Suzuki GRAND VITARA Owner's Manual
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Suzuki GRAND VITARA Owner's Manual

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

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

Questions and answers

Kayhan
March 30, 2025

How to fix dampers of air conditioner on suzuki grand vitara I only get hot air seems that the damper does not move

0
1 comments:
Mr. Anderson
March 31, 2025

To fix air conditioner dampers on a Suzuki Grand Vitara that only blows hot air, follow these steps:

1. Check for DTCs (Diagnostic Trouble Codes):
- Connect a scan tool to the DLC (Data Link Connector) with the ignition off.
- Turn the ignition on and check for DTCs, specifically DTC B1512.

2. Check Mode Selector Operation:
- Start the A/C system.
- Turn the mode selector to "DEF" and then to "FOOT" position.
- Wait 1 minute and recheck for DTCs.

3. Inspect Actuator Linkage:
- Check for any obstructions in the actuator linkage.
- Ensure the actuator linkage moves smoothly.

4. Check Wiring to Actuator:
- With the ignition off, disconnect the connector from the air flow control actuator.
- Inspect the wiring, especially the GRY/RED and GRY/BLK terminals, for proper connection.

If there are faults or obstructions in the actuator or wiring, repair or replace the faulty components. This should restore proper damper function and allow cold air to flow.

This answer is automatically generated

0

Related Manuals for Suzuki GRAND VITARA

Summary of Contents for Suzuki GRAND VITARA

  • Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 3 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
  • Page 4 Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Transmission / Transaxle .......... 5-i General Information ..........0A-1 Precautions .............. 5-1 Maintenance and Lubrication ......... 0B-1 Automatic Transmission/Transaxle ......5A-1 Manual Transmission/Transaxle ......5B-1 Engine .................

  • Page 7: Precautions

    Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Air Bag Warning ..........00-11 Discharge Headlight Warning ......00-11 Precautions............00-1 A/C System Caution.......... 00-11 Precautions for Vehicles Equipped with Fastener Caution..........00-11 a Supplemental Restraint (Air Bag) System ..00-1 Suspension Caution ..........

  • Page 8: Air Bag Locations

    • If the air bag system and another vehicle 3. Contact coil assembly 11. Side-sensor (if equipped) system both need repair, SUZUKI 4. Air bag harness in main harness 12. Seat belt pretensioner recommends that the air bag system be 5.

  • Page 9: Diagnosis, Servicing And Handling

    Precautions: 00-2 Servicing and Handling Diagnosis • When troubleshooting air bag system, be sure to WARNING follow “Air Bag Diagnostic System Check: in Section 8B”. Bypassing these procedures may result in Many of service procedures require extended diagnostic time, incorrect diagnosis, and disconnection of “A/B”...
  • Page 10 00-3 Precautions: • Never dispose of live (undeployed) air bag WARNING (inflator) modules (driver, passenger, side Driver and Passenger Seat Belt and curtain). If disposal is necessary, be Pretensioners sure to deploy them according to deployment procedures described in “Air •...

  • Page 11: General Precautions

    Precautions: 00-4 General Precautions CAUTION S5JB0A0000002 The WARNING and CAUTION describe some general • Even when the accident was light enough precautions that you should observe when servicing a not to cause air bags to activate, be sure to vehicle. These general precautions apply to many of the inspect system parts and other related service procedures, and they will not necessarily be parts according to instructions under...
  • Page 12 00-5 Precautions: CAUTION • Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.g. buttons) may cause damage to the vehicle’s finish. I2RH01010026-01 •...
  • Page 13 • When use of a certain type of lubricant, bond or sealant is specified, be sure to remove the old one thoroughly and use the specified type. “A”: Sealant 99000–31150 (SUZUKI Bond No.1207C) I2RH01010033-01 • For vehicles equipped with fuel injection...

  • Page 14: Precaution In Servicing Full-Time 4Wd Vehicle

    00-7 Precautions: Precaution in Servicing Full-Time 4WD Vehicle • Use care not to expose connectors and electrical parts to water which will be a S5JB0A0000018 WARNING cause of a trouble. This full-time 4WD vehicle can not be converted to 2WD manually. Observe the following caution in servicing.

  • Page 15: Precautions For Catalytic Converter

    Precautions: 00-8 • When testing with 2-wheel brake tester, be sure to observe the following instructions. Otherwise, drive train damage and personal injury may result. – Shift transmission to N (Neutral) position. – Shift transfer to N (Neutral) position if transfer position is selectable.

  • Page 16: Precaution For Can Communication System

    00-9 Precautions: Precaution for CAN Communication System • When disconnecting and connecting coupler, make S5JB0A0000005 sure to turn ignition switch OFF, or electronic parts • The loose (1) in the wire harnesses twist of the CAN may get damaged. lines except around the connector (3) should be within 100 mm (3.9 in.).
  • Page 17 Precautions: 00-10 • When installing vehicle parts, be careful so that the • When taking measurements at electrical connectors wiring harness is not interfered with or caught by any using a tester probe, be sure to insert the probe (2) other part.

  • Page 18: Precautions For Installing Mobile Communication Equipment

    Type Description: in Section 7B”. components or wiring must be performed When replenishing or changing refrigerant only by an authorized SUZUKI dealer. Refer and compressor oil and when replacing to “Air Bag System Components, Wiring parts, make sure that the material or the part and Connectors Location: in Section 8B”...

  • Page 19: Suspension Caution

    Precautions: 00-12 Suspension Caution Brakes Caution and Note S5JB0A0000010 S5JB0A0000012 CAUTION CAUTION All brake fasteners are important attaching • All suspension fasteners are an important parts in that they could affect the attaching part in that it could affect the performance of vital parts and systems, and/ performance of vital parts and systems, or could result in major repair expense.
  • Page 20 00-13 Precautions: When checking system circuits including an electronic Continuity Check control unit such as ECM, TCM, ABS control module, 1) Measure resistance between connector terminals at etc., it is important to perform careful check, starting with both ends of the circuit being checked (between “A- items which are easier to check.
  • Page 21 Precautions: 00-14 b) Also, if measured values were as listed in the 3) Measure resistance between terminal at one end of following, it means that there is a resistance circuit (“A-1” terminal in the figure) and body ground. (abnormality) of such level that corresponds to If continuity is indicated, it means that there is a short the voltage drop in the circuit between terminals to ground between terminals “A-1”...

  • Page 22: Intermittent And Poor Connection Inspection

    00-15 Precautions: Intermittent and Poor Connection Inspection • Poor terminal-to-wire connection. S5JB0A0006002 Check each wire harness in problem circuits for poor Most intermittent are caused by faulty electrical connection by shaking it by hand lightly. If any connections or wiring, although a sticking relay or abnormal condition is found, repair or replace.

  • Page 23: General Information

    Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Crankcase Ventilation Hoses and Connections Inspection (Vehicle without General Description ..........0A-1 A/F Sensor) ............0B-7 Abbreviations ............0A-1 PCV Valve Inspection .........0B-7 Symbols .............. 0A-2 Fuel Evaporative Emission Control System Wire Color Symbols ..........

  • Page 24: General Information

    0A-1 General Information: General Information General Description Abbreviations S5JB0A0101001 FWD: Front Wheel Drive 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center ABS: Anti-lock Brake System GEN: Generator AC: Alternating Current GND: Ground A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HC: Hydrocarbons A/F: Air Fuel Mixture Ratio HO2S: Heated Oxygen Sensor...

  • Page 25: Symbols

    (engine, transmission, transfer, differential) SOHC: Single Over Head Camshaft Apply fluid (brake, power steering, automatic fluid) TBI: Throttle Body Fuel Injection (Single-Point Fuel Apply SUZUKI SUPER GREASE A Injection, SPI) 99000-25010 TCC: Torque Converter Clutch Apply SUZUKI SUPER GREASE C...

  • Page 26: Wire Color Symbols

    0A-3 General Information: Wire Color Symbols There are two kinds of colored wire used in this vehicle. S5JB0A0101004 One is single-colored wire and the other is dual-colored Symbol Wire Color (striped) wire. As the color symbol, the single-colored Black wire uses only one, three or five alphabets (i.e. “G” or Blue “GRN”);...

  • Page 27: General Information

    General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.

  • Page 28: Vehicle Lifting Points

    0A-5 General Information: Vehicle Lifting Points S5JB0A0101006 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending of what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
  • Page 29 General Information: 0A-6 When using floor jack To perform service with either front or rear vehicle end jacked up, be sure to place safety stands (1) under WARNING chassis frame so that body is securely supported. And then check to ensure that chassis frame does not •...

  • Page 30: Engine Supporting Points

    0A-7 General Information: Engine Supporting Points Vehicle Identification Number S5JB0A0101010 S5JB0A0101007 The vehicle identification number is punched on the front WARNING dash panel in engine room and it is also attached on the When using engine supporting device (1), be left front top of instrument panel depending on vehicle sure to observe the followings.

  • Page 31: Component Location

    General Information: 0A-8 Component Location Warning, Caution and Information Label Location S5JB0A0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
  • Page 32 0A-9 General Information: I5JB0A010009-03 1. Air bag label on driver air bag (inflator) module 4. Air bag label on passenger air bag (inflator) module 7. Air bag label on side air bag module 2. Air bag label on contact coil assembly 5.

  • Page 33: Maintenance And Lubrication

    Maintenance and Lubrication: 0B-1 Maintenance and Lubrication Precautions Precautions for Maintenance and Lubrication S5JB0A0200001 Air Bag Warning Refer to “Air Bag Warning: in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S5JB0A0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...

  • Page 34: Maintenance Recommended Under Severe Driving Conditions

    0B-2 Maintenance and Lubrication: Km (x 1,000) Interval Miles (x 1,000) Months Clutch (fluid leakage, level) (I: — — — Tires (wear, damage, rotation) / wheels (damage) (I: Suspension system (tightness, damage, rattle, breakage) (I: — — — Steering system (tightness, damage, breakage, rattle) (I: —...
  • Page 35 Maintenance and Lubrication: 0B-3 Severe Maintenance Maintenance Maintenance Interval Condition Code Operation Every 10,000 km Nickel plug (6,000 miles) or 8 months A B C – E F – H Spark plugs Iridium plug Every 30,000 km (Highly recommended) (18,000 miles) or 24 months Every 15,000 km –...

  • Page 36: Repair Instructions

    0B-4 Maintenance and Lubrication: Repair Instructions Engine Accessory Drive Belt Inspection Power Steering Pump and A/C Compressor (If S5JB0A0206001 Equipped) Drive Belt (M16 Engine) WARNING Inspect belt for cracks, cuts, deformation, wear cleanliness and tension. If any defect exists, adjust or All inspection and replacement are to be replace.

  • Page 37: Engine Oil And Filter Change

    Maintenance and Lubrication: 0B-5 Engine Oil and Filter Change 4) Apply engine oil to new oil filter O-ring. S5JB0A0206003 WARNING • New and used engine oil can be hazardous. Be sure to read “General Precautions: in Section 00” and observe what in written there.

  • Page 38: Engine Coolant Change

    0B-6 Maintenance and Lubrication: 7) Replenish oil until oil level is brought to FULL level 8) Check oil filter and drain plug for oil leakage. mark on dipstick. (oil pan and oil filter capacity). The 9) Start engine and run it for 3 minutes. Stop it and wait filler inlet is at the top of the cylinder head cover.

  • Page 39: Exhaust System Inspection

    Maintenance and Lubrication: 0B-7 Exhaust system Inspection Air Cleaner Filter Replacement S5JB0A0206006 S5JB0A0206013 Replace air cleaner filter with new one referring to “Air WARNING Cleaner Filter Removal and Installation: For M16A To avoid danger of being burned, do not Engine with VVT in Section 1D” or “Air Cleaner Filter touch exhaust system when it is still hot.

  • Page 40: Fuel Evaporative Emission Control System Inspection

    0B-8 Maintenance and Lubrication: Fuel Evaporative Emission Control System Brake Drums and Shoes Inspection S5JB0A0206048 Inspection Check rear brake drums and brake linings for excessive S5JB0A0206047 wear and damage, while wheels and drums are 1) Visually inspect hoses for cracks, damage, or removed.

  • Page 41: Parking Brake Lever And Cable Inspection

    Maintenance and Lubrication: 0B-9 Parking Brake Lever and Cable Inspection Clutch Fluid Inspection S5JB0A0206024 S5JB0A0206018 1) Check system for evidence of fluid leakage. 1) Inspect brake cable for damage and smooth Repair leaky point if any. movement. 2) Check reservoir for fluid level referring to “Clutch Replace cable if it is in deteriorated condition.

  • Page 42: Wheel Discs Inspection

    0B-10 Maintenance and Lubrication: Wheel Discs Inspection Rear S5JB0A0206026 • - Check shock absorber for damage, deformation, oil Inspect each wheel disc for dents, distortion and cracks. leakage and operation. A disc in badly damaged condition must be replaced. • - Check coil spring, upper arm, lower arm, control rod and trailing rod for deformation and damage.

  • Page 43: Propeller Shafts And Drive Shafts Inspection

    Maintenance and Lubrication: 0B-11 5) Check boots of steering linkage for damage (leaks, detachment, tear, dent, etc.). If damage is found, replace it with new one. If any dent is found on steering rack boots, correct it to original shape by turning steering wheel to the right or left as far as it stops and holding it for a few seconds.

  • Page 44: Automatic Transmission Fluid Change

    0B-12 Maintenance and Lubrication: Automatic Transmission Fluid Change Differential Oil Inspection S5JB0A0206033 S5JB0A0206035 1) Inspect transmission case for evidence of fluid 1) Check differential for evidence of oil leakage. leakage. Repair leaky point, if any. Repair leaky point if any. 2) Make sure that vehicle is placed level.

  • Page 45: Power Steering (P/S) System Inspection

    Maintenance and Lubrication: 0B-13 Power Steering (P/S) System Inspection S5JB0A0206038 1) Visually check power steering system for fluid leakage and hose for damage and deterioration. Repair or replace defective parts, if any. I5JB0A020026-01 Engine Hood Check that secondary latch operates properly (check I5JB0A020016-02 that secondary latch keeps hood from opening all the 2) Check fluid level with engine stopped.
  • Page 46 0B-14 Maintenance and Lubrication: Engine Start Parking brake Check engine start for readiness. Check that lever has proper travel. WARNING WARNING Before performing the following check, be With vehicle parked on a fairly steep slope, sure to have enough room around the make sure nothing is in the way downhill to vehicle.

  • Page 47: Specifications

    Refer to “A/T Fluid Change: in Section 5A”. Power steering fluid An equivalent of DEXRON®-II Water resistance chassis grease Clutch linkage pivot points (SUZUKI SUPER GREASE A 99000-25010) Door hinges Engine oil or water resistance chassis grease Hood latch assembly Key lock cylinder...
  • Page 48 0B-16 Maintenance and Lubrication:...

  • Page 49: Engine

    Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Precautions............. 1-1 Stop (but Engine Can Be Started)....1A-57 Precautions for Engine.......... 1-1 Malfunction Indicator Lamp Remains ON Engine General Information and after Engine Starts ..........1A-59 DTC P0010: Camshaft Position Actuator...
  • Page 50 1-ii Table of Contents DTC P0137 / P0138: O2 Sensor (HO2S) DTC P1603: TCM Trouble Code Detected Circuit Low Voltage / High Voltage (For J20 Engine) ...........1A-170 (Sensor-2) ............. 1A-107 DTC P1674: CAN Communication (Bus Off DTC P0140: O2 Sensor (HO2S) Circuit No Error) .............1A-171 Activity Detected (Sensor-2) ......
  • Page 51 Table of Contents 1-iii Vacuum Hose and Purge Valve Chamber Electric Load Current Sensor On-Vehicle Inspection............1B-3 Inspection (For J20 Engine) ......1C-16 EVAP Canister Purge Valve Inspection ....1B-3 Electric Load Current Sensor Removal EVAP Canister Inspection........1B-4 and Installation (For J20 Engine) ....1C-16 EGR Valve Removal and Installation ....
  • Page 52 1-iv Table of Contents Pistons, Piston Rings, Connecting Rods 1st Timing Chain and Chain Tensioner and Cylinders Disassembly and Assembly ..1D-44 Components............1D-91 Cylinders, Pistons and Piston Rings 1st Timing Chain and Chain Tensioner Inspection............1D-45 Removal and Installation.........1D-92 Piston Pins and Connecting Rods 1st Timing Chain and Chain Tensioner Inspection............1D-94 Inspection............1D-47...
  • Page 53 Table of Contents 1-v General Description ........... 1E-11 Fuel System ..........1G-1 Engine Lubrication Description ......1E-11 Precautions............1G-1 Diagnostic Information and Procedures..1E-13 Precautions on Fuel System Service ....1G-1 Oil Pressure Check ........... 1E-13 General Description ..........1G-1 Repair Instructions ..........
  • Page 54 1-vi Table of Contents Ignition Spark Test ..........1H-6 Diagnostic Information and Procedures .... 1J-3 Battery Inspection ..........1J-3 Repair Instructions ..........1H-7 Generator Symptom Diagnosis ......1J-4 High-Tension Cord Removal and Installation Generator Test (Undercharged Battery (For M16 Engine) ..........1H-7 Check)............... 1J-4 High-Tension Cord Inspection (For M16 Generator Test (Overcharged Battery Engine)..............1H-7...

  • Page 55: Precautions

    Precautions: Precautions Precautions Precautions for Engine S5JB0A1000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service: in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble: in Section 1A”. Precautions on Fuel System Service Refer to “Precautions on Fuel System Service: in Section 1G”.

  • Page 56: Engine General Information And Diagnosis

    • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan • Communication of ECM, BCM, combination meter, tool or OBD generic scan tool (Vehicle without keyless start control module (if equipped) ABS diagnosis connector).

  • Page 57: Precautions For Dtc Troubleshooting

    Engine General Information and Diagnosis: 1A-2 Precautions For DTC Troubleshooting • Wire colors of the special tool’s connectors are S5JB0A1100005 different from the ones of the ECM connectors. • Before performed trouble shooting, be sure to read However, the circuit arrangement of the special tool’s the “Precautions of ECM Circuit Inspection: ”.

  • Page 58: Engine Diagnosis General Description

    ECM and malfunction indicator lamp (1) operate as follows. • It is possible to communicate by using not only SUZUKI scan tool (2) but also OBD generic scan tool. • Malfunction indicator lamp (1) lights when the ignition (Diagnostic information can be accessed by using a switch is turned ON (but the engine at stop) with the scan tool.)
  • Page 59 2 driving cycle detection logic. In addition, DTC can be read by not only using SUZUKI scan tool but also displayed on odometer (5) Freeze Frame Data (Vehicle Not Equipped with of the combination meter. (i.e. when diagnosis switch...
  • Page 60 OBD serial data line (3) (K line of ISO 9141) is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module (in ECM), BCM (Body electrical Control...

  • Page 61: Engine And Emission Control System Description

    Engine General Information and Diagnosis: 1A-6 Engine and Emission Control System Description S5JB0A1101004 The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, and intake manifold. Fuel delivery system includes fuel pump, delivery pipe, etc.
  • Page 62 1A-7 Engine General Information and Diagnosis: ECM Transmission Data Keyless Start control hydrauric Combination Control Module module unit/control (for A/T Meter (if equipped) (for J20 module model) engine) assembly Engine torque signal Accelerator pedal position Engine speed Throttle position Stand by to engage air conditioning compressor Top gear inhibit Torque converter clutch...
  • Page 63 Engine General Information and Diagnosis: 1A-8 ECM Reception Data ABS hydraulic (for A/T model) unit/control module assmbly Torque reduction request Slip control signal Transmission malfunction indication on Transmission emissions related malfunction active Transmission gear selector position Daytime running light active (if equipped with DRL) Air conditioning switch ON (if equipped with A/C)

  • Page 64: Air Intake System Description

    1A-9 Engine General Information and Diagnosis: Air Intake System Description S5JB0A1101006 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “Description of Electric Throttle Body System: ”.), intake manifold tuning (IMT) valve (4) which adjusts the distributor pipe length of intake manifold to (A) or (B) (for J20 engine) (for the details, refer to “IMT (Intake Manifold Tuning) System: For J20 Engine in Section 1D”.) and intake manifold (5).

  • Page 65: Description Of Electric Throttle Body System

    Engine General Information and Diagnosis: 1A-10 Description of Electric Throttle Body System S5JB0A1101009 The Electric Throttle Body System consists of electric throttle body assembly, accelerator pedal position (APP) sensor assembly, ECM and throttle actuator control relay. Among them, assembly components are as follows. •...

  • Page 66: Description Of Electric Throttle Body System Calibration

    1A-11 Engine General Information and Diagnosis: Description of Electric Throttle Body System Calibration S5JB0A1101010 ECM calculates controlled opening of the throttle valve on the basis of the completely closed throttle valve position of the electric throttle body system. The completely closed position data is saved in memory of ECM. However, the completely closed position of the throttle valve of the electric throttle body system (signal voltage from throttle position sensor when throttle is completely closed) differs one from the other depending on individual differences of the throttle valve and throttle position sensor.

  • Page 67: A/F Sensor Description

    Engine General Information and Diagnosis: 1A-12 I5JB0A110009-01 6. Ignition switch 8. Battery A/F Sensor Description S5JB0A1101012 A/F sensor (1), in place of the conventional heated Oxygen sensor-1, is installed in the center of the exhaust manifold joining section and it consists of a zirconia element (2) which causes the output current to vary according to difference in the oxygen concentration, a heater (3) which activates the element and an adjusting resistor (4) which adjusts individual difference of the sensor.

