR valve signal Measurement CH1: “C01-20” to “C01-58” CH1: “C01-4” to “C01-58” terminal CH2: “C01-2” to “C01-58” Measurement CH2: “C01-3” to “C01-58” Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV terminal...
  • Page 234 1A-184 Engine General Information and Diagnosis: Reference waveform No.5 Ignition coil No.2 and No.3 signal (2) with engine idling Measurement CH1: “C01-20” to “C01-58” terminal CH2: “C01-5” to “C01-58” Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 40 ms/DIV •...
  • Page 235 Engine General Information and Diagnosis: 1A-185 Reference waveform No.8 Reference waveform No.10 Heated oxygen sensor-1 signal (1) with engine idling Heated oxygen sensor-2 heater signal (4) with engine idling Measurement CH1: “C01-10” to “C01-57” terminal CH2: “C01-46” to “C01-58” Measurement CH1: “C01-11”...
  • Page 236 1A-186 Engine General Information and Diagnosis: Reference waveform No.11 Reference waveform No.12 No.3 fuel injector signal (2) with engine idling No.4 fuel injector signal (2) with engine idling Measurement CH1: “C01-20” to “C01-58” Measurement CH1: “C01-20” to “C01-58” terminal CH2: “C01-16” to “C01-58” terminal CH2: “C01-17”...
  • Page 237 Engine General Information and Diagnosis: 1A-187 Reference waveform No.13 Reference waveform No.14 CMP sensor signal with engine idling CMP sensor signal with engine idling Measurement CH1: “C01-20” to “C01-58” Measurement CH1: “C01-20” to “C01-58” terminal CH2: “C01-21” to “C01-58” terminal CH2: “C01-21”...
  • Page 238 1A-188 Engine General Information and Diagnosis: Reference waveform No.15 Reference waveform No.17 Mass air flow sensor signal (1) with engine racing Manifold absolute pressure sensor signal (1) with ignition switch turned ON Measurement CH1: “C01-26” to “C01-27” terminal CH2: “C01-54” to “C01-55” Measurement CH1: “C01-53”...
  • Page 239 Engine General Information and Diagnosis: 1A-189 Reference waveform No.19 Reference waveform No.21 Knock sensor signal at engine speed 4000 r/min. Oil control valve signal with engine idling (for engine with VVT system) Measurement CH1: “C01-56” to “C01-58” terminal Measurement CH1: “C01-60” to “C01-59” Oscilloscope CH1: 1 V/DIV terminal...
  • Page 240 1A-190 Engine General Information and Diagnosis: Reference waveform No.23 Reference waveform No.24 CAN communication line signal from ABS / ESP® Ignition pulse (engine revolution) signal (2) with engine control module assembly or TCM with ignition switch idling turned ON Measurement CH1: “C01-20”...
  • Page 241 Engine General Information and Diagnosis: 1A-191 Reference waveform No.25 Ignition pulse (engine revolution) signal (2) with engine idling Measurement CH1: “C01-20” to “C01-58” terminal CH2: “E01-4” to “C01-58” Oscilloscope CH1: 5 V/DIV, CH2: 5 V/DIV setting TIME: 10 ms/DIV • After warmed up to normal Measurement operating temperature condition...
  • Page 242 1A-192 Engine General Information and Diagnosis: Reference waveform No.28 Reference waveform No.29 Ignition coil signal and fuel injector signal with engine Throttle position sensor main (1) and sub (2) signal cranking Measurement CH1: “C01-54” to “C01-58” CH1: “C01-20” to “C01-58” terminal CH2: “C01-40”...
  • Page 243 Engine General Information and Diagnosis: 1A-193 Resistance Check 1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation in Section 1C”. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Connect special tool to ECM connectors (1) securely. NOTE Do not connect the other connector of special tool to ECM.

  • Page 244: Ecm Power And Ground Circuit Check

    1A-194 Engine General Information and Diagnosis: ECM Power and Ground Circuit Check S7RW0A1104077 Wiring Diagram WHT/RED E01-2 BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL E01-16 BLK/RED GRY/RED C01-14 RED/BLK C01-53 E01-55 RED/BLU E01-54 GRY/BLU C01-55...
  • Page 245 Engine General Information and Diagnosis: 1A-195 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • 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 Circuit fuse check...
  • Page 246 1A-196 Engine General Information and Diagnosis: Step Action ECM ground circuit check Substitute a known- “BLK/ORN” or “BLK” good ECM and recheck. wire is open or high 1) Turn ignition switch to OFF position. resistance circuit. 2) Disconnect connectors from ECM. 3) Measure resistance between each “E01-31”, “C01-58”, “C01-15”...

  • Page 247: Fuel Injector Circuit Check

    Engine General Information and Diagnosis: 1A-197 Step Action Sensor power source circuit check ECM power and ground Go to Step 12. circuit is in good 1) Connect connectors to ECM with ignition switch turned condition. OFF. 2) Turn ON ignition switch, measure each voltage between “C01-14”, “E01-35”, “E01-34”...
  • Page 248 1A-198 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • 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 Fuel injector check for operating sound...

  • Page 249: Fuel Pump And Its Circuit Check

    Engine General Information and Diagnosis: 1A-199 Fuel Pump and Its Circuit Check S7RW0A1104079 Wiring Diagram BLK/WHT BLK/WHT E01-29 BLK/WHT E01-15 GRN/WHT BLK/YEL C01-58 BLK/ORN BLK/RED C01-15 C01-30 E01-31 BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 BRN/WHT E01-60 BLK/YEL 39 38 32 31 39 38 32 31 54 53...
  • Page 250 1A-200 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • 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 Fuel pump control system check for operation...
  • Page 251 Engine General Information and Diagnosis: 1A-201 Step Action Fuel pump relay drive signal check Go to Step 7. Substitute a known- good ECM and recheck. 1) Measure voltage within 2 second after ignition switch is turned ON. Is voltage 0 – 1 V? Wire circuit check Go to Step 8.

  • Page 252: Fuel Pressure Check

    1A-202 Engine General Information and Diagnosis: Fuel Pressure Check S7RW0A1104080 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I3RM0A110081-01 1. Injector 2. Delivery pipe 3. Fuel filter and fuel pump Troubleshooting NOTE Before using following flow, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.

  • Page 253: A/C Condenser Cooling Fan Control System Inspection

    Engine General Information and Diagnosis: 1A-203 Step Action Fuel line check Faulty fuel pressure Repair or replace regulator. damaged or damaged 1) Check fuel pipe, fuel hose and joint for damage or part. deform. Are they in good condition? Was fuel pressure higher than specification in Step 1? Go to Step 6.
  • Page 254 1A-204 Engine General Information and Diagnosis: Troubleshooting Step Action Check A/C condenser fan control system Intermittent trouble. Go to Step 2. Check for intermittent Is A/C condenser fan started when A/C is operating? referring to “Intermittent and Poor Connection Inspection in Section 00”.
  • Page 255 Engine General Information and Diagnosis: 1A-205 Step Action Check wire circuit Go to Step 10. Open wire in “RED” circuit. 1) Install “A/C” fuse “20 A” to individual circuit fuse box No.1. 2) Connect A/C condenser cooling fan control relay to individual circuit fuse box No.1 with ignition switch turn OFF.

  • Page 256: A/C System Circuits Check

    1A-206 Engine General Information and Diagnosis: A/C System Circuits Check S7RW0A1104082 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED E01-1 BLK/YEL 12V 5V BLK/RED RED/BLK E01-58 BLU/YEL BLK/RED E01-47 BLU/YEL BLK/YEL BLK/WHT BLU/WHT E01-19 BLU/WHT E01-19 E01-18 GRN/WHT WHT/BLU E01-3 GRY/RED C01-14 RED/BLU E01-55...
  • Page 257 Engine General Information and Diagnosis: 1A-207 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • 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”. •...
  • Page 258 1A-208 Engine General Information and Diagnosis: Step Action A/C evaporator outlet air temp. sensor check Go to Step 7. Faulty A/C evaporator outlet air temp. sensor 1) Disconnect connectors from ECM with ignition switch or its circuit. turned OFF. 2) Check for proper connection to “E01-57” and “E01-54” wire terminals of ECM connector.
  • Page 259 Engine General Information and Diagnosis: 1A-209 Step Action A/C compressor relay circuit check Go to Step 12. Go to Step 13. 1) Measure voltage between “E01-47” wire terminal of ECM connector and vehicle body ground under following conditions respectively. Voltage between “E01-47” terminal of ECM connector and ground While engine running and A/C switch turned OFF: 10 –...

  • Page 260: Electric Load Signal Circuit Check

    1A-210 Engine General Information and Diagnosis: Electric Load Signal Circuit Check S7RW0A1104083 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BRN/WHT E01-60 E01-31 12V 5V BLK/RED E01-1 BLK/YEL E01-16 BLK/RED /BLU BLK/YEL BLU/WHT E01-19 E01-19 BLU/WHT BLK/WHT E01-18 E01-3 E01-18 E01-3 39 38...
  • Page 261 Engine General Information and Diagnosis: 1A-211 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • 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 DTC check...

  • Page 262: Radiator Cooling Fan Control System Check .1A-212

    1A-212 Engine General Information and Diagnosis: Radiator Cooling Fan Control System Check S7RW0A1104084 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 E01-46 LT GRN BLU/RED C01-58 BLK/ORN C01-15 C01-30 E01-31 LT GRN C01-24 C01-55 39 38 32 31 39 38 32 31...

  • Page 263: Repair Instructions

    Engine General Information and Diagnosis: 1A-213 Step Action Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 / Go to corresponding Go to Step 2. P0118) and/or radiator cooling fan circuit (DTC P0480)? DTC flow. Radiator cooling fan control circuit check Radiator cooling fan Perform from Step 2 to control system is in...

  • Page 264: Special Tools And Equipment

    1A-214 Engine General Information and Diagnosis: 1) Connect SUZUKI scan tool to DLC (1) with ignition 2) Warm up engine to normal operating temperature. switch turned OFF. 3) Check engine idle speed and “IAC throttle opening” by using “Data List” mode on scan tool to check “IAC Special tool throttle opening”.

  • Page 265: Aux. Emission Control Devices

    5) With engine idling (without depressing accelerator S7RW0A1204001 pedal), open EGR valve by using “Step EGR 1) Connect SUZUKI scan tool to data link connector Control” mode in “Engine / Active Test” menu. In this (DLC) (1) with ignition switch turned OFF.

  • Page 266: Vacuum Passage Inspection

    1) Prepare to operate EVAP canister purge valve as follows. passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire. a) When using SUZUKI scan tool: If check result is not satisfactory, check vacuum...

  • Page 267: Vacuum Hose Inspection

    Aux. Emission Control Devices: 1B-3 Vacuum Hose Inspection 3) Check resistance between two terminals of EVAP S7RW0A1206004 canister purge valve. Check hoses for connection, leakage, clog and If resistance is not as specified, replace EVAP deterioration. canister purge valve. Replace as necessary. EVAP canister resistance 30 –...

  • Page 268: Evap Canister Inspection

    1B-4 Aux. Emission Control Devices: EVAP Canister Inspection EGR Valve Inspection (If Equipped) S7RW0A1206006 S7RW0A1206008 1) Check resistance between following terminals of WARNING EGR valve (1) in each pair. DO NOT SUCK nozzles on EVAP canister. If found faulty, replace EGR valve assembly. Fuel vapor inside EVAP canister is harmful.

  • Page 269: Pcv Hose Inspection

    7) After checking, remove plug and install PCV valve. 8) Install air cleaner assembly securely. Special Tools and Equipment Special Tool S7RW0A1208001 09917–47011 SUZUKI scan tool (SUZUKI- SDT) Vacuum pump gauge — This kit includes following items. 1. SUZUKI-SDT 2.

  • Page 270: Engine Electrical Devices

    1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Repair Instructions Engine Control Module (ECM) Removal and Installation Reverse removal procedure noting the following: Installation S7RW0A1306001 • Tighten ECM mounting bolts to specified torque. CAUTION Tightening torque As ECM consists of precision parts, be ECM mounting bolt (a): 8 N·m (0.8 kgf-m, 6.0 lb- careful not to expose it to excessive shock.

  • Page 271: Manifold Absolute Pressure (Map) Sensor Inspection (If Equipped)

    Engine Electrical Devices: 1C-2 Manifold Absolute Pressure (MAP) Sensor CAUTION Inspection (If Equipped) • Do not disassemble electric throttle body S7RW0A1306002 1) Remove air cleaner assembly. assembly. 2) Disconnect connector from MAP sensor. • Do not expose electric throttle body assembly to excessive shock like a 3) Remove MAP sensor.
  • Page 272 1C-3 Engine Electrical Devices: 4) Take off finger from opened throttle valve (1) which is Throttle Actuator (Motor) Check at full open position and check that it moves 1) Turn OFF ignition switch. smoothly by its return spring and open spring force 2) Disconnect connector from electric throttle body back to default position (position where throttle valve assembly.

  • Page 273: Electric Throttle Body System Calibration

    Engine Electrical Devices: 1C-4 b) For throttle position sensor (sub), arrange 3 new 1.5 V batteries (1) in series (check that total voltage is 4.5 – 5.0 V) and connect its positive terminal to “Vin” terminal (2) and negative terminal to “Ground” terminal (3) of sensor. Then using voltmeter, connect positive terminal to “Vout 2”...

  • Page 274: Accelerator Pedal Position (App) Sensor Assembly On-Vehicle Inspection

    1C-5 Engine Electrical Devices: Accelerator Pedal Position (APP) Sensor NOTE Assembly On-Vehicle Inspection After replacing APP sensor assembly, S7RW0A1306005 perform calibration of throttle valve referring 1) Check that APP sensor assembly has been mounted to “Electric Throttle Body System to vehicle body properly (no pinched floor carpet, Calibration”.

  • Page 275: Engine Coolant Temperature (Ect) Sensor Removal And Installation

    Engine Electrical Devices: 1C-6 Engine Coolant Temperature (ECT) Sensor 2) For APP sensor (sub), arrange 3 new 1.5 V batteries (1) in series (check that total voltage is 4.5 – 5.0 V) Removal and Installation and connect its positive terminal to “Vin 2” terminal S7RW0A1306008 Removal (2) and negative terminal to “Ground 2”...

  • Page 276: Engine Coolant Temperature (Ect) Sensor Inspection

    1C-7 Engine Electrical Devices: Engine Coolant Temperature (ECT) Sensor Heated Oxygen Sensor (HO2S-1 and HO2S-2) Inspection Heater On-Vehicle Inspection (If Equipped) S7RW0A1306009 S7RW0A1306010 Immerse temperature sensing part of ECT sensor (1) in 1) Disconnect sensor connector. water (or ice) and measure resistance between sensor 2) Using ohmmeter, measure resistance between terminals while heating water gradually.

  • Page 277: Camshaft Position (Cmp) Sensor Removal And Installation

    Engine Electrical Devices: 1C-8 Camshaft Position (CMP) Sensor Removal and Installation Reverse removal procedure noting the following. Installation S7RW0A1306012 • Tighten heated oxygen sensor (1) to specified torque. Removal Tightening torque 1) Disconnect negative cable at battery. Heated oxygen sensor (a): 45 N·m (4.5 kgf-m, 2) Disconnect connector from CMP sensor.

  • Page 278: Camshaft Position (Cmp) Sensor Inspection

    1C-9 Engine Electrical Devices: Camshaft Position (CMP) Sensor Inspection S7RW0A1306013 Visual check • Check that O-ring is free from damage. • Check that end face of sensor and signal rotor tooth are free from any metal particles and damage. I4RS0B130015-01 Performance check 1) Remove metal particles on end face of CMP sensor, if any.

  • Page 279: Crankshaft Position (Ckp) Sensor Inspection

    Engine Electrical Devices: 1C-10 Installation CKP sensor resistance Resistance varies from less than 220 Ω (ON) to 1) Install crankshaft position sensor to cylinder block. infinity (OFF) or from infinity (OFF) to less than 220 Tighten CKP sensor bolt to specified torque. Ω...

  • Page 280: Main Relay, Fuel Pump Relay, Starting Motor Control Relay, Throttle Actuator Control Relay And Radiator Cooling Fan Relay Inspection

    1C-11 Engine Electrical Devices: Main Relay, Fuel Pump Relay, Starting Motor 1) Disconnect negative cable at battery. Control Relay, Throttle Actuator Control Relay 2) Disconnect MAF and IAT sensor connector. and Radiator Cooling Fan Relay Inspection 3) Connect voltmeter to “BLK/RED” wire terminal (2) of S7RW0A1306017 MAF and IAT sensor connector (1) disconnected and 1) Disconnect negative cable at battery.

  • Page 281: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Removal And Installation

    Engine Electrical Devices: 1C-12 Mass Air Flow (MAF) and Intake Air Intake Air Temperature (IAT) Sensor Inspection S7RW0A1306020 Temperature (IAT) Sensor Removal and Installation CAUTION S7RW0A1306019 Do not heat up MAF and IAT sensor more CAUTION than 100 °C (212 °F). Otherwise, MAF and IAT sensor will be damaged.

  • Page 282: Specifications

    1C-13 Engine Electrical Devices: Specifications Tightening Torque Specifications S7RW0A1307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft ECM mounting bolt ECT sensor 11.0 Heated oxygen sensor 32.5 CMP sensor bolt (non-VVT model) CMP sensor bolt (VVT model) CKP sensor bolt Knock sensor 16.0 MAF and IAT sensor screw...

  • Page 283: Engine Mechanical

    Engine Mechanical: 1D-1 Engine Mechanical Engine General Description Engine Construction Description S7RW0A1401001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
  • Page 284 1D-2 Engine Mechanical: I5RW0C140033-01 [A]: For engine with VVT system [B]: For engine without VVT system...

  • Page 285: Camshaft Position Control (Vvt Variable Valve Timing) System Description

    Engine Mechanical: 1D-3 Camshaft Position Control (VVT Variable Valve Timing) System Description S7RW0A1401002 System Description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high.
  • Page 286 1D-4 Engine Mechanical: Oil Control Valve Timing Holding The oil control valve switches and adjusts the hydraulic When the duty ratio of the signal output from the ECM pressure applied to the cam timing sprocket by moving shows that of holding, the spool valve of the oil control the spool valve (1) according to the duty pulse signals valve is located at hold position.

  • Page 287: Diagnostic Information And Procedures

    Engine Mechanical: 1D-5 Targeted Timing Varying Operation Driving condition Valve timing Target of control Effect To shorten the valve opening overlap in Engine running at idle Stabilization of the engine Most retarded order to prevent the exhaust gas speed rotation at idle speed. counterflow to intake manifold.

  • Page 288: Engine Vacuum Check

    1D-6 Engine Mechanical: Engine Vacuum Check 8) Disengage clutch (1) (to lighten starting load on engine) for M/T vehicle, and depress accelerator S7RW0A1404002 The engine vacuum that develops in the intake line is a pedal (2) all the way to make throttle fully open. good indicator of the condition of the engine.

  • Page 289: Valve Lash (Clearance) Inspection

    Engine Mechanical: 1D-7 7) Install air cleaner assembly with air suction hose referring to “Air Cleaner Assembly Removal and Installation”. 8) Run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification. Vacuum specification (at sea level) 59 –...
  • Page 290 1D-8 Engine Mechanical: 2) Lift down the valve by turning crankshaft to 360°. 4) Turn camshaft by approximately 90° clockwise and remove shim (3). 3) Hold tappet at that position using special tool as follows. WARNING a) Remove its housing bolts. Never put in the hand between camshaft and b) Check housing No.
  • Page 291 Engine Mechanical: 1D-9 6) Select new shim No. (1) with a thickness as close as 8) Lift valve by turning crankshaft counterclockwise (in possible to calculated value. opposite direction against above Step 4)) and remove special tool. Available new shims No. Special tool Thickness mm Thickness mm...

  • Page 292: Repair Instructions

    1D-10 Engine Mechanical: Repair Instructions Air Intake System Components S7RW0A1406001 I6RW0B140001-01 1. Air cleaner assembly 5. To throttle body 2. Air cleaner outlet hose 6. Marking : Align marking (6) of air cleaner assembly with marking (6) of air cleaner outlet hose. 3.

  • Page 293: Air Cleaner Assembly Removal And Installation

    Engine Mechanical: 1D-11 Air Cleaner Assembly Removal and Installation Cylinder Head Cover Removal and Installation S7RW0A1406004 S7RW0A1406005 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Disconnect MAF sensor connector (1). 2) Remove air cleaner assembly with air suction hose referring to “Air Cleaner Assembly Removal and 3) Remove EVAP canister purge valve (2).
  • Page 294 (2) to cylinder head cover “A”: Water tight sealant 99000–31250 (3) as shown in figure. (SUZUKI Bond No.1207F) I2RH0B140037-01 3) Install cylinder head cover to cylinder head. NOTE When installing cylinder head cover, use care...

  • Page 295: Throttle Body And Intake Manifold Components

    Engine Mechanical: 1D-13 Throttle Body and Intake Manifold Components S7RW0A1406006 I6RW0D140001-01 1. Intake manifold 8. To cylinder head cover 15. Brake booster hose 22. Throttle body outlet water hose No.2 2. O-ring 9. Gasket (with EGR) 16. To brake booster 23.

  • Page 296: Throttle Body On-Vehicle Inspection

    1D-14 Engine Mechanical: Throttle Body On-Vehicle Inspection Installation S7RW0A1406007 1) Clean mating surfaces and install new throttle body Check electric throttle body assembly referring to gasket (1) to intake manifold. “Throttle Valve Operation Check” and “Electric Throttle Body Assembly Operation Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”.

  • Page 297: Intake Manifold Removal And Installation

    Engine Mechanical: 1D-15 Intake Manifold Removal and Installation Installation S7RW0A1406010 Reverse removal procedure for installation noting the following. Removal • Use new gasket and O-ring. 1) Remove throttle body referring to “Electric Throttle • Tighten EVAP canister purge valve bracket bolt to Body Assembly Removal and Installation”.

  • Page 298: Engine Mountings Components

    1D-16 Engine Mechanical: Engine Mountings Components S7RW0A1406011 I6RW0D140002-01 [A]: For 4WD model 4. Engine left mounting 12. Dynamic damper : Be sure to direct paint mark to forward. [B]: For 2WD model 5. Engine rear mounting 13. Mounting member cushion : Be sure to direct paint mark to forward.

  • Page 299: Engine Assembly Removal And Installation

    Engine Mechanical: 1D-17 F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 1. Engine right mounting bracket 9. Engine front mounting : 95 N⋅m (9.5 kgf-m, 69.0 lb-ft) : Be sure to direct yellow mark to forward. 2.
  • Page 300 1D-18 Engine Mechanical: [B]: For M/T model 34. steering gear box 17) Remove oil pressure switch bracket (1). I5RW0A140011-01 2. Exhaust manifold 18) Remove suspension control arm referring to “Suspension Control Arm Removal and Installation in Section 2B”. 19) Disconnect right and left drive shaft joints from differential gear referring to “Front Drive Shaft Assembly Removal and Installation: Front in Section 3A”.
  • Page 301 Engine Mechanical: 1D-19 25) Remove engine right mounting bracket (1) and 27) Lower engine with transaxle, front suspension frame, engine left mounting bush bolt (2). front lower cross member, transfer (for 4WD model) and steering gear case. CAUTION Before lowering engine, in order to avoid damage to A/C compressor, make clearance by rising it.
  • Page 302 1D-20 Engine Mechanical: 6) Install engine right mounting bracket (1) and engine 8) Connect steering lower shaft from pinion shaft left mounting bush bolt (2), and then tighten bolt and referring to “Steering Lower Shaft Removal and nuts to specified torque. Installation in Section 6B”.
  • Page 303 Engine Mechanical: 1D-21 12) Install oil pressure switch bracket (1). 16) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and Installation: Manual Type in Section 7B” or “Compressor Assembly Removal and Installation: Automatic Type in Section 7B”. 17) Adjust A/C compressor drive belt referring to “Compressor Drive Belt Removal and Installation: Manual Type in Section 7B”...

  • Page 304: Timing Chain Cover Components

    1D-22 Engine Mechanical: Timing Chain Cover Components S7RW0A1406013 I5RW0C140041-01 [A]: For engine with VVT 8. Timing chain cover mounting 17. Oil control valve [B]: For engine without VVT 9. Oil gallery pipe No.1 18. Oil control valve mounting nut 1. Crankshaft pulley bolt 10.

  • Page 305: Timing Chain Cover Removal And Installation

    Engine Mechanical: 1D-23 Timing Chain Cover Removal and Installation 5) Remove cylinder head cover referring to “Cylinder S7RW0A1406014 Head Cover Removal and Installation”. 6) Remove oil pan referring to “Oil Pan and Oil Pump CAUTION Strainer Removal and Installation in Section 1E”. •...
  • Page 306 “B” to mating surface of timing Timing chain cover nut (b): 25 N·m (2.5 kgf-m, chain cover as shown in figure. 18.0 lb-ft) “A”: Water tight sealant 99000–31140 (SUZUKI 6) Apply engine oil to new O-rings (2) and install them Bond No.1207B) to cap (3).

  • Page 307: Timing Chain Cover Inspection

    Engine Mechanical: 1D-25 Timing Chain Cover Inspection 8) For engine with VVT, install new O-ring (1) to oil gallery pipes No.2 (2) and No.3 (3). S7RW0A1406015 9) For engine with VVT, install oil gallery pipes No.2 Oil Seal and No.3 to cylinder head (4) and timing chain cover Check oil seal lip for fault or other damage.

  • Page 308: Oil Control Valve Removal And Installation (For Engine With Vvt)

    1D-26 Engine Mechanical: Oil Control Valve Removal and Installation (For Oil Control Valve Inspection (For Engine with Engine with VVT) VVT) S7RW0A1406016 S7RW0A1406017 Removal Oil Control Valve Remove oil gallery pipe No.1 and oil control valve from 1) Inspect strainer (1) and mating surface (2) of oil timing chain cover.

  • Page 309: Timing Chain And Chain Tensioner Components

    Engine Mechanical: 1D-27 Timing Chain and Chain Tensioner Components S7RW0A1406018 I5RW0C140044-01 1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Timing chain 6. Chain tensioner adjuster mounting bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) : Apply engine oil.
  • Page 310 1D-28 Engine Mechanical: Installation 3) Install timing chain to camshaft timing sprockets as follows. CAUTION • For engine with VVT After timing chain is removed, never turn Install timing chain by aligning dark blue plates (1) crankshaft and camshafts independently of timing chain and triangle mark (2) on camshaft more than such an extent (“a”, “b”) as shown timing sprockets.
  • Page 311 Engine Mechanical: 1D-29 5) Apply engine oil to sliding surface of timing chain 7) Check that triangle mark (2) and/or circle mark (5) on No.1 guide (1) and install it as shown in figure. intake and exhaust camshaft timing sprockets are in Tighten guide bolts to specified torque.
  • Page 312 1D-30 Engine Mechanical: 8) Screw in plunger (1) by turning body (2) in arrow 10) Apply engine oil to timing chain, and then turn direction and install a retainer (3) (wire) to hold crankshaft clockwise by 2 revolutions and check that plunger in place.

  • Page 313: Timing Chain And Chain Tensioner Inspection

    Engine Mechanical: 1D-31 Timing Chain and Chain Tensioner Inspection Timing Chain S7RW0A1406020 Check timing chain for wear or damage. Timing Chain No.1 Guide Check shoe (1) for wear or damage. I2RH01140077-01 Timing Chain Tensioner Adjuster Check that tooth surface (1) are free from damage. I2RH0B140068-01 Timing Chain Tensioner Check shoe (1) for wear or damage.

  • Page 314: Camshaft, Tappet And Shim Components

    1D-32 Engine Mechanical: Camshaft, Tappet and Shim Components S7RW0A1406021 I4RS0B140014-03 [A]: For engine with VVT 4. Exhaust camshaft 9. Camshaft bearing : Install a bearing half with some holes to upper side of intake camshaft No.1 bearing. [B]: For engine without VVT 5.

  • Page 315: Camshaft, Tappet And Shim Removal And Installation

    Engine Mechanical: 1D-33 Camshaft, Tappet and Shim Removal and 4) Loosen camshaft housing bolts in such order as indicated in figure and remove them. Installation S7RW0A1406022 “12” “13” “20” “21” “16” “17” “8” “9” CAUTION “2” • Keep working table, tools and hands clean “5”...
  • Page 316 1D-34 Engine Mechanical: Installation 3) Install intake camshaft (1) and exhaust camshaft (2). Align knock pin (3) and match mark (4) with notches 1) Install tappets and shims to cylinder head. (5) as shown in figure. Apply engine oil around tappet and then install it to cylinder head.
  • Page 317 Engine Mechanical: 1D-35 6) Check position of camshaft housings. 8) For engine with VVT, with hexagonal section (1) of Embossed marks are provided on each camshaft intake camshaft (2) held stationary with spanner or housing, indicating position and direction for the like, tighten bolt of intake cam timing sprocket installation.

  • Page 318: Camshaft, Tappet And Shim Inspection

    1D-36 Engine Mechanical: Camshaft, Tappet and Shim Inspection Camshaft Runout S7RW0A1406023 Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. Intake Cam Timing Sprocket Assembly (For engine If measured runout exceeds limit, replace camshaft. with VVT) Camshaft runout limit Fit intake cam timing sprocket assembly to camshaft (2)
  • Page 319 Engine Mechanical: 1D-37 6) Tighten camshaft housing bolts evenly and gradually If measured camshaft journal clearance exceeds in numerical order (“1” through “21”) by repeating limit, measure journal (housing) bore and outside tightening sequence two or three times until diameter of camshaft journal. Replace camshaft or specified torque is obtained.
  • Page 320 1D-38 Engine Mechanical: Camshaft bearing thickness (For engine with Wear of Tappet and Shim VVT) Check tappet and shim for pitting, scratches, or damage. : 1.5120 – 1.5180 mm (0.0596 – 0.0597 in.) If any malcondition is found, replace. I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance.

  • Page 321: Valves And Cylinder Head Components

    Engine Mechanical: 1D-39 Valves and Cylinder Head Components S7RW0A1406024 I4RS0A140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2. Valve spring retainer 8.

  • Page 322: Valves And Cylinder Head Removal And Installation

    1D-40 Engine Mechanical: Valves and Cylinder Head Removal and 8) Check all around cylinder head for any other parts required to be removed or disconnected and remove Installation or disconnect whatever necessary. S7RW0A1406025 9) Remove exhaust manifold, if necessary referring to Removal “Exhaust Manifold Removal and Installation in 1) Remove engine assembly from vehicle referring to...
  • Page 323 Engine Mechanical: 1D-41 5) Install cylinder head to cylinder block. Cylinder head bolt diameter measurement Apply engine oil to new cylinder head bolts and points tighten them gradually as follows. “a”: 83.5 mm (2.81 in.) “b”: 115 mm (4.53 in.) a) Tighten cylinder head bolts (“1”...

  • Page 324: Valves And Cylinder Head Disassembly And Assembly

    1D-42 Engine Mechanical: Valves and Cylinder Head Disassembly and 3) Release special tools (Valve lifter), and remove spring retainer and valve spring. Assembly S7RW0A1406026 4) Remove valve from combustion chamber side. 5) Remove valve stem seal (1) from valve guide and Disassembly valve spring seat (2).
  • Page 325 Engine Mechanical: 1D-43 3) Ream valve guide bore with special tool (5.5 mm Assembly reamer). After reaming, clean bore. 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as Special tool to remove burrs and make it truly round.
  • Page 326 1D-44 Engine Mechanical: 6) Install valve to valve guide. 8) Using special tools (Valve lifter), compress valve Before installing valve to valve guide, apply engine spring and fit two valve cotters (1) into groove in oil to stem seal, valve guide bore and valve stem. valve stem.

