Page 2 OPERATING INSTRUCTION CONTENTS ACROBAT READER SCREEN DISPLAY HOW TO READ MANUAL DATA...
Page 3 ACROBAT READER SCREEN DISPLAY...
Page 4 Page only display Only a page is displayed on the entire screen. Bookmark and page display A bookmark is displayed in the left of the screen and a page in the right. Thumbnails and page display Thumbnails are displayed in the left of the screen and a page in the right.
Page 5 HOW TO READ MANUAL DATA 1. By opening (i.e. double-click the icon) the “TOP.pdf” file on CD-ROM, the Acro- bat Reader is automaticaly booted and the title screen shown below. Example: 2. Click on the title screen then, the Manual List displays below. From the list, select the number assigned to the manual to be displayed and click the part number.
Page 6 3. Then, the “Important” page of each manual displays. At the same time, a “Book- mark” frame also displays on the left side of the screen. Example: “Important” page “Bookmark” frame...
Page 7 4. Click (left-button) “Foreword” in the Bookmark and “Foreword” page displays. Example: “Foreword” “Important” page “Foreword” “Foreword” page...
Page 8 5. Click (left-button) “Table of Contents” in the Bookmark, “Table of Contents” page displays. Example: “Table of Contents” “Foreword” page “Related manuals” “Table of Contents” page “Table of Contents” • To jump to a reference manual On the “Foreword” page, the link is pasted from manual name and manual part number of the “Related Manuals”.
Page 9 6. Perform the following procedure ((1) or (2)) to jump from “Table of Contents” page to first page contents of a section. (1) Click (Left-button) in the appropriate link jumps to that section (Linked at the loca- tion, at which the pointer “ ”...
Page 10 7. From here on, the following operations can be executed. Select the appropriate operation according to your needs. • To jump to a page that contains a title Jump to the first page of each section, on which linked to the page that contains each title.
Page 11 • To print the data (1) On a specific page or pages: Refer to the page number (“B”) given on the bottom of the screen and take note of it. Select “Print” (“A”) in the File menu and specify the page number(s) to be printed.
Page 12 3. Search necessary information in the reverse order of manual group number. For Petrol (Gasoline) Engine Model Applicable Manual Group (No.: (1) - (14)) Language Model Category Service Manual Wiring Diagram Manual Model A: SY413/SY416 (1), (3), (4) 1995-1996 Model B: SY418 1995-1996 (1), (2), (3), (4) Model C:...
Page 13 For Petrol (Gasoline) Engine Model Applicable Manual Group (No.: (1) - (14)) Language Model Category Service Manual Wiring Diagram Manual Model G: SY413/SY416/SY418 (13), (14) 2000 Face Lifting (1), (2), (3), (4), (6), (7), (8), (10) English French German Spanish...
Page 14 VIN TABLE Model A: The VIN within the range shown in the table are categorized as “Model A” GA11S-100001 GA11S-140000 GA31S-100001 GA31S-140000 GC11S-100001 GC11S-140000 GC31S-100001 GC31S-140000 JS2GA21HS 5100001 JS2GA21HS 5140000 JS2GA21HT 5100001 JS2GA21HT 5140000 JS2GA31HS 5100001 JS2GA31HT 5100001 JS2GA31HV 5100001 JS2GA21SS 5100001 JS2GA21ST 5100001 JS2GA31SS 5100001...
Page 15 Model C: The VIN within the range shown in the table are categorized as “Model C” JSAEGA11S00108641 JSAEGA11S00140000 JSAEGA31S00107758 JSAEGA31S00140000 JSAEGB31S00100224 JSAEGB31S00140000 JSAEGC11S00109524 JSAEGC11S00140000 JSAEGC31S00121188 JSAEGC31S00140000 JSAEGD31S00100366 JSAEGD31S00140000 Model D: The VIN within the range shown in the table are categorized as “Model D” GC31W-100001 GC31W-140000 GC41W-100001...
Page 16 Model E: The VIN within the range shown in the table are categorized as “Model E” GA11S-140001 GA11S-160000 GA31S-140001 GC11S-140001 GC11S-160000 GC31S-140001 GC31S-160000 GC31W-140001 GC31W-160000 GD31W-140001 JSAEGA11S00140001 JSAEGA11S00160000 JSAEGA31S00140001 JSAEGA31S00160000 JSAEGB31S00140001 JSAEGB31S00160000 JSAEGC11S00140001 JSAEGC11S00160000 JSAEGC31S00140001 JSAEGC31S00160000 JSAEGC31SV5140001 JSAEGC31SW0140001 JSAEGC31SW5160000 JSAEGD31S00140001 JSAEGD31S00160000 JSAEGC41S00140001 JSAEGC41S00160000...
Page 17 Model F: The VIN within the range shown in the table are categorized as “Model F” GA11S-160001 GA11S-200000 GC11S-160001 GC11S-200000 GC31S-160001 GC31S-200000 GC31W-160001 GC31W-200000 JSAEGA11S00160001 JSAEGA11S00200000 JSAEGA31S00160001 JSAEGA31S00200000 JSAEGB31S00160001 JSAEGB31S00200000 JSAEGC11S00160001 JSAEGC11S00200000 JSAEGC31S00160001 JSAEGC31S00200000 JSAEGC31SW5160001 JSAEGC31SX0160001 JSAEGD31S00160001 JSAEGD31S00200000 JSAEGC41S00160001 JSAEGC41S00200000 JSAEGC51S00160001 JSAEGC51S00200000 JSAEGC51SX0160001...
Page 18 Model G: The VIN within the range shown in the table are categorized as “Model G” GA11S-200001 GC11S-200001 GC31S-200001 GC31W-200001 JSAEGA11S00200001 JSAEGA31S00200001 JSAEGB31S00200001 JSAEGA41S00200001 JSAEGC11S00200001 JSAEGC31S00200001 JSAEGC31S15200001 JSAEGC31S10200001 JSAEGD31S00200001 JSAEGC41S00200001 JSAEGC51S00200001 JSAEGC51S10200001 JSAEGC11W00200001 JSAEGC31W00200001 JSAEGC31W15200001 JSAEGC31W10200001 JSAEGD31W00200001 JSAEGC41W00200001 JS2GA11S 15200001 JS2GA31S 15200001 JS2GA41S 15200001 JS2GB31S 15200001...
Page 19 NEXT MANUAL LIST Manual Language Manual Part Name Manual Part Number Group 99500-60G00-01E 99500-60G00-01F SY413/SY416 99500-60G00-01G Service Manual 99500-60G00-01S 99500-60G00-01D 99501-62G00-01E 99501-62G00-01F SY418 Service Manual 99501-62G00-01G 99501-62G00-01S 99501-60G01-01E 99501-60G01-01F SY416/SY418 99501-60G01-01G Supplementary Service Manual (for suspension control system) 99501-60G01-01S 99501-60G01-01D...
Page 20 BACK NEXT MANUAL LIST Manual Language Manual Part Name Manual Part Number Group 99501-60G20-18E SY413/SY416 99501-60G20-18F Supplementary Service Manual 99501-60G20-18G (for oxygen sensor heater 99501-60G20-18S equipped vehicle) 99501-60G20-18D 99501-60G30-01E 99501-60G30-01F SY416/SY418 99501-60G30-01G Supplementary Service Manual (for wagon) 99501-60G30-01S 99501-60G30-01D 99501-60G41-01E...
Page 21 BACK MANUAL LIST Manual Language Manual Part Name Manual Part Number Group SY413/SY416/SY418 99500-60G20-01E Service Manual 99501-60G60-01F SY413/SY416/SY418 (10) 99501-60G60-01G Supplementary Service Manual 99501-60G60-01S 99501-66G00-01E 99501-66G00-01F SY419 99501-66G00-01G (11) Supplementary Service Manual 99501-66G00-01S 99501-66G00-01D 99500-66G10-01E 99500-66G10-01F SY419 (12) Service Manual...
Page 22 SERVICE MANUAL 99500-60G00-01E...
Page 1367 Prepared by SUZUKI MOTOR CORPORATION Automobile Department Overseas Service Department 1st Ed, Feb., 1995 2nd Ed, Oct., 2001 Printed in Japan Printing: 1360...
Page 1370 D Service on or around the air bag system ings. Pay special attention to the messages high- components must be performed only by lighted by these signal words. an authorized SUZUKI dealer. Please ob- serve all WARNINGS, CAUTIONS and WARNING: “Service Precautions” under “On-Vehicle Indicates a potential hazard that could result Service”...
Page 1371 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 (lubricant, sealants, etc.) as specified in each description.
Page 1372 TABLE OF CONTENTS TABLE OF CONTENTS SECTION SECTION ENGINE GENERAL INFORMATION Engine (G13/G16 Engine without General Information WU-TWC) Maintenance and Lubrication Engine General Information and HEATING AND VENTILATION Diagnosis (G13/G16 Engine with WU-TWC) Heater and Ventilation Engine General Information and Air Conditioning (Optional) Diagnosis STEERING, SUSPENSION,...
Page 1373 GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ....0A- 2 Identification Whether Vehicle Equipped With WU-TWC or Not ....0A-16 PRECAUTIONS .
Page 1374: How To Use This Manual
0A-2 GENGERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the first page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a TABLE OF CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
Page 1375 D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
Page 1376 0A-4 GENGERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BO- WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules D For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature...
Page 1377 GENERAL INFORMATION 0A-5 WARNING: D During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. D Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mount- ing bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the ve- hicle to ensure proper operation of the air bag system.
Page 1378 0A-6 GENGERAL INFORMATION CAUTION: D Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions un- der “Repair and Inspection Required after an Acci- dent”...
Page 1379: General Precautions
GENERAL INFORMATION 0A-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
Page 1380 0A-8 GENGERAL INFORMATION D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be re- installed in the proper order and position.
Page 1381 GENERAL INFORMATION 0A-9 D When disconnecting vacuum hoses, attach a tag describ- ing the correct installation positions so that the hoses can be reinstalled correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
Page 1382 0A-10 GENGERAL INFORMATION D Use care not to expose connectors and electrical parts to water which will be a cause of a trouble. PRECAUTION FOR CATALYTIC CONVERTER For vehicles equipped with a catalytic converter, use only un- leaded gasoline and be careful not to let a large amount of un- burned gasoline enter the converter or it can be damaged.
Page 1383 GENERAL INFORMATION 0A-11 D When connecting connectors, also hold connectors and put them together until they lock securely (a click is heard). D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, TCM, ABS control module, SDM etc).
Page 1384 0A-12 GENGERAL INFORMATION D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. D Before measuring voltage at each terminal, check to make sure that battery voltage is 11V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis.
Page 1385: Precaution For Installing Mobile Communication Equipment
GENERAL INFORMATION 0A-13 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-telephone, be sure to ob- serve the following precautions. Failure to follow cautions may adversely affect electronic con- trol system. D Keep the antenna as far away as possible from the vehicle’s electronic control unit.
Page 1386 0A-14 GENGERAL INFORMATION PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE When performing any of the following types of work, be sure to make the vehicle as front wheel drive by cutting transmission of driving force to the rear wheels. Otherwise, rear wheels are driven and vehicle accidents, damage and personal injury may result.
Page 1387: Intermittent And Poor Connection
GENERAL INFORMATION 0A-15 INTERMITTENT AND POOR CONNECTION Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diag- nostic flow chart, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 1388 0A-16 GENGERAL INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The number is located on the front dash panel in the engine room. IDENTIFICATION WHETHER VEHICLE G13/G16 EQUIPPED WITH WU-TWC OR NOT It can be identified by the shape of exhaust manifold (1) and ex- haust pipe (2).
Page 1389 GENERAL INFORMATION 0A-17 WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION/WARNING labels are attached on the vehicle equipped with air bag system only.
Page 1390: Vehicle Lifting Points
0A-18 GENGERAL INFORMATION VEHICLE LIFTING POINTS FOR 2WD VEHICLE : Support position for frame contact hoist and safety stand : Floor jack position FOR 4WD VEHICLE : Support position for frame contact hoist and safety stand : Floor jack position...
Page 1391 GENERAL INFORMATION 0A-19 When using frame contact hoist: WARNING: D Before applying hoist to underbody, always take ve- SUPPORT LOCATION: Forward of embossed- hicle balance throughout service into consideration. mark Vehicle balance on hoist may change depending on what part to be removed. D 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 1392: Abbreviations And Symbols May Be Used In This Manual
0A-20 GENGERAL INFORMATION ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL ABBREVIATIONS : Anti-Lock Brake System, EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control Module : American Petroleum Institute : Engine Control Module : Automatic Transmission Fluid ECT Sensor : Engine Coolant Temperature...
Page 1393 GENERAL INFORMATION 0A-21 : Junction Box (Junction Block) : Throttle Body Fuel Injection (Single-Point Fuel Injection, SPI) : Left Hand : Torque Converter Clutch LSPV : Load Sensing Proportioning : Transmission Control Module Valve (A/T Controller, A/T Control Module) MAF Sensor : Mass Air Flow Sensor TP Sensor : Throttle Position Sensor...
Page 1394 0A-22 GENGERAL INFORMATION WIRE COLOR SYMBOLS Symbol Wire Color Symbol Wire color Black Orange Blue Brown White Green Yellow Gray Pink LT BLU Light blue Violet LT GRN Light green There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire.
Page 1395: Metric Fasteners
GENERAL INFORMATION 0A-23 FASTENER INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replace- ment fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification em- bossed on the head of each bolt.
Page 1396: Standard Tightening Torque
0A-24 GENGERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation 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 fasten- NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque...
Page 1397 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1398 0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at Interval: the same intervals respectively. This interval should be judged by This interval should be judged by ( 1,000) odometer reading or months,...
Page 1399 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at Interval: the same intervals respectively. This interval should be judged by This interval should be judged by ( 1,000) odometer reading or months, whichever comes first.
Page 1400 0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
Page 1401 MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and adjusting belt tension. 1.3L, 1.6L Engine Vehicle with A/C A/C Compressor and/or Power Steering Pump Drive Belt Inspection (If equipped) 1) Detach air cleaner assembly from vehicle body and shift its position.
Page 1402 0B-6 MAINTENANCE AND LUBRICATION Water Pump Belt Replacement Replace belt with new one. Refer to SECTION 6B for replacement procedure of pump belt. NOTE: When replacing belt with a new one, adjust belt tension to 5 – 7 mm (0.20 – 0.27 in.). 1.
Page 1403 MAINTENANCE AND LUBRICATION 0B-7 ITEM 1-3 (Except 1.8L Engine model) Valve Lash Inspection 1) Remove cylinder head cover. 2) Inspect intake and exhaust valve lash and adjust as necessary. Refer to SECTION 6A1 for valve lash inspection and adjust- ment procedure. When cold (Cool- When hot (Cool- ant temperature...
Page 1404 0B-8 MAINTENANCE AND LUBRICATION 4) Apply engine oil to new oil filter O-ring. 5) Screw new filter on oil filter stand by hand until filter O-ring con- tacts mounting surface. CAUTION: To tighten oil filter properly, it is important to accurate- ly identify the position at which filter O-ring first con- tacts mounting surface.
Page 1405 MAINTENANCE AND LUBRICATION 0B-9 ITEM 1-5 1.3L and 1.6L Engine model Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still hot. Scald- ing fluid and steam can be blown out under pressure if cap is taken off too soon.
Page 1406 0B-10 MAINTENANCE AND LUBRICATION When carrying out periodic maintenance or vehicle is raised for other service, check exhaust system as follows: D Check rubber mountings for damage and deterioration. D Check exhaust system for leakage, loose connections, dents, and damages. If bolts or nuts are loose, tighten them to specification.
Page 1407: Emission Control System
MAINTENANCE AND LUBRICATION 0B-11 ITEM 3-2 Fuel Lines Inspection D Check fuel lines for loose connection, deterioration or damage which could cause leakage. Make sure all clamps are secure. D Replace any damaged or deteriorate parts. There should be no sign of fuel leakage or moisture at any fuel connection.
Page 1408 0B-12 MAINTENANCE AND LUBRICATION BRAKE ITEM 5-1 Brake Discs, Pads, Drums and Shoes Inspection Brake discs and pads 1) Remove wheel and caliper but don’t disconnect brake hose from caliper. 2) Check disc brake pads and discs for excessive wear, damage and deflection.
Page 1409 MAINTENANCE AND LUBRICATION 0B-13 ITEM 5-3 Brake Fluid Change Change brake fluid as follows. Drain existing fluid from brake system completely, fill system with specified fluid and carry out air purge operation. For air purging procedure, refer to SECTION 5. ITEM 5-4 “a”: Parking brake lever stroke: Brake Lever and Cable Inspection...
Page 1410 0B-14 MAINTENANCE AND LUBRICATION ITEM 6-2 Tire and Wheel Disc Inspection [Tire inspection] 1) Check tire for uneven or excessive wear, or damage. If defec- tive, replace. 1. Wear indicator 2) Check inflating pressure of each tire and adjust pressure to specification as necessary.
Page 1411 MAINTENANCE AND LUBRICATION 0B-15 ITEM 6-3 Propeller Shaft Inspection (4WD vehicle only) 1) Check propeller shaft connecting bolts for looseness. If loose- ness is found, tighten to specified torque. 2) Check propeller shaft joints for wear, play and damage. If any defect is found, replace.
Page 1412 0B-16 MAINTENANCE AND LUBRICATION 2) Check steering linkage for looseness and damage. Repair or replace defective parts, if any. 3) Check boots of steering linkage and steering gear case for dam- age (leaks, detachment, tear, etc.). If damage is found, replace defective boot with new one.
Page 1413 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-7 Rear Differential Oil Inspection and Change (4WD vehicle only) [Inspection] 1) Inspect rear differential case for evidence of oil leakage. Repair leaky point, if any. 2) Make sure that the vehicle is placed level for oil level check. 3) Remove level plug of differential.
Page 1414 0B-18 MAINTENANCE AND LUBRICATION [Fluid cooler hose change] 4-speed A/T Replace inlet and outlet hoses of cooler hose and their clamps. For replacement procedure, refer to ON-VEHICLE SERVICE in SECTION 7B or 7B1. 1. Radiator 2. Inlet hose (Outlet from oil cooler) 3.
Page 1415 MAINTENANCE AND LUBRICATION 0B-19 FINAL INSPECTION On automatic transmission vehicles, try to start the en- gine in each gear. The starter should crank only in “P” WARNING: (Park) or “N” (Neutral). When carrying out road tests, select a safe On manual transmission vehicles, place the shift lever place where no man or no running vehicle is in “Neutral,”...
Page 1416 0B-20 MAINTENANCE AND LUBRICATION [Parking brake] Body, Wheels and Power Transmitting System Check that lever has proper travel. Check that body, wheels and power transmitting sys- tem are free from abnormal noise and abnormal vibra- WARNING: tion or any other abnormal condition. With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any personal injury or property damage.
Page 1417 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1418 1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION COMPONENTS 1. Side face air 2. Demister air 3. Center face air 4. Foot air 5. Defroster air 6. Heater unit 7. Air duct 8. Blower motor unit 9. Control lever assembly 10. Defroster nozzle 11.
Page 1419 HEATER AND VENTILATION 1A-3 WIRING CIRCUIT For LH vehicle 1. Main fuse box 2. Generator 3. Cassette fuse 4. Fuse and relay box 5. Ignition switch 6. Junction box (J/B) 7. Blower fan motor relay 8. Blower fan motor 9. Blower fan motor resistor 10.
Page 1420 1A-4 HEATER AND VENTILATION For RH vehicle 1. Main fuse box 2. Generator 3. Cassette fuse 4. Fuse and relay box 5. Ignition switch 6. Junction box (J/B) 7. Blower fan motor relay 8. Blower fan motor 9. Blower fan motor resistor 10.
Page 1421 HEATER AND VENTILATION 1A-5 HEATER CONTROL OPERATION The heater and ventilation provide temperature control, ventilation and defrosting functions. Their operation is controlled by selecting the positions of the control levers and mode select switch on the instrument panel. Each lever / switch position and function of heater and ventilation are as given below. Switch Lever C Lever B...
Page 1422 1A-6 HEATER AND VENTILATION BODY VENTILATION The body ventilation system of this vehicle is equipped with air conditioning that consists of a fresh air intake lo- cated at the cowl top panel. Ventilating air is drawn into the interior from the intake grille and drawn out from the ventilator outlet provided at each side of the body outer panel.
Page 1423 HEATER AND VENTILATION 1A-7 DIAGNOSIS Trouble Possible cause Remedy D Fuse blown D Replace fuse to check for short. Heater blower won’t work D Blower resistor faulty D Check continuity. even when its switch is ON. D Blower motor faulty D Replace motor.
Page 1424 1A-8 HEATER AND VENTILATION ON-VEHICLE SERVICE BLOWER FAN MOTOR 1. Blower fan motor unit 2. Blower fan motor resistor 3. Blower fan motor relay 4. Blower fan 5. Blower fan motor assembly REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system.
Page 1425 HEATER AND VENTILATION 1A-9 BLOWER FAN MOTOR RESISTOR REMOVAL 1) Disconnect resistor coupler. 2) Remove heater blower fan motor resistor. INSPECTION Check blower fan motor resistor for each terminal-to-terminal con- tinuity. If there is no continuity, replace blower fan motor resistor. INSTALLATION Reverse removal procedure for installation.
Page 1426: Heater Unit
1A-10 HEATER AND VENTILATION HEATER UNIT For LH vehicle For RH vehicle 1. Heater case 2. Damper 3. Heater core 4. Control lever 5. Mode actuator...
Page 1427 HEATER AND VENTILATION 1A-11 REMOVAL WARNING: Failure to follow the following procedure and WARNING may cause air bag deployment, personal injury, damage to parts, or air bag being unable to deploy. D Never rest a steering column assembly on steering wheel with air bag (inflator) module face down and col- umn vertical.
Page 1428 1A-12 HEATER AND VENTILATION 8) Pull out heater core from unit. 1. Heater core INSTALLATION Reverse removal procedure for installation, and then noting the fol- lowing instructions. D When installing each part, be careful not to catch any cable or wiring harness.
Page 1429 HEATER AND VENTILATION 1A-13 HEATER CONTROL LEVER ASSEMBLY REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag, disable air bag system. Refer to “Disab- ling Air Bag System” in SECTION 9J. 3) Remove control lever knobs and center garnish mounting screw.
Page 1430 1A-14 HEATER AND VENTILATION HEATER CONTROL CABLES 1. Heater unit 2. Blower fan motor unit 3. Fresh air control cable 4. Air control cable 5. Heater control lever assembly REMOVAL 1) Remove control lever assembly. Refer to “HEATER CONTROL LEVER ASSEMBLY” in this section. 2) Remove heater control cables from control lever assembly.
Page 1431 HEATER AND VENTILATION 1A-15 D Fresh Air Control (FRESH-CIRC Selector) Cable – Move control lever to “CIRCULATION” position as full as pos- sible. – Push lever fully in arrow direction and fix cable with clamp in position as shown. D After installing control cables, be sure that control knobs move smoothly and stop at proper position.
Page 1432 1A-16 HEATER AND VENTILATION INSPECTION Mode Control Switch D Check if continuity exists between each pair of terminals listed below when mode control button is pressed. Indicator lamp Mode Mode control switch terminals FACE F – M BI-LEVEL F – N FOOT F –...
Page 1433 HEATER AND VENTILATION 1A-17 MODE ACTUATOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system. Refer to “Disabling Air Bag System” in SECTION 9J. 3) Disconnect mode actuator coupler. 4) Disconnect mode actuator rod from heater unit. 5) Remove mode actuator from heater unit.
Page 1434 1A-18 HEATER AND VENTILATION REAR DUCT (EXCEPT HATCH-BACK MODEL) 1. Rear duct 2. Rear hose LH 3. Rear hose RH 4. Heater unit REMOVAL 1) Remove front seat. 2) Remove console box, parking brake lever cover and console box front extension. 3) Take off carpet till rear duct is totally exposed.
Page 1435 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1436 1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION The present vehicle can be optionally provided with an air conditioning. This Section covers the description, charg- ing of refrigerant, etc. of the air conditioning. MAJOR COMPONENTS AND REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM For LH Vehicle For RH Vehicle : Liquid...
Page 1437 AIR CONDITIONING (OPTIONAL) 1B-3 FUNCTION OF EACH COMPONENT COMPRESSOR Compresses the gas vaporized in the evaporator. Thus compressed gas is sent to the condenser where it is changed into liquid refrigerant whose heat of vaporization can be reused. Compressors used for the air conditioning of vehicle include recip- rocating-, vane rotary-, swash plate-, and wobble plate- types.
Page 1438 1B-4 AIR CONDITIONING (OPTIONAL) DUAL PRESSURE SWITCH A control switch to stop further rotation of the compressor by turn- ing OFF the electric circuits of the magnetic clutch and condenser cooling fan when the cycling refrigerant is abnormally dropped or risen in pressure.
Page 1439 AIR CONDITIONING (OPTIONAL) 1B-5 WIRING CIRCUIT For LH model 1. Main fuse box 11. Mode controller 2. Fuse and relay box 12. A/C amplifier 3. Cassette fuse 13. ECM 4. Junction box (J/B) 14. Condenser fan motor relay 5. Ignition switch 15.
Page 1440 1B-6 AIR CONDITIONING (OPTIONAL) For RH model 1. Main fuse box 11. Mode controller 2. Fuse and relay box 12. A/C amplifier 3. Cassette fuse 13. ECM 4. Junction box (J/B) 14. Condenser fan motor relay 5. Ignition switch 15. Compressor relay 6.
Page 1441 AIR CONDITIONING (OPTIONAL) 1B-7 FUNCTION OF EACH CONTROL COMPONENT D A/C ON-OFF control: RELAY (condenser fan/magnet clutch) High refrigerant pressure: A relay to operate the condenser fan motor and mag- above 3140 kPa netic clutch. The motor continues operation as long as (32 kg/cm , 455 psi) .
Page 1442: Refrigerant Recovery
1B-8 AIR CONDITIONING (OPTIONAL) RECOVERY, EVACUATION AND CHARGING REFRIGERANT RECOVERY When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharg- ing it into atmosphere would cause adverse effect to environments. NOTE: When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
Page 1443 AIR CONDITIONING (OPTIONAL) 1B-9 CHARGING SYSTEM WITH REFRIGERANT The air conditioning system contains HFC-134a (R-134a). Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service con- tainer. When charging refrigerant recovered by using the refrigerant recovery and recycling equipment (when recycling refrigerant), follow the procedure described in the equipment manufacturer’s instruction manual.
Page 1444 1B-10 AIR CONDITIONING (OPTIONAL) PROCEDURE OF CHARGING 1) Check to make sure that hoses are routed properly after eva- cuating the system (see left figure). 2) Connect the manifold gauge set in position. Thus open refriger- ant container valve to purge the charging line. Then open the low pressure-side valve.
Page 1445 AIR CONDITIONING (OPTIONAL) 1B-11 6) After the system has been charged with specified amount (600 g, 21.0 oz) of refrigerant or when low and high pressure gauges have indicated specified value below respectively, close low pressure side valve of manifold gauge set. At this time, look into the sight glass of receiver/dryer and check that there are no bubbles in it, which means that the system is fully charged.
Page 1446 1B-12 AIR CONDITIONING (OPTIONAL) LEAK-TESTING REFRIGERANT SYSTEM Whenever a refrigerant leak is suspected in the system or any ser- vice operation has been performed which may result in disturbing lines or connections, it is advisable to test for leaks. Common sense should be used in performing any refrigerant leak test, since the need and extent of any such test will, in general, depend upon the nature of a complaint and the type of a service performed on...
Page 1447 AIR CONDITIONING (OPTIONAL) 1B-13 DIAGNOSIS Condition Possible cause Correction No cooling or warm air. Magnetic clutch does not engage properly a) Fuse blown Replace fuse and check for short. b) Magnet clutch faulty Check clutch. c) A/C switch faulty Check switch. d) thermistor faulty Check thermistor.
Page 1448 1B-14 AIR CONDITIONING (OPTIONAL) TROUBLESHOOTING PROCEDURE USING MANIFOLD GAUGE SET This procedure enables the technician to discover and repair cool- ing problems by having the pressures of both the high and low pressure sides indicated on the respective gauges of the manifold gauge set.
Page 1449 AIR CONDITIONING (OPTIONAL) 1B-15 MANIFOLD GAUGE kg/cm CONDITION CAUSE CORRECTION 0.15 – 0.25 1.37 – 1.57 1.5 – 2.5 14 – 16 Normal condition. –––––––––– –––––––––– 21.3 – 35.5 200 – 227 D The low pressure side reads D Dust particles or water D Clean expansion valve.
Page 1450 1B-16 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE NOTE 1/2 inch pipe : 20 – 25 N·m (2.0 – 2.5 kg-m, 14.5 – 18.0 lb-ft) When servicing air conditioning system, the following 5/8 inch pipe : 30 – 35 N·m rules must be observed. (3.0 –...
Page 1451 AIR CONDITIONING (OPTIONAL) 1B-17 REFRIGERATING SYSTEM 1. Receiver/Dryer 2. Sight glass 3. Bubbles A. CHARGE OF REFRIGERANT The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its max. cooling capacity for a few minutes.
Page 1452 1B-18 AIR CONDITIONING (OPTIONAL) B. CONDENSER Inspection Check a) condenser fins for blockage, b) condenser fittings for leakage, and c) condenser fins for damage. Clogged condenser fins should be washed with water, and should be dried with compressed air. NOTE: Be careful not to damage condenser fins.
Page 1453 AIR CONDITIONING (OPTIONAL) 1B-19 9) Disconnect fan motor wire at coupler. 10) Remove condenser together with fan and receiver/dryer. NOTE: Be careful not to damage fins of condenser and radiator. 11) Remove cooling fan and receiver/dryer from condenser. Installation Reverse removal sequence to install condenser, noting following point.
Page 1454 1B-20 AIR CONDITIONING (OPTIONAL) D. EVAPORATOR (COOLING UNIT) Removal 1) Disconnect negative (–) cable at battery. 2) Disable air bag system. Refer to “Disabling Air Bag System” in Section 9J. 3) Recover refrigerant by using recovery and recycling equip- ment. Be sure to follow the instruction manual for the equip- ment.
Page 1455 AIR CONDITIONING (OPTIONAL) 1B-21 Inspection 1) Check evaporator fins for blockage. If found clogged, use com- pressed air to clean the fins. NOTE: Do not use water for cleaning of evaporator. 2) Check inlet and outlet fittings for crack or scratch. Repair them as required.
Page 1456 1B-22 AIR CONDITIONING (OPTIONAL) F. EVAPORATOR THERMISTOR A thermistor is a temperature sensor to sense the temperature of air discharge from evaporator. The electrical characteristic is shown left. When temperature is lower than specified, amplifier makes mag- net clutch turn off to prevent evaporator from frosting. Removal Refer to items REMOVAL and DISASSEMBLY in the section of EVAPORATOR.
Page 1457 AIR CONDITIONING (OPTIONAL) 1B-23 G. REFRIGERANT LINES Inspection 1) Use a leak tester to check hoses and pipes for any gas leakage. 2) Check each hose or pipe clamp for tightness. Retighten or replace loose clamp as required, if any. Removal 1) Recover refrigerant by using recovery and recycling equip- ment.
Page 1458 1B-24 AIR CONDITIONING (OPTIONAL) ADJUSTMENT OF IDLE SPEED WITH A/C ON Refer to “6E1” or “6E2” of ELECTRONIC FUEL INJECTION sec- tion. DUAL PRESSURE SWITCH This vehicle is equipped with switch which operates according to high or low pressure. Inspection 1) Check switches for continuity at normal temperature (approx.
Page 1459 AIR CONDITIONING (OPTIONAL) 1B-25 COMPRESSION SYSTEM General Information When servicing the compressor, keep dirt or foreign The operations described below are based on bench material away from getting on or into the compressor overhaul with compressor removed from the vehicle, parts and system.
Page 1460 1B-26 AIR CONDITIONING (OPTIONAL) A. COMPRESSOR Inspection 1) Install manifold gauge set, referring to “Troubleshooting pro- cedure using manifold gauge set” in this section. 2) Run engine at fast idle. 3) Check compressor for the following: i) High pressure gauge reading is not low and low pressure gauge reading is not higher than normal.
Page 1461 AIR CONDITIONING (OPTIONAL) 1B-27 Installation Reverse removal procedure noting the following point. 1) Tighten (a) first, and then (b). Tightening Torque (a), (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) 2) Pour new compressor oil by the same amount as that drained from compressor.
Page 1462 1B-28 AIR CONDITIONING (OPTIONAL) C. DRIVE BELT (FOR 1.3L and 1.6L ENGINE MODELS) Inspection 1) Check belt for wear and crack, and replace it as required. 2) Check belt tension by measuring how much it deflects when pushed at intermediate point between Power Steering (P/S) pump pulley and crank pulley with about 100 N (10 kg, 22 Ib) force.
Page 1463 AIR CONDITIONING (OPTIONAL) 1B-29 E. MAGNET CLUTCH 1. Armature plate screw 2. Armature plate 3. Circlip 4. Magnet clutch 5. Washer 6. Shim 7. Oil felt ring 8. Magnet clutch coil 9. Lip type seal 10. Compressor front head 11. Compressor body assembly 12.
Page 1464 1B-30 AIR CONDITIONING (OPTIONAL) 4) Remove lead wire clamp. 5) Remove felt ring and shims from shaft. 6) Using special tool (C), remove circlip. Special Tool (C): 09900-06107 7) Remove magnet clutch lead wire clamp screw, and disconnect magnet clutch read wire. 8) Remove magnet clutch with puller.
Page 1465 AIR CONDITIONING (OPTIONAL) 1B-31 5) Adjust clearance, between armature plate and magnet clutch by putting shim on compressor shaft. Standard clearance “a”: 0.3 – 0.5 mm (0.012 – 0.020 in.) 6) Tighten new armature plate screw as specified below. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) Special Tool (A): 09991-06020...
Page 1466 1B-32 AIR CONDITIONING (OPTIONAL) F. LIP TYPE SEAL Removal 1) Remove magnet clutch, referring to “C. MAGNET CLUTCH” in this section. 2) Remove front head mounting screw (8 pcs). 1. Case 2. Front head 3) Remove front head pushing cylinder shaft. NOTE: Be careful not to remove cylinder from case.
Page 1467 AIR CONDITIONING (OPTIONAL) 1B-33 2) Coat special tool (F) surface with oil and install it to the shaft. Special Tool (F): 09991-06040 3) Install O-ring to case. 4) Apply A/C oil to lip seal and O-ring. 5) Install front head assembly. 1.
Page 1468 1B-34 AIR CONDITIONING (OPTIONAL) PERFORMANCE TEST After finishing all repairs, make sure to carry out performance test of air conditioning system as follows. PROCEDURE 1) Connect high and low side charging hose of manifold gauge set to hose fittings of compressor. 2) Run engine, and keep compressor speed at 2,000 rpm.
Page 1469 AIR CONDITIONING (OPTIONAL) 1B-35 HOW TO READ RELATIVE HUMIDITY (5F) Measure wet-bulb temperature and dry-bulb temperature on the psychrometer at the evaporator air inlet, follow lines at those temperatures and read the relative humidity curve at their intersection. Example: If dry-bulb temperature is 905F and wet-bulb temperature is 785F, the relative humidity is HOW TO READ RELATIVE HUMIDITY (5C) Measure wet-bulb temperature and dry-bulb...
Page 1470 1B-36 AIR CONDITIONING (OPTIONAL) SPECIAL TOOLS 09900-06107 09900-06108 Snap ring pliers Snap ring pliers 09991-06030 09991-06040 (Opening type) (Closing type) Armature plate remover Lip type seal protector 09991-06050 09991-06020 09991-06010 Lip type seal installer Armature plate spanner Magnet clutch pulley installer...
Page 1471 D Service on or around Air Bag System Components or Wiring must be performed only by an au- thorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in SEC- TION 9J under “On-Vehicle Service” and the Air Bag System Component and Wiring Location view in SECTION 9J before performing service on or around Air Bag System Components or Wiring.
Page 1472 3-2 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) GENERAL DIAGNOSIS Since the problems in steering, suspension, wheels and tires 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 1473 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) 3-3 GENERAL DIAGNOSIS CHART B Condition Possible Cause Correction Shimmy, Shake or 1. Tire or wheel out of balance. Balance wheels or replace tire and/or wheel. Vibration 2. Loose wheel bearings. Replace wheel bearing. 3.
Page 1474 3-4 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) GENERAL DIAGNOSIS CHART C Condition Possible Cause Correction Rack and Pinion Noise 1. Loose steering gear case bolts. Tighten. (Rattle or Chuckle) 2. Worn rack bush. Replace. 3. Rack and pinion adjustment. Check and adjust rack & pinion torque. (Manual steering only.) Abnormal Noise, 1.
Page 1475 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) 3-5 GENERAL DIAGNOSIS CHART D Condition Possible Cause Correction Low or Uneven Trim 1. Broken or sagging springs. Replace. Height 2. Over loaded. Check loading. Right-to-left trim height 3. Incorrect springs. Replace. (H) difference should be within 15 mm (0.6 in) with curb weight.
Page 1476: Wear Indicators
3-6 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear has many causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, im- proper alignment. If the following conditions are noted, rotation is necessary: 1) Front tire wear is different from rear.
Page 1477 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) 3-7 1) Ride vehicle to determine whether the front or rear waddles. 2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end of ve- hicle.
Page 1478 3-8 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment. 2) Uneven brake adjustment.
Page 1479 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ......Preliminary Checks Prior to Adjusting Front Alignment .
Page 1480 3A-2 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel.
Page 1481 FRONT END ALIGNMENT 3A-3 STEERING ANGLE When tie rod or tie rod end was replaced, check toe and then also steering angle with turning radius gauge. If steering angle is not correct, check if right and left tie rods are equal in length ( “A”...
Page 1482 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are per- forming service on or near the air bag system components or wiring.
Page 1483 3B-2 MANUAL RACK AND PINION GENERAL DESCRIPTION The rack and pinion steering system consists of two main components, the rack and the pinion. When the steering wheel is turned, the motion is transmitted to the steering shaft, shaft joint and then to the pinion. Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear motion.
Page 1484 MANUAL RACK AND PINION 3B-3 ON-VEHICLE SERVICE LUBRICATION *SUZUKI SUPER GREASE (E) 99000-25050, When inner parts of the steering gear case were or Lithium grease (applicable for -405C 1305C disassembled, they should be washed clean be- or -405F 2665F) fore reassembly.
Page 1485 3B-4 MANUAL RACK AND PINION REMOVE AND INSTALL MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE) REMOVAL 1) Slide driver’s seat as far back as possible. 2) Pull off front part of floor mat on driver’s side and remove steer- ing shaft joint covers.
Page 1486 MANUAL RACK AND PINION 3B-5 INSTALLATION 1) Mount steering gear case to body and tighten gear case mount bolts to specified torque. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) 1. Vehicle body 3. Case mount bolt 2. Steering gear case 4.
Page 1487 3B-6 MANUAL RACK AND PINION REMOVE AND INSTALL RACK BOOT/TIE REMOVAL 1) Remove steering gear case by performing Steps 1) to 8) in STEERING GEAR CASE REMOVAL of this section. 2) For ease of adjustment after installation, make marking of tie rod end lock nut position of tie rod thread.
Page 1488 MANUAL RACK AND PINION 3B-7 INSTALLATION 1. Steering rack 2. Tie rod lock washer 1) Install new tie rod lock washer as shown and tie rod to rack. 3. Tie rod Align straight part “A” of washer with flat part “B” of rack. 2) Tighten tie rod inside ball to specified torque.