  • Page 68: Electronic Control System Description

    1A-13 Engine General Information and Diagnosis: AFS- AFS+ AFH+ AFH- AFRV AFRG I5JB0A110010-02 10. Electrode 13. Lean 11. A/F signal processing circuit 14. Rich 12. CPU 15. 0.4 V Electronic Control System Description S5JB0A1101007 The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
  • Page 69 Engine General Information and Diagnosis: 1A-14 Engine and Emission Control System Flow Diagram I5JB0A110011-03...
  • Page 70 1A-15 Engine General Information and Diagnosis: ECM Input / Output Circuit Diagram For J20 engine BLU/ORN BLU/BLK E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 C37-44 BLU/RED BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41 WHT/RED C37-52 BLK/YEL C37-1 C37-51...
  • Page 71 Engine General Information and Diagnosis: 1A-16 1. Accelerator pedal position (APP) sensor 26-1. Sub fuel level sensor 52. A/C compressor (if equipped with A/C) assembly 2. Shield wire 27. Stop lamp switch 53. “CPRSR” fuse 3. CMP sensor 28. Stop lamp 54.
  • Page 72 1A-17 Engine General Information and Diagnosis: For M16 engine BLU/ORN BLU/BLK E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 C37-44 BLU/RED BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41 WHT/RED C37-52 C37-1 C37-51 WHT/BLU BLK/YEL C37-2 PNK/BLK PNK/GRN C37-16 PNK/BLU...
  • Page 73 Engine General Information and Diagnosis: 1A-18 1. Accelerator pedal position (APP) sensor 22. Stop lamp switch 44. Radiator cooling fan motor No.1 assembly 2. Shield wire 23. Stop lamp 45. Radiator cooling fan motor No.2 3. CMP sensor 24. DLC 46.
  • Page 74 1A-19 Engine General Information and Diagnosis: Terminal Wire color Circuit Terminal Wire color Circuit Electric load current sensor — — signal (for J20 engine) CO adjusting resistor signal (if Throttle position sensor (sub) GRN/WHT equipped) signal Oxygen signal of heated Ground for throttle position oxygen sensor-2 sensor...
  • Page 75 Engine General Information and Diagnosis: 1A-20 Terminal Wire color Circuit Terminal Wire color Circuit CAN (high) communication line (active high signal) to ABS WHT/RED — — hydraulic unit / control module assembly 12 V serial communication line PPL/WHT — — of data link connector Cruise control main switch BLK/WHT...

  • Page 76: Engine And Emission Control Input / Output Table

    1A-21 Engine General Information and Diagnosis: Engine and Emission Control Input / Output Table S5JB0A1101008 ELECTRIC CONTROL DEVICE OUTPUT INPUT For detecting fuel level FUEL LEVEL SENSOR BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR (if equipped with A/C) BLOWER SWITCH A/C SWITCH (if equipped with A/C) A/C EVAP OUTLET AIR TEMP.

  • Page 77: Schematic And Routing Diagram

    Engine General Information and Diagnosis: 1A-22 Schematic and Routing Diagram Engine and Emission Control System Diagram S5JB0A1102001 I5JB0A110015-04...

  • Page 78: Component Location

    1A-23 Engine General Information and Diagnosis: 1. Air cleaner 18. Radiator cooling fan motor 35. Immobilizer coil antenna (if equipped) 2. EVAP canister purge valve 19. Combination meter 36. Main relay 3. MAF and IAT sensor 20. BCM 37. Wheel speed sensor (VSS) 4.
  • Page 79 Engine General Information and Diagnosis: 1A-24 Information sensors Control devices Others 1. MAF and IAT sensor a: Fuel injector A: ECM 2. Electric throttle body assembly (built-in b: EVAP canister purge valve B: Combination meter throttle position sensor and throttle actuator) 3.

  • Page 80: Diagnostic Information And Procedures

    1A-25 Engine General Information and Diagnosis: Information sensors Control devices Others 1. MAF and IAT sensor a: Fuel injector A: ECM 2. Electric throttle body assembly (built-in b: EVAP canister purge valve B: Combination meter throttle position sensor and throttle actuator) 3.
  • Page 81 Engine General Information and Diagnosis: 1A-26 Step Action Rechecking and record of DTC / Freeze frame data Go to Step 9. Go to Step 10. 1) Recheck for DTC and freeze frame data referring to “DTC Check: ”. Is there any DTC(s)? Engine basic inspection and engine symptom Go to Step 11.
  • Page 82 1A-27 Engine General Information and Diagnosis: Customer problem inspection form (Example) I2RH01110010-01 NOTE This form is a standard sample. It should be modified according to conditions characteristic of each market.

  • Page 83: Malfunction Indicator Lamp (Mil) Check

    Engine General Information and Diagnosis: 1A-28 Step 2: DTC / Freeze Frame Data Check, Record and Step 11: Final Confirmation Test Clearance Confirm that the problem symptom has gone and the First, check DTC (including pending DTC), referring to engine is free from any abnormal conditions. If what has “DTC Check: ”.

  • Page 84: Dtc Clearance

    1A-29 Engine General Information and Diagnosis: Using Scan Tool 1) Prepare SUZUKI scan tool or OBD generic scan tool (vehicle not equipped with diagnosis connector). 2) With ignition switch turned OFF, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.

  • Page 85: Dtc Table

    Engine General Information and Diagnosis: 1A-30 NOTE Without Using Scan Tool 1) Turn ignition switch to OFF position. DTC and freeze frame data stored in ECM memory are also cleared in the following 2) Disconnect battery negative cable for specified time cases.
  • Page 86 1A-31 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) 1 driving *P0102 Mass air flow circuit low input Output voltage of MAF sensor is less than specification. cycle 1 driving *P0103 Mass air flow circuit high input Output voltage of MAF sensor is more than specification.
  • Page 87 Engine General Information and Diagnosis: 1A-32 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Throttle position sensor (sub) Output voltage of throttle position sensor (sub) is higher 1 driving *P0223 circuit high than specification. cycle Misfire of such level as to cause damage to three way *2 driving Random misfire detected *P0300...
  • Page 88 1A-33 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Battery voltage is higher than specification even through generator control is maximum regulation, or battery P0620 Generator control circuit voltage is lower than specification even through generator —...
  • Page 89 Engine General Information and Diagnosis: 1A-34 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Difference between the opening angle based on throttle Throttle position sensor (main / 1 driving *P2135 position sensor (main) and the opening angle based on sub) voltage correlation cycle throttle position sensor (sub) is more than specification.
  • Page 90 1A-35 Engine General Information and Diagnosis: For Vehicle Equipped with A/T When using OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also the following DTC(s) is displayed on OBD generic scan tool simultaneously. Detecting condition DTC No.

  • Page 91: Fail-Safe Table

    Engine General Information and Diagnosis: 1A-36 Fail-Safe Table S5JB0A1104006 When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC No.

  • Page 92: Scan Tool Data

    1A-37 Engine General Information and Diagnosis: DTC No. Detected item Fail-safe operation P2122 Pedal position sensor (main) circuit low input • Throttle valve is fixed at the opening of about 7° P2123 Pedal position sensor (main) circuit high input from its completely closed position (default P2127 Pedal position sensor (sub) circuit low input opening).
  • Page 93 Engine General Information and Diagnosis: 1A-38 Normal condition / Scan tool data Vehicle condition reference values FUEL TANK LEVEL Ignition switch ON 0 – 100% BATTERY VOLTAGE Ignition switch ON / engine at stop 10 – 14 V At 2000 r/min. with no load after warming up 10.0 –...
  • Page 94 1A-39 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values 1300 – 1480 kPa (for J20 engine), 1150 – 1280 kPa (for A/C ON (A/C is operating) at M16 engine) For more details, ambient temperature: 30 °C refer to pressure of high (86 °F) and humidity: 50% pressure gage under “A/C...
  • Page 95 Engine General Information and Diagnosis: 1A-40 Normal condition / Scan tool data Vehicle condition reference values APP SENSOR 2 VOLT Accelerator pedal released 0.3 – 0.4 V Ignition switch ON (ACCELERATOR PEDAL after warmed up Accelerator pedal depressed POSITION (APP) SENSOR 1.7 –...
  • Page 96 1A-41 Engine General Information and Diagnosis: BRAKE SW (ON/OFF) ACTIVE: Activating This parameter indicates the state of the brake switch. INACTIVE: warming up or at stop. INTAKE TUNING SOL (INTAKE MANIFOLD TUNING A/F B1 S1 ACT (A/F SENSOR, ACTIVE / INACTIVE): VALVE, ON/OFF): This parameter indicates activation condition of A/F sensor...
  • Page 97 Engine General Information and Diagnosis: 1A-42 A/C SWITCH (ON/OFF) APP SENSOR 2 VOLT (ACCELERATOR PEDAL ON: Command for A/C operation being output from ECM POSITION (APP) SENSOR (SUB) OUTPUT VOLTAGE, to HVAC. OFF: Command for A/C operation not being output. The Accelerator Pedal Position (APP) Sensor (Sub) reading provides accelerator pedal opening information A/C COMP RELAY (A/C COMPRESSOR RELAY, ON/...

  • Page 98: Visual Inspection

    1A-43 Engine General Information and Diagnosis: Visual Inspection S5JB0A1104008 Visually check the following parts and systems. Inspection item Reference section • Engine oil – level, leakage “Engine Oil and Filter Change: in Section 0B” • Engine coolant – level, leakage “Coolant Level Check: in Section 1F”...

  • Page 99: Engine Basic Inspection

    Engine General Information and Diagnosis: 1A-44 Engine Basic Inspection S5JB0A1104009 This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in “Visual Inspection: ”. Follow the flow carefully. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
  • Page 100 Check ignition timing Go to “Engine Symptom Check ignition control Diagnosis: ”. related parts referring to 1) Using SUZUKI scan tool, select “Misc Test” mode on “Ignition Timing SUZUKI scan tool and fix ignition timing to initial one. Inspection: in Section 1H”.
  • Page 101 Engine General Information and Diagnosis: 1A-46 Step Action 10 Check fuel supply Go to Step 12. Go to Step 11. 1) Check to make sure that enough fuel is filled in fuel tank. 2) Turn ON ignition switch for 2 seconds and then OFF. 3) Repeat Step 2) a few times.
  • Page 102 1A-47 Engine General Information and Diagnosis: Step Action 13 Check fuel injector for operation Go to “Engine Symptom Go to “Fuel Injector Diagnosis: ”. Circuit Check: ”. 1) Install spark plugs and connect injector connectors. 2) Using sound scope (1), check operating sound of each injector (2) when cranking engine.

  • Page 103: Engine Symptom Diagnosis

    Engine General Information and Diagnosis: 1A-48 Engine Symptom Diagnosis S5JB0A1104010 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection: ” and “Engine Basic Inspection: ”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug...
  • Page 104 1A-49 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Low oil pressure Improper oil viscosity “Engine Oil and Filter Change: in Section 0B” Malfunctioning oil pressure switch “Oil Pressure Switch Inspection: in Section 9C” Clogged oil strainer “Oil Pan and Oil Pump Strainer Cleaning: For J20 Engine in Section 1E”...
  • Page 105 Engine General Information and Diagnosis: 1A-50 Condition Possible cause Correction / Reference Item Engine noise – Worn piston, ring and cylinder bore “Pistons, Piston Rings, Connecting Rods and Connecting rod noise Cylinders Inspection and Cleaning: For J20 Engine in Section 1D” or “Cylinders, Pistons NOTE and Piston Rings Inspection: For M16A Engine Before checking...
  • Page 106 1A-51 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection: in Section 1F” Poor water pump performance “Water Pump Inspection: in Section 1F” Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning: in Section 1F”...
  • Page 107 Engine General Information and Diagnosis: 1A-52 Condition Possible cause Correction / Reference Item Excessive engine oil Blown cylinder head gasket “Cylinder Head Inspection: For J20 Engine in consumption – Oil Section 1D” or “Cylinder Head Inspection: For leakage M16A Engine with VVT in Section 1D” Leaky camshaft oil seals “Camshaft, Tappet and Shim Inspection: For J20 Engine in Section 1D”...
  • Page 108 1A-53 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Surge – Engine power Leaky or loosely connected high-tension “High-Tension Cord Removal and Installation variation under steady cord (for M16 engine) (For M16 Engine): in Section 1H” throttle or cruise.
  • Page 109 Engine General Information and Diagnosis: 1A-54 Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection: in Section 1H” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) Inspection: in Section 1H” Leaks, loose connection or “High-Tension Cord Removal and Installation disconnection of high-tension cord (for...
  • Page 110 1A-55 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection: in Section 1H” engine fails to idle Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation (for M16 engine) (For M16 Engine): in Section 1H”...
  • Page 111 Engine General Information and Diagnosis: 1A-56 Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection: in Section 1H” (HC) emission or carbon Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation monoxide (CO) (for M16 engine) (For M16 Engine): in Section 1H”...

  • Page 112: Malfunction Indicator Lamp Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)

    1A-57 Engine General Information and Diagnosis: Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S5JB0A1104011 Wiring Diagram E23-4 WHT/RED WHT/RED E23-19 WHT/BLU WHT/BLU G28-13 G28-15 PPL/RED BLK/YEL BLK/WHT E23-29 C37-15 BLK/ORN C37-30 BLK/ORN...
  • Page 113 Engine General Information and Diagnosis: 1A-58 Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action MIL power supply check...

  • Page 114: Malfunction Indicator Lamp Remains On After Engine Starts

    1A-59 Engine General Information and Diagnosis: Step Action Combination meter circuit check Substitute a known- “BLK” wire is open or good combination meter high resistance circuit. 1) Turn ignition switch to OFF position. and recheck. If MIL still 2) Measure resistance between “G28-15” terminal of remains OFF, substitute combination meter connector and vehicle body ground.

  • Page 115: Dtc P0010: Camshaft Position Actuator Circuit (For M16 Engine)

    Engine General Information and Diagnosis: 1A-60 DTC P0010: Camshaft Position Actuator Circuit (For M16 Engine) S5JB0A1104013 System and Wiring Diagram BRN/WHT C37-60 C37-15 BLK/ORN C37-59 BRN/YEL C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL [A]: 39 38 32 31 39 38 32 31 54 53 47 46...
  • Page 116 1A-61 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 117: Dtc P0011 / P0012: Camshaft Position - Timing Over-Advanced Or System Performance / -Retarded (For M16 Engine)

    Engine General Information and Diagnosis: 1A-62 Step Action Oil control valve check Substitute a known- Faulty oil control valve. Check oil control valve referring to “Oil Control Valve good ECM and recheck. Inspection: For M16A Engine with VVT in Section 1D”. Is resistance within specified value? DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For M16 Engine)
  • Page 118 Engine with VVT in 3) Select menu to DATA LIST. Section 1D”. If OK, go to 4) Check that “VVT GAP” displayed on SUZUKI scan tool is Step 5. 0 – 5°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.

  • Page 119: Dtc P0030: Ho2S Heater Control Circuit (Sensor-1)

    Engine General Information and Diagnosis: 1A-64 Step Action Oil control valve check Replace camshaft Replace oil control timing sprocket. valve. 1) Check oil control valve referring to “Oil Control Valve Inspection: For M16A Engine with VVT in Section 1D”. Is it in good condition? DTC P0030: HO2S Heater Control Circuit (Sensor-1) S5JB0A1104088 Wiring Diagram...

  • Page 120: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1)

    1A-65 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 121 Engine General Information and Diagnosis: 1A-66 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Run engine at idle speed for 1 min. or more. 5) Check DTC and pending DTC.
  • Page 122 1A-67 Engine General Information and Diagnosis: Step Action A/F sensor and HO2S heater resistance check Go to Step 6. Replace defective sensor. 1) Disconnect connector from HO2S-2 with ignition switch turned OFF. 2) Check heater resistance of A/F sensor and HO2S referring to “Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection: in Section 1C”...
  • Page 123 Engine General Information and Diagnosis: 1A-68 Step Action HO2S heater relay circuit check Output wire of relay Repair or replace connector is open or defective circuit. 1) Measure wire resistance between coil ground terminal of short to ground. relay connector and vehicle body ground. Ω...

  • Page 124: Dtc P0037 / P0038: Ho2S Heater Control Circuit Low / High (Sensor-2)

    1A-69 Engine General Information and Diagnosis: DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) S5JB0A1104016 Wiring Diagram BLK/WHT *GRN BLK/RED C37-47 C37-11 GRY/GRN C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110032-01...
  • Page 125 Engine General Information and Diagnosis: 1A-70 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 126 1A-71 Engine General Information and Diagnosis: Step Action HO2S heater relay power circuit check Go to Step 6. Power circuit is open. 1) Remove integration relay No.2 (for J20 engine) (1) or HO2S heater relay (for M16 engine) (2) with ignition switch turned OFF.

  • Page 127: Dtc P0101: Mass Air Flow Circuit Range / Performance

    Engine General Information and Diagnosis: 1A-72 Step Action 10 HO2S heater control circuit check Go to Step 11. Repair or replace defective wire circuit. 1) Disconnect connector from ECM with ignition switch turned OFF. 2) Check for proper connection of HO2S-2 heater circuit terminal to ECM connector.
  • Page 128 1A-73 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • MAF volume is greater than 25 g/sec even if engine • Air intake system (clog or leakage) revolution is less than 900 rpm and intake manifold •...
  • Page 129 Engine General Information and Diagnosis: 1A-74 Step Action MAF sensor and its circuit check Go to Step 11. Go to Step 4. 1) With ignition switch turned OFF, connect scan tool to DLC. 2) Start engine and warm up to normal operation temperature.

  • Page 130: Dtc P0102: Mass Air Flow Circuit Low Input

    1A-75 Engine General Information and Diagnosis: Step Action MAF sensor signal circuit check Go to Step 9. “RED” wire is shorted to others circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between “RED”...
  • Page 131 Engine General Information and Diagnosis: 1A-76 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 132: Dtc P0103: Mass Air Flow Circuit High Input

    1A-77 Engine General Information and Diagnosis: Step Action MAF sensor output signal check Substitute a known- Faulty MAF and IAT good ECM and recheck. sensor. 1) Connect connectors to MAF and IAT sensor and ECM with ignition switch turned OFF. 2) Measure voltage between “C37-26”...
  • Page 133 Engine General Information and Diagnosis: 1A-78 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 134: Dtc P0106: Manifold Absolute Pressure Range / Performance

    1A-79 Engine General Information and Diagnosis: DTC P0106: Manifold Absolute Pressure Range / Performance S5JB0A1104020 Wiring Diagram GRY/RED GRY/RED C37-14 RED/WHT C37-55 C37-15 BLK/ORN C37-30 BLK/ORN GRY/GRN GRY/GRN C37-57 C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL 39 38 32 31 39 38 32 31 54 53 47 46...

  • Page 135: Dtc P0107: Manifold Absolute Pressure Circuit Low Input

    Engine General Information and Diagnosis: 1A-80 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 136 1A-81 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 137: Dtc P0108: Manifold Absolute Pressure Circuit High Input

    Engine General Information and Diagnosis: 1A-82 Step Action MAP sensor signal circuit check Go to Step 7. “RED/WHT” wire is shorted to ground 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Measure resistance between “C37-55” terminal of ECM connector and vehicle body ground.
  • Page 138 1A-83 Engine General Information and Diagnosis: Step Action MAP sensor power supply voltage check Go to Step 4. “GRY/RED” wire shorted to power circuit. 1) Disconnect connector from MAP sensor with ignition switch turned OFF. 2) Check for proper connection of MAP sensor at “GRY/ RED”, “RED/WHT”...

  • Page 139: Dtc P0111: Intake Air Temperature Circuit Range / Performance

    Engine General Information and Diagnosis: 1A-84 DTC P0111: Intake Air Temperature Circuit Range / Performance S5JB0A1104023 Wiring Diagram BLU/BLK C37-26 C37-27 C37-25 LT GRN GRY/GRN C37-57 GRY/GRN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110036-01 1.
  • Page 140 1A-85 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 141 Engine General Information and Diagnosis: 1A-86 Step Action Wire circuit check Go to Step 6. “LT GRN” wire is shorted to ground or 1) Disconnect connectors from ECM with ignition switch other circuit. turned OFF. If wire is OK, substitute 2) Measure resistance between “LT GRN”...

  • Page 142: Dtc P0112: Intake Air Temperature Sensor Circuit Low

    1A-87 Engine General Information and Diagnosis: DTC P0112: Intake Air Temperature Sensor Circuit Low S5JB0A1104024 Wiring Diagram Refer to “DTC P0111: Intake Air Temperature Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for •...
  • Page 143 Engine General Information and Diagnosis: 1A-88 Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “LT GRN”...

  • Page 144: Dtc P0113: Intake Air Temperature Sensor Circuit High

    1A-89 Engine General Information and Diagnosis: DTC P0113: Intake Air Temperature Sensor Circuit High S5JB0A1104025 Wiring Diagram Refer to “DTC P0111: Intake Air Temperature Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for •...
  • Page 145 Engine General Information and Diagnosis: 1A-90 Step Action IAT sensor voltage check Go to Step 7. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “LT GRN”...

  • Page 146: Dtc P0116: Engine Coolant Temperature Circuit Range / Performance

    1A-91 Engine General Information and Diagnosis: Step Action Ground circuit check “GRY/GRN” wire is Faulty ECM ground open circuit or high circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors resistance circuit. Poor substitute a known- connected.
  • Page 147 Engine General Information and Diagnosis: 1A-92 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
  • Page 148 1A-93 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Disconnect ECT sensor connector with ignition switch turned OFF. 2) Check for proper connection to ECT sensor connector at “PPL/YEL” and “GRY/GRN” wire terminals. 3) If OK, then with ignition switch ON, measure voltage between “PPL/YEL”...

  • Page 149: Dtc P0117: Engine Coolant Temperature Circuit Low

    Engine General Information and Diagnosis: 1A-94 Step Action 10 Ground circuit check “GRY/GRN” wire is high Faulty ECM ground resistance circuit. circuit. 1) Remove ECM from its bracket with ECM connectors connected. Poor “C37-57” If circuit is OK, connection. substitute a known- 2) Measure resistance between “C37-57”...

  • Page 150: Dtc P0118: Engine Coolant Temperature Circuit High

    1A-95 Engine General Information and Diagnosis: Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from ECT sensor with ignition switch turned OFF. 2) Check for proper connection to ECT sensor at “PPL/ YEL”...
  • Page 151 Engine General Information and Diagnosis: 1A-96 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and run it for 10 sec. or more. 4) Check DTC and pending DTC.
  • Page 152 1A-97 Engine General Information and Diagnosis: Step Action ECT sensor harness voltage check Go to Step 6. “PPL/YEL” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. If wire is OK, substitute a known-good ECM and 2) Turn ON ignition switch.

  • Page 153: Dtc P0122: Throttle Position Sensor (Main) Circuit Low

    Engine General Information and Diagnosis: 1A-98 DTC P0122: Throttle Position Sensor (Main) Circuit Low S5JB0A1104073 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK BLU/BLK E23-16 WHT/GRN E23-50 BLU/ORN...
  • Page 154 1A-99 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
  • Page 155 Engine General Information and Diagnosis: 1A-100 Step Action ECM voltage check “WHT” wire is open or Go to Step 5. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “C37- 53”...