  • Page 327: Valves And Valve Guides Inspection

    Engine Mechanical: 1D-45 Valves and Valve Guides Inspection S7RW0A1406027 Valve Guide Valve stem-to-guide clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
  • Page 328 1D-46 Engine Mechanical: Valve head radial runout Valve seat repair Check each valve for radial runout with a dial gauge and A valve seat not producing a uniform contact with its “V” block. To check runout, rotate valve slowly. If runout valve or showing width of seating contact that is out of exceeds its limit, replace valve.

  • Page 329: Cylinder Head Inspection

    Engine Mechanical: 1D-47 Cylinder Head Inspection Distortion for cylinder head surface on piston side S7RW0A1406028 Limit: 0.03 mm (0.001 in.) • Remove all carbon deposits from combustion chambers. NOTE Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing.

  • Page 330: Valve Spring Inspection

    1D-48 Engine Mechanical: Valve Spring Inspection Pistons, Piston Rings, Connecting Rods and S7RW0A1406029 Cylinders Components S7RW0A1406030 Valve Spring Free Length and Preload Referring to data, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening.

  • Page 331: Pistons, Piston Rings, Connecting Rods And Cylinders Removal And Installation

    Engine Mechanical: 1D-49 Pistons, Piston Rings, Connecting Rods and 3) When installing piston and connecting rod assembly into cylinder bore, point front mark (1) on piston head Cylinders Removal and Installation to crankshaft pulley side. S7RW0A1406031 Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.

  • Page 332: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly

    1D-50 Engine Mechanical: b) Force piston pin out. 5) Install bearing cap (1): Point arrow mark (2) on cap to crankshaft pulley side. After applying engine oil to rod bolts and tighten cap nuts (3) gradually as follows. a) Tighten all cap nuts to 15 N⋅m (1.5 kgf-m, 11.0 lb- ft).

  • Page 333: Cylinders, Pistons And Piston Rings Inspection

    Engine Mechanical: 1D-51 Cylinders, Pistons and Piston Rings Inspection 3) Install piston rings to piston: S7RW0A1406033 • As indicated in figure, 1st and 2nd rings have “T” mark (4) respectively. When installing these piston Cylinder rings to piston, direct marked side of each ring Visual inspection toward top of piston.
  • Page 334 1D-52 Engine Mechanical: Piston Piston clearance Standard (used piston): 0.032 – 0.061 mm (0.0013 – Visual inspection 0.0024 in.) Inspect piston for faults, cracks or other damages. Standard (new piston with coating): 0.010 – 0.051 Damaged or faulty piston should be replaced. mm (0.0004 –...

  • Page 335: Piston Pins And Connecting Rods Inspection

    Engine Mechanical: 1D-53 Piston Pins and Connecting Rods Inspection Piston Ring S7RW0A1406034 Piston ring end gap To measure end gap, insert piston ring (2) into cylinder Piston Pin bore and then measure the gap by using thickness Visual inspection gauge (1). Check piston pin, connecting rod small end bore and If measured gap exceeds limit, replace ring.
  • Page 336 1D-54 Engine Mechanical: Connecting Rod Connecting rod bolt deformation (Plastic deformation tightening bolt) Big-end side clearance Measure each thread diameter of connecting rod bolt (2) Check big-end of connecting rod for side clearance, with at “A” on 32 mm (1.25 in.) from bolt mounting surface rod fitted and connected to its crank pin in the normal and “B”...

  • Page 337: Crank Pin And Connecting Rod Bearings Inspection

    Engine Mechanical: 1D-55 Crank Pin and Connecting Rod Bearings Connecting Rod Bearing General Information Service connecting rod bearings are available in Inspection standard size and 0.25 mm (0.0098 in.) undersize S7RW0A1406035 bearing, and standard size bearing has 5 kinds of Crank Pin Diameter bearings differing in tolerance.
  • Page 338 1D-56 Engine Mechanical: 4) Install rod bearing cap (1) to connecting rod. Selection of Connecting Rod Bearings When installing cap, be sure to point arrow mark (2) NOTE on cap to crankshaft pulley side, as shown in figure. After applying engine oil to rod bolts, tighten cap nuts •...
  • Page 339 Engine Mechanical: 1D-57 2) Next, check crankshaft pin diameter. On crank web 3) There are five kinds of standard bearings differing in No.3, four alphabets are stamped as shown in figure. thickness. To distinguish them, they are painted in Three kinds of alphabet (“A”, “B” and “C”) represent the following colors at the position as indicated in the following crankshaft pin diameter respectively.

  • Page 340: Main Bearings, Crankshaft And Cylinder Block Components

    1D-58 Engine Mechanical: Main Bearings, Crankshaft and Cylinder Block Components S7RW0A1406036 I6RW0D140003-01 1. CKP sensor 11. Rear oil seal 21. Oil filter adapter bolt : See “A” 2. Knock sensor 12. Input shaft bearing 22. Spring pin 3. Cylinder block 13.

  • Page 341: Main Bearings, Crankshaft And Cylinder Block Removal And Installation

    Engine Mechanical: 1D-59 5. Main bearing 15. Flywheel or drive plate bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) : See “B” 6. Sensor plate 16. Rear oil seal housing mounting bolt : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft) 7. Crankshaft timing sprocket key 17.
  • Page 342 1D-60 Engine Mechanical: Installation 2) Install main bearings to cylinder block. Upper half of bearing (1), has an oil groove (2). NOTE Install it to cylinder block (3), and the other half without oil groove to bearing cap. • Use new bearing cap No.1 bolts. They are Make sure that two halves are painted in the same deformed once they are used because they color.
  • Page 343 Main bearing cap No.1 bolt ((1) – (10)): housing (1). Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) and 60° by the specified “A”: Water tight sealant 99000–31250 (SUZUKI procedure Bond No.1207F) Main bearing cap No.2 bolt ((11) – (20)): Sealant amount for rear oil seal housing Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the...

  • Page 344: Crankshaft Inspection

    1D-62 Engine Mechanical: 9) Install rear oil seal housing (1) and tighten new bolts 13) Install camshafts, tappet and shim referring to to specified torque by using special tool. “Camshaft, Tappet and Shim Removal and Installation”. Special tool 14) Install timing chain referring to “Timing Chain and (A): 09911–97720 Chain Tensioner Removal and Installation”.
  • Page 345 Engine Mechanical: 1D-63 2) Tighten main bearing cap No.1 bolts (1) – (10) and 3) Use a dial gauge to read displacement in axial main bearing cap No.2 bolts (11) – (20) gradually as (thrust) direction of crankshaft. follows. If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard a) Tighten bolts (1) –...

  • Page 346: Main Bearings Inspection

    1D-64 Engine Mechanical: Main Bearings Inspection 4) Tighten main bearing cap No.1 bolts (1) – (10) and S7RW0A1406039 main bearing cap No.2 bolts (11) – (20) gradually as follows. General Information a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m, •...
  • Page 347 Engine Mechanical: 1D-65 Crankshaft bearing cap bore Selection of Main Bearings Standard bearing Stamped Bearing cap bore diameter (without If bearing is in malcondition, or bearing clearance is out alphabet bearing) of specification, select a new standard bearing according (number) to the following procedure and install it.
  • Page 348 1D-66 Engine Mechanical: 4) From number stamped on crank web No.2 and alphabets stamped on cylinder block, determine new standard bearing to be installed to journal, by referring to the table shown. For example, if number stamped on crank web No.2 is “1” and alphabet stamped on cylinder block is “B”, install a new standard bearing painted in “Brown”...
  • Page 349 Engine Mechanical: 1D-67 • If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. a. Regrind journal to the following finished diameter. Finished journal diameter 51.7320 – 51.7500 mm (2.0367 – 2.0374 in.) b. Using micrometer, measure regrind journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.

  • Page 350: Sensor Plate Inspection

    1D-68 Engine Mechanical: Sensor Plate Inspection Cylinder Block Inspection S7RW0A1406040 S7RW0A1406043 Check sensor plate for crack damage. If malcondition is found, replace it. Distortion of Gasketed Surface Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It.

  • Page 351: Specifications

    Engine Mechanical: 1D-69 Specifications Tightening Torque Specifications S7RW0A1407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolt Tighten 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) by the specified procedure EVAP canister purge valve bracket bolt Cylinder head cover bolt Tighten 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified procedure Engine right mounting bracket nut...

  • Page 352: Special Tools And Equipment

    For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RW0A1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Water tight sealant SUZUKI Bond No.1207B...
  • Page 353 Engine Mechanical: 1D-71 09916–14521 09916–34542 Valve spring compressor Reamer handle attachment 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67020 Valve guide installer handle Tappet holder (Overseas) 09916–67021 09916–77310...

  • Page 354: Engine Lubrication System

    1E-1 Engine Lubrication System: Engine Lubrication System Engine General Description Engine Lubrication Description S7RW0A1501001 The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block.

  • Page 355: Diagnostic Information And Procedures

    Engine Lubrication System: 1E-2 Diagnostic Information and Procedures Oil Pressure Check 3) Install special tools (oil pressure gauge) to vacated S7RW0A1504001 threaded hole of oil pressure switch. WARNING Special tool To avoid the danger of being burned, do not (A): 09915–77310 touch the exhaust system when the system is (B): 09915–78211 hot.

  • Page 356: Repair Instructions

    1E-3 Engine Lubrication System: 8) Start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) Connect oil pressure switch coupler (1). I2RH0B150006-01 Repair Instructions Oil Pan and Oil Pump Strainer Components S7RW0A1506001 I5RH0A150002-02 1.

  • Page 357: Oil Pan And Oil Pump Strainer Removal And Installation

    I4RS0A150005-01 3) Apply sealant continuously to oil pan mating surface as shown in the figure. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)

  • Page 358: Oil Pan And Oil Pump Strainer Cleaning

    1E-5 Engine Lubrication System: 4) Install oil pan to cylinder block temporarily. 9) Install clutch housing lower plate (1) and then tighten clutch housing lower plate bolt to specified torque. 5) Insert dowel pin (1) in hole (2) of oil pan in order to locate oil pan precisely.

  • Page 359: Oil Pump Components

    Engine Lubrication System: 1E-6 Oil Pump Components S7RW0A1506004 I4RS0A150010-01 1. Rotor plate 6. Rotor plate bolt : 11 N⋅m (1.1 kgf-m 8.0 lb-ft) 2. O-ring 7. Relief valve : Do not reuse. 3. Outer rotor 8. Spring : Apply thin coat of engine oil to sliding surface. 4.

  • Page 360: Oil Pump Inspection

    1E-7 Engine Lubrication System: Oil Pump Inspection Reassembly S7RW0A1506007 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, Oil Seal oil seal lip portion, inside surfaces of oil pump case Check oil seal lip for fault or other damage.
  • Page 361 Engine Lubrication System: 1E-8 Radial clearance Relief valve spring free length and load Check radial clearance between outer rotor (1) and case Check relief valve spring free length and load as shown (2) using thickness gauge (3). in the figure. If the measured valve spring length is lower If clearance exceeds its limit, replace outer rotor or case.

  • Page 362: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RW0A1508001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.

  • Page 363: Engine Cooling System

    Engine Cooling System: 1F-1 Engine Cooling System Engine General Description Cooling System Description The coolant recovery system is standard. The coolant in S7RW0A1601001 the radiator expands with heat, and the coolant is The cooling system consists of the radiator cap, radiator, overflowed to the reservoir.

  • Page 364: Schematic And Routing Diagram

    1F-2 Engine Cooling System: Schematic and Routing Diagram Coolant Circulation S7RW0A1602001 While the engine is warmed up (thermostat closed), coolant circulates as follows. I5RW0C160001-02 1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core 2. Radiator outlet hose 4.

  • Page 365: Diagnostic Information And Procedures

    Engine Cooling System: 1F-3 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S7RW0A1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.

  • Page 366: Repair Instructions

    1F-4 Engine Cooling System: Repair Instructions Cooling System Components S7RW0A1606001 I5RW0C160012-01 1. Radiator 11. Thermostat case water outlet pipe 21. Heater outlet No.1 hose 2. Reservoir 12. Thermostat case 22. Radiator cooling fan assembly For disassembly and reassembly, refer to “Radiator Cooling Fan Disassembly and Reassembly”.

  • Page 367: Coolant Level Check

    Engine Cooling System: 1F-5 Coolant Level Check NOTE S7RW0A1606002 After installing radiator cap to radiator, make WARNING sure that the ear of cap lines is parallel to radiator. To help avoid danger of being burned, do not remove radiator cap while engine and Cooling system and radiator cap holding radiator are still hot.

  • Page 368: Cooling System Flush And Refill

    1F-6 Engine Cooling System: Cooling System Flush and Refill 7) Remove reservoir cap (2) and reservoir (1). S7RW0A1606005 8) Pour out any fluid, scrub and clean inside of WARNING reservoir with soap and water. Flush it well with clean water and drain, Reinstall To help avoid danger of being burned, do not reservoir.

  • Page 369: Thermostat Removal And Installation

    Engine Cooling System: 1F-7 Thermostat Removal and Installation Thermostat Inspection S7RW0A1606007 S7RW0A1606008 Removal • Make sure that air bleed valve (1) of thermostat is 1) Drain coolant referring to “Cooling System Draining”. clean. 2) Remove intake manifold referring to “Intake Manifold •...

  • Page 370: Radiator Cooling Fan Assembly On-Vehicle Inspection

    1F-8 Engine Cooling System: Radiator Cooling Fan Assembly On-Vehicle Inspection S7RW0A1606009 1) Check continuity between terminals. If there is no continuity, replace radiator fan assembly. “ a ” “ c ” I5RW0A160004-01 2) Connect battery to radiator fan motor coupler as shown in figure, then check that the radiator fan “...

  • Page 371: Radiator Cooling Fan Disassembly And Reassembly

    Engine Cooling System: 1F-9 Radiator On-Vehicle Inspection and Cleaning 5) Remove cooling fan mounting bolts (1). S7RW0A1606013 6) Remove radiator cooling fan assembly (2). Inspection Check radiator for leakage or damage. Straighten bent fins, if any. Cleaning Clean frontal area of radiator cores. I5RW0C160014-01 Installation Reverse removal procedure for installation noting the...

  • Page 372: Water Pump / Generator Drive Belt Tension Inspection And Adjustment

    1F-10 Engine Cooling System: Water Pump / Generator Drive Belt Tension 5) Check belt tension for specification after turning crankshaft two rotations clockwise. Inspection and Adjustment S7RW0A1606015 6) Tighten generator adjusting bolt (1) as specified WARNING torque. Tightening torque • Disconnect negative cable at battery Generator adjusting bolt (c): Tighten 7.0 N⋅m before checking and adjusting belt (0.7 kgf-m, 5.0 lb-ft) by the specified procedure.

  • Page 373: Water Pump Removal And Installation

    1) Apply sealant to mating surface of water pump (1) as pulley (3) and generator pulley (4). shown in figure. 2) Adjust belt tension referring to “Water Pump / “A”: Water tight sealant 99000–31250 (SUZUKI Generator Drive Belt Tension Inspection and Bond No.1207F) Adjustment”.

  • Page 374: Water Pump Inspection

    For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RW0A1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...

  • Page 375: Fuel System

    Fuel System: 1G-1 Fuel System Engine Precautions Precautions on Fuel System Service S7RW0A1700001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. •...

  • Page 376: General Description

    1G-2 Fuel System: General Description Fuel System Description Fuel Pump Description S7RW0A1701001 S7RW0A1701003 The fuel pump (1) is an in-tank type electric pump. CAUTION Incorporated in the pump assembly are; This engine requires the unleaded fuel only. a fuel filter (2), a fuel pressure regulator (3) and a fuel The leaded and/or low lead fuel can result in level sensor (gauge) (4).

  • Page 377: Schematic And Routing Diagram

    Fuel System: 1G-3 Schematic and Routing Diagram Fuel Delivery System Diagram S7RW0A1702001 I7RW01170002-02 1. Fuel tank 4. Delivery pipe 7. Fuel filter 2. Fuel pump assembly 5. Fuel injector 8. Fuel level sensor (gauge) 3. Fuel pressure regulator 6. Fuel feed line 9.

  • Page 378: Fuel Cut Operation Inspection

    1G-4 Fuel System: 4) Check that battery voltage is 11 V or more. 7) Remove special tools from fuel delivery pipe and fuel feed hose. 5) Measure fuel pressure at each condition. If measured pressure is out of specification, refer to 8) Connect fuel feed hose to fuel delivery pipe and “Fuel Pressure Check in Section 1A”...

  • Page 379: Repair Instructions

    Fuel System: 1G-5 Repair Instructions Fuel System Components S7RW0A1706001 I6RW0D170001-01 1. Fuel tank 11. Fuel vapor line 21. Fuel pump bolt 2. Fuel pump assembly 12. Fuel tank protector 22. Fuel tank inlet valve 3. Fuel tank filler hose 13. Insulator 23.

  • Page 380: Fuel Hose Disconnecting And Reconnecting

    1G-6 Fuel System: 9. Fuel tank bolt 19. Grommet 10. Fuel tank belt 20. O-ring Fuel Hose Disconnecting and Reconnecting S7RW0A1706002 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk of fire and personal injury. For Connection Other Than Quick Joint •...

  • Page 381: Fuel Pressure Relief Procedure

    Fuel System: 1G-7 Clamp other than around fuel tank 4. Red mark For Quick Joint Disconnecting 1) Remove mud, dust and/or foreign material between pipe (1) and quick joint (fuel pipe) (2) by blowing compressed air. 2) Unlock joint lock by inserting special tool between pipe and quick joint.

  • Page 382: Fuel Leakage Check Procedure

    1G-8 Fuel System: Fuel Pipe Removal and Installation 6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3 S7RW0A1706006 seconds each time in order to dissipate fuel pressure WARNING in lines.

  • Page 383: Fuel Injector On-Vehicle Inspection

    Fuel System: 1G-9 Fuel Injector On-Vehicle Inspection Fuel Injector Removal and Installation S7RW0A1706007 S7RW0A1706008 1) Using sound scope (1) or such, check operating WARNING sound of injector (2) when engine is running or cranking. Before starting the following procedure, be Cycle of operating sound should vary according to sure to observe “Precautions on Fuel System engine speed.

  • Page 384: Fuel Injector Inspection

    1G-10 Fuel System: Fuel Injector Inspection Installation Reverse removal procedure for installation noting the S7RW0A1706009 following. WARNING • Replace injector O-ring (1) with new one using care not to damage it. • Before starting the following procedure, be sure to observe “Precautions on Fuel •...
  • Page 385 If fuel leaks (1) more than the following iii) Turn fuel pump ON by using scan tool. specifications, replace. Special tool Fuel leakage (A): SUZUKI scan tool (SUZUKI-SDT) Less than 1 drop/min. I2RH0B170013-01 9) Remove injector from special tool (A) and disconnect I5RW0C110011-01 b) When not using scan tool: special tool (B) from injector.

  • Page 386: Fuel Filler Cap Inspection

    1G-12 Fuel System: Fuel Filler Cap Inspection S7RW0A1706010 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk of fire and personal injury. Remove cap (1), and check gasket for even filler neck imprint, and deterioration or any damage.

  • Page 387: Fuel Tank Removal And Installation

    Fuel System: 1G-13 Fuel Tank Removal and Installation 6) Remove exhaust center pipe referring to “Exhaust S7RW0A1706013 Pipe and Muffler Removal and Installation in Section WARNING 1K”. 7) Remove propeller shaft (For 4WD model) referring to Before starting the following procedure, be “Propeller Shaft Assembly Removal and Installation sure to observe “Precautions on Fuel System in Section 3D”.

  • Page 388: Fuel Tank Inspection

    1G-14 Fuel System: Installation 4) Connect fuel filler hose (1) and breather hose (2) to filler neck (3) as shown in figure, and clamp them CAUTION securely. • When connecting joint, clean outside Tightening torque surfaces of pipe where joint is to be Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m, inserted, push joint into pipe till joint lock 1.0 lb-ft)

  • Page 389: Fuel Tank Purging Procedure

    Fuel System: 1G-15 Fuel Tank Purging Procedure S7RW0A1706015 WARNING • Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk of fire and personal injury. • This purging procedure will not remove all fuel vapor.

  • Page 390: Main Fuel Level Sensor Removal And Installation

    1G-16 Fuel System: Installation 5) Install fuel tank to vehicle. Refer to “Fuel Tank Removal and Installation”. CAUTION Main Fuel Level Sensor Removal and When connecting joint, clean outside surface of pipe where joint is to be inserted, push Installation joint into pipe till joint lock clicks and check S7RW0A1706018 CAUTION...

  • Page 391: Fuel Pump Inspection

    Fuel System: 1G-17 Fuel Pump Inspection S7RW0A1706019 • Check fuel pump assembly for damage. • Check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank. • For electrical circuit, refer to “Fuel Pump and Its Circuit Check in Section 1A”.

  • Page 392: Special Tools And Equipment

    (09912- 58413). 58413). 09912–58490 09919–47020 3-way joint & hose Quick joint remover 09930–88530 SUZUKI scan tool (SUZUKI- SDT) Injector test lead — This kit includes following items. 1. SUZUKI-SDT 2. DLC3 cable 3. USB cable 4. AC/DC power supply 5.

  • Page 393: Ignition System

    Ignition System: 1H-1 Ignition System Engine General Description Ignition System Construction S7RW0A1801001 The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.

  • Page 394: Schematic And Routing Diagram

    1H-2 Ignition System: Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S7RW0A1802001 BLK/WHT GRN/WHT C01-5 GRN/YEL C01-6 BLK/WHT E01-29 BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED E01-16 BLK/RED C01-58 BLK/ORN RED/YEL C01-20 C01-15 C01-30 C01-21 E01-31 BLK/ORN 39 38 32 31 39 38...

  • Page 395: Component Location

    Ignition System: 1H-3 Component Location Ignition System Components Location S7RW0A1803001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I5RW0C180002-01 1. ECM 7. ECT sensor 13. Battery fuse box 2.

  • Page 396: Diagnostic Information And Procedures

    1H-4 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis S7RW0A1804001 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to start Loose connection or disconnection of Connect securely.
  • Page 397 Ignition System: 1H-5 Step Action Ignition coil assembly power supply and ground circuit Go to Step 7. Repair or replace. check 1) Check ignition coil assembly power supply and ground circuits for open and short. Are circuits in good condition? Ignition coil assembly check Go to Step 8.

  • Page 398: Repair Instructions

    1H-6 Ignition System: Ignition Spark Test 5) Crank engine and check if each spark plug sparks. S7RW0A1804004 1) Remove air cleaner assembly with air intake pipe. 2) Disconnect all injector couplers from injectors. WARNING Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.

  • Page 399: High-Tension Cord Inspection

    Ignition System: 1H-7 High-Tension Cord Inspection Spark Plug Inspection S7RW0A1806002 S7RW0A1806004 Measure resistance of high-tension cord (1) by using CAUTION ohmmeter. If resistance exceeds specification, replace high-tension • When servicing the iridium / platinum cord(s). spark plugs (slender center electrode type plugs), do not touch the center electrode High-tension cord resistance to avoid damage to it.

  • Page 400: Ignition Coil Assembly (Including Ignitor) Removal And Installation

    Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft) Special tool 3) Install high-tension cord (3) to ignition coil assembly (A): SUZUKI scan tool (SUZUKI-SDT) while gripping its cap. I5RW0C110011-01 2) Start engine and warm it up to normal operating...

  • Page 401: Specifications

    Ignition System: 1H-9 Initial ignition timing 7) If ignition timing is out of specification, check the fixed with SUZUKI scan tool: 5 ± 3° BTDC (at followings. specified idle speed) • CKP sensor • CKP sensor plate Ignition order 1 – 3 – 4 – 2 •...

  • Page 402: Starting System

    1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Cranking System Circuit Diagram S7RW0A1902001 I4RS0A190001-01 1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch 2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery 3. Magnetic switch 8.
  • Page 403 Starting System: 1I-2 Condition Possible cause Correction / Reference Item Motor not running (No Transmission range sensor is not in P or Shift in P or N, or adjust sensor. (A/T model) operating sound of N, or not adjusted (A/T model) magnetic switch) Battery run down Recharge battery.

  • Page 404: Cranking System Test

    1I-3 Starting System: Condition Possible cause Correction / Reference Item Starting motor does not Fused contact points of magnetic switch Replace magnetic switch. stop running Short-circuit between turns of magnetic Replace magnetic switch. switch coil (layer short-circuit) Failure of returning action in ignition Replace.

  • Page 405: Repair Instructions

    Starting System: 1I-4 Repair Instructions Starting Motor Dismounting and Remounting S7RW0A1906001 I4RS0A190002-01 : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft) Dismounting 1) Disconnect negative (–) battery lead at battery. 2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) Detach shift &...

  • Page 406: Starting Motor Components

    1I-5 Starting System: Starting Motor Components S7RW0A1906002 I4RS0A190003-01 1. Front housing 7. Plate 13. Planetary gear 19. Rear bush 2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut 3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft) 4.

  • Page 407: Starting Motor Inspection

    Starting System: 1I-6 Starting Motor Inspection Hold-in coil open circuit test S7RW0A1906003 Check for continuity across magnetic switch “S” terminal (1) and coil case. If no continuity, coil is open and should Plunger be replaced. Inspect plunger for wear. Replace if necessary. I2RH01190011-01 Rear Bracket Bush I2RH01190008-01...
  • Page 408 1I-7 Starting System: Spring • Check commutator for uneven wear with armature (1) Inspect brush springs for wear, damage or other supported on V-blocks (2). If deflection of dial gauge abnormal conditions. Replace if necessary. (4) pointer exceeds limit, repair or replace. Brush spring tension NOTE Standard: 2.2 kg (4.85 lb)
  • Page 409 Starting System: 1I-8 • Inspect the commutator (1) for insulator (2) depth. Gears Correct or replace if below limit. Inspect the internal gear and the planetary gears for wear, damage or other abnormal conditions. Replace if Commutator insulator depth “a” necessary.

  • Page 410: Specifications

    1I-9 Starting System: Front Housing Bush Inspect the bush for wear or damage. Replace if necessary. I2RH01190024-01 Specifications Cranking System Specifications S7RW0A1907001 Voltage 12 volts Output 1.2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)

  • Page 411: Charging System

    Charging System: 1J-1 Charging System Engine General Description Battery Description Built-In Indicator (If Equipped) S7RW0A1A01001 The battery has a built-in temperature compensated The battery has three major functions in the electrical indicator in the top of the battery. This indicator is to be system.

  • Page 412: Generator Description

    1J-2 Charging System: Care of battery WARNING • Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. • Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid.

  • Page 413: Diagnostic Information And Procedures

    Charging System: 1J-3 Charging System Circuit The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage is being controlled by ECM under some conditions while driving.

  • Page 414: Generator Symptom Diagnosis

    1J-4 Charging System: Generator Symptom Diagnosis Noise from generator may be caused by loose drive S7RW0A1A04002 pulley, loose mounting bolts, worn or dirty bearings, CAUTION defective diode, or defective stator. • Do not mistake polarities of “IG” terminal and “L” terminal. •...

  • Page 415: Generator Test (Overcharged Battery Check)

    Charging System: 1J-5 2) Run engine from idling up to 2,000 rpm with all 3) Ground “F” terminal and start engine, then measure accessories turned off and read meters. voltage at “B” terminal as shown in figure. If voltage is higher than standard value, check •...

  • Page 416: Repair Instructions

    1J-6 Charging System: Repair Instructions Jump Starting in Case of Emergency 1) Set parking brake and place automatic transaxle in S7RW0A1A06001 PARK (NEUTRAL on manual transaxle). Turn off With Auxiliary (Booster) Battery ignition, turn off lights and all other electrical loads. 2) Check electrolyte level.

  • Page 417: Water Pump / Generator Drive Belt Tension Inspection And Adjustment

    Charging System: 1J-7 Remounting 1) Reverse removal procedure. 2) Tighten battery cables securely. NOTE Check to be sure that ground cable has enough clearance to hood panel by terminal. I5RW0C160006-01 3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tension to specification described at step 2) by loosening / tightening generator adjust bolt (1).

  • Page 418: Water Pump / Generator Drive Belt Removal And Installation

    1J-8 Charging System: Water Pump / Generator Drive Belt Removal and installation Installation 1) Install belt (1) to water pump pulley (2), crankshaft S7RW0A1A06004 pulley (3) and generator pulley (4). Removal 2) Adjust belt tension referring to “Water Pump / 1) Disconnect negative cable at battery.

  • Page 419: Generator Components

    Charging System: 1J-9 Generator Components S7RW0A1A06006 I4RS0A1A0004-01 1. Pulley nut 8. Rotor 15. Insulator : 111 N⋅m (11.1 kgf-m, 80.5 lb-ft) 2. Pulley 9. End housing bearing 16. Regulator : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft) 3. Drive end frame 10.

  • Page 420: Generator Inspection

    1J-10 Charging System: Generator Inspection S7RW0A1A06007 Rotor 1) Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or regulator.
  • Page 421 Charging System: 1J-11 4) Check slip rings for roughness or scoring. If rough or scored, replace the rotor. Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace the rotor. Slip ring diameter Standard: 14.2 –...

  • Page 422: Specifications

    1J-12 Charging System: Specifications Charging System Specifications S7RW0A1A07001 Battery NOTE The battery used in each vehicle is one of the following two types, depending on specification. Battery type 46B24R 55B24R Rated capacity AH/5HR, 12 Volts 40.6 42.5 Electrolyte L (US / lmp pt.) —...

  • Page 423: Exhaust System

    Exhaust System: 1K-1 Exhaust System Engine General Description Exhaust System Description S7RW0A1B01001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.

  • Page 424: Repair Instructions

    1K-2 Exhaust System: Repair Instructions Exhaust System Components S7RW0A1B06001 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I7RW0A1B0001-01 [A]: Sedan model 10.

  • Page 425: Exhaust Manifold Removal And Installation

    Exhaust System: 1K-3 9. Exhaust No.2 pipe 21. Exhaust pipe clamp Exhaust Manifold Removal and Installation 6) Remove exhaust manifold (1) and its gasket from S7RW0A1B06002 cylinder head. Removal WARNING To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down.

  • Page 426: Exhaust Pipe And Muffler Removal And Installation

    1K-4 Exhaust System: 3) Install exhaust manifold stiffener (2). 6) Connect HO2S-1 connector (1) (connector color: Tighten exhaust manifold stiffener bolts to specified black) and HO2S-2 connector (2) (connector color: torque. green), and then fit coupler to bracket securely. Tightening torque Exhaust manifold stiffener bolt (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft) 4) Install new seal ring and connect exhaust No.1 pipe...
  • Page 427 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Specifications .............2B-19 Tightening Torque Specifications......2B-19 Precautions............. 2-1 Special Tools and Equipment ......2B-20 Precautions on Suspension ........2-1 Recommended Service Material .......2B-20 Suspension General Diagnosis....2A-1 Special Tool ............2B-20 Diagnostic Information and Procedures....2A-1 Rear Suspension ........
  • Page 428 2-ii Table of Contents Wheels and Tires Specifications ......2D-6 Tightening Torque Specifications......2D-6...

  • Page 429: Precautions

    Precautions: Precautions Suspension Precautions Precautions on Suspension S7RW0A2000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. General Precautions Refer to “General Precautions in Section 00”. Vehicle Lifting Points Refer to “Vehicle Lifting Points in Section 0A”.

  • Page 430: Suspension General Diagnosis

    2A-1 Suspension General Diagnosis: Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S7RW0A2104001 Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tires. Tires not adequately inflated Adjust tire pressure. Broken or sagging coil springs Replace coil springs.
  • Page 431 Suspension General Diagnosis: 2A-2 Condition Possible cause Correction / Reference Item Suspension bottoms Overloaded Check loading. Faulty strut (shock absorber) Replace strut (shock absorber). Incorrect, broken or sagging coil springs Replace coil springs. Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners bushes.