Page 1489 4. Rack damper screw lock nut INSTALLATION 1) Apply grease lightly to sliding part of plunger against rack. Grease: SUZUKI SUPER GREASE E (99000-25050) 2) Install rack plunger, rack plunger spring, rack damper screw to steering case in direction shown. Tighten rack damper screw to specified torque.
Page 1490 MANUAL RACK AND PINION 3B-9 REMOVE AND INSTALL STEERING PINION REMOVAL 1) Remove rack plunger. 2) Remove bearing plug with special tool (A). Special Tool (43 mm socket) (A): 09944-26011 3) Tap on position as shown with plastic hammer to separate pin- ion assembly from housing.
Page 1491 3B-10 MANUAL RACK AND PINION REMOVE AND INSTALL STEERING RACK REMOVAL 1) Remove steering gear case. 2) Remove boot wires and clips. 3) Move both boots toward tie rod end. 4) Unbend bent part of tie rod lock washers and remove tie rods from right and left sides of steering rack.
Page 1492 MANUAL RACK AND PINION 3B-11 REMOVE AND INSTALL PINION BEARING REMOVAL 1) Remove rack from steering gear case, referring to STEERING RACK REMOVAL of this section. 2) Pull out pinion bearing from gear case with special tools (A)and (B) as shown. Special Tools (A): 09921-20200 (B): 09930-30104...
Page 1493 3B-12 MANUAL RACK AND PINION REMOVE AND INSTALL RACK BUSHING REMOVAL NOTE: When removing rack bushing, be careful not to pull out bush- ing by holding gear case in a vise. Or housing (pipe) may come off gear case. For this work, be sure to use the specified spe- cial tool.
Page 1494 MANUAL RACK AND PINION 3B-13 RACK AND PINION INSPECTION STEERING RACK BOOT Hoist vehicle. Inspect each boot for tear. A torn boot allows entry of dust and wa- ter which can cause wear to steering rack and pinion to produce noise as well as rust to result in malfunction of steering system.
Page 1495: Steering Rack
3B-14 MANUAL RACK AND PINION RACK PLUNGER 1) Inspect rack plunger for wear or damage. 2) Inspect rack plunger spring for deterioration. In either case, if found defective, replace. 1. Rack plunger 2. Plunger spring STEERING PINION 1) Inspect pinion teeth surface for wear or damage. 2) Inspect oil seal for damage.
Page 1496 MANUAL RACK AND PINION 3B-15 STEERING WHEEL Check steering wheel for play and rattle, holding car in straight for- ward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.2 in.) If steering wheel play is not within specification, inspect as follows and replace if found defective.
Page 1497 3B-16 MANUAL RACK AND PINION REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Sliding part of rack against steering hous- ing (All around rack plunger, rack bushing and rack) D Sliding part against steering pinion (Oil seal Lithium grease SUPER GREASE (E)
Page 1498 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are per- forming service on or near the air bag system components or wiring.
Page 1499 3B1-2 POWER STEERING (P/S) SYSTEM GENERAL DESCRIPTION The power steering (P/S) system in this vehicle reduces the driver’s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all built in the steering gear box.
Page 1500 POWER STEERING (P/S) SYSTEM 3B1-3 STEERING GEAR BOX The steering gear box consists of two sections: one including a cyl- inder and the other a valve. Main components of the cylinder sec- tion are a gear box, a rack and a tube and those of the valve section are a valve case, a sleeve and a stub shaft.
Page 1501 3B1-4 POWER STEERING (P/S) SYSTEM POWER STEERING (P/S) PUMP The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft. 1. Suction connector 2. O-ring 3. Pressure switch 4. Flow control valve (Relief valve) 5.
Page 1502 POWER STEERING (P/S) SYSTEM 3B1-5 FLOW CONTROL VALVE As the discharge rate of the P/S pump increases in proportion to the pump revolution speed, a flow control valve is added to control it so that the optimum amount of fluid for steering operation is sup- plied according to the engine speed (driving condition).
Page 1503 3B1-6 POWER STEERING (P/S) SYSTEM RELIEF VALVE The relief valve located in the flow control valve controls the maxi- mum hydraulic pressure. The steel ball in the relief valve is under the hydraulic pressure in the circuit coming through orifice A .
Page 1504 POWER STEERING (P/S) SYSTEM 3B1-7 DIAGNOSIS Condition Possible Cause Correction D Fluid deteriorated, low viscosity, different type of Steering wheel feels Replace fluid. heavy fluid mixed D Pipes or hoses deformed, air entering through (at low speed) Replace defective part. joint D Insufficient air purging from P/S circuit Purge air.
Page 1505 3B1-8 POWER STEERING (P/S) SYSTEM Condition Possible Cause Correction D Mismatched or uneven tire Vehicle pulls to Replace tire. D Low or uneven tire inflation pressure one side during Inflate tires to proper pressure or straight driving adjust right & left tires inflation pressure.
Page 1506 POWER STEERING (P/S) SYSTEM 3B1-9 ON-VEHICLE SERVICE INSPECTION STEERING WHEEL PLAY Check steering wheel for looseness or rattle by trying to move it in its shaft direction and lateral direction. If found defective, repair or replace. Check steering wheel for play, holding car in straight forward condi- tion on the ground and with engine stopped.
Page 1507 3B1-10 POWER STEERING (P/S) SYSTEM POWER STEERING BELT For vehicle equipped with A/C (1.3 L and 1.6 L engine models) 1) Detach air cleaner assembly from body and shift its position. Push 2) Check that belt is free from any damage and properly fitted in pulley groove.
Page 1508 POWER STEERING (P/S) SYSTEM 3B1-11 GENERATOR BELT (1.8 L engine model) Vehicle without A/C 1) Remove engine under cover of right side from vehicle body. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found replace generator belt by refer- ring to “GENERATOR BELT”...
Page 1509 3B1-12 POWER STEERING (P/S) SYSTEM FLUID LEAKAGE Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided. Then visually check gear box, P/S pump and P/S fluid reservoir themselves and each joint of their connecting pipes for leakage.
Page 1510 POWER STEERING (P/S) SYSTEM 3B1-13 HYDRAULIC PRESSURE IN P/S CIRCUIT [1.3 L and 1.6 L engine models] 1) After cleaning joint of high pressure hose and P/S pump thor- oughly, disconnect hose from pump and install special tool (oil pressure gauge, attachment and hose). Tighten each flare nut to specified torque.
Page 1511 3B1-14 POWER STEERING (P/S) SYSTEM 5) Check relief pressure D Increase engine speed to about 1,500 r/min (rpm). Close gauge valve gradually while watching pressure increase in- dicated by gauge and take reading of relief pressure (maxi- mum hydraulic pressure). Relief pressure: 7200 –...
Page 1512 POWER STEERING (P/S) SYSTEM 3B1-15 TIE ROD END BOOT Check boot for crack and damage and if any, replace it with a new one. STEERING SHAFT JOINT Check each shaft joint for wear, breakage and any other damage and if any, replace it with a new one. AIR BLEEDING PROCEDURE 1) Jack up the front end of vehicle and apply safety stands.
Page 1513 3B1-16 POWER STEERING (P/S) SYSTEM REMOVE, INSPECT AND INSTALL TIE ROD REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove split pin and tie rod end castle nut. 1. Tie rod end 2. Knuckle 3. Castle nut 4. Split pin 3) Using special tool, remove tie rod end from knuckle.
Page 1514 POWER STEERING (P/S) SYSTEM 3B1-17 3) Bend split pin as shown in figure. 1. Castle nut 2. Split pin 4) After installing wheels, lower vehicle and tighten wheel nuts to specified torque. 5) Check that proper amount of toe-in is obtained. (Refer to FRONT WHEEL ALIGNMENT.) 6) After confirming proper amount of toe-in, tighten tie rod end lock nut to specified torque.
Page 1515 3B1-18 POWER STEERING (P/S) SYSTEM REMOVE AND INSTALL POWER STEERING GEAR BOX POWER STEERING GEAR BOX COMPONENTS [1.3 L and 1.6 L engine models] [1.8 L engine model] 1. Steering pinion side mount 2. Steering rack side mount 3. Gasket 4.
Page 1516 POWER STEERING (P/S) SYSTEM 3B1-19 REMOVAL 1) Take out fluid in P/S fluid reservoir with syringe or such. 2) After removing joint covers, loosen steering shaft upper joint bolt (but it must not be removed) and remove lower joint bolt. CAUTION: Be sure to set front wheels (tires) in straight direction and remove ignition key from key cylinder before the...
Page 1517 3B1-20 POWER STEERING (P/S) SYSTEM 8) [1.8 L engine model] [1.8 L engine model] i) Remove engine under cover (both sides), exhaust pipe No.2 and mounting member. ii) Remove exhaust pipe rear stiffener. iii) Remove engine rear mounting bracket No.2 with engine rear mounting bracket from engine block and transmission case.
Page 1518 POWER STEERING (P/S) SYSTEM 3B1-21 D Use specified torque as given below. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) (b): 20 N·m (2.0 kg-m, 14.5 lb-ft) (c): 33 N·m (3.3 kg-m, 24.0 lb-ft) (d): 35 – 55 N·m (3.5 – 5.5 kg-m, 25.5 – 39.5 lb-ft) (e): 25 N·m (2.5 kg-m, 18.0 lb-ft) D For installing each part, refer to respective section as indicated be- low.
Page 1519 3B1-22 POWER STEERING (P/S) SYSTEM REMOVE AND INSTALL TIE ROD/RACK BOOT REMOVAL Make marking here. 1) Remove steering gear box from vehicle referring to STEERING GEAR BOX REMOVAL in this section. 2) For ease of adjustment after installation, make marking of tie rod end lock nut position of tie rod thread.
Page 1520 POWER STEERING (P/S) SYSTEM 3B1-23 5) Install tie rod end lock nut and tie rod end to tie rod. Position lock nut to marking made in removal. Marking made in removal. NOTE: When tie rod was replaced, measure length “A” on re- moved tie rod and use it on new replacement tie rod so as to position lock nut properly.
Page 1521 3B1-24 POWER STEERING (P/S) SYSTEM REMOVE AND INSTALL POWER STEERING PUMP COMPONENTS [1.3 L and 1.6 L engine models] Tightening Torque (a) : 55 N·m (5.5 kg-m, 40.0 lb-ft) (b) : 10 N·m (1.0 kg-m, 7.5 lb-ft) (c) : 35 N·m (3.5 kg-m, 25.5 lb-ft) (d) : 65 N·m (6.5 kg-m, 47.5 lb-ft) [1.8 L engine model] 1.
Page 1522 POWER STEERING (P/S) SYSTEM 3B1-25 REMOVAL (1.3 L and 1.6 L engine models) NOTE: Be sure to clean each joint of suction and discharge sides thoroughly before removal. 1) Remove engine under cover of right side, loosen belt tension pulley and remove P/S V-ribbed belt. 2) Disconnect high pressure hose and suction hose from pump.
Page 1523 3B1-26 POWER STEERING (P/S) SYSTEM 4) Disconnect high pressure hose and suction hose from power steer- ing pump. As fluid flows out of disconnected joints, put a container under joints or a plug to hose. CAUTION: When disconnecting, take care not to cause damage to generator.
Page 1524 POWER STEERING (P/S) SYSTEM 3B1-27 DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP DISASSEMBLY 1) Clean its exterior thoroughly. 2) With aluminum plates placed on vise first, grip pump body with 3) Remove suction connector bolt, suction connector and O-ring from pump body. 4) Remove power steering pressure switch (terminal set) from pump body.
Page 1525 3B1-28 POWER STEERING (P/S) SYSTEM Rotor and Vane D Check sliding surfaces of rotor and vane for wear and damage. D Check clearance between rotor and vane. Clearance: Standard 0.01 mm (0.0004 in.) Limit 0.06 mm (0.0023 in.) Replace pump assembly if any defect is found in above checks. 1.
Page 1526 POWER STEERING (P/S) SYSTEM 3B1-29 REASSEMBLY Reverse disassembly procedure for assembly, noting the follow- ing. 1) Apply grease to oil seal lip and apply power steering fluid to slid- ing surface of the shaft then insert pulley’s shaft from oil seal side of the pump body.
Page 1527 3B1-30 POWER STEERING (P/S) SYSTEM 9) Apply power steering fluid to each vane. 10) Install vanes (10 pieces) to rotor. 1. Rotor 2. Vane 11) Apply power steering fluid to O-ring. 12) Install O-ring to pump body. 1. O-ring 13) Apply power steering fluid to sliding surface of pump cover and rotor.
Page 1528 POWER STEERING (P/S) SYSTEM 3B1-31 16) Apply power steering fluid to O-ring of terminal switch. 1. Pressure switch 17) Install pressure switch to pump body. Tightening Torque (b): 28 N m (2.8 kg-m, 20.0 lb-ft) 18) Apply power steering fluid to relief valve (flow control valve). 19) Install relief valve (flow control valve) to pump body.
Page 1529 3B1-32 POWER STEERING (P/S) SYSTEM TORQUE SPECIFICATIONS Tightening torque Fastening Parts Fastening Parts N·m kg-m lb-ft 1. Gear box mounting bolts 40.0 2. Gear box cylinder pipe flare nuts 14.5 3. Gear box high & low pressure pipe flare nuts 24.0 4.
Page 1530 POWER STEERING (P/S) SYSTEM 3B1-33 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT SUPER GREASE (A) D Oil seal lip of P/S pump pulley shaft Lithium grease (99000-25010) D Sliding part of rack against steering housing Lithium grease D Steering rack and pinion gear teeth...
Page 1531 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-1 SECTION 3C STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) NOTE: D All steering wheel and column fasteners are important parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 1532 3C-2 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) GENERAL DESCRIPTION The double tube type steering column has three important features in addition to the steering function: 1) The column is energy absorbing, designed to compress in a front-end collision to minimize the possibility of an injury to the driver of the vehicle.
Page 1533 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-3 For 4-spoke type For 4-spoke type steering wheel and tilt steering column 1. Steering wheel pad 2. Steering wheel nut 3. Steering wheel bumper 4. Steering wheel 5. Steering wheel lower cover 6.
Page 1534 3C-4 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) ON-VEHICLE SERVICE STEERING WHEEL For 3-spoke type REMOVAL 1) Disconnect negative battery cable. 2) Pull out steering wheel pad, and then remove it by turning it counterclockwise. 1. Pad 3) Remove screw of horn harness. 4) Remove steering wheel bumper from Steering wheel.
Page 1535 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-5 For 4-spoke type REMOVAL 1) Disconnect negative battery cable. 2) Remove pad screw. 3) Remove pad by pulling it upward and disconnect horn harness. 4) Remove steering shaft nut. 5) Make alignment marks on steering wheel and shaft for a guide during reinstallation.
Page 1536 3C-6 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) COMBINATION SWITCH REMOVAL 1) Disconnect negative battery cable. 2) Before removing this switch, remove steering wheel. Refer to “STEERING WHEEL” earlier in this section. 3) Remove hole cover. 1. Hole cover 4) Remove steering column cover screws (3 pcs).
Page 1537 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-7 10) Remove combination switch from steering column. 1. Combination switch assembly INSPECTION Check combination switch wire harness for any signs of scorching, melting or other damage. If it is damaged, replace. INSTALLATION 1) Install combination switch to steering column.
Page 1538 3C-8 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 7) Install hole cover. 1. Hole cover 8) Install steering wheel to its shaft. Refer to “STEERING WHEEL” earlier in this section. 9) Connect battery negative cable. STEERING COLUMN CAUTION: D Once the steering column is removed from the vehicle, the column is extremely susceptible to damage.
Page 1539 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-9 3) Remove hole cover. 1. Hole cover 4) Loosen clamp. 5) Remove band binding steering column and harness (for com- bination switch). 6) Disconnect white 4-P connector (for auto cruise, optional). 7) Disconnect three connectors for combination switch wire har- ness from junction/fuse block.
Page 1540 3C-10 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 11) Remove steering column mounting nuts (4 pcs). 12) If equipped with shift (key) interlock cable, remove shift (key) interlock cable screw and then disconnect its cable from igni- tion switch with ignition switch turned at “ACC” position. After disconnecting, turn ignition switch to “LOCK”...
Page 1541 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-11 2) Take measurement “b” as shown. If it is shorter than specified length, replace column assembly with new one. Length “b”: 513 mm (20.20 in.) 3) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play.
Page 1542 3C-12 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 5) Install bolt to steering shaft upper joint and tighten it to speci- fied torque. NOTE: After tightening column nuts, bolt to steering shaft upper joint should be tightened. Tightening Torque (c): 25 N·m (2.5 kg-m, 18.0 lb-ft) 1.
Page 1543 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-13 STEERING LOCK (IGNITION SWITCH) REMOVAL 1) Disconnect negative battery cable. 2) Remove steering column. Refer to “STEERING COLUMN” ear- lier in this section. 1. Steering column 2. Steering lock 3) Using center punch as shown, loosen and remove steering lock 1.
Page 1544 3C-14 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) STEERING SHAFT LOWER JOINT REMOVAL 1) Turn steering wheel so that vehicle’s front tires are at straight- ahead position. 2) Turn ignition switch to “LOCK” position and remove key. 3) Remove hole cover. 1.
Page 1545 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-15 INSTALLATION 1) Align flat part of lower joint shaft with bolt hole of upper joint as shown. Then insert lower joint shaft into upper joint. 2) Be sure that front wheels and steering wheel are in straight- for- ward state and insert lower joint into steering pinion shaft.
Page 1546 3C-16 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) CHECKING STEERING COLUMN FOR AC- CIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering col- umn.
Page 1547 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-17 TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts N·m kg-m lb-ft 1. Steering shaft nut 23.5 2. Steering shaft joint bolts 18.0 3. Steering column mounting nuts 10.5 SPECIAL TOOL 09944-36011 Steering wheel remover...
Page 1548 AIR BAG STEERING WHEEL AND COLUMN 3C1-1 SECTION 3C1 AIR BAG STEERING WHEEL AND COLUMN WARNING: The procedures in this section must be followed in the order listed to temporarily disable the Air Bag System and prevent false diagnostic codes from setting. Failure to follow procedures could result in possible air bag deployment, personal injury or other- wise unneeded air bag system repairs.
Page 1549 3C1-2 AIR BAG STEERING WHEEL AND COLUMN GENERAL DESCRIPTION STEERING COLUMN This double tube type steering column has following three important features in addition to the steering function: D The column is energy absorbing type, designed to contract in a front-end collision. D The ignition switch and lock are mounted conveniently on this column.
Page 1550: Service Precautions
AIR BAG STEERING WHEEL AND COLUMN 3C1-3 ON-VEHICLE SERVICE SERVICE PRECAUTIONS D WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to follow the instructions. WARNING: When performing service on or around air bag system components or air bag system wiring, follow the procedures listed below to temporarily disable the air bag system.
Page 1551 3C1-4 AIR BAG STEERING WHEEL AND COLUMN ENABLING AIR BAG SYSTEM 1) Turn ignition switch to “LOCK” and remove key. 2) Connect Yellow connector of passenger air bag (inflator) mod- ule and Yellow connector of driver air bag (inflator) module re- spectively, and be sure to lock each connector with lock lever.
Page 1552 AIR BAG STEERING WHEEL AND COLUMN 3C1-5 D When grease, cleaning agent, oil water, etc., got on the air bag ALWAYS CARRY AIR BAG (INFLATOR) MODULE (inflator) modules (driver and passenger), wipe it off immediately WITH TRIM COVER with a dry cloth. (AIR BAG OPENING) AWAY FROM BODY.
Page 1553 3C1-6 AIR BAG STEERING WHEEL AND COLUMN Contact Coil and Combination Switch Assembly Do not turn contact coil (on combination switch) more than allow- able number of turns (about two and a half turns from the center positIon clockwise or counterclockwise respectively), or coil will break.
Page 1554 AIR BAG STEERING WHEEL AND COLUMN 3C1-7 DRIVER AIR BAG (INFLATOR) MODULE WARNING: When handling an air bag (inflator) module, be sure to read “HANDLING PRECAUTIONS” given earlier in this section and observe each instruction. Failure to follow them could cause a damage to the air bag (inflator) mod- ule or result in personal injury.
Page 1555 3C1-8 AIR BAG STEERING WHEEL AND COLUMN Check air bag (inflator) module visually and if any of the following is found, replace it with a new one. D Air bag being deployed D Trim cover (pad surface) being cracked D Wire harness or connector being damaged D Air bag (inflator) module being damaged or having been ex- posed to strong impact (dropped) 1.
Page 1556 AIR BAG STEERING WHEEL AND COLUMN 3C1-9 STEERING WHEEL CAUTION: Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil (on the com- bination switch) more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively), or coil will break.
Page 1557 3C1-10 AIR BAG STEERING WHEEL AND COLUMN 3) Turn contact coil counterclockwise slowly with a light force till contact coil will not turn any further. NOTE: Contact coil can turn about 5 turns at maximum, that is, if it is at the center position, can turn about two and a half turns both clockwise and counterclockwise.
Page 1558 AIR BAG STEERING WHEEL AND COLUMN 3C1-11 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY CAUTION: Do not turn contact coil (on combination switch) more than allowable number of turns (about two and a half turns from the center position clockwise or counter- clockwise respectively), or coil will break.
Page 1559 3C1-12 AIR BAG STEERING WHEEL AND COLUMN 10) Disconnect three connectors for contact coil and combination switch wire harness from junction/fuse block. 1. Junction/fuse block 11) Remove contact coil and combination switch assembly from steering column. 1. Contact coil and combination switch assembly INSPECTION Check contact coil and combination switch wire harness for any signs of scorching, melting or other damage.
Page 1560 AIR BAG STEERING WHEEL AND COLUMN 3C1-13 3) Connect three connectors for contact coil and combination switch wire harness to junction/fuse block. 1. Junction/fuse block 4) Connect yellow connector (for air bag) and white 4-P connec- tor (for auto cruise, optional). 5) Tighten clamp and band for contact coil and combination switch wire harness.
Page 1561 3C1-14 AIR BAG STEERING WHEEL AND COLUMN STEERING COLUMN CAUTION: D Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. D Dropping the column assembly on its end could col- lapse the steering shaft. D Loosen the plastic shear pins which maintain column length.
Page 1562 AIR BAG STEERING WHEEL AND COLUMN 3C1-15 8) Disconnect three connectors for contact coil and combination switch assembly wire harness from junction/fuse block. 1. Junction/fuse block 9) Disconnect three connectors for ignition switch wire harness from junction/fuse block. 1. Junction/fuse block 10) Remove steering joint upper cover.
Page 1563 3C1-16 AIR BAG STEERING WHEEL AND COLUMN 14) Remove steering column from vehicle. WARNING: Never rest a steering column assembly on the steer- ing wheel with the air bag (inflator) module face down and column vertical. Otherwise, personal inju- ry may result. INSPECTION NOTE: Vehicles involved in accidents resulting in body damage,...
Page 1564 AIR BAG STEERING WHEEL AND COLUMN 3C1-17 INSTALLATION 1) Align flat part “A” of lower joint shaft with bolt hole “B” of upper side joint of steering column as shown. Then insert upper side joint of steering column into lower joint shaft. 1.
Page 1565 3C1-18 AIR BAG STEERING WHEEL AND COLUMN 7) Connect three connectors for ignition switch wire harness from junction/fuse block. 8) If contact coil and combination switch assembly is removed, install contact coil and combination switch assembly. Refer to “Contact Coil and Combination Assembly” earlier in this section.
Page 1566 AIR BAG STEERING WHEEL AND COLUMN 3C1-19 STEERING LOCK (IGNITION SWITCH) REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Disable air bag system. Refer to “Disabling Air Bag System” un- der “Service Precautions” earlier in this section. 3) Remove steering column. Refer to “STEERING COLUMN” ear- lier in this section.
Page 1567 3C1-20 AIR BAG STEERING WHEEL AND COLUMN STEERING SHAFT LOWER JOINT CAUTION: Never turn steering wheel while steering shaft lower joint is removed. Should it have been turned and contact coil (on combina- tion switch) have got out of its centered position, it needs to be centered again.
Page 1568 AIR BAG STEERING WHEEL AND COLUMN 3C1-21 TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts N·m kg-m Ib-ft 1. Steering shaft nut 23.5 2. Steering shaft joint bolts 18.0 3. Steering column mounting nuts 10.5 4. Driver air bag (inflator) module bolts 17.0 SPECIAL TOOLS 09944-36011...
Page 1569: Front Suspension
FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION NOTE: D All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 1570 3D-2 FRONT SUSPENSION GENERAL DESCRIPTION The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehicle body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also installed a little lower to the rubber mount.
Page 1571 FRONT SUSPENSION 3D-3 1. Nut 2. Support 3. Bearing 4. Coil spring upper seat 5. Coil spring seat 6. Dust cover 7. Bump stopper 8. Coil spring 9. Coil spring lower seat 10. Strut...
Page 1572 3D-4 FRONT SUSPENSION ON-VEHICLE SERVICE REMOVE AND INSTALL STABILIZER BAR AND/OR BUSHINGS 1. Stabilizer bar 2. Mount bush 3. Mount bracket 4. Joint 5. Joint nut 6. Link washer 7. Link cushion 8. Centering washer 9. Mount bolt 10. Link nut REMOVAL 1) Remove stabilizer link nuts, washers and cushions.
Page 1573 FRONT SUSPENSION 3D-5 REMOVE AND INSTALL STRUT ASSEMBLY NOTE: When disassembling strut assembly, loosen strut nut a little before removing strut assembly from vehicle. This will make disassembly easier. Note, however, nut must not be removed at this point. REMOVAL 1) Hoist vehicle, allowing front suspension to hang free.
Page 1574 3D-6 FRONT SUSPENSION INSTALLATION 1) Install strut assembly by reversing REMOVAL Steps 1) – 7). Insert bolts in such a direction as shown. 2) Torque all fasteners to specification. Tightening Torque (a): 28 N·m (2.8 kg-m, 20.5 lb-ft) (b): 90 N·m (9.0 kg-m, 65.0 lb-ft) NOTE: Don’t twist brake hose when installing it.
Page 1575 FRONT SUSPENSION 3D-7 DISASSEMBLE AND ASSEMBLE STRUT ASSEMBLY DISASSEMBLY 1) With special tool (A) placed to spring as shown, turn special tool bolts alternately until spring tension is released. Whether it is re- leased or not can be known by whether strut turns lightly while strut spring is held stationary.
Page 1576 3D-8 FRONT SUSPENSION 2) Install coil spring lower seat and compressing coil spring, and mate spring end with stepped part of lower seat as shown. 3) Install bump stopper and dust cover onto strut rod. For installing direction, refer to above figure in DISASSEMBLY. 4) Pull strut rod as far up as possible and use care not to allow it to retract into strut.
Page 1577 FRONT SUSPENSION 3D-9 REMOVE AND INSTALL WHEEL HUB, WHEEL STUD/WHEEL BEARING OUTSIDE INNER RACE REMOVAL 1) Hoist vehicle and remove wheel. 2) Uncalk drive shaft nut. 1. Drive shaft nut 3) Depress foot brake pedal and hold it there. Remove drive shaft nut.
Page 1578 3D-10 FRONT SUSPENSION 10) Remove wheel bearing inner race. Special Tools (C): 09913-65810 (D): 09913-85230 1. Bearing inner race INSTALLATION 1. Oil hydraulic press 2. Rod Install Hub Bolts 3. Hub bolt Insert new stud in hub hole. Rotate stud slowly to assure serration are aligned with those made by original bolt.
Page 1579 FRONT SUSPENSION 3D-11 4) Install brake disc. Tightening Torque (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) 5) Install brake caliper/caliper carrier. 6) Tighten caliper carrier bolts to specified torque. Tightening Torque (b): 85 N·m (8.5 kg-m, 61.5 lb-ft) 7) Depress foot brake pedal and hold it there. Tighten new drive shaft nut to specified torque.
Page 1580 3D-12 FRONT SUSPENSION REMOVE AND INSTALL SUSPENSION ARM / BUSHING REMOVAL 1) Hoist vehicle and remove wheels. 2) Remove stabilizer link nut, washer and cushion. 3) Remove ball stud bolt. 4) Remove suspension arm front bushing bolt. 5) Remove suspension arm rear bracket bolt and nut. 6) Remove rear bracket and suspension arm.
Page 1581 FRONT SUSPENSION 3D-13 INSTALLATION 1) Install front bushing. Before installing bushing, apply soap water on its circumfer- ence to facilitate installation Install bushing in such direction shown in figure. 1. Press 2. Front bushing 3. Suspension arm 2) Install rear bushing to suspension arm as follows. First, push in rear bushing in such direction and angle as shown in figure (A) and drive it into such position as shown in figure (B).
Page 1582 3D-14 FRONT SUSPENSION REMOVE AND INSTALL KNUCKLE/BEARING REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove wheel hub. Refer to Step 2) – 8) in WHEEL HUB RE- MOVAL of this section. 3) Disconnect tie-rod end from knuckle with special tool (A). Special Tool (A): 09913-65210 1.
Page 1583 FRONT SUSPENSION 3D-15 3) Connect tie-rod end to knuckle and tighten tie-rod end castle nut to specified torque. Install new split pin. 4) For installation procedures following the above, refer to Steps 2) – 9) in WHEEL HUB INSTALLATION of this section. Split pin 1.
Page 1584 3D-16 FRONT SUSPENSION REMOVE OIL SEALS, SNAP RING AND WHEEL BEARING Once bearing outer race is removed, bearing set (outer race, bear- ings and inner races) should be replaced with new one. D Remove outside oil seal, snap ring, outside bearing and inside oil seal in that order.
Page 1585 FRONT SUSPENSION 3D-17 Inside Oil Seal With hole in inside oil seal matched with projection on knuckle (for vehicle without ABS) or wheel speed sensor installation hole in knuckle (for vehicle with ABS), drive in Oil seal until its stepped sur- face contacts knuckle by using special tools (C) and (E).
Page 1586 3D-18 FRONT SUSPENSION REMOVE AND INSTALL SUSPENSION FRAME 1. Stabilizer bar 2. Suspension arm (Left) 3. Suspension arm (Right) 4. Engine rear mounting 5. Mounting member-2WD vehicle only 6. Suspension frame 7. Washer 2WD vehicle 8. Cushion only 9. Spacer 10.
Page 1587 FRONT SUSPENSION 3D-19 INSTALLATION 1. Suspension frame 1) Install suspension frame to body, and tighten bolt to specified torque. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft) 2) Install mounting member, spacers and cushions to suspension frame if removed and tighten bolts and nuts to specified torque. Tightening Torque (b): 55 N·m (5.5 kg-m, 40.0 lb-ft) (g): 45 N·m (4.5 kg-m, 33.0 lb-ft)
Page 1588 3D-20 FRONT SUSPENSION FRONT SUSPENSION INSPECTION STABILIZER BAR AND/OR BUSHING Inspect for damage or deformation. If defective, replace. Bushing Inspect for damage, wear or deterioration. If defective, replace. 2. Stabilizer bar mount bush 3. Link cushion STRUT ASSEMBLY 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.
Page 1589 FRONT SUSPENSION 3D-21 SUSPENSION ARM/STEERING KNUCKLE Inspect for cracks, deformation or damage. SUSPENSION ARM BUSHING Inspect for damage, wear or deterioration. SUSPENSION ARM JOINT 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. NOTE: Suspension arm and arm joint cannot be separated.
Page 1590 3D-22 FRONT SUSPENSION WHEEL DISC, NUT & BEARING 1) Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. 2) Check wheel nuts for tightness and, as necessary retighten them to specification. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 3) Check wheel bearing for wear.
Page 1591 FRONT SUSPENSION 3D-23 TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts kg-m lb-ft 1. Strut Bracket nut 65.0 2. Strut nut 47.0 3. Strut support nut 20.5 4. Ball stud nut 43.5 5. Suspension arm rear bracket bolt and nut 27.0 6.
Page 1592 3D-24 FRONT SUSPENSION REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Lithic wheel bearing SUPER GREASE (A) Wheel bearing, wheel bearing oil grease (99000-25010) seal lip SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 2. 09900-00414 09913-65810 09913-85230 Hexagon wrench bit 09913-65210...
Page 1593 REAR SUSPENSION (2WD VEHICLE) 3E-1 SECTION 3E REAR SUSPENSION (2WD VEHICLE) NOTE: D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 1594 3E-2 REAR SUSPENSION (2WD VEHICLE) GENERAL DESCRIPTION The rear suspension is a strut type independent suspension equipped with control rods (dual-link) and a trailing rod. The upper end of the strut is anchored to the vehicle body by the strut support. The strut and strut support are isolated by a rubber mount.
Page 1595 REAR SUSPENSION (2WD VEHICLE) 3E-3 ON-VEHICLE SERVICE REMOVE AND INSTALL REAR STRUT ASSEMBLY 1. Strut assembly 2. Strut upper cap 3. Strut support nut 4. Strut bracket bolt 5. Strut bracket nut 6. Rear knuckle REMOVAL NOTE: When servicing component parts of strut assembly, loosen strut upper nut a little before removing strut assembly.
Page 1596 3E-4 REAR SUSPENSION (2WD VEHICLE) 4) Remove strut bracket bolts and nuts. And then take brake hose off strut bracket using care not to de- form brake pipe. 5) Remove strut support nuts. Hold strut by hand so that it will not fall off. 6) Remove strut assembly.
Page 1597 REAR SUSPENSION (2WD VEHICLE) 3E-5 DISASSEMBLE AND ASSEMBLE REAR STRUT ASSEMBLY 1. Strut upper cap 2. Strut upper nut 3. Strut support 4. Spring upper seat 5. Spring (rubber) seat 6. Strut dust cover 7. Bump stopper 8. Coil spring 9.
Page 1598 3E-6 REAR SUSPENSION (2WD VEHICLE) ASSEMBLY 1) Compress spring with special tool (A) until total length becomes about 290 mm (11.42 in.) as shown. Length “a”: 290 mm (11.42 in.) A: Upper side (small diam.) B: Lower side (large diam.) 2) Install coil spring lower seat and compressing coil spring, mate large-dia.
Page 1599 REAR SUSPENSION (2WD VEHICLE) 3E-7 8) Put strut support on spring upper seat. Tighten strut upper nut to specified torque and then apply water- proof coating (paint or lacquer) all around nut and strut rod thread. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) 9) Loosen and remove special tool (A) from compressing coil spring.
Page 1600 3E-8 REAR SUSPENSION (2WD VEHICLE) REMOVE AND INSTALL STABILIZER BAR AND/OR BUSHINGS (IF EQUIPPED) 1. Stabilizer bar 2. Mount bush 3. Mount bracket 4. Joint 5. Joint nut 6. Link nut 7. Mount bolt REMOVAL CAUTION: To avoid the risk of being burned, start your work after the exhaust system has cooled down.
Page 1601 REAR SUSPENSION (2WD VEHICLE) 3E-9 REMOVE AND INSTALL CONTROL ROD WITH STABILIZER WITHOUT STABILIZER 1. No.1 control rod 5. Control rod inner bolt (inner bolt) 10. Suspension frame cap 2. No.2 control rod 6. No.2 control rod bolt (inner bolt) 11.
Page 1602 3E-10 REAR SUSPENSION (2WD VEHICLE) 5) Remove suspension frame cap. 6) Remove No.2 control rod from suspension frame and knuckle. 7) Remove No.1 control rod from suspension frame and knuckle. 1. Suspension frame 2. Suspension frame cap 3. No.1 control rod 4.
Page 1603 REAR SUSPENSION (2WD VEHICLE) 3E-11 3) For vehicles equipped with ABS, attach ABS wheel speed sen- 1. No.2 control rod 2. ABS sensor pipe sor pipe to No.2 control rod. (if equipped) 4) Install stabilizer bar (if equipped). Refer to Step 1) thru 3) in STA- BILIZER BAR INSTALLATION of this section.
Page 1604 3E-12 REAR SUSPENSION (2WD VEHICLE) REMOVE AND INSTALL TRAILING ROD REMOVAL 1) Hoist vehicle. 2) Detach parking brake cable clamp from trailing rod. 3) Remove trailing rod bolts and trailing rod. 1. Trailing rod 2. Parking brake cable 3. Bolt INSTALLATION 1) Install trailing rod and tighten bolts by hand.
Page 1605 REAR SUSPENSION (2WD VEHICLE) 3E-13 REMOVE AND INSTALL SUSPENSION FRAME WITHOUT STABILIZER BAR WITH STABILIZER BAR 1. Suspension frame 5. No.2 control rod 2. Suspension frame cap 6. Rear strut damper 3. Suspension frame bolt 7. Stabilizer bar 4. No.1 control rod REMOVAL 1) Hoist vehicle and remove rear wheels.
Page 1606 3E-14 REAR SUSPENSION (2WD VEHICLE) 8) Remove suspension frame bolts and suspension frame. 9) Remove rear strut damper. 1. Suspension frame 2. Bolt 3. Fuel tank INSTALLATION 1) Install rear strut damper. Tightening Torque for rear strut damper 30 N·m (3.0 kg-m, 22.0 lb-ft) 2) Install suspension frame and tighten suspension frame bolts to specified torque.
Page 1607 REAR SUSPENSION (2WD VEHICLE) 3E-15 REMOVE AND INSTALL WHEEL HUB (WHEEL BEARING) ASSEMBLY AND WHEEL STUD (HUB BOLT) Wheel bearing and wheel hub form a solid unit. When wheel bearing is found defective and its replacement is nec- essary, replace hub assembly. REMOVAL 1) Hoist vehicle and remove brake disc or brake drum referring to SECTION 5.
Page 1608 3E-16 REAR SUSPENSION (2WD VEHICLE) INSTALLATION 1) Install hub bolts. Refer to FRONT WHEEL STUD INSTALLATION in SECTION 3D in the Service Manual mentioned in FOREWORD of this manual for installation procedure. 2) For ABS equipped vehicle, check ABS wheel speed sensor ro- tor for damage.
Page 1609 REAR SUSPENSION (2WD VEHICLE) 3E-17 REMOVE AND INSTALL KNUCKLE REMOVAL 1) Hoist vehicle and remove wheel hub referring to WHEEL HUB REMOVAL of SECTION 3E or 3E1. 2) Remove E ring securing brake hose. 1. E ring 2. Brake hose bracket 3) Disconnect brake pipe from wheel cylinder and put wheel cylin- der bleeder plug cap onto pipe to prevent fluid from spilling.
Page 1610 3E-18 REAR SUSPENSION (2WD VEHICLE) INSTALLATION 1) Install rear knuckle to strut, and connect control rods and trail- ing rod to knuckle. At this point, temporarily tighten them by hand. 2) Tighten strut bracket bolts and nuts to specified torque. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft) 3) Apply water tight sealant to mating surfaces of brake back...
Page 1611 REAR SUSPENSION (2WD VEHICLE) 3E-19 11) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable. (For adjustment, see SECTION 12) Tighten parking brake lever cover screws.
Page 1612 3E-20 REAR SUSPENSION (2WD VEHICLE) REMOVE AND INSTALL KNUCKLE REMOVAL 1) Hoist vehicle and remove wheel hub referring to WHEEL HUB REMOVAL in this section. 2) If the vehicle is equipped with ABS, remove rear wheel speed sensor, refer to SECTION 5B of Service Manual mentioned in FOREWORD of this manual.
Page 1613 REAR SUSPENSION (2WD VEHICLE) 3E-21 INSTALLATION 1) Install rear knuckle to strut, and connect control rods and trail- ing rod to knuckle. At this point, temporarily tighten them by hand. 2) Tighten strut bracket bolts and nuts to specified torque. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft) 1.
Page 1614 3E-22 REAR SUSPENSION (2WD VEHICLE) REAR SUSPENSION INSPECTION STRUT ASSEMBLY 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled. 2) Strut function check Check and adjust tire pressure as specified. Bounce vehicle body three or four times continuously by pushing rear end on the side with strut to be checked.