  • Page 156: Dtc P0123: Throttle Position Sensor (Main) Circuit High

    1A-101 Engine General Information and Diagnosis: DTC P0123: Throttle Position Sensor (Main) Circuit High S5JB0A1104074 Wiring Diagram Refer to “DTC P0122: Throttle Position Sensor (Main) Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of throttle position sensor (main) is more than •...
  • Page 157 Engine General Information and Diagnosis: 1A-102 Step Action ECM voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from electric throttle body assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “WHT”, “GRN”...
  • Page 158 1A-103 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 8. “BLK” wire is shorted to “WHT” wire. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “BLK” and “WHT” wire terminals of electric throttle body assembly connector.

  • Page 159: Dtc P0131 / P0132 / P0134: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1)

    Engine General Information and Diagnosis: 1A-104 DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1) S5JB0A1104032 Wiring Diagram BLK/WHT *GRN C37-38 C37-37 RED/YEL C37-35 RED/BLU C37-34 PNK/BLU C37-32 C37-31 BLK/YEL 39 38 32 31...

  • Page 160: Dtc P0133: O2 Sensor (Ho2S) Circuit Slow Response (Sensor-1)

    1A-105 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Run engine at idle speed for 1 min. or more. 5) Check DTC and pending DTC.
  • Page 161 Engine General Information and Diagnosis: 1A-106 A/F Sensor Description Refer to “A/F Sensor Description: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Ratio between integrated value of A/F sensor output variation and integrated value of • A/F sensor short term fuel trim variation is more than specification while vehicle is running •...

  • Page 162: Dtc P0137 / P0138: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-2)

    1A-107 Engine General Information and Diagnosis: DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2) S5JB0A1104035 Wiring Diagram BLK/WHT *GRN BLK/RED C37-47 C37-11 GRY/GRN C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
  • Page 163 Engine General Information and Diagnosis: 1A-108 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
  • Page 164 1A-109 Engine General Information and Diagnosis: Step Action HO2S-2 ground check Go to Step 5. “GRN” and/or “GRY/ GRN” wire is open or 1) Disconnect connector from HO2S-2 with ignition switch high resistance circuit. turned OFF. Poor “C37-57” terminal 2) Check for proper connection to HO2S-2 connector at connection.

  • Page 165: Dtc P0140: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-2)

    Engine General Information and Diagnosis: 1A-110 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) S5JB0A1104036 Wiring Diagram Refer to “DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2): ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S-2 voltage is higher than specified value after warming up engine...

  • Page 166: Dtc P0171 / P0172 / P2195 / P2196: Fuel System Too Lean / Rich / Stuck Lean / Stuck Rich

    1A-111 Engine General Information and Diagnosis: Step Action HO2S-2 signal circuit check Go to Step 5. “RED” wire is shorted to other circuit. 1) Turn ON ignition switch. 2) Measure voltage between “RED” wire terminal of HO2S- 2 connector and vehicle body ground. Is voltage 0 V? HO2S-2 heater circuit check Go to Step 6.
  • Page 167 Engine General Information and Diagnosis: 1A-112 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0171: • Vacuum leakage Total fuel trim (short term fuel trim + long term fuel trim) is higher • Exhaust gas leakage than specified range for 30 to 90 sec (depending on ECT) •...
  • Page 168 1A-113 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 169 Engine General Information and Diagnosis: 1A-114 Step Action A/F sensor adjusting resistor power /ground circuit Go to step 11. Go to Step 10. check 1) Disconnect connector from A/F sensor with ignition switch turned OFF. 2) Check for proper connection to A/F sensor connector. 3) If connections are OK, check A/F sensor adjusting resistor circuit for the following.

  • Page 170: Dtc P0222: Throttle Position Sensor (Sub) Circuit Low

    1A-115 Engine General Information and Diagnosis: DTC P0222: Throttle Position Sensor (Sub) Circuit Low S5JB0A1104075 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK BLU/BLK E23-16 WHT/GRN E23-50 BLU/ORN...
  • Page 171 Engine General Information and Diagnosis: 1A-116 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
  • Page 172 1A-117 Engine General Information and Diagnosis: Step Action ECM voltage check “WHT” wire is open or Go to Step 5. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “C37- 53”...

  • Page 173: Dtc P0223: Throttle Position Sensor (Sub) Circuit High

    Engine General Information and Diagnosis: 1A-118 DTC P0223: Throttle Position Sensor (Sub) Circuit High S5JB0A1104076 Wiring Diagram Refer to “DTC P0222: Throttle Position Sensor (Sub) Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of throttle position sensor (sub) is more than specified value •...
  • Page 174 1A-119 Engine General Information and Diagnosis: Step Action ECM voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from electric throttle body assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “RED”, “WHT”...
  • Page 175 Engine General Information and Diagnosis: 1A-120 Step Action Wire harness check Go to Step 8. “RED” wire is shorted to “WHT” wire. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “WHT” and “RED” wire terminals of electric throttle body assembly connector.

  • Page 176: Dtc P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected

    1A-121 Engine General Information and Diagnosis: DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S5JB0A1104038 System Description ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
  • Page 177 Engine General Information and Diagnosis: 1A-122 Step Action Does fuel level meter indicate “E” level (empty)? Add fuel and recheck. Go to Step 3. Fuel quality check Go to Step 4. Clean in fuel system circuit and change fuel. 1) Check that there is fuel of good quality in the fuel tank. Is it OK? Ignition system check Go to Step 5.

  • Page 178: Dtc P0327 / P0328: Knock Sensor Circuit Low / High

    1A-123 Engine General Information and Diagnosis: DTC P0327 / P0328: Knock Sensor Circuit Low / High S5JB0A1104039 Wiring Diagram C37-56 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110046-01 1. Knock sensor 2.
  • Page 179 Engine General Information and Diagnosis: 1A-124 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. Knock sensor circuit check Intermittent trouble. Go to Step 3. Check for intermittent 1) Remove ECM from its bracket with ECM connectors referring to “Intermittent connected.

  • Page 180: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit (For J20 Engine)

    1A-125 Engine General Information and Diagnosis: DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For J20 Engine) S5JB0A1104089 Wiring Diagram BLK/WHT BLK/YEL E23-29 BLK/YEL BLK/YEL [A]: BLK/RED [B]: BLK BLK/YEL C37-22 BLK/YEL BLK/RED WHT/RED BLK/YEL WHT/GRN C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/RED...
  • Page 181 Engine General Information and Diagnosis: 1A-126 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 182: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit (For M16 Engine)

    1A-127 Engine General Information and Diagnosis: DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For M16 Engine) S5JB0A1104040 Wiring Diagram BLK/WHT BLK/YEL E23-29 BLK/YEL BLK/YEL BLK/YEL C37-22 BLK/YEL BLK/RED WHT/RED BLK/YEL WHT/GRN C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/RED BLK/RED BLK/YEL E23-60 BLK/YEL...
  • Page 183 Engine General Information and Diagnosis: 1A-128 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 3 – 5 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to...
  • Page 184 1A-129 Engine General Information and Diagnosis: Step Action Ground circuit check Go to Step 6. “BLK/YEL” wire is open or high resistance. 1) Turn ignition switch to OFF position. 2) Measure resistance between “BLK/YEL” wire terminal of CKP sensor connector and engine ground. Ω...

  • Page 185: Dtc P0340: Camshaft Position (Cmp) Sensor Circuit

    Engine General Information and Diagnosis: 1A-130 DTC P0340: Camshaft Position (CMP) Sensor Circuit S5JB0A1104041 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL WHT/GRN C37-48 BLK/YEL BLK/RED BLK/RED E23-60 BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED E23-16 BLU/BLK BLU/BLK WHT/RED C37-52 BLK/YEL...
  • Page 186 1A-131 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 187 Engine General Information and Diagnosis: 1A-132 Step Action Was terminal “Vout” voltage in Step 3 within specification? Go to Step 5. “WHT/RED” wire is open or shorted to ground / power supply circuit. If wire and connection are OK, substitute a known-good ECM and recheck.

  • Page 188: Dtc P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected

    1A-133 Engine General Information and Diagnosis: DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected S5JB0A1104042 System and Wiring Diagram I5JB0A110051-01 1. EGR valve 4. Sensed information 7. “IG COIL” fuse 10. Main relay 2. Intake manifold 5.
  • Page 189 Engine General Information and Diagnosis: 1A-134 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0401: • EGR valve Difference in intake manifold absolute pressure between opened EGR valve • EGR passage and closed EGR valve is smaller than specified value. •...
  • Page 190 Go to Step 5. EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch turned OFF, install SUZUKI scan tool to DTC. 2) Check EGR system referring to “EGR System Inspection: in Section 1B”.

  • Page 191: Dtc P0403: Exhaust Gas Recirculation Control Circuit

    Engine General Information and Diagnosis: 1A-136 DTC P0403: Exhaust Gas Recirculation Control Circuit S5JB0A1104043 Wiring Diagram Refer to “DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area EGR valve output voltage is different from output command with more •...
  • Page 192 1A-137 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 5. Faulty wire(s) are shorted to ground 1) With ignition switch turned OFF, measure resistance circuit. between engine ground and each “YEL/BLK”, “YEL/ RED”, “YEL/GRN”, “YEL” wire terminals of EGR valve If wires are OK, connector.

  • Page 193: Dtc P0420: Catalyst System Efficiency Below Threshold

    Engine General Information and Diagnosis: 1A-138 DTC P0420: Catalyst System Efficiency below Threshold S5JB0A1104044 System and Wiring Diagram C37-38 C37-37 C37-57 C37-11 BLU WHT I5JB0A110053-02 1. A/F sensor 3. Warm up three way catalytic converter 5. ECM 2. HO2S-2 4. Three way catalytic converter Circuit Description ECM monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by HO2S-2.
  • Page 194 1A-139 Engine General Information and Diagnosis: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...

  • Page 195: Dtc P0443: Evaporative Emission System Purge Control Valve Circuit

    Engine General Information and Diagnosis: 1A-140 DTC P0443: Evaporative Emission System Purge Control Valve Circuit S5JB0A1104045 Wiring Diagram I5JB0A110054-02 1. EVAP canister purge valve 4. Fuse box No.2 7. “FI” fuse 2. Main relay 5. Ignition switch 8. “IGN” fuse 3.
  • Page 196 1A-141 Engine General Information and Diagnosis: DTC Troubleshooting WARNING In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas water heater. NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”.

  • Page 197: Dtc P0462: Fuel Level Sensor Circuit Low

    Engine General Information and Diagnosis: 1A-142 DTC P0462: Fuel Level Sensor Circuit Low S5JB0A1104047 Wiring Diagram BLK/RED BLK/RED E23-60 BLU/BLK BLU/BLK E23-1 BLK/RED E23-16 BLU/BLK E23-15 WHT/GRN BLK/WHT BLK/YEL BLU/BLK 12 V YEL/RED E23-24 WHT/GRN YEL/GRN BLK/YEL 39 38 32 31 39 38 32 31 54 53...
  • Page 198 Go to Step 5. Intermittent trouble. tool Check for intermittent referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection turned OFF. Inspection: in Section 2) Turn ON ignition switch and check fuel level displayed 00”.

  • Page 199: Dtc P0463: Fuel Level Sensor Circuit High

    Go to Step 6. Intermittent trouble. tool Check for intermittent referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection turned OFF. Inspection: in Section 2) Turn ON ignition switch and check fuel level displayed 00”.
  • Page 200 1A-145 Engine General Information and Diagnosis: Step Action Short circuit check for fuel level sensor output signal Go to Step 8. “YEL/RED” wire shorted circuit to other circuit. 1) Turn ON ignition switch and measure voltage between “E23-24” terminal of ECM connector and vehicle body ground.

  • Page 201: Dtc P0480: Fan 1 (Radiator Cooling Fan) Control Circuit

    Engine General Information and Diagnosis: 1A-146 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit S5JB0A1104048 Wiring Diagram YEL/GRN RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL BLU/BLK BLK/YEL C37-58 E23-48 YEL/GRN RED/YEL PPL/YEL C37-24 GRY/GRN...
  • Page 202 1A-147 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 203 Engine General Information and Diagnosis: 1A-148 Step Action Wire circuit check Go to Step 7. “RED/BLK” wire is shorted to other circuit. 1) Measure voltage between “RED/BLK” wire terminal of radiator cooling fan relay No.1 connector and vehicle body ground with ignition switch turned ON. Is voltage 0 V? Wire circuit check Go to Step 20.
  • Page 204 1A-149 Engine General Information and Diagnosis: Step Action 12 Wire circuit check Go to Step 13. “RED” wire is shorted to other circuit. 1) Measure voltage between “RED” wire terminal of radiator cooling fan relay No.2 connector and vehicle body ground with ignition switch turned ON. Is voltage 0 V? 13 Wire circuit check Go to Step 20.

  • Page 205: Dtc P0500: Vehicle Speed Sensor (Vss) Malfunction

    Engine General Information and Diagnosis: 1A-150 Step Action 18 Wire circuit check Go to Step 19. “RED/YEL” wire is shorted to other circuit. 1) Measure voltage between “RED/YEL” wire terminal of radiator cooling fan relay No.3 connector and vehicle body ground with ignition switch turned ON. Is voltage 0 V? 19 Wire circuit check Go to Step 20.
  • Page 206 1A-151 Engine General Information and Diagnosis: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...

  • Page 207: Dtc P0504: Brake Switch "A"/"B" Correlation (For J20 Engine)

    Engine General Information and Diagnosis: 1A-152 DTC P0504: Brake Switch “A”/“B” Correlation (For J20 Engine) S5JB0A1104096 Wiring Diagram BLK/YEL BLU/BLK YEL/GRN E23-8 WHT/GRN GRN/WHT GRN/WHT E23-20 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110107-02 1.
  • Page 208 1A-153 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 209: Dtc P0532: A/C Refrigerant Pressure Sensor Circuit Low

    Engine General Information and Diagnosis: 1A-154 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low S5JB0A1104051 Wiring Diagram GRY/RED GRY/RED C37-14 GRY/BLK C37-12 C37-15 BLK/ORN C37-30 BLK/ORN GRY/GRN GRY/GRN C37-57 C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL 39 38 32 31 39 38 32 31 54 53 47 46...
  • Page 210 1A-155 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 211: Dtc P0533: A/C Refrigerant Pressure Sensor Circuit High

    Engine General Information and Diagnosis: 1A-156 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High S5JB0A1104052 Wiring Diagram Refer to “DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area A/C refrigerant pressure sensor signal voltage is higher •...

  • Page 212: Dtc P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance

    1A-157 Engine General Information and Diagnosis: Step Action A/C refrigerant pressure sensor ground circuit check Go to Step 7. Go to Step 6. 1) Turn OFF ignition switch, measure resistance between engine ground and “GRY/GRN” wire terminal of A/C refrigerant pressure sensor connector. Ω...

  • Page 213: Dtc P0616: Starter Relay Circuit Low

    Engine General Information and Diagnosis: 1A-158 Step Action DTC recheck Go to Step 2. Intermittent trouble. 1) Clear DTC referring to “DTC Clearance: ”. Check for intermittent referring to “Intermittent 2) Turn OFF ignition switch. and Poor Connection 3) Turn ON ignition switch and check DTC. Inspection: in Section 00”...
  • Page 214 1A-159 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”.

  • Page 215: Dtc P0617: Starter Relay Circuit High

    Engine General Information and Diagnosis: 1A-160 DTC P0617: Starter Relay Circuit High S5JB0A1104055 Wiring Diagram Refer to “DTC P0616: Starter Relay Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Engine starter signal is high voltage for 180 seconds •...

  • Page 216: Dtc P0620: Generator Control Circuit

    1A-161 Engine General Information and Diagnosis: DTC P0620: Generator Control Circuit S5JB0A1104090 System and Wiring Diagram BRN/BLK C37-8 C37-28 BRN/BLK 39 38 32 31 39 38 32 31 47 46 54 53 47 46 54 53 I5JB0A110063-01 1. Generator 3. Field coil 5.
  • Page 217 Engine General Information and Diagnosis: 1A-162 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 218: Dtc P0625 / P0626: Generator Field Terminal Circuit Low / High

    1A-163 Engine General Information and Diagnosis: DTC P0625 / P0626: Generator Field Terminal Circuit Low / High S5JB0A1104091 System and Wiring Diagram Refer to “DTC P0620: Generator Control Circuit: ”. Generator Control System Description Refer to “Generator Control System Description: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 219 Engine General Information and Diagnosis: 1A-164 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 220: Dtc P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine)

    1A-165 Engine General Information and Diagnosis: DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine) S5JB0A1104092 Wiring Diagram I5JB0A110064-02 1. IMT vacuum solenoid valve 4. Fuse box No.2 7. “FI” fuse 2. Main relay 5. Ignition switch 8.
  • Page 221 Engine General Information and Diagnosis: 1A-166 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 222: Dtc P1501 / P1502: Electric Load Current Sensor Circuit Low / High

    1A-167 Engine General Information and Diagnosis: DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High S5JB0A1104093 System and Wiring Diagram GRY/RED C37-14 GRY/RED C37-9 GRY/GRN C37-57 GRY/GRN GRY/GRN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
  • Page 223 Engine General Information and Diagnosis: 1A-168 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 224: Dtc P1510: Ecm Back-Up Power Supply Malfunction

    1A-169 Engine General Information and Diagnosis: DTC P1510: ECM Back-Up Power Supply Malfunction S5JB0A1104056 Wiring Diagram E23-2 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110066-01 1. ECM 2. “DOME” fuse Circuit Description Battery voltage is supplied so that DTC memory, values for engine control learned by ECM, etc.

  • Page 225: Dtc P1603: Tcm Trouble Code Detected (For J20 Engine)

    Engine General Information and Diagnosis: 1A-170 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 226: Dtc P1674: Can Communication (Bus Off Error)

    1A-171 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 227 Engine General Information and Diagnosis: 1A-172 [A]: Keyless start control module connector (if equipped) (viewed from harness side) 2. ABS hydraulic unit / control module assembly [B]: ECM connector (viewed from harness side) 3. Combination meter [C]: TCM connector (for A/T model) (viewed from harness side) 4.
  • Page 228 1A-173 Engine General Information and Diagnosis: Step Action ECM, TCM (for A/T model), BCM, ABS hydraulic unit / Go to Step 4. Intermittent trouble. control module assembly, 4WD control module (for J20 Check for intermittent engine), combination meter and keyless start control referring to “Intermittent module (if equipped) connectors check and Poor Connection...
  • Page 229 Engine General Information and Diagnosis: 1A-174 Step Action DTC check in ECM Go to Step 10. “G44-19” or “G44-18” circuit wire between 1) Disconnect connector from keyless start control module keyless start control (if equipped) with ignition switch turned OFF. module and CAN circuit 2) Check ECM for DTC.
  • Page 230 1A-175 Engine General Information and Diagnosis: Step Action 15 CAN communication line circuit continuity check Go to Step 16. Repair open or high resistance of CAN 1) Measure resistance at following connector terminals. communication line • Between “E23-4” terminal of ECM connector and circuit referring to “E03-10”...

  • Page 231: Dtc P1676: Can Communication (Reception Error For Tcm (For A/T Model))

    Engine General Information and Diagnosis: 1A-176 Step Action 17 Check for short circuit of CAN communication line to Substitute a known- Repair short to power power circuit good ABS hydraulic unit supply of CAN / control module and communication line 1) Measure voltage at following connector terminals with recheck.
  • Page 232 1A-177 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 233 Engine General Information and Diagnosis: 1A-178 Step Action DTC check in ECM Go to Step 9. “E92-17” or “E92-7” circuit wire between 1) Disconnect connectors from TCM (for A/T model) with TCM and CAN circuit ignition switch turned OFF. junction connector is 2) Check ECM for DTC.
  • Page 234 1A-179 Engine General Information and Diagnosis: Step Action 13 CAN communication line circuit continuity check Go to Step 14. Repair open or high resistance of CAN 1) Disconnect connectors from all control modules communication line communicating by CAN with ignition switch turned OFF. circuit referring to 2) Measure resistance at following connector terminals.

  • Page 235: Dtc P1678: Can Communication (Reception Error For Bcm)

    Engine General Information and Diagnosis: 1A-180 Step Action 17 DTC check in BCM Check TCM power and Substitute a known- ground circuit. If circuit good ECM and recheck. 1) Connect connectors to all control modules is OK, substitute a communicating by CAN with ignition switch turned OFF. known-good TCM and 2) Check DTC U1101 in BCM.
  • Page 236 1A-181 Engine General Information and Diagnosis: Step Action ECM, ABS hydraulic unit / control module and BCM Go to Step 5. Intermittent trouble. connector check Check for intermittent referring to “Intermittent 1) Check for proper connection at each ECM, ABS and Poor Connection hydraulic unit / control module and BCM connector Inspection: in Section...
  • Page 237 Engine General Information and Diagnosis: 1A-182 Step Action DTC check in ECM Go to Step 12. “E91-22” or “E91-23” circuit wire between 1) Disconnect connector from 4WD control module (for J20 4WD control module engine) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.
  • Page 238 1A-183 Engine General Information and Diagnosis: Step Action 15 CAN communication line circuit ground short check Go to Step 16. Repair short to ground of CAN communication 1) Measure resistance at following connector terminals. line circuit referring to • Between “E23-4” terminal of ECM connector and “Precaution for CAN vehicle body ground Communication...

  • Page 239: Dtc P1685: Can Communication (Reception Error For Abs Control Module)

    Engine General Information and Diagnosis: 1A-184 DTC P1685: CAN Communication (Reception Error for ABS Control Module) S5JB0A1104094 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error): ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ABS hydraulic •...
  • Page 240 1A-185 Engine General Information and Diagnosis: Step Action ECM power and ground circuit check Go to Step 6. Repair ECM power and/ or ground circuits. 1) Check ECM power and ground circuits referring to “ECM Power and Ground Circuit Check: ”. Are they in good condition? DTC check in ABS hydraulic unit / control module Go to “DTC U1073:...
  • Page 241 Engine General Information and Diagnosis: 1A-186 Step Action DTC check in ECM Go to Step 12. “E91-22” or “E91-23” circuit wire between 1) Disconnect connector from 4WD control module (for J20 4WD control module engine) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.

  • Page 242: Dtc P2101: Throttle Actuator Control Motor Circuit Range / Performance

    1A-187 Engine General Information and Diagnosis: Step Action 17 ABS warning lamp check Substitute a known- Substitute a known- good ABS hydraulic unit good ECM and recheck. 1) Connect connectors to all control modules / control module communicating by CAN. assembly and recheck.
  • Page 243 Engine General Information and Diagnosis: 1A-188 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of throttle actuator output (duty output) is • Throttle actuator circuit inconsistent with throttle actuator control command. • Electric throttle body assembly (1 driving detection logic) •...