  • Page 432: Front Suspension

    2B-1 Front Suspension: Front Suspension Suspension General Description Front Suspension Construction S7RW0A2201001 CAUTION There are two types of front suspension mounting bolt. One is pre-coated with friction stabilizer. The other is not. Never reuse pre-coated bolt to prevent it from loosening. Be sure to replace pre-coated bolt with a new one whenever loosening once.

  • Page 433: Front Wheel Alignment Construction

    Front Suspension: 2B-2 Front Wheel Alignment Construction • Check for loose of ball joints. Check tie-rod ends; if S7RW0A2201002 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 434: Camber And Caster Check

    2B-3 Front Suspension: Camber and Caster Check Toe (Total) (“b” – “a”) Front: IN 1.0 ± 1.0 mm (0.0394 ± 0.0394 in.) S7RW0A2206019 Check camber and caster by camber caster kingpin gauge (1) and turning radius gauge (2). If measured value is out of specified value, check following items for damage, deformation and crack.

  • Page 435: Steering Angle Check And Adjustment

    Front Suspension: 2B-4 Outside: 32°6’ (Reference) Reference information Side slip When checked with side slip tester, side slip should satisfy following specification. Side slip (On one person) IN 3.0 to 0 mm/m (IN 0.118 to 0 in./3.3 ft) If side slip is greatly difference, front wheel alignment may not be correct.

  • Page 436: Front Strut Assembly Removal And Installation

    2B-5 Front Suspension: Front Strut Assembly Removal and Installation 4) Remove brake hose mounting bolt (1). Remove S7RW0A2206003 brake hose (2) from bracket and wheel speed sensor harness (3) from strut bracket as shown in figure. CAUTION 5) Remove strut bracket bolts and nuts (4). When rebound stopper and strut assembly were removed, check strut support lower nut for specified torque before installing strut...

  • Page 437: Front Strut Assembly Disassembly And Reassembly

    Front Suspension: 2B-6 Front Strut Assembly Disassembly and • Lower hoist and vehicle in unloaded condition, tighten strut nut (b) to specified torque. Reassembly S7RW0A2206004 Tightening torque Strut nut (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft) Disassembly 1) Attach special tool (A) to coil spring as shown. Turn NOTE special tool bolts alternately until coil spring tension Don’t twist brake hose and wheel speed...

  • Page 438: Front Strut Assembly Check

    2B-7 Front Suspension: 2) Install compressed coil spring to strut, and place coil spring end (2) onto spring lower seat (1) as shown. 1,(a) NOTE End of coil spring must not interfere with step of spring lower seat. I5RW0A220010-02 Front Strut Assembly Check S7RW0A2206005 •...

  • Page 439: Front Wheel Hub And Steering Knuckle Components

    Front Suspension: 2B-8 Front Wheel Hub and Steering Knuckle Components S7RW0A2206006 I7RW0A220005-01 1. Front wheel hub 4. Steering knuckle 7. Dust cover 2. Circlip 5. Drive shaft nut : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft) : Calk, after tightening. 3. Wheel bearing 6.
  • Page 440 2B-9 Front Suspension: 12) Uncaulk and remove dust cover (1). 6) Pull out wheel hub (1) with special tools. Special tool (A): 09943–17912 (B): 09942–15511 CAUTION When wheel hub is removed, replace wheel bearing with new one. I2RH01220032-01 13) Remove circlip from knuckle. 14) Using hydraulic press (1) and special tool, remove wheel bearing.
  • Page 441 Front Suspension: 2B-10 16) Remove hub bolts (1) with copper hammer or 2) Install new circlip (1). hydraulic press. CAUTION Never remove bolt unless replacement is necessary. Be sure to use a new bolt for replacement. I2RH01220037-01 3) Insert new hub bolt (1) in hub hole. Rotate hub bolt slowly to assure that serrations are aligned with those made by original bolt.
  • Page 442 Strut bracket nut (b): 140 N·m (14.0 kgf-m, 101.5 lb-ft) I7RW01220007-01 7) Apply grease lightly to end face of inner ring (1). “A”: Grease 99000–25121 (SUZUKI Super 3, (b) Grease H) NOTE Do not apply the grease to the encoder section to avoid the encoder malfunction.

  • Page 443: Front Wheel Bearing And Wheel Hub Inspection

    Front Suspension: 2B-12 Front Wheel Bearing and Wheel Hub Inspection 13) Connect tie-rod end to steering knuckle, referring to “Tie-Rod End Removal and Installation in Section S7RW0A2206021 • Check wheel bearing noise and smooth wheel rotation 6C”. by rotating wheel. If defective, replace bearing. 14) Install brake disc (2) and brake caliper (3).

  • Page 444: Suspension Control Arm Removal And Installation

    2B-13 Front Suspension: Suspension Control Arm Removal and 3) Install wheel and tighten wheel nuts to specified torque. Installation S7RW0A2206009 Tightening torque CAUTION Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft) When removing and installing steering 4) Lower hoist with vehicle in unloaded condition, knuckle assembly, be careful not to damage tighten control arm bolts to specified torque.

  • Page 445: Suspension Control Arm / Steering Knuckle Check

    Front Suspension: 2B-14 Assembly Suspension Control Arm / Steering Knuckle Check CAUTION S7RW0A2206011 Inspect for cracks, deformation or damage. Be sure to use new bush. If defective, replace. 1) Front bush Suspension Control Arm Bush Inspection Press-fit front bush (1) by using special tools and S7RW0A2206012 press (2).

  • Page 446: Front Suspension Frame, Stabilizer Bar And/Or Bush Components

    2B-15 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or Bush Components S7RW0A2206014 I8RW01220009-03 [A]: Non-pre-coated bolt 4. Stabilizer bar mounting bracket bolt : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) [B]: Pre-coated bolt with friction stabilizer 5. Suspension control arm : 95 N⋅m (9.5 kgf-m, 69.0 lb-ft) 1.
  • Page 447 Front Suspension: 2B-16 10) Remove engine rear mounting nut and mounting Installation member nut referring to “Engine Mountings CAUTION Components in Section 1D”. There are two types of front suspension 11) Support front suspension frame (2) with mission jack (1). mounting bolt.
  • Page 448 2B-17 Front Suspension: 3) Support front suspension frame (2) with mission jack 10) Install suspension control arms referring to (1) and jack up it. “Suspension Control Arm Removal and Installation”. 11) Install stabilizer joint (1) and tighten nut to specified torque.

  • Page 449: Front Suspension Frame Check

    Front Suspension: 2B-18 Front Suspension Frame Check Stabilizer Joint S7RW0A2206016 1) Check for smooth rotation. Inspect for cracks, deformation or damage. 2) Check damages of ball stud. If defective, replace. 3) Check damages of dust cover. NOTE Stabilizer joint (1) cannot be disassembled. If there is any damage to either parts, stabilizer joint must be replaced as a complete unit.

  • Page 450: Specifications

    2B-19 Front Suspension: Specifications Tightening Torque Specifications S7RW0A2207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end lock nut 32.5 Strut bracket nut 14.0 101.5 Brake hose mounting bolt 19.0 Stabilizer joint nut 36.5 Strut nut 36.5 Wheel nut 61.5 Strut support lower nut 40.0...

  • Page 451: Special Tools And Equipment

    Front Suspension: 2B-20 Special Tools and Equipment Recommended Service Material S7RW0A2208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease H P/No.: 99000–25121 Special Tool S7RW0A2208002 09913–65810 09913–75510 Crankshaft bearing puller Bearing installer 09913–75821 09913–85230 Bearing installer attachment Bearing remover tool 09925–14520...

  • Page 452: Rear Suspension

    2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components S7RW0A2306001 I7RW0A230001-01 F: Forward 7. Vehicle body 16. Rear drive shaft nut [A]: 2WD model 8. Rear shock absorber 17. Rear wheel hub assembly [B]: 4WD model 9. Lower washer : 73 N⋅m (7.3 kgf-m, 53.0 lb-ft) 1.

  • Page 453: Rear Wheel Alignment Inspection

    Rear Suspension: 2C-2 Rear Wheel Alignment Inspection 4) Support rear axle by using floor jack to prevent it S7RW0A2306012 from lowering. Measure toe and camber referring to “Inspection” under 5) Remove absorber lower nut (1) and lower washer. “Front Wheel Alignment Inspection and Adjustment in 6) Remove absorber upper nut (2).
  • Page 454 2C-3 Rear Suspension: Installation 3) Remove floor jack from rear axle. 1) Install absorber upper bushes (1). 4) Install rear wheel and tighten wheel nuts to specified torque. NOTE Tightening torque For proper installing direction of absorber Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft) upper bushes (1), refer to the figure.

  • Page 455: Rear Shock Absorber Inspection

    Rear Suspension: 2C-4 Rear Shock Absorber Inspection Rear Coil Spring Removal and Installation S7RW0A2306003 S7RW0A2306005 • Inspect for deformation or damage. CAUTION • Inspect bushes for wear or damage. Removal and Installation both coil springs • Inspect for evidence of oil leakage. (right and left) at the same time to avoid rear Replace any defective parts.
  • Page 456 2C-5 Rear Suspension: 5) Detach each lower end (2) of shock absorbers (1) Installation (right and left) from rear axle. CAUTION 6) Lower rear axle gradually as far down as the coil Install spring upper seat (1) and spring low spring can be removed.

  • Page 457: Spring Upper Seat / Spring Lower Seat Inspection

    Rear Suspension: 2C-6 Rear Axle Removal and Installation 4) Remove floor jacks from rear axle. S7RW0A2306007 5) Remount rear differential (4WD model) referring to CAUTION “Rear Differential Dismounting and Remounting in Section 3B”. Do not drop brake fluid onto painted surface. Painted surfaces will be damaged.

  • Page 458: Rear Axle And Coil Spring Inspection

    2C-7 Rear Suspension: Installation 6) Connect rear height sensor link (if equipped) to rear axle referring to “Height Sensor Removal and CAUTION Installation (If Equipped) in Section 9B”. Never reuse rear axle bolts and rear hub 7) Install exhaust center pipe and muffler. bolts.

  • Page 459: Rear Wheel Hub Assembly Inspection

    Rear Suspension: 2C-8 Rear Wheel Hub Assembly Inspection 3) Remove rear brake shoe. S7RW0A2306013 4) Disconnect brake pipe flare nut (1) from wheel • Check noise and smooth rotation of wheel by rotating cylinder (3) and put bleeder plug cap (4) onto pipe wheel.
  • Page 460 2C-9 Rear Suspension: 8) If necessary, remove wheel stud bolts (1) with 2) Install brake back plate, rear wheel hub and new rear copper hammer or hydraulic press. hub bolts and then tighten rear hub bolts to specified torque. CAUTION Tightening torque Never remove bolt unless replacement is Rear hub bolt (a): 73 N·m (7.3 kgf-m, 53.0 lb-ft)

  • Page 461: Specifications

    Rear Suspension: 2C-10 6) Install brake drum referring to Step 1) and 2) of “Installation” under “Rear Brake Drum Removal and Installation in Section 4C”. 7) Pull up parking brake lever. 1,(a) Install new rear drive shaft nut (1) to specified torque, and then caulk drive shaft nut (1) (4WD model).

  • Page 462: Wheels And Tires

    2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions in Wheels and Tires Servicing Studs S7RW0A2400001 If a broken stud is found, replace it referring to “Front • Wheel repairs that use welding, heating, or peeling Wheel Hub, Steering Knuckle and Wheel Bearing are not approved.

  • Page 463: Wheels Description

    Wheels and Tires: 2D-2 Whenever a tire is dismounted from its wheel, it should Replacement wheels must be equivalent to the original be remounted so that the tire and wheel are matched. If equipment wheels in load capacity, diameter, rim with the tire’s paint dot cannot be located, a line should be offset and mounting configuration.

  • Page 464: Irregular And/Or Premature Wear Description

    2D-3 Wheels and Tires: Irregular and/or Premature Wear Description S7RW0A2401003 Irregular and premature wear has many causes. Some of them are as follows: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, tire rotation is necessary: •...

  • Page 465: Radial Tire Lead / Pull Description

    Wheels and Tires: 2D-4 Equipment manufacture’s recommendations Inflate tires to recommended pressure Road test vehicle on level unrouned road in both directions Switch front tires side to side and road test again Lead corrected, Leads reverses direction Leads in same direction if roughness results, replace tires Put tires back in original position Install a known-good tire on one front side...

  • Page 466: Repair Instructions

    2D-5 Wheels and Tires: Repair Instructions Wheel Discs Inspection Tire Rotation S7RW0A2406001 S7RW0A2406003 Inspect each wheel disc for dents, distortion and cracks. To equalize wear, rotate tires periodically as shown in A disc in badly damaged condition must be replaced. figure.

  • Page 467: Tire Mounting And Dismounting

    Wheels and Tires: 2D-6 Use a tire changing machine to mount or dismount tires. Tightening order “1” – “2” – “3” – “4” – “5” Follow equipment manufacturer’s instructions. Do not use hand tools or tire irons alone to change tires as they Tightening torque may damage tire beads or wheel rim.
  • Page 468 2D-7 Wheels and Tires:...
  • Page 469 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Precautions............3B-1 Precaution for Rear Differential Oil Leakage..3B-1 Precautions............. 3-1 Precautions in Diagnosing Trouble .....3B-1 Precautions on Driveline / Axle ......3-1 General Description ..........3B-2 Drive Shaft / Axle ........3A-1 Rear Differential Description .......3B-2 Coupling Description ...........3B-2 Front .................3A-1...
  • Page 470 3-ii Table of Contents DTC U0100: Lost Communication with ECM ..3B-27 Diagnostic Information and Procedures ....3C-1 DTC U0121: Lost Communication with ABS / Transfer Symptom Diagnosis......3C-1 ESP® Control Module........3B-27 Repair Instructions ..........3C-2 DTC U0155: Lost Communication with Transfer Oil Level Check........3C-2 Instrument Panel Cluster (IPC) Control Transfer Oil Change..........3C-2 Module ............3B-27...

  • Page 471: Precautions

    Precautions: Precautions Driveline / Axle Precautions Precautions on Driveline / Axle S7RW0A3000001 Precaution for Rear Differential Oil Leakage Refer to “Precaution for Rear Differential Oil Leakage in Section 3B”. Precaution in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 3B”. Precaution on CAN Troubleshooting Refer to “Precaution on CAN Troubleshooting in Section 1A”.

  • Page 472: Drive Shaft / Axle

    3A-1 Drive Shaft / Axle: Front Drive Shaft / Axle Driveline / Axle Front General Description Front Drive Shaft Construction S7RW0A3111001 A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For A/T vehicle, a tripod type constant velocity joint is used on the differential side and center shaft side.

  • Page 473: Diagnostic Information And Procedures

    Drive Shaft / Axle: Front 3A-2 Diagnostic Information and Procedures Front Drive Shaft Symptom Diagnosis S7RW0A3114001 Condition Possible cause Correction / Reference Item Abnormal noise Worn or breakage of the drive shaft joint Replace. Worn or breakage of the center bearing Replace. Repair Instructions Front Drive Shaft Components S7RW0A3116001...

  • Page 474: Front Drive Shaft Assembly On-Vehicle Inspection

    3A-3 Drive Shaft / Axle: Front Front Drive Shaft Assembly On-Vehicle 5) Remove brake hose mounting bolt (1) and brake hose (2) from bracket and then detach wheel speed Inspection sensor harness (3) from strut bracket. S7RW0A3116002 • Check boots for breakage or deterioration. 6) Remove suspension control arm ball joint bolt (4) •...

  • Page 475: Front Drive Shaft Disassembly And Reassembly

    Drive Shaft / Axle: Front 3A-4 Front Drive Shaft Disassembly and Reassembly 9) Remove drive shaft assembly. S7RW0A3116004 10) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from Disassembly differential side gear, if equipped. For DOJ type CAUTION Disassembly of wheel side joint is not...
  • Page 476 3A-5 Drive Shaft / Axle: Front 2) Remove differential side (or center shaft side) boot 5) Draw away cage (1) by using bearing puller (2), and small band (1) using flat end rod (2) or the like. remove boot (3) from shaft. I5RS0B310005-01 3) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out...
  • Page 477 Drive Shaft / Axle: Front 3A-6 For tripod joint type 2) Wipe off grease from shaft and take off snap ring (1) using snap ring pliers (2). CAUTION • Disassembly of wheel side joint is not allowed. If any noise or damage exists in it, replace it as assembly.
  • Page 478 3A-7 Drive Shaft / Axle: Front Reassembly For DOJ type Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly and DOJ housing are washed thoroughly and air dried.
  • Page 479 Drive Shaft / Axle: Front 3A-8 10) Install damper (1) to specified position on drive shaft. 14) Apply grease to entire surface of cage. Use specified grease in tube included in spare parts. Drive shaft damper installing position 15) Insert cage into joint housing (2) and fit snap ring (1) “a”: 354 mm (13.9 in.) (right side) into groove of joint housing (2).
  • Page 480 3A-9 Drive Shaft / Axle: Front 17) Fit boot (1) to grooves of shaft and housing (2) and 19) Fasten differential side (or center shaft side) boot adjust length to specification below. band. Insert screw driver into boot and allow air to enter •...
  • Page 481 Drive Shaft / Axle: Front 3A-10 For tripod joint type Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly (1) and tripod joint housing (2) are washed thoroughly and air dried.
  • Page 482 3A-11 Drive Shaft / Axle: Front 8) Install damper (1) to specified position on drive shaft, 12) Fit boot (1) to grooves of shaft and housing (2) adjust if equipped. length to specification below. 13) Insert screw driver into boot and allow air to enter Drive shaft damper installing position boot so that air pressure in boot becomes the same “a”: 354 mm (13.9 in.) (right side)

  • Page 483: Center Shaft And Center Bearing Support Disassembly And Reassembly (If Equipped)

    Drive Shaft / Axle: Front 3A-12 Center Shaft and Center Bearing Support 15) Fasten differential side (or center shaft side) boot big band (1) and small band (5) by drawing hooks (2) Disassembly and Reassembly (If Equipped) with special tool and engage hooks (3) in slot and S7RW0A3116005 Disassembly window (4).

  • Page 484: Specifications

    “a”: 0 – 1 mm (0 – 0.04 in.) “b”: 8 – 9 mm (0.13 – 0.35 in.) • Be sure to apply grease to oil seal lip and bearing side space indicated in the figure. I5RW0A311008-01 “A”: Grease 99000–25011 (SUZUKI Super Grease “A” “A” “a” “b”...

  • Page 485: Special Tools And Equipment

    Drive Shaft / Axle: Front 3A-14 Special Tools and Equipment Recommended Service Material S7RW0A3118001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 NOTE Required service material is also described in the following. “Front Drive Shaft Components: Front”...

  • Page 486: Rear

    3A-15 Drive Shaft / Axle: Rear Rear General Description Rear Drive Shaft Construction S7RW0A3121001 Refer to “Front Drive Shaft Construction: Front”. Repair Instructions Rear Drive Shaft Components S7RW0A3126001 I5RW0A312001-01 1. Differential side joint (Constant velocity DOJ joint) 6. Wheel side joint (Constant velocity ball joint) 11.

  • Page 487: Rear Drive Shaft Assembly Removal And Installation

    Drive Shaft / Axle: Rear 3A-16 Rear Drive Shaft Assembly Removal and Rear Drive Shaft Disassembly and Reassembly S7RW0A3126003 Installation Disassembly S7RW0A3126002 Refer to “Front Drive Shaft Disassembly and Removal Reassembly: Front” note the following point which is 1) Hoist vehicle and remove rear wheel. different from the front drive shaft is described.
  • Page 488 3A-17 Drive Shaft / Axle: Rear Reassembly • Fasten differential side boot band as follows. Refer to “Front Drive Shaft Disassembly and CAUTION Reassembly: Front” note the following points which is different from the front drive shaft is described. • Bend each boot band against forward •...

  • Page 489: Specifications

    Drive Shaft / Axle: Rear 3A-18 Specifications Tightening Torque Specifications S7RW0A3127001 NOTE The specified tightening torque is also described in the following. “Rear Drive Shaft Components: Rear” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RW0A3128001...

  • Page 490: Differential

    – Disconnect main fuse from fuse box • Diagnostic information stored in 4WD control 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 491: General Description

    Differential: 3B-2 General Description Rear Differential Description S7RW0A3201001 The differential assembly uses a hypoid bevel pinion and gear. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between hypoid bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.

  • Page 492: 4Wd Control System Description

    3B-3 Differential: 4WD Control System Description S7RW0A3201004 4WD Shift Control The 4WD control module operates the coupling assembly according to the 2WD/4WD switch operation to the selected position (2WD, 4WD-auto or 4WD-lock). Also, the 4WD control system has 4WD AUTO indicator and 4WD LOCK indicator in order to inform the 4WD control system condition.

  • Page 493: Input / Output Signal Table Of 4Wd Control Module

    – Coupling air temperature sensor – Coupling assembly • DTC can be checked by using SUZUKI scan tool (3) connected to DLC (4). • When 4WD control module detects any malfunction, 4WD control module will switch off the current to coupling assembly and vehicle is changed to 2WD position.

  • Page 494: Can Communication System Description

    3B-5 Differential: CAN Communication System Description S7RW0A3201010 Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. When 4WD control module receive the signal of abnormal as following information, vehicle is not changed to 4WD- auto and 4WD-lock position. 4WD Control Module Transmission Data ESP®...

  • Page 495: Schematic And Routing Diagram

    Differential: 3B-6 Schematic and Routing Diagram 4WD Control System Wiring Circuit Diagram S7RW0A3202007 RED/WHT L174-1 G26-13 L102-1 G26-3 L102-4 G26-2 G26-14 GRY/YEL L174-5 L174-4 BLK/ORN G26-25 G26-21 G26-24 G26-12 RED/BLK G26-22 G26-23 G26-11 WHT/RED G26-10 I7RW01320001-01 1. Coupling assembly 6. ECM 11.
  • Page 496 3B-7 Differential: Terminal Arrangement of 4WD Control Module I4JA01332038-01 [A]: Connector “G26” viewed from harness side Terminal Circuit Terminal Circuit G26-2 Coupling assembly (power) G26-14 “4WD lock” switch G26-3 Coupling assembly (ground) G26-21 Data link connector (DLC) G26-10 Ground G26-22 CAN communication line (high) G26-11 Power source for internal memory...

  • Page 497: Component Location

    Differential: 3B-8 Component Location 4WD Control System Components Location S7RW0A3203004 I5RW0A320002-04 1. 4WD control module 3. 4WD LOCK indicator 5. Coupling assembly 2. 4WD AUTO indicator 4. 2WD/4WD switch 6. Coupling air temperature sensor...

  • Page 498: Diagnostic Information And Procedures

    3B-9 Differential: Diagnostic Information and Procedures 4WD Control System Check S7RW0A3204001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC check, record and clearance Print DTC or write them...
  • Page 499 Differential: 3B-10 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 500: 4Wd Position Indicator Operation Check

    3B-11 Differential: 4WD Position Indicator Operation Check Step 2. DTC check, record and clearance First, referring to “DTC Check”, check DTC and pending S7RW0A3204002 1) Turn ignition switch to OFF position. DTC. If DTC exists, print or write down DTC and then clear malfunction DTC(s) by referring to “DTC 2) Check that 4WD position indicators turn on for about Clearance”.

  • Page 501: Visual Inspection

    4) Read DTC according to instructions displayed on 4) Erase DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer SUZUKI scan tool. Refer to SUZUKI scan tool to SUZUKI scan tool operator’s manual for further operator’s manual for further details.

  • Page 502: Dtc Table

    3B-13 Differential: DTC Table S7RW0A3204007 Detecting condition DTC No. Detecting item position (DTC will set when detecting) Indicator 4WD control module power Battery voltage is lower than lower limit voltage for C1240 supply circuit malfunction 4WD control module diagnosis. Internal circuit malfunction of Internal power supply malfunction of 4WD control C1243 4WD control module...

  • Page 503: Scan Tool Data

    Differential: 3B-14 Scan Tool Data S7RW0A3204009 Normal condition / reference Scan tool data Vehicle condition values Accelerator pedal released 0 – 5% Ignition switch ON after Accel pedal Pos Accelerator pedal depressed warmed up engine 90 – 100% fully Engine speed At engine idle speed Engine idle speed is display 2WD/4WD switch selected to 2WD position...

  • Page 504: Rear Differential Symptom Diagnosis

    3B-15 Differential: Rear Differential Symptom Diagnosis S7RW0A3204010 Condition Possible cause Correction / Reference Item Gear noise Deteriorated or water mixed lubricant Repair and replenish referring to “Rear Differential Oil Change”. Inadequate or insufficient lubricant Repair and replenish referring to “Rear Differential Oil Change”.

  • Page 505: 4Wd Position Indicator Does Not Come On At Ignition Switch On But Engine Stops

    Differential: 3B-16 4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops S7RW0A3204012 Wiring Diagram G26-11 WHT/RED RED/BLK G26-12 WHT/RED G26-22 G26-23 G26-10 I7RW01320004-01 [A]: 4WD control module connector “G26” (viewed from harness side) 4. Combination meter 1.

  • Page 506: 4Wd Position Indicator Remains On Steady At Ignition Switch

    3B-17 Differential: Step Action CAN communication circuit check Go to Step 4. Repair or replace. 1) Check CAN communication circuit between combination meter and 4WD control module referring to “DTC U0073: Control Module Communication Bus Off”. Is CAN communication circuit in good condition? “METER”...

  • Page 507: Dtc C1240: 4Wd Control Module Power Supply Circuit Malfunction

    Differential: 3B-18 DTC C1240: 4WD Control Module Power Supply Circuit Malfunction S7RW0A3204014 Wiring Diagram G26-12 RED/BLK WHT/RED G26-11 G26-10 I7RW01320005-01 [A]: 4WD control module connector “G26” (viewed from harness side) 3. “4WD” fuse 1. 4WD control module 4. Main fuse box 2.

  • Page 508: Dtc C1243: Internal Circuit Malfunction Of 4Wd Control Module

    3B-19 Differential: Step Action Ground circuit check Substitute a known- Repair ground circuit. good 4WD control 1) Turn ignition switch to OFF position. module and recheck. 2) Check for proper connection to “G26-10” terminal of 4WD control module connector. 3) If OK, measure resistance between “G26-10” terminal of 4WD control module connector and vehicle body ground.
  • Page 509 Differential: 3B-20 DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Turn ignition switch to ON position for 10 seconds. 3) Check DTC. Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check”.

  • Page 510: Dtc C1251: Coupling Air Temperature Sensor Circuit Short

    3B-21 Differential: DTC C1251: Coupling Air Temperature Sensor Circuit Short S7RW0A3204017 Wiring Diagram G26-25 G26-24 I7RW01320006-01 [A]: 4WD control module connector “G26” (viewed from harness side) 2. 4WD control module 1. Coupling air temperature sensor DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Input signal from coupling air temperature sensor is lower than...

  • Page 511: Dtc C1252: Coupling Assembly Circuit Open

    Differential: 3B-22 Step Action Coupling assembly ground circuit check Go to Step 4. “ORN” wire is shorted to ground circuit. 1) Disconnect connector from 4WD control module with ignition switch turned OFF. 2) Measure resistance between “ORN” terminal of coupling air temperature sensor connector and “G26-24”...
  • Page 512 3B-23 Differential: DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Start engine and select 2WD/4WD switch to “LOCK” position. 3) Keep engine running at 2000 rpm for 10 seconds. or more. 4) Stop engine and check DTC. Troubleshooting Step Action Was “4WD control system check”...

  • Page 513: Dtc C1253: Coupling Assembly Circuit Short

    Differential: 3B-24 DTC C1253: Coupling Assembly Circuit Short S7RW0A3204019 Wiring Diagram L102-1 G26-3 L102-4 G26-2 I7RW01320007-01 [A]: 4WD control module connector “G26” (viewed from harness side) 1. Coupling assembly [B]: Coupling assembly connector “L102” (viewed from harness side) 2. 4WD control module DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...

  • Page 514: Dtc C1254: 2Wd/4Wd Switch Malfunction

    3B-25 Differential: Step Action Coupling assembly check Substitute a known- Replace coupling good 4WD control assembly. 1) Check coupling assembly referring to “Coupling module and recheck. Assembly Inspection”. Is it in good condition? Coupling assembly circuit check “YEL” wire is shorted to Substitute a known- ground circuit.
  • Page 515 Differential: 3B-26 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area 2WD/4WD switch combination different from specification is • 2WD/4WD switch detected for more than 5 seconds. • 2WD/4WD switch circuit • 4WD control module DTC Confirmation Procedure 1) Clear DTC using scan tool.

  • Page 516: Dtc U0073: Control Module Communication Bus Off

    3B-27 Differential: DTC U0073: Control Module Communication Bus Off S7RW0A3204021 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0100: Lost Communication with ECM S7RW0A3204022 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0121: Lost Communication with ABS / ESP® Control Module S7RW0A3204023 Refer to “Troubleshooting for CAN-DTC in Section 1A”.
  • Page 517 Differential: 3B-28 Terminal arrangement of 4WD control module connector (Viewed from harness side) I4JA01332054-01 Terminal Normal Wire Color Circuit Condition Number Voltage G26-1 — — — — Coupling assembly G26-2 About 5 V Ignition switch turned ON position (ground) • Run engine at idle speed and 2WD/4WD switch at 4WD lock position 10 –...
  • Page 518 3B-29 Differential: Terminal Normal Wire Color Circuit Condition Number Voltage Coupling air G26-24 temperature sensor 0 – 1 V Ignition switch turned ON position (ground) Coupling air G26-25 temperature sensor About 2.5 V Ignition switch turned ON position (power) G26-26 —...

  • Page 519: Repair Instructions

    3) Apply sealant to thread of level / filler plug, and then • It is highly recommended to use API GL-5 tighten it to specified torque. 80W-90 gear oil. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Differential oil specification : API GL-5 (For SAE classification, refer to Tightening torque viscosity chart [A] in figure.)

  • Page 520: 2Wd/4Wd Switch Removal And Installation

    3B-31 Differential: 2WD/4WD Switch Removal and Installation 4WD Control Module Removal and Installation S7RW0A3206003 S7RW0A3206005 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Remove console box (2). 2) Remove center ventilation louver referring to “Center Ventilation Louver Removal and Installation in 3) Remove 2WD/4WD switch (1) from console box.

  • Page 521: Coupling Air Temperature Sensor Inspection

    Differential: 3B-32 Coupling Air Temperature Sensor Inspection Coupling Assembly Inspection S7RW0A3206007 S7RW0A3206008 • Check coupling assembly for oil leakage. If leakage CAUTION exists, replace it. Do not heat up coupling air temperature • Measure resistance between “a” terminal and “b” sensor more than 100 °C (212 °F).

  • Page 522: Rear Differential Mountings Components

    3B-33 Differential: Rear Differential Mountings Components S7RW0A3206009 I5RW0A320022-04 1. Rear differential 6. Front mounting to body bolt 11. Rear mounting bolt 2. Front mounting arm 7. Front mounting to body nut : 80 N⋅m (8.0 kgf-m, 58.0 lb-ft) 3. Mounting arm bolt 8.

  • Page 523: Front Mounting Arm And/Or Rear Mounting Bracket Assembly Removal And Installation

    Differential: 3B-34 Front Mounting Arm and/or Rear Mounting Rear Differential Dismounting and Remounting S7RW0A3206012 Bracket Assembly Removal and Installation Dismounting S7RW0A3206010 Remove and install front mounting arm and/or rear 1) Lift up vehicle and drain oil from rear differential. mounting bracket after rear differential removed. 2) Remove propeller shaft referring to “Propeller Shaft For tightening torque of each bolt and nut, refer to “Rear Assembly Removal and Installation in Section 3D”.