Page 1615 REAR SUSPENSION (2WD VEHICLE) 3E-23 Stabilizer joint (if equipped) 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. NOTE: Stabilizer joint cannot be disassembled. If there is any damage to either, stabilizer joint assembly must be replaced as a complete unit.
Page 1616 3E-24 REAR SUSPENSION (2WD VEHICLE) REAR SUSPENSION FASTENERS Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to TORQUE SPECIFICATIONS of this section. WHEEL DISC, NUT & BEARING D Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced.
Page 1617: Rear Wheel Alignment
REAR SUSPENSION (2WD VEHICLE) 3E-25 REAR WHEEL ALIGNMENT Among factors for rear wheel alignment, only toe setting can be ad- justed. Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to the damage caused by haz- ardous road conditions or collision, whether the damage is in body or in suspension should be determined and damaged body should be repaired or damaged suspension should be replaced.
Page 1618 3E-26 REAR SUSPENSION (2WD VEHICLE) ADJUSTMENT 1) Loosen right and left No.2 control rod inner nuts. 2) Adjust toe to satisfy specification by turning right and left No.2 control rod inner bolts (cam bolts) by the same amount. 3) After adjustment, tighten right and left nuts to specified torque while holding cam bolt with another wrench to prevent it from turning.
Page 1619 61.5 Wheel speed sensor bolt 17.0 (For vehicles equipped with ABS) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Indicated on reservoir tank cap or Brake fluid described in owner’s manual of ve- Brake reservoir tank hicle SEALING COMPOUND 366E Joint seam of knuckle and brake...
Page 1620 3E-28 REAR SUSPENSION (2WD VEHICLE) SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 2. 09900-00414 09943-17912 Hexagon wrench bit 09942-15511 09940-71431 Rear wheel hub remover (Brake drum remover) 6 mm Sliding hammer Spring compressor 09945-26010 Socket wrench 17 mm...
Page 1621 REAR SUSPENSION (4WD VEHICLE) 3E1-1 SECTION 3E1 REAR SUSPENSION (4WD VEHICLE) NOTE: D For the items not found in this section, refer to the SECTION 3E (2WD vehicle) of this manual. D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense.
Page 1622 3E1-2 REAR SUSPENSION (4WD VEHICLE) GENERAL DESCRIPTION 1. Vehicle body 2. Strut assembly 3. Rear knuckle 4. Suspension frame 5. Control rod 6. Trailing rod 7. Brake drum 8. Wheel bearing 9. Brake back plate 10. Drive shaft 11. ABS wheel speed sensor (if equipped)
Page 1623 REAR SUSPENSION (4WD VEHICLE) 3E1-3 ON-VEHICLE SERVICE REMOVE AND INSTALL SUSPENSION FRAME 1. Suspension frame 2. No.1 control rod 3. No.2 control rod 4. Differential 5. Differential mounting 6. Differential mounting bracket REMOVAL 1) Hoist vehicle and remove wheels (right and left). 2) Drain differential oil.
Page 1624 3E1-4 REAR SUSPENSION (4WD VEHICLE) 9) To facilitate reinstallation, put match marks on No.2 propeller shaft flange and differential flange. Disconnect No.2 propeller shaft from differential. 10) Remove differential, differential mounting and mounting bracket from suspension frame. 11) Remove suspension frame from vehicle body. 1.
Page 1625 REAR SUSPENSION (4WD VEHICLE) 3E1-5 REMOVE AND INSTALL WHEEL HUB, WHEEL STUD/WHEEL BEARING OUTSIDE INNER RACE REMOVAL 1) Hoist vehicle and remove wheel. 2) Uncaulk drive shaft nut. 3) Pull up parking brake lever fully and remove drive shaft nut. 4) Remove brake drum referring to BRAKE DRUM REMOVAL of SECTION 5.
Page 1626 3E1-6 REAR SUSPENSION (4WD VEHICLE) INSTALLATION 1) Install hub bolts. Refer to FRONT WHEEL STUD INSTALLATION in SECTION 3D for installation procedure. 2) Install outside inner race to wheel hub using special tool. Installing direction is as shown. Special Tool (E): 09940-53111 1.
Page 1627 REAR SUSPENSION (4WD VEHICLE) 3E1-7 REMOVE AND INSTALL KNUCKLE, WHEEL BEARING/OIL SEAL REMOVAL Once bearing outer race is removed, bearing set (outer race, bear- ings and inner races) should be replaced with new one. 1) Remove wheel hub referring to WHEEL HUB REMOVAL of this section.
Page 1628 Tightening torque Fastening parts Fastening parts kg-m lb-ft Rear suspension frame bolt 65.0 Rear drive shaft nut 17.5 126.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUPER GREASE A Lithic wheel bearing grease Wheel bearing, wheel bearing oil seal lip (99000-25010)
Page 1629 REAR SUSPENSION (4WD VEHICLE) 3E1-9 SPECIAL TOOLS 09924-84510-004 09925-88210 09913-65810 09913-75520 Bearing installer adapter (C) Bearing puller attachment Bearing puller Bearing installer 09940-53111 09942-15511 09943-17912 09944-78210 Bearing installer Sliding hammer Brake drum remover Bearing installer support 09951-18210 Oil seal remover & installer No.2...
Page 1630: Wheels And Tires
WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 1631: Replacement Tires
3F-2 WHEELS AND TIRES GENERAL DESCRIPTION TIRES This vehicle is equipped with following tire. 175/70 R13, 185/60 R14 or 195/55 R15 The tire is of tubeless type. The tire is designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressures.
Page 1632 WHEELS AND TIRES 3F-3 REPLACEMENT WHEELS Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, air leak through welds, have elongated bolt holes, if lug nuts won’t stay tight, or if they are heavily rusted. Wheels with greater runout than specification may cause objec- tional vibrations.
Page 1633 3F-4 WHEELS AND TIRES MATCHED TIRES AND WHEELS (For vehicle equipped with steel wheels) Tires and wheels are matchmounted at the assembly plant. This means that the radially stiffest part of the tire, or “high spot”, is matched to the smallest radius or “low spot” of the wheel. This is done to provide the smoothest possible ride.
Page 1634 WHEELS AND TIRES 3F-5 TIRE PLACARD The tire placard is located on the left door (right door for right-hand side steering vehicle) lock pillar and should be referred to for tire information. The placard lists the maximum load, tire size and cold tire pressure where applicable.
Page 1635 3F-6 WHEELS AND TIRES Wheel nuts must be tightened in sequence given in figure and to proper torque to avoid bending wheel or brake disc. NOTE: Before installing wheels, remove any build-up of corrosion on wheel mounting surface and brake disc mounting surface by scraping and wire brushing.
Page 1636: Balancing Wheels
WHEELS AND TIRES 3F-7 TIRE REPAIR There are many different materials and techniques on the market to repair tires. As not all of these work on all types of tires, tire manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from each tire manufacturer.
Page 1637 3F-8 WHEELS AND TIRES WARNING: Wheel spin should be limited to 35 mph (55 km/h) as indicated on speedometer. This limit is necessary because speedometer only indicates one-half of actual wheel speed when one drive wheel is spinning and the other drive wheel is stopped. Unless care is taken in limiting drive wheel spin, spinning wheel can reach excessive speeds.
Page 1638 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1639 3G-2 SUSPENSION CONTROL SYSTEM GENERAL DESCRIPTION The suspension control system consists of front and rear adjustable shock absorbers, shock absorber adjusting actuators, a mode selector switch and a suspension control module. The suspension control system is capable of setting the vehicle suspension to various damping positions by use of the mode selector switch and automatically depending on sensed informations input to the suspension control module.
Page 1640 SUSPENSION CONTROL SYSTEM 3G-3 Mode selector Mode “SPORT” “SPORT” light “SPORT” “AUTO” or switch judgment signal lights light “SPORT” signal Speedometer Vehicle speed Vehicle speed “AUTO” or “SPORT” signal (VSS) signal judgment Brake light Brake ON Dive condition switch signal judgment Ignition coil or Engine speed...
Page 1641 3G-4 SUSPENSION CONTROL SYSTEM Suspension control module and “SPORT” light operation Mode selector “SPORT” indicator light Vehicle condition Vehicle condition Mode Mode Damping force Damping force switch Diag. switch OFF Diag. switch ON For 2 seconds after Holding state be- Depending on ignition switch is SPORT/AUTO...
Page 1642 SUSPENSION CONTROL SYSTEM 3G-5 GRAVITY SENSOR Gravity sensor is installed in front of shift lever (selector lever for A/T) and consists of weight, piezoelectric element, amplifier, filter. As weight moves up and down in accordance with vertical move- ment (vibration) of vehicle, that movement, after being converted into electric signal by piezoelectric element, is transmitted through amplifier and filter to suspension control module as voltage signal.
Page 1643 3G-6 SUSPENSION CONTROL SYSTEM ENGINE SPEED SIGNAL This signal is sent from the ECM. Receiving this signal, suspension control module detects the en- gine speed. 1. Suspension control module 2. ECM 3. Tachometer VEHICLE SPEED SENSOR The vehicle speed sensor, located on the transmission, generates a signal in proportion to the vehicle speed (Signal À).
Page 1644 SUSPENSION CONTROL SYSTEM 3G-7 DIAGNOSIS SWITCH TERMINAL 1. Diagnosis connector 1 The diagnosis switch terminal is included in the diagnosis connec- 2. Diagnosis connector 2 tor 2 in the relay box. When diagnosis switch terminal is grounded, 3. Relay box 4.
Page 1645 3G-8 SUSPENSION CONTROL SYSTEM SUSPENSION CONTROL (AUTO MODE ONLY) ROLLING CONTROL DURING QUICK STEER- This control function suppresses rolling which occurs when vehicle enters a corner to improve steering stability by increasing damping force of absorber according to steering angle speed, engine speed and vehicle speed.
Page 1646 SUSPENSION CONTROL SYSTEM 3G-9 DIAGNOSIS Suspension control module has on-board diagnostic system (a system with self-diagnosis function) as described previously. Investigate where the trouble is by referring to “DIAGNOSTIC FLOW CHART” and “DIAGNOSTIC TROUBLE CODE TABLE” on later pages. PRECAUTIONS IN DIAGNOSING TROUBLES Refer to Section 0A of Service Manual mentioned in Foreword of this manual.
Page 1647 3G-10 SUSPENSION CONTROL SYSTEM DIAGNOSTIC FLOW CHART START Does “SPORT” light turn ON for 2 seconds when ignition switch is turned ON and mode selector switch is in AUTO mode? “SPORT” light “SPORT” (“SPORT” light turns OFF or flashes) doesn’t light doesn’t Ground diagnosis switch terminal turn OFF...
Page 1648 SUSPENSION CONTROL SYSTEM 3G-11 DIAGNOSTIC TROUBLE CODE TABLE EXAMPLE: When throttle opening signal is failure (Code No.21) DIAGNOSTIC “SPORT” LIGHT TROUBLE DIAGNOSTIC ITEM DIAGNOSIS FLASHING PATTERN CODE NO. Steering sensor Gravity sensor Throttle opening signal Diagnose trouble according to “DIAGNOS- TIC FLOW CHART”...
Page 1649 3G-12 SUSPENSION CONTROL SYSTEM CODE NO.13 STEERING SENSOR CIRCUIT (SENSOR CIRCUIT OPEN: SIGNAL VOLTAGE HIGH) 1. Steering sensor 2. Steering sensor coupler 3. Suspension control module coupler 4. Suspension control module Terminal arrangement of suspension control module (Viewed from harness side) 1.
Page 1650 SUSPENSION CONTROL SYSTEM 3G-13 CODE NO.14 GRAVITY SENSOR CIRCUIT (SENSOR CIRCUIT OPEN OR SHORTED TO GROUND SIGNAL VOLTAGE HIGH OR LOW) 1. Gravity sensor 2. Gravity sensor coupler 3. Suspension control module coupler 4. Suspension control module Terminal arrangement of suspension control module coupler (Viewed from harness side) 1.
Page 1651 3G-14 SUSPENSION CONTROL SYSTEM CODE NO.21 THROTTLE OPENING SIGNAL CIRCUIT (THROTTLE POSITION SENSOR CIRCUIT OR THROTTLE OPENING CIRCUIT FAULTY) 1. Throttle position sensor 2. ECM 3. ECM coupler 4. Suspension control module coupler 5. Suspension control module Terminal arrangement of suspension control module coupler Terminal arrangement of ECM coupler (Viewed from harness side) with WU TWC...
Page 1652 SUSPENSION CONTROL SYSTEM 3G-15 CODE NO.22 VEHICLE SPEED SENSOR CIRCUIT (VEHICLE SPEED SIGNAL NOT INPUTTED ALTHOUGH ENGINE SPEED IS HIGHER THAN ABOUT 3,000 R/MIN. AND THROTTLE OPENING IS LESS THAN 10 DEG. FOR LONGER THAN 4 SECONDS) 1. Vehicle speed sensor 2.
Page 1653 3G-16 SUSPENSION CONTROL SYSTEM CODE NO.23 ENGINE SPEED SIGNAL CIRCUIT (ENGINE SPEED SIGNAL NOT INPUTTED ALTHOUGH VEHICLE SPEED IS HIGHER THAN 10 KM/H FOR LONGER THAN 20 SECONDS) (For 1.6 L engine model) 1. Suspension control module 2. To tachometer 3.
Page 1654 SUSPENSION CONTROL SYSTEM 3G-17 CODE NO.31 ACTUATOR CIRCUIT (ACTUATOR CIRCUIT OPEN OR SHORTED GROUND) 1. Suspension control module 2. Front left actuator 3. Front right actuator 4. Rear left actuator 5. Rear right actuator Terminal arrangement of suspension control module coupler (Viewed from harness side) 1 Disconnect suspension control module coupler with ignition switch OFF.
Page 1655 3G-18 SUSPENSION CONTROL SYSTEM SUSPENSION CONTROL MODULE AND ITS CIRCUIT CHECK Suspension control module can be checked at suspension control module couplers by measuring voltage and resistance. CAUTION: Suspension control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to suspension control module with coupler discon- nected from it.
Page 1656 SUSPENSION CONTROL SYSTEM 3G-19 TERMI- STANDARD CIRCUIT CONDITION VOLTAGE Power source for back-up circuit 10 – 14V Ignition switch ON and OFF Front actuator 1 Rear actuator 2 4 – 8V Ignition switch ON Front actuator 2 Rear actuator 3 Rear actuator 1 Power source 10 –...
Page 1657 3G-20 SUSPENSION CONTROL SYSTEM RESISTANCE CHECK 1) Disconnect suspension control module couplers from suspen- sion control module with ignition switch OFF. CAUTION: Never touch terminals of suspension control module itself or connect voltmeter of ohmmeter. 2) Check resistance of each two terminals of disconnected cou- plers.
Page 1658 SUSPENSION CONTROL SYSTEM 3G-21 TROUBLE DIAGNOSIS This section describes trouble diagnosis of suspen- When diagnostic trouble code No.12 is indicated by sion control system parts whose trouble is not indi- the on-board diagnostic system (self-diagnosis func- cated on-board diagnostic system tion) and assuredly those suspension basic parts as (self-diagnostic function).
Page 1659 3G-22 SUSPENSION CONTROL SYSTEM ON-VEHICLE SERVICE SUSPENSION CONTROL MODULE REMOVAL 1) Disconnect negative cable at battery. 2) Remove parking brake cover. 3) Disconnect couplers. 4) Remove suspension control module. 1. Suspension control module 2. Parking brake lever INSTALLATION Reverse removal procedure for installation. STEERING SENSOR ON-VEHICLE INSPECTION 1) Disconnect steering sensor coupler with ignition switch OFF.
Page 1660 SUSPENSION CONTROL SYSTEM 3G-23 INSTALLATION For installation, reverse removal procedure, surely referring to Section 3C (without air bag) or 3C1 (with air bag). GRAVITY SENSOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove parking brake cover front extension. 3) Remove front console silensor.
Page 1661 3G-24 SUSPENSION CONTROL SYSTEM MODE SELECTOR SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove mode selector switch from parking brake cover. 3) Disconnect mode selector switch coupler. 1. Screw driver 2. Selector switch INSPECTION Check continuity between mode selector switch terminals. Mode selector switch position Ohmmeter indicator AUTO...
Page 1662 SUSPENSION CONTROL SYSTEM 3G-25 INSPECTION 1) Check resistance between each two terminals of actuator cou- pler. Terminals Standard resistance 1 and 2 2 and 3 4.6 – 14W 3 and 1 If check results are as specified, proceed to next operation 1.
Page 1663 3G-26 SUSPENSION CONTROL SYSTEM STRUT ASSEMBLY INSPECTION 1) Remove absorber adjusting actuator. 2) Check to make sure that damping force is changed depending on absorber adjusting rod position. If not, replace strut. NOTE: Turn absorber adjusting rod by using long nosed plier or the like.
Page 1664 FRONT DRIVE SHAFT 4-1 SECTION 4 FRONT DRIVE SHAFT (Double Offset Joint (DOJ) Type) NOTE: The DOJ type drive shaft can be identified by the outside shape of the differential side joint which has no dent. CONTENTS GENERAL DESCRIPTION ............... 4- 2 REMOVAL (Left side shaft) .
Page 1665 4-2 FRONT DRIVE SHAFT GENERAL DESCRIPTION A constant velocity ball joint is used on the wheel side of front drive shaft and a constant velocity double offset joint (DOJ) on the differential side. [1.3 L and 1.6 L engine models] [1.8 L engine model] 1.
Page 1666 FRONT DRIVE SHAFT 4-3 REMOVAL (Left Side Shaft) ON FLOOR Undo caulking and remove drive shaft nut and washer. 1. Drive shaft nut A: Undo caulking ON LIFT 1) Drain transmission oil. 2) By using large size screwdrivers, pull out drive shaft joint so as to release snap ring fitting of joint spline at differential side.
Page 1667 4-4 FRONT DRIVE SHAFT REMOVAL (Right Side Shaft) ON FLOOR Undo caulking and remove drive shaft nut and washer. 1. Drive shaft nut A: Undo caulking ON LIFT 1) By using plastic hammer, drive out drive shaft joint so as to re- lease snap ring fitting of joint spline at center shaft.
Page 1668 FRONT DRIVE SHAFT 4-5 DISASSEMBLY (Drive Shaft) 1) Remove boot band of differential side joint. 1. Boot band 2) Slide boot toward the center of shaft and remove snap ring from outer race, then take shaft out of outer race. 1.
Page 1669 4-6 FRONT DRIVE SHAFT INSPECTION D Check boots for breakage or deterioration. Replace them as necessary. D Check circlip, snap ring and boot bands for breakage or de- formation. Replace as necessary. DISASSEMBLY (Center Shaft and Center Bearing Support) [1.3 L and 1.6 L Engine Models] 1) Remove right side oil seal from center bearing support.
Page 1670 FRONT DRIVE SHAFT 4-7 3) Remove bearing support circlips. 4) Remove center bearing from center bearing support. 1. Circlip REASSEMBLY (Drive Shaft) 1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air. 2) Clean boots with cloth. Do not wash boots in degreaser, such as gasoline or kerosene, etc.
Page 1671 4-8 FRONT DRIVE SHAFT 6) Apply grease to entire surface of cage. Use joint grease in tube included in differential side boot set or DOJ set of spare parts. 7) Insert cage into outer race and fit snap ring into groove of outer race.
Page 1672 FRONT DRIVE SHAFT 4-9 LEFT SIDE DRIVE SHAFT Differential side Dimensions to use when fixing boot with boot band. *Fill grease [1.3 L and 1.6 L engine model] 80 – 100 g (2.8 – 3.5 oz) [1.8 L engine model] 70 –...
Page 1673 4-10 FRONT DRIVE SHAFT D When installing right side oil seal, use care so that it is in proper direction by referring to left figure. “A”: Grease 99000-25010 1. Right side oil seal [1.8 L Engine Model] Install center shaft by reversing removal procedure and noting the following points.
Page 1674 FRONT DRIVE SHAFT 4-11 INSTALLATION Install drive shaft assembly by reversing removal procedure and noting the following points. D Clean front wheel bearing oil seal and then apply grease. Replace it if required. “A”: Grease 99000-25010 1. Front wheel bearing D Install wheel side joint to steering knuckle first and then DOJ to oil seal 2.
Page 1675 Center bearing support bolt 36.5 Stabilizer joint nut 20.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) SUZUKI BOND NO. 1215 Sealant Oil drain plug for manual transmission (99000-31110) SPECIAL TOOL...
Page 1676 FRONT DRIVE SHAFT 4A-1 SECTION 4A FRONT DRIVE SHAFT (Tripod Joint Type) NOTE: The tripod joint type drive shaft can be identified by 3 dent lines on outside of differential side joint (cylin- der shape). CONTENTS GENERAL DESCRIPTION ............... 4A- 1 REMOVAL .
Page 1677 4A-2 FRONT DRIVE SHAFT REMOVAL RIGHT SIDE SHAFT WITH CENTER SHAFT AND LEFT SIDE SHAFT Refer to REMOVAL description in SECTION 4 of this manual. RIGHT SIDE SHAFT WITHOUT CENTER SHAFT 1) Undo caulking and remove drive shaft nut and washer. 2) With vehicle lifted up, remove wheel.
Page 1678 FRONT DRIVE SHAFT 4A-3 DISASSEMBLY DRIVE SHAFT (4 A/T MODEL) 1) Remove tripod joint boot band, then take out tripod joint hous- ing. 1. Tripod joint housing 2) Remove grease from shaft and take off circlip by using special tool, then pull out spider from shaft. Special Tool (A): 09900-06107 CAUTION:...
Page 1679 4A-4 FRONT DRIVE SHAFT 2) Remove grease from shaft and take off circlip by using special tool. Special Tool (A): 09900-06107 1. Spider 2. Bearing 3. Circlip 3) Draw away spider by using bearing puller as shown. CAUTION: D When removing a spider, be sure to use bearing puller with 3 arms.
Page 1680 FRONT DRIVE SHAFT 4A-5 REASSEMBLY 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 tripod joint housing are washed thoroughly and air dried, and boots are cleaned with cloth if they are to be reused.
Page 1681 4A-6 FRONT DRIVE SHAFT v) Cut off boot band at about 7 mm (0.28 in.) from clip. 1. Metal fixture 2. Clip vi) Clamp boot band with clip. 3. Boot band vii)Fix small diameter side of boot with boot band by repeating sequence i) to v).
Page 1682 FRONT DRIVE SHAFT 4A-7 10) Before fixing boot band, insert screwdriver into boot on outer race side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure. 11) Fixing boot with boot band, referring to sequence i) to vii) of Step 4).
Page 1683 4A-8 FRONT DRIVE SHAFT 7) Facing its chamfered spline inward (wheel side), then fasten it with circlip. Special Tool (A): 09900-06107 8) Fill up differential side boot inside with grease, then install hous- ing and joint it with boot. 9) Fasten boot with bands. 1.
Page 1684 FRONT DRIVE SHAFT 4A-9 CENTER SHAFT AND CENTER BEARING SUPPORT Install center shaft by reversing removal procedure and noting fol- lowing points. D When installing bearing support circlip, make sure that it fits in circlip groove in center bearing support securely as shown. 1.
Page 1685 4A-10 FRONT DRIVE SHAFT INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points. D Clean front wheel bearing oil seal and then apply grease. Replace it if required. “A”: Grease 99000-25010 1. Front wheel bearing oil seal 2.
Page 1686 20.5 Tie-rod end nut 32.5 Wheel nut 61.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) SUZUKI BOND NO. 1215 Sealant Oil drain plug for manual transmission (99000-31110) SPECIAL TOOLS 09900-06107...
Page 1687: Propeller Shafts
PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS CONTENTS GENERAL DESCRIPTION ............... . . 4B-1 CONSTRUCTION AND OPERATION .
Page 1688 4B-2 PROPELLER SHAFTS CONSTRUCTION AND OPERATION RBC (ROTARY BLADE COUPLING) The main components of the rotary blade coupling are: pressure generation section (silicon chamber) and torque transmission section (multi-plate clutch). The pressure generation section consists of a blade which is in mesh with the coupling shaft at the output side through spline and silicon oil filling the section with a small amount of air.
Page 1689 PROPELLER SHAFTS 4B-3 ON-VEHICLE SERVICE REMOVAL 1) Hoist vehicle. 2) Before removing propeller shaft, give match marks on joint flange and propeller shaft as shown. 3) Separate No.2 propeller shaft from rear differential case. 4) Remove No.1 propeller shaft from transmission case flange. 5) Remove propeller shaft center support brackets from vehicle body.
Page 1690 4B-4 PROPELLER SHAFTS INSTALLATION 1) Reverse removal procedure to install propeller shaft, noting fol- lowing point. D When installing propeller shaft, align the match marks. Otherwise, vibration may occur during driving. D Use following specification to torque universal joint flange. Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 Ib-ft) (b): 50 N·m (5.0 kg-m, 36.5 Ib-ft)
Page 1691 REAR DRIVE SHAFT 4C-1 SECTION 4C REAR DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ............... . . 4C-1 Removal .
Page 1692 4C-2 REAR DRIVE SHAFT REMOVAL 1. Washer 2. Nut 1) Remove caulking of spindle nut and then remove spindle nut and washer. 2) Remove tire and drain rear differential oil. 3) Hoist vehicle. 4) Remove parking brake wire mounting bolt, ABS wheel speed sensor wire bracket mounting bolt (if equipped), rear control rod outer bolts and rear trailing rod rear bolt.
Page 1693 REAR DRIVE SHAFT 4C-3 INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points. D Be sure to use new drive shaft center nut. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 Ib-ft) (b): 175 N·m (17.5 kg-m, 126.5 Ib-ft) D Clean front wheel bearing oil seal and then apply grease.
Page 1694 65.0 Rear trailing rod rear bolt Drive shaft center nut 17.5 126.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Differential oil seal lips (99000-25010) SUZUKI BOND NO. 1215 Sealant Differential oil drain plug (99000-31110)
Page 1695 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1696 5-2 BRAKES PARKING BRAKE LEVER/CABLE ..5-31 REAR DISC BRAKE INSPECTION ..5-64 Parking Brake routing ....5-31 Inspect Brake Pad Lining .
Page 1697 BRAKES 5-3 GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and two in rear). The master cylinder is a tandem master cylinder. The brake pipes are connected to the master cylinder and they make two independent circuits.
Page 1698 5-4 BRAKES FOR LEFT-HAND STEERING VEHICLES WITH ABS [For vehicles equipped with P valve] Right Side FRONT Left Side 1. Brake booster 2. Master cylinder 3. Secondary side 4. Primary side 5. Proportioning valve 6. 4-way joint 7. Parking brake lever [For vehicles equipped with LSPV] 8.
Page 1699 BRAKES 5-5 FRONT DISC BRAKE CALIPER ASSEMBLY This caliper has a single bore. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping action on the disc.
Page 1700 5-6 BRAKES REAR DRUM BRAKE ASSEMBLY The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main- tained appropriate at all times. NOTE: Replace all components included in repair kits to service this drum brake. Lubricate parts as specified. WARNING: If any hydraulic component is removed or brake line disconnected, bleed the brake system.
Page 1701 BRAKES 5-7 REAR DISC BRAKE CALIPER ASSEMBLY This caliper assembly serves for both foot brake and parking brake. It has a single floating piston and a self pad-disc clearance adjusting system which maintains appropriate pad-disc clearance at all time. This caliper assembly also has a manual adjustment gear which ables the adjustment of self pad-disc clearance manually.
Page 1702 5-8 BRAKES MASTER CYLINDER ASSEMBLY The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the below figure) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on left front wheel brake (caliper) and right rear wheel brake (caliper).
Page 1703 BRAKES 5-9 [1.8L engine RH model] 1. Cylinder body 2. Secondary piston 3. Spring 4. Stem 5. Retainer spring 6. Blank 7. Primary piston 8. Spring 9. Stem 10. Packing cup 11. Blank 12. Packing cup 13. Sleeve 14. O-ring 15.
Page 1704 5-10 BRAKES BOOSTER ASSEMBLY The booster is located between the master cylinder and the brake pedal. It is so designed that the force created when the brake pedal is depressed is mechanically increased combined with the engine vacuum. Its operation is as follows.
Page 1705 BRAKES 5-11 PROPORTIONING VALVE (P VALVE) The proportioning valve is included within the brake circuit which connects the master cylinder and the wheel brakes. It is installed on dash panel under engine hood and controls the hydraulic pressure applied to the rear wheel brakes after predetermined pressure has been reached.
Page 1706 5-12 BRAKES LSPV (Load Sensing Proportioning Valve) ASSEMBLY As shown below, LSPV is included within the brake circuit which connects the master cylinder and the rear wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Page 1707: Road Testing Brakes
BRAKES 5-13 DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE FLUID Brakes should be tested on dry, clean, smooth and Improper brake fluid, mineral oil or water in the fluid reasonably level roadway which is not crowned. Road may cause the brake fluid to boil or the rubber compo- test brakes by making brake applications with both nents in the hydraulic system to deteriorate.
Page 1708 5-14 BRAKES BRAKE DIAGNOSIS CHART A Condition Possible Cause Correction D Brake oil leakage from brake lines. Not enough braking Locate leaking point and repair. D Brake disc or pads stained with oil. force Clean or replace. D Overheated brakes. Determine cause and repair.
Page 1709 BRAKES 5-15 BRAKE DIAGNOSIS CHART A Condition Possible Cause Correction D Front lining worn out. Noise (high pitched Replace linings. squeak without brake applied) D Maladjusted sensor spring length of LSPV, if Rear brake locked Check or adjust. prematurely equipped. D Malfunctioning LSPV assembly, if equipped.
Page 1710 5-16 BRAKES BRAKE DIAGNOSIS CHART B Condition Possible Cause Correction D Partial brake system failure. Excessive pedal Check brake systems and repair as necessary. D Insufficient fluid in master cylinder travel (Pedal stroke Fill reservoirs with approved brake fluid. too large) reservoirs.
Page 1711 BRAKES 5-17 BRAKE DIAGNOSIS CHART B Condition Possible Cause Correction D Damaged or loose wheel bearings. Pedal pulsation Replace wheel bearings. D Distorted steering knuckle or rear (Pedal pulsates Replace knuckle or rear wheel spindle. when depressed for wheel spindle. D Excessive disc lateral runout.
Page 1712 5-18 BRAKES BRAKE DIAGNOSIS CHART C Condition Possible Cause Correction D Parking brake applied. Brake warning light Release parking brake and check if brake lights after engine start warning light turns off. D Insufficient amount of brake fluid. Add brake fluid. D Brake fluid leaking from brake line.
Page 1713: Brake Pedal Free Height Adjustment
BRAKES 5-19 ON-VEHICLE SERVICE BRAKE PEDAL FREE HEIGHT ADJUSTMENT Check brake pedal free height. If it is not within specification, check and adjust the following item 1) and 2). Brake pedal free height “a” from asphalt sheet : 157 – 167 mm (6.18 – 6.57 in.) 1) Check measurement between booster mounting surface and center of clevis pin hole.
Page 1714: Front Brake Disc Inspection
5-20 BRAKES FRONT BRAKE DISC INSPECTION Refer to “FRONT DISC BRAKE INSPECTION” in this section for inspection point and procedure. FRONT BRAKE PAD LINING INSPECTION Inspect pad linings periodically according to maintenance sched- ule whenever wheels are removed (for tire rotation or other rea- son).
Page 1715: Rear Brake Disc Inspection
BRAKES 5-21 REAR BRAKE DISC INSPECTION Refer to “REAR DISC BRAKE INSPECTION” in this section for in- spection point and procedure. REAR BRAKE PAD LINING INSPECTION Inspect pad linings periodically according to maintenance sched- ule whenever wheels are removed (for tire rotation or other rea- son).
Page 1716 5-22 BRAKES MASTER CYLINDER INSPECTION [For 1.8L engine RH model] Check for a cracked master cylinder casting or brake fluid around the master cylinder. Leaks are indicated only if there is at least a drop of fluid. A damp condition is not abnormal. CAUTION: D Brake master cylinder cannot be disassembled in prin- ciple.
Page 1717: Parking Brake Inspection And Adjustment
BRAKES 5-23 PARKING BRAKE INSPECTION AND ADJUSTMENT a) Inspection Hold center parking brake lever grip and pull it up. Pulling force: 20 – 25 kg (44 – 55 lbs) (for vehicles with drum brake) 10 – 15 kg (22 – 30 lbs) (for vehicles with disc brake) With parking brake lever pulled up as above, count ratchet notches in “A”...
Page 1718: Flushing Brake Hydraulic System
5-24 BRAKES b) Adjustment NOTE: Make sure for following conditions before cable adjustment. D No air is trapped in brake system. D Brake pedal travel is proper. D Brake pedal has been depressed a few times with about 30 kg (66 Ibs) load. D Parking brake lever has been pulled up few times.
Page 1719 BRAKES 5-25 BLEEDING BRAKES CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. Right wheel cylinder Bleeding operation is necessary to remove air whenever it entered Right brake caliper hydraulic brake system.
Page 1720: Brake Hose And Pipe Inspection
5-26 BRAKES 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug. Tightening Torque (b): 11 N m (1.1 kg-m, 8.0 lb-ft) 7) Then attach bleeder plug cap. 8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
Page 1721 BRAKES 5-27 BRAKE HOSE/PIPE REMOVE AND INSTALL FRONT BRAKE HOSE/PIPE 1) Raise, suitably support vehicle and remove wheel if necessary. 2) Clean dirt and foreign material from both hose ends or pipe end fittings. Remove brake hose or pipe. 3) Install it by reversing removal procedure, noting the following points. For installation, make sure that steering wheel is in straightforward position and hose has no twist or kink.
Page 1722 5-28 BRAKES [For right-hand steering vehicles without ABS] TOP SIDE FRONT SIDE CLAMP: G Clamp E Clamp G Front 1. Master cylinder [For right-hand steering vehicles with ABS] 2. P (Proportioning) valve (shown) or 6-way joint (for vehicles with LSPV, not shown) 3.
Page 1723 BRAKES 5-29 REMOVE AND INSTALL REAR BRAKE HOSE/PIPE 1) Raise, suitably support vehicle and remove wheel if necessary. 2) Clean dirt and foreign material from both hose ends or pipe end fittings. Remove brake hose or pipe. 3) Install it by reversing removal procedure, noting the following points. D Install clamps properly referring to figure below.
Page 1724 5-30 BRAKES [For vehicles with LSPV] “T” : Top side 1. To P valve, 4 or 6-way joint “L” : Left side 2. Pipe cover “R” :Right side 3. Clamp 4. 4-way joint 5. E-ring 6. Flexible hose 7. LSPV 8.
Page 1725 BRAKES 5-31 PARKING BRAKE LEVER/CABLE PARKING BRAKE ROUTING NOTE: Block wheels when servicing vehicle with parking brake released. Clamp G VIEW: D 1. Parking brake lever Clamp F 2. Pin 3. Equalizer 4. Brake cable 5. Locking nut [For vehicles with rear drum brake] Clamp G VIEW: C Clamp F...
Page 1726 5-32 BRAKES REMOVE AND INSTALL PARKING BRAKE LEVER REMOVAL NOTE: See NOTE at the beginning of this section. 1) Remove parking brake lever cover. 2) Disconnect lead wire of parking brake switch at coupler. NOTE: Don’t disassemble parking brake lever switch. It must be removed and installed as a complete switch assembly.
Page 1727 BRAKES 5-33 INSTALLATION 1) Install in reverse order of REMOVAL procedure. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 2) After all parts are installed, parking brake lever needs to be ad- justed. Refer to “PARKING BRAKE INSPECTION AND AD- JUSTMENT”...
Page 1728 5-34 BRAKES 4) Disconnect cable from parking brake lever by referring to steps 1), 2) and 3) of “REMOVAL” under “REMOVE AND INSTALL PARKING BRAKE LEVER” in this section. 5) Remove cable from vehicle body. [For vehicles with rear disc brake] 1) Disconnect cable from parking brake lever by referring to steps 1), 2) and 3) of “REMOVAL”...
Page 1729 BRAKES 5-35 D Install brake cable spring and nipple end to parking brake shoe 1. Parking brake shoe lever 2. Spring Up side lever securely as shown. 3. Nipple end FRONT SIDE D For brake shoe installation, refer to steps 1) and 2) of “INSTAL- LATION”...
Page 1730 5-36 BRAKES D For proper routing and secure clamping of parking brake cable, re- fer to figure in “PARKING BRAKE ROUTING”. D For installation of cable to parking brake lever, refer to “INSTALLA- TION” under “ REMOVE AND INSTALL PARKING BRAKE LE- VER”...
Page 1731: Front Disc Brake
BRAKES 5-37 FRONT DISC BRAKE 1. Caliper 2. Caliper pin bolt 3. Disc REMOVE AND INSTALL PAD (SHOE &LINING) REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolts. 3) Remove caliper from caliper carrier. 1. Caliper 2. Wire hook 3.
Page 1732 5-38 BRAKES REMOVE AND INSTALL CALIPER ASSEMBLY REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove brake flexible hose mounting bolt from caliper. As this will allow fluid to flow out of hose, have a container ready before- hand. 1. Caliper 2.
Page 1733 BRAKES 5-39 REMOVE AND INSTALL SEAL, PISTON, 1. Boot retaining ring DUST BOOT AND BLEEDER PLUG REMOVAL 1) Before disassembly, clean all around caliper with brake fluid. 2) Remove piston boot retaining ring and boot from caliper; pry off with a flat-bladed tool. Be careful not to damage boot. 3) Blow compressed air into cylinder through bolt hole where flex- ible hose was fitted.
Page 1734 5-40 BRAKES Slide Bush, Boot and Bleeder Plug 1) Check that slide bushes and boots for wear, corrosion, damage, movement or deterioration. If it is found faulty, correct or re- place. D Apply rubber grease to bush outer surface. And then make sure that each bush slides easily through each caliper bolt hole.
Page 1735 BRAKES 5-41 6) Insert piston into cylinder by hand and fit boot in boot groove in piston. 7) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out. NOTE: Boot’s face “B”...
Page 1736 5-42 BRAKES REMOVE AND INSTALL DISC REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper assembly by loosening carrier bolts (2 pieces). CAUTION: During removal, be careful not to damage brake flex- ible hose and not to depress brake pedal. 3) Remove brake disc screw (If equipped).
Page 1737 BRAKES 5-43 FRONT DISC BRAKE INSPECTION INSPECT BRAKE PAD LINING Check pad lining for wear. When wear exceeds limit, replace with new one. CAUTION: Never polish pad lining with sandpaper. If lining is pol- ished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc.
Page 1738 5-44 BRAKES INSPECT BRAKE DISC Before this inspection, brake pads must be removed referring to steps 1) to 4) of “REMOVAL” under “REMOVE AND INSTALL PAD” in this section. Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspec- tion or replacement are normal and disc is not defective unless they are serious.
Page 1739 BRAKES 5-45 DRUM AND COMPONENTS REMOVE AND INSTALL BRAKE DRUM REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove brake drum screws (2 pieces). 1. Screw 2. Brake drum 3) Release parking brake lever. 4) Remove parking brake lever cover and loosen parking brake cable locking nut.
Page 1740 5-46 BRAKES INSTALLATION NOTE: See NOTE at the beginning of this section. 1) Before installing brake drum, to maximize brake shoe-to-drum clearance, put screwdriver between rod and ratchet and push down ratchet as shown in figure. 1. Rod 2. Ratchet NOTE: 1.
Page 1741 BRAKES 5-47 REMOVE AND INSTALL BRAKE SHOE 1. Shoe hold down pins 2. Shoe hold down spring REMOVAL 1) Perform steps 1) to 6) of “REMOVAL” under “REMOVE AND INSTALL BRAKE DRUM” in this section. 2) Remove shoe hold down springs by turning shoe hold down pins.