  • Page 244: Dtc P2102: Throttle Actuator Control Motor Circuit Low

    1A-189 Engine General Information and Diagnosis: Step Action Throttle actuator circuit check Go to Step 4. “BLU/YEL” wire and/or “BLU/RED” wire is 1) Turn OFF ignition switch. shorted to ground 2) Measure resistance between “BLU/YEL” wire terminal of circuit. electric throttle body assembly connector and engine ground, between “BLU/RED”...
  • Page 245 Engine General Information and Diagnosis: 1A-190 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 246: Dtc P2103: Throttle Actuator Control Motor Circuit High

    1A-191 Engine General Information and Diagnosis: DTC P2103: Throttle Actuator Control Motor Circuit High S5JB0A1104079 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Power supply voltage of throttle actuator control circuit is •...

  • Page 247: Dtc P2111: Throttle Actuator Control System - Stuck Open

    Engine General Information and Diagnosis: 1A-192 DTC P2111: Throttle Actuator Control System - Stuck Open S5JB0A1104080 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Throttle valve default opening is greater than 7° from • Electric throttle body assembly complementary closed position when diagnosing throttle •...

  • Page 248: Dtc P2119: Throttle Actuator Control Throttle Body Range / Performance

    1A-193 Engine General Information and Diagnosis: DTC P2119: Throttle Actuator Control Throttle Body Range / Performance S5JB0A1104081 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the measured (actual) throttle valve •...
  • Page 249 Engine General Information and Diagnosis: 1A-194 Step Action Throttle actuator circuit check Go to Step 4. “BLU/YEL” wire and/or “BLU/RED” wire is open 1) Disconnect connector from electric throttle body or high resistance. assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “BLU/YEL”...

  • Page 250: Dtc P2122: Pedal Position Sensor (Main) Circuit Low Input

    1A-195 Engine General Information and Diagnosis: DTC P2122: Pedal Position Sensor (Main) Circuit Low Input S5JB0A1104082 Wiring Diagram E23-56 WHT/BLU E23-55 E23-54 ORN/BLU E23-53 BLU/GRN E23-52 BLU/YEL E23-51 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110070-01...
  • Page 251 Engine General Information and Diagnosis: 1A-196 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 252 1A-197 Engine General Information and Diagnosis: Step Action Wire harness check Substitute a known- “WHT” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “E23-56” terminal of ECM connector and engine ground.

  • Page 253: Dtc P2123: Pedal Position Sensor (Main) Circuit High Input

    Engine General Information and Diagnosis: 1A-198 DTC P2123: Pedal Position Sensor (Main) Circuit High Input S5JB0A1104083 Wiring Diagram Refer to “DTC P2122: Pedal Position Sensor (Main) Circuit Low Input: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of accelerator pedal position sensor (main) •...
  • Page 254 1A-199 Engine General Information and Diagnosis: Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from accelerator pedal position (APP) sensor assembly with ignition switch turned OFF. 2) Check for proper connection to accelerator pedal position (APP) sensor assembly at “WHT”, “WHT/BLU”...

  • Page 255: Dtc P2127: Pedal Position Sensor (Sub) Circuit Low Input

    Engine General Information and Diagnosis: 1A-200 Step Action Ground circuit check “ORN” wire is open or Faulty ECM ground high resistance circuit. circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors substitute a known- connected. good ECM and recheck.
  • Page 256 1A-201 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 257: Dtc P2128: Pedal Position Sensor (Sub) Circuit High Input

    Engine General Information and Diagnosis: 1A-202 Step Action Wire harness check Substitute a known- “ORN/BLU” wire is good ECM and recheck. shorted to ground 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Measure resistance between “E23-53” terminal of ECM connector and engine ground.
  • Page 258 1A-203 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
  • Page 259 Engine General Information and Diagnosis: 1A-204 Step Action Wire harness check Substitute a known- “ORN/BLU” wire is good ECM and recheck. shorted to power circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Check for proper connection of ECM connector at “E23- 53”...

  • Page 260: Dtc P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation

    1A-205 Engine General Information and Diagnosis: DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation S5JB0A1104086 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK BLU/BLK E23-16 WHT/GRN...
  • Page 261 Engine General Information and Diagnosis: 1A-206 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 262 1A-207 Engine General Information and Diagnosis: Step Action Wire harness check Substitute a known- “WHT” wire is shorted to good ECM and recheck. other circuit. 1) Measure voltage between “C37-53” terminal of ECM connector and engine ground with ignition switch turned Is voltage 0 V? Wire harness check Go to Step 9.

  • Page 263: Dtc P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation

    Engine General Information and Diagnosis: 1A-208 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation S5JB0A1104087 Wiring Diagram E23-56 WHT/BLU E23-55 E23-54 ORN/BLU E23-53 BLU/GRN E23-52 BLU/YEL E23-51 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110070-01...
  • Page 264 1A-209 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions For DTC Troubleshooting: ”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...

  • Page 265: Dtc P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction

    Engine General Information and Diagnosis: 1A-210 Step Action Wire harness check Substitute a known- “WHT” wire or “ORN/ good ECM and recheck. GRN” wire is shorted to 1) Measure voltage between “E23-56” terminal of ECM other circuit. connector and engine ground, between “E23-53” terminal of ECM connector and engine ground with ignition switch turned ON.
  • Page 266 1A-211 Engine General Information and Diagnosis: DTC Confirmation Procedure DTC P2227: WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...

  • Page 267: Inspection Of Ecm And Its Circuits

    Engine General Information and Diagnosis: 1A-212 Inspection of ECM and Its Circuits S5JB0A1104063 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
  • Page 268 1A-213 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ 10 – 14 V Output signal is active low (“Reference C37-1 Fuel injector No.1 Engine running at idle pulse.
  • Page 269 Engine General Information and Diagnosis: 1A-214 Terminal Wire Circuit Normal voltage Condition Remarks color 0.5 – 1.0 V Ignition switch turned ON. Run engine at 2000 rpm, Electric load 1.3 – 1.7 V headlight switch turned current sensor C37-9 — signal (for J20 Run engine at 2000 rpm, engine)
  • Page 270 1A-215 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ Output signal is active low PNK/ 10 – 14 V C37-16 Fuel injector No.3 Engine running at idle pulse.
  • Page 271 Engine General Information and Diagnosis: 1A-216 Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON, 3.3 – 3.8 V ECT at 0 °C, 32 °F. Engine coolant PPL/ Ignition switch turned ON, C37-24 temp. (ECT) 1.38 – 1.72 V —...
  • Page 272 1A-217 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 2.6 – 2.8 V A/F sensor signal Engine running at idle C37-37 (“Reference — (–) after warmed up engine. waveform No.18: ”) 3.0 – 3.2 V A/F sensor signal Engine running at idle C37-38...
  • Page 273 Engine General Information and Diagnosis: 1A-218 Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V or 4 – 5 V Ignition switch turned ON. — *4 – 5 V Sensor signal is pulse. ↑↓ Pulse frequency which WHT/ CKP sensor signal 0 –...
  • Page 274 1A-219 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color *0 – 0.6 V ↑↓ Output signal is active Oil control valve 10 – 14 V BRN/ At the moment of ignition high pulse. Duty ratio C37-60 output (for M16 (“Reference...
  • Page 275 Engine General Information and Diagnosis: 1A-220 Terminal Wire Circuit Normal voltage Condition Remarks color For 2 sec. from the time ignition switch is turned 0 – 2.5 V ON or while engine is WHT/ Fuel pump relay running. E23-15 — output On and after 2 sec.
  • Page 276 1A-221 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color E23-40 — — — — — E23-41 — — — — — E23-42 — — — — — E23-43 — — — — — E23-44 — —...
  • Page 277 Engine General Information and Diagnosis: 1A-222 Terminal Wire Circuit Normal voltage Condition Remarks color BLU/ Throttle actuator E23-50 0 – 1 V Ignition switch turned ON. — control relay output Ground for BLU/ accelerator pedal E23-51 Below 0.3 V Ignition switch turned ON. —...
  • Page 278 1A-223 Engine General Information and Diagnosis: Reference waveform No.1 Reference waveform No.3 Fuel injector signal (1) with engine idling No.2 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-2” to “C37-58” terminal terminal CH2: “C37-2” to “C37-58” Oscilloscope CH1: 20 V/DIV Oscilloscope...
  • Page 279 Engine General Information and Diagnosis: 1A-224 Reference waveform No.5 Reference waveform No.7 Generator field coil monitor signal (1) at engine idling Heated oxygen sensor-2 signal (1) with engine idling Measurement CH1: “C37-8” to “C37-58” Measurement CH1: “C37-11” to “C37-57” terminal CH2: “C37-28”...
  • Page 280 1A-225 Engine General Information and Diagnosis: Reference waveform No.9 Reference waveform No.11 EVAP canister purge valve signal No.4 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-13” to “C37-58” terminal terminal CH2: “C37-17” to “C37-58” Oscilloscope CH1: 10 V/DIV Oscilloscope...
  • Page 281 Engine General Information and Diagnosis: 1A-226 Reference waveform No.12 Reference waveform No.13 Ignition coil signal (1) with engine idling Ignition coil No.4 signal (2) with engine idling (for J20 engine) Measurement CH1: “C37-20” to “C37-58” terminal Measurement CH1: “C37-52” to “C37-58” Oscilloscope CH1: 2 V/DIV terminal...
  • Page 282 1A-227 Engine General Information and Diagnosis: Reference waveform No.15 Reference waveform No.16 • Ignition coil No.2 signal (1) with engine idling (for J20 • Ignition coil No.1 signal (1) with engine idling (for J20 engine) engine) • Ignition coil No.2 and No.3 signal (2) with engine idling •...
  • Page 283 Engine General Information and Diagnosis: 1A-228 Reference waveform No.19 Reference waveform No.17 Mass air flow sensor signal (1) with engine racing Intake manifold tuning vacuum solenoid valve signal with engine racing (for J20 engine) Measurement CH1: “C37-26” to “C37-27” terminal CH2: “C37-54”...
  • Page 284 1A-229 Engine General Information and Diagnosis: Reference waveform No.20 Reference waveform No.21 CMP sensor signal with engine idling CMP sensor signal with engine idling CH1: “C37-52” to “C37-58” CH1: “C37-52” to “C37-58” Measurement Measurement CH2: “C37-51” to “C37-36” (for J20 CH2: “C37-51”...
  • Page 285 Engine General Information and Diagnosis: 1A-230 Reference waveform No.22 Reference waveform No.23 Throttle actuator output signal with ignition switch turned Throttle actuator output signal with ignition switch turned Measurement CH1: “C37-45” to “C37-58” Measurement CH1: “C37-45” to “C37-58” terminal CH2: “C37-44” to “C37-58” terminal CH2: “C37-44”...
  • Page 286 1A-231 Engine General Information and Diagnosis: Reference waveform No.25 Reference waveform No.27 Manifold absolute pressure sensor signal (1) with engine Knock sensor signal at engine speed 4000 r/min. racing Measurement CH1: “C37-56” to “C37-58” Measurement CH1: “C37-55” to “C37-57” terminal terminal CH2: “C37-54”...
  • Page 287 Engine General Information and Diagnosis: 1A-232 Reference waveform No.31 Reference waveform No.29 Oil control valve signal with engine racing (for M16 Ignition coil signal and fuel injector signal with engine engine) cranking Measurement CH1: “C37-52” to “C37-58” CH1: “C37-60” to “C37-59” terminal Measurement CH2: “C37-21”...
  • Page 288 1A-233 Engine General Information and Diagnosis: Resistance Check 1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C”. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Connect special tool to ECM connectors securely. NOTE Do not connect the other connector of special tool to ECM.

  • Page 289: Ecm Power And Ground Circuit Check

    Engine General Information and Diagnosis: 1A-234 ECM Power and Ground Circuit Check S5JB0A1104064 Wiring Diagram E23-2 BLK/YEL BLK/WHT E23-29 C37-15 BLK/ORN C37-30 BLK/ORN WHT/GRN C37-29 BLK/YEL C37-48 BLK/YEL BLK/RED BLK/RED E23-60 C37-58 BLK/YEL BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16 GRY/RED C37-14 C37-9 RED/WHT...
  • Page 290 1A-235 Engine General Information and Diagnosis: Circuit Description When the ignition switch is turned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM. And then ECM supplies 5 V power to each sensor (electric load current sensor (for J20 engine), MAP sensor, A/C refrigerant pressure sensor, APP sensor and TP sensor).
  • Page 291 Engine General Information and Diagnosis: 1A-236 Step Action Main relay circuit check Go to Step 5. Go to Step 9. 1) Turn ignition switch to OFF position. 2) Check “FI” fuse (1) (20 A) in fuse box No.2 for blowing. For J20 engine I5JB0A110097-02 For M16 engine...
  • Page 292 1A-237 Engine General Information and Diagnosis: Step Action Main relay circuit check Go to Step 9. “BLU/BLK” wire is open circuit or high resistance 1) Remove main relay (1) from fuse box No.2. circuit. For J20 engine I5JB0A110099-02 For M16 engine I5JB0A110100-02 2) Check for proper connection to main relay connector at “BLU/YEL”...

  • Page 293: Fuel Injector Circuit Check

    Engine General Information and Diagnosis: 1A-238 Step Action 12 Sensor 5 V power source circuit check Check internal short “GRY/RED”, “WHT” circuit of TP sensor, and/or “ORN/BLU” wire 1) Disconnect connectors from ECM, TP sensor, MAP MAP sensor, A/C is shorted to ground sensor, A/C refrigerant pressure sensor (if equipped with refrigerant pressure circuit.
  • Page 294 1A-239 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action Fuel injector check for operating sound...

  • Page 295: Fuel Pump And Its Circuit Check

    Engine General Information and Diagnosis: 1A-240 Fuel Pump and Its Circuit Check S5JB0A1104066 Wiring Diagram BLK/WHT E23-29 BLK/YEL BLK/WHT BLK/WHT E23-15 WHT/GRN WHT/GRN BLK/RED C37-15 BLK/ORN C37-30 BLK/ORN BLU/BLK C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16 BLK/RED E23-60...
  • Page 296 1A-241 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action Fuel pump control system check for operation...
  • Page 297 Engine General Information and Diagnosis: 1A-242 Step Action Fuel pump relay drive signal check Go to Step 7. Substitute a known- good ECM and recheck. 1) Measure voltage within 2 second after ignition switch is turned ON. Is voltage 0 – 1 V? Wire circuit check Go to Step 8.

  • Page 298: Fuel Pressure Check

    1A-243 Engine General Information and Diagnosis: Fuel Pressure Check S5JB0A1104067 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I2RH01110133-01 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter and fuel pump...
  • Page 299 Engine General Information and Diagnosis: 1A-244 Troubleshooting NOTE Before using following flow, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.

  • Page 300: A/C System Circuits Check

    1A-245 Engine General Information and Diagnosis: A/C System Circuits Check S5JB0A1104069 Wiring Diagram WHT/BLU WHT/RED PNK/GRN YEL/RED WHT/BLK WHT/RED E23-4 BLK/RED WHT/BLU E23-19 *RED WHT/RED YEL/GRN YEL/GRN E23-49 RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 BLU/BLK RED/YEL E23-48 YEL/GRN C37-14 GRY/RED GRY/BLK C37-12...
  • Page 301 Engine General Information and Diagnosis: 1A-246 Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
  • Page 302 1A-247 Engine General Information and Diagnosis: Step Action A/C refrigerant pressure sensor voltage check Go to Step 10. Check amount of refrigerant. If OK, 1) Check A/C refrigerant pressure sensor voltage referring replace A/C refrigerant to “Inspection of ECM and Its Circuits: ”. pressure sensor.

  • Page 303: Electric Load Signal Circuit Check

    Engine General Information and Diagnosis: 1A-248 Electric Load Signal Circuit Check S5JB0A1104070 Wiring Diagram WHT/RED E23-4 WHT/BLU E23-19 C37-7 BLU/ORN E03-8 WHT/BLU WHT/RED E03-10 G31-1 E03-12 E03-6 G31-3 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110104-02...
  • Page 304 1A-249 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action DTC check...

  • Page 305: Radiator Cooling Fan Low Speed Control System Check

    Engine General Information and Diagnosis: 1A-250 Radiator Cooling Fan Low Speed Control System Check S5JB0A1104071 Wiring Diagram YEL/GRN RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL BLU/BLK BLK/YEL C37-58 E23-48 YEL/GRN RED/YEL PPL/YEL C37-24 GRY/GRN C37-57...
  • Page 306 1A-251 Engine General Information and Diagnosis: Step Action Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 / Go to corresponding Go to Step 2. P0118) and/or radiator cooling fan circuit (DTC P0480)? DTC flow. Low speed radiator cooling fan control circuit check Radiator cooling fan low Perform from Step 2 to speed control system is...
  • Page 307 Engine General Information and Diagnosis: 1A-252 Step Action Wire circuit check Go to Step 8. “BLU/YEL” wire is shorted to ground 1) Disconnect radiator cooling fan motor No.1 connector circuit. with ignition switch turned OFF. 2) Measure resistance between “BLU/YEL” wire terminal of radiator cooling fan relay No.2 connector and vehicle body ground.

  • Page 308: Radiator Cooling Fan High Speed Control System Check

    1A-253 Engine General Information and Diagnosis: Step Action 15 Radiator cooling fan relay check Substitute a known- Replace radiator cooling good ECM and recheck. fan relay. 1) Check radiator cooling fan relay referring to “Radiator Cooling Fan Relay Inspection: in Section 1F”. Is it in good condition? 16 Radiator cooling fan motor check Substitute a known-...
  • Page 309 Engine General Information and Diagnosis: 1A-254 Step Action Wire circuit check Go to Step 5. “BLU/BLK” wire is open circuit. 1) Disconnect radiator cooling fan relay No.3 from relay box with ignition switch turned OFF. 2) Turn ON ignition switch. 3) Measure voltage between “BLU/BLK”...

  • Page 310: Repair Instructions

    1A-255 Engine General Information and Diagnosis: Repair Instructions Idle Speed and IAC Throttle Valve Opening 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Inspection S5JB0A1106001 Special tool Before idle speed check, make sure of the following.

  • Page 311: Special Tools And Equipment

    58413). 09912–58490 09930–76420 3-way joint & hose Timing-light (dry cell type) 09933–06320 SUZUKI scan tool ECM check harness (120P) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.

  • Page 312: Aux. Emission Control Devices

    Aux. Emission Control Devices Diagnostic Information and Procedures EGR System Inspection S5JB0A1204001 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu.

  • Page 313: Evap Canister Purge Valve And Its Circuit Inspection

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

  • Page 314: Vacuum Hose And Purge Valve Chamber Inspection

    1B-3 Aux. Emission Control Devices: 3) Check resistance between two terminals of EVAP canister purge valve. If resistance is not as specified, replace EVAP canister purge valve. EVAP canister purge valve resistance 30 – 34 Ω at 20 °C (68 °F) I3RM0A120008-01 4) With coupler disconnected, apply vacuum (–60 kPa I5JB0A120006-01...

  • Page 315: Evap Canister Inspection

    Aux. Emission Control Devices: 1B-4 EVAP Canister Inspection EGR Valve Inspection S5JB0A1206006 S5JB0A1206008 1) Check resistance between following terminals of WARNING EGR valve (1) in each pair. Do not suck nozzles on EVAP canister. Fuel If found faulty, replace EGR valve assembly. vapor inside EVAP canister is harmful.

  • Page 316: Pcv Valve Removal And Installation

    1B-5 Aux. Emission Control Devices: PCV Valve Removal and Installation S5JB0A1206011 Removal 1) Disconnect PCV hose from PCV valve. 2) Remove PCV valve from cylinder head cover. Installation Reverse removal procedure noting the following. • For J20 engine, apply sealant to thread part of PCV valve (1).

  • Page 317: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A1208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 Special Tool S5JB0A1208002 09917–47011...

  • Page 318: Engine Electrical Devices

    1C-1 Engine Electrical Devices: Engine Electrical Devices Repair Instructions Engine Control Module (ECM) Removal and b. Insert ECM connectors to ECM until it stops with unlocked lock lever. Installation S5JB0A1306004 CAUTION As ECM consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect negative cable at battery.

  • Page 319: Electric Throttle Body Assembly On-Vehicle Inspection

    Engine Electrical Devices: 1C-2 Throttle Valve Visual Check 1) Remove air cleaner outlet hose (for J20 engine) or air intake pipe (for M16 engine). 2) Check that there isn’t any foreign matter caught between throttle valve and throttle body housing. If there is, take it out after removing throttle body referring to “Electric Throttle Body Assembly Removal and Installation: For J20 Engine in Section...
  • Page 320 1C-3 Engine Electrical Devices: Electric Throttle Body Assembly Operation Check Throttle Position Sensor Performance Check 1) Remove air cleaner outlet hose (for J20 engine) or 1) Remove air cleaner outlet hose (for J20 engine) or air intake pipe (for M16 engine). air intake pipe (for M16 engine).

  • Page 321: Electric Throttle Body System Calibration

    Engine Electrical Devices: 1C-4 4.097 - 5.007 4.000 - 4.880 3.675 - 4.245 3.883 - 4.453 1.604 - 1.916 1.33 - 1.63 I5JB0A130016-01 0.724 - 1.036 [A]: For J20 engine 0.45 - 0.75 [B]: For M16 engine c) Measure output voltage variation while throttle valve is opened and closed as following I5JB0A130017-02 specification.

  • Page 322: Accelerator Pedal Position (App) Sensor Assembly On-Vehicle Inspection

    1C-5 Engine Electrical Devices: Accelerator Pedal Position (APP) Sensor Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection Assembly Removal and Installation S5JB0A1306024 S5JB0A1306027 1) Check that accelerator pedal position (APP) sensor CAUTION assembly has been mounted to vehicle body • Do not expose accelerator pedal position properly (no pinched floor carpet, etc).

  • Page 323: Accelerator Pedal Position (App) Sensor Assembly Inspection

    Engine Electrical Devices: 1C-6 Accelerator Pedal Position (APP) Sensor Accelerator pedal position (APP) sensor (sub) output voltage [B]: 0.44 – 1.74 V, varying according Assembly Inspection to depressed extent of accelerator pedal S5JB0A1306026 Check accelerator pedal position (APP) sensor (main and sub) output voltage as following steps.