  • Page 524: Rear Differential Components

    3B-35 Differential: Rear Differential Components S7RW0A3206013 1217G 1217G I5RW0A320026-02 1. Flange nut 13. Differential cover bolt 25. Differential gear 2. Companion flange 14. Spacer 26. Spring washer 3. Oil seal 15. Rear bearing 27. Thrust washer : Apply grease 99000-25010 to oil seal lip. 4.

  • Page 525: Rear Differential Disassembly And Reassembly

    Differential: 3B-36 Rear Differential Disassembly and Reassembly 6) Remove coupling assembly (1) by using hydraulic S7RW0A3206014 press. Disassembly CAUTION 1) Remove rear mounting bracket from rear differential Do not drop coupling assembly. If it is referring to “Front Mounting Arm and/or Rear dropped, replace it with a new one.
  • Page 526 3B-37 Differential: 8) Remove oil seals from rear differential (1) using special tool. Special tool (A): 09913–50121 I5RW0A320035-01 b) Drive out differential side pinion shaft pin with special tool and hammer. Special tool (B): 09922–85811 I5RW0A320032-01 c) Disassemble differential gears (2), pinions (3), 9) Remove differential cover (1) using special tool, and washers and shaft (4) in differential case (1).
  • Page 527 Differential: 3B-38 14) Using a hammer and brass bar (1), drive out front 1) Press-fit bevel pinion bearing outer races to bearing outer race (2). differential carrier (1) by using special tools and hydraulic press as shown in the figure. Special tool (A): 09913–85210 (B): 09913–75510...
  • Page 528 3B-39 Differential: 4) Align holes of pinion shaft and differential case and 6) Press-fit differential right side bearing (1) with special drive in differential pinion shaft pin till they are flush tools and hydraulic press. with end surface of case. Special tool Special tool (A): 09913–80113...
  • Page 529 Differential: 3B-40 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
  • Page 530 3B-41 Differential: 9) Set special tools and make drive bevel pinion 12) Apply gear oil to drive bevel pinion bearings, install mounting dummy. special tools with bearings to differential carrier as shown in figure. Special tool (A): 09922–76120 Special tool (B): 09922–76250 (A): 09922–76140 (B): 09922–76420...
  • Page 531 Differential: 3B-42 14) Set dial gauge to bevel pinion mounting dummy and 16) Necessary adjusting shim thickness is the same make 0 (zero) adjustment on surface plate. value as measured value by dial gauge. Necessary shim thickness Dial gauge measured NOTE “e”...
  • Page 532 Install oil seal horizontally to surface of differential carrier. Bevel pinion bearing preload (Bevel pinion rotational torque) “A”: Grease 99000–25010 (SUZUKI Super : 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb- Grease A) in.) Distance between differential carrier and oil seal “a”...
  • Page 533 Differential: 3B-44 23) Remove differential cover. 25) As final step, check gear tooth contact as follows. 24) To measure bevel gear backlash, set dial gauge at a) After cleaning 10 drive bevel gear teeth, paint right angle to bevel gear tooth, fix drive bevel pinion them with gear marking compound evenly by and read dial gauge while moving bevel gear.
  • Page 534 3B-45 Differential: Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
  • Page 535 1.5 mm “a” (0.059 in.) in diameter, mate differential cover with differential carrier, and then tighten bolts to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Differential cover bolt: 23 N·m (2.3 kgf-m, 17.0 lb-ft)

  • Page 536: Rear Differential Inspection

    NOTE differential carrier as shown in figure, and then tighten bolts to specified torque. Install oil seal horizontally to surface of rear differential case. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) “A”: Grease 99000–25010 (SUZUKI Super Grease A) Tightening torque Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0...

  • Page 537: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RW0A3208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...

  • Page 538: Special Tool

    3B-49 Differential: Special Tool S7RW0A3208002 09900–20607 09900–20701 Dial gauge Magnetic stand 09912–34510 09913–50121 Case separator Oil seal remover 09913–60910 09913–65135 Bearing and gear puller (40- Bearing puller 60mm) 09913–70123 09913–75510 Bearing installing tool Bearing installer 09913–75810 09913–75830 Bearing installer Steering pinion bush installer 09913–80113 09913–85210...
  • Page 539 Universal joint assembling tool 09927–27910 09930–40113 Holder, bevel pinion Flywheel rotor holder 09951–26020 SUZUKI scan tool Bush remover & installer — support This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.

  • Page 540: Transfer

    3C-1 Transfer: Transfer Driveline / Axle General Description Transfer Description S7RW0A3301001 The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction drive gear, reduction driven gear and bevel gear of transfer.

  • Page 541: Repair Instructions

    5) Apply sealant to thread of drain plug (1), and tighten S7RW0A3306001 it to specified torque. 1) Lift up vehicle and check oil leakage. Repair leaky “A”: Sealant 99000–31260 (SUZUKI Bond point, if any. No.1217G) 2) Remove oil level / filler plug (1) and check oil...

  • Page 542: Transfer Dismounting And Remounting

    1) Disconnect negative cable at battery. • Apply grease to left case (1) as shown in figure. 2) Drain transaxle oil and transfer oil. “A”: Grease 99000–25010 (SUZUKI Super Grease 3) Remove drive shafts assembly referring to “Front Drive Shaft Assembly Removal and Installation: Front in Section 3A”.

  • Page 543: Transfer Assembly Components

    Transfer: 3C-4 • Pour transaxle oil and transfer oil referring to “Manual Transaxle Oil Change in Section 5B” and “Transfer Oil Change”. Transfer Assembly Components S7RW0A3306004 1217G 1322 1217G 1217G I5RW0A330007-05 1. Transfer output flange nut 15. Dowel pin 29. Transfer right case : After tightening nut so as rotational torque : Apply sealant 99000-31260 to of bevel pinion to be in specified value,...

  • Page 544: Transfer Assembly Disassembly And Reassembly

    3C-5 Transfer: 9. Pump seal 23. Reduction drive gear right bearing : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 10. Pinion shaft front taper roller bearing 24. Intermediate shaft : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft) 11. Bevel pinion 25. Oil protect plate bolt : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) : Apply thread lock cement 99000-32110 to thread part.
  • Page 545 2) Clean mating surface of right and left cases, and m, 40.0 lb-ft) apply sealant to right case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) 1, (a) “A” 1, (a)

  • Page 546: Reduction Drive Gear Assembly Disassembly And Reassembly

    I5RW0A330016-02 2) Install bearings (1) to reduction drive gear (2) using 12) Apply grease to new right case oil seal No.1 lip. special tool, bearing puller (3) and hydraulic press “A”: Grease 99000–25010 (SUZUKI Super (4). Grease A) Special tool 13) Drive right case oil seal No.1 (1) in transfer right...

  • Page 547: Reduction Driven Gear Assembly Disassembly And Reassembly

    Transfer: 3C-8 Reduction Driven Gear Assembly Disassembly Reassembly and Reassembly CAUTION S7RW0A3306007 Disassembly • Bevel gear and pinion must be replaced as 1) Remove left bearing (1) and bevel gear (2) using a set when either replacement becomes special tool, bearing puller (3) and hydraulic press necessary.

  • Page 548: Transfer Right Case And Left Case Disassembly And Reassembly

    Apply grease to oil seal lip. (B): 09924–84510–005 Special tool (A): 09925–15410 “A”: Grease 99000–25010 (SUZUKI Super Grease A) Oil seals installing depth “a”: 23.5 – 24.0 mm (0.925 – 0.945 in.) “b”: 38.0 – 39.0 mm (1.496 – 1.535 in.) “b”...

  • Page 549: Transfer Output Retainer Assembly Disassembly And Reassembly

    Transfer: 3C-10 Transfer Output Retainer Assembly 5) Drive out front taper roller bearing (1) from bevel pinion (3) by using bearing puller (2) and hydraulic Disassembly and Reassembly press. S7RW0A3306009 Disassembly 1) Uncaulk transfer output flange nut. 2) Remove transfer output flange nut while holding flange (1) by using special tool.
  • Page 550 3C-11 Transfer: Reassembly b) Install bevel pinion dummy (1), rear taper roller bearing (2) and special tools to transfer output CAUTION retainer (3). • Bevel gear and pinion must be replaced as Special tool a set when either replacement becomes (A): 09922–76140 necessary.
  • Page 551 Transfer: 3C-12 c) Tighten bevel pinion nut (special tool) so that e) Obtain adjusting shim thickness by the following specified bearing preload is obtained. equation. NOTE Distance Distance Necessary Before taking measurement, check for Distance “d” “e” shim – rotation by hand more than 15 revolutions. “c”...
  • Page 552 3) Press-fit front taper roller bearing (1) by using I5RW0A330041-02 6) Apply grease to new oil seal lip. special tool and hydraulic press. “A”: Grease 99000–25010 (SUZUKI Super Special tool Grease A) (A): 09925–18011 7) Drive in oil seal (1) by using special tools and hammer.

  • Page 553: Transfer Assembly Inspection

    Transfer: 3C-14 Transfer Assembly Inspection 8) Install transfer output flange (1) by tapping with plastic hammer and tighten transfer output flange nut S7RW0A3306010 • Check each bearing for smooth rotation, wear or gradually so as rotational torque of bevel pinion to be discoloration in specified value.
  • Page 554 3C-15 Transfer: 4) Bring painted part up and check contact pattern referring to the following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart. NOTE • Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check. •...

  • Page 555: Specifications

    Transfer: 3C-16 Tooth contact pattern Diagnosis and remedy These contact patterns, located on toe or heel on both drive and coast sides, mean that 1) both pinion and gear are defective, 2) retainer is not true, or 3) gear is not properly seated on transfer case.

  • Page 556: Special Tools And Equipment

    3C-17 Transfer: Special Tools and Equipment Recommended Service Material S7RW0A3308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
  • Page 557 Transfer: 3C-18 09922–76430 09924–07710 Bevel pinion front collar Synchronizer hub installer 09924–74510 09924–84510–005 Bearing and oil seal handle Bearing installer attachment 09925–15410 09925–16310 Oil seal installer Bearing installer 09925–18011 09925–98221 Transmission gear, bush Bearing installer and bearing installer 09930–40113 09940–54910 Flywheel rotor holder Front fork oil seal install driver...

  • Page 558: Propeller Shaft

    3D-1 Propeller Shaft: Propeller Shaft Driveline / Axle Precautions Propeller Shaft Caution S7RW0A3400001 CAUTION • All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.

  • Page 559: Repair Instructions

    Propeller Shaft: 3D-2 Repair Instructions Propeller Shaft Joint Check 4) Remove propeller shaft by removing center support S7RW0A3406001 nuts (1). If universal joints and ball joint are suspected of producing chattering or rattling noise, inspect them for CAUTION wear. For universal joint, check to see if cross spider Use care not to drop it.

  • Page 560: Specifications

    3D-3 Propeller Shaft: Specifications Tightening Torque Specifications S7RW0A3407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Propeller shaft bolt 17.0 Center support nut 40.0 NOTE The specified tightening torque is also described in the following. “Propeller Shaft Construction” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
  • Page 561 Table of Contents 4- i Section 4 Brakes CONTENTS Precautions ..........4-1 Front Brakes ..........4B-1 Precautions............. 4-1 Repair Instructions ..........4B-1 Precautions for Brakes.......... 4-1 Front Disc Brake Components ......4B-1 Front Disc Brake Pad On-Vehicle Inspection..4B-2 Brake Control System and Diagnosis ... 4A-1 Front Disc Brake Pad Removal and Precautions............4A-1 Installation ............4B-2...
  • Page 562 4-ii Table of Contents Tightening Torque Specifications......4D-4 Front Wheel Speed Sensor Removal and Installation ............4E-35 ABS............4E-1 Front and Rear Wheel Speed Sensor Inspection............4E-36 Precautions............4E-1 Rear Wheel Speed Sensor Removal and Precautions in Diagnosing Troubles ....4E-1 Installation (4WD Model).........4E-36 Precautions in On-Vehicle Service......
  • Page 563 Table of Contents 4-iii Visual Inspection ..........4F-22 DTC U0114: Lost Communication with Four- ESP® Warning Light Does Not Come ON at Wheel Drive Clutch Control Module ....4F-48 Ignition Switch ON .......... 4F-23 DTC U0123: Lost Communication with Yaw ESP®...

  • Page 564: Precautions

    4-1 Precautions: Precautions Brakes Precautions Precautions for Brakes S7RW0A4000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. Brake Caution Refer to “Brake Caution in Section 00”. ESP®...

  • Page 565: Brake Control System And Diagnosis

    Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brakes Precautions Precautions on Brake S7RW0A4100001 Air Bag Warning Refer to“Air Bag Warning in Section 00”. Brakes Diagnosis Note Refer to “Brakes Diagnosis Note”. General Description Brakes Construction S7RW0A4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front disc brake and four in rear drum brake).

  • Page 566: Brake Pedal Foot Protection System Construction (If Equipped)

    4A-2 Brake Control System and Diagnosis: Brake Pedal Foot Protection System Construction (If Equipped) S7RW0A4101002 Should a front crash occur and the engine push the dash panel toward the interior side, the brake pedal bracket is also pushed toward the interior side. In this case, the brake pedal lever comes off from the brake pedal, thereby preventing the brake pedal from moving rearward.

  • Page 567: Brakes Symptom Diagnosis

    Brake Control System and Diagnosis: 4A-3 Brakes Symptom Diagnosis S7RW0A4104002 Condition Possible cause Correction / Reference Item Not enough braking force Brake fluid leakage from brake lines Locate leaking point and repair. Brake disc or pad stained with fluid, Clean or replace. grease or other oil Overheated brakes Determine cause and repair.
  • Page 568 4A-4 Brake Control System and Diagnosis: Condition Possible cause Correction / Reference Item Dragging brakes (A very Master cylinder pistons not returning Replace master cylinder. light drag is present in all correctly brakes immediately after Restricted brake pipes or hoses Check for soft hoses or damaged pipes and pedal is released) replace with new hoses and/or new brake...

  • Page 569: Repair Instructions

    Brake Control System and Diagnosis: 4A-5 Repair Instructions Brake Pedal Components Brake Pedal Free Height Inspection S7RW0A4106001 S7RW0A4106002 CAUTION 1) Check brake pedal free height. If it is not within specification, check and adjust following item 2) to If equipped Brake Pedal Foot Protection System, never disassemble brake pedal assembly.

  • Page 570: Excessive Pedal Travel Inspection

    4A-6 Brake Control System and Diagnosis: Excessive Pedal Travel Inspection Brake Fluid Level Inspection S7RW0A4106004 S7RW0A4106005 1) Start engine. CAUTION 2) Depress brake pedal a few times. Do not use shock absorber fluid or any other 3) With brake pedal depressed with approximately 300 fluid which contains mineral oil.

  • Page 571: Brake Light Switch Adjustment

    Brake Control System and Diagnosis: 4A-7 Brake Light Switch Adjustment 1) Fill master cylinder reservoir with specified brake S7RW0A4106006 fluid and keep at least one-half full of fluid during Adjustment should be made as follows. Pull up brake bleeding operation. pedal toward you and while holding it there, adjust Brake fluid switch position so that clearance between end of thread...

  • Page 572: Front Brake Hose / Pipe Components

    4A-8 Brake Control System and Diagnosis: Front Brake Hose / Pipe Components S7RW0A4106019 I7RW0A410001-01 [A]: LHD 3. From ABS (ESP®) hydraulic unit to right front brake 9. Master cylinder fixing nut [B]: RHD 4. From ABS hydraulic unit to left front brake : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) [C]: ABS model 5.

  • Page 573: Front Brake Hose And Pipe Removal And Installation

    Brake Control System and Diagnosis: 4A-9 Front Brake Hose and Pipe Removal and Installation S7RW0A4106008 CAUTION Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid, flush it with water immediately if any fluid is spilled. Removal 1) Hoist vehicle and remove tire and wheel.

  • Page 574: Rear Brake Hose / Pipe Components

    4A-10 Brake Control System and Diagnosis: Rear Brake Hose / Pipe Components S7RW0A4106020 I6RW0D410001-01 1. To left rear brake hose 5. Left rear brake hose to left brake 2. To right rear brake hose 6. Right rear brake hose to right brake 3.

  • Page 575: Master Cylinder And Brake Booster Components

    Brake Control System and Diagnosis: 4A-11 Master Cylinder and Brake Booster Components S7RW0A4106011 CAUTION Never disassemble master cylinder and brake booster. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. I7RW01410017-03 1. Reservoir 6.

  • Page 576: Master Cylinder Reservoir Removal And Installation

    4A-12 Brake Control System and Diagnosis: Master Cylinder Reservoir Removal and Installation Installation 1) When using new grommets (2), lubricate them with S7RW0A4106012 the same fluid as the one to fill reservoir with. CAUTION Then press-fit grommets (2) to master cylinder (3). Do not allow brake fluid to get on painted 2) Install reservoir (1) to master cylinder.

  • Page 577: Master Cylinder Removal And Installation

    Brake Control System and Diagnosis: 4A-13 6) Fill reservoir with specified brake fluid up to its MAX 3) Drain brake fluid in reservoir. level. 4) Disconnect clutch reservoir hose from reservoir (M/T 7) After completing the work, bleed air from brake model).

  • Page 578: Master Cylinder Inspection

    4A-14 Brake Control System and Diagnosis: Master Cylinder Inspection 4) Connect brake pipe to master cylinder and tighten flare nuts to specified torque. S7RW0A4106014 • Depress brake pedal a few times and retain brake Tightening torque pedal. If pedal gone down, replace the brake master Brake pipe flare nut for M10 (a): 16 N·m (1.6 kgf- cylinder assembly.
  • Page 579 Brake Control System and Diagnosis: 4A-15 4) If pedal travel doesn’t change, air tightness isn’t Check Air Tightness Under Load obtained. 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed. NOTE If defective, inspect vacuum lines and sealing parts, and replace any faulty part.

  • Page 580: Brake Booster Removal And Installation

    4A-16 Brake Control System and Diagnosis: Brake Booster Removal and Installation 3) Connect vacuum hose to booster referring to S7RW0A4106016 “Master Cylinder and Brake Booster Components”. Removal 4) Install front brake pipe (from master cylinder primary 1) Remove master cylinder assembly from booster and secondary to ABS hydraulic unit pipe) referring referring to “Master Cylinder Removal and to “Front Brake Hose and Pipe Removal and...

  • Page 581: Special Tool

    Brake Control System and Diagnosis: 4A-17 Specifications Tightening Torque Specifications S7RW0A4107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Front brake caliper bleeder plug Rear wheel cylinder bleeder plug Flexible hose joint bolt 17.0 Master cylinder fixing nut 13.0 Brake pipe flare nut for M10 12.0 Brake pipe flare nut for M12 14.0...

  • Page 582: Front Brakes

    4B-1 Front Brakes: Front Brakes Brakes Repair Instructions Front Disc Brake Components S7RW0A4206001 I8RW01420001-01 1. Caliper 9. Disc brake piston 17. Brake flexible hose : Apply rubber grease included in piston : Be sure to direct mark (18) to seal set or brake fluid to contact surface of inside of vehicle “I”...

  • Page 583: Front Disc Brake Pad On-Vehicle Inspection

    Front Brakes: 4B-2 Front Disc Brake Pad On-Vehicle Inspection 4) Remove brake pads (3). S7RW0A4206002 Inspect pad linings periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end and inspection hole of caliper and check lining thickness of outside and inside pads.

  • Page 584: Front Disc Brake Pad Inspection

    4B-3 Front Brakes: 3) Install caliper and tighten caliper pin bolts to Front Disc Brake Caliper Removal and specified torque. Installation S7RW0A4206005 Tightening torque Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft) Removal 1) Hoist vehicle and remove front wheel. 2) Remove brake flexible hose joint bolt (1) from caliper (2).

  • Page 585: Front Disc Brake Caliper Disassembly And Assembly

    Front Brakes: 4B-4 Front Disc Brake Caliper Disassembly and 3) Connect flexible hose (3) to caliper as shown in figure. Assembly S7RW0A4206006 4) Tighten flexible hose joint bolt to specified torque. Disassembly Tightening torque Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m, CAUTION 17.0 lb-ft) Clean around caliper with brake fluid before...
  • Page 586 4B-5 Front Brakes: Assembly • Install piston seal, boot and piston to caliper referring Assemble parts in reverse order of disassembly, to the following instructions. observing the following instructions. 1) Replace with a new piston seal (1) at every overhaul. After applying rubber grease included in piston seal CAUTION set or brake fluid, fit piston seal (1) into groove in...

  • Page 587: Front Disc Brake Caliper Check

    Front Brakes: 4B-6 4) Insert piston into cylinder by hand and fit boot in boot groove in piston. NOTE Check that boot is fitted in boot groove securely all around piston and cylinder. I8RW01420003-01 Slid pin Before installing caliper to carrier, check for its smooth movement in thrust direction.

  • Page 588: Front Brake Disc Inspection

    4B-7 Front Brakes: Front Brake Disc Inspection 3) Pull brake disc off by using 8 mm bolts (1) (2 pcs). S7RW0A4206009 • Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of disc, measure deflection of disc.

  • Page 589: Specifications

    Front Brakes: 4B-8 Specifications Tightening Torque Specifications S7RW0A4207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Caliper pin bolt 19.0 Flexible hose joint bolt 17.0 Bleeder plug Caliper carrier bolt 61.5 NOTE The specified tightening torque is also described in the following. “Front Disc Brake Components”...

  • Page 590: Rear Brakes

    4C-1 Rear Brakes: Rear Brakes Brakes Repair Instructions Rear Drum Brake Components S7RW0A4306001 I6RW0D430001-01 1. Brake drum 10. Wheel cylinder 19. Bleeder plug 2. Brake shoe 11. Brake back plate : 73 N⋅m (7.3 kgf-m, 53 lb-ft) 3. Shoe return spring 12.

  • Page 591: Rear Brake Drum Removal And Installation

    Rear Brakes: 4C-2 Rear Brake Drum Removal and Installation Rear Brake Drum and Shoe Inspection S7RW0A4306002 S7RW0A4306003 Removal Brake Drum 1) Hoist vehicle and remove rear wheel. Inspect brake drum for wear. 2) Release parking brake lever. If drum inner diameter is exceeds the limit or uneven or 3) Remove brake drum (1) by using 8 mm bolts (2) (2 stepped wear is excessive, replace the drum.

  • Page 592: Rear Brake Shoe On-Vehicle Inspection

    4C-3 Rear Brakes: Rear Brake Shoe Removal and Installation Brake Shoe S7RW0A4306005 CAUTION NOTE Never polish lining with sandpaper. If lining is When replacing brake shoe, replace it on the polished with sandpaper, hard particles of right and left. sandpaper will be deposited in lining and may damage drum.

  • Page 593: Rear Brake Adjuster And Shoe Lever Check

    Rear Brakes: 4C-4 2) Remove brake shoe referring to “Rear Brake Shoe Installation Install parts in reverse order of removal, noting the Removal and Installation”. following. 3) Loosen brake pipe flare nut (1) but only within the • Before installing rear brake shoe to brake back plate, extent that fluid does not leak.

  • Page 594: Wheel Cylinder Inspection

    4C-5 Rear Brakes: 5) Install brake shoes. Refer to “Rear Brake Shoe Brake Back Plate Removal and Installation Removal and Installation”. S7RW0A4306009 6) Install brake drum. Refer to “Rear Brake Drum Removal Removal and Installation”. 1) Remove rear wheel hub referring to “Rear Wheel 7) Fill reservoir with brake fluid and bleed brake Hub Assembly Removal and Installation in Section system.

  • Page 595: Specifications

    Rear Brakes: 4C-6 Specifications Tightening Torque Specifications S7RW0A4307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Wheel cylinder mounting bolt Rear brake pipe flare nut 12.0 Parking cable cap nut NOTE The specified tightening torque is also described in the following. “Rear Drum Brake Components”...

  • Page 596: Parking Brake

    4D-1 Parking Brake: Parking Brake Brakes Repair Instructions Parking Brake Cable Components S7RW0A4406004 ( a ) ( a ) ( a ) ( a ) ( a ) ( b ) ( b ) ( b ) ( a ) ( b ) I6RW0D440001-01 T: Top side...

  • Page 597: Parking Brake Inspection And Adjustment

    Parking Brake: 4D-2 Parking Brake Inspection and Adjustment After confirming that the conditions are all satisfied, S7RW0A4406001 adjust parking brake lever stroke by loosening or Inspection tightening adjust nut (1). Hold center of parking brake lever grip and pull it up with 200 N (20 kg, 44 lbs) force.

  • Page 598: Parking Brake Lever Removal And Installation

    4D-3 Parking Brake: Parking Brake Lever Removal and Installation Installation S7RW0A4406003 1) Install in reverse order of removal procedure. Check equalizer inclined angle. Removal Tightening torque 1) Remove console box. Parking brake lever bolt (a): 26 N·m (2.6 kgf-m, 2) Block vehicle wheels and release parking brake 19.0 lb-ft) lever.

  • Page 599: Specifications

    Parking Brake: 4D-4 Specifications Tightening Torque Specifications S7RW0A4407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Parking brake lever bolt 19.0 NOTE The specified tightening torque is also described in the following. “Parking Brake Cable Components” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.

  • Page 600: Abs

    To ensure that the trouble diagnosis is done accurately and smoothly, observe the following and follow “ABS Check”. • Diagnostic information stored in ABS control 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 601: General Description

    ABS: 4E-2 General Description ABS Description S7RW0A4501001 The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This ABS has also the following function.

  • Page 602: Abs Hydraulic Unit / Control Module Assembly Description

    4E-3 ABS: ABS Hydraulic Unit / Control Module Assembly Description S7RW0A4501002 ABS control module is a component of ABS hydraulic unit / control module assembly and has the following functions. Self-Diagnosis Function ABS control module diagnoses conditions of the system component parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the ABS warning light as described.

  • Page 603: Schematic And Routing Diagram

    ABS: 4E-4 Schematic and Routing Diagram ABS Schematic S7RW0A4502001 INPUT OUTPUT ABS control module Hydraulic unit Wheel speed sensor (LF) Pump motor Pump motor driver (transistor) Wheel speed sensor (LR) Solenoid valve power Wheel speed sensor (RF) supply driver (transistor) Wheel speed sensor (RR) LF inlet solenoid valve Brake light switch...

  • Page 604: Abs Wiring Circuit Diagram

    4E-5 ABS: 1. ABS hydraulic unit / control module assembly 9. Brake light switch 17. Wheel speed sensor (Left-rear) 2. ABS control module 10. ABS warning light 18. Battery 3. ABS hydraulic unit 11. EBD warning light (Brake warning light) 19.
  • Page 605 ABS: 4E-6 WHT/RED WHT/BLU GRN/ORN E08-9 E08-7 GRN/WHT GRN/ORN GRN/YEL E08-6 E08-23 GRN/BLK E08-3 RED/BLK E08-24 WHT/BLU E08-25 WHT/RED E08-26 RED/BLK E08-2 RED/BLU E08-13 E08-16 E08-1 E08-12 E08-11 RED/BLK E08-22 E08-18 WHT/BLK E08-17 E08-21 LT GRN/BLK LT GRN E08-10 E08-20 E08-19 I7RW0A450002-01 [A]: Junction block with BCM...

  • Page 606: Component Location

    4E-7 ABS: Terminal Circuit CAN communication line (high) for ECM CAN communication line (high) for BCM G sensor ground (4WD model) — — G sensor signal (4WD mode) Brake light switch — Ignition switch Left-rear wheel speed sensor (–) Left-front wheel speed sensor (+) CAN communication line (low) for ECM CAN communication line (low) for BCM —...

  • Page 607: Diagnostic Information And Procedures

    ABS: 4E-8 Diagnostic Information and Procedures ABS Check S7RW0A4504001 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 608 4E-9 ABS: Step 1: Malfunction Analysis 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 609: Abs Warning Light Check

    ABS: 4E-10 Problem symptom confirmation Step 7: Final Confirmation Test Check if what the customer claimed in “Customer Confirm that the problem symptom has gone and the Questionnaire” is actually found in the vehicle and if that ABS is free from any abnormal conditions. If what has symptom is found, whether it is identified as a failure.

  • Page 610: Dtc Table

    4) Read DTC according to instructions displayed on any traffic accident possibility and be very SUZUKI scan tool and print it or write it down. Refer careful during testing to avoid occurrence of to SUZUKI scan tool operator’s manual for further an accident.

  • Page 611: Scan Tool Data

    ABS: 4E-12 Scan Tool Data Scan Tool Data Definition S7RW0A4504007 Battery Volt (V) The parameter data below are values measured with the Battery Voltage is an analog input signal read by the scan tool when the normally operating vehicle is under ABS control module.
  • Page 612 4E-13 ABS: ABS Warning Light Does Not Come ON at Ignition Switch ON S7RW0A4504008 Wiring Diagram WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 RED/BLK E08-23 G241-31 G241-16 G241-7 G241-10 G04-4 G04-2 E04-1 E08-2 E04-2 E08-13 RED/BLK E04-5 L01-6 RED/BLU G241 4 5 6 7 8 9 10 11 12 13 14 15 16 20 2122 23 24 25 26 27 28 29 30 3132 I6RW0D450007-01...
  • Page 613 ABS: 4E-14 WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E08-23 RED/BLK E08-26 G241-31 G241-16 G241-7 E08-2 G241-10 E08-13 G241 G05-1 4 5 6 7 8 9 10 11 12 13 14 15 16 G05-3 20 2122 23 24 25 26 27 28 29 30 3132 G05-7 RED/BLK RED/BLU...

  • Page 614: Abs Warning Light Comes On Steady

    4E-15 ABS: Step Action Combination meter power source circuit check Go to Step 4. Repair power source circuit for combination 1) Remove combination meter with ignition switch turned meter. OFF. 2) Check for proper connection to “RED/BLK” and “BLK” wire of combination meter connector. 3) If OK then turn ON ignition switch and measure voltage at “RED/BLK”...

  • Page 615: Ebd Warning Light (Brake Warning Light) Comes On Steady

    ABS: 4E-16 EBD Warning Light (Brake Warning Light) Comes ON Steady S7RW0A4504010 Wiring Diagram Referring to “Wiring Diagram” under “ABS Warning Light Does Not Come ON at Ignition Switch ON”. Circuit Description EBD warning light (brake warning light) is controlled by ABS control module and BCM through light driver module in combination meter.

  • Page 616: Serial Data Link Circuit Check

    4E-17 ABS: Step Action CAN communication line circuit check Substitute a known- Repair CAN good combination meter communication line 1) Turn ignition switch to OFF position. and recheck. If EBD circuit. 2) Disconnect connectors of all control modules warning light remains communicating by means of CAN.
  • Page 617 ABS: 4E-18 WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E08-23 RED/BLK E08-26 G241-31 G241-16 G241-7 E08-2 G241-10 E08-13 G05-1 G05-3 G05-4 G05-2 E08-16 G241 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 13 12 20 2122 23 24 25 26 27 28 29 30 3132 39 38 34 33 32 31...
  • Page 618 4E-19 ABS: Trouble shooting Step Action Scan tool communication check Go to Step 2. Go to Step 3. Can scan tool communicate with BCM? ABS hydraulic unit / control module assembly power Go to Step 3. Repair ABS hydraulic and ground circuit check unit / control module assembly power or 1) Check that ABS hydraulic unit / control module assembly...

  • Page 619: Dtc C1013: Control Module Mismatch

    ABS: 4E-20 DTC C1013: Control Module Mismatch S7RW0A4504012 Wiring Diagram GRN/ORN E08-9 GRN/ORN E08-6 GRN/YEL GRN/BLK E08-3 I7RW01450005-04 [A]: ABS control module connector (viewed from terminal side) 3. Ignition switch 6. ABS hydraulic unit / control module assembly 1. Battery 4.