Page 1742 5-48 BRAKES REMOVE AND INSTALL WHEEL CYLINDER REMOVAL 1) Perform steps 1) to 6) of “REMOVAL” under “REMOVE AND INSTALL BRAKE DRUM” in this section. 2) Perform steps 2) to 4) of “REMOVAL” under “REMOVE AND INSTALL BRAKE SHOE” in this section. 3) Loosen brake pipe flare nut but only within the extent that fluid does not leak.
Page 1743 BRAKES 5-49 5) Install brake shoes, referring to steps 1) and 2) of “INSTALLA- TION” under “REMOVE AND INSTALL BRAKE SHOE” in this section. 6) Install brake drum, referring to steps 1) to 4) of “INSTALLA- TION” under “REMOVE AND INSTALL BRAKE DRUM” in this section.
Page 1744 5-50 BRAKES 5) Pull wheel hub off by using special tools. Special Tool (A): 09943-17912 (B): 09942-15511 1. Wheel hub 6) Perform steps 2) to 4) of “REMOVAL” under “REMOVE AND INSTALL BRAKE SHOE” in this section. 7) Perform steps 3) and 4) of “REMOVAL” under “REMOVE AND INSTALL WHEEL CYLINDER”...
Page 1745 BRAKES 5-51 3) Install parking brake cable to brake plate. 1. Brake back plate 2. Cable stopper ring 3. Brake cable 4) Install wheel cylinder, and tighten wheel cylinder bolts and [2WD vehicle] brake pipe flare nut to specified torque by referring to steps 1) to 4) of “INSTALLATION”...
Page 1746 5-52 BRAKES BRAKE DRUM AND COMPONENTS INSPECTION INSPECT BRAKE DRUM Inspect drum for cleanliness. Check wear of its braking surface by measuring its inside diameter. Brake drum ID Standard : 200 mm (7.87 in.) Service limit : 202 mm (7.95 in.) Whenever brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves.
Page 1747 BRAKES 5-53 INSPECT BRAKE SHOE & LINING Where lining is worn out beyond service limit, replace shoe. Brake lining thickness (lining + shoe rim) Standard : 6.1 mm (0.24 in.) Service limit : 2.8 mm (0.11 in.) If one of brake linings is worn to service limit, all linings must be re- placed at the same time.
Page 1748 5-54 BRAKES INSPECT PARKING SHOE LEVER Inspect brake shoe lever for free movement against brake shoe web. If defective, correct or replace.
Page 1749: Rear Disc Brake
BRAKES 5-55 REAR DISC BRAKE REMOVE AND INSTALL PAD (SHOE & LINING) REMOVAL 1) Hoist vehicle, remove wheel and release parking brake. 2) Remove manual adjustment gear cover. 3) Turn manual adjustment gear counterclockwise with an Allen wrench so to have piston and brake pads away from the disc. 1.
Page 1750 5-56 BRAKES INSTALLATION NOTE: See NOTE at the beginning of this section. 1) Install antirattle spring, pad shims (plates), pads, and pad re- tract spring. 1. Caliper NOTE: 2. Brake pad 3. Shim Do not forget to install pad retract spring. 4.
Page 1751 BRAKES 5-57 REMOVE AND INSTALL CALIPER ASSEMBLY REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove brake flexible hose mounting bolt from caliper. As this will allow fluid to flow out of hose, have a container ready before- hand. 1. Caliper 2.
Page 1752 5-58 BRAKES INSTALLATION 1) Install caliper carrier to knuckle. Tightening Torque for caliper carrier 50 N·m (5.0 kg-m, 36.0 lb-ft) 2) Install caliper to caliper carrier. 3) Install caliper pin bolt. Tightening Torque (a) : 38 N·m (3.8 kg-m, 27.5 lb-ft) 1.
Page 1753 BRAKES 5-59 REMOVE AND INSTALL SEAL, PISTON, BOOT, BLEEDER PLUG AND PARKING BRAKE CAM REMOVAL 1) Before disassembly, clean all around caliper with brake fluid. 2) Remove piston boot around the piston. 1. Piston 2. Piston boot 3. Caliper 3) Remove piston by turning the manual adjustment gear clock- wise with an Allen wrench until the manual adjustment gear can be turned very lightly.
Page 1754 5-60 BRAKES 8) Remove parking brake return spring. 1. Caliper ass’y 2. Parking brake lever 3. Parking brake return spring 4. Plier 9) Remove lever with push rod and lever shaft seal. 1. Caliper ass’y 2. Parking brake lever 3. Lever shaft seal 4.
Page 1755 BRAKES 5-61 2) Install push rod and new O-ring to adjuster screw. Apply ample amount of rubber grease to push rod and adjuster screw. See NOTE at the beginning of this installation. 1. Push rod 2. Adjuster screw 3. O-ring 3) Install adjuster screw ass’y to caliper.
Page 1756 5-62 BRAKES 8) Once the piston is fitted all the way down, confirm that the boot is fitted properly in the groove of caliper’s cylinder by turning manual adjustment gear clockwise to have the piston move up about halfway. NOTE: Boot’s face “B”...
Page 1757 BRAKES 5-63 REMOVE AND INSTALL DISC REMOVAL 1) Hoist vehicle, remove wheel and pull parking brake lever. 2) Remove brake disc screws (2 pieces). 3) Release parking brake lever. 1. Brake disc 2. Screw 4) Follow step 2) to 8) of “REMOVAL” under “REMOVE AND INSTALL PAD (SHOE &...
Page 1758 5-64 BRAKES REAR DISC BRAKE INSPECTION INSPECT BRAKE PAD LINING Check pad lining for wear. When wear exceeds limit, replace with new one. CAUTION: Never polish pad lining with sandpaper. If lining is pol- ished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc.
Page 1759 BRAKES 5-65 INSPECT BRAKE DISC Before this inspection, brake pads must be removed (according to step 1) to 8) of “REMOVAL” under “REMOVE AND INSTALL PAD (SHOE & LINING)” of “REAR DISC BRAKE” in this section. Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspec- tion or replacement are normal and disc is not defective unless they are serious.
Page 1760 5-66 BRAKES MASTER CYLINDER REPAIR REMOVE AND INSTALL MASTER CYLINDER ASSEMBLY REMOVAL NOTE: Do not allow brake fluid to get on painted surfaces. [1.8L engine RH model] 1) Disconnect air flow meter coupler. 2) Remove air cleaner outlet hose. 1. Power steering fluid reservoir 2.
Page 1761 BRAKES 5-67 [Other than 1.8L engine RH model] 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir. 3) Take out fluid with syringe or such. 1. Reservoir 2. Cap 3. Lead wire 4) Remove reservoir pin or bolt. Use special tool for pin removal. Special Tool (A): 09922-85811 5) Remove reservoir.
Page 1762 5-68 BRAKES [Other than 1.8L engine RH model] 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with. Then press-fit grommets to mas- ter cylinder. Grommets must be seated in place. 2) Install reservoir on master cylinder with pin or bolt. NOTE: when inserting pin, drive till both of its ends at the right and left of reservoir become the same length.
Page 1763 BRAKES 5-69 [Other than 1.8L engine RH model] 1) Disconnect reservoir lead wire at coupler. 2) Clean around reservoir cap and take out fluid with syringe or such. 3) Disconnect brake pipes from master cylinder. CAUTION: Brake fluid is extremely damaging to paint. Do not allow brake fluid to get on painted surfaces.
Page 1764 5-70 BRAKES [Other than 1.8L engine RH model] 1) Install master cylinder as shown and torque attaching nuts to specification. Tightening Torque (a): 13 N m (1.3 kg-m, 9.5 lb-ft) 2) Attach hydraulic lines and torque flare nuts to specification. Tightening Torque (b): 16 N m (1.6 kg-m, 11.5 lb-ft)
Page 1765 BRAKES 5-71 DISASSEMBLE AND ASSEMBLE MASTER CYLINDER WARNING: 1.8L engine RH model’s brake master cylinder cannot be disassembled. When any part of it other than primary piston as described in CAUTION above has been disassembled, or when anything faulty is found in it, it must be replaced as an assembly.
Page 1766 5-72 BRAKES DISASSEMBLY 1) Remove circlip. 2) Remove primary piston. 1. Circlip 2. Master cylinder 3) Remove piston stopper bolt. Then remove secondary piston by blowing compressed air into hole from which piston stopper bolt was removed. Be cautious during removal as secondary piston jumps out. 1.
Page 1767 BRAKES 5-73 5) Install piston stopper bolt with pistons pushed in all the way and [For vehicles not equipped with ABS] tighten it to specified torque. Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft) (b): 2.5 N m (0.25 kg-m, 2.0 lb-ft) 6) For installation on vehicle, refer to “INSTALLATION”...
Page 1768 5-74 BRAKES MASTER CYLINDER INSPECTION WARNING: [For vehicles not equipped with ABS] 1.8L engine RH model’s brake master cylinder cannot be disassembled. When any part of it other than primary pis- ton as described in CAUTION above has been disas- sembled, or when anything faulty is found in it, it must be replaced as an assembly.
Page 1769: Fill Reservoir
BRAKES 5-75 FILL RESERVOIR NOTE: Do not use shock absorber fluid or any other fluid which con- tains mineral oil. Do not use container which has been used for mineral oil or which is wet from water. Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake sys- tem and water will mix with brake fluid, lowering fluid boiling point.
Page 1770: Brake Booster
5-76 BRAKES BRAKE BOOSTER [1.8L engine RH model] [Other than 1.8L engine RH model] 1. Brake master cylinder ass’y 2. Gasket 3. Blank 4. Booster ass’y 5. Brake vacuum hose 6. Nut 7. Nut 8. Clevis pin 9. Push rod clevis 10.
Page 1771 BRAKES 5-77 3) Detach power steering pump high pressure hose from power 1. Power steering pump 2. High pressure hose steering pump. As fluid flows out of disconnected joint, have a 3. Throttle body container under joint or plug the hose. 4) Remove throttle body.
Page 1772 5-78 BRAKES [1.8L engine RH model] 1) Install booster to dash panel as shown. Then connect booster push rod clevis to pedal arm with clevis pin and cotter pin. 2) Torque booster attaching nuts to specification. Tightening torque (a): 13 N·m (1.3 kg-m, 9.5 lb-ft) 1.
Page 1773 BRAKES 5-79 [Other than 1.8L engine RH model] 1) Install booster to dash panel as shown. Then connect booster push rod clevis to pedal arm with clevis pin and clip. 2) Tighten booster attaching nuts to the specified torque. Tightening torque (a): 13 N·m (1.3 kg-m, 9.5 lb-ft) 3) Connect brake vacuum hose to brake booster.
Page 1774 5-80 BRAKES BRAKE BOOSTER INSPECTION AND ADJUSTMENT INSPECT BOOSTER PARTS RUBBER PARTS Wipe fluid from rubber parts and carefully inspect each rubber part for cuts, nicks or other damage. If there is any question as to serviceability of rubber parts, replace them.
Page 1775 BRAKES 5-81 3) If measurement is out of specified value, adjust depth by turning adjusting screw of piston rod. Special Tool (C): 09952-16020 Reference When adjusted as above, if negative pressure is applied to booster with engine at idle, piston to piston rod clearance “a” should be- come the specified range below.
Page 1776 5-82 BRAKES [For Vehicle Equipped with ABS] 1) Remove piston rod seal from booster. 2) Measure depth of piston rod, i.e. distance between piston rod and mating surface of booster-to-master cylinder. Depth of piston rod “c”: 9.63 – 9.87 mm (0.38 – 0.39 in.) 3) If measurement is out of specified value, adjust depth by turning adjusting screw of piston rod.
Page 1777 BRAKES 5-83 INSPECT BOOSTER OPERATION There are two ways to perform this inspection, with and without a tester. Ordinarily, it is possible to roughly determine its condition without using a tester. NOTE: For this check, make sure that no air is in hydraulic line. INSPECTION WITHOUT TESTER Check Air Tightness 1) Start engine.
Page 1778 5-84 BRAKES 2) Start engine while depressing brake pedal. If pedal travel in- creases a little, operation is satisfactory. But no change in pedal travel indicates malfunction. Check Air Tightness Under Load 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed.
Page 1779 BRAKES 5-85 LSPV (Load Sensing Proportioning Valve) REMOVE AND INSTALL LSPV REMOVAL 1) Clean around reservoir cap and take out fluid with syringe or such. 2) Hoist vehicle. 3) Disconnect brake pipes from LSPV. 4) Remove bracket bolts and adjusting nut. 5) Remove LSPV assembly from vehicle body.
Page 1780 5-86 BRAKES 2) Torque each bolt and nut to specification as indicated respec- tively in figure. Tightening Torque (a):23 N·m (2.3 kg-m, 17.0 lb-ft) (b):16 N·m (1.6 kg-m, 11.5 lb-ft) 3) Upon completion of installation, fill reservoir tank with specified fluid and bleed air from brake system.
Page 1781 BRAKES 5-87 FLUID PRESSURE TEST Front Test procedure for LSPV assembly is as follows. Before testing, confirm the following. D Fuel tank is filled with fuel fully. D Vehicle is equipped with spare tire, tools, jack and jack handle. 1) Place vehicle on level floor and set 200 kg (442 lbs) weight slow- ly on axle housing center.
Page 1782 5-88 BRAKES As done above, apply 100 kg/cm pressure to front brake and check that rear brake pressure then is within specification as given below. Front brake Rear brake 4,600 – 5,000 kPa 3 Door 46 – 50 kg / cm 654 –...
Page 1783 17 0 LSPV adjusting nut REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of master Indicated on reservoir tank cap or de- Brake fluid scribed in owner’s manual of vehicle cylinder caliper, wheel cylinder and brake caliper when they are disassembled.
Page 1784 5-90 BRAKES SPECIAL TOOL 09943-17912 09922-85811 09942-15511 Brake drum remover 09950-78220 Connector pin remover Sliding hammer (Front wheel hub remover) Flare nut wrench (10 mm) 09952-16010 (For vehicle without ABS) 09952-36310 09952-36320 09950-96010 09952-16020 Fluid pressure gauge Fluid pressure gauge (For vehicle with ABS) Booster piston rod gauge attachment (7 mm)
Page 1785 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1786 5B-2 ANTILOCK BRAKE SYSTEM (ABS) DTC C1041/C1042 (DTC 41/42) Removal ......5B-32 –...
Page 1787 ANTILOCK BRAKE SYSTEM (ABS) 5B-3 GENERAL DESCRIPTION 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 is a 4-wheel type which controls the fluid pressure applied to the wheel cylinder of each of the four brakes to prevent each wheel from getting locked.
Page 1788 5B-4 ANTILOCK BRAKE SYSTEM (ABS) SYSTEM SCHEMATIC 1. Wheel speed sensor (Right-front) 7. Wheel speed sensor (Left-rear) 13. ABS hydraulic unit 2. Stop lamp switch 8. ABS warning lamp 14. G sensor (4WD vehicle only) 3. ABS control module 9. ABS pump motor relay 15.
Page 1789 ANTILOCK BRAKE SYSTEM (ABS) 5B-5 ABS COMPONENT PARTS LOCATION 1. Wheel speed sensor (Right-front) 6. Wheel speed sensor (Left-rear) 11. EBD warning lamp relay (if equipped) 2. Stop lamp switch 7. ABS hydraulic unit/control module assembly 12. Wheel speed sensor (Left-front) 3.
Page 1790 5B-6 ANTILOCK BRAKE SYSTEM (ABS) ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY 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 compo- nent 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 lamp and outputs it through the diagnosis output terminal as described below.
Page 1791 ANTILOCK BRAKE SYSTEM (ABS) 5B-7 4) When an abnormality in the system is detected, ABS warning lamp lights and the area where that abnormality lies is stored in the memory of EEPROM in ABS control module. 5) When diagnosis switch terminal of DIAG-2 connector (monitor connector) is grounded, the abnormal area is output as DTC from Diag.
Page 1792 5B-8 ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSIS To ensure that the trouble diagnosis is done accurately and smoothly, observe “Precautions in Diagnosing Troubles” and follow “ABS Diagnostic Flow Table”. PRECAUTION IN DIAGNOSING TROUBLES D If the vehicle was operated in any of the following ways, ABS warning light may light momentarily but this does not indicate anything abnormal in ABS.
Page 1793 ANTILOCK BRAKE SYSTEM (ABS) 5B-9 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 questionaire form as shown below will facilitate collecting information to the point re- quired for proper analysis and diagnosis.
Page 1794 5B-10 ANTILOCK BRAKE SYSTEM (ABS) 2. PROBLEM SYMPTOM CONFIRMATION Check if what the customer claimed in Step 1 is actually found in the vehicle and if that symptom is found, wheth- er it is identified as a failure. (This step should be shared with the customer if possible.) When ABS warning lamp is not operated correctly, proceed to “Diagnostic Flow Table-A, B or C”.
Page 1795 ANTILOCK BRAKE SYSTEM (ABS) 5B-11 ABS WARNING LAMP CHECK Turn the ignition switch to “ON” position and check that “ABS” warning lamp lights for about 2 seconds and then goes “OFF” posi- tion. If anything faulty is found, advance to Diagnostic flow table-A, B or C.
Page 1796 2) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool oper- ator’s manual for further details. 5) After completing the check, turn ignition switch to OFF position and disconnect SUZUKI scan tool from DLC.
Page 1797 DTC (DTC 12) is displayed; not malfunction DTC. 1. Service wire 2. Diagnosis switch terminal NOTE: 3. Ground terminal 4. DIAG-2 connector It is also possible to clear DTC by using SUZUKI scan tool. 5. DIAG-1 connector Refer to Cartridge Manual for procedure to clear DTC.
Page 1798 5B-14 ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE (DTC) TABLE (displayed (indicated VOLTMETER INDICATION by ABS DIAGNOSTIC AREA (or ABS warning lamp flashing pattern) SUZUKI warning scan tool) lamp) – Normal C1013 ABS hydraulic unit/control module assembly C1015 G sensor...
Page 1799 ANTILOCK BRAKE SYSTEM (ABS) 5B-15 SYSTEM CIRCUIT Wire color : Black : Blue LT GRN/RED : Light green/Red RED/BLU : Red/Blue BLK/BLU : Black/Blue BLU/YEL : Blue/Yellow : Orange RED/BLK : Red/Black BLK/RED : Black/Red : Brown PNK/GRN : Pink/Green :White BLK/ORG : Black/Orange...
Page 1800 5B-16 ANTILOCK BRAKE SYSTEM (ABS) TABLE – A ABS WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON -1. Main fuse -2. Ignition switch -3. Circuit fuse for IG -4. ABS warning lamp -5. ABS hydraulic unit / control module assembly 5-1.
Page 1801 Perform diagnostic trouble code check. Is there any Go to step 2. Go to step 3. DTC (including code No.12, NO CODES on SUZUKI scan tool) exists? Is malfunction DTC (other than code No.12) exists at Go to step 7 of ABS Go to step 3.
Page 1802 5B-18 ANTILOCK BRAKE SYSTEM (ABS) TABLE – C ABS WARNING LAMP CIRCUIT CHECK – THE LAMP FLASHES CONTINUOUSLY WHILE IGNITION SWITCH IS ON POSITION Refer to TABLE – A for System Circuit Diagram. CIRCUIT DESCRIPTION When the diagnosis switch terminal is shorted or connected to the ground with the ignition switch ON position, the diagnostic trouble code (DTC) is indicated by flashing of the ABS warning lamp only in the following cases.
Page 1803 ANTILOCK BRAKE SYSTEM (ABS) 5B-19 TABLE – D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAGNOSIS SWITCH TERMINAL CONNECTED TO GROUND Refer to TABLE – A for System Circuit Diagram. CIRCUIT DESCRIPTION When the diag. switch terminal is connected to the ground with the ignition switch turned ON, the ABS control mod- ule outputs a diagnostic trouble code by flashing ABS warning lamp.
Page 1804 5B-20 ANTILOCK BRAKE SYSTEM (ABS) TABLE – E EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK (IF EQUIPPED) – LAMP COMES “ON” STEADY -1. Main fuse -2. Ignition switch -3. Circuit fuse for IG -4. EBD warning lamp -5. ABS hydraulic unit / control module assembly -6.
Page 1805 ANTILOCK BRAKE SYSTEM (ABS) 5B-21 DTC C1013 (DTC 13) – SYSTEM SPECIFICATIONS DIFFERENT FROM ABS CONTROL MODULE SPECIFICATIONS DESCRIPTION When abnormal signal is inputted to a no-used terminal of control module while running or wrong ABS hydraulic unit/control module assembly is installed, this DTC will be set. INSPECTION 1) Ignition switch OFF.
Page 1806 5B-22 ANTILOCK BRAKE SYSTEM (ABS) 4WD Vehicle STEP ACTION Is G sensor installed floor securely? Go to step 2. Tighten sensor or bracket screw se- curely. If not, using new screw. 1) Ignition switch OFF. Go to step 3. Replace G sensor. 2) Remove G sensor with bracket.
Page 1807 ANTILOCK BRAKE SYSTEM (ABS) 5B-23 DTC C1021/C1022 (DTC 21/22) – RIGHT-FRONT WHEEL SPEED SENSOR CIRCUIT DTC C1025/C1026 (DTC 25/26) – LEFT-FRONT WHEEL SPEED SENSOR CIRCUIT DTC C1031/C1032 (DTC 31/32) – RIGHT-REAR WHEEL SPEED SENSOR CIRCUIT DTC C1035/C1036 (DTC 35/36) – LEFT-REAR WHEEL SPEED SENSOR CIRCUIT 1.
Page 1808 5B-24 ANTILOCK BRAKE SYSTEM (ABS) INSPECTION STEP ACTION 1) Disconnect the applicable sensor connector with igni- Go to step 2. Replace sensor. tion switch OFF. 2) Measure resistance between sensor terminals. Resistance of wheel speed sensor: 1.2 – 1.6 kW (at 20_C, 68_F) 3) Measure resistance between each terminal and body ground.
Page 1809 ANTILOCK BRAKE SYSTEM (ABS) 5B-25 Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5...
Page 1810 5B-26 ANTILOCK BRAKE SYSTEM (ABS) DTC C1041/C1042 (DTC 41/42) – RIGHT-FRONT SOLENOID CIRCUIT DTC C1045/C1046 (DTC 45/46) – LEFT-FRONT SOLENOID CIRCUIT DTC C1051/C1052 (DTC 51/52) – RIGHT-REAR SOLENOID CIRCUIT DTC C1055/C1056 (DTC 55/56) – LEFT-REAR SOLENOID CIRCUIT 1. ABS hydraulic unit/ control module assembly 1-1.
Page 1811 ANTILOCK BRAKE SYSTEM (ABS) 5B-27 DTC C1057 (DTC 57) – SOLENOID AND PUMP MOTOR POWER SOURCE CIRCUIT 1. ABS hydraulic unit/ control module assembly 1-1. ABS fail-safe relay (Solenoid valve relay) 1-2. ABS pump motor relay 2. ABS hydraulic unit/ control module connector DESCRIPTION...
Page 1812 5B-28 ANTILOCK BRAKE SYSTEM (ABS) DTC C1061 (DTC 61) – ABS PUMP MOTOR CIRCUIT -1. ABS hydraulic unit / control module assembly 1-1. ABS pump motor relay 1-2. ABS pump motor 1-3. ABS fail safe relay -2. ABS hydraulic unit/ control module connector of harness DESCRIPTION...
Page 1813 ANTILOCK BRAKE SYSTEM (ABS) 5B-29 DTC C1063 (DTC 63) – ABS FAIL-SAFE RELAY CIRCUIT 1. Ignition switch 2. ABS hydraulic unit/ control module assembly 2-1. ABS fail-safe relay (Solenoid valve relay) 3. ABS hydraulic unit/ control module connector of harness DESCRIPTION The ABS control module monitors the voltage at the terminal of the solenoid circuit constantly with the ignition switch turned ON.
Page 1814 5B-30 ANTILOCK BRAKE SYSTEM (ABS) DTC C1071 (DTC 71) – ABS CONTROL MODULE DESCRIPTION This DTC will be set when an internal fault is detected in the ABS control module. INSPECTION STEP ACTION 1) Ignition switch OFF. Substitute a Repair or replace. 2) Disconnect connectors from ABS control module.
Page 1815 ANTILOCK BRAKE SYSTEM (ABS) 5B-31 ON-VEHICLE SERVICE PRECAUTION When connectors are connected to ABS hydraulic unit/control module assembly, do not disconnect connectors of sensors etc. and turn ignition switch is ON position. Then DTC will be set in ABS control module. ABS HYDRAULIC UNIT OPERATION CHECK 1) Check that basic brake system other than ABS is in good condition.
Page 1816 5B-32 ANTILOCK BRAKE SYSTEM (ABS) ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY CAUTION: Never disassemble ABS hydraulic unit/ control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit/control module assembly. 1.
Page 1817 ANTILOCK BRAKE SYSTEM (ABS) 5B-33 4) Remove three nuts and take out ABS hydraulic unit/control module assembly from bracket. CAUTION: D Do not give an impact to hydraulic unit. D Use care not to allow dust to enter hydraulic unit. D Do not place hydraulic unit on its side or upside down.
Page 1818 5B-34 ANTILOCK BRAKE SYSTEM (ABS) FRONT WHEEL SPEED SENSOR NOTE: 1. Left front wheel speed sensor 2. Left front strut Never remove sensor rotor from drive shaft outside joint. 3. Sensor rotor Refer to Section 4 for replacement procedure of joint with sensor. 4.
Page 1819 ANTILOCK BRAKE SYSTEM (ABS) 5B-35 REMOVAL 1) Disconnect negative cable at battery. 2) Hoist vehicle and remove wheel. 3) Disconnect front wheel speed sensor connector. 4) Push out grommet of harness from inner fender to outside of ve- hicle. 1. Front wheel speed sensor harness 2.
Page 1820 5B-36 ANTILOCK BRAKE SYSTEM (ABS) INSTALLATION 1. Grommet 2. Clamp bolt 1) Check that no foreign material is attached to sensor and rotor. 3. Sensor bolt 2) Install it by reversing removal procedure. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) CAUTION: D Do not pull wire harness or twist more than neces- sary when installing front wheel speed sensor.
Page 1821 ANTILOCK BRAKE SYSTEM (ABS) 5B-37 REAR WHEEL SPEED SENSOR NOTE: 1. Left rear wheel speed sensor Never remove sensor rotor from wheel hub or drive shaft outside joint. 2. No.2 control rod Refer to Section 3E for replacement procedure of wheel hub with rotor and 3.
Page 1822 5B-38 ANTILOCK BRAKE SYSTEM (ABS) SENSOR INSPECTION D Check sensor (pole piece) for damage or bent. D Check sensor for resistance. Resistance between terminals: 1.2 – 1.6 kW at 20_C (68_F) Resistance between terminal and sensor body: 1MW or more If any faulty is found, replace.
Page 1823 ANTILOCK BRAKE SYSTEM (ABS) 5B-39 ABS WARNING LAMP RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove ABS warning lamp relay from relay box. 3) Check resistance between each two terminals. Between “1” and “3”: 78 – 96 W at 20_C (68_F) Between “2”...
Page 1824 5B-40 ANTILOCK BRAKE SYSTEM (ABS) G SENSOR (IF EQUIPPED) REMOVAL 1) Turn ignition switch to OFF position. 2) Remove console box extension (right and left). 3) Disconnect connector from sensor. 4) Remove sensor with bracket from floor. CAUTION: D Do not separate sensor and bracket. It will lead to erroneous assembly.
Page 1825 4. DLC cable 5. Test lead / probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09950-78220 09931-76011 Flare nut wrench (10 mm) SUZUKI scan tool (Tech-1A) kit Mass storage cartridge 09931-76030 16 / 14 pin DLC cable...
Page 1826 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1827 7A-2 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) GENERAL DESCRIPTION CONSTRUCTION AND SERVICING The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three shafts: input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 1828 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-3 1. Input shaft 16. 5th speed synchronizer ring 31. Low speed sleeve & hub 2. Oil seal 17. Synchronizer ring spring 32. Low speed synchronizer key 3. Input shaft R bearing 18. 5th synchronizer spring 33.
Page 1829 7A-4 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) GEAR SHIFT MECHANISM Movement of gear shift control lever is transmitted to gear shift shaft through gear shift control shaft, and gear shift & select shaft through gear shift arm and gear shift yoke, and then gear shift & select lever to each gear shift yoke, shaft and fork or arm.
Page 1830 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-5 1) When gear is shifted to 5th speed, 5th & reverse gear shift cam 1. Gear shift & select shaft turns clockwise with gear shift & select shaft and it is pushed up 2.
Page 1831 7A-6 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) DIAGNOSIS Condition Possible Cause Correction Gears slipping out of mesh D Worn shift fork shaft Replace. D Worn shift fork or synchronizer sleeve Replace. D Weak or damaged locating springs Replace. D Worn bearings on input shaft or countershaft Replace.
Page 1832 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-7 ON-VEHICLE SERVICE OIL CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it. 3) Drain old oil and fill new specified oil by specified amount (up to level hole).
Page 1833 7A-8 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) DIFFERENTIAL SIDE OIL SEAL REPLACEMENT 1) Lift up vehicle and drain transmission oil. 2) Remove ball stud bolt and link nut, and then separate suspen- sion arm from knuckle. 1. Steering knuckle 3.
Page 1834 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-9 6) Insert drive shaft joint or center drive shaft to differential gear. With right side drive shaft, install center bearing support. CAUTION: D Be careful not to scratch oil seal lip with drive shaft joint while inserting.
Page 1835 7A-10 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) GEAR SHIFT CONTROL 1. Control lever knob 23. Rod nut 2. Boot No.2 24. O-ring 3. Boot cover 25. Control shaft bush 26. Control shaft bolt 4. Boot 5. Gear shift control lever 27.
Page 1836 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-11 REMOVAL 1. Extension rod On Lift 2. Housing nut 1) Disconnect gear shift control shaft from gear shift control lever 3. Control lever guide plate by removing control shaft bolt and nut. 4.
Page 1837 7A-12 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 2) Apply thread lock cement and then install knob to control lever. Make sure that knob is aligned with lever. 3) Install control lever assembly and related parts as they were. For positioning control lever, loosely install 4 guide plate bolts and 4 control lever housing nuts first, adjust position and then tighten those nuts and bolts.
Page 1838 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-13 INSTALLATION 1) Check O-ring and VSS surface for their flawlessness, apply oil to O-ring and driven gear and then install VSS to transmission. Tightening Torque (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) 1.
Page 1839 7A-14 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) UNIT REPAIR OVERHAUL DISMOUNTING OF TRANSMISSION UNDER HOOD 1) Disconnect battery ground cable. 2) Remove clutch cable joint nut, joint pin from cable and then cable itself from bracket. 3) Undo wiring harness clamps and couplers. 4) Remove transmission fastening bolts.
Page 1840 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-15 15) Remove engine mounting LH No.1 bracket. 16) Remove other attached parts from transmission, if any. 17) Pull transmission out so as to disconnect input shaft from clutch disc and then lower it. 1.
Page 1841 7A-16 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) D Set each clamp for wiring securely. 1. Clutch release arm D After connecting clutch cable, be sure to adjust its play properly (Refer to p. 7C-4 for free travel of clutch pedal). Pedal play “a”: 15 –...
Page 1842 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-17 6) Unfasten caulking of countershaft nut, install main shaft 5th gear and special tool to stop rotation of shafts, and then remove countershaft nut. Special Tool (C): 09927-76010 1. Input shaft 5th gear 2.
Page 1843 7A-18 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7) Pull out gear shift & select shaft assembly. 1. Gear shift & select shaft 8) Remove reverse shaft bolt with washer. 9) Remove 11 case bolts from outside and another 2 from clutch housing side.
Page 1844 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-19 RIGHT CASE 1) Remove differential gear assembly from right case. 2) Remove bolt and then pull out speedometer driven gear. CAUTION: Be careful not to damage speedometer driven gear case when removing it. 1.
Page 1845 2) Install input shaft oil seal facing its spring side upward. Use spe- cial tool and hammer for installation and apply grease to oil seal lip. “B”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool (A): 09951-76010 3) Install countershaft R bearing cup by using special tools and hammer.
Page 1846 6) Install differential side R oil seal until it becomes flush with case surface by using special tool with hammer, and then apply grease to its lip. NOTE: Face diff. side oil seal spring side inward. “B”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool 1. Gear shift shaft (E): 09913-75810 2. Boot 3.
Page 1847 7A-22 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 3) Install countershaft L bearing cup into case bore by tapping it with plastic hammer lightly. INPUT SHAFT ASSEMBLY 1. Input shaft 2. R bearing Disassembly 3. Bearing puller 1) Remove input shaft R bearing by using bearing puller and press.
Page 1848 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-23 Inspection and Reassembly 1) Clean all components thoroughly, inspect them for any ab- normality and replace with new ones as necessary. 2) If synchronizer parts need to be repaired, check clearance “a” between ring and gear, each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Page 1849 7A-24 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 6) Install 3rd gear needle bearing, apply oil to it, then install 3rd gear and synchronizer ring. 7) Drive in high speed sleeve & hub assembly by using special tool and hammer. NOTE: D While press-fitting sleeve &...
Page 1850 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-25 COUNTERSHAFT ASSEMBLY 1. Countershaft 2. L bearing cone Disassembly 3. 4th gear 1) Drive out L bearing cone with 4th gear by using puller and press. 4. Puller (Place flat side up) CAUTION: D Use puller and press that will bear at least 5 ton (11,000 lb) safely.
Page 1851 7A-26 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) Inspection and Reassembly 1) Clean all components thoroughly, inspect them for any ab- normality and replace with new ones as necessary. 2) If synchronizer parts need to be repaired, check clearance ”a” between ring and gear, each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Page 1852 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-27 7) Drive in low speed sleeve & hub assembly by using special tool and hammer. NOTE: D Support shaft with special tool as illustrated left so that retainer of bearing cone will be free from compression. D Make sure that synchronizer ring key slots are aligned with keys while press-fitting sleeve &...
Page 1853 7A-28 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) GEAR SHIFTER Gear Shift & Select Shaft Assembly 1) To disassemble component parts, use special tools and 2.8 – 3.0 mm (0.11 in.) pin remover in addition. Special Tool (A): 09922-85811(4.5 mm) (B): 09925-78210 (6.0 mm) 2) Clean all parts thoroughly, inspect them and replace with new ones as required.
Page 1854 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-29 5th & REV Gear Shifter 1) Disassemble component parts by using special tool and ham- mer. Special Tool (A): 09922-85811 (4.5 mm) 2) Replace or correct parts as required and assemble shafts mak- ing sure that component parts are in proper order as shown left.
Page 1855 7A-30 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) DIFFERENTIAL ASSEMBLY Disassembly 1) Using special tool, remove R bearing. Special Tool (A): 09913-65810 (B): 09925-88210 2) Take out speedometer drive gear. NOTE: In case that half-moon type puller is used with press for bearing removal, remove final gear in advance.
Page 1856 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-31 Right side Right side 1. Differential gear D Using similar procedure to the above, set dial gauge tip to gear shoulder. D Move gear up and down by hand and read dial gauge. 2) If thrust play is out of specification, select suitable thrust washer from among following available size, install it and check again that specified gear play is obtained.
Page 1857 7A-32 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) ASSEMBLING UNIT DIFFERENTIAL TO LEFT CASE 1) Install differential assembly into right case. 2) Insert speedometer driven gear case assembly applied with oil to its O ring and gear, then tighten it with bolt. CAUTION: D While inserting case assembly into transmission, turn final gear by hand slightly so that gear can...
Page 1858 6) Clean mating surfaces of both right and left cases, coat mating surface of left case with sealant evenly then mate it with right case. Sealant: SUZUKI BOND No.1215, 99000-31110 7) Tighten case bolts from outside to specified torque. Tightening Torque (b): 19 N·m (1.9 kg-m, 14.0 lb-ft)
Page 1859 7A-34 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) FIFTH GEARS 1. Input shaft 2. L bearing cup 1) To seat countershaft L bearing cup to bearing cone, tap cup by using special tool and plastic hammer. Special Tool (A): 09913-84510 2) Put a shim on bearing cup provisionally, place straight edge over it and compress it by hand through straight edge, and then measure “a”...
Page 1860 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-35 CAUTION: Do not reuse left case plate screws and bolts. Be sure to use new adhesive pre-coated screws and new adhesive pre-coated bolts. Otherwise, screws and/or bolts may loosen. 4) Place left case plate inserting its end in groove of shift guide shaft and tighten new adhesive pre-coated screws and new adhesive pre-coated bolts temporarily with less than specified torque.
Page 1861 7A-36 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7) Install 5th gear to counter shaft facing machined boss A inward. 1. Countershaft 5th gear A: Machined boss (Inside) B: No machining (Outside) 8) Install needle bearing to input shaft, apply oil then install 5th gear and special tool to stop shaft rotation.
Page 1862 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-37 13) Drive in spring pin facing its slit A outward. 14) Install steel ball, tighten shift fork plug applied with thread lock cement. “A”: Thread lock 1322, 99000-32110 Tightening Torque (c): 9 N·m (0.9 kg-m, 6.5 lb-ft) 15) Fit hub plate and fix it with circlip.
Page 1863 (c): 23 N·m (2.3 kg-m, 17.0 lb-ft) 7) Clean mating surface of left case and put gear shift guide case applied with sealant on it. Sealant: SUZUKI BOND No.1215, 99000-31110 8) Place wiring harness clamp bracket and fasten it together with gear shift guide case.
Page 1864 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-39 TIGHTENING TORQUE SPECIFICATIONS Tightening Torque Fastening portion Fastening portion kg-m lb-ft 1. Oil filler/level plug 15 5 15.5 2. Oil drain plug 3. Ball stud bolt and nut 43.5 4. Gear shift control housing nuts for boot cover 0.45 5.
Page 1865 7A-40 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCTS D Oil seal lips SUZUKI SUPER GREASE A D Gear shift control lever Lithium grease (99000-25010) D Gear shift control shaft bushes D Oil drain plug D Gear shift shaft bolt SUZUKI BOND NO.1215...
Page 1866 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 7A-41 09922-85811 09917-58010 09923-73210 09916-46010 Spring pin remover 4.5 mm Bearing remover Bearing remover Valve guide remover 09923-78210 09924-74510 09925-18011 09923-74510 Bearing installer Installer attachment Bearing installer Bearing remover 09925-68210 09925-88210 09925-58210 09925-78210 Bearing outer race installer Bearing puller attachment Spring pin remover 6 mm...
Page 1867 7A-42 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS) 09951-16060 09951-76010 09941-64511 Bush remover Bearing installer Bearing remover...
Page 1868 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1869 7A1-2 MANUAL TRANSMISSION (J18 ENGINE MODEL) GENERAL DESCRIPTION CONSTRUCTION AND SERVICING The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three shafts: input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 1870 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-3 1. Input shaft 16. 5th speed synchronizer ring 31. Low speed sleeve & hub 2. Oil seal 17. Snap ring 32. Low speed synchronizer key 3. Input shaft R bearing 18. 5th synchronizer spring 33.
Page 1871 7A1-4 MANUAL TRANSMISSION (J18 ENGINE MODEL) ON-VEHICLE SERVICE OIL CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it. 3) Drain old oil and fill new specified oil by specified amount (up to level hole).
Page 1872 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-5 UNIT REPAIR OVERHAUL DISMOUNTING OF TRANSMISSION UNDER HOOD 1) Disconnect battery ground cable. 2) Remove clutch operating cylinder from T/M with hose still at- tached. 3) Remove gear control cables. 4) Remove select cable lever with bracket. 5) Undo wiring harness clamps and couplers.