  • Page 324: Engine Coolant Temperature (Ect) Sensor Inspection

    1C-7 Engine Electrical Devices: Air Fuel Ratio (A/F) Sensor On-Vehicle Installation Reverse removal procedure noting the following. Inspection S5JB0A1306028 • Clean mating surfaces of ECT sensor and water outlet Heater cap. 1) Disconnect A/F sensor connector. • Check O-ring for damage and replace, if necessary. 2) Using ohmmeter, measure resistance of Sensor •...

  • Page 325: Heated Oxygen Sensor (Ho2S-2) Heater On-Vehicle Inspection

    Engine Electrical Devices: 1C-8 Heated Oxygen Sensor (HO2S-2) Heater On- Vehicle Inspection S5JB0A1306010 1) Disconnect sensor connector. 2) Using ohmmeter, measure resistance of sensor heater between terminals “V ” and “GND” at sensor connector. If found faulty, replace oxygen sensor. NOTE Temperature of sensor affects resistance 1,(a)

  • Page 326: Camshaft Position (Cmp) Sensor Inspection

    1C-9 Engine Electrical Devices: 2) Connect connector to CMP sensor securely. 3) Connect negative cable to battery. Camshaft Position (CMP) Sensor Inspection S5JB0A1306012 Visual check • Check that O-ring is free from damage. • Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.

  • Page 327: Crankshaft Position (Ckp) Sensor Inspection

    Engine Electrical Devices: 1C-10 Installation Installation Reverse removal procedure noting the following. 1) Install crankshaft position sensor to cylinder block. • Apply engine oil to O-ring of sensor. Tighten CKP sensor bolt to specified torque. • Tighten CKP sensor bolt to specified torque. Tightening torque CKP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) Tightening torque...

  • Page 328: Knock Sensor Removal And Installation

    1C-11 Engine Electrical Devices: Resistance check CKP sensor resistance Resistance varies from less than 220 Ω (ON) to Measure resistance between “1” and “2” terminals of infinity (OFF) or from infinity (OFF) to less than 220 Ω CKP sensor. (ON) CKP sensor resistance 480 –...

  • Page 329: Control Relay Inspection

    Engine Electrical Devices: 1C-12 Control Relay Inspection Integration Relay No.2 (For J20 Engine) S5JB0A1306018 1) Disconnect negative cable at battery. Control Relay 2) Remove included in integration relay No.2 (1) from 1) Disconnect negative cable at battery. fuse box No.2 (2). 2) Remove main relay (1), fuel pump relay (3), starting motor control relay (2), throttle actuator control relay (4) and HO2S heater relay (5) (for M16 engine) from...

  • Page 330: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor On-Vehicle Inspection

    1C-13 Engine Electrical Devices: Mass Air Flow (MAF) and Intake Air 7) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases. Temperature (IAT) Sensor On-Vehicle Inspection MAF signal voltage between “C37-26” terminal S5JB0A1306019 circuit and “C37-27”...

  • Page 331: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Inspection

    Engine Electrical Devices: 1C-14 Installation Reverse removal procedure noting the followings. • Tighten MAF and IAT sensor screws to specified torque. Tightening torque MAF and IAT sensor screw (a): 1.5 N·m (0.15 kgf- m, 1.1 lb-ft) I5JB0A130034-02 (2.45) • Connect MAF and IAT sensor connector securely. Mass Air Flow (MAF) and Intake Air (0.58) Temperature (IAT) Sensor Inspection...
  • Page 332 1C-15 Engine Electrical Devices: 2) Check resistance of intake manifold tuning vacuum solenoid valve. If resistance is as specified, proceed to next operation check. If not, replace intake manifold tuning vacuum solenoid valve. Resistance of intake manifold tuning vacuum solenoid valve Between two terminals: 33 –...

  • Page 333: Electric Load Current Sensor On-Vehicle Inspection (For J20 Engine)

    If electric load current sensor circuit and charging system is in good condition, electric load current sensor is faulty. Without Using SUZUKI Scan Tool 1) Measure sensor voltage between “C37-9” terminal of ECM connector and vehicle body ground referring to “Inspection of ECM and Its Circuits: in Section 1A”.

  • Page 334: Specifications

    1C-17 Engine Electrical Devices: Specifications Tightening Torque Specifications S5JB0A1307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Accelerator pedal position (APP) sensor assembly nut APP sensor assembly bracket nut ECT sensor 12.5 1.25 A/F sensor 32.5 Heated oxygen sensor 32.5 CMP sensor bolt CKP sensor bolt CKP sensor bolt...

  • Page 335: Engine Mechanical

    Engine Mechanical: For M16A Engine with VVT 1D-1 Engine Mechanical For M16A Engine with VVT General Description Engine Construction Description S5JB0A1411001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V”...

  • Page 336: Camshaft Position Control (Vvt Variable Valve Timing) System Description

    1D-2 Engine Mechanical: For M16A Engine with VVT Camshaft Position Control (VVT Variable Valve Timing) System Description S5JB0A1411002 System Description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high.
  • Page 337 Engine Mechanical: For M16A Engine with VVT 1D-3 Oil Control Valve The oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ECM. By this operation, the intake valve timing is varied continuously.

  • Page 338: Diagnostic Information And Procedures

    1D-4 Engine Mechanical: For M16A Engine with VVT Targeted Timing Varying Operation Driving condition Valve timing Target of control Effect To shorten the valve opening overlap in Engine running at idle Stabilization of the engine Most retarded order to prevent the exhaust gas speed rotation at idle speed.

  • Page 339: Engine Vacuum Check

    Engine Mechanical: For M16A Engine with VVT 1D-5 I2RH0B140003-01 I3RH0B140009-01 8) Disengage clutch (to lighten starting load on engine) Engine Vacuum Check for M/T vehicle, and depress accelerator pedal (1) all S5JB0A1414002 the way to make throttle fully open. The engine vacuum that develops in the intake line is a good indicator of the condition of the engine.

  • Page 340: Valve Lash (Clearance) Inspection

    1D-6 Engine Mechanical: For M16A Engine with VVT 6) Run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification. Vacuum specification (at sea level) 59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at specified idle speed 7) After checking, disconnect special tool (Vacuum gauge) from PCV hose.
  • Page 341 Engine Mechanical: For M16A Engine with VVT 1D-7 Special tool selection table No. on camshaft Embossed mark on housing special tool I3, I4, I5 IN345 E3, E4, E5 EX345 I2RH0B140013-01 1. Special tool 2. Magnet 5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table.

  • Page 342: Repair Instructions

    1D-8 Engine Mechanical: For M16A Engine with VVT 6) Select new shim No. (1) with a thickness as close as Special tool possible to calculated value. (A): 09916–67020 (A): 09916–67021 Available new shims No. Thickness mm Thickness mm Shim No. Shim No.

  • Page 343: Air Cleaner Filter Inspection And Cleaning

    Engine Mechanical: For M16A Engine with VVT 1D-9 Air Cleaner Filter Inspection and Cleaning 8) Remove oil level gauge (1). S5JB0A1416002 9) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head Inspection cover. Check air cleaner filter for dirt.
  • Page 344 (2) as shown. Cylinder head cover bolt (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft) “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) 5) Connect PCV hose (2) to PCV valve (3). 6) Connect breather hose (4). 7) Install oil level gauge (1).

  • Page 345: Throttle Body And Intake Manifold Components

    Engine Mechanical: For M16A Engine with VVT 1D-11 Throttle Body and Intake Manifold Components S5JB0A1416009 I5JB0A141005-05 [A]: Installing location of intake manifold bolt and nut 7. EVAP canister purge valve 14. Intake manifold bolt (short) 1. Intake manifold 8. EVAP canister purge valve hose 15.

  • Page 346: Electric Throttle Body Assembly Removal And Installation

    1D-12 Engine Mechanical: For M16A Engine with VVT Electric Throttle Body Assembly Removal and Installation Installation 1) Clean mating surfaces and install new throttle body S5JB0A1416045 gasket to intake manifold. 2) Install electric throttle body assembly (1) to intake Removal manifold.

  • Page 347: Intake Manifold Removal And Installation

    Engine Mechanical: For M16A Engine with VVT 1D-13 Intake Manifold Removal and Installation 8) Remove intake manifold (1) and EGR pipe bolt (2) S5JB0A1416010 from cylinder head, and then remove its gaskets. Removal 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure: in Section 1G”.

  • Page 348: Engine Mountings Components

    1D-14 Engine Mechanical: For M16A Engine with VVT Engine Mountings Components S5JB0A1416012 I5JB0A141015-02 1. Engine front mounting 4. Engine rear mounting member : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Engine front mounting right bracket 5. Engine rear mounting : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft) 3.
  • Page 349 Engine Mechanical: For M16A Engine with VVT 1D-15 • Each wire harness clamps 7) Disconnect MAF sensor connector (1). 8) Remove air cleaner case (2). 12) Disconnect the following hoses: • Brake booster hose (22) from intake manifold • Radiator inlet and outlet hoses (26) from each pipe •...
  • Page 350 1D-16 Engine Mechanical: For M16A Engine with VVT 17) With hose connected, detach A/C compressor from 24) Disconnect transmission from engine referring to its bracket (if equipped) referring to “Compressor “Manual Transmission Assembly Dismounting and Assembly Removal and Installation for M16 Engine Remounting: in Section 5B”, if necessary.
  • Page 351 Engine Mechanical: For M16A Engine with VVT 1D-17 7) Remove engine jack. 17) Install air intake pipe (2). 8) Install front and rear propeller shafts referring to 18) Connect breather union (1) to air intake pipe (2). “Propeller Shaft Removal and Installation: in Section 3D”.

  • Page 352: Timing Chain Cover Components

    1D-18 Engine Mechanical: For M16A Engine with VVT Timing Chain Cover Components S5JB0A1416014 I5JB0A141020-01 1. Crankshaft pulley bolt 9. Oil gallery pipe No.1 17. Oil control valve 2. Crankshaft pulley 10. Copper washer : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.

  • Page 353: Timing Chain Cover Removal And Installation

    Engine Mechanical: For M16A Engine with VVT 1D-19 Timing Chain Cover Removal and Installation S5JB0A1416015 CAUTION • Keep working table, tools and hands clean while overhauling. • Use special care to handle aluminum parts so as not to damage them. •...
  • Page 354 6) Apply engine oil to new O-rings and install them to water outlet pipe (2). “A”: Water tight sealant 99000–31140 (SUZUKI Bond No.1207B) 7) Install water outlet pipe (2) to timing chain cover (1).

  • Page 355: Timing Chain Cover Inspection

    Engine Mechanical: For M16A Engine with VVT 1D-21 Timing Chain Cover Inspection 9) Install oil gallery pipes No.2 and No.3 to cylinder head (4) and timing chain cover (5). S5JB0A1416016 Tighten bolts to specified torque. Oil Seal Tightening torque Check oil seal lip for fault or other damage. Replace as Oil gallery pipe No.2 and No.3 bolt (a): 11 N·m ( necessary.

  • Page 356: Oil Control Valve Inspection

    1D-22 Engine Mechanical: For M16A Engine with VVT Oil Control Valve Inspection Installation S5JB0A1416044 1) Install new O-ring (4) to oil control valve. 2) Install oil control valve to timing chain cover. Oil Control Valve Tighten nuts to specification. 1) Inspect strainer (1) and mating surface (2) of oil control valve for clog or damage.

  • Page 357: Timing Chain And Chain Tensioner Components

    Engine Mechanical: For M16A Engine with VVT 1D-23 Timing Chain and Chain Tensioner Components S5JB0A1416017 I4RS0A140012-01 1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Timing chain 6. Chain tensioner adjuster mounting bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) : Apply engine oil.
  • Page 358 1D-24 Engine Mechanical: For M16A Engine with VVT Installation CAUTION After timing chain is removed, never turn crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown in the figure. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be Approx.
  • Page 359 Engine Mechanical: For M16A Engine with VVT 1D-25 6) Apply engine oil to sliding surface of chain tensioner 8) Screw in plunger (1) by turning body (2) in arrow (1) and install chain tensioner and spacer. direction and install a retainer (3) (wire) to hold Tighten tensioner bolt to specified torque.

  • Page 360: Timing Chain And Chain Tensioner Inspection

    1D-26 Engine Mechanical: For M16A Engine with VVT 10) Apply engine oil to timing chain and then turn Timing Chain Tensioner crankshaft clockwise by 2 revolutions and check that Check shoe (1) for wear or damage. match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is in match with notch (4) on cylinder black as shown in the figure.

  • Page 361: Camshaft, Tappet And Shim Components

    Engine Mechanical: For M16A Engine with VVT 1D-27 Camshaft, Tappet and Shim Components S5JB0A1416020 I4RS0A140013-01 1. Intake camshaft 5. Shim 9. Upper camshaft bearing : Shim No. on it faces tappet side. : Install a bearing half with some holes to upper side of intake camshaft No.1 bearing.
  • Page 362 1D-28 Engine Mechanical: For M16A Engine with VVT 4) Loosen camshaft housing bolts in such order as Installation indicated in the figure and remove them. 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to “12”...
  • Page 363 Engine Mechanical: For M16A Engine with VVT 1D-29 7) After applying engine oil to housing bolts, tighten them temporarily first. Then tighten them by the numerical order in the figure. Tighten a little at a time and evenly among bolts and repeat tightening “a”...

  • Page 364: Camshaft, Tappet And Shim Inspection

    1D-30 Engine Mechanical: For M16A Engine with VVT Camshaft, Tappet and Shim Inspection Camshaft Runout S5JB0A1416022 Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. Intake Cam Timing Sprocket Assembly If measured runout exceeds limit, replace camshaft. Fit intake cam timing sprocket assembly to camshaft (2) Camshaft runout limit and hold hexagonal section of camshaft by using...
  • Page 365 Engine Mechanical: For M16A Engine with VVT 1D-31 6) Tighten camshaft housing bolts in such order as If measured camshaft journal clearance exceeds indicated in the figure a little at a time till they are limit, measure journal (housing) bore and outside tightened to specified torque.
  • Page 366 1D-32 Engine Mechanical: For M16A Engine with VVT Wear of Tappet and Shim Check tappet and shim for pitting, scratches, or damage. If any malcondition is found, replace. I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head.

  • Page 367: Valves And Cylinder Head Components

    Engine Mechanical: For M16A Engine with VVT 1D-33 Valves and Cylinder Head Components S5JB0A1416023 I4RS0A140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2.

  • Page 368: Valves And Cylinder Head Removal And Installation

    1D-34 Engine Mechanical: For M16A Engine with VVT Valves and Cylinder Head Removal and Installation Installation 1) Clean mating surface of cylinder head and cylinder S5JB0A1416024 block. Remove oil, old gasket and dust from mating surface. Removal 2) Install knock pins (1) to cylinder block. 1) Remove engine assembly from vehicle referring to 3) Install new cylinder head gasket (2) to cylinder block.

  • Page 369: Valves And Cylinder Head Disassembly And Assembly

    Engine Mechanical: For M16A Engine with VVT 1D-35 d) Repeat Step c). 2) Using special tools (Valve lifter), compress valve spring and then remove valve cotters (1) also by e) Tighten bolt “A” to specified torque. using special tool (Forceps). NOTE Special tool Be sure to tighten M8 bolt “A”...
  • Page 370 1D-36 Engine Mechanical: For M16A Engine with VVT 6) Using special tool (Valve guide remover), drive valve 2) Install valve guide to cylinder head. guide out from combustion chamber side to valve Heat cylinder head uniformly at a temperature of 80 to 100 °C (176 to 212 °F) so that head will not be spring side.
  • Page 371 Engine Mechanical: For M16A Engine with VVT 1D-37 4) Install valve spring seat to cylinder head. 7) Install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1)) 5) Install new valve stem seal (1) to valve guide. and bottom end (small-pitch end (2)).

  • Page 372: Valves And Valve Guides Inspection

    1D-38 Engine Mechanical: For M16A Engine with VVT Valves and Valve Guides Inspection S5JB0A1416026 Valve Guide Valve stem-to-guide clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to- guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
  • Page 373 Engine Mechanical: For M16A Engine with VVT 1D-39 Valve head radial runout Valve seat repair Check each valve for radial runout with a dial gauge and A valve seat not producing a uniform contact with its “V” block. To check runout, rotate valve slowly. If runout valve or showing width of seating contact that is out of exceeds its limit, replace valve.

  • Page 374: Cylinder Head Inspection

    1D-40 Engine Mechanical: For M16A Engine with VVT Cylinder Head Inspection S5JB0A1416027 • Remove all carbon deposits from combustion chambers. NOTE Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to valves and valve seats, too.

  • Page 375: Valve Spring Inspection

    Engine Mechanical: For M16A Engine with VVT 1D-41 Valve Spring Inspection Cylinder Head Bolt Measure each thread diameter of cylinder head bolt (1) S5JB0A1416028 at “A” on 83.5 mm (2.81 in.) from seat side of flange bolt Valve Spring Free Length and Preload and “B”...

  • Page 376: Pistons, Piston Rings, Connecting Rods And Cylinders Components

    1D-42 Engine Mechanical: For M16A Engine with VVT Pistons, Piston Rings, Connecting Rods and Cylinders Components S5JB0A1416029 I2RH0B140108-01 [A]: 1) Tighten all nuts to 15 N⋅m (1.5 kgf-m). 7. Connecting rod bearing 2) Then retighten all nuts by turning through 45°. 3) Repeat Step 2) again.
  • Page 377 Engine Mechanical: For M16A Engine with VVT 1D-43 Installation 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. NOTE Do not apply oil between connecting rod and bearing or between bearing cap and bearing. 2) Install guide hoses (1) over connecting rod bolts.

  • Page 378: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly

    1D-44 Engine Mechanical: For M16A Engine with VVT Pistons, Piston Rings, Connecting Rods and Assembly Cylinders Disassembly and Assembly 1) Decarbonize piston head and ring grooves using a S5JB0A1416031 suitable tool. 2) Install piston pin to piston (1) and connecting rod (2): Disassembly a) After applying engine oil to piston pin and piston 1) Using piston ring expander, remove two...

  • Page 379: Cylinders, Pistons And Piston Rings Inspection

    Engine Mechanical: For M16A Engine with VVT 1D-45 NOTE 4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure. If any one of four cylinders has to be rebored, rebore all four to the same next oversize. This is necessary for the sake of uniformity and balance.
  • Page 380 1D-46 Engine Mechanical: For M16A Engine with VVT Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston.

  • Page 381: Piston Pins And Connecting Rods Inspection

    Engine Mechanical: For M16A Engine with VVT 1D-47 Piston Pins and Connecting Rods Inspection Connecting Rod S5JB0A1416033 Big-end side clearance Piston Pin Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal Visual inspection manner.

  • Page 382: Crank Pin And Connecting Rod Bearings Inspection

    1D-48 Engine Mechanical: For M16A Engine with VVT Crank Pin and Connecting Rod Bearings Connecting rod bolt deformation (Plastic deformation tightening bolt) Inspection Measure each thread diameter of connecting rod bolt (2) S5JB0A1416034 at “A” on 32 mm (1.25 in.) from bolt mounting surface Crank Pin Diameter and “B”...
  • Page 383 Engine Mechanical: For M16A Engine with VVT 1D-49 Connecting Rod Bearing General Information a) Tighten all cap nuts to 15 N⋅m (1.5 kgf-m, 11.0 lb- Service connecting rod bearings are available in standard size and 0.25 mm (0.0098 in.) undersize b) Retighten them to 45°...
  • Page 384 1D-50 Engine Mechanical: For M16A Engine with VVT Selection of Connecting Rod Bearings 2) Next, check crankshaft pin diameter. On crank web No.3, four alphabets are stamped as shown in the NOTE figure. Three kinds of alphabet (“A”, “B” and “C”) represent •...
  • Page 385 Engine Mechanical: For M16A Engine with VVT 1D-51 3) There are five kinds of standard bearings differing in 4) From number stamped on connecting rod and its cap thickness. To distinguish them, they are painted in and alphabets stamped on crank web No.3, the following colors at the position as indicated in the determine new standard bearing to be installed to figure.

  • Page 386: Main Bearings, Crankshaft And Cylinder Block Components

    1D-52 Engine Mechanical: For M16A Engine with VVT Main Bearings, Crankshaft and Cylinder Block Components S5JB0A1416035 I5JB0A141026-02...

  • Page 387: Main Bearings, Crankshaft And Cylinder Block Removal And Installation

    Engine Mechanical: For M16A Engine with VVT 1D-53 1. CKP sensor (if equipped) 10. Rear oil seal housing 19. Spring pin : See “A” : See “C” 2. Knock sensor 11. Rear oil seal 20. Sensor plate bolt 3. Cylinder block 12.
  • Page 388 1D-54 Engine Mechanical: For M16A Engine with VVT Installation 3) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to NOTE crank webs. • All parts to be installed must be perfectly 4) Confirm that dowel pins (3) are installed to intake side of each journal.
  • Page 389 8) Apply sealant to mating surface of rear oil seal Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft) housing (1). “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) Sealant amount for rear oil seal housing Width: “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)

  • Page 390: Crankshaft Inspection

    1D-56 Engine Mechanical: For M16A Engine with VVT Crankshaft Inspection 2) Tighten main bearing cap No.1 bolts (1) – (10) and S5JB0A1416037 main bearing cap No.2 bolts (11) – (20) gradually as follows. Crankshaft Runout Using a dial gauge, measure runout at center journal. NOTE Rotate crankshaft slowly.

  • Page 391: Main Bearings Inspection

    Engine Mechanical: For M16A Engine with VVT 1D-57 NOTE Main Bearings Inspection S5JB0A1416038 After checking the thrust play, make sure that thread deformation of each bearing cap No.1 General Information bolt referring to “Main Bearing Cap No.1 • Service main bearings are available in standard size Bolt”...
  • Page 392 1D-58 Engine Mechanical: For M16A Engine with VVT 4) Tighten main bearing cap No.1 bolts (1) – (10) and main bearing cap No.2 bolts (11) – (20) gradually as follows. NOTE If main bearing cap No.1 bolt is reused, make sure to check main bearing cap No.1 bolt for deformation referring to “Main Bearing Cap No.1 Bolt”...
  • Page 393 Engine Mechanical: For M16A Engine with VVT 1D-59 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in the figure. Three kinds of alphabets (“A”, “B” and “C”) or numbers (“1”, “2”...
  • Page 394 1D-60 Engine Mechanical: For M16A Engine with VVT Undersize bearing (0.25 mm (0.0098 in.)) • 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure. Each color represents the following thickness at the center of bearing.