  • Page 620: Dtc C1015: G Sensor Circuit (4Wd Model)

    4E-21 ABS: DTC C1015: G Sensor Circuit (4WD Model) S7RW0A4504013 Wiring Diagram Refer to “Wiring Diagram” under “DTC C1013: Control Module Mismatch”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • G sensor signal voltage is out of specified range. •...

  • Page 621: Dtc 1016: Brake Light Switch

    ABS: 4E-22 DTC 1016: Brake Light Switch S7RW0A4504014 Wiring Diagram GRN/ORN E08-9 GRN/WHT E08-7 I7RW01450006-05 [A]: ABS control module connector (viewed from terminal side) 3. Ignition switch 6. Brake light 1. Battery 4. Junction block assembly 7. ABS hydraulic unit / control module assembly 2.

  • Page 622: Dtc C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor Or Encoder

    4E-23 ABS: DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder S7RW0A4504015 DTC C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit DTC C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor or Encoder...
  • Page 623 ABS: 4E-24 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. Check tire condition Go to Step 3. Replace tire or adjust tire pressure and 1) Check that tire pressure is specifications. recheck. Are they in good condition? Wheel speed sensor circuit check Go to Step 4.

  • Page 624: Dtc C1033: Wheel Speed Sensor Deviation

    4E-25 ABS: DTC C1033: Wheel Speed Sensor Deviation S7RW0A4504016 Wiring Diagram Refer to “Wiring Diagram” under “DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...

  • Page 625: Dtc C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid

    ABS: 4E-26 DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid S7RW0A4504017 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left- Rear Inlet Solenoid DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left- Rear Outlet Solenoid Wiring Diagram E08-24...

  • Page 626: Dtc C1057: Power Supply Voltage Too High / Too Low

    4E-27 ABS: DTC C1057: Power Supply Voltage Too High / Too Low S7RW0A4504018 Wiring Diagram GRN/ORN E08-9 E08-23 I7RW01450009-03 [A]: ABS control module connector (viewed from terminal side) 2. Main fuse box 4. Junction block assembly 1. Battery 3. Ignition switch 5.

  • Page 627: Dtc C1061: Pump Motor Circuit

    ABS: 4E-28 DTC C1061: Pump Motor Circuit S7RW0A4504019 Wiring Diagram E08-25 WHT/RED E08-26 I7RW01450010-02 [A]: ABS control module connector (viewed from terminal side) 3. Pump motor driver (transistor) 1. Battery 4. ABS pump motor 2. Main fuse box 5. ABS hydraulic unit / control module assembly DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...

  • Page 628: Dtc C1063: Solenoid Valve Power Supply Driver Circuit

    4E-29 ABS: DTC C1063: Solenoid Valve Power Supply Driver Circuit S7RW0A4504020 Wiring Diagram GRN/ORN E08-9 WHT/BLU E08-24 E08-23 I7RW01460015-01 [A]: ABS control module connector (viewed from terminal side) 4. Junction block assembly 1. Battery 5. Solenoid valve power supply driver (transistor) 2.

  • Page 629: Dtc C1071: Control Module Internal Defect

    ABS: 4E-30 DTC C1071: Control Module Internal Defect S7RW0A4504021 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area ABS control module internal defect is detected. • ABS control module DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”.

  • Page 630: Repair Instructions

    4) Set transmission to neutral (P range for A/T) and release parking brake. 5) Turn each wheel gradually by hand to check if brake dragging occurs. If it does, correct. 6) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. I5RW0A450007-01 Special tool...

  • Page 631: Abs Hydraulic Unit / Control Module Assembly Components

    8) Perform the following checks with help of another person. Brake pedal (1) should be depressed and then select testing wheel by SUZUKI scan tool and the wheel (2) should be turned by another person’s hand. At this time, check that: •...

  • Page 632: Abs Hydraulic Unit / Control Module Assembly On-Vehicle Inspection

    4E-33 ABS: ABS Hydraulic Unit / Control Module Assembly 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit / On-Vehicle Inspection control module assembly (3). S7RW0A4506003 CAUTION Special tool Never disassemble ABS hydraulic unit / (A): 09950-78220 control module assembly, loosen blind plug NOTE...

  • Page 633: Front And Rear Wheel Speed Sensor On-Vehicle Inspection

    ABS: 4E-34 Installation 2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”. 1) Install hydraulic unit / control module assembly by reversing removal procedure noting the following. 3) Check each installed part for fluid leakage and Install ABS hydraulic unit / control module assembly perform “ABS Hydraulic Unit Operation Check”.

  • Page 634: Front Wheel Speed Sensor Removal And Installation

    4E-35 ABS: Front Wheel Speed Sensor Removal and 5) Measure voltage at resistance without wheel rotation.If voltage is out of specification, check Installation sensor, mating encoder and their installation S7RW0A4506006 conditions. CAUTION Voltage at the resistance (115 Ω) without wheel •...

  • Page 635: Front And Rear Wheel Speed Sensor Inspection

    ABS: 4E-36 Rear Wheel Speed Sensor Removal and Installation Installation (4WD Model) 1) Check that no foreign material is attached to sensor S7RW0A4506008 (1) and wheel speed sensor encoder (included in CAUTION wheel hub assembly). Rear wheel speed sensor is included in rear 2) Install it by reversing removal procedure.

  • Page 636: Front Wheel Speed Sensor Encoder On-Vehicle Inspection

    4E-37 ABS: Front Wheel Speed Sensor Encoder On-Vehicle Rear Wheel Speed Sensor Encoder On-Vehicle Inspection Inspection S7RW0A4506010 S7RW0A4506012 Before inspecting front wheel speed sensor encoder, For 4WD model remove front drive shaft referring to “Front Drive Shaft Refer to “Rear Wheel Speed Sensor On-Vehicle Assembly Removal and Installation: Front in Section Inspection”.

  • Page 637: G Sensor Removal And Installation (4Wd Model)

    ABS: 4E-38 G Sensor Removal and Installation (4WD Model) G Sensor Inspection (4WD Model) S7RW0A4506014 S7RW0A4506015 Connect positive cable of 12 V battery to “A” terminal of CAUTION sensor and ground cable to “C” terminal. • Do not drop and shock G sensor. It will Then using voltmeter, check voltage between terminals affect its original performance.

  • Page 638: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S7RW0A4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.

  • Page 639: Electronic Stability Program

    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 640: Precautions In Speedometer Test Or Other Tests

    ESP® OFF switch or using SUZUKI scan tool to complete the tests correctly. When using 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 641: Electronic Stability Program Construction

    Electronic Stability Program: 4F-3 Electronic Stability Program Construction S7RW0A4601005 I7RS0B460001-03 1. ESP® control module 6. Steering angle sensor 11. ESP® OFF switch 2. Hydraulic unit 7. Brake light switch 12. Electronic signal 3. ECM 8. Yaw rate/ G sensor 13. CAN signal 4.
  • Page 642 4F-4 Electronic Stability Program: I7RS0B460002-01 2. Brake caliper (front-right) 3. Brake caliper (front-left) 4. Brake caliper (rear-right) 5. Brake caliper (rear-left) Steering angle sensor The steering angle sensor is assembled with the contact coil as a unit and mounted to the steering column. Detecting the angle as the steering wheel is turned, it sends that information to the ESP®...

  • Page 643: On-Board Diagnosis System Description

    Electronic Stability Program: 4F-5 ESP® OFF switch This switch is momentary type. And this is attached to console box. ESP® OFF light in combination meter lights up by pushing the switch more than 5 seconds. Then it informs that ESP® (except for ABS) is controlled not to work to driver. The operation of ESP®...

  • Page 644: Warning Light, Indicator Light Description

    4F-6 Electronic Stability Program: Warning Light, Indicator Light Description S7RW0A4601003 There are five types of warning light and indicator light in instrument cluster, which are controlled by ESP® control module. They give warning / indication to driver by changing the modes light ON / blinking / light OFF. I7RW01460001-01 1.

  • Page 645: Can Communication System Description

    Electronic Stability Program: 4F-7 CAN Communication System Description S7RW0A4601004 Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. ESP® control module communicates control data with each control module as follows. ESP® Control Module Transmission Data 4WD control Combination Steering angle...

  • Page 646: Schematic And Routing Diagram

    4F-8 Electronic Stability Program: Schematic and Routing Diagram Electronic Stability Program Schematic S7RW0A4602001 INPUT OUTPUT ESP® hydraulic unit / control module assembly Master cylinder pressure sensor Hydraulic unit ESP® control module Pump motor driver Pump motor (transistor) Solenoid valve power supply driver Battery Voltage LF inlet solenoid valve...

  • Page 647: Electronic Stability Program Wiring Circuit Diagram

    Electronic Stability Program: 4F-9 Electronic Stability Program Wiring Circuit Diagram S7RW0A4602002 WHT/RED WHT/BLU GRN/ORN E08-9 E08-6 GRN/YEL GRN/WHT E08-7 WHT/RED GRN/ORN E08-24 WHT/BLU RED/BLK GRN/ORN WHT/RED E08-25 G04-5 E04-9 E08-16 E08-23 L313-3 PPL/WHT E08-26 E04-5 RED/BLK RED/BLU L01-6 E08-2 E04-1 E08-13 E04-2 L34-1...

  • Page 648: Component Location

    4F-10 Electronic Stability Program: 4. Junction block assembly 18. ABS warning light 32. Left-rear wheel speed sensor 5. Brake light switch 19. EBD warning light (brake warning light) 33. Right-rear wheel speed sensor 6. Brake light 20. ESP® warning light 34.
  • Page 649 Electronic Stability Program: 4F-11 I6RW0A460005-02 1. ESP® warning light 7. ESP® OFF switch 13. Yaw rate / G sensor 2. EBD warning light (brake warning light) 8. Rear wheel speed sensor 14. Data link connector 3. ABS warning light 9. Rear wheel encoder 15.

  • Page 650: Diagnostic Information And Procedures

    4F-12 Electronic Stability Program: Diagnostic Information and Procedures Electronic Stability Program Check S7RW0A4604001 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 651 Electronic Stability Program: 4F-13 Step 1: Malfunction Analysis 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 652: Esp® Warning Light Check

    4F-14 Electronic Stability Program: Step 2: Driving Test ESP® Warning Light Check Test the vehicle at 40 km/h for more than a minute S7RW0A4604002 1) Turn ignition switch ON. including left and right turns and check if any trouble symptom (such as ESP® warning light and/or ABS 2) Check that ESP®...

  • Page 653: Dtc Table

    4) Read DTC according to instructions displayed on 1) Turn ignition switch to OFF position. SUZUKI scan tool and print it or write it down. Refer 2) Connect SUZUKI scan tool to data link connector to SUZUKI scan tool operator’s manual for further (1).
  • Page 654 4F-16 Electronic Stability Program: ESP® (displayed Detecting condition (DTC will be set Diagnostic Items warning warning warning on SUZUKI when detecting) light light light scan tool) • Steering angle sensor internal defect is detected. • Steering angle sensor signal is out of C1024 Steering angle sensor —...
  • Page 655 Electronic Stability Program: 4F-17 ESP® (displayed Detecting condition (DTC will be set Diagnostic Items warning warning warning on SUZUKI when detecting) light light light scan tool) • Wheel speed is different from other wheel speed (vehicle speed) for more than specified time.
  • Page 656 4F-18 Electronic Stability Program: ESP® (displayed Detecting condition (DTC will be set Diagnostic Items warning warning warning on SUZUKI when detecting) light light light scan tool) • Solenoid valve power supply driver circuit is shorted to power circuit in ESP® control module.

  • Page 657: Dtc Clearance

    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 658 4F-20 Electronic Stability Program: Fail-safe operation DTC No. TCS / Fail-safe condition resolutive stability C1038 — C1039 — C1040 — — C1041 — — — C1042 — — — C1043 — — — C1044 — — — When ESP® control module detects the system as normal, after C1045 —...

  • Page 659: Scan Tool Data

    Electronic Stability Program: 4F-21 Scan Tool Data S7RW0A4604009 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 660: Visual Inspection

    4F-22 Electronic Stability Program: Scan Tool Data Definition Steering angle Sen (Neutral, Non neutral) This indicates steering wheel angle measured by Battery volt (V) steering angle sensor is in straight-ahead or not. Battery Voltage is an analog input signal read by the ESP®...

  • Page 661: Esp® Warning Light Does Not Come On At Ignition Switch

    Electronic Stability Program: 4F-23 ESP® Warning Light Does Not Come ON at Ignition Switch ON S7RW0A4604010 Wiring Diagram WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E08-23 E08-26 E04-1 E08-2 E04-2 E08-13 RED/BLK G04-4 G04-2 G241-31 G241-10 G241-7 G241 G241-16 I7RW0A460003-01 [A]: ESP® control module connector (viewed from terminal side) 3.

  • Page 662: Esp® Warning Light Comes On Steady

    4F-24 Electronic Stability Program: Step Action Combination meter power source circuit check Go to Step 4. Repair power source circuit for combination 1) Remove combination meter with ignition switch turned meter. OFF. 2) Check for proper connection to G241-31 and G241-16 wire of combination meter connector.

  • Page 663: Abs Warning Light Does Not Come On At Ignition Switch

    Electronic Stability Program: 4F-25 ABS Warning Light Does Not Come ON at Ignition Switch ON S7RW0A4604044 Wiring Diagram WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E08-23 E08-26 E04-1 E08-2 E04-2 E08-13 RED/BLK G04-4 G04-2 G241-31 G241-10 G241-7 G241 G241-16 I7RW0A460003-01 [A]: ESP® control module connector (viewed 3.

  • Page 664: Ebd Warning Light (Brake Warning Light) Comes On Steady

    4F-26 Electronic Stability Program: EBD Warning Light (Brake Warning Light) Comes ON Steady S7RW0A4604046 Wiring Diagram WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E08-23 E08-26 E04-5 RED/BLK RED/BLK L01-6 RED/BLK E04-1 E08-2 E04-2 E08-13 G04-4 G04-2 G241-31 G241-10 G241 G241-7 G241-16 I7RW0A460004-01 [A]: ESP®...
  • Page 665 Electronic Stability Program: 4F-27 Troubleshooting Step Action Parking brake and brake fluid level check Go to Step 2. Release parking brake completely and/or 1) Make sure that: replenish brake fluid. • Parking brake is completely released. • Brake fluid level is upper than the minimum level. Are the check results OK? ABS warning light operation check Perform “ABS Warning...

  • Page 666: Serial Data Link Circuit Check

    4F-28 Electronic Stability Program: Serial Data Link Circuit Check S7RW0A4604047 Wiring Diagram WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E04-9 E08-16 L313-3 PPL/WHT E08-23 E08-26 G04-5 G04-3 G04-1 RED/BLK E04-1 E08-2 E04-2 E08-13 G04-4 G04-2 G241 G241-31 L313 G241-10 G241-7 G241-16 I7RW0A460005-01 [A]: ESP®...
  • Page 667 Electronic Stability Program: 4F-29 Troubleshooting Step Action Scan tool communication check Go to Step 2. Go to Step 3. Can scan tool communicate with BCM? ESP® hydraulic unit / control module assembly power Go to Step 3. Repair ESP® hydraulic and ground circuit check unit / control module assembly power or...

  • Page 668: Dtc C1016: Brake Light Switch

    4F-30 Electronic Stability Program: DTC C1016: Brake Light Switch S7RW0A4604016 Wiring Diagram E01-20 E08-7 GRN/WHT GRN/WHT 3938 32 31 3938 32 31 5453 5453 4746 47 46 I6RW0H460006-01 [A]: ESP® control module connector (viewed from terminal side) 3. Junction block assembly 8.
  • Page 669 Electronic Stability Program: 4F-31 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program Check”. Check brake light switch circuit Go to Step 3. Repair or replace. 1) Check brake light, brake light (brake pedal) switch and their circuit referring to “Brake Light Symptom Diagnosis in Section 9B”.

  • Page 670: Dtc C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor

    4F-32 Electronic Stability Program: DTC C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor S7RW0A4604017 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area C1017: • Yaw rate / G sensor • Lateral G sensor signal is out of specified range. •...

  • Page 671: Dtc C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor Or Encoder

    Electronic Stability Program: 4F-33 DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder S7RW0A4604019 DTC C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit DTC C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor or Encoder...
  • Page 672 4F-34 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program Check”. Check tire condition Go to Step 3. Replace tire or adjust tire pressure and 1) Check that tire pressure is specifications. recheck.

  • Page 673: Dtc C1024: Steering Angle Sensor

    Electronic Stability Program: 4F-35 DTC C1024: Steering Angle Sensor S7RW0A4604020 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • Steering angle sensor internal defect is detected. • CAN communication circuit • Steering angle sensor signal is out of specified range. •...

  • Page 674: Dtc C1033: Wheel Speed Sensor Deviation

    4F-36 Electronic Stability Program: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • ESP® OFF switch keeps ON for 60 seconds. • ESP® OFF switch • ESP® OFF switch circuit is shorted to ground. • ESP® OFF switch circuit •...
  • Page 675 Electronic Stability Program: 4F-37 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program Check”. Check DTC for ESP® Go to “DTC C1021 / Go to Step 3. C1022 / C1025 / C1026 1) Connect scan tool to DLC with ignition switch turned / C1031 / C1032 / OFF.

  • Page 676: Dtc C1034 / C1039: Yaw Rate / G Sensor Power Supply Failure / Internal Failure

    4F-38 Electronic Stability Program: DTC C1034 / C1039: Yaw Rate / G Sensor Power Supply Failure / Internal Failure S7RW0A4604023 Wiring Diagram GRN/ORN E08-2 E08-13 L34-1 [B] L34 L34-2 L34-3 L34-4 BLK/ORN I6RW0H460009-01 [A]: ESP® control module connector (viewed from 3.

  • Page 677: Dtc C1037: Steering Angle Sensor Power Supply Failure

    Electronic Stability Program: 4F-39 Step Action Check yaw rate / G sensor power supply circuit Go to Step 5. “GRN/ORN” wire circuit open or high resistance. 1) Turn ignition switch to OFF position. 2) Disconnect yaw rate / G sensor connector. 3) Check for proper connection to yaw rate / G sensor connector terminals at “L34-1”...

  • Page 678: Dtc C1038: Steering Angle Sensor Detect Rolling Counter

    4F-40 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program Check”. DTC check for ESP® Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.

  • Page 679: Dtc C1040: Esp® Continuous Operation

    Electronic Stability Program: 4F-41 DTC C1040: ESP® Continuous Operation S7RW0A4604026 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • ESP® control is active for more than specified time. • ESP® control module • ESP® control module requested pressure reduction or keeping all wheel speed sensor for more than specified time.
  • Page 680 4F-42 Electronic Stability Program: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • Solenoid valve circuit is opened, shorted to power, • ESP® control module ground and/or each valve in ESP® hydraulic unit / control module assembly. •...

  • Page 681: Dtc C1057: Power Supply Voltage Too High / Too Low

    Electronic Stability Program: 4F-43 DTC C1057: Power Supply Voltage Too High / Too Low S7RW0A4604048 Wiring Diagram GRN/ORN E08-9 E08-23 I6RW0H460012-01 [A]: ESP® control module connector (viewed from terminal side) 2. Main fuse box 4. Junction block assembly 1. Battery 3.

  • Page 682: Dtc C1061: Pump Motor Circuit

    4F-44 Electronic Stability Program: DTC C1061: Pump Motor Circuit S7RW0A4604029 Wiring Diagram E08-25 WHT/RED E08-26 I6RW0H460013-01 [A]: ESP® control module connector (viewed from terminal side) 2. Main fuse box 4. Pump motor 1. Battery 3. Pump motor driver (transistor) 5. ESP® hydraulic unit / control module assembly DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...

  • Page 683: Dtc C1063: Solenoid Valve Power Supply Driver Circuit

    Electronic Stability Program: 4F-45 DTC C1063: Solenoid Valve Power Supply Driver Circuit S7RW0A4604030 Wiring Diagram GRN/ORN E08-9 WHT/BLU E08-24 E08-23 I6RW0H460014-01 [A]: ESP® control module connector (viewed from terminal side) 4. Junction block assembly 1. Battery 5. Solenoid valve power supply driver 2.

  • Page 684: Dtc C1071: Control Module Internal Defect

    4F-46 Electronic Stability Program: DTC C1071: Control Module Internal Defect S7RW0A4604049 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area ESP® control module internal defect is detected. • ESP® control module DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2.

  • Page 685: Dtc C1091: Can Invalid Data From Ecm

    Go to applicable DTC Substitute a known- diag. flow. good ESP® hydraulic 1) Connect SUZUKI scan tool to DLC with ignition switch unit / control module turned OFF. assembly and recheck. 2) Turn ignition switch ON and check DTC for ECM.

  • Page 686: Dtc U0073: Control Module Communication Bus Off

    4F-48 Electronic Stability Program: DTC U0073: Control Module Communication Bus Off S7RW0A4604035 Refer to “Troubleshooting for Communication Error with Scan Tool Using CAN in Section 1A”. DTC U0100: Lost Communication with ECM / PCM S7RW0A4604036 Refer to “Troubleshooting for Communication Error with Scan Tool Using CAN in Section 1A”. DTC U0101: Lost Communication with TCM S7RW0A4604037 Refer to “Troubleshooting for Communication Error with Scan Tool Using CAN in Section 1A”.
  • Page 687 Electronic Stability Program: 4F-49 Troubleshooting Step Action Check fuse Go to Step 2. Replace fuse and check for short circuit to ® Are main fuses and circuit fuses for ESP in good ground. condition? Check ESP® control module power supply circuit Go to Step 3.

  • Page 688: Repair Instructions

    5) Turn each wheel gradually by hand to check if braked ragging occurs. If it does, correct. I4RH01450021-01 6) Connect SUZUKI scan tool to data link connector 9) Check for all 4-wheels condition respectively. If a (DLC) (1) with ignition switch OFF.

  • Page 689: Esp® Hydraulic Unit / Control Module Assembly On-Vehicle Inspection

    Check hydraulic unit for fluid leakage. 5) Select menu “SENSOR CALIBRATION” under If any, repair or replace. “MISC. TEST” mode of SUZUKI scan tool and calibrate sensor. Refer to scan tool operator's ESP® Hydraulic Unit / Control Module manual for further derails.
  • Page 690 (1) from bracket (3) using 3) Check each installed part for fluid leakage. flat end rod or the like (2). 4) Connect SUZUKI Scan Tool. 5) Turn ignition switch to ON position. And SLIP indicator light flush. (Other than replace with new one) If other than SLIP indicator light lights, check DTC and repair it.

  • Page 691: Front Wheel Speed Sensor On-Vehicle Inspection

    1) Check that basic brake system other than ESP® Vehicle Inspection in Section 4E”. refer to “Brakes Diagnosis Note in Section 4A”. 2) Connect SUZUKI scan tool to data link connector Front Wheel Speed Sensor Removal and (DLC) (1) with ignition switch OFF.

  • Page 692: Yaw Rate / G Sensor On-Vehicle Inspection

    “DATA LIST” of SUZUKI scan tool. 5) Check “G Sensor (lateral)” under “DATA LIST” of If pressure displayed on SUZUKI scan tool is out of SUZUKI scan tool in the following vehicle conditions. specification, replace ESP® hydraulic unit / control •...

  • Page 693: Yaw Rate / G Sensor Removal And Installation

    Electronic Stability Program: 4F-55 Yaw Rate / G Sensor Removal and Installation 3) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to S7RW0A4606016 scan tool operator's manual for further derails. CAUTION 4) Check “Yaw rate sensor”...

  • Page 694: Yaw Rate / G Sensor Inspection

    Before each inspection, confirm steering angle sensor calibration is completed. If calibration is incompleted, calibrate sensor referring to “Sensor Calibration”. 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool...

  • Page 695: Steering Angle Sensor Removal And Installation

    Electronic Stability Program: 4F-57 Steering Angle Sensor Removal and Installation S7RW0A4606019 Removal 1) Remove steering wheel and contact coil cable assembly. Refer to “Steering Wheel Removal and Installation” and “Contact Coil Cable Assembly Removal and Installation”. 2) Remove steering angle sensor (2) from contact coil cable assembly (3) while opening fitting parts (1) of contact coil cable assembly.

  • Page 696: Specifications

    Special Tool S7RW0A4608001 09950–78220 09956–02311 Flare nut wrench (10 mm) Brake pressure gauge 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 697: Automatic Transmission/Transaxle

    Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Line Pressure Test ..........5A-34 “P” Range Test..........5A-35 Precautions............. 5-1 A/T Symptom Diagnosis........5A-35 Precautions on Transmission / Transaxle ..... 5-1 Transmission Warning Light Circuit Check – Automatic Transmission/Transaxle..5A-1 Light Remains “ON”...
  • Page 698 5-ii Table of Contents DTC P1702: Internal Control Module Memory Transmission Control Module (TCM) Check Sum Error ..........5A-70 Removal and Installation.........5A-99 DTC P1723: Range Select Switch A/T Relay Inspection .........5A-99 Malfunction............5A-70 Differential Side Oil Seal Replacement ...5A-100 DTC P1878: Torque Converter Clutch A/T Fluid Cooler Hoses Replacement .....5A-100 Automatic Transaxle Unit Components...5A-101 Shudder ............

  • Page 699: Manual Transmission/Transaxle

    Table of Contents 5-iii Manual Transmission/Transaxle .... 5B-1 Differential Components........5B-36 Differential Disassembly and Reassembly..5B-36 General Description ..........5B-1 Specifications .............5B-38 Manual Transaxle Construction ......5B-1 Tightening Torque Specifications......5B-38 Diagnostic Information and Procedures....5B-5 Special Tools and Equipment ......5B-39 Manual Transaxle Symptom Diagnosis....5B-5 Recommended Service Material .......5B-39 Repair Instructions ..........5B-5 Special Tool ............5B-39...

  • Page 700: Precautions

    5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions on Transmission / Transaxle S7RW0A5000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 5A”. Precautions for Disassembly and Reassembly Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
  • Page 701 • Diagnostic information stored in TCM memory can be may occur and often time would be wasted. cleared as well as checked by using SUZUKI scan As the automatic transaxle consists of high precision tool or CAN communication OBD generic scan tool.
  • Page 702 5A-2 Automatic Transmission/Transaxle: Part Inspection and Correction Table CAUTION Part Inspect for Correction • Keep component parts in group for each Casted part, Small flaw, burr Remove with oil subassembly and avoid mixing them up. machined part stone. • Clean all parts with cleaning solvent Deep or grooved Replace part.

  • Page 703: General Description

    Automatic Transmission/Transaxle: 5A-3 General Description A/T Description S7RW0A5101001 This automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up mechanism.
  • Page 704 5A-4 Automatic Transmission/Transaxle: Slip controlled lock-up function (if equipped) Even at a lower speed than when the TCC gets engaged completely, control over the TCC pressure control solenoid works to cause the TCC to slip (be engaged slightly), thereby improving the transmission efficiency. While such slip control is being executed, the oil pressure applied to the TCC is controlled by the TCC pressure control solenoid so that the difference between the engine speed and the input shaft speed becomes close to the specified value.
  • Page 705 Automatic Transmission/Transaxle: 5A-5 I5RW0C510070-01 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23. Short planet pinion 4. Input shaft 14.
  • Page 706 Wet type multiple-disc brake... 3 sets One-way clutch... 2 sets Reduction gear ratio 1.023 Final gear reduction ratio 4.277 Lubrication Lubrication system Force feed system by oil pump Cooling Cooling system Radiator assisted cooling (water-cooled) Fluid used SUZUKI ATF 3317 or Mobil ATF 3309...

  • Page 707: Clutch / Brake / Planetary Gear Function Of Automatic Transaxle

    Automatic Transmission/Transaxle: 5A-7 Clutch / Brake / Planetary Gear Function of Automatic Transaxle S7RW0A5101002 I4RS0A510001-01 1. Input shaft and intermediate shaft 8. One-way No.2 clutch 15. Front sun gear 2. Direct clutch 9. 2nd brake 16. Rear sun gear 3. Reduction drive gear 10.

  • Page 708: Table Of Component Operation

    5A-8 Automatic Transmission/Transaxle: Table of Component Operation S7RW0A5101003 Part Selector Gear Shift solenoid Shift solenoid TCC solenoid Forward Reverse position position Direct clutch valve-A (No.1) valve-B (No.2) valve clutch clutch × × × × Parking × × × Reverse × ×...

  • Page 709: Automatic Gear Shift Table

    Automatic Transmission/Transaxle: 5A-9 Solenoid Shift Shift Selector Gear Timing solenoid solenoid Condition position position solenoid solenoid valve-A valve-B valve valve (No.1) (No. 2) × × × × × × (3rd) When fail-safe function is operating : ON (Turn power ON) ×: OFF (Turn power OFF) : ON only when TCC is operating Valve status...
  • Page 710 5A-10 Automatic Transmission/Transaxle: Lock-up Throttle Vehicle speed km/h (mph) Remark clutch status opening (%) • D range • Except throttle opening shift from low Over 85% 158 – 163 (98 – 101) to high at vehicle speed 160 km/h (100 mph) or more with Lock-up ON 4th gear lock-up condition.

  • Page 711: A/T Diagnosis General Description

    • For Euro OBD model, it is possible to communicate with TCM through data link connector (DLC) (2) by using not only SUZUKI scan tool (3) but also CAN communication OBD generic scan tool. (Diagnostic information can be checked and erased by using scan I6RW0B510001-01 tool.)

  • Page 712: Can Communication System Description

    5A-12 Automatic Transmission/Transaxle: CAN Communication System Description S7RW0A5101006 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 Hydrauric 4WD control Unit / Control Combination module Module Assembly...
  • Page 713 Automatic Transmission/Transaxle: 5A-13 Schematic and Routing Diagram Transmission Control Module (TCM) Wiring Diagram S7RW0A5102001 LT/GRN C06-11 C06-12 C07-23 C06-16 BLK/WHT C07-25 BLK/ORN C06-15 BLK/YEL WHT RED C06-7 C06-14 BLU/BLK C06-17 WHT/BLU C06-5 12V 12V C06-3 WHT/BLK C06-4 C06-2 LT GRN/BLK C06-24 WHT/RED C07-9...
  • Page 714 5A-14 Automatic Transmission/Transaxle: 1. TCM 15. Shift solenoid valve-A (No.1) 29. “ST SIG” fuse 2. Input shaft speed sensor 16. Shift solenoid valve-B (No.2) 30. “ST” fuse 3. Output shaft speed sensor / VSS 17. Timing solenoid valve 31. MIL 4.

  • Page 715: A/T System Diagram

    Automatic Transmission/Transaxle: 5A-15 A/T System Diagram S7RW0A5102002 Torque converter with Planetary gear Final gear Engine unit torque converter clutch reduction unit Clutches and Regulator valves brakes Oil pump in valve body Control valves in valve body Pressure control solenoid valve Shift solenoid valves, TCC solenoid valve and Timing solenoid valve...

  • Page 716: Component Location

    5A-16 Automatic Transmission/Transaxle: Component Location Electronic Shift Control System Components Location S7RW0A5103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0D510004-01 [A]: Junction block with BCM model 7. Input shaft speed sensor 15.

  • Page 717: Diagnostic Information And Procedures

    Automatic Transmission/Transaxle: 5A-17 6. Output shaft speed sensor (VSS) 14. Transmission range sensor Diagnostic Information and Procedures A/T System Check S7RW0A5104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis.
  • Page 718 5A-18 Automatic Transmission/Transaxle: Step 1. Customer Complaint Analysis Record details of the problem such as failure, complaint and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 719 Automatic Transmission/Transaxle: 5A-19 Step 2. DTC / Freeze Frame Data Check, Record and Step 8. A/T Basic Check and A/T Symptom Clearance Diagnosis First, referring to “DTC Check”, check DTC and pending Perform basic check of A/T according to “A/T Basic DTC.