Page 1873 7A1-6 MANUAL TRANSMISSION (J18 ENGINE MODEL) 12) Remove engine LH mounting with bracket. 13) Remove other attached parts from transmission, if any. 14) Pull transmission out so as to disconnect input shaft from clutch disc and then lower it. 1. Engine mounting LH No.1 bracket 2.
Page 1874 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-7 DISASSEMBLING UNIT GEAR SHIFT AND SELECT SHAFT ASSEMBLY AND FIFTH GEARS 1) Remove gear shift interlock bolt and 5th to REV interlock guide bolt from transmission case. 2) Remove gear shift & select shaft assembly. 1.
Page 1875 7A1-8 MANUAL TRANSMISSION (J18 ENGINE MODEL) MAIN SHAFT AND COUNTERSHAFT 1) For removal procedure, refer to Steps 3), 6) and 8) of Gear Shift- er, Main Shaft and Countershaft of Disassembling Unit in SEC- TION 7A. 2) Remove transmission case outside bolts and clutch housing bolts.
Page 1876 2) Install input shaft oil seal facing its spring side upward. Use special tool and hammer for installation and apply grease to oil seal lip. “B”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool (A): 09913-84510 3) Install countershaft R bearing cup by using special tools and hammer.
Page 1877 7A1-10 MANUAL TRANSMISSION (J18 ENGINE MODEL) INPUT SHAFT ASSEMBLY Disassembly 1) Remove input shaft R bearing spacer and circlip. 2) For disassembly procedure, refer to Steps 2) to 7) of same item of Sub Assembly Service in SECTION 7A. Inspection and Reassembly 1) For inspection and reassembly procedure, refer to Steps 1) to 4) of same item of Sub Assembly Service in SECTION 7A.
Page 1878 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-11 COUNTERSHAFT ASSEMBLY 1) For disassembly procedure, refer to Steps 1) to 8) of same item of Sub Assembly Service in SECTION 7A. Inspection and Reassembly 1) For inspection and reassembly procedure, refer to Steps 1) to 6) of same item of Sub Assembly Service in SECTION 7A.
Page 1879 7A1-12 MANUAL TRANSMISSION (J18 ENGINE MODEL) GEAR SHIFTER Gear Shift & Select Shaft Assembly 1) To disassemble component parts, use special tools and 2.8 – 3.0 mm (0.11 in.) pin remover in addition. Special Tool (A): 09922-85811 (4.5 mm) (B): 09925-78210 (6.0 mm) 2) Clean all parts thoroughly, inspect them and replace with new ones as required.
Page 1880 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-13 3) Disassemble component parts by using spring pin remover and hammer. Special Tool (A): 09922-85811 (4.5 mm) 4) Assemble shift shafts as shown while making sure that compo- nent parts are in proper order. NOTE: D Correct shaft surface by using oilstone, if any scratch or dent is found.
Page 1881 7A1-14 MANUAL TRANSMISSION (J18 ENGINE MODEL) DIFFERENTIAL ASSEMBLY Disassembly 1) Using special tool, remove R bearing. Special Tool (A): 09913-61510 (B): 09925-88210 NOTE: Change removed bearing to new one. 2) Take out speedometer drive gear. 3) Remove L bearing by using puller while supporting its center shaft as described above.
Page 1882 CAUTION: Use of any other bolts than specified ones is prohib- ited. Thread lock cement “A”: 99000-32030 (SUZUKI BOND 1303B) Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft) 1. Final gear bolt 2. Final gear 3. Soft jawed vise...
Page 1883 7A1-16 MANUAL TRANSMISSION (J18 ENGINE MODEL) ASSEMBLING UNIT DIFFERENTIAL TO LEFT CASE 1) Install differential assembly into right case. 2) Measure clearance “A” (between differential side face and side bearing outer race) and “B” (bearing retainer). 3) Select the shim referring to the following table. Clearance Thickness of bearing A –...
Page 1884 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-17 4) Insert speedometer driven gear case assembly applied with oil to its O-ring and gear, then tighten it with bolt. CAUTION: D While inserting case assembly into transmission, turn final gear by hand slightly so that gear can mesh easily.
Page 1885 7A1-18 MANUAL TRANSMISSION (J18 ENGINE MODEL) 5) Check locating springs for deterioration and replace with new ones as necessary. REF No. Locating spring Service (Left Standard free length limit figure) 53.1 mm 50.5 mm Low speed (2.091 in.) (1.988 in.) 46.1 mm 44.0 mm High speed...
Page 1886 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-19 4) Install needle bearing to input shaft, apply oil then install input 1. Countershaft 5th gear 2. Input shaft shaft 5th gear. 5th gear 5) Engage gear double meshing to tighten countershaft nut and tighten it to specified torque.
Page 1887 14) Clean mating surface of both left case and side cover, coat mating surface with sealant evenly, mate it with left case and then tighten with 8 bolts. “B”: SUZUKI BOND No.1215, 99000-31110 Tightening Torque for left cover bolts (a): 10 N·m (1.0 kg-m, 7.5 Ib-ft) 1.
Page 1888 4) Install washer and gear shift interlock bolt applied with thread lock cement and them tighten it to specified torque. Thread lock cement “A”: 99000-32110 (SUZUKI BOND No.1322) Tightening Torque (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) 5) Install washer and 5th to REV interlock guide bolt applied with thread lock cement and then tighten it to specified torque.
Page 1889 7A1-22 MANUAL TRANSMISSION (J18 ENGINE MODEL) TIGHTENING TORQUE SPECIFICATIONS Tightening Torque Fastening Parts Fastening Parts N·m kg-m lb-ft 1. Oil filler/level plug 15 5 15.5 2. Oil drain plug 3. Speedometer driven gear case bolt 0.55 4. Center bearing support bolts 36.5 5.
Page 1890 MANUAL TRANSMISSION (J18 ENGINE MODEL) 7A1-23 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A D Oil seal lips Lithium grease (99000-25010) D Drain plug D Mating surface of transmission case SUZUKI BOND NO.1215 Sealant D Mating surface of driven case...
Page 1891 7A1-24 MANUAL TRANSMISSION (J18 ENGINE MODEL) 09922-85811 09913-84510 09913-85210 09913-85230 Spring pin remover 4.5 mm Bearing installer Bearing installer Bearing removing jig 09924-74510 Bearing & oil seal installer 09923-74510 09923-78210 09924-84510-004 Bearing remover Bearing installer handle Bearing installer attachment 09925-78210 09925-88210 09927-76010 09930-30104...
Page 1892 MANUAL TRANSMISSION 7A2-1 SECTION 7A2 MANUAL TRANSMISSION (4WD) NOTE: For the descriptions (items) not found in this section, refer to Section 7A1. CONTENTS GENERAL DESCRIPTION ..............7A2- 2 DIAGNOSIS .
Page 1893 7A2-2 MANUAL TRANSMISSION GENERAL DESCRIPTION This transmission uses a full-time 4WD system in which a rotary blade coupling is installed between propeller shaft No.1 and No.2 so that optimum amount of drive force is distributed to the front and rear wheels according to the driving conditions.
Page 1894 MANUAL TRANSMISSION 7A2-3 1. Input shaft 16. 5th speed synchronoizer ring 31. Low speed sleeve & hub 2. Oil seal 17. Washer 32. Low speed synchronizer key 3. Input shaft R bearing 18. 5th synchronizer spring 33. Spacer 4. Input shaft 3rd gear 19.
Page 1895 7A2-4 MANUAL TRANSMISSION 1. Bevel gear set 16. Transfer clutch sleeve 30. Transfer lock bolt 2. Shim 17. Nut 31. Gasket 3. Front bearing 18. Transfer output shaft 32. Oil seal 4. Shim 19. Circlip 33. Front differential 5. Transfer pinion spacer 20.
Page 1896 MANUAL TRANSMISSION 7A2-5 GEAR SHIFT MECHANISM The gear shifting control system consists of following main parts. Movement of gear shift control lever is trans- mitted to gear shift & select shaft through gear shift and gear select cables. 1. Gear shift control cable 7.
Page 1897 7A2-6 MANUAL TRANSMISSION 1) When shift lever is at neutral position between 3rd and 4th gear, shift cam is under guide bolt and can turn freely clockwise (to 3rd gear) and counterclockwise (to 4th gear). 1. Shift & select shaft 2.
Page 1898 MANUAL TRANSMISSION 7A2-7 DIAGNOSIS Condition Possible Cause Correction D Worn shift fork shaft Gears slipping out of Replace D Worn shift fork or synchronizer sleeve mesh Replace D Weak or damaged locating springs Replace D Worn bearings on input shaft or counter- Replace shaft D Worn chamfered tooth on sleeve and gear...
Page 1899 7A2-8 MANUAL TRANSMISSION ON-VEHICLE SERVICE PRECAUTION IN SERVICING (FULL-TIME 4WD) When performing any of the following types of work, it is necessary to make the vehicle as front wheel drive by cutting transmission of driving force to the rear wheels. Testing following items Towing vehicle with Driving front wheels...
Page 1900 (up to level hole). 4) Torque drain and level/filler plugs as specified below. Apply sealant to drain plug before installation. “A”: SUZUKI BOND No.1215, 99000-31110 Tightening Torque 1. Oil level/filler plug (a): 21 N·m (2.1 kg-m, 15.5 lb-ft) 2.
Page 1901 Distance “a”: 1.0 – 1.5 mm (0.04 – 0.06 in.) 5) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make sure of its smoothness. “A”: SUZUKI SUPER GREASE A, 99000-25010 1. Differential side oil seal...
Page 1902 MANUAL TRANSMISSION 7A2-11 6) Insert drive shaft joint or center drive shaft to differential gear. With right side drive shaft, install center bearing support. CAUTION: D Be careful not to scratch oil seal lip with drive shaft joint while inserting. D Make sure to insert drive shaft joint fully and seat its snap ring as it was.
Page 1903 7A2-12 MANUAL TRANSMISSION GEAR SHIFT CONTROL 1. Gear shift control lever knob Tightening Torque 2. Gear shift control lever (a): 6 N·m (0.6 kg-m, 4.5 lb-ft) 3. Gear select control arm (b): 13 N·m (1.3 kg-m, 9.5 lb-ft) 4. Gear shift control cable 5.
Page 1904 MANUAL TRANSMISSION 7A2-13 REMOVAL 1) Remove parking brake lower cover and console box. 2) Remove E-rings and clips from shift & select control cables. 3) Remove gear shift lever assembly. 1. Shift & select control 2. E-rings cables 3. Clip INSTALLATION Reverse removal procedure for installation and note as follows.
Page 1905 7A2-14 MANUAL TRANSMISSION UNIT REPAIR OVERHAUL DISMOUNTING OF TRANSMISSION 1) Take down engine with transmission referring to Section 6A1. 2) Remove transmission control cable bracket. 3) Remove starter motor. 4) Remove center bearing support mounting bolts and center drive shaft. 5) Remove transmission stiffener 6) Remove bolts and nuts fastening engine and transmission.
Page 1906 MANUAL TRANSMISSION 7A2-15 DISASSEMBLING UNIT REMOVAL OF TRANSFER AND DIFFERENTIAL 1) Remove differential side bearing retainer. 2) Remove speedometer driven gear. 3) Remove transfer assembly and differential from transmission. CAUTION: Be careful not to damage gear teeth surface. 1. Side bearing retainer GEAR SHIFT AND SELECT SHAFT ASSEMBLY AND FIFTH GEARS 1) Remove gear shift interlock bolt and 5th to REV interlock guide...
Page 1907 7A2-16 MANUAL TRANSMISSION MAIN SHAFT AND COUNTER SHAFT 1) For removal procedure, refer to Steps 3), 6) and 8) of Gear Shift- er, Main Shaft and Counter Shaft in Section 7A (DISASSEM- BLING UNIT). 2) Remove transmission case outside bolts and clutch housing bolts.
Page 1908 2) Install input shaft oil seal facing its spring side upward. Use spe- cial tool and hammer for installation and apply grease to oil seal lip. “B”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool (A): 09913-84510 3) Install countershaft R bearing cup by using special tools and hammer.
Page 1909 7A2-18 MANUAL TRANSMISSION INPUT SHAFT ASSEMBLY Disassembly 1) Remove input shaft R bearing spacer and circlip. 2) For disassembly procedure, refer to Steps 2) to 7) of same item in Section 7A. Inspection and Reassembly 1) For inspection and reassembly procedure, refer to Steps 1) to 4) of same item in Section 7A.
Page 1910 MANUAL TRANSMISSION 7A2-19 COUNTERSHAFT ASSEMBLY 1) For disassembly procedure, refer to Steps 1) to 8) of same item in Section 7A. Inspection and Reassembly 1) For inspection and reassembly procedure, refer to Steps 1) to 6) of same item in Section 7A. 2) Drive in low speed sleeve &...
Page 1911 7A2-20 MANUAL TRANSMISSION GEAR SHIFTER Gear Shift & Select Shaft Assembly 1) To disassemble component parts, use special tools and 2.8 – 3.0 mm (0.11 in.) pin remover in addition. Special Tool (A): 09922-85811 (4.5 mm) (B): 09925-78210 (6.0 mm) 2) Clean all parts thoroughly, inspect them and replace with new ones as required.
Page 1912 MANUAL TRANSMISSION 7A2-21 3) Disassemble component parts by using spring pin remover and hammer. Special Tool (A): 09922-85811 (4.5 mm) 4) Assemble shift shafts as shown while making sure that compo- nent parts are in proper order. NOTE: D Correct shaft surface by using oil stone, if any scratch or dent is found.
Page 1913: Transfer Assembly
7A2-22 MANUAL TRANSMISSION TRANSFER ASSEMBLY Disassembly 1) Remove rear mounting. 2) Remove output case bolts. 1. Rear mounting 2. Output case 3. Output case bolt 3) Remove transfer lock bolt from rear case. 1. Transfer lock bolt 2. Driven case 3.
Page 1914 MANUAL TRANSMISSION 7A2-23 7) Loosen driven case bolt and remove driven case. 1. Driven case bolt 2. Driven case 8) Drive driven gear out of rear case. 1. Rear case 2. Driven gear 3. Bar (rod) 9) Using special tool, hold drive gear securely and loosen output pinion nut.
Page 1915 7A2-24 MANUAL TRANSMISSION 12) Remove caulking of output shaft nut and loosen it with flange fixed as shown. Special Tool (A): 09930-40113 1. Box (30 mm) 2. Output flange 13) Using special tool, remove output flange. Special Tool (A): 09913-60910 1.
Page 1916: Output Shaft
MANUAL TRANSMISSION 7A2-25 Inspection and reassembly 1) Check tooth surface of gear and rotation of bearing and replace with new one if necessary As long as no abnormal condition such as noise exists before removal, replacement is unnecessary. 2) Drive in No.2 bearing by using special tools and hammer. Special Tool (A): 09913-84510 (B): 09926-58010...
Page 1917 2. No.2 bearing Sub Assembly Service Output case 1) If oil seal is removed,install new oil seal with grease applied to oil seal lip by using special tool. “A”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool (A): 09913-75810 Clearance 1. Oil seal 2 Output case “a”: 1.0 –...
Page 1918 MANUAL TRANSMISSION 7A2-27 2) Install output shaft to output case. 3) Install output No.1 bearing circlip 1. Circlip 4) Install output flange, washer and nut. 5) Tighten nut to specified torque by using special tool and then caulk nut. Special Tool (A): 09930-40113 Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft)
Page 1919 1) If shift fork shaft oil seal is removed, push in new oil seal with grease applied to oil seal lip by using 1 7 mm socket. “A”: SUZUKI SUPER GREASE A, 99000-25010 1. Shift fork shaft oil seal 2. 17 mm socket...
Page 1920 MANUAL TRANSMISSION 7A2-29 6) Using following table, select necessary shim(s). UNIT (mm) Shim to use 0.60 0.63 0.66 0.69 0.72 0.75 0.78 0.81 0.84 0.87 0.30 Measured level difference 0.976 – 1.005 1.006 – 1.035 1.036 – 1.065 1.066 – 1.095 1.096 –...
Page 1921 7A2-30 MANUAL TRANSMISSION Bevel pinion shim adjustment (Mounting distance adjustment) 1) Place bearings, spacer, shim(s) and drive gear on bevel pinion dummy of special tool (Bevel pinion dummy set) and tighten bevel pinion nut to specified torque. Use new nut. Tightening Torque (a): 120 N·m (12.0 kg-m, 87.0 lb-ft) Special Tool...
Page 1922 MANUAL TRANSMISSION 7A2-31 5) Using the following table, select necessary shim (s). UNIT (mm) Shim to use Measured 0.60 0.63 0.66 0.69 0.72 0.75 0.78 0.81 0.84 0.87 0.30 level difference Dimension “b” 0.586 – 0.615 0.616 – 0.645 0.646 – 0.675 0.676 –...
Page 1923 7A2-32 MANUAL TRANSMISSION Drive bevel gear backlash adjustment and side bearing preload adjustment 1) Using special tool, install differential assembly into rear case. Special Tool (A): 09927-56030 1. Rear case 2) Using depth gauge, measure depth “a” down to bearing outer race and obtain difference with dimension “b”...
Page 1924 MANUAL TRANSMISSION 7A2-33 6) Using torque wrench, measure preload. Standard value of preload: 0.5 – 1.3 N·m (5 – 13 kg-cm, 0.37 – 0.94 lb-ft) Special Tool (A): 09915–24550 NOTE: D Apply thin coat of gear oil to bearing before measure- ment.
Page 1925 7A2-34 MANUAL TRANSMISSION Inspection of gear tooth surface contact Upon completion of assembly, apply red lead paste to tooth surface of drive bevel gear and turn it by hand to check its contact with drive bevel pinion. Adjust if check result is not satisfactory. NOTE: Apply red lead paste all around bevel gear but not so much as to become sticky.
Page 1926 MANUAL TRANSMISSION 7A2-35 DIFFERENTIAL ASSEMBLY Disassembly 1) Using special tool, remove R bearing. Special Tool (A): 09913-61510 (B): 09925-88210 NOTE: Change removed bearing to new one. 2) Remove L bearing by using puller while supporting its center shaft as described above. 1.
Page 1927 CAUTION: Use of any other bolts than specified ones is prohib- ited. Thread lock cement “A”: 99000-32030 (SUZUKI BOND No. 1303B) 1. Final gear bolts 3. Soft jawed vise Tightening Torque 2. Final gear (a): 73 N·m (7.3 kg-m, 53.0 lb-ft)
Page 1928 MANUAL TRANSMISSION 7A2-37 5) Check locating springs for deterioration and replace with new ones as necessary. REF No. Locating spring Service Standard (Left free length limit figure) 53.1 mm 50.5 mm Low speed (2.091 in.) (1.988 in.) 46.1 mm 44.0 mm High speed (1.815 in.) (1.732 in.)
Page 1929 7A2-38 MANUAL TRANSMISSION 4) Install needle bearing to input shaft, apply oil then install input 1. Countershaft 5th gear 2. Input shaft shaft 5th gear. 5th gear 5) Engage gear double meshing to tighten Countershaft nut and tighten it to specified torque. Tightening Torque (a): 70 N·m (7.0 kg-m, 51.0 lb-ft) 6) Assemble 5th speed synchronizer sleeve and hub with keys...
Page 1930 14) Clean mating surface of both left case and side cover, coat mating surface with sealant evenly, mate it with left case and then tighten with 8 bolts. “B”: SUZUKI BOND No.1215, 99000-31110 Tightening Torque for left cover bolts (a): 10 N·m (1.0 kg-m, 7.5 lb-ft) 1.
Page 1931 4) Install washer and gear shift interlock bolt applied with thread lock cement and them tighten it to specified torque. Thread lock cement “A”: 99000-32110 (SUZUKI BOND No.1322) Tightening Torque (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) 5) Install washer and 5th to REV interlock guide bolt applied with thread lock cement and then tighten it to specified torque.
Page 1932 2) Clean mating surface to both rear case and driven case, coat mating surface of rear case with sealant evenly then mate it with driven case. Sealant “A”: 99000-31110 (SUZUKI BOND No.1215) 1. Driven gear 2. Rear case 3) Tighten driven case bolts to specified torque.
Page 1933 11) Clean mating surface to both driven case and output case, coat mating surface of driven case with sealant evenly then mate it with output case. Sealant “A”: 99000-31110 (SUZUKI BOND No.1215) 1. Box (30 mm) 12) Tighten output case bolts to specified torque. Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
Page 1934 NOTE: Face oil seal spring side inward. Distance “a”: 1.0 – 1.5 mm (0.04 – 0.06 in.) Special Tool (A): 09913-75810 “A”: SUZUKI SUPER GREASE A, 99000-25010 1. Differential side oil seal...
Page 1935 7A2-44 MANUAL TRANSMISSION 5) Check O-ring and VSS surface for their flawlessness, apply oil to O-ring and driven gear and then install VSS to transmission. Tightening Torque (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) 1. VSS 2. O-ring 3. Driven gear 6) Check side bearing retainer O-ring for flawlessness, apply oil to O-ring and then install to transmission.
Page 1936 MANUAL TRANSMISSION 7A2-45 TIGHTENING TORQUE SPECIFICATIONS Tightening Torque Fastening portion Fastening portion N·m kg-m lb-ft 1. Transfer shift fork shaft lock bolt 14.0 2. Oil filler/level plug 15.5 3. Speedometer driven gear case bolt 0.55 4. Center bearing support bolts 36.5 5.
Page 1937 7A2-46 MANUAL TRANSMISSION REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A D Oil seal lips Lithium grease (99000-25010) D Drain plug D Mating surface of transmission case SUZUKI BOND NO.1215 D Mating surface of driven case Sealant...
Page 1938 MANUAL TRANSMISSION 7A2-47 09913-76010 09913-80112 09913-84510 09913-85210 Bearing installer Bearing installer Bearing installer Bearing installer 09913-85230 09915-24550 09922-77241 09922-77270 Bearing removing jig Adapter socket Dial depth gauge Bevel pinion dummy set 09922-85811 09924-74510 Spring pin remover 09923-74510 09923-78210 Bearing & oil seal installer Bearing remover Bearing installer handle...
Page 1939 7A2-48 MANUAL TRANSMISSION 09927-25411 09927-56030 09927-76030 09930-30104 Bevel pinion holder Gear holder tool Bevel pinion holder Sliding shaft 09930-40113 09940-54910 09941-64511 09951-16060 Rotor holder Bearing installer Bearing remover Bush remover 09951-16090 09951-76010 Oil seal installer Bearing installer...
Page 1940 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” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 1941 7B-2 AUTOMATIC TRANSMISSION (3 A/T) Throttle position sensor check ..7B-45 TRANSMISSION UNIT REPAIR OVERHAUL 7B- 61 Dismounting ......7B- 62 ON-VEHICLE SERVICE .
Page 1942 AUTOMATIC TRANSMISSION (3 A/T) 7B-3 GENERAL DESCRIPTION The automatic transmission consists of the hydraulic torque converter, electronically controlled 3-speed automatic transmission, countershaft and differential. The transmission consists of 2 planetary gears, 2 disk clutches, 1 band brake, 1 disk brake and 1 one-way clutch. Its operation is controlled by selecting a position from 6 positions (P, R, N, D, 2 and L ranges) manually by means of the selector lever installed on the compartment floor.
Page 1943 7B-4 AUTOMATIC TRANSMISSION (3 A/T) COMPONENTS OPERATION CHART Forward Direct Second 1st & Reverse One-way Parking Lock Range Gear Clutch Clutch Brake Brake Clutch Pawl Parking – – – – Reverse – – – – Neutral – – – – –...
Page 1944 AUTOMATIC TRANSMISSION (3 A/T) 7B-5 ELECTRONIC SHIFT CONTROL SYSTEM [For vehicle with WU-TWC] 1. PCM 9. Shift indicator (if equipped) 15. Ignition switch 2. Camshaft position (CMP) sensor 10. Output shaft speed sensor (A/T VSS) 16. Main relay 3. Throttle position (TP) sensor 11.
Page 1945 7B-6 AUTOMATIC TRANSMISSION (3 A/T) [For vehicle without WU-TWC] 1. PCM 9. Shift indicator (if equipped) (No.2, 2nd brake solenoid valve) 2. Camshaft position (CMP) sensor 10. Output shaft speed sensor (A/T VSS) 16. Ignition switch 3. Throttle position (TP) sensor 11.
Page 1946 AUTOMATIC TRANSMISSION (3 A/T) 7B-7 POWER TRAIN CONTROL MODULE (PCM) The PCM controls the shift solenoid-B (No.2, 2nd brake solenoid valve) and the shift solenoid-A (No.1, direct clutch solenoid valve) by sending electric signals to them so as to attain automatic gear shift between the 1st and 2nd gears, and the 2nd and 3rd gears.
Page 1947 7B-8 AUTOMATIC TRANSMISSION (3 A/T) TRANSMISSION RANGE SENSOR (SHIFT SWITCH) Being linked with the selector lever, this sensor changes selector lever positions into electric signals and send them to the engine control module. The contact points of this sensor for P and N ranges are also connected with the starting motor circuit.
Page 1948 AUTOMATIC TRANSMISSION (3 A/T) 7B-9 OUTPUT SHAFT SPEED SENSOR (A/T VSS) The output shaft speed sensor consists of a magnetic core with magnet and coil. It is mounted on transmission case with 0.6 mm (0.024 in.) air gap between the core end and countershaft gear tooth.
Page 1949 7B-10 AUTOMATIC TRANSMISSION (3 A/T) BRAKE INTERLOCK SYSTEM (If equipped) This system is so designed that select lever cannot be shifted from P range position unless the ignition switch is turned to “ON” and brake pedal is depressed. Also, ignition key cannot be pulled out of key hole unless selector lever is in P range.
Page 1950 AUTOMATIC TRANSMISSION (3 A/T) 7B-11 SHIFT LOCK SOLENOID When the select lever is in P range, the ignition key position is “ON” and depressing the brake pedal cause the electric current to flow to the solenoid. As the lock plate is drawn toward the solenoid in this state, it frees the detent pin, which then allows the select lever to be shifted from P range to any other position.
Page 1951 MIL turn OFF although DTC stored in its memory will remain. D It is possible to communicate with PCM through data link con- necter (DLC) by using SUZUKI scan tool (Tech-1). (Diagnostic information can be checked and erased by using a scan tool) 2 Driving Cycle Detection Logic Refer to Section 6-1 or 6-2 for details.
Page 1952 (DTC) in its memory. D It is possible to communicate with PCM through data link con- necter (DLC) by using SUZUKI scan tool (Tech-1). (Diagnostic information can be checked and erased by using a scan tool)
Page 1953 Such disconnection will clear memorized information in PCM. D Using SUZUKI scan tool (Tech-1) the diagnostic information stored in PCM memory can be checked and cleared as well. Before its use, be sure to read Operator’s (instruction) Manual supplied with it carefully to have good understanding of its functions and usage.
Page 1954 AUTOMATIC TRANSMISSION (3 A/T) 7B-15 AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform 1) Perform customer complaint analysis referring to the customer next page.
Page 1955 7B-16 AUTOMATIC TRANSMISSION (3 A/T) 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 (shown in next page) will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 1956 AUTOMATIC TRANSMISSION (3 A/T) 7B-17 CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS j Vehicle does not move (R, D, 2, L range) j No upshift automatically (j 1st to 2nd j 2nd to 3rd j 2 range j D range) j No downshift automatically (j 3rd to 2nd j 2nd to 1st j 2 range j D range) j No gear change manually (j 1st $ 2nd j 2nd $ 3rd) j Automatic shift point too high or too low...
Page 1957 3) Turn ignition switch ON. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool oper- ator’s manual for further details. 5) After completing the check, turn ignition switch OFF and discon- nect SUZUKI scan tool from data link connector (DLC).
Page 1958 DIAGNOSTIC TROUBLE CODE(S) CLEARANCE [Using SUZUKI scan tool] 1) Turn ignition switch OFF. 2) After setting cartridge to SUZUKI scan tool, connect it to data link connector (DLC) located on underside of instrument panel at driver’s seat side. Special Tool...
Page 1959 7B-20 AUTOMATIC TRANSMISSION (3 A/T) DIAGNOSTIC TROUBLE CODE (DTC) TABLE A: Using scan tool for vehicle with WU-TWC B: Using scan tool and not using scan tool for vehicle without WU-TWC C: Driving cycles when MIL lighting for vehicle with WU-TWC D: Driving cycles when PCM stores DTC in its memory for vehicle without WU-TWC DTC NO.
Page 1960 AUTOMATIC TRANSMISSION (3 A/T) 7B-21 VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D A/ T fluid– – – – – level, leakage, color Section 0B D A/ T fluid hoses – – – – – disconnection, looseness, deterioration Section 7B D Throttle cable –...
Page 1961 When using SUZUKI scan tool: Flow Table. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 2 or L) on display when shifting manual selector to each range.
Page 1962 AUTOMATIC TRANSMISSION (3 A/T) 7B-23 SYMPTOM-TO-INSPECTION TABLE APPLICABLE DIAGNOSTIC FLOW TABLE. OR SYMPTOM CHECK (DESCRIBED IN THIS SECTION) No starting or slipping in any drive range A/ T DIAGNOSTIC FLOW TABLE A-1 Gear change failure A/ T DIAGNOSTIC FLOW TABLE A-2 Excessive shock at range selection or gear change A/ T DIAGNOSTIC FLOW TABLE A-3 Engine brake fails to operate...
Page 1963 7B-24 AUTOMATIC TRANSMISSION (3 A/T) COMPONENT LOCATION INFORMATION SENSORS CONTROLLED DEVICES OTHERS 1. Throttle position sensor a. Shift solenoid-A A. PCM 2. Transmission range sensor (Direct clutch solenoid valve) B. Main relay 3. Output shaft speed sensor b. Shift solenoid-B D.
Page 1964 AUTOMATIC TRANSMISSION (3 A/T) 7B-25 DTC P0705/DTC NO.72 TRANSMISSION RANGE SENSOR (SWITCH) CIRCUIT MALFUNCTION NOTE: *1: For vehicle with WU-TWC *2: For vehicle without WU-TWC 1. PCM 2. Transmission range sensor 3. From ignition switch 4. Shift indicator 5. Backup lamp 6.
Page 1965 Intermittent Go to Step 3. When using SUZUKI scan tool: trouble. Check 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. for intermittent 2) Turn ignition switch ON and check transmission range referring to signal (P, R, N, D, 2 or L) on display when shifting manual “INTERMITTENT...
Page 1966 AUTOMATIC TRANSMISSION (3 A/T) 7B-27 Fig. 4 for Step 4. Fig. 5 for Step 4. Terminal Range...
Page 1967 7B-28 AUTOMATIC TRANSMISSION (3 A/T) DTC P0720/DTC NO.24 OUTPUT SPEED SENSOR (A/T VSS) CIRCUIT MALFUNCTION Counter shaft gear NOTE: *1: For vehicle with WU-TWC *2: For vehicle without WU-TWC 1. PCM 2. Output shaft speed sensor 3. Terminal arrangement of PCM coupler (Viewed from harness side) CIRCUIT DESCRIPTION –...
Page 1968 AUTOMATIC TRANSMISSION (3 A/T) 7B-29 TROUBLESHOOTING STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW Go to Step 2. Go to TABLE” performed? ”AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE”. Check Output Shaft Speed Sensor for Resistance. Go to Step 3. Replace output 1) Disconnect output shaft speed sensor connector with shaft speed ignition switch OFF.
Page 1969 7B-30 AUTOMATIC TRANSMISSION (3 A/T) DTC P0753/DTC NO.61 OR 62 SHIFT SOLENOID-A (NO.1) ELECTRICAL DTC P0758/DTC NO.63 OR 64 SHIFT SOLENOID-B (NO.2) ELECTRICAL NOTE: *1: For vehicle with WU-TWC *2: For vehicle without WU-TWC 1. PCM 2. Shift solenoid-A (No.1, Direct clutch solenoid) 3.
Page 1970 Intermittent Go to Step 3. When using SUZUKI scan tool: trouble. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. Check for 2) Turn ignition switch ON. intermittent 3) Select “Data list” mode on scan tool. See Fig. 1.
Page 1971 7B-32 AUTOMATIC TRANSMISSION (3 A/T) DTC P0751 SHIFT SOLENOID-A (No.1) PERFORMANCE OR STUCK OFF DTC P0756 SHIFT SOLENOID-B (No.2) PERFORMANCE OR STUCK OFF CIRCUIT DESCRIPTION PCM monitors throttle opening, engine speed, vehicle speed and gear position and compares the actual engine speed and its specified value (i.e., engine speed obtained by PCM through calculation using the throttle open- ing/gear position and vehicle speed).
Page 1972 AUTOMATIC TRANSMISSION (3 A/T) 7B-33 TROUBLESHOOTING STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW Go to Step 2. Go to TABLE” performed? “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE”. Is DTC other than shift malfunction (DTC P0751 / P0756) Go to applicable Go to Step 3. displayed? DTC Flow Table.
Page 1973 7B-34 AUTOMATIC TRANSMISSION (3 A/T) TABLE A-1 NO STARTING OR SLIPPING IN ANY DRIVE RANGE STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC Go to Step 2. Go to FLOW TABLE” performed? “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE”. Is engine rpm at stall test normal? Transmission Go to Step 3.
Page 1974 AUTOMATIC TRANSMISSION (3 A/T) 7B-35 TABLE A-2 GEAR CHANGE FAILURE STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC Go to Step 2. Go to “AUTOMATIC FLOW TABLE” performed? TRANSMISSION DIAGNOSTIC FLOW TABLE”. Disconnect solenoid valve wire coupler and perform manu- Go to Step 3. 1-2 shift valve sticks al road test.
Page 1975 7B-36 AUTOMATIC TRANSMISSION (3 A/T) STALL TEST This test is to check overall performance of automatic transmission and engine by measuring stall speed at D and R ranges. Be sure to perform this test only when transmission fluid is at nor- mal operating temperature (70–805C/158–1765F) and its level is between FULL HOT and LOW HOT.
Page 1976 AUTOMATIC TRANSMISSION (3 A/T) 7B-37 LINE PRESSURE TEST This test is to check oil pressure system for operation by measuring oil pressure in oil pressure line. Make sure to perform this test only when transmission fluid is at normal operating temperature. NOTE: D Make sure that transmission fluid level is between FULL HOT and LOW HOT marks on oil level gauge at normal oper-...
Page 1977 7B-38 AUTOMATIC TRANSMISSION (3 A/T) 9) Possible causes for out-of-specification line pressure are as follows. Check each part which is suspected to be the cause. Line pressure Possible causes D Regulator valve defective Higher than specification D Throttle valve in valve body in D and R ranges defective D Accelerator cable and oil...
Page 1978 AUTOMATIC TRANSMISSION (3 A/T) 7B-39 ROAD TEST This test is to check if upshift and downshift take place at specified speeds while actually driving vehicle on a level road. WARNING: D Carry out the test in very little traffic area to prevent an accident.
Page 1979 7B-40 AUTOMATIC TRANSMISSION (3 A/T) MANUAL ROAD TEST This test checks the gears being used in L, 2 or D range when driv- en with unoperated gear shift control system. Test drive vehicle on a level road. 1) With selector lever in P range, start engine and warm it up. 2) After warming up engine, disconnect coupler of solenoid valve wire as shown in left figure.
Page 1980 AUTOMATIC TRANSMISSION (3 A/T) 7B-41 “P” RANGE TEST 1) Stop vehicle on a slope, shift selector lever to P range and at the same time apply parking brake. 2) After stopping engine, release parking brake lever gradually and check that vehicle remains stationary. SHIFT SOLENOID VALVE CHECK WITHOUT BATTERY VOLTAGE Whenever shift solenoid valves are removed from transmission,...
Page 1981 7B-42 AUTOMATIC TRANSMISSION (3 A/T) TABLE B-1 GEAR SHIFT FAILURE IN “D” OR “2” RANGE STEP ACTION Was “TABLE A-2 GEAR CHANGE FAILURE” performed? Go to Step 2. Go to “TABLE A-2”. Is gear no shift at all? Go to Step 3. Go to Step 4.
Page 1982 AUTOMATIC TRANSMISSION (3 A/T) 7B-43 TRANSMISSION RANGE SENSOR CHECK Check transmission range sensor referring to Step 2 of DTC P0705 Flow Table. OUTPUT SHAFT SPEED SENSOR CHECK 1) Turn OFF ignition switch. 2) Disconnect coupler(s) from powertrain control module. 3) Bring ohmmeter probes in touch with coupler terminals from harness side.
Page 1983 7B-44 AUTOMATIC TRANSMISSION (3 A/T) Separately from the above inspection, output shaft speed sensor itself can be checked on its resistance by disconnecting coupler. NOTE: D Function of output shaft speed sensor can be checked by measuring generated pulse as voltage. D For its measurement, use an analog type voltmeter while spinning wheels on lift and with selector lever in “D”...
Page 1984: Throttle Position Sensor Check
AUTOMATIC TRANSMISSION (3 A/T) 7B-45 3) Disconnect shift solenoid valve coupler from harness. 4) Apply 12 V to each terminal in solenoid valve coupler and check to be sure that a click sound is heard from each of shift sole- noid-A and -B.
Page 1985 7B-46 AUTOMATIC TRANSMISSION (3 A/T) ON-VEHICLE SERVICE MAINTENANCE SERVICE CHANGING FLUID 1) Raise vehicle. 2) With transmission cool, remove drain plug and drain fluid. 3) Install drain plug gasket and drain plug to oil pan, and tighten drain plug to specification. Tightening Torque (a): 21 N·m (2.1 kg–m, 15.5 Ib-ft) 4) Remove oil level gauge from oil filler tube, and add new fluid...
Page 1986 AUTOMATIC TRANSMISSION (3 A/T) 7B-47 FLUID LEVEL HOT Level Check at Normal Operating Temperature Be sure to check fluid level at every engine oil change. As automat- ic transmission is designed to operate at normal operating temper- ature which corresponds to 70_C–80_C (158_F – 176_F) of fluid, perform fluid level check when fluid temperature is within the above temperature range.
Page 1987 7B-48 AUTOMATIC TRANSMISSION (3 A/T) COLD Level Check at Room Temperature of About 25_C (77_F) If transmission was overhauled or fluid was drained for oil pan (and or valve body) service, refill fluid after assembling and check its lev- el according to following procedure. 1) Place vehicle on level surface.
Page 1988 Mount these cross slotted bolts in such positions as shown in figure after applying sealant to their threads. However, do not apply sealant to other 13 bolts. CAUTION: Do not use sealant to gasket surface. “A”: SUZUKI BOND No.1215, 99000-31110...
Page 1989 7B-50 AUTOMATIC TRANSMISSION (3 A/T) 5) Tighten oil pan bolts to the following torque one after another di- agonally. CAUTION: Over tightening of bolts may cause fluid leakage. Tightening Torque (a): 5 N·m (0.5 kg-m, 4.0 lb-ft) (b): 21 N·m (2.1 kg-m, 15.0 lb-ft) 1.
Page 1990 AUTOMATIC TRANSMISSION (3 A/T) 7B-51 INSTALLATION 1) Install solenoid valve wire harness to transmission case. If grommet seal (O ring) is damaged, replace. 2) Install direct clutch and 2nd brake solenoid valves to lower valve body. If solenoid seal (O ring) is damaged, replace. Tightening Torque (a): 8 N·m (0.8 kg-m, 6.0 lb-ft) 1.
Page 1991 7B-52 AUTOMATIC TRANSMISSION (3 A/T) OIL PRESSURE CONTROL CABLE REMOVAL 1) Disconnect oil pressure control cable from accelerator cable af- ter removing cable cover. 2) Drain transmission fluid. 3) Remove oil pan. 4) Disconnect oil pressure control cable from throttle valve cam. NOTE: Oil pressure control cable can be disconnected from throttle valve cam without removal of 2nd brake solenoid.