  • Page 395: Sensor Plate Inspection

    Engine Mechanical: For M16A Engine with VVT 1D-61 New undersize crankshaft main bearing specification Measured journal diameter 51.7440 – 51.7500 mm 51.7380 – 51.7439 mm 51.7320 – 51.7379 mm (2.0372 – 2.0373 in.) (2.0370 – 2.0371 in.) (2.0367 – 2.0369 in.) A (1) Red and Purple Red and Brown...

  • Page 396: Flywheel Inspection

    1D-62 Engine Mechanical: For M16A Engine with VVT Flywheel Inspection Cylinder Block Inspection S5JB0A1416041 S5JB0A1416042 Visual Inspection Distortion of Gasketed Surface Using straightedge and thickness gauge, check • If ring gear is damaged, cracked or worn, replace gasketed surface for distortion and, if flatness exceeds flywheel.

  • Page 397: Specifications

    Engine Mechanical: For M16A Engine with VVT 1D-63 Specifications Tightening Torque Specifications S5JB0A1417001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolts 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) for tightening of special tool Camshaft housing bolt Cylinder head cover bolt Air intake pipe bolt Starting motor terminal nut Generator terminal nut...

  • Page 398: Special Tools And Equipment

    1D-64 Engine Mechanical: For M16A Engine with VVT Special Tools and Equipment Recommended Service Material S5JB0A1418001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250...
  • Page 399 Engine Mechanical: For M16A Engine with VVT 1D-65 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67020 Valve guide installer handle Tappet holder (Overseas) 09916–67021 09916–77310 Tappet holder...

  • Page 400: For J20 Engine

    1D-66 Engine Mechanical: For J20 Engine For J20 Engine General Description Engine Construction Description S5JB0A1421001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration consisting of 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
  • Page 401 Engine Mechanical: For J20 Engine 1D-67 I5JB0A142069-02...

  • Page 402: Air Cleaner Element Introduction

    1D-68 Engine Mechanical: For J20 Engine Air Cleaner Element Introduction S5JB0A1421002 This air cleaner element is dry type. Remember that it needs cleaning according to “Air Cleaner Filter Inspection and Cleaning: For J20 Engine”. IMT (Intake Manifold Tuning) System S5JB0A1421003 Description I5JB0A142062-01 IMT (Intake manifold tuning) system consists of the following items:...
  • Page 403 Engine Mechanical: For J20 Engine 1D-69 [A + B] (rpm) (rpm) [A]: [B]: I5JB0A142063-02 [A]: IMT valve open 1. IMT valve 3. Engine torque [B]: IMT valve closed 2. Intake manifold 4. Engine speed IMT (Intake manifold tuning) system varies effective length of intake pipe by opening and closing IMT valve in order to improve air volumetric efficiency.

  • Page 404: Diagnostic Information And Procedures

    1D-70 Engine Mechanical: For J20 Engine System Operation IMT vacuum solenoid valve open: When IMT vacuum solenoid valve is OFF, the actuator side of IMT vacuum solenoid valve is lead to relief port. Under this condition, the negative pressure is not applied to IMT valve actuator. The IMT valve, therefore, is totally opened due to the force of return spring in IMT valve actuator.

  • Page 405: Engine Vacuum Check

    12) After checking, install spark plugs (2) and ignition Special tool coils (1). (A): 09915–67311 (B): 09918–08210 (C): 09355–35754–600 Hose, SUZUKI GENUINE PARTS (D): 09367–04002 3-way joint, SUZUKI GENUINE PARTS I2RH01140002-01 13) Install ignition coil couplers. 14) Connect injector wire harness at coupler. 15) Install engine cover. I5JB0A142002-01 5) Start engine and run engine at specified idle speed, and read vacuum gauge.

  • Page 406: Valve Lash (Clearance) Inspection

    1D-72 Engine Mechanical: For J20 Engine Valve Lash (Clearance) Inspection 5) Check valve lashes with thickness gauge (4) S5JB0A1424003 according to the following procedure. 1) Remove negative cable at battery. a) Check valve lashes of cylinder No.1. 2) Remove cylinder head cover referring to “Cylinder b) Turn crankshaft pulley by 180°...
  • Page 407 Engine Mechanical: For J20 Engine 1D-73 Replacement of Shim c) Hold down the tappet so as not to contact the shim by installing special tool on camshaft 1) Close the valve whose shim (2) is to be replaced by housing with housing bolt (1) tighten housing turning crankshaft, then turn tappet (3) till its cut bolts to specified torque.
  • Page 408 1D-74 Engine Mechanical: For J20 Engine 5) Using a micrometer (2), measure the thickness of 7) Install new shim facing shim No. side with tappet. the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table.

  • Page 409: Repair Instructions

    Engine Mechanical: For J20 Engine 1D-75 Repair Instructions Air Cleaner Assembly Removal and Installation Air Cleaner Filter Removal and Installation S5JB0A1426044 S5JB0A1426002 Removal Removal 1) Disconnect breather hose (1) from air cleaner outlet 1) Remove air cleaner upper case (1) from lower case hose (2).

  • Page 410: Throttle Body And Intake Manifold Components

    1D-76 Engine Mechanical: For J20 Engine Throttle Body and Intake Manifold Components S5JB0A1426007 I5JB0A142005-01 1. Intake manifold 4. Electric throttle body assembly : Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is found, replace it with new one. 2.

  • Page 411: Throttle Body Cleaning

    Engine Mechanical: For J20 Engine 1D-77 6) Disconnect connector (3) from electric throttle body 9) Perform calibration of electric throttle body assembly assembly. referring to “Electric Throttle Body System Calibration: in Section 1C” if replaced. Throttle Body Cleaning S5JB0A1426010 Clean electric throttle body assembly referring to “Throttle Valve Operation Check”...

  • Page 412: Cylinder Head Cover Removal And Installation

    1D-78 Engine Mechanical: For J20 Engine Cylinder Head Cover Removal and Installation 9) Remove EVAP canister purge valve bracket (10) form intake manifold. S5JB0A1426013 Removal 1) Disconnect negative cable at battery. 2) Remove engine cover. 3) Disconnect ignition coil couplers (1). 4) Remove ignition coils (4).
  • Page 413 4) Apply sealant “A” to cylinder head sealing surface “5”, (a) “1”, (a) “3”, (a) area as shown in figure. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) “4”, (a) “2”, (a) “6”, (a) I5JB0A142014-01 8) Install oil level gauge (1).

  • Page 414: Engine Mountings Components

    1D-80 Engine Mechanical: For J20 Engine Engine Mountings Components S5JB0A1426043 I5JB0A142016-01 1. Engine front mounting 6. Engine splash cover 2. Engine front mounting right bracket 7. Engine front mounting nut 3. Engine front mounting left bracket 8. Engine rear mounting member bolt 4.

  • Page 415: Engine Assembly Removal And Installation

    Engine Mechanical: For J20 Engine 1D-81 Engine Assembly Removal and Installation 10) Disconnect the following hoses: S5JB0A1426019 • Brake booster hose (21) from intake manifold • Radiator inlet and outlet hoses (22) from each Removal pipe 1) Relieve fuel pressure according to “Fuel Pressure •...
  • Page 416 1D-82 Engine Mechanical: For J20 Engine 12) For M/T model, remove shift control lever referring to 20) Remove engine rear mounting member bolts (1). “Transmission Shift Control Lever Removal and Installation: in Section 5B”. 13) Remove exhaust No.1, No.2 and center pipes referring to “Exhaust System Components: in Section 1K”.
  • Page 417 Engine Mechanical: For J20 Engine 1D-83 Installation 13) Install water pump and generator drive belt referring to “Water Pump and Generator Drive Belt Removal 1) Install clutch cover and clutch disk referring to and Installation (For J20 Engine): in Section 1J”. “Clutch Cover, Clutch Disc and Flywheel Removal and Installation: in Section 5C”, if removed.

  • Page 418: Timing Chain Cover Components

    1D-84 Engine Mechanical: For J20 Engine Timing Chain Cover Components S5JB0A1426020 1207B 1207F I5JB0A142021-01 1. Crankshaft pulley bolt 6. Timing chain cover bolt and nut : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) 2. Crankshaft pulley 7. Idler pulley : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.
  • Page 419 Engine Mechanical: For J20 Engine 1D-85 5) Remove crankshaft pulley (1). Installation To remove crankshaft pulley, use special tools 1) Clean sealing surfaces on timing chain cover, (Steering wheel remover, Bearing puller attachment) cylinder block and cylinder head. with it as shown in figure. Remove oil, oil sealant and dust from sealing surface.
  • Page 420 4) Apply engine oil to oil seal lip, then install timing in figure. chain cover (1). Tighten bolts and nut to specified torque. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) NOTE “B”: Water tight sealant 99000–31140 (SUZUKI Before installing timing chain cover, check Bond No.1207B)

  • Page 421: Timing Chain Cover Cleaning And Inspection

    Engine Mechanical: For J20 Engine 1D-87 NOTE 11) Install engine assembly to vehicle referring to “Engine Assembly Removal and Installation: For J20 Be sure to use the following bolts instead of Engine”. pins in order to fix crank pulley by special tool.

  • Page 422: 2Nd Timing Chain And Chain Tensioner Removal And Installation

    1D-88 Engine Mechanical: For J20 Engine 2nd Timing Chain and Chain Tensioner 5) Turn crankshaft clockwise to meet the following conditions. Removal and Installation S5JB0A1426024 • Key on crankshaft match with mark on cylinder block (I). CAUTION • Arrow mark on idler sprocket points upward (II). After 2nd timing chain is removed, never turn •...
  • Page 423 Engine Mechanical: For J20 Engine 1D-89 7) Remove intake and exhaust camshaft timing 4) Install 2nd timing chain by aligning yellow plate (1) of sprocket bolts (1). To remove them, fit a spanner (4) 2nd timing chain and match marks on idler sprocket. to hexagonal part (3) at the center of camshaft to hold it stationary.

  • Page 424: 2Nd Timing Chain And Chain Tensioner Inspection

    1D-90 Engine Mechanical: For J20 Engine At this time, check timing marks (3, 5 and 7) of 6) Tighten intake and exhaust camshaft timing sprocket bolts (1) to specified torque. To tighten it, fit a sprockets are in match with timing marks (4, 6 and 8) spanner (2) to hexagonal part (3) at the center of of cylinder head, cylinder block and lower crank camshaft to hold it stationary.

  • Page 425: 1St Timing Chain And Chain Tensioner Components

    Engine Mechanical: For J20 Engine 1D-91 Timing Chain Check timing chain for wear or damage. I2RH01140077-01 Tensioner Adjuster No.2 I2RH01140075-01 Check shoe (1) for wear or damage and latch functions 1. Timing chain guide No.2 properly. Camshaft Sprocket Check teeth of sprocket for wear or damage. I2RH01140078-01 I2RH01140076-01 1st Timing Chain and Chain Tensioner Components...

  • Page 426: 1St Timing Chain And Chain Tensioner Removal And Installation

    1D-92 Engine Mechanical: For J20 Engine 1st Timing Chain and Chain Tensioner Removal 2) Check that match mark (1) on crankshaft timing sprocket is in match with timing mark (2) on lower and Installation crankcase. S5JB0A1426027 CAUTION After timing chain is removed, never turn crankshaft and camshafts independently more than its allowable turning range described referring to “2nd Timing Chain and...
  • Page 427 Engine Mechanical: For J20 Engine 1D-93 I2RH01140086-01 I2RH01140089-01 2. Spacer 12) Check that dark blue and yellow plates of 1st timing chain are in match with match marks on sprockets 8) With latch of tensioner adjuster No.1 returned and respectively. plunger (1) pushed back into body, insert stopper (4) into latch (2) and body (3).

  • Page 428: 1St Timing Chain And Chain Tensioner Inspection

    1D-94 Engine Mechanical: For J20 Engine 1st Timing Chain and Chain Tensioner Idler Sprocket Check teeth and bush (1) of sprocket for wear or Inspection damage. S5JB0A1426028 Timing Chain Guide No.1 Check shoe for wear or damage. I2RH01140094-01 1st Timing Chain I2RH01140091-01 Check timing chain for wear or damage.

  • Page 429: Camshafts, Tappet And Shim Components

    Engine Mechanical: For J20 Engine 1D-95 Camshafts, Tappet and Shim Components S5JB0A1426029 I5JB0A142028-01 1. Intake camshaft 5. Exhaust camshaft housing 9. Timing chain guide No.2 2. Exhaust camshaft 6. Shim 10. Camshaft housing bolt : Direct shim No. side toward tappet. 3.
  • Page 430 1D-96 Engine Mechanical: For J20 Engine 2) Match match mark (1) on crank timing sprocket and 5) Check position of camshaft housings. mating surface of cylinder block and lower Embossed marks are provided on each camshaft crankcase (2). housing, indicating position and direction for installation.

  • Page 431: Camshaft, Tappet And Shim Inspection

    Engine Mechanical: For J20 Engine 1D-97 9) Install timing chain cover. Refer to “Timing Chain Camshaft Journal Wear Cover Removal and Installation: For J20 Engine” for Check camshaft journals and camshaft housings for installation. pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder 10) Install cylinder head cover.
  • Page 432 1D-98 Engine Mechanical: For J20 Engine 6) Remove housing, and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point. Journal clearance Standard Limit 0.020 – 0.074 mm (0.0008 – 0.12 mm (0.0047 in.) 0.0029 in.) I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter...

  • Page 433: Valves And Cylinder Head Components

    Engine Mechanical: For J20 Engine 1D-99 Valves and Cylinder Head Components S5JB0A1426032 I5JB0A142039-01 1. Cylinder block 7. Valve stem seal 13. Cylinder head bolt (M6) : Be sure to tighten cylinder head bolt (M8) after securing cylinder head bolt (M10). 2.
  • Page 434 1D-100 Engine Mechanical: For J20 Engine 7) Loosen cylinder head bolts (M10) in such order as numbered in figure and remove them. NOTE Don’t forget to remove cylinder head bolt (M6) (3) as shown in figure. “5” “9” “11” “7” “3”...

  • Page 435: Valves And Cylinder Head Disassembly And Assembly

    Engine Mechanical: For J20 Engine 1D-101 Valves and Cylinder Head Disassembly and d) Tighten cylinder head bolts (M10) to 52 N⋅m (5.2 kgf-m, 38.0 lb-ft) according to numerical order in Assembly figure. S5JB0A1426034 e) In the same manner as in step b), retighten Disassembly cylinder head bolts (M10) to 103 N⋅m (10.3 kgf- 1) When servicing cylinder head, remove intake...
  • Page 436 1D-102 Engine Mechanical: For J20 Engine 3) Release special tool, and remove spring retainers Assembly and valve springs. 1) Before installing valve guide into cylinder head, ream 4) Remove valve from combustion chamber side. guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round.
  • Page 437 Engine Mechanical: For J20 Engine 1D-103 3) Ream valve guide bore with special tool (6.0 mm 6) Install valve to valve guide. reamer). After reaming, clean bore. Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem. Special tool (A): 09916–34542 (B): 09916–37810...

  • Page 438: Valves And Valve Guides Inspection

    1D-104 Engine Mechanical: For J20 Engine 9) Install intake manifold referring to “Intake Manifold Removal and Installation: For J20 Engine”. 10) Install exhaust manifold referring to “Exhaust Manifold Removal and Installation (For J20 Engine Model): in Section 1K”. 11) Install injectors referring to “Fuel Injector Removal and Installation: in Section 1G”. Valves and Valve Guides Inspection S5JB0A1426035 Valve Guide...
  • Page 439 Engine Mechanical: For J20 Engine 1D-105 Valve Valve head radial runout Check each valve for radial runout with a dial gauge and Visual inspection “V” block. To check runout, rotate valve slowly. If runout exceeds its limit, replace valve. • Remove all carbon from valves. •...

  • Page 440: Cylinder Head Inspection

    1D-106 Engine Mechanical: For J20 Engine Cylinder Head Inspection Valve seat repair A valve seat not producing a uniform contact with its S5JB0A1426047 • Remove all carbon deposits from combustion valve or showing width of seating contact that is out of chambers.

  • Page 441: Valve Spring Inspection

    Engine Mechanical: For J20 Engine 1D-107 Valve Spring Inspection S5JB0A1426048 Valve Spring Free Length and Preload Referring to data, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.

  • Page 442: Pistons, Piston Rings, Connecting Rods And Cylinders Components

    1D-108 Engine Mechanical: For J20 Engine Pistons, Piston Rings, Connecting Rods and Cylinders Components S5JB0A1426036 I5JB0A142048-02 1. Top ring 8. Piston pin : “TOP” mark provided on piston ring comes to facing up. 2. 2nd ring 9. Piston pin circlip : “TOP”...

  • Page 443: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly

    Engine Mechanical: For J20 Engine 1D-109 3) Install piston and connecting rod assembly into 5) Install cylinder head. Refer to “Valves and Cylinder cylinder bore. Use special tool (Piston ring Head Removal and Installation: For J20 Engine” for compressor) to compress rings. Guide connecting installation.
  • Page 444 1D-110 Engine Mechanical: For J20 Engine Assembly NOTE Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. 1) Each piston (1) has stamped number (2) as shown.
  • Page 445 Engine Mechanical: For J20 Engine 1D-111 4) Install piston pin to piston (1) and connecting rod (3): 5) Install piston rings to piston: After applying engine oil to piston pin and piston pin • As indicated in figure at the left, 1st and 2nd rings holes in piston and connecting rod, fit connecting rod have “TOP”...

  • Page 446: Pistons, Piston Rings, Connecting Rods And Cylinders Inspection And Cleaning

    1D-112 Engine Mechanical: For J20 Engine Pistons, Piston Rings, Connecting Rods and Pistons Cylinders Inspection and Cleaning • Inspect piston for faults, cracks or other damages. S5JB0A1426039 Damaged or faulty piston should be replaced. • Piston diameter: Inspection As indicated in figure, piston diameter should be measured at a position 26.5 mm (1.04 in.) (“a”) from Cylinder piston skirt end in the direction perpendicular to piston...
  • Page 447 Engine Mechanical: For J20 Engine 1D-113 Piston rings To measure end gap, insert piston ring (2) into cylinder bore and then measure the gap by using thickness gauge (1). If measured gap is out of specification, replace ring. NOTE Clean carbon and any other dirt from top of cylinder bore before inserting piston ring.
  • Page 448 1D-114 Engine Mechanical: For J20 Engine Connecting rod Crank pin and connecting rod bearings • Big-end side clearance: • Inspect crank pin for uneven wear or damage. Check big-end of connecting rod for side clearance, Measure crank pin for out-of-round or taper with a with rod fitted and connected to its crank pin in the micrometer.
  • Page 449 Engine Mechanical: For J20 Engine 1D-115 • Connecting rod bearing clearance: e. Remove connecting rod bearing cap, and using a scale (2) on gauging plastic envelope, measure a. Before checking bearing clearance, clean bearing gauging plastic (1) width at the widest point and crank pin.
  • Page 450 1D-116 Engine Mechanical: For J20 Engine • Selection of connecting rod bearings: b. Next, check crank pin diameter. On crank web of No. 3 cylinder, four alphabets are stamped as NOTE shown in the figure. Three kinds of alphabet (“A”, “B” and “C”) •...
  • Page 451 Engine Mechanical: For J20 Engine 1D-117 • Connecting rod bolt Measure each thread diameter of connecting rod bolts (1) at “A” on 28.5 mm (1.12 in.) from bolt mounting surface and “B” on 42.0 mm (1.65 in.) from bolt mounting surface by using a micrometer (2). Calculate difference in diameters (“A”...

  • Page 452: Main Bearings, Crankshaft And Cylinder Block Components

    1D-118 Engine Mechanical: For J20 Engine Main Bearings, Crankshaft and Cylinder Block Components S5JB0A1426040 I5JB0A142056-02...

  • Page 453: Main Bearings, Crankshaft And Cylinder Block Removal And Installation

    Engine Mechanical: For J20 Engine 1D-119 1. Cylinder block 9. Check valve 17. Knock sensor 2. Lower crankcase 10. Flywheel : Tighten 40 N⋅m (4.0 kgf-m, 29.0 lb-ft), 0 : Apply sealant 99000-31250 to mating N⋅m (0 kgf-m, 0 lb-ft), 40 N⋅m (4.0 kgf-m, surface.
  • Page 454 Make sure that two halves are painted in the same surface area as shown in figure. color. “A”: Water tight sealant 99000–31250 (SUZUKI 2) Install new O-ring (2) to cylinder block. Bond No.1207F) 3) Install knock pins (5) to cylinder block.
  • Page 455 Engine Mechanical: For J20 Engine 1D-121 9) Pull out dowel pin (2) from crankshaft (1) and then install rear oil seal (3) by using special tools and plastic hammer. Special tool (A): 09911–97710 (B): 09911–97811 10) Install dowel pin (2). I2RH01140176-01 2.

  • Page 456: Main Bearings, Crankshaft And Cylinder Block Inspection

    1D-122 Engine Mechanical: For J20 Engine 12) Install flywheel (drive plate for A/T). 18) Install, timing chain sprockets, timing chains, timing Using special tool, lock flywheel or drive plate, and chain tensioner, tensioner adjusters, timing chain tighten flywheel or drive plate bolts (1) applied with guides, timing chain cover, crankshaft pulley, water sealant to specification.
  • Page 457 Engine Mechanical: For J20 Engine 1D-123 Crankshaft thrust play Out-of-round and taper (uneven wear) of journals Measure this play with crankshaft set in cylinder block in An unevenly worn crankshaft journal shows up as a the normal manner, that is, with thrust bearing and lower difference in diameter at a cross section or along its crankcase installed.
  • Page 458 1D-124 Engine Mechanical: For J20 Engine Selection of main bearings Main bearing clearance Check clearance by using gauging plastic according to STANDARD BEARING: the following procedure. If engine is under the following conditions, select a new standard bearing as followings and install it. 1) Remove lower crankcase.
  • Page 459 Engine Mechanical: For J20 Engine 1D-125 2) Next, check journal bore diameter. On lower 3) There are 5 kinds of standard bearings differing in crankcase five alphabets are stamped as shown in thickness. To distinguish them, they are painted (1) figure.
  • Page 460 1D-126 Engine Mechanical: For J20 Engine 4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal by referring to table shown. For example, if number stamped on crank web No.2 is “5” and alphabet stamped on lower crankcase is “A”, install new standard bearings painted in “Green”...
  • Page 461 Engine Mechanical: For J20 Engine 1D-127 • If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. a. Regrind journal to the following finished diameter. Finished journal diameter 57.7380 – 57.7560 mm (2.27315 – 2.27385 in.) b.
  • Page 462 1D-128 Engine Mechanical: For J20 Engine Oil Pump Chain 2) Using micrometer, measure piston diameter. Check oil pump chain for wear or damage. 3) Calculate cylinder bore diameter to be rebored as follows. D = A + B – C D: Cylinder bore diameter to be rebored.