  • Page 720: Transmission Warning Light Check

    5A-20 Automatic Transmission/Transaxle: Inspection item Referring Also check the following items at engine start, if possible. • Malfunction indicator lamp ----- Operation “Malfunction Indicator Lamp (MIL) Check” • Transmission warning light ----- Operation “Transmission Warning Light Check (Non-Euro- OBD model)” •...
  • Page 721 Automatic Transmission/Transaxle: 5A-21 Detecting condition DTC No. Detecting item (DTC will set when detecting) Control module Programming P0602 Data programming error. — — Error Transmission range sensor circuit 1 driving 1 driving P0705 Multiple signals are inputted simultaneously. malfunction (PRNDL input) cycle cycle Transmission range sensor circuit...

  • Page 722: Dtc Check

    (DTC) in its memory and outputs the DTC to the scan tool. Therefore, check both of the control modules for any DTC with the SUZUKI scan tool because the DTC stored in ECM I5RW0C510072-01 3) Turn ignition switch ON.

  • Page 723: Dtc Clearance

    After repair or replace malfunction part(s), clear all DTCs connector (DLC). by performing the following procedure. NOTE 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection DTC and freeze frame data stored in TCM for “DTC Check”.
  • Page 724 5A-24 Automatic Transmission/Transaxle: DTC No. Trouble area Fail-safe operation P0787 Shift / Timing solenoid Control Circuit Low P0788 Shift / Timing solenoid Control Circuit High Pressure control solenoid control circuit P0962 • Power supply for all solenoid valves is cut. •...

  • Page 725: Scan Tool Data

    Automatic Transmission/Transaxle: 5A-25 DTC No. Trouble area Fail-safe operation • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. • Engine revolution is assumed to be 0 RPM. •...
  • Page 726 5A-26 Automatic Transmission/Transaxle: Normal condition / reference Scan tool data Vehicle condition values At vehicle stop SHIFT SOLENOID- At 60 km/h (37.5 mile/h) constant speed, 20% or less B COMMAND throttle opening and 3rd gear (“3” range) At vehicle stop SHIFT SOLENOID- At 60 km/h (37.5 mile/h) constant speed, 20% or less B MONITOR...
  • Page 727 Automatic Transmission/Transaxle: 5A-27 Scan Tool Data Definitions: TCC SOLENOID Electric current value ratio between electric current value GEAR POSITION being outputted from TCM to solenoid and maximum Current gear position computed by throttle position value can be outputted by TCM. coming from ECM and vehicle speed.

  • Page 728: A/T Basic Check

    5A-28 Automatic Transmission/Transaxle: MIL REQUEST OFF: Signal which TCM does not require combination ON: Signal which TCM requires combination meter to meter to turn on malfunction indicator lamp. turn on malfunction indicator lamp. A/T Basic Check S7RW0A5104010 This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in “Visual Inspection”.
  • Page 729 Automatic Transmission/Transaxle: 5A-29 Troubleshooting Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Faulty oil pump Inspect. If NG, replace. Seized or broken planetary gear Inspect. If NG, replace. Faulty one-way No.2 clutch Inspect.
  • Page 730 5A-30 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → 3 downshift fails to Malfunction of shift solenoid valve-A Inspect. If NG, replace. occur Malfunction of “3” position switch Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor (VSS) Malfunction of input shaft speed sensor Inspect.

  • Page 731: Manual Road Test

    Automatic Transmission/Transaxle: 5A-31 Manual Road Test S7RW0A5104012 WARNING Carry out test in very little traffic area to prevent an accident. Test requires 2 persons, a driver and a tester. The purpose of this test is to judge whether causal factor of trouble which occurred in automatic transaxle is electrical or mechanical by disconnecting valve body harness connector (1) and fixing automatic transaxle gear position.

  • Page 732: Stall Test

    5A-32 Automatic Transmission/Transaxle: Stall Test S7RW0A5104014 This test is to check overall performance of automatic transaxle and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is between FULL and LOW marks.

  • Page 733: Time Lag Test

    Automatic Transmission/Transaxle: 5A-33 Time Lag Test S7RW0A5104015 This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal. 2) Start engine.

  • Page 734: Line Pressure Test

    5A-34 Automatic Transmission/Transaxle: Line Pressure Test S7RW0A5104016 Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires the following conditions. • Automatic fluid is at normal operating temperature (70 – 80 °C / 158 – 176 °F). •...

  • Page 735: P" Range Test

    Automatic Transmission/Transaxle: 5A-35 “P” Range Test S7RW0A5104017 1) Stop vehicle on a slope of 5 degrees or more, shift select lever to “P” range and at the same time apply parking brake. 2) After stopping engine, depress brake pedal and release parking brake. 3) Then, release brake pedal gradually and check that vehicle remains stationary.
  • Page 736 5A-36 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → Poor 1 2 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Output shaft speed sensor (VSS) circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
  • Page 737 Automatic Transmission/Transaxle: 5A-37 Condition Possible cause Correction / Reference Item → Poor 3 4 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
  • Page 738 5A-38 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → Poor 3 2 shift Shift solenoid valve-A circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Output shaft speed sensor (VSS) circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
  • Page 739 Automatic Transmission/Transaxle: 5A-39 Condition Possible cause Correction / Reference Item Non operate TCC (lock- TCC solenoid valve circuit faulty Inspect circuit for open, short and intermittent. up) system If NG, repair. Shift solenoid valve-A and/or-B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
  • Page 740 5A-40 Automatic Transmission/Transaxle: Trouble Diagnosis 2 On-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Excessive shift shock Engine abnormal condition Inspect and repair engine. Malfunction of shift solenoid valve-A Inspect.
  • Page 741 Automatic Transmission/Transaxle: 5A-41 Condition Possible cause Correction / Reference Item → Poor 3 4 shift Malfunction of shift solenoid valve-B Inspect. If NG, replace. Malfunction of timing solenoid valve Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor (VSS) Malfunction of input shaft speed sensor Inspect.
  • Page 742 5A-42 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item Non operate TCC (lock- Malfunction of TCC solenoid valve Inspect. If NG, replace. up) system Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of output shaft speed Inspect.

  • Page 743: Transmission Warning Light Circuit Check - Light Remains "On" At Ignition Switch On (Non-Euro-Obd Model)

    Automatic Transmission/Transaxle: 5A-43 Condition Possible cause Correction / Reference Item Non operate TCC (lock- Faulty torque converter Replace. up) system → Excessive “N” “D” time Faulty oil pump Inspect. If NG, replace. Faulty forward clutch Inspect. If NG, replace. Faulty one-way No.2 clutch Inspect.

  • Page 744: Dtc P0602: Control Module Programming Error

    5A-44 Automatic Transmission/Transaxle: DTC P0602: Control Module Programming Error S7RW0A5104021 System Description Internal control module is installed in ECM. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Data programming error (1 driving cycle detection logic) DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF.
  • Page 745 Check transmission range sensor circuit for operation Intermittent trouble. Go to Step 5. Check by using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent OFF. and Poor Connection Inspection in Section 2) Turn ignition switch ON and check transmission range 00”.

  • Page 746: Dtc P0707: Transmission Range Sensor Circuit Low

    5A-46 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor Inspection and “RED”, “GRN/ORN”, range sensor. Adjustment”. “GRN”, “GRN/YEL” or “LT GRN/BLK” circuit Are check results satisfactory? shorted to power circuit or shorted each other.
  • Page 747 Check transmission range sensor circuit for operation Intermittent trouble. Go to Step 5. Check by using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent OFF. and Poor Connection Inspection in Section 2) Turn ignition switch ON and check transmission range 00”.

  • Page 748: Dtc P0711: Transmission Fluid Temperature Sensor "A" Control Range / Performance

    5A-48 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor Inspection and “RED”, “GRN/ORN”, range sensor. Adjustment”. “GRN”, “GRN/YEL” or “LT GRN/BLK” circuit Are check results satisfactory? open or short to ground. If wires and connections are OK, substitute a know-good TCM and...

  • Page 749: Dtc P0712: Transmission Fluid Temperature Sensor Circuit Low

    Automatic Transmission/Transaxle: 5A-49 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Inspect transmission fluid temperature sensor Go to Step 3 Replace transmission fluid temperature 1) Inspect transmission fluid temperature sensor referring sensor.

  • Page 750: Dtc P0713: Transmission Fluid Temperature Sensor Circuit High

    5A-50 Automatic Transmission/Transaxle: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
  • Page 751 Automatic Transmission/Transaxle: 5A-51 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.

  • Page 752: Dtc P0717: Input / Turbine Speed Sensor Circuit Malfunction

    5A-52 Automatic Transmission/Transaxle: DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction S7RW0A5104027 Wiring Diagram C07-6 C07-16 2.5V I6RW0B510010-01 1. TCM 2. Input shaft speed sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No input shaft speed sensor signal is detected although...

  • Page 753: Dtc P0722: Output Speed Sensor (Vss) Circuit No Signal

    Automatic Transmission/Transaxle: 5A-53 Step Action Inspect input shaft speed sensor “WHT” or “BLK” circuit Replace input shaft open or short. speed sensor. 1) Inspect input shaft speed sensor referring to “Input Shaft Speed Sensor Inspection”. Is result satisfactory? Check visually input shaft speed sensor and direct Intermittent trouble or Clean, repair or replace.
  • Page 754 5A-54 Automatic Transmission/Transaxle: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.

  • Page 755: Dtc P0741 / P0742: Tcc Circuit Performance Or Stuck Off / Tcc Circuit Stuck

    Automatic Transmission/Transaxle: 5A-55 Step Action Check output shaft speed sensor (VSS) gears visually Intermittent trouble or Replace drive gear and/ faulty TCM. or driven gear of output 1) Check output shaft speed sensor gears for the shaft speed sensor. followings. Check for intermittent referring to “Intermittent •...

  • Page 756: Dtc P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction

    5A-56 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. 1) Check TCC solenoid valve for operation referring to Clean fluid passage or Replace TCC solenoid “Solenoid Valves (Shift Solenoid Valves and Timing replace valve body valve.

  • Page 757: Dtc P0787: Shift / Timing Solenoid Control Circuit Low

    Automatic Transmission/Transaxle: 5A-57 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
  • Page 758 5A-58 Automatic Transmission/Transaxle: DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF, if available. 2) Clear DTC in TCM memory. 3) Start engine and shift select lever to “N” range. 4) Repeat shifting select lever from “N” range to “D” range and vice versa for 3 times. 5) Check DTC.

  • Page 759: Dtc P0788: Shift / Timing Solenoid Control Circuit High

    Automatic Transmission/Transaxle: 5A-59 DTC P0788: Shift / Timing Solenoid Control Circuit High S7RW0A5104032 Wiring Diagram C06-14 BLU/BLK I6RW0B510012-01 1. TCM 3. A/T 2. Timing solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of timing solenoid valve TCM terminal is high...

  • Page 760: Dtc P0961: Pressure Control Solenoid "A" Control Circuit Range / Performance

    5A-60 Automatic Transmission/Transaxle: Step Action Check timing solenoid valve resistance “BLU/BLK” circuit open. Replace timing solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1), (2) on transaxle. 3) Check for proper connection to solenoid valve at “BLU/ BLK”...
  • Page 761 Automatic Transmission/Transaxle: 5A-61 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between actual current of control solenoid valve • Malfunction of pressure control solenoid valve or its circuit and current of control solenoid valve circuit calculated circuit malfunction by TCM is more than specification.

  • Page 762: Dtc P0962: Pressure Control Solenoid Control Circuit Low

    5A-62 Automatic Transmission/Transaxle: Step Action Check for pressure control solenoid valve circuit Intermittent trouble or Repair “LT GRN/BLK” faulty TCM. Check for and/or “GRY” circuit. 1) Disconnect TCM connectors. intermittent referring to 2) Check for proper connection to TCM at terminals “C06- “Intermittent and Poor 2”...
  • Page 763 Automatic Transmission/Transaxle: 5A-63 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check pressure control solenoid valve resistance Go to Step 3. Replace pressure control solenoid valve or 1) Turn ignition switch OFF. valve body harness.

  • Page 764: Dtc P0963: Pressure Control Solenoid Control Circuit High

    5A-64 Automatic Transmission/Transaxle: Step Action Check pressure control solenoid valve circuit for open “GRY” or “LT GRN/BLK” Intermittent trouble or circuit open. faulty TCM. 1) Check resistance continuity between terminals “C06-2” and “C06-4” of disconnected harness side TCM Check for intermittent connector.
  • Page 765 Automatic Transmission/Transaxle: 5A-65 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check pressure control solenoid circuit for IG short Go to Step 3. “BRN/YEL” or “LT GRN” circuit shorted to power 1) Connect valve body harness connector.

  • Page 766: Dtc P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low

    5A-66 Automatic Transmission/Transaxle: DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low S7RW0A5104036 Wiring Diagram C06-16 BLK/YEL C06-15 16 15 I6RW0B510014-01 1. TCM 3. Shift solenoid valve-B (No.2) 2. Shift solenoid valve-A (No.1) [A]: Terminal arrangement of TCM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition...
  • Page 767 Automatic Transmission/Transaxle: 5A-67 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check shift solenoid valve resistance Go to Step 3. Replace applicable shift solenoid valve or valve 1) Turn ignition switch OFF. body harness.

  • Page 768: Dtc P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High

    5A-68 Automatic Transmission/Transaxle: DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High S7RW0A5104037 Wiring Diagram C06-16 BLK/YEL C06-15 16 15 I6RW0B510014-01 1. TCM 3. Shift solenoid valve-B (No.2) [A]: Terminal arrangement of TCM connector (viewed from harness side) 2.
  • Page 769 Automatic Transmission/Transaxle: 5A-69 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check shift solenoid valve circuit for IG short Go to Step 3. DTC P0974: “BRN” circuit shorted to power 1) Connect valve body harness connector.

  • Page 770: Dtc P1702: Internal Control Module Memory Check Sum Error

    5A-70 Automatic Transmission/Transaxle: DTC P1702: Internal Control Module Memory Check Sum Error S7RW0A5104038 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Calculation of current data stored in TCM is not correct comparing with pre-stored checking data in TCM. DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.

  • Page 771: Dtc P1878: Torque Converter Clutch Shudder

    Substitute a known- Go to Step 3. good TCM and recheck. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check “3” position switch signal on scan tool data display when shifting select lever to each range.

  • Page 772: Dtc P2762: Torque Converter Clutch (Tcc) Pressure Control Solenoid Control Circuit Range / Performance

    5A-72 Automatic Transmission/Transaxle: DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance S7RW0A5104041 Wiring Diagram C06-5 WHT/BLU C06-3 WHT/BLK I6RW0D510007-01 1. TCM 3. A/T 2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 773 Automatic Transmission/Transaxle: 5A-73 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve resistance Go to Step 3. Replace TCC solenoid valve or valve body 1) Turn ignition switch OFF. harness.

  • Page 774: Dtc P2763: Torque Converter Clutch (Tcc) Pressure Control Solenoid Control Circuit High

    5A-74 Automatic Transmission/Transaxle: DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High S7RW0A5104042 Wiring Diagram C06-5 WHT/BLU C06-3 WHT/BLK I6RW0D510007-01 1. TCM 3. A/T 2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 775 Automatic Transmission/Transaxle: 5A-75 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve circuit for IG short Go to Step 3. “WHT/BLU” or “WHT/ BLK” circuit shorted to 1) Connect valve body harness connector.

  • Page 776: Dtc P2764: Torque Converter Clutch (Tcc) Circuit Pressure Control Solenoid Control Circuit Low

    5A-76 Automatic Transmission/Transaxle: DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low S7RW0A5104043 Wiring Diagram C06-5 WHT/BLU C06-3 WHT/BLK I6RW0D510007-01 1. TCM 3. A/T 2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 777 Automatic Transmission/Transaxle: 5A-77 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve resistance Go to Step 3. Replace TCC solenoid valve or valve body 1) Turn ignition switch OFF. harness.

  • Page 778: Dtc U0073: Control Module Communication Bus Off

    5A-78 Automatic Transmission/Transaxle: DTC U0073: Control Module Communication Bus Off S7RW0A5104044 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0100: Lost Communication with ECM / PCM “A” S7RW0A5104045 Refer to “Troubleshooting for CAN-DTC in Section 1A”. Inspection of TCM and Its Circuits S7RW0A5104046 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance.
  • Page 779 Automatic Transmission/Transaxle: 5A-79 Connector “C06” Standard Terminal Wire color Circuit Condition voltage Ground 0 – 1 V Ignition switch ON LT GRN/ Pressure control 0.6 – 1.0 V Ignition switch ON solenoid valve (–) WHT/BLK TCC solenoid valve (–) 0.6 – 1.0 V Ignition switch ON *0 –...
  • Page 780 5A-80 Automatic Transmission/Transaxle: Connector “C07” Standard Terminal Wire color Circuit Condition voltage Transmission range 8 – 14 V Ignition switch ON, select lever at “R” range sensor (“R” range) 0 – 1 V Ignition switch ON, select lever at other than “R” range —...
  • Page 781 Automatic Transmission/Transaxle: 5A-81 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: “C06-4” to “C06-1” terminal Measurement CH1: “C06-7” to “C06-1” Oscilloscope CH1: 5 V/DIV terminal...

  • Page 782: Tcm Power And Ground Circuit Check

    5A-82 Automatic Transmission/Transaxle: Reference waveform No. 5 Output shaft speed sensor (VSS) signal at vehicle speed 60 km/h (37 mile/h). Measurement CH1: “C07-25” to “C06-1” terminal Oscilloscope CH1: 5 V/DIV setting TIME: 20 ms/DIV • After warmed up to normal operating temperature Measurement condition...

  • Page 783: Brake Interlock System Inspection

    Automatic Transmission/Transaxle: 5A-83 Troubleshooting Step Action Check TCM back-up power circuit Go to Step 2. “WHT/RED” circuit open or shorted to ground. 1) Disconnect TCM connector with ignition switch OFF. 2) Check for proper connection to TCM at “C06-24” terminal. 3) If OK, check voltage at terminal “C06-24”...

  • Page 784: Repair Instructions

    1) Connect san tool to DLC (1) with ignition switch OFF. CAUTION Special tool Do not use any fluid other than the specified (A): SUZUKI scan tool (SUZUKI-SDT) ATF. Use of any fluid other than the specified ATF may cause juddering or some other faulty condition to occur.

  • Page 785: A/T Fluid Change

    Fluid level check at room (cold) temperature between FULL HOT (2) and LOW HOT (3). If it is is recommended only for preparation of level below LOW HOT, add SUZUKI ATF 3317 or Mobil check under normal (hot) operating ATF 3309 up to FULL HOT.

  • Page 786: Select Lever Components

    5A-86 Automatic Transmission/Transaxle: 5) Lower vehicle and pour proper amount of SUZUKI Select Lever Assembly Removal and ATF 3317 or Mobil ATF 3309. Installation S7RW0A5106005 6) Check fluid level referring to “A/T Fluid Level Check”. Remove and install select lever referring to “Select Lever Components”.

  • Page 787: Select Lever Inspection

    Automatic Transmission/Transaxle: 5A-87 Select Lever Inspection Shift Lock Solenoid Inspection S7RW0A5106007 S7RW0A5106009 Check select lever for smooth and clear-cut movement Check that shift lock solenoid (1) actuate when battery individually. If a malfunction is found, replace select lever voltage is conducted. assembly.

  • Page 788: Select Cable Components

    5A-88 Automatic Transmission/Transaxle: Select Cable Components S7RW0A5106011 I5RW0C510031-01 [A]: View [A] 5. Clip 11. Radiator inlet hose [B]: View [B] 6. Manual select lever pin : 23 N⋅m (2.0 kgf-m, 17.0 lb-ft) : Apply lithium grease 99000-25011 to all around pin (0.15 g) 1.

  • Page 789: Key Interlock Cable Removal And Installation

    6) Shift select lever to “N” position. 7) Apply grease to select lever pin and install adjuster (cable end) to it. : Grease 99000–25011 (SUZUKI Super Grease I5RW0C510045-01 5) Turn ignition switch to LOCK position. 8) With both select lever and transmission range 6) Remove console box referring to “Console Box...
  • Page 790 5A-90 Automatic Transmission/Transaxle: Installation 1) Lay interlock cable to its original cabling route. I5RW0C510073-01 [A]: LH steering vehicle 2. Clamp 6. EPS control module [B]: RH steering vehicle 3. Steering lock assembly / Steering lock unit (if equipped with Keyless 7.

  • Page 791: Transmission Range Sensor Inspection And Adjustment

    Automatic Transmission/Transaxle: 5A-91 2) Turn ignition switch to ACC position. 9) With select lever set at “P” position, turn ignition key to ACC position and then check for the following 3) Insert cable casing cap (1) into key cylinder cover (2) conditions.

  • Page 792: Output Shaft Speed Sensor (Vss) Removal And Installation

    5A-92 Automatic Transmission/Transaxle: 3) Connect output shaft speed sensor connector (2) to 3) Check that engine starts in “N” and “P” ranges but it doesn’t start in “D”, “2”, “L” or “R” range. Also, check output shaft speed sensor (VSS) (1). that back-up lamp lights in “R”...

  • Page 793: Input Shaft Speed Sensor Removal And Installation

    Automatic Transmission/Transaxle: 5A-93 Input Shaft Speed Sensor Removal and Input Shaft Speed Sensor Inspection S7RW0A5106019 Installation 1) Disconnect negative cable at battery. S7RW0A5106018 Removal 2) Disconnect input shaft speed sensor connector (2). 1) Disconnect negative cable at battery. 3) Check resistance between input shaft speed sensor 2) Disconnect input shaft speed sensor connector (2).

  • Page 794: Transmission Fluid Temperature Sensor Inspection

    5A-94 Automatic Transmission/Transaxle: Installation Transmission Fluid Temperature Sensor Reverse removal procedure to install valve body Inspection harness and valve body assembly noting the following S7RW0A5106021 Warm up transmission fluid temperature sensor (2). points. Check resistance between terminals of valve body •...
  • Page 795 Automatic Transmission/Transaxle: 5A-95 Installation 6) Remove A/T oil pan (1) and oil pan gasket (2). 7) Remove oil strainer assembly (3). 1) Install shift solenoid valve-A (No.1) (1), shift solenoid valve-B (No.2) (2) and timing solenoid valve (3). Tightening torque Shift solenoid bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb- I4RS0A510029-01 2) Connect solenoid connectors identifying their...

  • Page 796: Solenoid Valves (Shift Solenoid Valves And Timing Solenoid Valve) Inspection

    5A-96 Automatic Transmission/Transaxle: Operation Check 4) Install oil strainer assembly (1). Shift solenoid valve-A (No.1) and -B (No.2) Tightening torque Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) CAUTION • Do not insert air gun against strainer installed on inlet of solenoid valve too deeply, when blowing air into solenoid valve.

  • Page 797: Pressure Control Solenoid Valves (Pressure Control Solenoid And Tcc Solenoid) Removal And Installation

    Automatic Transmission/Transaxle: 5A-97 Timing solenoid valve Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Solenoid) Removal CAUTION and Installation S7RW0A5106024 • Do not insert air gun against strainer Removal installed on inlet of solenoid valve too 1) Disconnect negative cable at battery. deeply, when blowing air into solenoid 2) Lift up vehicle.

  • Page 798: Pressure Control Solenoid Valves Inspection

    5A-98 Automatic Transmission/Transaxle: 10) Remove valve body assembly referring to Operation Check “Automatic Transaxle Unit Disassembly”. Check pressure control solenoid valves (Pressure control solenoid and TCC pressure control solenoid) 11) Remove pressure control solenoid valve and TCC operation in the either manner of the following. pressure control solenoid valve referring to “Valve Body Assembly Disassembly and Reassembly”.

  • Page 799: Transmission Control Module (Tcm) Removal And Installation

    Automatic Transmission/Transaxle: 5A-99 Not using regulated DC power supply 2) If the vehicle is equipped with air bag system, disable air bag system. Refer to “Disabling Air Bag 1) Connect pressure control solenoid valve (1) to System in Section 8B”. battery (2) setting 21 W bulb (4) on the way as shown in figure.

  • Page 800: Differential Side Oil Seal Replacement

    2. Outlet hose (Inlet to A/T fluid cooler) I5RW0A520006-02 4) Apply grease to new differential side oil seal lips. : Grease 99000–25030 (SUZUKI Super Grease C) 5) Install new differential side oil seals (1) by using special tool. Special tool (A): 09913–75510...

  • Page 801: Automatic Transaxle Unit Components

    Automatic Transmission/Transaxle: 5A-101 Automatic Transaxle Unit Components S7RW0A5106030 I5RW0C510050-01 1. Drive plate 6. Transaxle and engine fastening bolt : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft) 2. Drive plate bolt 7. Transaxle and engine fastening nut : 69 N⋅m (6.9 kgf-m, 50.0 lb-ft) 3.

  • Page 802: Automatic Transaxle Unit Dismounting And Remounting

    5A-102 Automatic Transmission/Transaxle: Automatic Transaxle Unit Dismounting and 4) Remove starting motor. Remounting 5) Remove bolts and nut fastening engine and S7RW0A5106031 transaxle, then detach transaxle from engine. Dismounting WARNING 1) Take down transaxle with engine. For its procedure, Be sure to keep transaxle with torque refer to “Engine Assembly Removal and Installation converter horizontal or facing up throughout in Section 1D”.
  • Page 803 Automatic Transmission/Transaxle: 5A-103 Remounting 3) Tighten drive plate to torque converter bolts. Align bolt hole of drive plate and torque converter then 1) Make sure that torque converter is installed correctly tighten bolts through torque converter housing lower to transaxle. plate opening.

  • Page 804: Automatic Transaxle Assembly Components .5A-104

    5A-104 Automatic Transmission/Transaxle: Automatic Transaxle Assembly Components S7RW0A5106032 I5RW0C510057-01...
  • Page 805 Automatic Transmission/Transaxle: 5A-105 1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly 2. Torque converter housing 38. Cooler check valve 74. Rear sun gear thrust bearing race : Apply sealant 99000-31230 to mating surface to transaxle case. 3.

  • Page 806: Automatic Transaxle Unit Disassembly

    5A-106 Automatic Transmission/Transaxle: Automatic Transaxle Unit Disassembly 4) Uncaulk lock washer (1), then remove lock nut (2) S7RW0A5106033 and lock washer. CAUTION • Thoroughly clean transaxle exterior before overhauling it. • Keep working table, tools and hands clean while overhauling. •...
  • Page 807 Automatic Transmission/Transaxle: 5A-107 9) Remove fluid cooler pipes (1) and pipe unions (2). 13) Disconnect connectors (2) from solenoid valves and transmission fluid temperature sensor (1). 10) Remove fluid level gauge (3) and fluid filler tube (4). I5RW0C510060-01 I5RW0C510038-02 11) Remove oil pan (1) and oil pan gasket (2). 14) Remove valve body assembly bolts.
  • Page 808 5A-108 Automatic Transmission/Transaxle: 19) Remove accumulator pistons and springs. 16) Remove valve body harness (1). To remove C2 (1), C1 (2) and B1 (3) accumulator CAUTION pistons and springs, position rag on pistons to catch each piston. To remove pistons, force low-pressure When pulling valve body harness out of compressed air (1 kg/cm , 15 psi, 100 kPa, max) into...
  • Page 809 Automatic Transmission/Transaxle: 5A-109 20) Remove transaxle case plug (1). I2RH0B510098-01 26) Remove oil pump assembly (1). I2RH0B510095-01 21) Remove torque converter housing bolts. 22) Remove torque converter housing (1) while tapping around it lightly with plastic hammer. I2RH0B510099-01 27) Remove direct clutch assembly (1). I3RM0B510060-01 23) Remove breather hose (1).
  • Page 810 5A-110 Automatic Transmission/Transaxle: 29) Remove input shaft rear thrust bearing (1) and thrust 32) Remove governor apply No.2 gasket (1). bearing race (2). NOTE If input shaft rear thrust bearing is not found, it may have been taken out with direct clutch assembly.
  • Page 811 Automatic Transmission/Transaxle: 5A-111 36) Remove 2nd brake gasket (1). I2RH0B510109-01 37) Measure O/D and 2nd coast brake piston stroke. If piston stroke exceeds specification, inspect and replace plates and discs. • Measure dimension “a” from mating surface of transaxle case to O/D and 2nd coast brake rear plate (1) using straightedge and micrometer caliper.
  • Page 812 5A-112 Automatic Transmission/Transaxle: 44) Remove rear planetary sun gear subassembly (1) 40) Remove O/D and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4). and one-way clutch No.1 assembly (2). I2RH0B510113-01 I2RH0B510117-01 41) Remove forward clutch hub (1). 45) Remove planetary gear thrust bearing (1).
  • Page 813 Automatic Transmission/Transaxle: 5A-113 2nd brake piston stroke 48) Remove O/D and 2nd coast brake retaining plate snap ring (1). “a”: 0.40 – 1.25 mm (0.016 – 0.049 in.) “a” I2RH0B510120-01 49) Remove front planetary sun gear (1). I2RH0B510123-01 52) Using special tool and hydraulic press, remove 2nd brake piston snap ring (1).
  • Page 814 5A-114 Automatic Transmission/Transaxle: 53) Remove 2nd brake piston assembly (1). 58) Check one-way clutch No.2 as follows. 54) Remove 2nd brake return spring subassembly (2). • Ensure planetary carrier (1) rotates only in counterclockwise direction “A”, never in clockwise direction “B”. •...
  • Page 815 Automatic Transmission/Transaxle: 5A-115 61) Measure 1st and reverse brake piston stroke. 63) Remove 1st and reverse brake retaining plate, discs If piston stroke exceeds specified value, and separator plates. disassemble, inspect and replace discs and plates. 64) Remove 1st and reverse brake return spring •...
  • Page 816 5A-116 Automatic Transmission/Transaxle: 67) Using special tools and hydraulic press, remove 69) Screwing 3 bolts (1), remove reduction drive gear planetary ring gear subassembly (1). (2). CAUTION CAUTION Do not reuse planetary ring gear Screw 3 bolts into reduction drive gear subassembly.
  • Page 817 Automatic Transmission/Transaxle: 5A-117 71) Remove parking lock pawl bracket (1). 75) Remove parking lock pawl rod (2) from manual valve lever (1). I2RH0B510145-01 76) Remove manual detent spring (1). I2RH0B510142-01 72) With slotted screwdriver, cut and unfold manual valve lever spacer (1) and proceed to remove manual valve lever spacer.

  • Page 818: Oil Pump Assembly Components

    5A-118 Automatic Transmission/Transaxle: Oil Pump Assembly Components S7RW0A5106034 I5RW0C510061-01 1. Oil seal 5. Oil pump drive gear : Apply automatic transaxle fluid. : Apply grease 99000-25030 to oil seal lip. 2. O-ring 6. Stator shaft assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft) 3.

  • Page 819: Oil Pump Assembly Inspection

    Special tool driven gear and body. If clearance exceeds its (A): 09913–85210 standard value, replace oil pump assembly. “A”: Grease 99000–25030 (SUZUKI Super Clearance between oil pump driven gear and oil Grease C) pump body Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.) I2RH0B510151-01 2.
  • Page 820 5A-120 Automatic Transmission/Transaxle: 3) Check side clearance of both gears. 5) Install direct clutch assembly (1) to stator shaft Using a straightedge (1) and a feeler gauge (2), assembly (2), then ensure that direct clutch measure side clearance between gears and pump assembly turns smoothly.