Page 1992 AUTOMATIC TRANSMISSION (3 A/T) 7B-53 SHIFT LOCK SOLENOID (If equipped) 1) Remove console box, and then select indicator. 2) Replace shift lock solenoid. 3) Install indicator and cover as they were. NOTE: D Shift selector lever to L range to facilitate work. D Check that detent pin is locked at “P”...
Page 1993 7B-54 AUTOMATIC TRANSMISSION (3 A/T) 5) Remove console box. 6) Remove cable bracket nut and detach cable end from key re- lease cam while pressing claws of release cam boss. At this time, be careful not to cause damage to its claws. 7) Remove interlock cable.
Page 1994 AUTOMATIC TRANSMISSION (3 A/T) 7B-55 8) With selector lever set at P range, turn ignition key to “ACC” 1. Detent pin position when knob button is pressed at position and then check for following conditions. P range. D With knob button released, ignition key can be turned from “ACC”...
Page 1995: System Inspection
7B-56 AUTOMATIC TRANSMISSION (3 A/T) SYSTEM INSPECTION (If equipped with interlock system) 1) Check to make sure that selector lever cannot be moved to any other range from P range when ignition switch key is at “ACC” or “LOCK” position or it is removed from keyhole of ignition switch.
Page 1996 AUTOMATIC TRANSMISSION (3 A/T) 7B-57 SELECT CABLE 1. Blank 2. Blank 3. Select cable 4. E ring (largest) 5. Cable bracket 6. Nut 7. Manual selector cable joint 8. Bush 9. Manual shift lever 10. Washer 11. E ring (small) 12.
Page 1997 7B-58 AUTOMATIC TRANSMISSION (3 A/T) ADJUSTMENT 1. Transmission range sensor 2. Select cable 1) Before tightening cable end nut, shift selector lever to N range. 3. Manual shift lever 2) Also shift manual shift lever to N range. 4. Manual select cable joint NOTE: Make sure that nut and cable joint have clearance under...
Page 1998 AUTOMATIC TRANSMISSION (3 A/T) 7B-59 3) After installing transmission range sensor to manual shift shaft, 1. Transmission range sensor 2. Select cable move transmission range sensor by hand in arrow direction as shown in left figure. Stop at the position where a “click” from joint is heard or felt by hand and then secure it.
Page 1999 Assemble selector by reversing removal procedure, replacing parts with new ones as necessary. Apply grease to portions indicated as “A” in left figure. “A”: SUZUKI SUPER GREASE A (99000-25010) NOTE: D When installing knob, make sure that there is a slight clear- ance between detent pin and cam bottom when knob button is pushed in all the way.
Page 2000 AUTOMATIC TRANSMISSION (3 A/T) 7B-61 TRANSMISSION UNIT REPAIR OVERHAUL 1. Input shaft 9. Rear planetary gear 2. Torque converter 10. 1st-reverse brake 3. Second brake band 11. One-way clutch 4. Second brake piston cover 12. Forward clutch 5. Front planetary gear 13.
Page 2001 7B-62 AUTOMATIC TRANSMISSION (3 A/T) DISMOUNTING 1. Drive plate 2. Screwdriver 1) Take down engine with transmission. (Refer to Section 6A1.) 2) Remove torque converter housing lower plate. 3) Remove drive plate bolts. To lock drive plate, engage a minus screwdriver with the drive plate gear.
Page 2002 AUTOMATIC TRANSMISSION (3 A/T) 7B-63 REMOUNTING 1. Drive plate 2. Screwdriver Reverse dismounting procedure. The important steps in installation are as follows. D Tighten drive plate bolts to specified torque. Tightening Torque (a): 18.5 N·m (1.85 kg-m, 13.5 lb-ft) D Tighten starting motor mounting bolts. 1.
Page 2003 7B-64 AUTOMATIC TRANSMISSION (3 A/T) TORQUE CONVERTER DIAGNOSIS STATOR ASSEMBLY FREEWHEELS If the stator roller clutch becomes ineffective, the stator assembly freewheels at all times in both directions. With this condition, the vehicle tends to have poor acceleration from a standstill. If poor ac- celeration problems are noted, what to be checked first are that the exhaust system is not blocked, the engine is running properly and the transmission is in 1st gear when starting out.
Page 2004 AUTOMATIC TRANSMISSION (3 A/T) 7B-65 DISASSEMBLY CAUTION: D Thoroughly clean transmission exterior before over- hauling it. D Keep working table, tools and hands clean while over- hauling. D Use special care to handle aluminum parts so as not to damage them. D Do not expose removed parts to dust.
Page 2005 7B-66 AUTOMATIC TRANSMISSION (3 A/T) 7) Remove 2 oil tubes from lower valve body. Remove them by pulling up tube end with a screwdriver. 8) Disconnect oil pressure control cable from throttle valve cam and then remove cable. 1. Oil pressure control cable 2.
Page 2006 AUTOMATIC TRANSMISSION (3 A/T) 7B-67 11) Remove second brake band cover and gasket. 12) After removing second brake band cover, check second brake piston stroke as follows. i) Scribe mark on piston rod as shown. ii) Blow air into oil hole and measure rod stroke. iii) If stroke is out of specification, replace piston rod with the one of different length or replace second brake band.
Page 2007 7B-68 AUTOMATIC TRANSMISSION (3 A/T) 15) Remove oil pump. i) Remove 6 oil pump securing bolts. ii) Remove oil pump by using special tool. CAUTION: Make sure that 2nd brake piston and piston rod have been removed before oil pump removal. If not, they may cause breakage of 2nd brake band.
Page 2008 AUTOMATIC TRANSMISSION (3 A/T) 7B-69 21) Remove front planetary ring gear and ring gear bearing. 1. Ring gear 2. Bearing 22) Remove front planetary gear assembly. 1. Front planetary gear assembly 23) Remove planetary sun gear and front planetary gear bearing. 1.
Page 2009 7B-70 AUTOMATIC TRANSMISSION (3 A/T) 26) Remove rear planetary ring gear, ring gear bearing and wash- ers. 1. Rear planetary ring gear 2. Ring gear bearing 3. Bearing race 27) Check 1st-reverse brake clearance. Measure clearance between snap ring and flange with feeler gauge.
Page 2010 AUTOMATIC TRANSMISSION (3 A/T) 7B-71 32) Remove reduction driven gear nut. i) Undo caulking. ii) Shift manual shift lever to P range so that output shaft is locked. iii) Loosen nut. CAUTION: Calmly apply torque to loosen nut so as not to damage reduction gear or parking lock pawl.
Page 2011 7B-72 AUTOMATIC TRANSMISSION (3 A/T) 36) Remove parking lock pawl, pawl shaft and sleeve, etc. 1. Parking lock pawl shaft 2. Parking lock pawl i) Pull out parking lock pawl shaft and spring. ii) Remove parking lock pawl. iii) Pull out parking lock pawl sleeve. iv) Remove manual detent spring assembly and manual shift shaft.
Page 2012 AUTOMATIC TRANSMISSION (3 A/T) 7B-73 CLUTCH AND BRAKE PARTS DIAGNOSIS SYMPTOMS Clutch Discs and Brake Band Dry and inspect them for pitting, flaking, wear, glazing, cracking, charring and chips or metal particles imbedded in lining. If discs or brake band show any of the above conditions, replacement is re- quired.
Page 2013 7B-74 AUTOMATIC TRANSMISSION (3 A/T) SUB ASSEMBLY SERVICE 1. Transmission case housing 6. Front planetary ring gear 2. Sun gear & sun gear 7. Upper & lower valve bodies input drum 8. Countershaft 3. Output shaft 9. Direct clutch 4. Oil pump 10.
Page 2014 AUTOMATIC TRANSMISSION (3 A/T) 7B-75 OIL PUMP 1. Oil pump body oil seal 2. Oil pump body 3. Cover seal (Apply grease) 4. Drive gear 5. Driven gear 6. Oil pump cover 7. Cover seal ring Removal 1) Remove 2 oil pump cover seal rings. 2) Remove oil pump cover seal (O ring).
Page 2015 Special Tool (A): 09913-85210 “A”: SUZUKI SUPER GREASE C, 99000-25030 2) Install driven gear and drive gear to pump body after applying fluid to gears. 3) Install pump cover to pump body and tighten 11 pump cover bolts to specification.
Page 2016 AUTOMATIC TRANSMISSION (3 A/T) 7B-77 DIRECT CLUTCH 1. Direct clutch washer 2. Direct clutch drum 3. Inner seal 4. Direct clutch piston 5. Outer seal 6. Return spring assembly 7. Return spring seat 8. Spring seat snap ring 9. Clutch plate 10.
Page 2017 7B-78 AUTOMATIC TRANSMISSION (3 A/T) 4) Remove spring seat and return spring assembly. 5) Remove direct clutch piston. Blow compressed air through drum oil hole to remove piston. If piston does not pop out, take out piston with long nose pliers. 1.
Page 2018 AUTOMATIC TRANSMISSION (3 A/T) 7B-79 4) Install clutch return spring assembly. 5) Install spring seat. 6) Install snap ring. Compress return springs and install spring seat snap ring in groove. Place special tool (clutch spring compressor) on spring seat and compress springs with press, and then, install snap ring using a screwdriver.
Page 2019 7B-80 AUTOMATIC TRANSMISSION (3 A/T) FORWARD CLUTCH 1. Input shaft seal ring 2. Direct clutch washer 3. Input shaft bearing race 4. Input shaft bearing 5. Bearing race 6. Input shaft 7. Inner seal 8. Forward clutch piston 9. Outer seal 10.
Page 2020 AUTOMATIC TRANSMISSION (3 A/T) 7B-81 4) Remove spring seat and springs. 5) Remove forward clutch piston. Blow compressed air through input shaft oil hole to remove pis- ton. If piston does not pop out, take it out with long nose pliers. 6) Remove inner and outer seals (O rings) from piston.
Page 2021 7B-82 AUTOMATIC TRANSMISSION (3 A/T) 5) Install discs, plates and flange in following order. i) Plate Õ ii) Disc Õ iii) Plate Õ iv) Disc Õ v) Plate Õ vi) Disc Õ vii) Flange NOTE: Before assembly, new discs should be soaked in automatic transmission fluid for 2 hours or more.
Page 2022 AUTOMATIC TRANSMISSION (3 A/T) 7B-83 VALVE BODY 1. Upper valve body assembly 9. Lower valve body assembly 17. Bolt 2. Valve body bolt 10. Oil strainer 18. 2nd brake accumulator piston 3. Valve body bolt 11. Bolt 19. B1 accumulator spring 4.
Page 2023 7B-84 AUTOMATIC TRANSMISSION (3 A/T) Important Steps in Disassembly and Reassembly of Valve Bodies D When disassembling valve body, be sure to keep each valve to- gether with its corresponding spring. D When removing upper valve body from lower one, be careful not to let 4 steel balls shown in figure fall off.
Page 2024 AUTOMATIC TRANSMISSION (3 A/T) 7B-85 COUNTERSHAFT AND OUTPUT SHAFT 1. Countershaft 7. Bearing backing plate 2. Output shaft 8. Snap ring 3. Snap ring 9. Reduction driven gear 4. Roller bearing 10. Reduction driven gear nut 5. Spacer 11. Output shaft seal ring 6.
Page 2025 7B-86 AUTOMATIC TRANSMISSION (3 A/T) 2) Install snap ring. 3) Install countershaft spacer to case. 4) Install another countershaft bearing (ball bearing) to case. Use special tools (Bearing installer attachment and installer handle). 5) Install bearing backing plate and snap ring. 1.
Page 2026 AUTOMATIC TRANSMISSION (3 A/T) 7B-87 DIFFERENTIAL ASSEMBLY Servicing procedure for differential assembly is similar to that for manual transmission. Refer to “DIFFERENTIAL ASSEMBLY” in Section 7A for further information. 1. Differential pinion 2. Differential gear 3. Side pinion shaft 4. Spring pin 5.
Page 2027 7B-88 AUTOMATIC TRANSMISSION (3 A/T) Disassembly 1) Remove differential side bearing (L). Use special tool and puller for its removal. Special Tool (A): 09925-88210 1. Side bearing (L) 2. Bearing puller 2) Remove final gear. 1. Differential side bearing (R) 2.
Page 2028 AUTOMATIC TRANSMISSION (3 A/T) 7B-89 4) Install speedometer drive gear. 5) Install diff. side bearing (R). Face its seal side inward and press- fit it by using special tool with copper hammer. While press-fit- ting, support differential assembly as illustrated so that left hand 1 Differential side bearing is floating.
Page 2029 7B-90 AUTOMATIC TRANSMISSION (3 A/T) 2) In the same manner as the above 1), measure dimension “b” of transmission case (from mating surface to bearing bore bot- tom). Dimension “b” = measured value – straightedge width “e” 1. Transmission case 2.
Page 2030 D Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly. D Use yellow petrolatum grease or Suzuki super grease C to retain parts in place. D Be sure to install thrust bearings and races in correct direction and position as shown in figure below.
Page 2031 7B-92 AUTOMATIC TRANSMISSION (3 A/T) 15. Planetary thrust washer 16. Rear planetary thrust washer 17. Sun gear pin 18. One-way clutch race snap ring 19. One-way clutch snap ring 20. One-way clutch 21. One-way clutch race 22. Rear planetary gear assembly 1.
Page 2032 AUTOMATIC TRANSMISSION (3 A/T) 7B-93 INSTALLATION 1. Second brake band 2. Pin 3. Piston cover snap ring 4. Piston cover 5. Cover seal (O ring) 6. Retainer (E ring) 7. Seal ring 8. Second brake piston 9. Piston seal 10. Piston spring 11.
Page 2033 7B-94 AUTOMATIC TRANSMISSION (3 A/T) 1. Manual shift shaft 2. Lower washer 3. Oil seal 4. Upper washer 5. Manual shift lever 6. Nut 7. Manual detent spring assembly 8. Parking lock pawl 9. Lock paw spring 10. Lock pawl shaft 11.
Page 2034 AUTOMATIC TRANSMISSION (3 A/T) 7B-95 vi) Install parking lock pawl. a. Shift manual shift lever to a position other than P. b. Install parking lock pawl. c. Install lock pawl shaft and lock pawl spring, and then, check to make sure that parking lock pawl moves smoothly when manual shift lever is moved.
Page 2035 7B-96 AUTOMATIC TRANSMISSION (3 A/T) 6) Install reduction driven gear on countershaft. i) Shift manual shift lever to P position so that output shaft is locked and cannot turn. ii) Tighten driven gear nut to specification. CAUTION: D Tighten nut by turning wrench by hand. D Tightening nut by hammering wrench may cause damage to parking lock pawl, output shaft and reduction gear.
Page 2036 AUTOMATIC TRANSMISSION (3 A/T) 7B-97 8) Using special tools (Output shaft remover and Bearing remov- er handle), push output shaft against rear cover side. i) Fit 4 projections of special tool (Output shaft remover) to 4 notches A in case. ii) Push bearing and output shaft against rear cover side by tapping special tool (Bearing remover handle) with a ham- mer lightly.
Page 2037 7B-98 AUTOMATIC TRANSMISSION (3 A/T) ii) Install discs, plates and flange in following order: (1) Plate Õ (2) Disc Õ (3) Plate Õ (4) Disc Õ (5) Plate Õ (6) Disc Õ (7) Plate Õ (8) Disc Õ (9) Flange (Flat side down) NOTE: When using new discs for installation, soak them in fluid for more than 2 hours before installation.
Page 2038 Apply grease to thrust washers and fit them before and behind planetary gear, one each. Make sure that different lug shapes match slots in planetary gear. “A”: SUZUKI SUPER GREASE C, 99000-25030 1. Thrust washer 17) Install rear planetary gear with teeth of 1st-reverse brake discs aligned.
Page 2039 21) Install sun gear pin and thrust washer on sun gear assembly. Apply grease to thrust washer so that it will not fall off. Check to make sure that pin is fitted in thrust washer notch. “A”: SUZUKI SUPER GREASE C, 99000-25030 1. Sun gear pin 2. Thrust washer 3.
Page 2040 AUTOMATIC TRANSMISSION (3 A/T) 7B-101 25) Install ring gear bearing and races on front planetary gear as- sembly in following order: i) Race (flange side up) ii) Bearing iii) Race (flange side down) Refer to “ASSEMBLING UNIT” in this section for proper instal- lation.
Page 2041 30) Apply grease to direct clutch washer, and install it on direct clutch with its grooved face outward and aligning washer pro- trusions to direct clutch drum groove. “A”: SUZUKI SUPER GREASE C, 99000-25030 1. Washer A: Groove B: Protrusions to be engaged in drum...
Page 2042 Do not apply thread locking compound to housing bolts. Tighten case housing bolts to specification. “B”: SUZUKI BOND No.1215, 99000-31110 A: Bolt with star-shaped recess in head Tightening Torque B: Install clamp for wiring harness (f): 20 N·m (2.0 kg-m, 14.5 Ib-ft)
Page 2043 Grease bearing race and install it with its flange side outward together with bearing. Install so that bearing does not get on bearing race flange. “A”: SUZUKI SUPER GREASE C, 99000-25030 1. Race 2. Bearing 40) Install another input shaft bearing race on oil pump.
Page 2044 AUTOMATIC TRANSMISSION (3 A/T) 7B-105 43) Align oil pump bolt hole with case bolt hole and push in pump gently by hand until it contacts case. Use care so that direct clutch washer does not fall off, and input shaft seal rings and pump cover seal rings will not come off or get damaged.
Page 2045 7B-106 AUTOMATIC TRANSMISSION (3 A/T) 47) Check second brake piston stroke as previously described. For checking procedure, refer to step 12) of “DISASSEMBLY” in this section. 48) Install second brake band cover with new gasket. Tightening Torque (h): 8 N·m (0.8 kg-m, 6.0 Ib-ft) 49) Install oil pressure control cable in case.
Page 2046 AUTOMATIC TRANSMISSION (3 A/T) 7B-107 51) Install valve body assembly to case. Align manual valve with pin on manual shift lever and lower valve body into place. Install 11 bolts in lower valve body. Each bolt length is given in figure. First, tighten 3 reamer bolts (positioning bolts) C and D lightly.
Page 2047 Tighten 15 oil pan bolts to specification. “B”: SUZUKI BOND No.1215, 99000-31110 Tightening Torque (j): 5.0 N·m (0.5 kg-m, 4.0 lb-ft) iv) Tighten oil pan drain plug to specification.
Page 2048 Distance “e”: More than 21.4 mm (0.85 in.) iii) Check torque converter for smooth rotation. iv) Apply grease around cup at the center of torque converter. “C”: SUZUKI SUPER GREASE A, 99000-25010 CAUTION: D Before installing converter, make sure that its pump hub portion is free from nicks, burrs or damage which may cause oil seal to leak.
Page 2049 7B-110 AUTOMATIC TRANSMISSION (3 A/T) DIMENSION DATA DATA ITEM ITEM Standard Limit 0.07 – 0.15 mm 0.3 mm Driven gear-to-body clearance 0.0028 – 0.0059 in 0.011 in 0.11 – 0.14 mm 0.3 mm Oil pump Gear tooth tip clearance 0.0043 – 0.0055 in 0.011 in 0.02 –...
Page 2050 AUTOMATIC TRANSMISSION (3 A/T) 7B-111 TIGHTENING TORQUE SPECIFICATIONS Tightening Torque Fastening Portion Fastening Portion N·m kg-m lb-ft 1. Transmission case plug 0.75 2. Drain plug 15.5 3. Oil pan bolts 4. Oil strainer bolts 0.55 5. Shift solenoid bolts 6. Output shaft speed sensor bolt 7.
Page 2051 7B-112 AUTOMATIC TRANSMISSION (3 A/T) SPECIAL TOOLS 09900-20606 09900-20701 09913-80112 09913-85210 Dial gauge Magnetic stand Bearing installer Bearing installer 1. 09916-14510 09918-48211 09924-74510 09925-18011 Valve lifter (Attachment 2 Oil pump remover Installer handle Remover handle is included) 09925-37811-001 09925-88210 09926-88310 09926-98310 Oil pressure gauge Bearing puller attachment...
Page 2052 09951-76010 09922-85811 Bush remover Bearing installer Spring pin remover (4.5 mm) 1. Storage case 2. Operator’s manual 3. SUZUKI scan tool 4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09931-76011 09931-76030...
Page 2053 Prepared by SUZUKI MOTOR CORPORATION Overseas Service Department 1st Ed. July, 2000 Printed in Japan Printing: July, 2000 1201...
Page 2054 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 2055 7B1-2 AUTOMATIC TRANSMISSION DTC P0720/DTC No.31 Output Speed VEHICLE SPEED SENSOR Sensor Circuit Malfunction ... . . 7B1-49 (VSS, SPEEDOMETER DRIVEN GEAR) . . . 7B1- 72 DTC P0725/DTC No.35 Engine Speed THROTTLE POSITION SENSOR .
Page 2056 AUTOMATIC TRANSMISSION 7B1-3 GENERAL DESCRIPTION This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up mechanism. The gear shift device consists of 2 sets of planetary gear units, 4 disc type clutches, a disc type brake, a band type brake and 2 one-way clutches.
Page 2057 7B1-4 AUTOMATIC TRANSMISSION 1. Torque converter clutch (TCC) 9. One-way clutch No.0 16. Counter drive gear (Reduction gear) 2. 2nd and 4th brake band 10. Forward clutch 17. Parking lock gear 3. Reverse clutch 11. Coast clutch 18. Counter driven gear (Reduction gear) 4.
Page 2058 AUTOMATIC TRANSMISSION 7B1-5 Item Specifications Torque Type 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism) converter Stall torque ratio More than 2.0 Type Internal gear type oil pump Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type “P”...
Page 2059 7B1-6 AUTOMATIC TRANSMISSION CLUTCH/BRAKE/PLANETARY GEAR 1. Forward clutch 7. 1st and reverse brake 13. One-way clutch No.1 2. Coast clutch 8. Front planetary ring gear 14. Counter drive gear 3. One-way clutch No.0 9. Front small planetary pinion gear 15. Counter driven gear 4.
Page 2060 AUTOMATIC TRANSMISSION 7B1-7 TABLE OF COMPONENT OPERATION Part Solenoid Solenoid Over- 1st/ One-way One-way Forward Reverse Coast 2nd/4th Selector Gear valve valve control drive reverse clutch clutch clutch clutch clutch brake No.1 No.2 solenoid clutch brake No.1 No.0 position position 4th (O/D) f: ON X: OFF...
Page 2061 7B1-8 AUTOMATIC TRANSMISSION ELECTRONIC SHIFT CONTROL SYSTEM 1. Engine 2. Transmission 3. Transmission control module (TCM) 4. Engine control module (ECM) 5. Throttle position sensor 6. Brake lamp (stop lamp) switch 7. Engine coolant temperature sensor 8. Transmission range sensor 9.
Page 2062 AUTOMATIC TRANSMISSION 7B1-9 TRANSMISSION CONTROL MODULE (TCM) The TCM is an electronic circuit component that controls gear shift and idle-up according to the signal from each sensor. It is a microcomputer of an IC, transistor, diode, etc. It is installed at the right side of the steering column. For Vehicle with WU-TWC 14.
Page 2063 7B1-10 AUTOMATIC TRANSMISSION For Vehicle without WU-TWC 14. Backup lamp 15. Shift indicator (if equipped) 16. Monitor connector No.2 17. Data link connector (DLC) 18. Shift solenoid-A (No. 1) 19. Shift solenoid-B (No. 2) 20. TCC (Lock-up) solenoid 21. Throttle pressure control solenoid 22.
Page 2064 AUTOMATIC TRANSMISSION 7B1-11 FAIL SAFE FUNCTION This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sen- sor or its circuit fails. The table below shows the fail safe function for each fail condition of sensor, solenoid or its circuit. DETECTED ITEM FAIL-SAFE OPERATION (NO.)
Page 2065 7B1-12 AUTOMATIC TRANSMISSION AUTOMATIC GEAR SHIFT DIAGRAM (FOR G16 ENGINE MODEL) Automatic shift schedule as a result of shift control is shown below. In case that select lever is shifted to L at a higher than 62 km/h (39 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower than that. No up shift is available in L.
Page 2066 AUTOMATIC TRANSMISSION 7B1-13 2 range POWER mode 2 range SNOW mode L range –––––: Up shift - - - - -: Down shift TCC Lock-up Diagram NORMAL mode POWER mode SNOW mode –––––: TCC ON - - - - -: TCC OFF...
Page 2067 7B1-14 AUTOMATIC TRANSMISSION AUTOMATIC GEAR SHIFT DIAGRAM (FOR J18 ENGINE MODEL) Automatic shift schedule as a result of shift control is shown below. In case that select lever is shifted to L at a higher than 52 km/h (33 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower than that. No up shift is available in L.
Page 2068 AUTOMATIC TRANSMISSION 7B1-15 2 range POWER mode 2 range SNOW mode TCC Lock-up Diagram NORMAL mode POWER mode SNOW mode –––––: TCC ON - - - - -: TCC OFF...
Page 2069 7B1-16 AUTOMATIC TRANSMISSION BRAKE INTERLOCK SYSTEM (if equipped) This system is so designed that select lever cannot be shifted from “P” range position unless the ignition switch is turned to “ON” and brake pedal is depressed. Also, ignition key cannot be pulled out of key hole unless selector lever is in “P”.
Page 2070 AUTOMATIC TRANSMISSION 7B1-17 When selector lever is shifted to any range other than P or when selector lever knob button is pushed at P. 1. Ignition key 2. Ignition switch 4. Release shaft 3. Interlock cable 5. Lock lever SHIFT LOCK SOLENOID When the select lever is in “P”...
Page 2071 7B1-18 AUTOMATIC TRANSMISSION DIAGNOSIS GENERAL DESCRIPTION This vehicle is equipped with an electronic transmission control system, which controls the automatic shift up and shift down timing, TCC operation, etc. suitably to vehicle driving conditions. TCM has an On-Board Diagnosis System which detects a malfunction in this system and abnormality of those parts that influence the engine exhaust emission.
Page 2072 DTC stored in ECM memory will also remain. D It is possible to communicate with ECM and/or TCM through data link connector (DLC) by using SUZUKI scan tool (Tech-1). (Diagnostic information can be checked and erased by using a scan tool.)
Page 2073 “O/D OFF” lamp. D It is possible to communicate with TCM through data link con- nector (DLC) by using SUZUKI scan tool (Tech-1). (Diagnostic information can be checked and erased by using a scan tool except DTC No.27, 36 and 38.) D It is also possible to check DTC stored in TCM memory by flash- ing of “...
Page 2074 D DTC stored in TCM can not be cleared by using ECM application of SUZUKI scan tool (Tech-1) in mass storage cartridge. Be sure to follow “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section when cleaning it.
Page 2075 7B1-22 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to the complaint analysis. next page.
Page 2076 AUTOMATIC TRANSMISSION 7B1-23 1. CUSTOMER COMPLAINT ANALYSIS (See CUSTOMER PROBLEM INSPECTION FORM) 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 2077 7B1-24 AUTOMATIC TRANSMISSION CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date of Reg.: Date of problem: Mileage: PROBLEM SYMPTOMS D Vehicle does not move (R, D, 2, L or any range) D No upshift automatically (D 1st to 2nd D 2nd to 3rd D 3rd to 4th (O / D) D 2 range D D range) D No downshift automatically (D 3rd to 2nd D 2nd to 1st D 4th (O / D) to 3rd D 2 range D D range) D No gear change manually (D 1st $ 3rd D 3rd $ 4th) D TCC no lock-up D TCC no lock-up off...
Page 2078 Section 6-1 or 6-2. NOTE: Method “A” is available only for vehicle with WU-TWC. B. Reading DTC from TCM by using SUZUKI scan tool with mass storage cartridge. 1) Set mass storage cartridge to scan tool and connect scan tool to DLC with ignition switch OFF.
Page 2079 7B1-26 AUTOMATIC TRANSMISSION DIAGNOSTIC TROUBLE CODE (DTC) CHECK USING “O/D OFF” LAMP STEP ACTION Check “O / D OFF” Lamp for Operation. Go to Step 2. Go to Step 3. 1) Check that O / D off switch is turned OFF. (Switch button is pushed).
Page 2080 A. To clear DTC stored in ECM – Refer to DTC clearance in Section 6-1 for clearance proce- dure. B. To clear DTC stored in TCM using SUZUKI scan tool 1) Turn ignition switch OFF. 2) Set mass storage cartridge to SUZUKI scan tool and con- nect scan tool to DLC.
Page 2081 7B1-28 AUTOMATIC TRANSMISSION DIAGNOSTIC TROUBLE CODE (DTC) TABLE A: Using scan tool for vehicle with WU-TWC B: Using scan tool for vehicle without WU-TWC and not using scan tool C: Driving cycles when MIL lighting and “O/D OFF” lamp flashing for vehicle with WU-TWC D: Driving cycles when “O/D OFF”...
Page 2082 NOTE: *1: DTC No. can not be read with SUZUKI scan tool. *2: Detecting of trouble (and DTC) is not applicable for vehicle without WU-TWC. *3: MIL does not light and also “O/D OFF” lamp does not flash although DTC is detected and stored at 1...
Page 2083 7B1-30 AUTOMATIC TRANSMISSION VISUAL INSPECTION Visually check the following parts and systems. INSPECTION ITEM REFERRING SECTION D A/ T fluid – – – – – level, leakage, color Section 0B D A/ T fluid hoses – – – – – disconnection, looseness, deterioration Section 7B1 D Throttle cable –...
Page 2084 AUTOMATIC TRANSMISSION 7B1-31 AUTOMATIC TRANSMISSION BASIC CHECK This check very important for troubleshooting when TCM and ECM has detected no malfunction DTC and no ab- normality has been found in visual inspection. Follow the flow table carefully. STEP ACTION Was “A/T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2.
Page 2085 7B1-32 AUTOMATIC TRANSMISSION TROUBLE DIAGNOSIS TABLE Perform troubleshooting referring to the following tables, according to “AUTOMATIC TRANSMISSION BASIC FLOW TABLE” when ECM and TCM have detected no malfunction DTC and no abnormality has been found in visual inspection. This section has 3 tables, Table-1 (Electrical circuit diagnosis table), Table-2 (Valve mechanism diagnosis table), Table-3 (Clutches, brake, etc.
Page 2086 AUTOMATIC TRANSMISSION 7B1-33 TROUBLE DIAGNOSIS TABLE-2 Condition Possible Cause Correction D Manual valve faulty Vehicle does not Clean or replace. D Primary regulator valve faulty move at any range. Clean or replace. 1st e 2nd D 1 – 2 shift valve faulty Clean or replace.
Page 2087 7B1-34 AUTOMATIC TRANSMISSION TROUBLE DIAGNOSIS TABLE-3 Condition Possible Cause Correction D Forward clutch faulty 1st, 2nd, 3rd, 4th gear Repair or replace. D Reverse clutch faulty Reverse gear Repair or replace. D Overdrive clutch faulty 3rd, 4th gear Repair or replace. D 2nd/4th brake faulty 2nd, 4th gear Repair or replace.
Page 2088 AUTOMATIC TRANSMISSION 7B1-35 ROAD TEST This test is to check if upshift and downshift take place at specified speeds while actually driving vehicle on a level road. WARNING: D Carry out test in very little traffic area to prevent an ac- cident.
Page 2089 7B1-36 AUTOMATIC TRANSMISSION MANUAL ROAD TEST This test checks the gears being used in “L”, “2” or “D” range when driven with unoperated gear shift control system. Test drive vehicle on a level road. NOTE: Before this test, check diagnosis code. 1) With select lever in “P”, start engine and warm it up.
Page 2090 AUTOMATIC TRANSMISSION 7B1-37 Test result Possible cause D Faulty engine output Lower than standard D Defective torque converter level D Low line pressure Higher than standard D Malfunctioning one-way clutch No.0 level in “D” range and/or coast clutch D Malfunctioning forward clutch D Malfunctioning one-way clutch No.1 D Low line pressure Higher than standard...
Page 2091 7B1-38 AUTOMATIC TRANSMISSION LINE PRESSURE TEST 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. D Automatic fluid is at normal operating temperature (70 to 80_C/158 –...
Page 2092 AUTOMATIC TRANSMISSION 7B1-39 ENGINE BRAKE TEST WARNING: Before test, make sure that there is no vehicle behind so as to prevent rear-end collision. 1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake operates. 2) In the same way as in Step 1), check engine brake for operation when select lever is shifted down to “L”...
Page 2093 7B1-40 AUTOMATIC TRANSMISSION TABLE A-1 “O/D OFF” LAMP CIRCUIT CHECK (LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON (BUT ENGINE AT STOP) WIRING DIAGRAM 1. TCM 2. Monitor connector No.2 3. “O/D OFF” lamp 4. IG fuse 5. Ignition switch 6.
Page 2094 AUTOMATIC TRANSMISSION 7B1-41 TABLE A-2 “O/D OFF” LAMP CIRCUIT CHECK (LAMP COMES ON STEADILY) WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to Table A-1 in this section. TROUBLESHOOTING STEP ACTION Check O / D off Switch Position. See Fig.1. Go to Step 2. Turn O / D off switch Is O / D off switch turned OFF (Is switch button at OFF OFF.
Page 2095 7B1-42 AUTOMATIC TRANSMISSION TABLE A-3 “O/D OFF” LAMP CIRCUIT CHECK (LAMP BLINKS OR REPEATS BRIGHT/DIM CONTINUOUSLY AT IGNITION SWITCH ON) WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to Table A-1 in this section. TROUBLESHOOTING STEP ACTION Check DTC by “O / D OFF” Lamp Blinking Pattern. Go to Step 2 of “A / T Go to Step 2.
Page 2096 AUTOMATIC TRANSMISSION 7B1-43 TABLE A-4 TCM POWER AND GROUND CIRCUIT CHECK 1. TCM 2. IG fuse 3. Ignition switch 4. Main fuse 5. Terminal arrangement of TCM coupler (Viewed from harness side) INSPECTION STEP ACTION Check TCM Power Circuit. Go to Step 2. “B / W”...
Page 2097 7B1-44 AUTOMATIC TRANSMISSION DTC P0705/DTC NO.34 TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. Transmission range sensor 3. From ignition switch 4. Shift indicator 5. Backup lamp 6. Terminal arrangement of TCM coupler (Viewed from harness side) TROUBLESHOOTING STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE”...
Page 2098 TRANSMISSION RANGE SENSOR CIRCUIT CHECK When using SUZUKI scan tool: 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 2 or L) on display when shifting select lever to each range.
Page 2099 7B1-46 AUTOMATIC TRANSMISSION DTC P0710/DTC NO.36 OR 38 TRANSMISSION TEMPERATURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. Transmission temperature sensor 3. Terminal arrangement of TCM coupler (Viewed from harness side) 4. Solenoid wire harness connector TROUBLESHOOTING STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOS- Go to Step 2.
Page 2100 AUTOMATIC TRANSMISSION 7B1-47 DTC P0715/DTC NO.37 INPUT/TURBINE SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM Forward clutch drum 1. TCM 2. Input shaft speed sensor 3. Terminal arrangement of TCM coupler (Viewed from harness side) TROUBLESHOOTING STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2.
Page 2101 7B1-48 AUTOMATIC TRANSMISSION Fig.1 for Step 3 Fig.2 for Step 4...
Page 2102 AUTOMATIC TRANSMISSION 7B1-49 DTC P0720/DTC NO.31 OUTPUT SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM Rotor 1. TCM 2. Output shaft speed sensor 3. Terminal arrangement of TCM coupler (Viewed from harness side) TROUBLESHOOTING STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2.
Page 2103 7B1-50 AUTOMATIC TRANSMISSION STEP ACTION Check Transmission Range Sensor for Operation referring Intermittent trouble Adjust or replace to step 2 of DTC P0705 Flow Table. or faulty TCM. transmission Is check result satisfactory? Check for intermittent range sensor. referring to “INTER- MITTENT AND POOR CONNECTION”...
Page 2104 AUTOMATIC TRANSMISSION 7B1-51 DTC P0725/DTC NO.35 ENGINE SPEED INPUT CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. ECM 3. To tachometer 4. Terminal arrangement of TCM coupler (Viewed from harness side) TROUBLESHOOTING STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2.
Page 2105 7B1-52 AUTOMATIC TRANSMISSION DTC P0741/DTC NO.29 TCC SYSTEM PERFORMANCE OR STUCK OFF TROUBLESHOOTING (DTC P0741/DTC NO.29) STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2. Go to “A / T DIAG- NOSTIC FLOW TABLE”. Check TCC Solenoid Valve for Operation referring to Go to Step 3.
Page 2106 AUTOMATIC TRANSMISSION 7B1-53 DTC P0743/DTC NO.25 OR 26 TCC SYSTEM ELECTRICAL WIRING DIAGRAM 1. TCC solenoid 2. TCM 3. Terminal arrangement of TCM coupler (Viewed from harness side) TROUBLESHOOTING STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2. Go to “A / T DIAG- NOSTIC FLOW TABLE”.
Page 2107 7B1-54 AUTOMATIC TRANSMISSION Fig.1 for Step 4 Solenoid connector on transmission...
Page 2108 AUTOMATIC TRANSMISSION 7B1-55 DTC P0745/DTC NO.41 OR 42 PRESSURE CONTROL SOLENOID MALFUNCTION WIRING DIAGRAM 1. Throttle pressure control solenoid 2. TCM 3. Terminal arrangement of TCM coupler (Viewed from harness side) TROUBLESHOOTING (DTC P0745/DTC NO.41 OR 42) STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2.
Page 2109 7B1-56 AUTOMATIC TRANSMISSION DTC P0751/DTC NO.17 SHIFT SOLENOID-A PERFORMANCE OR STUCK OFF DTC P0756/DTC NO.28 SHIFT SOLENOID-B PERFORMANCE OR STUCK OFF TROUBLESHOOTING STEP ACTION Was “A / T DIAGNOSTIC FLOW TABLE” performed? Go to Step 2. Go to “A / T DIAG- NOSTIC FLOW TABLE”...
Page 2110 AUTOMATIC TRANSMISSION 7B1-57 DTC P0753/DTC NO.21 OR 22 SHIFT SOLENOID-A ELECTRICAL DTC P0758/DTC NO.23 OR 24 SHIFT SOLENOID-B ELECTRICAL WIRING DIAGRAM 1. Shift solenoid-A 2. Shift solenoid-B 3. TCM 4. Terminal arrangement of TCM coupler (Viewed from harness side) TROUBLESHOOTING STEP ACTION Was “A / T DIAGNOSIS FLOW TABLE”...
Page 2111 7B1-58 AUTOMATIC TRANSMISSION Fig.1 for Step 4 T1-8 (Solenoid-B) T1-4 (Solenoid-A) Solenoid connector on transmission...
Page 2112 Go to Step 4. warmed engine. faulty TCM. When using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition referring to “INTERMIT- switch OFF. TENT AND POOR 2) Turn ignition switch ON. CONNECTION” in 3) Check “THROTTLE POSITION”...
Page 2113 7B1-60 AUTOMATIC TRANSMISSION Fig.1 for Step 3 Fig.2 for Step 3 90 – 100% (8 – 13 V) 50 – 80% (4 – 8 V)
Page 2114 AUTOMATIC TRANSMISSION 7B1-61 DTC P1702/DTC NO.52 INTERNAL CONTROL MODULE MEMORY TROUBLESHOOTING STEP ACTION 1) Turn ignition switch ON. Faulty TCM. Could be a temporary Replace TCM. malfunction of TCM. 2) Erase all DTCs referring to “DTC CLEARANCE” in this section. 3) Turn ignition switch OFF.