  • Page 463: Specifications

    Engine Mechanical: For J20 Engine 1D-129 Specifications Tightening Torque Specifications S5JB0A1427001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolts 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) for tightening of special tool Camshaft housing bolt Cylinder head cover nut Starting motor terminal nut Generator terminal nut Timing chain cover bolt and nut...

  • Page 464: Special Tools And Equipment

    1D-130 Engine Mechanical: For J20 Engine Special Tools and Equipment Recommended Service Material S5JB0A1428001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
  • Page 465 Engine Mechanical: For J20 Engine 1D-131 09916–16510 09916–34542 Valve lifter attachment Reamer handle 09916–37810 09916–38210 Valve guide reamer (6 mm) Valve guide reamer (11 mm) 09916–46020 09916–57340 Valve guide remover Valve guide installer attachment 09916–57350 09916–66510 Valve guide installer handle Tappet holder (6 mm) 09916–77310...
  • Page 466 1D-132 Engine Mechanical: For J20 Engine 09944–36011 Steering wheel remover...

  • Page 467: Engine Lubrication System

    Engine Lubrication System: For M16A Engine with VVT 1E-1 Engine Lubrication System For M16A Engine with VVT General Description Engine Lubrication Description S5JB0A1511001 The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter.
  • Page 468 1E-2 Engine Lubrication System: For M16A Engine with VVT I3RH0B150001-01...

  • Page 469: Diagnostic Information And Procedures

    Engine Lubrication System: For M16A Engine with VVT 1E-3 Diagnostic Information and Procedures Oil Pressure Check 3) Install special tools (oil pressure gauge) to vacated S5JB0A1514001 threaded hole of oil pressure switch. NOTE Special tool Prior to checking oil pressure, check the (A): 09915–77310 following.

  • Page 470: Repair Instructions

    1E-4 Engine Lubrication System: For M16A Engine with VVT 8) Start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) Connect oil pressure switch coupler (1). I5JB0A151003-01 Repair Instructions Oil Pan and Oil Pump Strainer Components S5JB0A1516001 I5JB0A151005-01 1.

  • Page 471: Oil Pan And Oil Pump Strainer Removal And Installation

    3) Apply sealant continuously to oil pan mating surface as shown in the figure. I5JB0A151006-01 5) Remove oil pan, and then oil pump strainer (1) from “A”: Sealant 99000–31260 (SUZUKI Bond cylinder block. No.1217G) Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)

  • Page 472: Oil Pan And Oil Pump Strainer Cleaning

    1E-6 Engine Lubrication System: For M16A Engine with VVT 4) Install oil pan to cylinder block temporarily. 9) Install clutch housing lower plate No.1 (1) and clutch housing lower plate No.2 (2). 5) Insert knock pin (1) in hole (2) of oil pan in order to locate oil pan precisely.

  • Page 473: Oil Pump Components

    Engine Lubrication System: For M16A Engine with VVT 1E-7 Oil Pump Components S5JB0A1516004 I4RS0A150010-01 1. Rotor plate 6. Rotor plate bolt 10. Circlip 2. O-ring 7. Relief valve : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3. Outer rotor 8. Spring : Do not reuse.

  • Page 474: Oil Pump Inspection

    1E-8 Engine Lubrication System: For M16A Engine with VVT Oil Pump Inspection Reassembly S5JB0A1516007 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, Oil Seal oil seal lip portion, inside surfaces of oil pump case Check oil seal lip for fault or other damage.
  • Page 475 Engine Lubrication System: For M16A Engine with VVT 1E-9 Radial clearance Relief valve spring free length and load Check radial clearance between outer rotor (1) and case Check relief valve spring free length and load as shown (2) using thickness gauge (3). in the figure.

  • Page 476: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A1518001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.

  • Page 477: For J20 Engine

    Engine Lubrication System: For J20 Engine 1E-11 For J20 Engine General Description Engine Lubrication Description S5JB0A1521001 The oil pump is trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block.
  • Page 478 1E-12 Engine Lubrication System: For J20 Engine I5JB0A151013-01...

  • Page 479: Diagnostic Information And Procedures

    Engine Lubrication System: For J20 Engine 1E-13 Diagnostic Information and Procedures Oil Pressure Check S5JB0A1524001 WARNING To avoid danger of being burned, do not touch exhaust manifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has cooled down.

  • Page 480: Repair Instructions

    1E-14 Engine Lubrication System: For J20 Engine Repair Instructions Oil Pan and Oil Pump Strainer Components S5JB0A1526001 1217G I5JB0A152004-02 1. Oil pan 8. Gasket : Apply sealant 99000-31260 to mating surface. 2. Oil pump strainer 9. Baffle plate 3. O-ring : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 4.

  • Page 481: Oil Pan And Oil Pump Strainer Removal And Installation

    Installation 1) Apply sealant to oil pan (1) mating surface S5JB0A1526002 continuously as shown in figure. Removal “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) 1) Remove oil level gauge. 2) Raise vehicle. Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) 3) Remove engine under cover (1).

  • Page 482: Oil Pan And Oil Pump Strainer Cleaning

    1E-16 Engine Lubrication System: For J20 Engine 5) Install front suspension frame referring to “Front 4) Install new gasket and drain plug (2) to oil pan after applying engine oil. Suspension Frame, Stabilizer Bar and/or Bushings Tighten drain plug to specified torque. Removal and Installation: in Section 2B”.

  • Page 483: Oil Pump Removal And Installation

    Engine Lubrication System: For J20 Engine 1E-17 Oil Pump Removal and Installation 2) Install oil pump chain guide (1), and tighten bolts to S5JB0A1526005 specified torque. CAUTION Tightening torque Don’t remove sprocket and inner rotor from Oil pump chain guide nut (a): 11 N·m (1.1 kgf-m, oil pump, otherwise damage of oil pump 8.0 lb-ft) center shaft and abnormal operation of oil...

  • Page 484: Oil Pump Inspection

    1E-18 Engine Lubrication System: For J20 Engine 5) Install oil pump case pins (5) to oil pump case No.2. • Measure free length and tension of oil relief spring. If the measured values of length or tension is less than the specification, replace oil pump relief valve set.
  • Page 485 Engine Lubrication System: For J20 Engine 1E-19 Side Clearance Using straightedge (5) and thickness gauge (4), measure side clearance. If side clearance exceeds its limit, replace oil pump assembly. Limit on side clearance 0.11 mm (0.0043 in.) I2RH01150025-01 1. Oil pump case No.1 3.

  • Page 486: Special Tools And Equipment

    1E-20 Engine Lubrication System: For J20 Engine Special Tools and Equipment Recommended Service Material S5JB0A1528001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.

  • Page 487: Engine Cooling System

    Engine Cooling System: 1F-1 Engine Cooling System General Description Cooling System Description This 50/50 mixture coolant solution provides freezing protection to –36 °C (–33 °F). S5JB0A1601001 The cooling system consists of the radiator cap, radiator, • Maintain cooling system freeze protection at –36 °C coolant reservoir, hoses, water pump, cooling fan and (–33 °F) to ensure protection against corrosion and thermostat.

  • Page 488: Schematic And Routing Diagram

    1F-2 Engine Cooling System: Schematic and Routing Diagram Coolant Circulation S5JB0A1602001 While the engine is warmed up (thermostat closed), coolant circulates as follows. I5JB0A161001-01 1. Radiator inlet hose 5. Thermostat 9. Heater core inlet hose 2. Radiator outlet hose 6. Water pump 10.

  • Page 489: Diagnostic Information And Procedures

    Engine Cooling System: 1F-3 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S5JB0A1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.

  • Page 490: Repair Instructions

    1F-4 Engine Cooling System: Repair Instructions Cooling System Components S5JB0A1606001 I5JB0A161003-03...
  • Page 491 Engine Cooling System: 1F-5 I5JB0A161004-03 [A]: M16 engine model 14. Thermostat 29. To cylinder head [B]: J20 engine model 15. Thermostat cap 30. To water pump 1. Radiator 16. Radiator inlet No.2 hose 31. To heater core 2. Reservoir 17. Water filler neck 32.

  • Page 492: Coolant Level Check

    1F-6 Engine Cooling System: Coolant Level Check Engine Cooling System Inspection and S5JB0A1606002 Cleaning WARNING S5JB0A1606003 WARNING To help avoid danger of being burned, do not remove radiator cap while engine and To help avoid danger of being burned, do not radiator are still hot.

  • Page 493: Cooling System Draining

    Engine Cooling System: 1F-7 Cooling System Draining 7) Remove reservoir (1) and remove cap (2) from S5JB0A1606019 reservoir (1). 1) Remove radiator cap. 8) Pour out any fluid, scrub and clean inside of 2) Drain coolant from radiator drain plug (1). reservoir with soap and water.

  • Page 494: Cooling Water Pipes Or Hoses Removal And Installation

    1F-8 Engine Cooling System: Cooling Water Pipes or Hoses Removal and 5) Remove thermostat cap (4) from thermostat case (3). Installation S5JB0A1606005 6) Remove thermostat from thermostat case (3). Removal 1) Drain coolant referring to “Cooling System Draining: ”. 2) To remove these pipes or hoses, loosen clamp on each hose and pull hose end off.

  • Page 495: Thermostat Removal And Installation

    Engine Cooling System: 1F-9 Thermostat Removal and Installation (For J20 Thermostat Inspection S5JB0A1606007 Engine Model) • Make sure that air bleed valve (1) of thermostat is S5JB0A1606022 Removal clean. Should this valve be clogged, engine would tend to 1) Drain coolant referring to “Cooling System Draining: overheat.

  • Page 496: Radiator Cooling Fan Motor On-Vehicle

    1F-10 Engine Cooling System: Radiator Cooling Fan Motor On-Vehicle Radiator Cooling Fan Relay Inspection S5JB0A1606020 Inspection 1) Disconnect negative (–) cable at battery. S5JB0A1606010 1) Check main and/or sub fan operation of radiator 2) Remove radiator cooling fan relay No.1 (1), No.3 (2) cooling fan as follows.

  • Page 497: Radiator Cooling Fan Assembly Removal And Installation

    Engine Cooling System: 1F-11 3) With hose connected, detach P/S fluid reservoir with reservoir bracket. 4) Remove air cleaner case and air cleaner suction pipe (2). 5) Remove reservoir (1) from radiator. “C” “A” “B” “A” I5JB0A161015-01 “B” 6) Remove cooling fan assembly. “D”...

  • Page 498: Radiator Removal And Installation

    Section 5A”. Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) Sealant quantity (to mating surface of water pump) Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)

  • Page 499: Water Pump Removal And Installation

    Engine Cooling System: 1F-13 Water Pump Removal and Installation (For J20 2) Install water pump assembly (1) to cylinder block and tighten bolts and nut to specified torque. Engine Model) S5JB0A1606023 Tightening torque Removal Water pump bolt and nut (a): 25 N·m (2.5 kgf-m, 1) Disconnect negative cable at battery.

  • Page 500: Water Pump Inspection

    For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...

  • Page 501: Fuel System

    Fuel System: 1G-1 Fuel System Precautions Precautions on Fuel System Service S5JB0A1700001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. • Disconnect negative cable at battery. •...

  • Page 502: Fuel Pump Description

    1G-2 Fuel System: Fuel Pump Description S5JB0A1701003 The fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) included and a fuel level gauge (3) attached. Also, the jet pump (4) installed in the fuel pump sucks up the fuel from the sub fuel level sensor side to main fuel level sensor side through the fuel suction pipe / hose by using the negative pressure produced when the part of...

  • Page 503: Diagnostic Information And Procedures

    Fuel System: 1G-3 Diagnostic Information and Procedures Fuel Pressure Inspection 4) Check that battery voltage is 11 V or more. S5JB0A1704001 5) Measure fuel pressure at each condition. WARNING If measured pressure is out of specification, refer to “Fuel Pressure Check: in Section 1A” and check Before starting the following procedure, be each possibly defective part.

  • Page 504: Fuel Cut Operation Inspection

    1G-4 Fuel System: Fuel Cut Operation Inspection 6) After checking fuel pressure, remove fuel pressure gauge. S5JB0A1704002 NOTE WARNING Before inspection, make sure that gear shift lever is in neutral position (shift select lever As fuel feed line is still under high fuel is “P”...

  • Page 505: Repair Instructions

    Fuel System: 1G-5 Repair Instructions Fuel System Components S5JB0A1706001 I5JB0A170001-03...
  • Page 506 1G-6 Fuel System: I5JB0A170002-03...
  • Page 507 Fuel System: 1G-7 [A]: For M16 engine model 11. Fuel pump gasket 24. To fuel tank [B]: For J20 engine model 12. Fuel tank bolt 25. To EVAP canister purge valve [C]: View A 13. Fuel pump bolt 26. Sub fuel level sensor 1.

  • Page 508: Fuel Hose Disconnecting And Reconnecting

    1G-8 Fuel System: Fuel Hose Disconnecting and Reconnecting S5JB0A1706023 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in figure. For Normal Clamp Fuel tank system NOTE...
  • Page 509 Fuel System: 1G-9 The other than fuel tank system [A]: With short pipe, fit hose as far as it reaches pipe joint as shown. [B]: With the following type pipe, fit hose as far as its peripheral projection as shown. [C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.

  • Page 510: Fuel Pressure Relief Procedure

    1G-10 Fuel System: Fuel Pressure Relief Procedure For Quick Joint (Fuel Vapor Line) S5JB0A1706002 CAUTION Disconnecting 1) Remove mud, dust and/or foreign material between This work must not be done when engine is pipe (1) and quick joint (fuel vapor line) (2) by hot.

  • Page 511: Fuel Lines On-Vehicle Inspection

    Fuel System: 1G-11 Fuel Lines On-Vehicle Inspection Installation S5JB0A1706004 1) Install clamps to marked®® location on pipes. If CAUTION clamp is deformed, its claw is bent or broken, replace it with new one. Due to the fact that fuel feed line (1) is under high pressure, use special care when 2) Install pipes with pipe clamps to vehicle.

  • Page 512: Fuel Injector Removal And Installation

    O-ring. Relief Procedure: ”. Replace O-ring with new one. 2) Disconnect negative cable at battery. “A”: Oil 99000–25320 (SUZUKI DI O RING 3) Disconnect fuel injector couplers. OIL(500CC)) 4) Disconnect fuel feed hose from fuel delivery pipe (1).

  • Page 513: Fuel Injector Inspection

    Fuel System: 1G-13 Fuel Injector Inspection S5JB0A1706008 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. 1) Install injector to special tool (injector checking tool). 2) Install pressure regulator to special tool (injector checking tool).
  • Page 514 Turn ignition switch ON, clear DTC and select “MISC TEST” mode on scan tool. iii) Turn fuel pump ON by using scan tool. Special tool (A): SUZUKI scan tool I5JB0A171010-01 iii) Turn ignition switch ON. 8) Apply battery voltage to injector (1) for 15 seconds and measure injected fuel volume with graduated cylinder.

  • Page 515: Fuel Pressure Regulator Removal And Installation

    Fuel System: 1G-15 Fuel Pressure Regulator Removal and Installation Reverse removal procedure for installation noting the Installation following. S5JB0A1706024 WARNING • Replace O-ring with new one using care not to damage it. Before starting the following procedure, be • Apply thin coat of fuel to O-ring and then install fuel sure to observe “Precautions on Fuel System pressure regulator (1) to delivery pipe.

  • Page 516: Fuel Filler Cap Inspection

    1G-16 Fuel System: Fuel Filler Cap Inspection 3) Hoist vehicle, and remove clamp (2) and fuel filler S5JB0A1706011 hose (1) from fuel filler neck. WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury.

  • Page 517: Fuel Tank Inlet Valve Inspection

    Fuel System: 1G-17 Fuel Tank Inlet Valve Inspection S5JB0A1706016 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. Check fuel tank inlet valve for the following. If any damage or malfunction is found, replace.
  • Page 518 1G-18 Fuel System: 12) Support fuel tank (1) with jack (2) and remove its 3) Install fuel tank to vehicle. mounting bolts. Tightening torque Fuel tank bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) I5JB0A171018-01 13) For M16 engine, lower fuel tank a little as to disconnect connectors (1) of fuel pump (2) and sub I5JB0A171020-01 fuel level gauge (3), then remove fuel tank.

  • Page 519: Fuel Tank Inspection

    Fuel System: 1G-19 Fuel Pump On-Vehicle Inspection 7) Install parking brake cable clamp to fuel tank cover referring to “Parking Brake Cable Location: in S5JB0A1706017 WARNING Section 4D” 8) Install rear propeller shaft referring to “Propeller Before starting the following procedure, be Shaft Removal and Installation: in Section 3D”...

  • Page 520: Fuel Pump Assembly Removal And Installation

    1G-20 Fuel System: Fuel Pump Assembly Removal and Installation Installation S5JB0A1706019 CAUTION WARNING When connecting joint, clean outside surface Before starting the following procedure, be of pipe where joint is to be inserted, push sure to observe “Precautions on Fuel System joint into pipe till joint lock clicks and check Service: ”...

  • Page 521: Main Fuel Level Sensor Removal And Installation

    Fuel System: 1G-21 Main Fuel Level Sensor Removal and Fuel Pump Inspection S5JB0A1706021 Installation • Check fuel pump assembly for damage. S5JB0A1706022 CAUTION • Check fuel suction filter for evidence of dirt and contamination. • Do not touch resister plate (1) and deform If present, replace or clean and check for presence of arm (2).

  • Page 522: Sub Fuel Level Sensor Inspection

    1G-22 Fuel System: Removal Installation Reverse removal procedure for installation noting the 1) Remove fuel tank from vehicle Referring to “Fuel following. Tank Removal and Installation: ” • Replace O-ring with new one using care not to 2) Disconnect sub fuel level sensor connector (1). damage it.

  • Page 523: Special Tools And Equipment

    Fuel System: 1G-23 Special Tools and Equipment Recommended Service Material S5JB0A1708001 Material SUZUKI recommended product or Specification Note SUZUKI DI O RING OIL(500CC) P/No.: 99000–25320 NOTE Required service material is also described in the following. “Fuel System Components: ” Special Tool S5JB0A1708002 09912–58413...

  • Page 524: Ignition System

    1H-1 Ignition System: Ignition System General Description Ignition System Construction For M16 engine, this ignition system does not have a S5JB0A1801001 distributor, it has two ignition coil assemblies (one is for The ignition system is an electronic (distributor less) No.1 and No.4 spark plugs and the other is for No.2 and ignition system.
  • Page 525 Ignition System: 1H-2 Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S5JB0A1802001 BLK/WHT BLK/WHT BLK/ORN BLK/ORN C37-21 BRN/BLK C37-20 BLK/WHT E23-29 BLK/YEL E23-60 BLK/RED BLK/RED BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16 WHT/GRN C37-15 BLK/ORN C37-30 BLK/ORN WHT/RED C37-52 C37-29 BLK/YEL C37-48 BLK/YEL...

  • Page 526: Component Location

    1H-3 Ignition System: 2. Main relay 10. No.4 spark plug 18. Ignition coil assembly for No.1 3. Ignition coil assembly for No.1 and No.4 spark 11. Sensed information (MAP sensor, ECT 19. Ignition coil assembly for No.2 plugs sensor, MAF and IAT sensor, TP sensor, Knock sensor, wheel speed signal (ABS), Electric load signal, Engine start signal, Torque reduction signal (TCM))

  • Page 527: Diagnostic Information And Procedures

    Ignition System: 1H-4 [A]: For M16 engine 7. ECT sensor 15. Ignition coil assembly for No.1 (for J20 engine) [B]: For J20 engine 8. MAF and IAT sensor 16. Ignition coil assembly for No.2 (for J20 engine) 1. ECM 9. Electric throttle body assembly 17.
  • Page 528 1H-5 Ignition System: Step Action DTC check Go to applicable DTC Go to Step 4. diag. flow. 1) Perform DTC check referring to “DTC Check: in Section 1A”. Is DTC stored in ECM? Electrical connection check Go to Step 5 for M16 Connect securely.
  • Page 529 Ignition System: 1H-6 Step Action 13 Knock sensor check Check CMP sensor, Substitute a known- CMP sensor rotor tooth good knock sensor and 1) Confirm that knock sensor circuit is in good condition of camshaft, CKP recheck. referring to “DTC P0327 / P0328: Knock Sensor Circuit sensor, CKP sensor Low / High: in Section 1A”.

  • Page 530: Repair Instructions

    1H-7 Ignition System: Repair Instructions High-Tension Cord Removal and Installation High-Tension Cord Inspection (For M16 Engine) S5JB0A1806002 (For M16 Engine) Measure resistance of high-tension cord (1) by using S5JB0A1806001 ohmmeter. Removal If resistance exceeds specification, replace high-tension 1) Remove engine cover. cord(s).

  • Page 531: Spark Plug Inspection

    Ignition System: 1H-8 Spark Plug Inspection Ignition Coil Assembly (Including ignitor) S5JB0A1806004 Removal and Installation S5JB0A1806005 CAUTION Removal 1) Disconnect negative cable at battery. • When servicing the iridium / platinum spark plugs (slender center electrode type 2) Remove engine cover. plugs), do not touch the center electrode 3) Disconnect ignition coil coupler.

  • Page 532: Ignition Coil Assembly (Including Ignitor) Inspection

    1H-9 Ignition System: Ignition Coil Assembly (Including ignitor) Installation Inspection 1) Install ignition coil assembly (2). S5JB0A1806006 2) Tighten ignition coil bolts (1) to specified torque, and then connect ignition coil coupler. For M16 Engine Measure secondary coil for resistance. Tightening torque If resistance is out of specification, replace ignition coil Ignition coil bolt for M16 engine (a): 10 N·m (1.0...
  • Page 533 No.1 cylinder and check that ignition timing is within • CKP sensor specification. • CKP sensor plate Initial ignition timing (fixed with SUZUKI scan • TP sensor tool) 5° – 15° BTDC (at specified idle speed) (for J20 • CMP sensor engine) •...