  • Page 821: Direct Clutch Assembly Components

    Automatic Transmission/Transaxle: 5A-121 Direct Clutch Assembly Components S7RW0A5106037 I2RH0B510160-01 1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate 2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring 3. Input shaft subassembly 8.

  • Page 822: Direct Clutch Assembly Disassembly And Reassembly

    5A-122 Automatic Transmission/Transaxle: Direct Clutch Assembly Disassembly and 4) Using a finger to block oil hole (1), apply compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – Reassembly 113 psi) to opposite hole, which will assist in removal S7RW0A5106039 of the clutch piston.
  • Page 823 Automatic Transmission/Transaxle: 5A-123 Reassembly Reverse disassembly procedure for assembly, noting the following points. • Use new seal ring and O-ring. Apply A/T fluid before installation. • Do not damage direct clutch return spring subassembly (1) and piston by pressing in direct clutch return spring subassembly passing through its original installing position over 0.7 mm (0.027 in.).

  • Page 824: Direct Clutch Assembly Inspection

    5A-124 Automatic Transmission/Transaxle: Direct Clutch Assembly Inspection Direct Clutch Return Spring Subassembly S7RW0A5106040 Measure free length of direct clutch return spring subassembly. Clutch Discs, Plates and Retaining Plate Direct clutch return spring subassembly free length Check that sliding surfaces of discs, separator plates “a”: 36.04 mm (1.419 in.) and retaining plate are not worn hard or burnt.

  • Page 825: Forward And Reverse Clutch Assembly Components

    Automatic Transmission/Transaxle: 5A-125 Forward and Reverse Clutch Assembly Components S7RW0A5106041 I3RM0B510061-01 1. Forward clutch balancer 8. Intermediate shaft seal ring 15. Forward clutch retaining plate 2. Forward clutch return spring subassembly 9. Reverse clutch plate snap ring 16. Forward clutch disc 3.

  • Page 826: Forward And Reverse Clutch Assembly Disassembly And Reassembly

    5A-126 Automatic Transmission/Transaxle: 2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm 2) Remove forward clutch plate snap ring (1) and take 57 – 113 psi) through oil hole (1) of transaxle rear out forward clutch retaining plate, discs and cover with the special tool attached on the upper separator plates from forward clutch drum.
  • Page 827 Automatic Transmission/Transaxle: 5A-127 6) Install intermediate shaft subassembly (1) to 9) Remove forward clutch drum O-ring (1) from forward transaxle rear cover (2). Apply compressed air (400 clutch drum (2). – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) to oil hole (3) of transaxle rear cover to remove forward clutch piston (4).
  • Page 828 5A-128 Automatic Transmission/Transaxle: • Apply A/T fluid to forward clutch separator plates (1), • Measure forward clutch piston stroke in the same discs (2) and retaining plate (3). manner as “Forward and Reverse Clutch Assembly Preliminary Check”. • Install forward clutch separator plates (1), discs (2) When piston stroke is out of specification, select and retaining plate (3), then snap ring (4) to forward forward clutch retaining plate with proper thickness...

  • Page 829: Forward And Reverse Clutch Assembly Inspection

    Automatic Transmission/Transaxle: 5A-129 • Install reverse clutch plate snap ring so that its both Forward and Reverse Clutch Assembly ends would be positioned in correct locations as Inspection shown in figure. S7RW0A5106044 Clutch, Discs, Separator Plates and Retaining Plate Check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt.

  • Page 830: 2Nd Brake Piston Assembly Components

    5A-130 Automatic Transmission/Transaxle: Forward Clutch Drum Lip Forward Clutch Piston Lip and Forward Clutch Balancer Lip Check each lip for wear, deformation, cut and/or Check each lip for wear, deformation, cut and/or hardening. If necessary, replace. hardening. If necessary, replace. I2RH0B510194-01 I2RH0B510195-01 2nd Brake Piston Assembly Components...

  • Page 831: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Components

    Automatic Transmission/Transaxle: 5A-131 2) Remove inner O-ring (1) and outer O-ring (2). Reassembly Reverse disassembly procedure for assembly, noting the following points. • Use new O-rings. Apply A/T fluid to the O-rings, before installation. • Install 2nd brake piston (1) to which A/T fluid is applied to 2nd brake cylinder (2).

  • Page 832: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Disassembly And Reassembly

    5A-132 Automatic Transmission/Transaxle: Transaxle Rear Cover (O/D and 2nd Coast Brake 4) Remove O/D and 2nd coast brake piston front O-ring (1) and rear O-ring (2). Piston) Assembly Disassembly and Reassembly S7RW0A5106048 Disassembly 1) Remove snap ring by using special tools and hydraulic press.

  • Page 833: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Inspection

    Automatic Transmission/Transaxle: 5A-133 Transaxle Rear Cover (O/D and 2nd Coast Brake Reassembly Reverse disassembly procedure for assembly, noting the Piston) Assembly Inspection following points. S7RW0A5106049 • Use new seal rings and O-rings. Apply A/T fluid to O/D and 2nd Coast Brake Return Spring seal rings and O-rings before installation.

  • Page 834: Countershaft Assembly Components

    5A-134 Automatic Transmission/Transaxle: Countershaft Assembly Components 2) Remove countershaft RH bearing (1) by using S7RW0A5106050 special tools. Special tool (A): 09913–61510 (B): 09926–58010 I2RH0B510211-01 Reassembly I2RH0B510209-01 1) Install new countershaft RH bearing (1) by using 1. Countershaft RH bearing 5. Bearing cap 2.

  • Page 835: Valve Body Assembly Components

    Automatic Transmission/Transaxle: 5A-135 3) Install countershaft LH bearing (1) with special tools and hydraulic press. Special tool (A): 09913–84510 (B): 09925–88210 I2RH0B510214-01 Valve Body Assembly Components S7RW0A5106052 I4RS0A510044-01 1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid. 2.

  • Page 836: Valve Body Assembly Disassembly And Reassembly

    5A-136 Automatic Transmission/Transaxle: Valve Body Assembly Disassembly and 4) Remove shift solenoid valve-A (1). Reassembly S7RW0A5106053 CAUTION When replacing pressure control solenoid valve and/or TCC pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing pressure control solenoid valve and/or TCC pressure control solenoid valve independently may cause excessive shift...

  • Page 837: Differential Assembly Components

    Automatic Transmission/Transaxle: 5A-137 Reassembly Reverse disassembly procedure for assembly, noting the following points. • Shift solenoid valve-A and -B are identical • After applying A/T fluid to new O-rings, fit them to solenoid valves, then install solenoid valves to valve body.

  • Page 838: Differential Assembly Disassembly And Reassembly

    5A-138 Automatic Transmission/Transaxle: Differential Assembly Disassembly and 4) Remove differential side LH bearing by using special tools. Reassembly S7RW0A5106055 Special tool (A): 09926–37610 Disassembly (B): 09926–37610–001 1) Remove final gear bolts (1), and then final gear (2). (C): 09926–37610–003 (D): 09926–37610–002 I2RH0B510225-01 2) Remove differential side RH bearing by using special tools.

  • Page 839: Differential Assembly Inspection

    Automatic Transmission/Transaxle: 5A-139 2) As shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. I2RH0B510233-01 6) Install new differential side LH bearing (1) by using I2RH0B510230-01 special tool and hydraulic press. 3) Tighten final gear bolts (1) to specified torque. NOTE NOTE Replace differential side LH bearing together...

  • Page 840: Torque Converter Housing Disassembly And Reassembly

    5A-140 Automatic Transmission/Transaxle: Torque Converter Housing Disassembly and 4) Remove countershaft RH bearing cup by using special tools. Reassembly S7RW0A5106057 Special tool (A): 09944–96011 Disassembly (B): 09942–15511 1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2). I2RH0B510239-01 5) Remove differential side RH bearing cup by using special tools.
  • Page 841 Differential side oil seal installing depth Torque converter housing plug (a): 7.5 N·m (0.75 “a”: 13.2 – 14.2 mm (0.52 – 0.56 in.) kgf-m, 5.5 lb-ft) 5) Apply grease to oil seal lip. “A”: Grease 99000–25030 (SUZUKI Super Grease C) “a” “A” I2RH0B510242-01 2) Using special tools, assemble differential side RH bearing cup.

  • Page 842: Transaxle Case Disassembly And Reassembly

    5A-142 Automatic Transmission/Transaxle: Transaxle Case Disassembly and Reassembly Reassembly S7RW0A5106058 1) Using special tools, assemble shim and differential side LH bearing cup. Disassembly 1) Remove differential side oil seal (1). NOTE Use shim with same thickness as the removed one. Special tool (A): 09924–74510 (B): 09944–88220...

  • Page 843: Automatic Transaxle Unit Inspection And Adjustment

    Differential side oil seal installing depth “a”: 3.8 – 4.8 mm (0.15 – 0.19 in.) 4) Apply grease to oil seal lip. “A”: Grease 99000–25030 (SUZUKI Super Grease C) “a” I2RH0B510253-01 Brake return spring subassembly “A”...
  • Page 844 5A-144 Automatic Transmission/Transaxle: One-way clutch No.1 assembly 3) Measure bearing preload (a) by using a special tool. 1) Install one-way clutch No.1 assembly (2) to rear Special tool planetary sun gear subassembly (1). (A): 09928–06050 2) Securing rear planetary sun gear subassembly, Differential side bearing preload (a) measured as ensure that one-way clutch No.1 assembly rotates starting torque...
  • Page 845 Automatic Transmission/Transaxle: 5A-145 Countershaft bearing preload 4) If bearing preload is out of specification, select shim with suitable thickness from among the list below 1) After applying A/T fluid to countershaft assembly (1) and replace it. Then adjust countershaft bearing and differential assembly (2), fit them.

  • Page 846: Automatic Transaxle Unit Assembly

    3) Install parking lock pawl rod (2) to manual valve lever or rotating surfaces of the parts before (1). assembly. • Use Suzuki Super Grease “C” to retain parts in place. • Be sure to install thrust bearings and races in correct direction and position.
  • Page 847 Automatic Transmission/Transaxle: 5A-147 6) Install parking lock pawl bracket (1) to transaxle 9) Install 1st and reverse brake return spring case. subassembly (1) to transaxle case (2). Tightening torque Parking lock pawl bracket bolt (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) I2RH0B510265-01 10) Apply A/T fluid to 1st and reverse brake discs (3), separator plates (2) and retaining plate (1), then...
  • Page 848 5A-148 Automatic Transmission/Transaxle: 12) Install 1st and reverse brake plate snap ring so that 14) Install reduction drive gear (1) to transaxle case (3) its both ends would be positioned in correct locations by using special tools and hydraulic press. as shown in figure.
  • Page 849 Automatic Transmission/Transaxle: 5A-149 16) Install new planetary ring gear subassembly (1) to 17) Using a small torque wrench, while turning to reduction drive gear (3) by using special tools and counter drive gear 100 rpm and measure the hydraulic press. preload.
  • Page 850 5A-150 Automatic Transmission/Transaxle: 20) Check for correct installation of planetary gear 22) Install one-way clutch outer race retainer (1). assembly as follows. Measure the distance “a” by using micrometer caliper (1) and straightedge (2). If measured value is out of specification, remove planetary gear assembly and reinstall it properly.
  • Page 851 Automatic Transmission/Transaxle: 5A-151 26) Apply A/T fluid to 2nd brake piston assembly (1), and 2nd brake piston stroke align the projection of 2nd brake piston assembly Standard: 0.40 – 1.25 mm (0.016 – 0.049 in.) with the groove of transaxle case, then put together. I2RH0B510282-01 27) Install 2nd brake piston snap ring (1) by using special tool and hydraulic press.
  • Page 852 I2RH0B510287-01 32) After applying grease to slide contact face of planetary carrier thrust washer (1), install it to planetary gear assembly. “A”: Grease 99000–25030 (SUZUKI Super Grease C) I2RH0B510291-01 37) After applying A/T fluid to rear sun gear thrust bearing (1), install it to forward clutch hub (2).
  • Page 853 Automatic Transmission/Transaxle: 5A-153 39) After applying A/T fluid to intermediate shaft thrust 41) Check for correct installation of forward and reverse bearing rear race (3), thrust bearing (2) and front clutch assembly as follows. race (1), install them to forward and reverse clutch Measure distance “a”...
  • Page 854 1.2 mm (0.047 in.) in 1.8 mm (0.071 in.) diameter. 2.0 mm (0.079 in.) 2.2 mm (0.087 in.) “A”: Sealant 99000–31230 (SUZUKI Bond 2.4 mm (0.094 in.) No.1216B) 2.6 mm (0.102 in.) “A” I2RH0B510301-01...
  • Page 855 Automatic Transmission/Transaxle: 5A-155 48) Install transaxle rear cover assembly on transaxle 53) After applying A/T fluid to differential assembly (1) case. and countershaft assembly (2), install them to transaxle case. 49) Install hook (2) to location shown in figure. 50) Tighten rear cover bolts (1). Tightening torque Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) I4RS0A510036-01...
  • Page 856 5A-156 Automatic Transmission/Transaxle: 57) Apply A/T fluid to direct clutch assembly (1). 59) Install oil pump assembly (1) to transaxle case. Install direct clutch assembly while rotating Tightening torque clockwise and counterclockwise frequently to fit Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m, clutch discs to mating hub.
  • Page 857 (0.14 in.) (1.90 in.) (1.30 in.) 4.05 mm 48.5 mm 32.5 mm “A”: Sealant 99000–31230 (SUZUKI Bond (0.16 in.) (1.90 in.) (1.28 in.) No.1216B) Tightening torque Torque converter housing bolt (a): 33 N·m (3.3 kgf-m, 24.0 lb-ft)
  • Page 858 5A-158 Automatic Transmission/Transaxle: 68) Install new O-rings to each accumulator piston and apply A/T fluid to them. Accumulator O-ring dimension Inside Section O-ring name diameter diameter Large B1 accumulator O-ring (2) Large C1 accumulator O-ring (2) 29.4 mm 2.6 mm Large C2 accumulator O-ring (2) (1.16 in.) (0.10 in.)
  • Page 859 Automatic Transmission/Transaxle: 5A-159 72) After applying A/T fluid to new O-ring, fit it to valve Valve body bolt length body harness connector (3), then install valve body Bolt Length “a” Pieces harness to transaxle case. A (1) 20 mm (0.79 in.) B (2) 28 mm (1.10 in.) CAUTION...
  • Page 860 5A-160 Automatic Transmission/Transaxle: 76) Install oil strainer assembly (1). 80) After applying A/T fluid to new O-rings, fit it to fluid cooler pipe unions (1). Then install fluid cooler pipe Tightening torque unions to transaxle case. Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) Tightening torque Fluid cooler pipe union (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
  • Page 861 Automatic Transmission/Transaxle: 5A-161 83) Install select cable bracket (1). 87) Install lock washer (1) and tighten lock nut (2) to specified torque. Tightening torque Select cable bracket bolt (a): 23 N·m (2.3 kgf-m, Tightening torque 17.0 lb-ft) Transmission range sensor lock nut (a): 7 N·m ( 0.7 kgf-m, 5.0 lb-ft) 2, (a) I5RW0C510069-02...
  • Page 862 “a”: More than 19.9 mm (0.783 in.) • Check torque converter for smooth rotation. • Apply grease around cup (6) at the center of torque converter. “C”: Grease 99000–25011 (SUZUKI Super Grease A) I2RH0B510335-01 95) Install engine mounting LH bracket (1). Tighten engine mounting LH bracket bolts and nut to specified torque referring to “Engine Mountings...
  • Page 863 Automatic Transmission/Transaxle: 5A-163 Specifications Tightening Torque Specifications S7RW0A5107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft A/T fluid drain plug 12.5 Transmission range sensor bolt 0.55 Output shaft speed sensor (VSS) bolt Input shaft speed sensor bolt 0.55 Valve body harness connector bolt 0.55 Shift solenoid bolt Oil strainer bolt...

  • Page 864: Special Tools And Equipment

    5A-164 Automatic Transmission/Transaxle: Special Tools and Equipment Recommended Service Material S7RW0A5108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 SUZUKI Super Grease C P/No.: 99000–25030 Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 NOTE Required service material is also described in the following.
  • Page 865 Automatic Transmission/Transaxle: 5A-165 09913–84510 09913–85210 Bearing installer Bearing installer 09923–78210 09924–74510 Bearing installer Bearing and oil seal handle 09925–37811–001 09925–88210 Oil pressure gauge Bearing puller attachment 09925–98210 09925–98221 Input shaft bearing installer Bearing installer 09926–37610 09926–37610–001 Bearing remover Bearing puller 09926–37610–002 09926–37610–003 Bearing puller attachment...
  • Page 866 Transfer bearing dummy 09951–18210 09952–06020 Oil seal remover & installer Dial gauge plate No.2 No. 2 SUZUKI scan tool (SUZUKI- SDT) — This kit includes following items. 1. SUZUKI-SDT 2. DLC3 cable 3. USB cable 4. AC/DC power supply 5.

  • Page 867: General Description

    Manual Transmission/Transaxle: 5B-1 Manual Transmission/Transaxle Transmission / Transaxle General Description Manual Transaxle Construction S7RW0A5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
  • Page 868 5B-2 Manual Transmission/Transaxle: 2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub 3. Input shaft 5th gear 8. Reverse gear shaft 13. Countershaft 5th gear 18. Countershaft 1st gear 4. Input shaft 4th gear 9.
  • Page 869 Manual Transmission/Transaxle: 5B-3 Gear Shift Mechanism The gear shifting control system consists of the following main parts. Movement of gear shift control lever is transmitted to gear shift & select shaft through gear shift and gear select cables. I5RW0A520003-02 1. Gear shift control cable 7.
  • Page 870 5B-4 Manual Transmission/Transaxle: 5th & Reverse Gear Shift Cam 3) When shift lever is shifted to 5th gear, shift & select 5th & reverse gear shift cam, cam guide return spring shaft (1) turns clockwise letting shift cam (2) off from and 5th to reverse interlock guide bolt are provided to guide bolt and pushed up by return spring.

  • Page 871: Diagnostic Information And Procedures

    3) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Transaxle oil level / filler plug (a): 21 N·m (2.1 kgf-m, 15.5 lb-ft)

  • Page 872: Manual Transaxle Oil Change

    7) Apply sealant to thread of level / filler plug, and then S7RW0A5206002 tighten it to specified torque. 1) Before changing or inspecting oil, be sure to stop “A”: Sealant 99000–31260 (SUZUKI Bond engine and lift vehicle horizontally. No.1217G) 2) With vehicle lifted up, check leakage.

  • Page 873: Differential Side Oil Seal Replacement

    1) Lift up vehicle and drain transaxle oil. sure of its smoothness. 2) Remove drive shaft assembly and center shaft “A”: Grease 99000–25011 (SUZUKI Super referring to “Front Drive Shaft Assembly Removal Grease A) and Installation: Front in Section 3A”.

  • Page 874: Gear Shift Control Lever And Cable Components

    5B-8 Manual Transmission/Transaxle: Gear Shift Control Lever and Cable Components S7RW0A5206004 I5RW0A520008-02 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft) 2. Cable bracket bolt 7. Gear shift control lever assembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) 3.

  • Page 875: And Installation

    Manual Transmission/Transaxle: 5B-9 Gear Shift Control Lever and Cable Removal Gear Select Control Cable Adjustment S7RW0A5206006 and Installation 1) Release lock plate (1) which restricts moving of S7RW0A5206005 cable end holder (2). Removal 2) Push cable end holder (2) out from adjuster (4) using 1) Remove console box.

  • Page 876: Back Up Light Switch Removal And Installation

    S7RW0A5206007 Removal lever securely. 1) Remove battery and tray with ECM. “A”: Grease 99000–25011 (SUZUKI Super 2) Disconnect back up light switch coupler (1). Grease A) 3) Remove back up light switch. 4) Push cable end holder (2) in the direction of A.

  • Page 877: Manual Transaxle Unit Components

    Manual Transmission/Transaxle: 5B-11 Manual Transaxle Unit Components S7RW0A5206009 I5RW0A520010-02 [A]: Forward 5. Ground cable bolt 10. Transaxle to engine nut 1. Engine 6. Ground cable 11. Stiffener bolt 2. Transaxle 7. Transaxle to engine bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 3.

  • Page 878: Manual Transaxle Unit Dismounting And Remounting

    5B-12 Manual Transmission/Transaxle: Manual Transaxle Unit Dismounting and 16) Remove transfer referring to “Transfer Dismounting and Remounting in Section 3C”, if equipped. Remounting S7RW0A5206010 17) Remove clutch housing lower plate. 18) Support transaxle with transmission jack. Dismounting 19) Remove left mounting (1) and left mounting bracket 1) Drain coolant.

  • Page 879: Gear Shift And Select Shaft Assembly Components

    Manual Transmission/Transaxle: 5B-13 Gear Shift and Select Shaft Assembly Components S7RW0A5206011 1217G 1217G 1217G I6RW0C520001-01 1. Gear shift & select shaft 7. Gear shift guide case bolt No.1 13. Oil seal : Apply sealant 99000-31260 to bolt thread. : Apply grease 99000-25011 to oil seal lip. 2.

  • Page 880: Gear Shift And Select Shaft Assembly Removal And Installation

    2) Install guide case bolts No.1 to which sealant has been applied and guide case bolts No.2 (2), and tighten them to specified torque. : Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque I5RW0A520017-02 Guide case bolt No.1: 23 N·m (2.3 kgf-m, 17.0 lb- 5) Connect gear shift and gear select control cables to transaxle.

  • Page 881: Gear Shift And Select Shaft Assembly Disassembly And Reassembly

    Manual Transmission/Transaxle: 5B-15 Gear Shift and Select Shaft Assembly Disassembly and Reassembly S7RW0A5206013 1) Push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and specified spring pin removers as shown bellow. Special tool (A): 09922–85811 4.5 mm (B): 09925–78210 6.0 mm...

  • Page 882: Manual Transaxle Assembly Components

    5B-16 Manual Transmission/Transaxle: Manual Transaxle Assembly Components S7RW0A5206014 I5RW0A520018-03 1. Transaxle right case 22. Shift fork bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 2. Transaxle left case 23. 5th gear shift fork : Apply sealant 99000-31260 to mating surface of left case and right case.

  • Page 883: Fifth Gear Disassembly And Reassembly

    : Apply thread lock 99000-32110 to all around thread part of bolt. 12. Left case plate bolt 33. Oil seal : Apply thread lock 99000-32110 to all around thread part of bolt. : Apply SUZUKI SUPER GREASE A 99000-25010 to Oil seal lip. 13. Side cover bolts 34. Outer race 14.
  • Page 884 5B-18 Manual Transmission/Transaxle: a) Install hub (1) to 5th speed synchronizer sleeve Reassembly (2) in specified direction as shown in figure. 1) Install countershaft 5th gear (1) to countershaft facing machined boss “A” inward. I4RH01520048-01 A: Chamfered side B: Long boss I2RH01520088-01 b) Fit 5th speed synchronizer levers (1) to hub (2) in A: Machined boss (Inside)

  • Page 885: Manual Transaxle Assembly Disassembly And Reassembly

    (5) on input shaft. (0.059 in.) in diameter, mate it with left case, and then tighten side cover bolts with specified torque. “B”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
  • Page 886 5B-20 Manual Transmission/Transaxle: 2) Remove bearing set shim. 8) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3). 3) Remove snap ring (1) using special tool. 9) Remove reverse gear shift lever bolts (4) and Special tool reverse gear shift lever (5).
  • Page 887 Manual Transmission/Transaxle: 5B-21 Reassembly 4) Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) and washer (6) 1) Install differential assembly into right case. into case (4) through idler gear and then align bolt 2) Join input shaft (5), countershaft (4), low speed gear hole “a”...
  • Page 888 1.5 mm (0.059 in.) Locating spring in diameter then mate it with right case (1). Locating spring free length Standard Service limit “A”: Sealant 99000–31260 (SUZUKI Bond 53.1 mm 47.8 mm Low speed (2) No.1217G)
  • Page 889 Manual Transmission/Transaxle: 5B-23 12) To seat countershaft left bearing outer race (2) to 15) By repeating step 14), select a suitable shim which bearing cone, tap cup by using special tool and adjusts clearance “a” to specification and put it on plastic hammer.

  • Page 890: Right Case Disassembly And Reassembly

    2) Remove differential side bearing outer race (1) using grease to oil seal lip. brass bar (2), if necessary. : Grease 99000–25011 (SUZUKI Super Grease A) Special tool (A): 09913–76010 I4RH01520024-01 I5RW0A520028-01...

  • Page 891: Left Case Disassembly And Reassembly

    Manual Transmission/Transaxle: 5B-25 Left Case Disassembly and Reassembly 2) Install countershaft right bearing outer race (1) by using special tools and hammer. S7RW0A5206018 Special tool Disassembly (A): 09913–75821 1) Removal oil gutter (1), if necessary. (B): 09924–84510–004 I4RH01520028-01 I5RW0A520029-02 2) Remove oil seal using flat end rod or the like. 3) Install differential side bearing outer race by using special tool and hammer.
  • Page 892 5B-26 Manual Transmission/Transaxle: Reassembly 3) Select shim closest to clearance “d” from among the following available sizes. 1) If oil gutter has been removed, install it with bolt to which thread lock cement has been applied. Available shim thickness Clearance “d” Select shim “A”: Thread lock cement 99000–32110 (Thread 0.800 –...

  • Page 893: Input Shaft And Countershaft Components

    Manual Transmission/Transaxle: 5B-27 Input Shaft and Countershaft Components S7RW0A5206019 I3RH0A520017-01 1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer center cone 2. Oil seal 13. Circlip 24. 2nd gear synchronizer inner ring : Apply grease 99000-25010 to oil seal lip. 3.

  • Page 894: Input Shaft Disassembly And Reassembly

    5B-28 Manual Transmission/Transaxle: Input Shaft Disassembly and Reassembly 3) Take out 4th gear needle bearing and high speed S7RW0A5206020 synchronizer ring. 4) Using special tool, remove circlip (1). Disassembly 1) Remove input shaft right bearing (2) from input shaft NOTE (1) using bearing puller (3) and hydraulic press.
  • Page 895 Manual Transmission/Transaxle: 5B-29 Reassembly 4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as 1) Clean all components thoroughly, inspect them for shown in figure. any abnormality and replace with new ones as necessary.
  • Page 896 5B-30 Manual Transmission/Transaxle: 6) Install 3rd gear needle bearing (4), apply oil to it, 8) Install circlip (1) and confirm that circlip is installed in then install 3rd gear (1) and synchronizer ring (2). groove securely. Install needle bearing (2) of apply oil to it and then install synchronizer ring (3) and 4th 7) Drive in high speed sleeve &...

  • Page 897: Countershaft Disassembly And Reassembly

    Manual Transmission/Transaxle: 5B-31 Countershaft Disassembly and Reassembly 3) Take out 2nd synchronizer outer ring, center cone S7RW0A5206021 and inner ring. 4) Using special tool, remove circlip (1). Disassembly 1) Drive out left bearing cone (2) with 4th gear (3) by NOTE using puller (4) and hydraulic press.
  • Page 898 5B-32 Manual Transmission/Transaxle: 6) Disassemble synchronizer sleeve & hub assembly. 7) Take out 1st gear needle bearing from shaft. 8) In order to remove right bearing (1) from countershaft, grind with a grinder (2) one part “a” of right bearing (1) as illustrated till it becomes thin. CAUTION Be careful not to grind too far not to damage the shaft (3).
  • Page 899 Manual Transmission/Transaxle: 5B-33 5) Fit low speed synchronizer sleeve (4) to hub (3), 7) Install needle bearing (4), apply oil to it, then install insert 3 keys (2) in it and then set springs (1) as 1st gear and 1st gear synchronizer ring (2). shown in figure.
  • Page 900 5B-34 Manual Transmission/Transaxle: 9) Install circlip (1) and confirm that circlip is installed in 11) Press-fit 4th gear (2) by using the same procedure at groove securely. step 10). Install needle bearing (2) and apply oil to needle 12) Install left bearing cone (1) by using special tool and bearing.

  • Page 901: Gear Shift Shaft Components

    Manual Transmission/Transaxle: 5B-35 Gear Shift Shaft Components S7RW0A5206022 I5RW0A520041-01 1. Low speed gear shift shaft 4. 5th & reverse gear shift guide shaft 7. 5th & reverse gear shift yoke 2. High speed gear shift shaft 5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft) 3.

  • Page 902: Differential Components

    5B-36 Manual Transmission/Transaxle: Differential Components S7RW0A5206025 I5RW0A520043-02 1. Differential pinion washer 6. Differential case : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 2. Differential pinion 7. Final gear : Do not reuse. 3. Differential side gear 8. Final gear bolt : Apply transaxle oil. 4.
  • Page 903 Manual Transmission/Transaxle: 5B-37 3) Support differential case (1) with soft jawed vise and Available side gear washer thickness remove final gear bolts then take out final gear. 0.85 mm (0.033 in.) 1.05 mm (0.041 in.) 0.9 mm (0.035 in.) 1.1 mm (0.043 in.) 4) Drive out differential pinion shaft (3) pin by using 0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
  • Page 904 5B-38 Manual Transmission/Transaxle: 5) Hold differential assembly with soft jawed vise (3), 4) Press-fit right bearing (1) by using special tools and hydraulic press. install final gear (2) and then tighten new final gear bolts (1). Special tool (A): 09925–15410 CAUTION (B): 09924–07720 Use of any other bolts than specified ones is...

  • Page 905: Special Tools And Equipment

    Manual Transmission/Transaxle: 5B-39 Special Tools and Equipment Recommended Service Material S7RW0A5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
  • Page 906 5B-40 Manual Transmission/Transaxle: 09913–76010 09913–80113 Bearing installer Bearing installer 09913–84510 09913–85210 Bearing installer Bearing installer 09913–85230 09922–85811 Bearing remover tool Spring pin remover (4.5 mm) 09923–78210 09924–07710 Bearing installer Synchronizer hub installer 09924–07720 09924–74510 Synchronizer hub installer Bearing and oil seal handle 09924–84510–004 09925–14520 Bearing installer attachment...
  • Page 907 Manual Transmission/Transaxle: 5B-41 09940–54910 09940–54950 Front fork oil seal install Bearing installer attachment driver 09941–64511 09942–15511 Bearing and oil seal remover Sliding hammer (30 mm Min.) 09944–96011 09952–06010 Bearing outer race remover Dial gauge plate No.1...

  • Page 908: Clutch

    5C-1 Clutch: Clutch Transmission / Transaxle General Description Clutch (Hydraulic Type) Construction S7RW0A5301001 The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.

  • Page 909: Diagnostic Information And Procedures

    Clutch: 5C-2 Diagnostic Information and Procedures Clutch System Symptom Diagnosis S7RW0A5304001 Condition Possible cause Correction / Reference Item Slipping Improper clutch pedal free travel Bleed air or replace master cylinder. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.

  • Page 910: Repair Instructions

    5C-3 Clutch: Repair Instructions Clutch Pedal Inspection 6) If “c” is not within specification, it is possible that air S7RW0A5306001 is trapped in this system. If suspected so, bleed air Cylinder Push Rod Play “a” referring to “Air Bleeding of Clutch System”.Upon 1) Press clutch pedal (1) gradually with finger, stop completion of above inspection, start engine and when slight increase of resistance is felt and...

  • Page 911: Clutch Fluid Pipe And Hose Components

    Clutch: 5C-4 Clutch Fluid Pipe and Hose Components S7RW0A5306004 I5RW0A530003-02 [A]: RH steering vehicle 3. Clutch reservoir hose 1. Clutch master cylinder 4. Brake master cylinder reservoir 2. Clutch fluid pipe Clutch Fluid Pipe Removal and Installation Installation S7RW0A5306005 Reverse removal procedure for installation noting the following.