Page 2115 Intermittent Go to Step 4. When using SUZUKI scan tool: trouble or faulty 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. TCM. Check for 2) Start cold engine. intermittent 3) Check “COOLANT TEMP SIGNAL” displayed on scan tool.
Page 2116 AUTOMATIC TRANSMISSION 7B1-63 DTC P1895/DTC NO.27 TORQUE REDUCTION SIGNAL CIRCUIT WIRING DIAGRAM 1. TCM 2. ECM 3. Terminal arrangement of TCM coupler (Viewed from harness side) NOTE: *1: Vehicle with WU-TWC *2: Vehicle without WU-TWC TROUBLESHOOTING STEP ACTION Was “AUTOMATIC TRANSMISSION DIAG- Go to Step 2.
Page 2117 7B1-64 AUTOMATIC TRANSMISSION INSPECTION OF TCM AND ITS CIRCUITS TCM and its circuits can be checked at TCM wiring couplers by measuring voltage and resistance. CAUTION: TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with coupler disconnected from it.
Page 2118 AUTOMATIC TRANSMISSION 7B1-65 NORMAL TERMINAL CIRCUIT CONDITION VOLTAGE Engine coolant temperature Voltage varies as specified in graph in Section 6, 6-1 or 6-2. signal (ECM) 10 – 14 V Ignition switch ON, selector lever in “D” range Transmission range sensor Transmission range sensor Ignition switch ON, selector lever in other than “D”...
Page 2119 7B1-66 AUTOMATIC TRANSMISSION NORMAL TERMINAL CIRCUIT CONDITION VOLTAGE Ignition switch ON, mode selector switch in about 0 V “SNOW” mode Mode selector switch (“SNOW” mode) if equipped Ignition switch ON, mode selector switch in other 10 – 14 V than “SNOW” mode Ignition switch ON, mode selector switch in about 0 V “POWER”...
Page 2120: Fluid Level
AUTOMATIC TRANSMISSION 7B1-67 ON-VEHICLE SERVICE MAINTENANCE SERVICE FLUID LEVEL LEVEL CHECK AT NORMAL OPERATING TEMPERATURE 1) Stop vehicle and place it level. 2) Apply parking brake and place chocks against wheels. 3) With selector at P position, start engine. 4) Warm up engine till fluid temperature reaches normal operating temperature (70 –...
Page 2121 7B1-68 AUTOMATIC TRANSMISSION CHANGING FLUID 1) Lift up vehicle. 2) With engine is cool, remove drain plug from oil pan and drain A/T fluid. 3) Install drain plug. Tightening Torque (a): 40 N·m (4.0 kg-m, 29.0 lb-ft) 1. Drain plug 2.
Page 2122: Select Lever
AUTOMATIC TRANSMISSION 7B1-69 SELECT LEVER 1. Select lever assembly 2. Knob assembly 3. Screw 4. Indicator assembly 5. Solenoid (if equipped) 6. Housing nut INSPECTION Check select lever for smooth and clear-cut movement and posi- Shift the select lever with its button pushed tion indicator for correct indication.
Page 2123 7B1-70 AUTOMATIC TRANSMISSION SELECT CABLE ADJUSTMENT 1) Before tightening cable end nut, shift select lever to “N”. 2) Also shift manual shift lever to “N”. NOTE: Make sure that nut and cable joint have clearance under 1. Transmission above conditions. range sensor If select cable has been moved, push it in arrow C direc- 2.
Page 2124 AUTOMATIC TRANSMISSION 7B1-71 INSPECTION 1) Disconnect transmission range sensor coupler. 2) Check that continuity exists as shown in below by moving selec- tor lever. Terminal No. Switch position 1. Manual shift lever 2. Transmission range sensor 3. Transmission range sensor coupler OUTPUT SHAFT SPEED SENSOR (A/T VSS) INSPECTION 1) Disconnect negative cable at battery.
Page 2125: Revolution Sensor
7B1-72 AUTOMATIC TRANSMISSION INPUT SHAFT SPEED SENSOR (FORWARD CLUTCH CYLINDER REVOLUTION SENSOR) INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect input shaft speed sensor coupler. 3) Check resistance between input shaft speed sensor terminals. Input shaft speed sensor standard resistance: 387 – 473 W at 20 C (68 F) 1.
Page 2126: Solenoid Valves
AUTOMATIC TRANSMISSION 7B1-73 O/D OFF SWITCH INSPECTION 1) Remove console box. 2) Disconnect O/D off switch coupler. 3) Check continuity between O/D off switch terminals. O/D off switch Continuity No continuity Continuity 1. O/D off switch coupler 2. O/D off switch MODE SELECT SWITCH INSPECTION Check that continuity exists as shown in below by changing mode...
Page 2127 7B1-74 AUTOMATIC TRANSMISSION INSPECTION Shift solenoid No.1 Shift solenoid No.2 Resistance Check TCC solenoid. Shift solenoid No.1 and No.2 and TCC solenoid Check resistance between terminal and solenoid body. Standard resistance: 11 – 15 W at 20 C, 68 F Throttle pressure control solenoid Check resistance between each terminals.
Page 2128 4) Apply sealant to mating surface of A/T side cover and A/T case by using a nozzle as shown in figure by such amount that its sec- tion is 1.5 mm (0.059 in) in diameter. “A”: 99000-31230 (SUZUKI BOND NO.1216B) 1. Nozzle...
Page 2129 7B1-76 AUTOMATIC TRANSMISSION 5) Install A/T side cover. NOTE: Don’t reuse bolts (A). 6) Install radiator with cooling fan, fan shroud, A/T fluid cooler hoses and pipe. 7) Install A/T fluid cooling pipe, using under bolts to specified torque. Tightening Torque (a): 27 N·m (2.7 kg-m, 19.5 lb-ft) 1.
Page 2130 AUTOMATIC TRANSMISSION 7B1-77 TRANSMISSION TEMPERATURE SENSOR INSPECTION 1) Lift up vehicle. 2) With engine is cool, remove drain plug and drain A/T fluid. 3) Install drain plug. (Refer to “CHANGING FLUID” in this sec- tion.) 4) Disconnect oil cooler inlet hose (outlet from oil cooler) from pipe, and remove A/T fluid pipe (lower side).
Page 2131 7B1-78 AUTOMATIC TRANSMISSION DIFFERENTIAL SIDE OIL SEAL REPLACEMENT 1) Lift up vehicle and drain transmission oil. 2) Remove drive shaft joints from differential gear of transmission. Refer to Section 4 (DRIVE SHAFT) for procedure to disconnect drive shaft joints. For differential side oil seal removal, it is not necessary to re- move drive shafts from steering knuckle.
Page 2132 AUTOMATIC TRANSMISSION 7B1-79 INTERLOCK CABLE (if equipped) NOTE: Don’t bend interlock cable excessively when removing and installing it, or system will not operate correctly. REMOVAL 1) Disconnect negative cable at battery and disable air bag sys- tem, referring to “DISABLING AIR BAG SYSTEM” in Section 9J. 2) Remove steering column hole cover and steering joint cover.
Page 2133 7B1-80 AUTOMATIC TRANSMISSION 3) Shift selector lever to “P” position and with lock plate manually moved toward front side of vehicle, push knob button of selec- tor lever. 4) Under above condition, fix key release cam inserting special tool into holes on cam and selector bracket. Special Tool (A): 09925-78210 (6 mm) 5) Connect cable end to key release cam.
Page 2134 AUTOMATIC TRANSMISSION 7B1-81 AUTOMATIC TRANSMISSION ASSEMBLY COMPONENTS Tightening Torque (kg-m, lb-ft) (a): Transmission to engine bolt / nut (9.0, 65.0) (b): Drive plate bolt (1.9, 14.0)
Page 2135 7B1-82 AUTOMATIC TRANSMISSION DISMOUNTING <G16 engine model> 1) Disconnect negative cable at battery and transmission. 2) Disconnect coupler for solenoids, vehicle speed sensor (for speedometer), shift lever switch, forward clutch cylinder revo- lution sensor and output shaft speed sensor. 3) Undo wiring harness clamps. 4) Disconnect select cable from transmission.
Page 2136 AUTOMATIC TRANSMISSION 7B1-83 21) By using large size screwdriver, pull out drive shaft joints at dif- ferential side so as to release snap ring fitting. 22) Disconnect stabilizer joints from suspension arms on both sides. 23) Remove ball stud bolts and nuts from both knuckles and de- tach suspension arms and then pull out both drive shaft joints from differential.
Page 2137 7B1-84 AUTOMATIC TRANSMISSION <J18 engine model> 1) Disconnect negative cable at battery and transmission. 2) Disconnect coupler for solenoids, vehicle speed sensor (for speedometer), transmission range sensor, forward clutch cyl- inder revolution sensor and output shaft speed sensor. 3) Undo wiring harness clamps. 4) Disconnect select cable from transmission.
Page 2138 AUTOMATIC TRANSMISSION 7B1-85 21) Support transmission with transmission jack. 22) Remove bolts from engine left mounting. 23) Remove transmission with torque converter from engine compartment. WARNING: Be sure to keep transmission with torque converter horizontal or facing up through out the work. Should it be tilted with torque converter down, converter may fall off and cause personal injury.
Page 2139 7B1-86 AUTOMATIC TRANSMISSION REMOUNTING <G16 engine model> For remounting, reverse dismounting procedure. Use following specified torques and note points listed below. Tightening Torque (a): 90 N m (9.0 kg-m, 65.0 lb-ft) (b): 19 N m (1.9 kg-m, 14.0 lb-ft) (c): 28 N m (2.8 kg-m, 20.5 lb-ft) (d): 60 N m (6.0 kg-m, 43.5 lb-ft)
Page 2140 AUTOMATIC TRANSMISSION 7B1-87 <J18 engine model> For remounting, reverse dismounting procedure. Use the following specified torques and note points listed below. Tightening Torque (a): 90 N m (9.0 kg-m, 65.0 lb-ft) (b): 19 N m (1.9 kg-m, 14.0 lb-ft) (c): 28 N m (2.8 kg-m, 20.5 lb-ft) (d): 60 N m (6.0 kg-m, 43.5 lb-ft)
Page 2141 7B1-88 AUTOMATIC TRANSMISSION UNIT REPAIR AUTOMATIC TRANSMISSION ASSEMBLY COMPONENTS Tightening Torque (kg-m, lb-ft) (a): A / T side cover bolt (1.8, 13.0) (b): A / T fluid pipe union bolt (2.7, 19.5) (c): Transmission case bolt (3.0, 22.0) (d): Oil reservoir plate bolt / tube clamp bolt (0.55, 4.0) (e): Roller bearing retainer...
Page 2142 AUTOMATIC TRANSMISSION 7B1-89 UNIT DISASSEMBLY CAUTION: Thoroughly clean transmission exterior before over- hauling it. Keep working table, tools and hands clean while over- hauling. Use special care to handle aluminum parts so as not to damage them. Do not expose removed parts to dust. Keep them clean always.
Page 2143 7B1-90 AUTOMATIC TRANSMISSION 4) Pull out transmission range sensor assembly. a) Remove manual shift lever. b) Pry off lock washer. c) Remove lock nut. d) Remove lock washer and rubber plate. e) Remove 2 bolts. 1. Transmission range sensor NOTE: 2.
Page 2144 AUTOMATIC TRANSMISSION 7B1-91 10) Remove 6 bolts of oil pump body, then remove oil pump body by hand. NOTE: Use care not to cause damage to shaft bushing surface. If oil pump body can’t be removed by hand, remove it by using gear puller as shown in figure.
Page 2145 7B1-92 AUTOMATIC TRANSMISSION 15) Release solenoid wiring harness from clamp. 16) Disconnect pressure control, No.1 shift, No.2 shift and lock up control solenoid couplers. 17) Remove valve body assembly by removing eight bolts. NOTE: Each bolt length is indicated in figure. CAUTION: Be careful not to let manual valve fall off when re- moving valve body assembly.
Page 2146 AUTOMATIC TRANSMISSION 7B1-93 b) Plug oil hole (1). c) Measure piston rod stroke while applying and releasing compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) from oil hole (2). Specified piston rod stroke: 1.98 – 2.42 mm (0.078 –...
Page 2147 7B1-94 AUTOMATIC TRANSMISSION 28) Remove tools and take out 2nd and 4th brake piston assembly and brake inner cover. NOTE: If 2nd and 4th brake piston assembly doesn’t come out, apply compressed air through oil hole (1) in figure of step 22)-b).
Page 2148 AUTOMATIC TRANSMISSION 7B1-95 36) Remove carrier for front/rear planetary ring gear and sun gear assembly with the following integral bearing installed. Integral bearing with race dimension Outside diameter : 32.3 mm (1.27 in.) Inside diameter : 19.0 mm (0.75 in.) Race thickness : 2.7 mm (0.11 in.) 37) Pull out sun gear assembly.
Page 2149 7B1-96 AUTOMATIC TRANSMISSION 41) Remove retainer ring and brake piston return spring. 42) Remove 1st and reverse brake piston with O-ring installed while applying and releasing compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) through oil hole section (1). NOTE: Never reuse removed O-rings.
Page 2150 AUTOMATIC TRANSMISSION 7B1-97 50) Clamp special tool in a vise and place transmission housing onto special tool above. Special Tool (A): 09927-76040 51) Measure transmission housing rotational torque using push- pull gauge or the like. Specified value: 0.05 – 0.15 N·m (0.005 – 0.015 kg-m, 0.037 – 0.108 lb-ft) 1.
Page 2151 7B1-98 AUTOMATIC TRANSMISSION SUBASSEMBLY OIL PUMP 1. O-ring 5. Oil pump body 8. Seal ring 2. Oil pump body oil seal 6. Knock pin 9. Clutch drum thrust washer 3. Driven gear 7. Stator shaft subassembly 10. Torx bolt 4. Drive gear DISASSEMBLY 1) Remove two seal rings and clutch drum thrust washer from sta- tor shaft subassembly back side.
Page 2152 AUTOMATIC TRANSMISSION 7B1-99 INSPECTION 1) Check body clearance of driven gear. Push driven gear to one side of body. Using a feeler gauge, measure clearance between driven gear and body. If clearance exceeds its limit, replace gear. Body clearance Standard : 0.075 – 0.15 mm (0.00295 – 0.0059 in.) 1.
Page 2153 7B1-100 AUTOMATIC TRANSMISSION REASSEMBLY 1. Oil pump body 1) Install pump body oil seal. Use special tool and hammer to install it, and then apply grease to its lip portion. Special Tool (A): 09944-66020 2) Install driven gear and drive gear to pump body after applying fluid to gears.
Page 2154 AUTOMATIC TRANSMISSION 7B1-101 FORWARD CLUTCH 1. Race 6. Clutch plate (t=1.8 mm) 10. O-ring 15. Transmission rear cover 2. Clutch drum oil seal ring 7. Clutch drum thrust washer 11. Forward clutch piston subassembly 16. Clutch plate (t=1.6 mm) 3. Snap ring 8.
Page 2155 7B1-102 AUTOMATIC TRANSMISSION DISASSEMBLY 1) Remove flange, discs and plates by removing snap ring in the following order. <G16 engine model> (1) Flange " (2) Disc " (3) Plate " (4) Disc " (5) Plate <J18 engine model> (1) Flange " (2) Disc " (3) Plate " (4) Disc " (5) Plate "...
Page 2156 AUTOMATIC TRANSMISSION 7B1-103 INSPECTION 1) Check that sliding surfaces of discs, plates and flanges are not worn or burnt. If necessary, replace. NOTE: D If disc lining is exfoliated or discolored, or part of printed numbers (“A” section) is defaced, replace all discs. D Before assembling new discs, soak them in A/T fluid for at least two hours.
Page 2157 7B1-104 AUTOMATIC TRANSMISSION 3) Coat new O-rings with A/T fluid. 4) Install new O-rings to forward clutch piston subassembly. 5) Press forward clutch piston subassembly to forward clutch drum subassembly with fingers. NOTE: Make sure that O-ring is not twisted or deviated from posi- tion during insertion of piston.
Page 2158 AUTOMATIC TRANSMISSION 7B1-105 11) Measure piston stroke of forward clutch piston subassembly again. Special Tool (A): 09900-20606 (B): 09900-20701...
Page 2159 7B1-106 AUTOMATIC TRANSMISSION OVERDRIVE CLUTCH COAST CLUTCH 1. Overdrive direct multiple D 5. Clutch plate 10. Snap ring 14. Overdrive clutch piston clutch assembly 6. Snap ring 11. Overdrive clutch return spring 15. Overdrive clutch drum 2. Snap ring 7. Clutch flange 12.
Page 2160 AUTOMATIC TRANSMISSION 7B1-107 3) Measure coast clutch piston stroke while applying and releas- ing compressed air (400 – 800 kPa, 4 – 8 kg-cm , 57 – 113 psi) through oil hole (1) by using special tools. Special Tool (A): 09900-20606 (B): 09900-20701 Specified piston stroke: 2.68 –...
Page 2161 7B1-108 AUTOMATIC TRANSMISSION 5) For removing coast clutch piston, install forward clutch assem- bly. 6) Remove coast clutch piston with O-rings using compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) through oil hole (1). 7) Remove O-rings from coast clutch piston.
Page 2162 AUTOMATIC TRANSMISSION 7B1-109 REASSEMBLY 1) Apply A/T fluid to new O-rings. 2) Install new O-rings to pistons. 3) Set coast clutch piston to overdrive clutch piston by pushing with fingers. 4) Press overdrive clutch and coast clutch piston to overdrive clutch drum.
Page 2163 7B1-110 AUTOMATIC TRANSMISSION 7) Install flanges, discs and plate of coast clutch in the following order. (1) Flange " (2) Disc " (3) Plate " (4) Disc " (5) Flange NOTE: Be sure to confirm that flat section of flange (5) selected in Step 6) faces toward piston side and also that flange (1) faces toward upper side.
Page 2164 AUTOMATIC TRANSMISSION 7B1-111 12) Install forward clutch assembly and overdrive direct multiple D clutch assembly to transmission rear cover. 13) Measure overdrive clutch piston stroke again, using special tools. Special Tool (A): 09900-20606 (B): 09900-20701 Specified piston stroke: 0.76 – 1.04 mm (0.03 – 0.040 in.) (G16 engine model) 1.
Page 2165 7B1-112 AUTOMATIC TRANSMISSION FRONT PLANETARY RING GEAR (F1), REAR PLANETARY RING GEAR (F0) 1. One-way clutch inner race 13. Thrust bearing race 25. One-way clutch race 2. Thrust washer 14. Planetary gear assembly 26. One-way clutch 3. Thrust bearing race 15.
Page 2166 AUTOMATIC TRANSMISSION 7B1-113 OPERATION CHECK OF ONE-WAY CLUTCHES 1) Install forward clutch assembly and overdrive/coast clutch as- sembly to transmission rear cover. 2) Install planetary ring gear assembly to forward clutch and install No.0 (F0) one-way clutch to planetary ring gear facing toward front side.
Page 2167 7B1-114 AUTOMATIC TRANSMISSION 3) Remove No.1 (F1) one-way clutch by removing snap ring. 1. No.1 (F1) one-way clutch 2. Snap ring 4) Remove thrust washer. Reference value for washer Outside diameter : Approximately 85.3 mm (3.36 in.) Inside diameter : Approximately 70.0 mm (2.76 in.) Thickness : Approximately 2.6 mm (0.10 in.) 1.
Page 2168 AUTOMATIC TRANSMISSION 7B1-115 9) Remove O-ring. NOTE: Never reuse O-ring after removal. 1. O-ring INSPECTION Visually check the following parts for scratches or discoloration. D Outer surface of one-way clutch inner race. D Outer surface of one-way clutch roller. D Inner surface of front planetary ring gear subassembly. 1.
Page 2169 7B1-116 AUTOMATIC TRANSMISSION 7) Apply A/T fluid to thrust bearing race and install it. 1. Thrust bearing race 8) Apply A/T fluid to thrust washer and install it. 1. Thrust washer 9) Set one-way clutch and one-way clutch inner race. NOTE: D Check to make sure that “A”...
Page 2170 AUTOMATIC TRANSMISSION 7B1-117 12) Coat two thrust bearing races with A/T fluid. 13) Install planetary gear assembly and overdrive clutch hub with snap ring. 14) Install two thrust bearing races. 15) Check operation of one-way clutch. 1. Snap ring 3. Planetary gear assembly 2.
Page 2171 7B1-118 AUTOMATIC TRANSMISSION REASSEMBLY 1) Set one-way clutch to one-way clutch outer race and rear plane- tary ring gear. NOTE: Check to make sure that thinner section “A” of one-way clutch faces toward front side. 2) Install the following parts, previously mentioned parts, one-way clutch retainer and thrust needle roller bearing.
Page 2172: Preliminary Inspection
AUTOMATIC TRANSMISSION 7B1-119 REVERSE CLUTCH 1. Oil pump body 7. Clutch plate 13. Thrust bearing race 2. Reverse clutch drum with bearing 8. Clutch No.3 disc 14. Seal ring 3. O-ring 9. Snap ring 15. Sun gear input flange 4. Reverse clutch piston 10.
Page 2173 7B1-120 AUTOMATIC TRANSMISSION 3) Remove snap ring of reverse clutch drum with bearing. 1. Reverse clutch drum subassembly with bearing 2. Snap ring 4) Install sun gear input flange (thrust washer installed) with retain- er ring. 5) Mount reverse clutch drum with bearing to oil pump body. 6) Measure piston stroke with compressed air (400 –...
Page 2174 AUTOMATIC TRANSMISSION 7B1-121 3) Remove No.3 clutch discs and clutch plates in the following or- der. (1) Disc " (2) Plate " (3) Disc " (4) Plate 4) Remove reverse clutch return spring by removing snap ring, us- ing special tool and hydraulic press. Special Tool (A): 09926-96010 NOTE:...
Page 2175 7B1-122 AUTOMATIC TRANSMISSION 3) Check to make sure that ball makes creaking noise when shak- ing the reverse clutch piston. (i.e., check that ball is free.) 4) Check that there is no leakage by applying low-pressure air onto ball. 1. Ball 5) Check that outer surface of reverse clutch with bearing is not worn or burnt.
Page 2176 : 18.7 mm (0.74 in.) Thickness : 2.6 mm (0.10 in.) 13) Coat thrust bearing race with grease. Grease: 99000-25030 (SUZUKI SUPER GREASE C) 14) Install thrust bearing race to input shaft. Race dimension Outside diameter : 33.3 mm (1.31 in.) Inside diameter : 21.7 mm (0.85 in.)
Page 2177 15) Install input shaft to reverse clutch drum. 16) Install sun gear input flange with retainer ring. 17) Coat thrust washer with grease. Grease: 99000-25030 (SUZUKI SUPER GREASE C) 18) Install thrust washer to reverse clutch assembly. 2. Thrust washer 1.
Page 2178 AUTOMATIC TRANSMISSION 7B1-125 COUNTER DRIVE GEAR 1. Counter drive gear 2. Angular ball bearing 3. Locknut DISASSEMBLY 1) Clamp special tool in vise and place counter drive gear onto the special tool. Special Tool (A): 09927-76040 1. Vise 2) Unstake lock section of lock nut and remove lock nut using spe- cial tool.
Page 2179 7B1-126 AUTOMATIC TRANSMISSION NOTE: If inner race of angular ball bearing remains on counter drive gear, remove it using gear puller and special tools. Special Tool (A): 09925-86010 (B): 09925-06010 1. Counter drive gear REASSEMBLY 1) Press new angular ball bearing into counter drive gear using special tool.
Page 2180 AUTOMATIC TRANSMISSION 7B1-127 5) Stake new lock nut, using standard punch in combination with Correct hammer. NOTE: When staking lock nut, point a suitable staking tool toward axis center shaft and stake lock nut securely as shown in figure. (Poor staking may cause abnormal noise.) Wrong Wrong 1.
Page 2181 7B1-128 AUTOMATIC TRANSMISSION COUNTER DRIVEN GEAR 1. Thrust needle roller bearing 5. Cylindrical roller bearing 2. Thrust bearing race 6. Lock nut (for output shaft speed sensor) 3. Differential drive pinion 7. Thrust bearing race 4. Counter driven gear 8. Thrust needle roller bearing DISASSEMBLY 1) Remove transmission housing.
Page 2182 AUTOMATIC TRANSMISSION 7B1-129 5) Remove cylindrical roller bearing by pressing differential drive 1. Cylindrical roller bearing pinion, using hydraulic press. 2. Differential drive pinion 3. Press REASSEMBLY 1. Counter driven gear 2. Differential drive 1) Press differential drive pinion to counter driven gear, using hy- pinion 3.
Page 2183 7B1-130 AUTOMATIC TRANSMISSION 5) Stake new lock nut for output shaft speed sensor, using stan- Correct dard punch in combination with hammer. NOTE: When staking lock nut for vehicle speed sensor, point a suitable staking tool toward differential drive pinion shaft axis center and stake lock nut securely, as shown in the figure.
Page 2184 AUTOMATIC TRANSMISSION 7B1-131 VALVE BODY 1. Front valve body assembly 10. Rear valve body assembly 19. Overdrive clutch accumulator piston 2. Rear valve body gasket 11. Reverse clutch accumulator piston 20. 2 – 3 shift timing valve 3. Separator plate 12.
Page 2185 7B1-132 AUTOMATIC TRANSMISSION DISASSEMBLY 1) Remove valve body assembly from transmission case. 2) Pull out manual valve. 3) Remove solenoids by removing bolts. 1. Throttle pressure control solenoid 2. No.1 shift solenoid 3. No.2 shift solenoid 4. TCC control solenoid 4) Remove 11 bolts from valve body front side.
Page 2186 AUTOMATIC TRANSMISSION 7B1-133 7) Remove six balls, oil solenoid strainer and check valves and compression springs. Spring Identifications Outside diameter Color Length Length 12.6 mm 5.2 mm 5.3 mm Light Spring 1 Blue (0.496 in.) (0.205 in.) (0.209 in.) blue 18.1 mm 6.2 mm 7.0 mm...
Page 2187 7B1-134 AUTOMATIC TRANSMISSION 9) Remove the following parts and springs by removing rear valve body cover bolts and key. Rear valve body cover Gasket Plate Forward clutch accumulator Overdrive clutch accumulator 2 – 3 timing valve Coast clutch modulator TCC control valve 2nd and 4th brake accumulator Reverse clutch accumulator Solenoid modulator valve...
Page 2188 AUTOMATIC TRANSMISSION 7B1-135 11) Remove front valve body cover, cover gaskets and plate by re- moving 4 bolts. NOTE: Never reuse used gasket. 12) Remove check valve, compression spring, three balls and oil solenoid strainers. 1. Check valve and compression spring 2.
Page 2189 7B1-136 AUTOMATIC TRANSMISSION COMPRESSION SPRING IDENTIFICATIONS Torque convertor side of front valve body Rear cover side of front valve body Torque convertor side of rear valve body Rear cover side of rear valve body Fig. A NOTE: The free lengths of No. 9 and No. 20 indicate length “L” as Fig. A. Free length Outside diameter Identification...
Page 2190 AUTOMATIC TRANSMISSION 7B1-137 REASSEMBLY 1) Install valves and compression springs to torque convertor side of front valve body. NOTE: To identify correct spring or valve, refer to compression 1. Check valve spring identification. and compres- sion spring 2) Place check balls, check valve, compression spring and oil so- 2.
Page 2191 7B1-138 AUTOMATIC TRANSMISSION 8) Place check balls, oil solenoid strainer, check valves and com- pression springs to rear valve body. Check Valve Spring Identification Outside diameter Identification 1. Check ball Free length mm (in.) color Spring 2. Check ball (large) mm (in ) mm (in.) 3.
Page 2192 AUTOMATIC TRANSMISSION 7B1-139 12) Install solenoid valves to valve body and tighten bolts to speci- fied torque. Tightening Torque (a): 6.8 N·m (0.68 kg-m, 4.9 lb-ft) NOTE: Don’t reuse solenoid valve O-rings. No.1 shift solenoid valve and No.2 shift solenoid valve are interchangeable with each other.
Page 2193 7B1-140 AUTOMATIC TRANSMISSION DIFFERENTIAL 1. Differential gear assembly 2. Bolt 3. Differential ring gear 4. Ring gear set bolt lock plate INSPECTION 1) Hold differential assembly with soft jawed vice and set special tools as shown. Special Tool (A): 09900-20606 (B): 09900-20701 2) Measure differential gear thrust play.
Page 2194 AUTOMATIC TRANSMISSION 7B1-141 DIFFERENTIAL RING GEAR REMOVAL 1) Unclamp 4 ring gear set bolt lock plates. 2) Remove 8 bolts and 4 ring gear set bolt lock plates. NOTE: Don’t reuse lock plates. 3) Remove differential ring gear. BEARING OUTER RACE REMOVAL 1) Remove differential side oil seal.
Page 2195 7B1-142 AUTOMATIC TRANSMISSION 6) Install differential assembly to transmission case and tighten case bolts to specified torque. Tightening Torque for transmission case 30 NVm (3.0 kg-m, 22.0 lb-ft) 7) Check preload of differential by using special tool. Special Tool (A): 09928-06050 Differential preload (starting torque) 1.0 –...
Page 2196 AUTOMATIC TRANSMISSION 7B1-143 TRANSMISSION HOUSING 1. Oil reservoir plate 2. Magnet REMOVAL 3. Retainer 4. Oil seal 1) Remove oil seal. NOTE: Never reuse removed oil seal. 2) Remove oil reservoir plate with three magnets by removing bolts. 3) Remove roller bearing retainer by removing bolt. 4) Remove cylindrical roller bearing, using special tools.
Page 2197: Transmission Case
7B1-144 AUTOMATIC TRANSMISSION 5) Tighten roller bearing retainer with bolt. Tightening Torque (a): 13 N·m (1.3 kg-m, 9.5 lb-ft) 6) Install transmission lubrication tube and clamp. 7) Tighten them with bolt. Tightening Torque (b): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) 8) Tighten oil reservoir plate (with three magnets installed) with bolts.
Page 2198 AUTOMATIC TRANSMISSION 7B1-145 UNIT ASSEMBLY 1) Apply lithium grease to new oil seal lip section. 2) Install new oil seal to transmission case. 3) Insert manual valve lever shaft to transmission case. 4) Install new spacer and manual valve lever to manual valve lever shaft.
Page 2199 7B1-146 AUTOMATIC TRANSMISSION 10) Coat new O-rings with A/T fluid. 11) Place 1st and reverse brake piston with O-rings installed. NOTE: Be careful not to damage O-rings during piston installa- tion. 1. 1st and reverse brake piston 12) Mount brake piston return spring. 1.
Page 2200 AUTOMATIC TRANSMISSION 7B1-147 17) Place compression spring for 2nd and 4th brake into transmis- sion case. 18) Apply A/T fluid to new O-rings. 19) Assemble 2nd and 4th brake piston assembly. a) Install rod washer, spring, brake piston and new E-ring to brake piston rod.
Page 2201 7B1-148 AUTOMATIC TRANSMISSION 24) Install brake cover to transmission case with snap ring, using snap ring plier. Special Tool (A): 09900-06108 (Snap ring plier) 1. Brake cover 2. Snap ring NOTE: It is best for the head section of piston rod to protrude from the inner side of transmission case approx.
Page 2202 : Approximately 18.9 mm (0.74 in.) Thickness : Approximately 2.6 mm (0.10 in.) 37) Coat race with grease. Grease: 99000-25030 (SUZUKI SUPER GREASE C) 1. Planetary carrier 3. Needle roller bearing 38) Install race to planetary carrier. 2. Sun gear 4.
Page 2203 42) Apply sealant to contacting surface of transmission case by using a nozzle as shown in figure by such amount that its sec- tion is 1.5 mm (0.059 in) in diameter. “A”: Sealant 99000-31230 (SUZUKI BOND NO.1216B) 43) Install five gaskets. NOTE: There is no installation direction for new gaskets.
Page 2204 AUTOMATIC TRANSMISSION 7B1-151 53) Install 2nd and 4th brake band. 54) Install 1st and reverse clutch while rotating counterclockwise and clockwise. 1. 2nd and 4th brake band 2. 1st and reverse clutch 55) Check for correct installation of input shaft as follows. Measure the distance “a”...
Page 2205 63) Apply sealant to transmission case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in) in diameter. “A”: Sealant 99000-31230 (SUZUKI BOND NO.1216B) 1. Gasket 2. Differential gear assembly 3. Oil pump body 4.
Page 2206 72) Apply sealant to transmission case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in) in diameter. “A”: Sealant 99000-31230 (SUZUKI BOND NO.1216B) 1. Nozzle 73) Tighten transmission side cover with bolts.
Page 2207 7B1-154 AUTOMATIC TRANSMISSION 76) Coat new O-ring with A/T fluid. 77) Tighten speedometer driven gear (vehicle speed sensor for speedometer) (with new O-ring installed) with bolt. Tightening Torque (a): 5.5 N·m (0.55 kg-m, 4.0 Ib-ft) 1. Speedometer driven gear (Vehicle speed sensor for speedometer) shaft sleeve subassembly.
Page 2208 AUTOMATIC TRANSMISSION 7B1-155 81) Install torque converter to input shaft. a) Install torque converter, using care not to damage oil seal of oil pump. b) After installing torque converter, check to make sure that distance “a” is within specification. Distance “a”: More than 21.4 mm (0.843 in.) c) Check torque converter for smooth rotation.
Page 2209 7B1-156 AUTOMATIC TRANSMISSION TIGHTENING TORQUE SPECIFICATION Tightening Torque Fastening Portion Fastening Portion N·m kg-m lb-ft Drain plug 29.0 Transmission range sensor bolts 14.5 Output shaft speed sensor bolt 0 55 0.55 Input shaft speed sensor bore Solenoid valve bolts 0.68 A/T side over bolts 18.9 A/T fluid pipe union bolts...
Page 2210 AUTOMATIC TRANSMISSION 7B1-157 SPECIAL TOOL 1. 09916-14510 09900-06108 Valve lifter Snap ring plier 09900-20606 09900-20701 2. 09916-48210 (Closing type) Dial gauge Magnetic stand Attachment 09924-74590 09921-57810 09924-74510 09924-84510-005 Input shaft oil seal Bearing remover Installer handle Bearing installer adapter (C) installer attachment 09925-16010 09925-06010...
Page 2211 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09928-06050 09931-76011 Differential preload adaptor Mass storage cartridge SUZUKI scan tool (Tech 1A) kit 1. 09941-54911 Bearing outer race remover 2. 09921-26010 09931-76030 Bearing outer race 09942-15511 09944-66020...
Page 2212 SUZUKI BOND NO.1216B Sealant Mating surface of case and rear cover (99000-31230) Mating surface of case and side cover Retaining parts in place when assembling SUZUKI SUPER GREASE C Oil seal lips (99000-25030) Oil pump O-ring Lithium grease SUZUKI SUPER GREASE A...
Page 2213 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 2214 7C-2 CLUTCH (CABLE TYPE) 1. Clutch cover 2. Pressure plate 3. Diaphragm spring 4. Release bearing 5. Release shaft 6. Transmission right case 7. Clutch disc 8. Torsional spring 9. Input shaft bearing 10. Input shaft 11. Crankshaft 12. Flywheel...
Page 2215 CLUTCH (CABLE TYPE) 7C-3 DIAGNOSIS Condition Possible cause Correction D Improper clutch pedal free travel. Slipping Adjust free travel. D Worn or oily clutch disc facing. Replace disc. D Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel. surface.
Page 2216 7C-4 CLUTCH (CABLE TYPE) ON-VEHICLE SERVICE 1. Adjust bolt 2. Lock nut 3. Pedal bracket MAINTENANCE SERVICE 4. Clutch pedal 5. Brake pedal CLUTCH PEDAL HEIGHT 6. Measure Adjust clutch pedal height with adjust bolt located on pedal bracket so that clutch pedal height exceeds brake pedal height by 15 mm (0.6 in.) and tighten lock nut.
Page 2217: Clutch Cable
CLUTCH (CABLE TYPE) 7C-5 CLUTCH CABLE REMOVAL 1) Remove clutch cable joint nut and disconnect joint pin from in- ner cable. 2) Remove 2 bolts at dash panel, unhook cable end from pedal top, and then take out cable. INSPECTION Inspect clutch cable and replace it if any of following conditions ex- ists.
Page 2218 7C-6 CLUTCH (CABLE TYPE) UNIT REPAIR OVERHAUL CLUTCH COVER, CLUTCH DISC AND FLYWHEEL 1. Flywheel 5. Release shaft 9. Clutch disc 2. Release shaft seal 6. No.1 bush 10. Clutch cover bolt 3. No.2 bush 7. Release bearing 11. Torsion spring 4.
Page 2219 CLUTCH (CABLE TYPE) 7C-7 INSPECTION Input Shaft Bearing Check bearing for smooth rotation and replace it if abnormality is found. Clutch Disc Measure depth of rivet head depression, i.e. distance between riv- et head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Page 2220 7C-8 CLUTCH (CABLE TYPE) INSTALLATION NOTE: Before assembling, make sure that flywheel surface and pres- sure plate surface have been cleaned and dried thoroughly. 1) Install flywheel to crankshaft and tighten bolts to specification. Special Tool (A): 09924-17810 Tightening Torque (a): 78 N·m (7.8 kg-m, 56.5 lb-ft) 1.
Page 2221 4) Slightly apply grease to input shaft, then join transmission as- sembly with engine. Refer to p. 7A-15 for remounting proce- dure. “A”: SUZUKI SUPER GREASE I, 99000-25210 NOTE: Turn crankshaft a little through flywheel gear while insert- ing transmission input shaft to clutch disc until splines mesh.
Page 2222 Special Tool (A): 09943-88211 (B): 09923-46020 or the like “A”: SUZUKI SUPER GREASE A, 99000-25010 2) Install release shaft with return spring applied to it. 1. Special tool (Joint pipe 09923-46020) or the like 2.
Page 2223 6) Hook return spring. 7) Apply grease to release bearing inside and release shaft arm, then set bearing. “A”: SUZUKI SUPER GREASE A, 99000-25010 8) Apply small amount of grease to input shaft spline and front end as well. “B”: SUZUKI SUPER GREASE I, 99000-25210 1.
Page 2224 17.0 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT D Cable end hook and joint pin. SUZUKI SUPER GREASE A D Release shaft bushes and seal. (99000-25010) D Release shaft arm. Lithium grease SUZUKI SUPER GREASE I Input shaft and front end.
Page 2225 CLUTCH (CABLE TYPE) 7C-13 SPECIAL TOOLS 09923-36330 09923-46020 09917-58010 09922-46010 Clutch center guide Joint pipe Bearing remover Bush remover 09925-98210 Input shaft bearing 09924-17810 09925-98221 09930-30104 installer Flywheel holder Bearing installer Sliding shaft 09943-88211 Bearing installer...
Page 2226 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 2227 7C1-2 CLUTCH (HYDRAULIC TYPE) GENERAL DESCRIPTION The clutch is a hydraulically controlled 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.
Page 2228 CLUTCH (HYDRAULIC TYPE) 7C1-3 CLUTCH MASTER CYLINDER 1. Piston return spring 2. Piston 3. Seal cup spring WHEN NOT OPERATING 4. Seal cup As the piston is pushed to the right as shown by the return spring 5. Reservoir force, no hydraulic pressure is generated in the chamber “a”. The spring force also compresses the seal cup spring, opening the oil passage between the reservoir and the chamber “a”.
Page 2229 7C1-4 CLUTCH (HYDRAULIC TYPE) DIAGNOSIS Condition Possible cause Correction D Improper clutch pedal free travel. Slipping Replace clutch arm or master cylinder. D Worn or oily clutch disc facing. Replace disc. D Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel. surface.