  • Page 912: Clutch Master Cylinder Removal And Installation

    I5RW0A530006-01 3. Brake booster Installation Reverse removal procedure for installation noting the following. • Apply grease to push rod tip. “A”: Grease 99000–25100 (SUZUKI Silicone Grease) I5RW0A530008-01 “A” I5RW0A530007-01 • Tighten clutch master cylinder nut to specified torque. Tightening torque Clutch master cylinder nut: 13 N·m (1.3 kgf-m, 9.5...

  • Page 913: Clutch Operating Cylinder Assembly Inspection

    Clutch: 5C-6 Installation 4) Remount transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting in 1) Install clutch operating cylinder assembly (2) to Section 5B”. transaxle. Tighten new mounting bolts to specified torque. 5) Bleed air from system and check clutch pedal free travel.

  • Page 914: Clutch Cover, Clutch Disc And Flywheel Removal And Installation

    5C-7 Clutch: Clutch Cover, Clutch Disc and Flywheel 4) Remove flywheel (1) from crankshaft using special tool. Removal and Installation S7RW0A5306011 Special tool (A): 09924–17810 Removal 1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting in Section 5B”. 2) Hold flywheel with special tool and remove clutch cover bolts (1), clutch cover (2) and clutch disc.

  • Page 915: Clutch Cover, Clutch Disc And Flywheel Inspection

    “Manual Transaxle Unit Dismounting and Special tool Remounting in Section 5B”. (B): 09925–98210 “A”: Grease 99000–25210 (SUZUKI Super Grease I) NOTE When inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the splines.

  • Page 916: Specifications

    5C-9 Clutch: Clutch Disc Clutch Cover Measure depth of rivet head depression, i.e. distance 1) Check diaphragm spring (1) for abnormal wear or between rivet head and facing surface. damage. If depression is found to have reached service limit at 2) Inspect pressure plate (2) for wear or heat spots.

  • Page 917: Special Tools And Equipment

    Clutch: 5C-10 Special Tools and Equipment Recommended Service Material S7RW0A5308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Silicone Grease P/No.: 99000–25100 SUZUKI Super Grease I P/No.: 99000–25210 Special Tool S7RW0A5308002 09921–26020 09923–36320 Bearing remover Clutch center guide (15 mm) 09924–17810...
  • Page 918 5C-11 Clutch:...

  • Page 919: Steering General Diagnosis

    Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Power Assisted Steering System... 6C-1 Precautions............. 6-1 Precautions............6C-1 Precautions on Steering........6-1 P/S System Note..........6C-1 Precautions in Diagnosing Troubles ....6C-1 Steering General Diagnosis....6A-1 General Description ..........6C-2 Precautions............6A-1 P/S System Description ........6C-2 Precautions for Steering Diagnosis.....
  • Page 920 6-ii Table of Contents Repair Instructions ..........6C-35 Steering Rack Plunger Removal and Steering Gear Case Assembly Components ..6C-35 Installation ............6C-40 Tie-Rod End Boot On-Vehicle Inspection ..6C-36 Steering Rack Plunger Inspection .....6C-41 Tie-Rod End Removal and Installation....6C-36 P/S Control Module Removal and Installation...6C-41 Tie-Rod End Initial Position Setting....6C-37 Torque Sensor and Its Circuit Inspection ..6C-42 Tie-Rod End Inspection........6C-37...

  • Page 921: Precautions

    Precautions: Precautions Steering Precautions Precautions on Steering S7RW0A6000001 Air Bag Warning Refer to “Air Bag System Service Warning in Section 00”. Precautions for Steering Diagnosis Refer to “Precautions for Steering Diagnosis in Section 6A”. Service Precautions of Steering Wheel and Column Refer to “Service Precautions of Steering Wheel and Column in Section 6B”.

  • Page 922: Steering Symptom Diagnosis

    6A-1 Steering General Diagnosis: Steering General Diagnosis Steering Precautions Precautions for Steering Diagnosis S7RW0A6100001 Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.

  • Page 923: Steering System Inspection

    Steering General Diagnosis: 6A-2 Condition Possible cause Correction / Reference Item Erratic steering when Worn wheel bearings Replace wheel bearing. braking Broken or sagging coil springs Replace coil spring. Wheel tires are inflated unequally Inflate tires to proper pressure. Disturbed front wheel alignment Check and adjust front wheel alignment.

  • Page 924: Steering Wheel And Column

    6B-1 Steering Wheel and Column: Steering Wheel and Column Steering Precautions Service Precautions of Steering Wheel and Column S7RW0A6200001 For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”. Service and Diagnosis For diagnosis and servicing, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”. Disabling Air Bag System For disabling air bag system, refer to “Disabling Air Bag System in Section 8B”.

  • Page 925: Diagnostic Information And Procedures

    Steering Wheel and Column: 6B-2 Diagnostic Information and Procedures Checking Steering Column for Accident • Check that there is no axial looseness “d” and no axially-vertical looseness “e” for steering column Damage shaft. S7RW0A6204001 NOTE If found defective, replace steering column assembly Vehicles involved in accidents resulting in with new one.

  • Page 926: Repair Instructions

    6B-3 Steering Wheel and Column: Repair Instructions Steering Wheel and Column Components S7RW0A6206001 I7RW01620001-01 1. Steering wheel 10. Steering column assembly mounting nut No.2 : After tightening column mounting nut No.2, tighten column mounting nut No.1. 2. Steering shaft nut 11.

  • Page 927: Steering Wheel Removal And Installation

    Steering Wheel and Column: 6B-4 Steering Wheel Removal and Installation 6) Remove steering wheel using special tool. S7RW0A6206002 Special tool CAUTION (A): 09944–36011 Do not turn the contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively) with steering wheel removed, or coil will break.

  • Page 928: Contact Coil Cable Assembly Removal And Installation

    6B-5 Steering Wheel and Column: 4) Connect horn connector and audio control switch 6) Remove contact coil cable assembly (1) with connector, if necessary. steering angle sensor (2) (ESP® model) from steering column. 5) Install driver air bag (inflator) module to steering wheel.

  • Page 929: Centering Contact Coil Cable Assembly

    Steering Wheel and Column: 6B-6 4) From the position where contact coil became unable 4) Install steering column upper cover (1) and lower cover (2). to turn any further (it stopped), turn it back clockwise about two and a half rotations and align center mark CAUTION with alignment mark (1).

  • Page 930: Steering Angle Sensor Inspection (Esp® Model)

    6B-7 Steering Wheel and Column: Installation Removal 1) Install steering angle sensor (2) by fitting WARNING engagement parts (1) of contact coil cable assembly to claws of steering angle sensor as shown in figure. Never rest a steering column assembly on the steering wheel with the air bag (inflator) module face down and column vertical.

  • Page 931: Steering Column Inspection

    Steering Wheel and Column: 6B-8 Installation 3) Align flat part “a” of steering lower shaft (1) with bolt hole “b” of shaft joint (2) of column as shown. Then CAUTION insert lower shaft into shaft joint of steering column. After tightening steering column mounting 4) Tighten lower shaft upper joint bolt (3) to specified nuts, shaft joint bolts should be tightened.

  • Page 932: Ignition Switch Cylinder Assembly Removal And Installation (Non- Keyless Start Model)

    6B-9 Steering Wheel and Column: Ignition Switch Cylinder Assembly Removal Steering Lock Assembly (Ignition Switch) and Installation (Non- Keyless Start Model) Removal and Installation S7RW0A6206008 S7RW0A6206009 Removal Removal 1) Disconnect negative (–) cable at battery. 1) Remove steering column. Refer to “Steering Column Removal and Installation”.

  • Page 933: Steering Lower Shaft Removal And Installation

    Steering Wheel and Column: 6B-10 5) Tighten new bolts (1) until head of each bolt is broken off. 6) Turn ignition key to “ACC” or “ON” position and check to be sure that steering shaft (2) rotates smoothly. Also check for lock operation. I5RW0A620008-01 I4RS0B620007-02 Installation...

  • Page 934: Specifications

    6B-11 Steering Wheel and Column: Specifications Tightening Torque Specifications S7RW0A6207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Steering shaft nut 24.0 Steering column mounting nut No.1 10.5 Steering column mounting nut No.2 10.5 Steering lower shaft assembly upper joint bolt 18.5 Steering lower shaft assembly lower joint bolt 18.5...

  • Page 935: Power Assisted Steering System

    Precautions in Diagnosing Troubles S7RW0A6300002 • Take a note of DTC indicated on the SUZUKI scan tool. • Before inspection, be sure to read “Precautions for Electrical Circuit Service in Section 00” and understand what is written there.

  • Page 936: General Description

    6C-2 Power Assisted Steering System: General Description P/S System Description S7RW0A6301001 This electronic power steering (EPS) system consists of a power steering (P/S) control module (3), a torque sensor (4), a P/S motor (5). In this system, the P/S control module determines the level and direction of the assist force for the steering wheel (1) according to the signal from the torque sensor and the vehicle speed signal from BCM (9).

  • Page 937: Eps Diagnosis General Description

    Power Assisted Steering System: 6C-3 EPS Diagnosis General Description S7RW0A6301002 The P/S system in this vehicle is controlled by the P/S control module. The P/S control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “On-Board Diagnostic System Description”...

  • Page 938: Schematic And Routing Diagram

    6C-4 Power Assisted Steering System: Schematic and Routing Diagram EPS System Wiring Circuit Diagram S7RW0A6302001 E13-1 LT GRN/ E11-1 E12-1 E61-2 E13-2 E12-2 E61-1 RED/BLK G241-31 G241-25 E11-5 E11-18 E31-5 L313-3 BLU/ E04-9 E11-11 E11-8 E31-3 G04-15 E11-4 [I]:G04-22 E31-2 E11-10 RED/ E01-26...

  • Page 939: Eps System Check

    Power Assisted Steering System: 6C-5 Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side) Terminal Circuit Terminal Circuit Ignition switch signal for P/S control E11-1 E11-13 — module E11-2 — E11-14 P/S active signal (idle up signal) E11-3 —...
  • Page 940 6C-6 Power Assisted Steering System: Step Action Steering symptom diagnosis and P/S system Go to Step 11. Check and repair symptom diagnosis malfunction part(s), and go to Step 11. 1) Check and repair according to “Steering Symptom Diagnosis in Section 6A” and “P/S System Symptom Diagnosis”.
  • Page 941 Power Assisted Steering System: 6C-7 Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.

  • Page 942: Eps" Warning Light Check

    Perform basic steering system check according to “Steering Symptom Diagnosis in Section 6A” first. When 2) Connect SUZUKI scan tool to data link connector the end of the flow has been reached, check the parts of (DLC) (1) located on underside of instrument panel the system suspected as a possible cause referring to at driver’s seat side.

  • Page 943: Dtc Clearance

    S7RW0A6304004 4) Erase DTC according to the instructions displayed 1) Turn ignition switch to OFF position. on SUZUKI scan tool. For further details, refer to 2) Connect SUZUKI scan tool to data link connector operator’s manual for SUZUKI scan tool.
  • Page 944 6C-10 Power Assisted Steering System: “EPS” Detecting condition DTC No. Detecting item Trouble area warning (DTC will set when detecting) light Vehicle speed signal is 0 km/h • Vehicle speed signal even though engine speed is circuit more than 4000 rpm for more than 60 seconds continuously •...

  • Page 945: Visual Inspection

    Power Assisted Steering System: 6C-11 “EPS” Detecting condition DTC No. Detecting item Trouble area warning (DTC will set when detecting) light Voltage between both motor drive circuit is more than 8.5 V or P/S motor circuit 1 driving 1 driving less than 0.2 V for 0.5 second C1141 voltage...

  • Page 946: Scan Tool Data

    6C-12 Power Assisted Steering System: Scan Tool Data S7RW0A6304007 NOTE When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with asterisk (*) mark in the following table is displayed on scan tool Scan tool data Vehicle condition Normal condition...

  • Page 947: P/S System Symptom Diagnosis

    Power Assisted Steering System: 6C-13 Motor Drive Voltage (V) Torque sensor Status (ON, OFF) This parameter indicates the voltage between motor This parameter indicates the output status of the torque terminals. sensor power supply. System Power Status (EPS System Power, ON, OFF) Fail Safe FET Status (ON, OFF) This parameter indicates input status of EPS system This parameter indicates the status of the motor drive...

  • Page 948: Dlc And Its Communication Check (No Communication To P/S Control Module)

    Scan tool condition check Go to step 3. Repair or replace defective part. 1) Make sure that SUZUKI scan tool is as follows. • Correct PCMCIA card (software) is used. • There are no deformation and wear for DLC cable terminals.
  • Page 949 Go to Step 4. Go to Step 6. 1) Check DLC terminal for deformation and wear. 2) If it is in good condition, connect SUZUKI scan tool to DLC with ignition switch tuned OFF. 3) Check if communication is possible by making communication with other control modules (BCM, ABS, HVAC control module or SDM).

  • Page 950: Eps" Warning Light Does Not Come On With Ignition Switch Turned On Before Engine Starts

    6C-16 Power Assisted Steering System: Step Action Scan tool operation check Scan tool is in good Recheck PCMCIA card condition, check and DLC cable for faulty 1) Check if communication is possible by making intermittent trouble condition. If they are communication with other vehicles.
  • Page 951 Power Assisted Steering System: 6C-17 Circuit Description Operation (ON/OFF) of “EPS” warning light is controlled by P/S control module through combination meter. If the P/S system is in good condition, P/S control module turns “EPS” warning light ON at the ignition switch ON, and then turns it OFF at the engine start.

  • Page 952: Eps" Warning Light Remains On Steady After Engine Starts

    Action Check DTC referring to “DTC Check”. Go to applicable DTC Go to Step 2. diag. flow. Is there any DTC(s) (NO CODES on SUZUKI scan tool)? “EPS” warning light circuit check Go to Step 3. Replace P/S control module.

  • Page 953: Dtc C1111 / C1113 / C1115: Torque Sensor Circuit Failure

    Power Assisted Steering System: 6C-19 DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure S7RW0A6304012 DTC C1111: Steering Torque Sensor (Main) Circuit Voltage DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation DTC C1115: Steering Torque Sensor (Sub) Circuit Voltage Wiring Diagram E13-1 E11-18...
  • Page 954 6C-20 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable diag. Go to Step 3. flow. Is DTC C1153 or C1116 indicated, together? Torque sensor signal circuit check Go to Step 4.

  • Page 955: Dtc C1116: Steering Torque Sensor Power Supply Circuit

    Power Assisted Steering System: 6C-21 DTC C1116: Steering Torque Sensor Power Supply Circuit S7RW0A6304013 Wiring Diagram E13-1 E11-18 E31-5 LT GRN/ E11-1 E11-8 E31-3 E31-2 E11-10 E11-20 E31-4 E11-9 E31-1 12 13 14 15 16 17 18 19 20 E11-19 E13-2 I6RW0C630005-02 [A]: P/S control module connector No.1 “E11”...

  • Page 956: Dtc C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure

    6C-22 Power Assisted Steering System: Step Action Torque sensor power supply circuit check Replace P/S control Repair or replace module. defective circuit. 1) Check that torque sensor power supply circuit is as follows. • Insulation resistance of wire harness is infinity between “Torque sensor power supply circuit”...
  • Page 957 Power Assisted Steering System: 6C-23 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC C1121: • Vehicle speed signal circuit Vehicle speed signal is 0 km/h even though engine speed • BCM is more than 4000 rpm for more than 60 seconds •...

  • Page 958: Dtc C1122: Engine Speed Signal

    6C-24 Power Assisted Steering System: Step Action Vehicle speed signal circuit check Go to Step 7. Go to Step 8. 1) With ignition switch turned OFF, disconnect connectors from BCM. 2) Check BCM connector for proper connection. 3) If OK, turn ON ignition switch, measure voltage between “G04-15”...
  • Page 959 Power Assisted Steering System: 6C-25 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Engine speed signal is less than 220 rpm for more than • Engine speed signal circuit 0.8 seconds. • ECM • P/S control module Engine speed signal is less than 220 rpm for more than 20 seconds continuously even though vehicle speed signal is more than 50 km/h.

  • Page 960: Dtc C1141 / C1142 / C1143 / C1145: Motor Circuit Failure

    6C-26 Power Assisted Steering System: DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure S7RW0A6304016 DTC C1141: P/S Motor Circuit Voltage DTC C1142: P/S Motor Circuit Range/Performance DTC C1143: P/S Motor Circuit Current Too High DTC C1145: P/S Motor Circuit Current Too Low Wiring Diagram E13-1 LT GRN/...

  • Page 961: Dtc C1153: P/S Control Module Power Supply Circuit

    Power Assisted Steering System: 6C-27 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable DTC Go to Step 3. diag. flow. Is DTC C1153 and/or C1155 indicated, together? Power supply and ground circuit check Go to Step 4.

  • Page 962: Dtc C1155: P/S Control Module Internal Failure

    6C-28 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. Battery voltage check Go to Step 3. Check charging system referring to “Generator 1) Check circuit fuse for P/S control module. Test (Undercharged 2) If OK, measure voltage between positive (+) battery Battery Check) in...

  • Page 963: P/S Control Module Power Supply And Ground Circuit Check

    Power Assisted Steering System: 6C-29 P/S Control Module Power Supply and Ground Circuit Check S7RW0A6304019 Wiring Diagram Refer to “DTC C1153: P/S Control Module Power Supply Circuit”. DTC Troubleshooting Step Action Circuit fuse check Go to Step 2. Replace fuse (s) and check for short in 1) Disconnect P/S control module connector with ignition circuits connected to...

  • Page 964: Inspection Of P/S Control Module And Its Circuits

    6C-30 Power Assisted Steering System: Inspection of P/S Control Module and Its Circuits S7RW0A6304020 The P/S control module and its circuits can be checked at the P/S control module wiring couplers by measuring voltage and resistance. CAUTION P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to the P/S control module with connectors disconnected from the P/S control module.
  • Page 965 Power Assisted Steering System: 6C-31 Terminal Wire color Circuit Normal voltage Condition Ignition switch signal for P/S E11-1 LT GRN/BLK 10 – 14 V Ignition switch ON control module E11-2 — — — — E11-3 — — — — *0 – 1 V ↑↓...
  • Page 966 6C-32 Power Assisted Steering System: Terminal Wire color Circuit Normal voltage Condition • Ignition switch ON Reference sensor power supply E11-20 About 3.0 – 3.5 V • Check voltage between “E11-20” and for torque sensor “E11-9” terminals *0 – 1 V ↑↓...
  • Page 967 Power Assisted Steering System: 6C-33 Reference waveform No.2 Reference waveform No.3 Motor output signal 1(1), Motor output signal 2(2), with Motor output signal 1(1), Motor output signal 2(2), with engine idling engine idling Measurement CH1: “E12-1” to vehicle body ground Measurement CH1: “E12-1”...

  • Page 968: Steering Wheel Play Check

    6C-34 Power Assisted Steering System: Steering Wheel Play Check Steering Force Check S7RW0A6304021 S7RW0A6304022 • Check steering wheel for looseness or rattle by 1) Place vehicle on level road and set steering wheel at moving it in its shaft direction and lateral direction. straight-ahead position.

  • Page 969: Repair Instructions

    Power Assisted Steering System: 6C-35 Repair Instructions Steering Gear Case Assembly Components S7RW0A6306001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle the figure is symmetrical. 1207F I7RW0A630004-01 1. Steering gear case 11. Clip 21. O-ring 2. Tie-rod lock washer 12.

  • Page 970: Tie-Rod End Boot On-Vehicle Inspection

    6C-36 Power Assisted Steering System: 9. Tie-rod end nut 19. Washer : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) (caulking nut) 10. Boot 20. Spring washer : Do not reuse. : Make sure of the direction of installation referring to “Steering Rack Plunger Removal and Installation”.

  • Page 971: Tie-Rod End Initial Position Setting

    Power Assisted Steering System: 6C-37 Tie-Rod End Initial Position Setting 2) Connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to specified torque. S7RW0A6306014 Set tie-rods to following specified length “A”. Tightening torque Initial position of tie-rod end “A” Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft) Driver side: Approx.

  • Page 972: Steering Gear Case Assembly Removal And Installation

    6C-38 Power Assisted Steering System: Steering Gear Case Assembly Removal and 2) Install steering gear case to vehicle, and then install front suspension frame referring to “Front Installation Suspension Frame, Stabilizer Bar and/or Bush S7RW0A6306006 Removal and Installation in Section 2B”. Removal 3) Install steering gear case to suspension frame (3) as follows.

  • Page 973: Steering Rack Boot Inspection

    4) Apply grease “A” to boot inside as shown in figure. Position boot properly in grooves of gear case (or rack side mount) and tie-rod. After this, check to ensure that boot is free from twist and dent. “A”: Grease 99000–25050 (SUZUKI Super Grease E) “A” IYSQ01630034-01 I7RW01632010-01...

  • Page 974: Steering Rack Plunger Removal And Installation

    6C-40 Power Assisted Steering System: 5) Clamp boot with clip and wire. Wire should be new 7) Tighten tie-rod end lock nut to specified torque. and should go around the boot twice. Tightening torque Pull its both ends together by screwdriver or such Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5 and make sure that the wire won’t be crossed.

  • Page 975: Steering Rack Plunger Inspection

    After tightening rack damper screw to specified torque, turn it back by 10° or less. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) Tightening torque Rack damper screw (a): Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and loosen 180° and then tighten 3.9 N⋅m (0.39 kgf-m, 3.0 lb-ft) and turn...

  • Page 976: Torque Sensor And Its Circuit Inspection

    6C-42 Power Assisted Steering System: Torque Sensor and Its Circuit Inspection 5) Turn ON ignition switch without engine running and S7RW0A6306012 select scan tool “Data List” mode due to checking 1) Check that torque sensor circuit is in good condition “Sensor (Main) Torque”...

  • Page 977: P/S Motor And Its Circuit Inspection

    Power Assisted Steering System: 6C-43 P/S Motor and Its Circuit Inspection 8) Using ammeter (2), check that P/S motor current (1) S7RW0A6306013 is as following table with idling engine. If check result 1) Check motor circuit referring to Step 2 to 3 of “DTC is not satisfactory, check P/S control module for C1141 / C1142 / C1143 / C1145: Motor Circuit torque sensor signal and P/S motor output referring...

  • Page 978: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RW0A6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease E P/No.: 99000–25050 Water tight sealant SUZUKI Bond No.1207F...
  • Page 979 Table of Contents 7- i Section 7 HVAC CONTENTS Precautions ..........7-1 Precautions on Servicing A/C System ....7B-1 General Description ..........7B-2 Precautions............. 7-1 Sub-Cool A/C System Description ......7B-2 Precautions on HVAC ........... 7-1 A/C Operation Description at ECM .....7B-3 Heater and Ventilation......7A-1 Schematic and Routing Diagram ......7B-4 A/C System Air Flow Diagram......7B-4 Schematic and Routing Diagram......7A-1...
  • Page 980 7-ii Table of Contents Compressor Drive Belt Removal and DTC B1513: Temperature Control Actuator Installation ............7B-31 (Motor) and/or Its Circuit Malfunction ....7B-63 Compressor Assembly Removal and DTC B1514: Air Flow Control Actuator (Motor) Installation ............7B-31 and/or Its Circuit Malfunction......7B-64 Compressor Assembly Components....
  • Page 981 Table of Contents 7-iii Condenser Cooling Fan Inspection....7B-84 Compressor Drive Belt Inspection and Condenser Assembly On-Vehicle Inspection..7B-84 Adjustment ............7B-84 Condenser Assembly Removal and Compressor Drive Belt Removal and Installation ............7B-84 Installation ............7B-84 Evaporator Inspection ........7B-84 Compressor Assembly Removal and Evaporator Temperature Sensor Removal Installation ............7B-84 and Installation ..........

  • Page 982: Precautions

    7-1 Precautions: Precautions HVAC Precautions Precautions on HVAC S7RW0A7000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. A/C System Caution Refer to “A/C System Caution: Manual Type in Section 7B” or “A/C System Caution: Automatic Type in Section 7B”. Precautions on Servicing A/C System Refer to “Precautions on Servicing A/C System: Manual Type in Section 7B”...

  • Page 983: Heater And Ventilation

    Heater and Ventilation: 7A-1 Heater and Ventilation HVAC Schematic and Routing Diagram Heater and Ventilation Diagram S7RW0A7102002 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C710001-02 Air flow 7.

  • Page 984: Heater And Ventilation Wiring Circuit Diagram

    7A-2 Heater and Ventilation: Heater and Ventilation Wiring Circuit Diagram S7RW0A7102001 Non–A/C RED/BLK G155-1 BLK/YEL BLK/WHT BLK/WHT G155-6 G155-7 BLK/RED BLU/WHT G155-3 G155-2 G154-9 BLU/WHT BLK/ORN RED/BLK G154-14 BLK/RED G154-13 G154-10 GRN/YEL G154-8 G154-4 RED/YEL RED/BLU G154-3 G154-7 BLK/RED I8RW01710001-01 [A]: Hatchback model 4.

  • Page 985: Diagnostic Information And Procedures

    Heater and Ventilation: 7A-3 Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S7RW0A7104001 Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check related fuses, and then check for short operate with blower circuit to ground. speed selector ON Blower motor relay faulty Check blower motor relay referring to “Blower...

  • Page 986: Repair Instructions

    7A-4 Heater and Ventilation: Repair Instructions HVAC Unit Components Installation S7RW0A7106001 Reverse removal procedure noting the following For non-A/C and manual A/C, refer to “HVAC Unit instructions. Components: Manual Type in Section 7B”. • Be careful not to catch any cable and wiring harness For auto A/C, refer to “HVAC Unit Components: in inappropriate position.

  • Page 987: Blower Motor Resistor Removal And Installation

    Heater and Ventilation: 7A-5 • Check for operation and current. 4) Disconnect connector (1) from blower motor resistor (2), and then remove blower motor resistor from a. Put blower motor (1) in a soft-jawed vise. HVAC unit by removing screws (3). b.

  • Page 988: Blower Motor Relay Inspection

    7A-6 Heater and Ventilation: Blower Motor Relay Inspection S7RW0A7106007 1) Disconnect negative (–) cable at battery. 2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”. 3) Remove junction block assembly (2). 4) Disconnect blower motor relay (1) from junction block assembly (2).

  • Page 989: Hvac Control Unit Removal And Installation

    Heater and Ventilation: 7A-7 HVAC Control Unit Removal and Installation RH steering vehicle S7RW0A7106009 Removal 1) Disconnect negative (–) cable at battery. 2) Remove steering column hole cover from instrument panel. 3) Remove audio unit from instrument panel referring to “Audio Unit Removal and Installation (If Equipped) in Section 9C”.
  • Page 990 7A-8 Heater and Ventilation: b. Move temperature control lever (1) to “MAX HOT” c. Move air flow control plate (1) to “DEF” position “c” position “a” (LH steering vehicle) or “MAX COOL” (LH steering vehicle) or “VENT” position “d” (RH position “b”...

  • Page 991: Blower Speed Selector Inspection

    Heater and Ventilation: 7A-9 Blower Speed Selector Inspection Air Intake Control Actuator Removal and S7RW0A7106010 Installation Check blower speed selector for each terminal to S7RW0A7106012 terminal continuity. If check result does not meet the following conditions, replace HVAC control unit. Removal 1) Disconnect negative cable from battery.

  • Page 992: Air Intake Control Actuator Inspection

    7A-10 Heater and Ventilation: Air Intake Control Actuator Inspection Installation Reverse removal procedure noting the following S7RW0A7106013 Check air intake control actuator as follows: instruction. 1) Using service wire, connect battery positive terminal • Be sure to insert the linkage rod (1) into the hole (2) of to “d”...

  • Page 993: Center Ventilation Louver Removal And Installation

    Heater and Ventilation: 7A-11 Center Ventilation Louver Removal and 3) Remove side ventilation louver (1) from instrument panel while pressing clips (2). Installation S7RW0A7106014 Removal 1) Disconnect negative (–) cable from battery. 2) Remove audio unit from instrument panel referring to “Audio Unit Removal and Installation (If Equipped) in Section 9C”.

  • Page 994: Rear Duct Removal And Installation (If Equipped)

    7A-12 Heater and Ventilation: Rear Duct Removal and Installation (If HVAC Air Filter Removal and Installation (If Equipped) Equipped) S7RW0A7106016 S7RW0A7106017 Removal 1) Remove glove box from instrument panel. 2) Remove air filter (1) from HVAC unit while releasing claws (2). I6RW0C710010-01 Installation I7RW01710019-01...

  • Page 995: Air Conditioning System

    Air Conditioning System: Manual Type 7B-1 Air Conditioning System HVAC Manual Type Precautions A/C System Caution S7RW0A7210001 CAUTION The A/C system of this vehicle uses HFC-134a (R-134a) refrigerant, specified compressor oil and specified parts. Do not use CFC-12 (R-12) refrigerant, R-12 exclusive use compressor oil and R-12 exclusive parts in this A/C system, do not attempt to use R-12 servicing equipment.

  • Page 996: General Description

    7B-2 Air Conditioning System: Manual Type Refrigerant Recovery When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environments referring to “Recovery” in “Operation Procedure for Refrigerant Charge: Manual Type”. Refrigerant Charge After performing compressor oil replenishment and evacuation, charge a proper amount of refrigerant to A/C system referring to “Charge”...

  • Page 997: A/C Operation Description At Ecm

    Air Conditioning System: Manual Type 7B-3 A/C Operation Description at ECM S7RW0A7211003 ECM controls the A/C compressor relay and condenser cooling fan relay according to signals from HVAC control unit, A/C refrigerant pressure sensor, ECT sensor and evaporator temperature sensor. The A/C switch ON signal from HVAC control unit is transmitted to ECM through BCM.

  • Page 998: Schematic And Routing Diagram

    7B-4 Air Conditioning System: Manual Type Schematic and Routing Diagram A/C System Air Flow Diagram S7RW0A7212001 I7RW01721002-03 A: Air flow 5. Discharge hose 11. Foot air 17. Air intake door B: Refrigerant flow 6. Suction hose 12. Front defroster air 18.

  • Page 999: A/C System Wiring Diagram

    Air Conditioning System: Manual Type 7B-5 A/C System Wiring Diagram S7RW0A7212002 BLU/YEL BLK/YEL E01-47 RED/BLK E01-58 BLK/RED E01-1 G155-1 BLK/RED E01-16 BLK/WHT BLK/YEL BRN/WHT E01-60 G155-6 BLK/WHT G155-7 BLK/WHT E01-29 G155-3 BLU/WHT G155-2 BLU/WHT E01-19 G155-5 RED/BLK GRY/RED C01-14 G154-6 RED/BLU E01-55 G154-5...

  • Page 1000: Manual A/C Electronic Input Output Diagram

    7B-6 Air Conditioning System: Manual Type Manual A/C Electronic Input Output Diagram S7RW0A7212003 A/C refrigerant pressure sensor Condensor cooling fan relay A/C evaporator temperature sensor Compressor relay ECT sensor ABS / ESP® control Wheel speed sensor (VSS) module HVAC control unit Blower speed selector Blower motor resistor Blower motor...

  • Page 1001: Electronic Control System Components Location

    Air Conditioning System: Manual Type 7B-7 Electronic Control System Components Location S7RW0A7213002 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C721003-01 [A]: Junction block assembly viewed from relay side 6.

  • Page 1002: Diagnostic Information And Procedures

    7B-8 Air Conditioning System: Manual Type Diagnostic Information and Procedures A/C System Performance Inspection 5) Warm up engine to the normal operating S7RW0A7214001 temperature and keep it at the specified idle speed. 1) Confirm that vehicle and environmental conditions 6) Turn A/C switch ON, set blower speed selector at are as follows.

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