Page 2230: Clutch Pedal
CLUTCH (HYDRAULIC TYPE) 7C1-5 ON-VEHICLE SERVICE MAINTENANCE SERVICE CLUTCH PEDAL Clutch Pedal Free Height “A” 1) Check “A” for conformance to below specification. Clutch pedal height “A” Left hand steering vehicle : 191 – 201 mm (7.52 – 7.91 in.) Right hand steering vehicle : 202 –...
Page 2231 7C1-6 CLUTCH (HYDRAULIC TYPE) Cylinder Push Rod Play “D” 1) Press clutch pedal gradually with finger, stop when slight in- crease of resistance is felt and measure how much pedal has moved (push rod play) as represented by “D” as shown. Then check its conformance to below specification.
Page 2232 CLUTCH (HYDRAULIC TYPE) 7C1-7 CLUTCH FLUID PIPE AND HOSE For left-hand steering vehicle For right-hand steering vehicle 1. Master cylinder 2. Pipe 3. Hose 4. Operating cylinder 5. Clamp REMOVAL NOTE: Do not allow fluid to get on painted surface. 1) Remove dust and dirt from each joint of hose and pipe to be dis- connected and clean around reservoir cap.
Page 2233 7C1-8 CLUTCH (HYDRAULIC TYPE) INSTALLATION Reverse removal procedure for installation, and note the following instruction. NOTE: D For air bleeding of master cylinder alone, it must be re- moved from vehicle body. (For procedures of removal and installation of master cylin- der and air bleeding, refer to “CLUTCH MASTER CYL- INDER”...
Page 2234 CLUTCH (HYDRAULIC TYPE) 7C1-9 CLUTCH MASTER CYLINDER REMOVAL 1) Clean around reservoir cap and take out fluid with syringe or such. 2) Remove clevis. 3) Disconnect fluid pipe from master cylinder. NOTE: Do not allow fluid to get on painted surfaces. 4) Remove master cylinder attaching nuts.
Page 2235 7C1-10 CLUTCH (HYDRAULIC TYPE) 6) Fill reservoir with specified brake fluid and check fluid leakage. 7) After installation, bleed air from system. (Refer to Section 5 for air bleed procedure.) 8) Check clutch pedal free travel. (Refer to “MAINTENANCE SER- VICE”...
Page 2236 5. Hose 2) Apply small amount of grease to rod tip. NOTE: Don’t allow any grease to be on boot. “A”: GREASE 99000-25010(SUZUKI SUPER GREASE A) 3) Install clutch operating cylinder and tighten attaching bolts to specified torque. Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
Page 2237 7C1-12 CLUTCH (HYDRAULIC TYPE) UNIT REPAIR OVERHAUL 1. Reservoir cap 6. Circlip 2. Cylinder 7. Boot 3. Piston assembly 8. Lock nut CLUTCH MASTER CYLINDER 4. Push rod 9. Clevis 5. Piston stopper DISASSEMBLY 1) Remove boot and then circlip with piston pushed in. 1.
Page 2238 CLUTCH (HYDRAULIC TYPE) 7C1-13 REASSEMBLY NOTE: Before installation, wash each part in specified brake fluid. 1) Apply brake fluid to inside of piston assembly and cylinder body. 2) Install piston assembly into cylinder. 3) With piston pushed down, install circlip as shown. 4) Install boot.
Page 2239 7C1-14 CLUTCH (HYDRAULIC TYPE) NOTE: Polishing bore of cylinder with anything abrasive is prohib- ited, as damage to cylinder bore may occur. Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot be kept away from cylinder bore surfaces.
Page 2240 CLUTCH (HYDRAULIC TYPE) 7C1-15 CLUTCH COVER, CLUTCH DISC AND FLYWHEEL 1. Release shaft seal 2. No.2 bush 3. Release shaft 4. No.1 bush 5. Release bearing 6. Clutch cover 7. Clutch disc 8. Clutch cover bolt 9. Flywheel REMOVAL 1) Dismount transmission. Refer to “DISMOUNTING OF TRANS- MISSION”...
Page 2241 7C1-16 CLUTCH (HYDRAULIC TYPE) INSPECTION Input Shaft Bearing Check bearing for smooth rotation and replace it if abnormality is found. Clutch Disc Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Page 2242 CLUTCH (HYDRAULIC TYPE) 7C1-17 INSTALLATION NOTE: Before assembling, make sure that flywheel surface and pres- sure plate surface have been cleaned and dried thoroughly. 1) Install flywheel to crankshaft and tighten bolts to specification. Special Tool (A): 09924-17810 Tightening Torque (a): 70 N·m (7.0 kg-m, 51.0 lb-ft) 1.
Page 2243 4) Slightly apply grease to input shaft, then join transmission as- sembly with engine. Refer to “REMOUNTING” under “UNIT RE- PAIR OVERHAUL” in Section 7A. “A”: GREASE 99000-25210 (SUZUKI SUPER GREASE I) NOTE: When inserting transmission input shaft to clutch disc, turn crankshaft little by little to match the spline mesh.
Page 2244 Special Tool (A): 09943-88211 (B): 09923-46020 or the like “A”: GREASE 99000-25010 (SUZUKI SUPER GREASE A) 2) Install release shaft with return spring applied to it. 1. Special tool (Joint pipe 09923-46020) or the like 2.
Page 2245 6) Hook return spring. 7) Apply grease to release bearing inside and release shaft arm, then set bearing. “A”: GREASE 99000-25010 (SUZUKI SUPER GREASE A) 8) Apply small amount of grease to input shaft spline and front end as well.
Page 2246 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Clutch master cylinder clevis D Release shaft bushes and seal. SUZUKI SUPER GREASE A D Release shaft arm. (99000-25010) Lithium grease D Push rod tip of operating cylinder. SUZUKI SUPER GREASE I Input shaft spline front end.
Page 2247 7C1-22 CLUTCH (HYDRAULIC TYPE) SPECIAL TOOL 09913-76010 09921-20210 09922-46010 09923-36320 Bearing installer Bearing remover Bush remover Clutch center guide 09924-17810 09925-46010 09925-98221 09930-30104 Flywheel holder Bush remover Bearing installer Sliding shaft 09943-88211 Bearing installer...
Page 2248 REAR DIFFERENTIAL 7F-1 SECTION 7F REAR DIFFERENTIAL CONTENTS GENERAL DESCRIPTION ............... . 7F- 2 DIAGNOSIS .
Page 2249 7F-2 REAR DIFFERENTIAL GENERAL DESCRIPTION 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 bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Page 2250 REAR DIFFERENTIAL 7F-3 DIAGNOSIS Condition Possible Cause Correction D Deteriorated or water mixed lubricant Gear noise Repair and replenish D Inadequate or insufficient lubricant Repair and replenish D Maladjusted backlash between bevel pinion Adjust as prescribed and gear D Improper tooth contact in the mesh be- Adjust or replace tween bevel pinion and gear D Loose bevel gear securing bolts...
Page 2251 7F-4 REAR DIFFERENTIAL ON-VEHICLE SERVICE MAINTENANCE SERVICE NOTE: Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage. CHANGING OIL NOTE: It is highly recommended to use SAE 80W-90 viscosity. 1) Before oil change or inspection, be sure to stop engine and set vehicle horizontally.
Page 2252 REAR DIFFERENTIAL 7F-5 UNIT REPAIR OVERHAUL DISMOUNTING 1) Hoist vehicle and remove wheels. 2) Drain oil from rear differential. (Refer to “OIL CHANGE” in this section.) 3) Remove parking brake cable from trailing rod. 4) If vehicle is equipped with ABS, remove wheel speed sensor harness from No.2 control rod.
Page 2253 7F-6 REAR DIFFERENTIAL DISASSEMBLY 1) Remove rear cover. 2) Remove breather plug from rear cover. 1. Rear cover 2. Breather plug 3) Remove differential side bearing stopper and then remove dif- ferential side bearing retainer. Special Tool (A): 09923-58520 4) Using some appropriate rod, drive out differential side bearing outer races.
Page 2254 REAR DIFFERENTIAL 7F-7 10) Remove caulking of flange nut with special tool and power wrench. (C): 09930-40113 1. Power wrench 2. Flange 11) Remove flange and washer from drive bevel pinion, and then drive out drive bevel pinion. Special Tool (D): 09913-85230 (E): 09913-65135 12) Remove rear bearing by using bearing puller and press.
Page 2255 7F-8 REAR DIFFERENTIAL INSPECTION D Check flange for wear or damage. D Check bearings for wear or discoloration. D Check differential carrier for cracks. D Check drive bevel pinion and bevel gear for wear or cracks. D Check side gears, pinion gears and pinion shaft for wear or dam- age.
Page 2256 REAR DIFFERENTIAL 7F-9 2) Check pinion gear for smooth rotation. 1. Differential case 2. Pinion 3) Align pinion shaft hole position with differential case and drive in differential pinion shaft pin till they are flush with end surface of case. Special Tool (A): 09922-85811 4) Apply thread lock cement to thread of bevel gear bolts.
Page 2257 7F-10 REAR DIFFERENTIAL DRIVE BEVEL PINION To engage bevel pinion and gear correctly, it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described on following pages. Shown in this page are relative positions of bevel pinion, differential carrier and mounting dummy.
Page 2258 REAR DIFFERENTIAL 7F-11 1) Install bevel pinion dummy with front and rear bearings into dif- ferential carrier and then tighten 36 mm nut (Spare parts No.09159-28002) lightly by hand. Special Tool (B): 09922-77280 2) Install flange to bevel pinion dummy. 3) Install special tool to flange by using 4 flange nuts.
Page 2259 7F-12 REAR DIFFERENTIAL 7) Obtain adjusting shim thickness by using measured value by dial gauge (which represents C in page 7F-10) in following equation. Necessary Dial gauge Measurement = 80 + – shim thick- measured printed on ness (F) value (C) pinion (E) 80 in above equation is A + B of mounting dummy as shown in page 7F-10.
Page 2260 REAR DIFFERENTIAL 7F-13 13) Install flange to bevel pinion and tightening flange nut gradual- ly with special tool and power wrench to specified torque while turning bevel pinion. Set preload of bevel pinion to specification. NOTE: D Before taking measurement with spring balance, check for smooth rotation by hand.
Page 2261 7F-14 REAR DIFFERENTIAL 5) To measure drive bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix drive bevel pinion, tighten both re- tainers and read dial gauge while moving bevel gear. NOTE: D Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
Page 2262 REAR DIFFERENTIAL 7F-15 8) Check gear tooth surface contact. Apply red lead paste to tooth surface of drive bevel gear and turn it by hand to check its contact with drive bevel pinion. Check contact pattern, referring to following chart. If contact pattern is not normal, readjust or replace as necessary accord- ing to instruction in chart.
Page 2263 7F-16 REAR DIFFERENTIAL TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY If adjustment is impossible, replace differential carrier. D Drive bevel gear or drive bevel pinion defective. D Poor squareness of differential carrier. D Differential carrier surface where gear is installed is defective. Replace defective part as an assembly.
Page 2264 REAR DIFFERENTIAL 7F-17 REMOUNTING 1) Install propeller shaft to joint flange aligning match marks. 2) Install rear differential to mounting bracket and tighten 6 mount- ing bolts to specified torque. Tightening Torque (a): 50 N·m (5.0 kg-m, 36.5 lb-ft) 3) Tighten 4 propeller shaft flange bolts to specified torque. Tightening Torque (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) 1.
Page 2265 RECOMMENDED MATERIALS SUZUKI PRODUCT THREAD LOCK CEMENT Thread lock cement Bevel gear bolts SUPER 1333B (99000-32020) SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) D Rear differential drain and level/filler plugs SUZUKI BOND NO.1215 D Breather plug cover...
Page 2266 REAR DIFFERENTIAL 7F-19 SPECIAL TOOLS 09913-65135 09913-75520 09900-20606 09900-20701 Bearing puller Bearing installer Dial gauge Magnetic stand 09913-85210 09913-85230 09922-75222 09922-77280 Bearing installer Bearing removing jig Preload adjuster Bearing pinion adjuster set 09923-58520 Differential side bearing 09922-85811 09923-78210 09924-74510 adjuster No.2 Spring pin remover Bearing installer Installer attachment...
Page 2267 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 2268 8-2 BODY ELECTRICAL SYSTEM REAR WINDOW WIPER AND WASHER Wiring Circuit ......8-52 (IF EQUIPPED) .
Page 2269 BODY ELECTRICAL SYSTEM 8-3 GENERAL DESCRIPTION The body electrical components of this vehicle are designed to operate on 12 volts power supplied by the battery. The electrical system utilizes negative grounded polarity. WIRING All body low voltage wires are insulated. The insulation is color coded for identification of individual body circuit. WIRE COLOR SYMBOLS Symbol Wire Color Symbol Wire color Black...
Page 2270 8-4 BODY ELECTRICAL SYSTEM INSTRUMENTS AND GAUGES COMBINATION METER WIRING NOTE: D “l” : Australian spec. vehicle only. D Terminal arrangement of instrument harness coupler viewed from harness side. Coupler K Coupler L Coupler M Coupler K Coupler L Coupler M 1.
Page 2271 BODY ELECTRICAL SYSTEM 8-5 TROUBLE DIAGNOSIS Trouble Possible cause Correction Speedometer shows no IG. fuse blown Replace fuse to check for short. operation. Speed sensor faulty Check speed sensor. Speedometer faulty Replace speedometer. Wiring or grounding faulty Repair. Fuel level meter shows IG.
Page 2272 8-6 BODY ELECTRICAL SYSTEM SPEEDOMETER AND SENSOR DESCRIPTION OF CIRCUIT The speedometer circuit consists of the speedometer installed inside the combination meter and the speed sensor installed to the transmission case. WIRING CIRCUIT 1. Battery 2. Main fuse 3. Ignition switch 4.
Page 2273 BODY ELECTRICAL SYSTEM 8-7 FUEL LEVEL METER AND GAUGE UNIT DESCRIPTION OF CIRCUIT The fuel level meter circuit consists of the fuel level meter installed inside the combination meter and the fuel level gauge(s) installed to the fuel tank. Current flowing through the meter coil is changed to control the meter pointer. That is, when fuel is full, the fuel level gauge unit resistance is decreased with more current flowing into the meter coil, causing the meter pointer to point at the “F”...
Page 2274 8-8 BODY ELECTRICAL SYSTEM INSPECTION FUEL LEVEL METER 1) Remove rear seat. 2) Disconnect “P/BI” lead wire going to gauge unit. 3) Use a bulb (12V 3.4W) in position to ground lead wire as illus- trated. 4) Turn ignition switch ON. Make sure that bulb is lighted with meter pointer fluctuating sev- 1.
Page 2275 BODY ELECTRICAL SYSTEM 8-9 ENGINE COOLANT TEMPERATURE METER AND SENDER GAUGE DESCRIPTION OF CIRCUIT The engine coolant temperature meter is located in the instrument panel and its sender gauge on the inlet man- ifold. The circuit is as shown below. The sender gauge shows different resistance values depending on the coolant temperature.
Page 2276 8-10 BODY ELECTRICAL SYSTEM ILLUMINATION CONTROLLER Inspection Use a bulb to wire as illustrated. Make sure that illumination controller knob is turned clockwise to brighten test light and counterclockwise to darken it. 1. Battery 2. Illumination controller 3. Test light (12V, 3.4W) OIL PRESSURE LIGHT DESCRIPTION OF CIRCUIT The oil pressure circuit consists of the oil pressure switch installed to the cylinder block and the light (warning light)
Page 2277: Brake Warning Light
BODY ELECTRICAL SYSTEM 8-11 BRAKE WARNING LIGHT DESCRIPTION OF CIRCUIT The brake warning light circuit consists of a brake fluid level switch installed in the master cylinder reservoir, and the light (brake warning light) inside the combination meter. Also, this circuit is additionally provided with the park- ing brake switch which warns that the parking brake is applied.
Page 2278 8-12 BODY ELECTRICAL SYSTEM SEAT BELT WARNING LIGHT/BUZZER (if equipped) DESCRIPTION OF CIRCUIT The seat belt warning light/buzzer circuit is a system to light and sound the light and buzzer respectively for several seconds, urging the driver to wear his seat belt. After several seconds, the light goes OFF and the buzzer stops sounding whether the seat belt is worn or not.
Page 2279 BODY ELECTRICAL SYSTEM 8-13 IGNITION SWITCH KEY REMAINDER WARNING BUZZER DESCRIPTION OF CIRCUIT The ignition switch key remainder warning buzzer circuit is a system to sound the buzzer if the driver leaves the vehicle the with ignition switch key inserted so as to urge him to take it out. NOTE: –...
Page 2280 8-14 BODY ELECTRICAL SYSTEM LIGHT REMAINDER WARNING BUZZER DESCRIPTION OF CIRCUIT The light remainder warning buzzer circuit is a system designed to sound the buzzer if the driver opens the door (driver’s side) while the lights (headlight and small light) are still on, warning him to turn off the lights. NOTE: –...
Page 2281 BODY ELECTRICAL SYSTEM 8-15 LIGHTING SYSTEMS HEADLIGHTS 1. Headlight 2. Bulb 3. Socket cover 4. Front position light 5. Turn signal light WIRING CIRCUIT 1. Battery 2. Main fuse 3. Relay/fuse box 4. Junction/fuse block 5. Headlight 6. Diode unit 7.
Page 2282 8-16 BODY ELECTRICAL SYSTEM TROUBLE DIAGNOSIS Trouble Possible cause Correction D Bulb burnt Out Only one light does not light. Replace bulb. D Fuse blown Replace fuse. D Socket, wiring or grounding faulty Repair as necessary. D Main fuse and/or fuses blown Headlights do not light.
Page 2283 BODY ELECTRICAL SYSTEM 8-17 BULB REPLACEMENT WARNING: Don’t touch when bulb is hot. 1) Disconnect negative (–) cable at battery. 2) Remove air cleaner box. 3) Disconnect harness from bulb. 4) Remove socket cover and bulb. 1. Bulb 2. Spring 5) Replace bulb and install in reverse removal procedure.
Page 2284 8-18 BODY ELECTRICAL SYSTEM DAYTIME RUNNING LIGHT (D.R.L.) SYSTEM (if equipped) GENERAL DESCRIPTION With this system, low beam of headlights and small lights turn ON when the engine is started and they turn OFF when it is stopped. This system is so designed that the lighting switch has a priority. That is, when the lighting switch is set to the small light position while the engine is running and this system is at work (headlights and small lights are ON), only small lights remain ON and headlights turn OFF.
Page 2285 BODY ELECTRICAL SYSTEM 8-19 TROUBLE DIAGNOSIS When a trouble has occurred in this system, check and correct it according to the following flow chart. Check that daytime running light controller makes clicking sound just when engine starts running. Clicking sound heard No clicking sound Check headIights Check oil pressure warning light...
Page 2286 8-20 BODY ELECTRICAL SYSTEM HEADLIGHT BEAM LEVELING SYSTEM (If equipped) GENERAL DESCRIPTION This system consists of the headlight leveling switch and headlight leveling actuator. It is used to lower both head- light aiming angles from the initial setting level by operating the leveling switch on the instrument. NOTE: When inspecting and adjusting the headlight beam, make sure to set the leveling switch to the “0”...
Page 2287 BODY ELECTRICAL SYSTEM 8-21 WIRING CIRCUIT 1. Ignition switch 2. Junction box 3-1. Leveling motor (LH) 3-2. Leveling motor (RH) 4. Leveling switch 5. Joint connector INSPECTION LEVELING SWITCH To check the switch operation, substitute it with a new one. If proper operation is obtained, it means the switch is defective.
Page 2288 8-22 BODY ELECTRICAL SYSTEM HEADLIGHT WASHER (If equipped) WIRING CIRCUIT 1. Fuse 2. Head light cleaner motor 3. DRL controller 4. Headlight washer switch 5. Joint connector TROUBLE DIAGNOSIS Trouble Possible cause Correction D Washer hose or nozzle clogged Washer malfunctions. Repair.
Page 2289 BODY ELECTRICAL SYSTEM 8-23 COMBINATION SWITCH Combination switch incorporates lighting, turn signal, hazard warning light, dimmer, passing light and wiper/wash- er switches and steering angle sensor. NOTE: Terminal arrangement of combination switch coupler A. Horn switch B. Air bag inflator (if equipped) viewed from harness coupler.
Page 2290 8-24 BODY ELECTRICAL SYSTEM IGNITION (MAIN) SWITCH Inspection 1) Disconnect negative (–) cable at battery. 2) Disable air bag system. Refer to “Disabling Air Bag System” in Section 9J. 3) Disconnect main switch lead wire connectors from junction/fuse block and air bag harness. Checking continuity between terminals Use a circuit tester to check the continuity at each switch position.
Page 2291 BODY ELECTRICAL SYSTEM 8-25 TURN SIGNAL AND HAZARD WARNING LIGHTS WIRING CIRCUIT NOTE: D – – – – –: German spec. vehicle only D This figure shows LH steering vehicle. 1. Battery 2. Main fuse 3. Ignition switch 4. Junction box 9.
Page 2292 8-26 BODY ELECTRICAL SYSTEM HAZARD SWITCH Removal 1) Remove heater control lever knobs. 2) Remove center console garnish. 3) Detach hazard switch. 4) Disconnect hazard switch coupler. 1. Center console garnish mounting screw Inspection Use a circuit tester to check the continuity of each switch position. If any continuity is not obtained, replace switch.
Page 2293 BODY ELECTRICAL SYSTEM 8-27 CLEARANCE, TAIL AND LICENSE LIGHTS WIRING CIRCUIT < For Sedan and Hatchback > < For Wagon > 1. Battery 2. Main fuse 3. Junction box 4. Tail light relay 5. Front clearance light 6. Front side maker light (if equipped) 7.
Page 2294 8-28 BODY ELECTRICAL SYSTEM BACK-UP LIGHTS WIRING CIRCUIT < For Sedan and Hatchback > < For Wagon > 1. Battery 2. Main fuse 3. Ignition switch 4. Junction box 5. Back up light switch (Transmission range switch) 6. Joint connector 7.
Page 2295 BODY ELECTRICAL SYSTEM 8-29 REAR FOG LIGHT (If equipped) WIRING CIRCUIT 1. Fuse 7. Joint connector 2. Tail light relay 8. Not used 3. Junction box 4. Lighting switch A. Wagon model 5. Rear fog light switch B. 3 door/4door model 6.
Page 2296 8-30 BODY ELECTRICAL SYSTEM INSPECTION REAR FOG LIGHT SWITCH Use a circuit tester to check rear fog light switch for continuity. Hold the switch button (ON or OFF) pushed during checking switch as shown. NOTE: Rear fog lamps light up only when headlamps or front fog lamps (if equipped) are on.
Page 2297: Brake Lights
BODY ELECTRICAL SYSTEM 8-31 BRAKE LIGHTS WIRING CIRCUIT NOTE: – – – – –: German spec. vehicle only. 1. Battery 2. Main fuse 3. Junction box 4. Stop light switch 5. Joint connector 6. Brake light (Driver side) 7. Brake light (Passenger side) 8.
Page 2298 8-32 BODY ELECTRICAL SYSTEM RADIO (If equipped) WIRING CIRCUIT NOTE: – – – – –: German spec. vehicle only. 1. Battery 2. Main fuse 3. Ignition switch 4. Junction box 5. Radio 6. Front speaker (LH) 7. Front speaker (RH) 8.
Page 2299: Cigarette Lighter
BODY ELECTRICAL SYSTEM 8-33 CIGARETTE LIGHTER WIRING CIRCUIT 1. Battery 2. Main fuse 3. Ignition switch 4. Junction box 5. Cigarette lighter 6. Joint connector TROUBLE DIAGNOSIS Trouble Possible cause Correction D Fuse blown Cigarette lighter does not work. Replace fuse to check for short. D Main switch faulty Check switch.
Page 2300 8-34 BODY ELECTRICAL SYSTEM REAR WINDOW DEFOGGER (If equipped) The rear window defogger system has horizontal ceramic silver compound elements and two vertical bus bar. The system is operated by the defogger switch in the instrument panel. WIRING DIAGRAM NOTE: –...
Page 2301 BODY ELECTRICAL SYSTEM 8-35 DEFOGGER WIRE NOTE: D When cleaning rear window glass, use a dry cloth to wipe it along wire direction. D When cleaning glass, do not use detergent or abrasive con- taining glass cleaner. D When measuring wire voltage, use a tester with negative 1.
Page 2302 8-36 BODY ELECTRICAL SYSTEM REPAIR DEFOGGER CIRCUIT 1) Use white gasoline for cleaning. 2) Apply masking tape at both upper and lower sides of heat wire to be repaired. 3) Apply commercially-available repair agent with a fine-tip brush. 4) Two to three minutes later, remove masking tapes previously applied.
Page 2303 BODY ELECTRICAL SYSTEM 8-37 WINDSHIELD WIPERS (FRONT WIPER) AND WASHER The windshield wiper is 3-speed type and the windshield washer is equipped with a separate-type washer pump. The washer tank is located inside of the front part of the left front fender. It has washer pumps for the front and rear respectively.
Page 2304 8-38 BODY ELECTRICAL SYSTEM WIRING CIRCUIT 1. Battery 5. Wiper and washer switch 9. Wiper intermittent relay 2. Main fuse 6. Wiper motor 10. Joint connector 3. Ignition switch 7. Washer pump 4. Junction box 8. Wiper return switch TROUBLE DIAGNOSIS Trouble Possible cause Correction...
Page 2305 BODY ELECTRICAL SYSTEM 8-39 INSPECTION WIPER/WASHER SWITCH Use a circuit tester to check switch for each terminal-to-terminal continuity referring to “COMBINATION METER” in this section. WIPER MOTOR REMOVAL 1) Disconnect wiper motor coupler. 2) Remove wiper motor assembly mounting bolt, and remove wip- er motor assembly from wiper link.
Page 2306 8-40 BODY ELECTRICAL SYSTEM INSPECTION Connect battery (+) and (–) terminals to pump (+) and (–) terminals respectively to check pumping rate. INSTALLATION Reverse removal procedure for installation. INTERMITTENT WIPER RELAY 1) Disconnect combination switch couplers from junction box. 2) Turn wiper switch on to INT position. 3) Apply 12 V DC to terminals intermittently by connecting and dis- connecting service wire tips as shown in figure.
Page 2307 BODY ELECTRICAL SYSTEM 8-41 REAR WINDOW WIPER AND WASHER (If equipped) The rear window wiper is of the one-speed type, and its washer is equipped with a separate-type washer pump. < For Hatchback > < For Wagon > 1. Wiper motor assembly 2.
Page 2308 8-42 BODY ELECTRICAL SYSTEM DESCRIPTION OF CIRCUIT AND TROUBLE DIAGNOSIS Refer to “WINDSHIELD WIPER” in this section. INSPECTION WIPER AND WASHER SWITCHES Refer to “COMBINATION SWITCH” in this section. WASHER PUMP In the same manner as with the windshield washer pump, check pumping rate.
Page 2309 BODY ELECTRICAL SYSTEM 8-43 POWER WINDOW CONTROL SYSTEM (If equipped) The power window control system is so designed that it electrically controls up & down movement of side door window glass by means of the motor which is installed to the window regulator. The system consists of the ignition switch, power window switches.
Page 2310 8-44 BODY ELECTRICAL SYSTEM POWER SLIDING ROOF (If equipped) WIRING CIRCUIT * 29: Refer to “POWER SUPPLY DIAGRAM”. A: RH steering vehicle B: LH steering vehicle O: OPEN (slide switch) C: CLOSE (slide switch) U: UP (tilt switch) D: DOWN (tilt switch) 1.
Page 2311 BODY ELECTRICAL SYSTEM 8-45 OPERATION TROUBLE DIAGNOSIS Condition Possible cause Correction D Foreign object stuck in sliding roof rail Sliding roof does not operate Remove or clean stuck object. D Misinstallation of sliding roof rail (sliding roof motor runs OK) Install correctly.
Page 2312 8-46 BODY ELECTRICAL SYSTEM INSPECTION SLIDING ROOF SWITCH Inspect switch continuity between terminals. SLIDE SWITCH TILT SWITCH OPEN (UP) CLOSE (DOWN) If any of continuity is not obtained, replace sliding roof switch. 1. Sliding roof switch 2. Sliding roof switch coupler SLIDING ROOF DRIVE GEAR ASSEMBLY Inspection of Motor 1) Disconnect sliding roof drive gear assembly coupler.
Page 2313: Circuit Breaker
BODY ELECTRICAL SYSTEM 8-47 CIRCUIT BREAKER NOTE: This inspection must be done with the complete sliding roof assembly installed of the vehicle. 1) Disconnect coupler from sliding roof drive gear assembly. 2) Connect (–) Battery lead terminal C2, (+) battery lead to termi- nal C1, then open sliding roof completely.
Page 2314 8-48 BODY ELECTRICAL SYSTEM LIMIT SWITCH 1 AND LIMIT SWITCH 2 1) Remove limit switch from sliding roof drive gear assembly and check continuity between terminal when limit switch is ON and OFF. SLIDE SWITCH TILT SWITCH 1. Limit Switch 2.
Page 2315 BODY ELECTRICAL SYSTEM 8-49 5) Connect sliding roof switch to sliding roof sub wire. 6) Connect limit switch wires to sliding roof sub wire connector where they should be connected. 1. Sliding roof sub wire coupler 2. Limit switch 1 3.
Page 2316 8-50 BODY ELECTRICAL SYSTEM 9) Connect sliding roof sub wire to sliding roof control relay. 10) Check voltage and resistance at the following condition. If any of measured value does not below standard values, re- place sliding roof control relay. 1.
Page 2317 BODY ELECTRICAL SYSTEM 8-51 Power Window Main Switch Sedan model (LH steering vehicle) Inspect switch continuity between terminals. (A) Driver side window switch (11) DOWN Passenger and rear side window switches. SWITCH TERMINAL POSITION CONNEC- (11) (12) Hatch-Back model (10) UNLOCK DOWN 1.
Page 2318 8-52 BODY ELECTRICAL SYSTEM POWER DOOR LOCK CONTROL SYSTEM (If equipped) The power door lock control system consists of the power door lock controller, door lock switch, door lock actuator and related wiring harness. WIRING CIRCUIT NOTE: – – – – –: German spec. vehicle only 1.
Page 2319 BODY ELECTRICAL SYSTEM 8-53 KEYLESS ENTRY SYSTEM (if equipped) GENERAL DESCRIPTION The keyless entry system uses radio wave. When the button on the transmitter is pressed, a signal is transmitted in the form of radio wave to the receiver. Then the signal causes the door lock controller to lock and unlock the door.
Page 2320 8-54 BODY ELECTRICAL SYSTEM TROUBLE DIAGNOSIS Condition Possible Cause Correction D Fuse blown The power door lock func- Replace fuse to check for short. D Code registration error tion is available but the Register code. D Transmitter battery dead keyless entry function is Replace battery.
Page 2321 BODY ELECTRICAL SYSTEM 8-55 CODE REGISTRATION PROCEDURE 1) Start of code registration (Initial conditions: IG switch OFF, all doors closed) 2) Open the door and then turn ON the IG switch within 10 se- conds. 3) Turn OFF the IG switch within 10 seconds after it is turned ON. 4) Turn the door switch ON and OFF 3 times within 20 seconds af- ter the IG switch is turned OFF.
Page 2322 8-56 BODY ELECTRICAL SYSTEM INSPECTION Power Door Lock Switch Inspect switch continuity between terminals. LOCK UNLOCK 1. Door lock switch 2. Door lock switch coupler Power Door Lock Controller 1) Disconnect power door lock controller coupler. 2) Connect (+) cord and (–) cord of 12V battery to coupler terminal (1), (5) and (6) as shown in figure.
Page 2323 BODY ELECTRICAL SYSTEM 8-57 Power Door Lock Actuator Front Door 1) Disconnect power door lock actuator coupler. 2) Connect (+) cord and (–) cord of 12V battery to coupler terminal (1) and (2). 3) Actuator is proved to be operating properly if (–) cord connec- tion to terminal (1) results in “Lock”...
Page 2324 8-58 BODY ELECTRICAL SYSTEM POWER MIRROR CONTROL SYSTEM (If equipped) The power mirror control system consists of the power mirror control switch, mirror actuator and related wiring harness. WIRING CIRCUIT A: LH steering vehicle with power window 1. Ignition switch B: Other than A model 2.
Page 2325 BODY ELECTRICAL SYSTEM 8-59 INSPECTION Mirror Switch 1) Take out mirror switch from instrument panel. 2) Check continuity at each switch position by using a circuit tester. If any continuity is not obtained, replace mirror switch. DOWN LEFT RIGHT Door Mirror 1) Remove garnish and screws from door.
Page 2326 8-60 BODY ELECTRICAL SYSTEM WIRING HARNESS ROUTING NOTE: These figures show LH steering vehicle. ENGINE ROOM < 1.3L and 1.6L Engine models > < 1.8L Engine model > 1. Main harness (RH) 2. Main harness (LH) 3. Engine harness 4. Instrument panel harness 5.
Page 2327 BODY ELECTRICAL SYSTEM 8-61 NOTE: These figures show LH steering vehicle. INSTRUMENT PANEL NOTE: Battery cable (+) is included in Engine harness. FLOOR < Sedan model > 1. Floor harness (passenger side) 2. Floor harness (drive side) 3. Rear door harness (RH) 4.
Page 2328 8-62 BODY ELECTRICAL SYSTEM FLOOR < Wagon model > 1. Floor harness (RH) 2. Floor harness (LH) 3. Roof wire 4. Sliding roof wire 5. Sliding roof sub wire 6. Fuel pump wire...
Page 2329 BODY ELECTRICAL SYSTEM 8-63 BACK DOOR < Hatch back model > < Wagon model > 1. Floor harness (passenger side) 2. Floor harness (drive side) 3. Back door harness...
Page 2330 8-64 BODY ELECTRICAL SYSTEM GROUNDING POINT NOTE: These figures show LH steering vehicle. ENGINE ROOM (For 1.3L and 1.6L ENGINE MODELS) ECM, TCM, speedometer, speed sensor and Battery ground cable tachometer < For A/T case > < For M/T case > A/C relay, ABS solenoid valve relay (fail safe RH turn signal/small light relay), horn, ABS pump motor relay, dual pres-...
Page 2331 BODY ELECTRICAL SYSTEM 8-65 NOTE: These figures show LH steering vehicle. ENGINE ROOM (FOR 1.8L ENGINE MODEL) ECM, TCM, speedometer, speed sensor and Battery ground cable tachometer < For A / T > < For M / T > A / C relay, ABS solenoid valve relay (fail safe RH turn signal / small light relay), horn, ABS pump motor relay, dual pressure switch and radiator fan motor.
Page 2332 8-66 BODY ELECTRICAL SYSTEM NOTE: These figures show LH steering vehicle. INSTRUMENT PANEL Turn signal/hazard indicator light, illumination controller, cruise main switch, coolant tempera- ture gauge, radio, cigarette lighter and power mirror switch Combination meter, brake fluid level switch, Heater blower motor turn signal/small light (LH), A/C amplifier, D.R.L.
Page 2333 BODY ELECTRICAL SYSTEM 8-67 NOTE: These figures show LH steering vehicle. FLOOR Ignition switch, combination switch, rear com- bination light (LH), rear side marker light, D.R.L., Rear combination light (RH), license light, rear headlight, turn signal/hazard relay, dome light, defogger, key cylinder switch (RH) and fuel drivers seat belt switch, power door lock control- pump and gauge (4WD model) ler, key cylinder switch (LH) and warning control-...
Page 2334 8-68 BODY ELECTRICAL SYSTEM NOTE: These figures show LH steering vehicle. FLOOR (Hatch-back model) Ignition switch, combination switch, rear combination Rear combination light (RH), license light, rear light (LH), D.R.L., headlight, turn signal / hazard relay, defogger, key cylinder switch (RH), back door dome light, drivers seat belt switch, cruise controller, switch, high-mounted stop light, rear wiper mo- power window main switch, power door lock controller,...
Page 2335 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 2336 8G-2 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC21 ECM/Immobilizer Control Module Code Inspection of ECM/PCM, Immobilizer Not Matched (Immobilizer Control Module Control Module and Its Circuit ..8G-29 Side) ....... . 8G-24 Voltage Check .
Page 2337 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-3 GENERAL DESCRIPTION The immobilizer control system is designed to prevent vehicle burglar and consists of following components. D Engine control module/Powertrain control module (ECM/PCM) D Immobilizer Control Module D Ignition key (with built-in transponder) D Coil antenna Operation of this system is as follows.
Page 2338 8G-4 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) <Vehicle not equipped with immobilizer indicator lamp> For G13/G16 engine For J18 engine For G13/G16 engine For J18 engine <Vehicle equipped with immobilizer indicator lamp> For G13/G16 engine For J18 engine 1. Coil antenna 2.
Page 2339 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-5 IGNITION KEY The ignition key for the immobilizer control system has a built-in transponder. Each transponder in the key has an each transmitting code (Transponder code). The code will transmitted from the key via the coil antenna to Immobilizer Control Module when the igni- tion switch is turned ON.
Page 2340 8G-6 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) ON-BOARD DIAGNOSTIC SYSTEM (SELF-DIAGNOSIS FUNCTION) Immobilizer Control Module and ECM/PCM diagnose troubles which may occur in the area including the following parts when the ignition switch is ON. They indicate the diagnosis result by using following items in the manner as described below.
Page 2341 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-7 <Vehicle equipped with immobilizer indicator lamp> With the ignition switch turned ON (but the engine at stop) regard- less of the condition of the engine and emission control system, ECM/PCM indicates whether a trouble has occurred in the immo- bilizer control system or not by causing the immobilizer indicator lamp to flash or turn ON.
Page 2342 ECM/PCM <Vehicle not equipped with immobilizer indicator lamp> D Before identifying diagnostic trouble code indicated by malfunc- tion indicator lamp or Suzuki scan tool, don’t disconnect cou- plers from ECM/PCM, battery cable from battery, ECM/PCM ground wire harness from engine.
Page 2343 OFF ignition switch and then ON. Then check what Suzuki scan tool and/or output of diagnostic out- put terminal indicates. Only when they indicate trouble code again, substitute a known- good ECM/PCM or Immobilizer Control Module and check again.
Page 2344 8G-10 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) [NOTES ON SYSTEM CIRCUIT INSPECTION] Refer to “Precautions for Electrical Circuit Service” and “Intermit- tents and Poor Connection” in Section 0A. [Precaution after replacing ECM/PCM or Immobilizer Control Module] D When ECM/PCM was replaced, including when replaced be- cause rechecking by using a known-good ECM/PCM was nec- essary during trouble diagnosis, the ECM/Immobilizer Control Module code must be registered in ECM/PCM and Immobilizer...
Page 2345 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-11 DIAGNOSTIC FLOW TABLE <Vehicle not equipped with immobilizer indicator lamp> STEP ACTION D If malfunction indicator lamp re- 1) Make sure that diagnosis switch Go to Step 3. terminal in monitor coupler is not mains ON, go to Step 2.
Page 2346 8G-12 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DIAGNOSTIC FLOW TABLE <Vehicle equipped with immobilizer indicator lamp> STEP ACTION D If immobilizer indicator lamp re- 1) Check immobilizer indicator lamp Go to Step 3. while ignition switch is ON (but mains ON, go to Step 2. D If immobilizer indicator lamp re- without starting engine).
Page 2347 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-13 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (IMMOBILIZER CONTROL MODULE) 1) Using analog type voltmeter, connect positive probe to diagnos- tic output terminal and negative probe to ground of immobilizer diagnostic coupler with ignition switch turned ON. 2) Read deflection of voltmeter indicator which represents DTC as shown in example below and write it down.

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