  • Page 534: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Special Tool S5JB0A1808001 09930–76420 SUZUKI scan tool Timing-light (dry cell type) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.

  • Page 535: Starting System

    Starting System: 1I-1 Starting System Precautions Cranking System Note S5JB0A1900001 NOTE Starting motor varies depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. General Description Cranking Circuit Introduction S5JB0A1901001 The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring.

  • Page 536: Diagnostic Information And Procedures

    1I-2 Starting System: Diagnostic Information and Procedures Cranking System Symptom Diagnosis S5JB0A1904001 Possible symptoms due to starting system trouble would be as follows: • Starting motor does not run (or runs slowly) • Starting motor runs but fails to crank engine •...

  • Page 537: Starting Motor Performance Test

    Starting System: 1I-3 Condition Possible cause Correction / Reference Item Starting motor running, Insufficient contact of magnetic switch Replace magnetic switch. but too slow (small main contacts torque) – Battery and Layer short-circuit of armature Replace. wiring are satisfactory Disconnected, burnt or worn Repair commutator or replace armature.
  • Page 538 1I-4 Starting System: Hold-In Test 1) While connected as above with plunger out, disconnect negative lead (2) from terminal “M” (1). 2) Check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch. IYSQ01190004-01 Plunger and Pinion Return Test 1) Disconnect negative lead (1) from switch body (2).

  • Page 539: Repair Instructions

    Starting System: 1I-5 Repair Instructions Starting Motor Dismounting and Remounting S5JB0A1906001 I5JB0A190001-02 [A]: For M16 Engine : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) [B]: For J20 Engine : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft) Dismounting 1) Disconnect negative (–) battery lead at battery.

  • Page 540: Starting Motor Components

    1I-6 Starting System: Starting Motor Components S5JB0A1906005 The starting motor consists of parts shown in below and has permanent magnets mounted in starting motor yoke (frame). The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected against possible dirt and water splash.

  • Page 541: Starting Motor Inspection

    Starting System: 1I-7 Starting Motor Inspection Hold-In coil open circuit test S5JB0A1906004 Check for continuity across magnetic switch “S” terminal and coil case. If no continuity exists, coil is open and Plunger should be replaced. Inspect plunger for wear. Replace if necessary. IYSQ01190030-01 IYSQ01190027-01 Rear Bracket Bush...
  • Page 542 1I-8 Starting System: Brush Holder • Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for contamination. Clean or correct as necessary. • Check for continuity across insulated brush (positive side) and grounded brush (negative side).
  • Page 543 Starting System: 1I-9 Ground test Pinion and Over-Running Clutch Check the commutator and armature core. If there is • Inspect pinion for wear, damage or other abnormal continuity, armature is grounded and must be replaced. conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction.

  • Page 544: Specifications

    1I-10 Starting System: Specifications Starting Motor Specifications S5JB0A1907001 1.2 kW Type [1.4 kW Type] Voltage 12 volts Output 1.2 kW [1.4 kW] Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 5.5 mm (0.22 in.) Number of pinion teeth Performance...

  • Page 545: Charging System

    Charging System: 1J-1 Charging System General Description Battery Description S5JB0A1A01001 The battery has three major functions in the electrical system. • It is a source of electrical energy for cranking the engine. • It acts as a voltage stabilizer for the electrical system. •...

  • Page 546: Generator Description

    1J-2 Charging System: • Green Dot: Battery is sufficiently charged for testing. • Dark: Battery must be charged before testing. If there is a cranking complaint, battery should be tested as described in “Battery Inspection: ”. Charging and electrical systems should also be checked at this time. •...

  • Page 547: Diagnostic Information And Procedures

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

  • Page 548: Generator Symptom Diagnosis

    1J-4 Charging System: Generator Symptom Diagnosis S5JB0A1A04001 A charging circuit wiring diagram for generator connection is shown in “Generator Description: ”. To avoid damage, always follow these precautions: CAUTION • Do not mistake polarities of “IG” terminal and “L” terminal. •...

  • Page 549: Generator Test (Overcharged Battery Check)

    Charging System: 1J-5 No-Load Check Load Check 1) Run engine from idling up to 2000 rpm and read 1) Run engine at 2000 rpm and turn on head light and meters. heater motor. 2) Measure current and if it is less than 30 A repair or NOTE replace generator.

  • Page 550: Repair Instructions

    1J-6 Charging System: Repair Instructions Jump Starting in Case of Emergency 1) Set parking brake and place automatic transmission S5JB0A1A06004 in PARK (NEUTRAL on manual transmission). With Auxiliary (Booster) Battery 2) Turn OFF ignition switch, turn OFF lights and all other electrical loads.

  • Page 551: Battery Dismounting And Remounting

    Charging System: 1J-7 Battery Dismounting and Remounting Water Pump and Generator Drive Belt Removal S5JB0A1A06005 and Installation (For M16 Engine) WARNING S5JB0A1A06011 Removal When handling battery, following safety 1) Disconnect negative cable at battery. precautions should be followed: 2) If vehicle equipped with A/C, remove compressor •...

  • Page 552: Water Pump And Generator Drive Belt Tension Inspection And Adjustment (For M16 Engine)

    1J-8 Charging System: Water Pump and Generator Drive Belt Tension 3) If belt is too tight or too loose, adjust it to proper tension by displacing generator position. Inspection and Adjustment (For M16 Engine) S5JB0A1A06012 4) To adjust belt tension, loosen generator adjusting WARNING bolt (3) and displace generator position by loosening on tightening adjuster bolt.

  • Page 553: Water Pump And Generator Drive Belt On-Vehicle Inspection (For J20 Engine)

    Charging System: 1J-9 Water Pump and Generator Drive Belt On-Vehicle Inspection (For J20 Engine) S5JB0A1A06013 [Type A] 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found, replace belt, referring to “Water Pump and Generator Drive Belt Removal and Installation (For J20 Engine): ”.

  • Page 554: Water Pump And Generator Drive Belt Removal And Installation (For J20 Engine)

    1J-10 Charging System: Water Pump and Generator Drive Belt Removal Installation and Installation (For J20 Engine) 1) Loosen tensioner by turning the tensioner pulley (2) S5JB0A1A06014 clockwise. Removal 2) While holding the tensioner, install generator belt (1). WARNING NOTE Disconnect negative (–) cable at battery •...

  • Page 555: Generator Dismounting And Remounting

    Charging System: 1J-11 Generator Dismounting and Remounting S5JB0A1A06006 I5JB0A1A0003-02 [A]: For M16 Engine 4. Generator adjusting bolt (For M16 Engine) 9. Generator [B]: For J20 Engine 5. Generator mounting bolt (For J20 Engine) : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft) 1.

  • Page 556: Generator Components

    1J-12 Charging System: Dismounting 1) Disconnect negative (–) cable at battery. 2) Disconnect MAF sensor coupler (For J20 Engine). 3) Remove air cleaner case and air cleaner outlet hose (For J20 Engine). 4) Disconnect generator lead wire (“B” terminal wire) and coupler from generator. 5) Remove generator belt.

  • Page 557: Generator Inspection

    Charging System: 1J-13 Generator Inspection S5JB0A1A06009 Rotor • Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or regulator.
  • Page 558 1J-14 Charging System: Stator • Using ohmmeter, check all leads for continuity. If there is no continuity, replace stator (1). IYSQ011A0037-01 • Using ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator.
  • Page 559 Charging System: 1J-15 Rectifier 1) Using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace rectifier (1).

  • Page 560: Specifications

    1J-16 Charging System: Specifications Charging System Specifications S5JB0A1A07001 Battery NOTE The battery used in each vehicle is one of the following two types, depending on specification. Battery type 55B24R (S) 55D23L Rated Capacity AH/5HR, 12 Volts Electrolyte L (US/Imp. pt) (6.55/5.46) (8.24/6.86) 1.28 when fully charged at 20 °C (68 °F)

  • Page 561: Exhaust System

    Exhaust System: 1K-1 Exhaust System General Description Exhaust System Description S5JB0A1B01001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
  • Page 562 1K-2 Exhaust System: For M16 Engine Model I5JB0A1B1002-03 [A]: Installing location of exhaust manifold bold and nut. 9. Exhaust pipe No.2 18. Exhaust pipe No.1 bracket bolt 1. Exhaust manifold gasket 10. Exhaust center pipe 19. Exhaust center pipe nut 2.
  • Page 563 Exhaust System: 1K-3 For J20 Engine Model I5JB0A1B1003-05 [A]: Installing location of exhaust manifold bold and nut. 10. Exhaust center pipe 20. Exhaust center pipe gasket 1. Exhaust manifold gasket 11. Muffler 21. Muffler mounting 2. Exhaust manifold 12. Mounting 22.

  • Page 564: Exhaust Manifold Removal And Installation (For M16 Engine Model)

    1K-4 Exhaust System: Exhaust Manifold Removal and Installation (For 2) Install exhaust pipe No.1 bracket (1). M16 Engine Model) Tightening torque S5JB0A1B06003 Exhaust pipe No.1 bracket bolt and nut (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) Removal WARNING To avoid danger of being burned, do not service exhaust system while it is still hot.

  • Page 565: Exhaust Pipe And Muffler Removal And Installation

    Exhaust System: 1K-5 7) Remove exhaust pipe No.1 bracket (1). 3) Install exhaust manifold cover (1). 8) Remove exhaust manifold (2) and its gasket (3) from 4) Connect water outlet pipe (2) from radiator inlet cylinder head. hose. 5) Connect fuel pipe (3) from fuel hoses. I5JB0A1B1008-01 6) Refill cooling system referring to “Cooling System I5JB0A1B1006-01...

  • Page 566: Specifications

    1K-6 Exhaust System: Specifications Tightening Torque Specifications S5JB0A1B07001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Exhaust manifold bolt and nut 36.5 Exhaust pipe No.1 bracket bolt and nut 36.5 Exhaust No.1 pipe nut 36.5 NOTE The specified tightening torque is also described in the following. “Exhaust System Components: ”...

  • Page 567: Suspension

    Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Tightening Torque Specifications......2B-23 Special Tools and Equipment ......2B-24 Precautions............. 2-1 Recommended Service Material .......2B-24 Precautions on Suspension ........2-1 Special Tool ............2B-24 Suspension General Diagnosis....2A-1 Rear Suspension ........2C-1 Diagnostic Information and Procedures....2A-1 General Description ..........2C-1 Suspension, Wheels and Tires Symptom...
  • Page 568 2-ii Table of Contents Rear Wheel Hub Assembly, Wheel Bearing Irregular and/or Premature Wear and Wheel Stud Inspection ......2C-27 Description ............2D-2 Rear Wheel Disc, Nut and Bearing Check ..2C-27 Wear Indicators Description ........2D-3 Rear Suspension knuckle Removal and Radial Tire Waddle Description......2D-3 Installation ............2C-28 Radial Tire Lead / Pull Description ......2D-4 Rear Suspension Knuckle Check......2C-31...

  • Page 569: Precautions

    Precautions: Precautions Precautions Precautions on Suspension S5JB0A2000001 Suspension Caution Refer to “Suspension Caution: in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution: in Section 00”. General Precautions Refer to “General Precautions: in Section 00”. Vehicle Lifting Points Refer to “Vehicle Lifting Points: in Section 0A”.

  • Page 570: Suspension General Diagnosis

    2A-1 Suspension General Diagnosis: Suspension General Diagnosis Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S5JB0A2104001 Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tires. Tires not adequately inflated Adjust tire pressure. Broken or sagging coil springs Replace coil springs.
  • Page 571 Suspension General Diagnosis: 2A-2 Condition Possible cause Correction / Reference Item Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners bushes. Faulty strut (shock absorber) or Replace strut (shock absorber) or tighten mounting mounting.

  • Page 572: Specifications

    2A-3 Suspension General Diagnosis: Specifications Wheel Alignment Specifications S5JB0A2107001 Wheel alignment specifications Item Front Rear IN 0 ± 2.0 mm IN 6.0 ± 2.0 mm Front and rear toe (“b” – “a”) (total) (0 ± 0.0787 in.) (0.2362 ± 0.0787 in.) Front camber (Non adjustable, for reference only) 0°...

  • Page 573: Front Suspension

    Front Suspension: 2B-1 Front Suspension General Description Front Suspension Construction S5JB0A2201001 I5JB0A220001-02 1. Front strut assembly 7. Tie-rod : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft) 2. Stabilizer bar 8. Stabilizer bar joint : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) 3. Steering knuckle : 135 N⋅m (13.5 kgf-m, 98.0 lb-ft) : 43 N⋅m (4.3 kgf-m, 31.0 lb-ft) 4.

  • Page 574: Front Wheel Alignment Construction

    2B-2 Front Suspension: Front Wheel Alignment Construction • Check for loose of ball joints. Check tie-rod ends; if S5JB0A2201002 excessive looseness is noted, it must be corrected Among factors for front wheel alignment, only toe setting before adjusting. can be adjusted. Camber and caster are not adjustable. •...
  • Page 575 Front Suspension: 2B-3 Adjustment Steering Angle Check and Adjustment When tie-rod or tie-rod end was replaced, check toe and 1) Loosen right and left tie-rod end lock nuts (1) first. then also steering angle with turning radius gauge (1). 2) Rotate right and left tie-rods (2) by the same amount If steering angle is not correct, check whether right and to align toe to specification.

  • Page 576: Front Strut Assembly Components

    2B-4 Front Suspension: Front Strut Assembly Components S5JB0A2206002 I5JB0A220004-01 1. Strut assembly 7. Strut support 13. Stabilizer joint 2. Coil spring 8. Strut support nut 14. Strut dust cover 3. Bump stopper 9. Strut nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 4.

  • Page 577: Front Strut Assembly Removal And Installation

    Front Suspension: 2B-5 Front Strut Assembly Removal and Installation S5JB0A2206003 Removal NOTE When servicing component parts of strut assembly, remove strut rod cap and then loosen strut nut a little before removing strut assembly. This will make service work easier. Note that the nut must not be removed at this point.
  • Page 578 2B-6 Front Suspension: Installation Install strut assembly by reversing removal procedure, noting the following instructions. • Insert bolts in such direction as shown in figure. • Tighten all fasteners to specified torque. Tightening torque Strut bracket nut (a): 135 N·m (13.5 kgf-m, 98.0 lb- Brake hose mounting bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft) Stabilizer joint nut (d): 60 N·m (6.0 kgf-m, 43.5 lb-...

  • Page 579: Front Strut Assembly Disassembly And Assembly

    Front Suspension: 2B-7 Front Strut Assembly Disassembly and Assembly For assembly, reverse disassembly procedure, noting Assembly the following instructions. S5JB0A2206004 1) Compress coil spring with special tool (A) until total Disassembly length becomes about 310 mm (12.2 in.) as shown. 1) Attach special tool (A) to coil spring as shown.

  • Page 580: Front Strut Assembly Check

    2B-8 Front Suspension: Front Strut Assembly Check 4) Pull strut rod as far up as possible and use care not to allow it to retract into strut. S5JB0A2206005 • Inspect strut for oil leakage, damage or deformation. 5) Attach coil spring seat to coil spring upper seat and If defect is found, replace strut as an assembly unit, then install strut dust cover firmly.

  • Page 581: Front Wheel Hub Assembly And Steering Knuckle Components

    Front Suspension: 2B-9 Front Wheel Hub Assembly and Steering Knuckle Components S5JB0A2206006 CAUTION Never disassemble front wheel hub assembly. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. I5JB0A220012-01 1. Front wheel hub assembly 4.
  • Page 582 2) Apply grease to end face of inner ring (2) before front wheel nub (1) installation. CAUTION Do not apply the grease to the encoder section to avoid the encoder malfunction. “A”: Grease 99000–25010 (SUZUKI Super Grease A) I5JB0A220015-01 7) Remove hub bolts (1) with copper hammer or hydraulic press.

  • Page 583: Steering Knuckle Removal And Installation

    Front Suspension: 2B-11 5) Install brake disk and brake caliper. 4) Disconnect front height sensor (if equipped) from suspension control arm for left side referring to 6) Tighten caliper carrier bolt to specified torque. “Height Sensor Removal and Installation (If Tightening torque Equipped): in Section 9B”.

  • Page 584: Front Wheel Hub, Disc, Nut And Bearing Check

    2B-12 Front Suspension: Installation 6) Connect front height sensor (if equipped) to For installation, reverse removal procedure, noting the suspension control arm for left side referring to following instructions. “Height Sensor Removal and Installation (If Equipped): in Section 9B”. 1) Connect steering knuckle to suspension arm. 7) Connect tie-rod end (1) to steering knuckle (2), 2) Install strut bracket bolts (2) and nuts (1).

  • Page 585: Suspension Control Arm Removal And Installation

    Front Suspension: 2B-13 5) Disconnect tie-rod end (1) from steering knuckle (2) • Check wear of wheel bearing. When measuring thrust play, apply a dial gauge to wheel hub as shown in with puller (3). figure. Thrust play limit 0.1 mm (0.004 in.) I5JB0A220020-01 6) Loosen ball joint nut (1).
  • Page 586 2B-14 Front Suspension: Installation 1) Install suspension control arm bolts (1) and tighten 3,(a) suspension control arm nuts (2) temporarily by hand. CAUTION If reuse suspension control arm nut, apply engine oil to thread and bearing. I5JB0A220028-01 4) Depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to specified torque.

  • Page 587: Suspension Control Arm / Bushing Disassembly And Assembly

    Front Suspension: 2B-15 Suspension Control Arm / Bushing Assembly Disassembly and Assembly CAUTION S5JB0A2206010 Apply grease (included in the repair kit) to Disassembly ball joint and inside of ball stud boot when 1) Remove rubber stopper (1). the ball stud boot is replaced. 2) Cut rubber (2) of flange of suspension control arm front bushing.

  • Page 588: Suspension Control Arm / Steering Knuckle Check

    2B-16 Front Suspension: Suspension Control Arm / Steering Knuckle Suspension Control Arm Joint Check S5JB0A2206013 Check • Check smooth rotation of ball stud. S5JB0A2206011 Inspect for cracks, deformation or damage. • Check damages of ball stud. If defective, replace. • Check damages of dust cover. NOTE Suspension control arm and arm joint cannot be separated.

  • Page 589: Front Suspension Frame, Stabilizer Bar And/Or Bushings Components

    Front Suspension: 2B-17 Front Suspension Frame, Stabilizer Bar and/or Bushings Components S5JB0A2206014 I5JB0A220040-02 F: Forward 6. Stabilizer joint nut 12. Stabilizer mount 1. Stabilizer bar 7. Suspension control arm : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 2. Stabilizer bushing 8. Control arm mounting bolt : 135 N⋅m (13.5 kgf-m, 98.0 lb-ft) 3.

  • Page 590: Front Suspension Frame, Stabilizer Bar And/Or Bushings Removal And Installation

    2B-18 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or 7) Disconnect front height sensor connector (1) (if equipped with head light auto leveling system) and Bushings Removal and Installation then detach clip (2). S5JB0A2206015 Removal 1) Hoist vehicle and remove wheels (right & left). 2) Remove engine under cover.
  • Page 591 Front Suspension: 2B-19 11) Remove front propeller shaft referring to “Propeller 15) Remove engine front body side mounting nuts (1). Shaft Removal and Installation: in Section 3D”. 16) Remove suspension frame mounting bolts (2), and 12) Fix radiator (2) to body with rope (1) to avoid the then lower suspension frame (3) with stabilizer bar, radiator (2) fall off when front suspension frame P/S gear box assembly and front differential...
  • Page 592 2B-20 Front Suspension: 18) Remove stabilizer bar (1) and bushing (2) from 4) Install P/S gear box assembly (1) and front suspension frame (3). differential assembly (2) referring to “P/S Gear Case Assembly Removal and Installation: in Section 6C” and “Front Differential Dismounting and Remounting: Front in Section 3B”.
  • Page 593 Front Suspension: 2B-21 6) Tighten suspension frame mounting bolts (1) and 8) Install hood referring to “Hood Removal and engine front body side mounting nuts (2) to specified Installation: in Section 9J”. torque. 9) Install front propeller shaft referring to “Propeller Shaft Removal and Installation: in Section 3D”.

  • Page 594: Front Suspension Frame Check

    2B-22 Front Suspension: Front Suspension Frame Check 14) Connect front fender lining clip (1) (if equipped with S5JB0A2206016 head light auto leveling system). Inspect for cracks, deformation or damage. If defective, replace. I5JB0A220056-01 I5JB0A220042-01 15) Install stabilizer joints (1), and tighten nuts to Front Stabilizer Bar, Bushing and/or Joint specified torque.
  • Page 595 Front Suspension: 2B-23 Stabilizer Joint 1) Check for smooth rotation. 2) Check damages of ball stud. 3) Check damages of dust cover. NOTE Stabilizer joint (1) cannot be disassembled. If there is any damage to either parts, stabilizer joint assembly must be replaced as a complete unit. I4RH01220007-01 Front Suspension Fasteners Check S5JB0A2206018...

  • Page 596: Special Tools And Equipment

    2B-24 Front Suspension: Special Tools and Equipment Recommended Service Material S5JB0A2208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Special Tool S5JB0A2208002 09900–00411 09900–00414 Hexagon bit socket Hexagon bit (6 mm) 09913–75821 09941–56510 Bearing installer attachment Socket wrench (19 mm) 09943–25010...

  • Page 597: Rear Suspension

    Rear Suspension: 2C-1 Rear Suspension General Description Rear Suspension Construction S5JB0A2301001 I5JB0A230001-03 [A]: View A 4. Control rod 9. Lower Arm : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) [B]: View B 5. Trailing rod : 105 N⋅m (10.5 kgf-m, 76.0 lb-ft) : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 1.

  • Page 598: Rear Wheel Alignment Construction

    2C-2 Rear Suspension: Rear Wheel Alignment Construction S5JB0A2301002 Among factors for rear wheel alignment, only toe and camber setting can be adjusted. Caster can’t be adjusted. Therefore, should caster be out of specification due to the damage caused by hazardous 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 599 Rear Suspension: 2C-3 Adjustment Lower arm adjustment Control rod adjustment 1) Loosen right and left lower arm mount nuts (1). 1) Loosen right and left control rod mount nuts (1). I5JB0A230004-01 I5JB0A230002-01 2) Adjust toe and camber to satisfy the specification by 2) Adjust toe and camber to satisfy the specification by turning right and left lower arm inner bolts (cam turning right and left control rod inner bolts (cam...

  • Page 600: Rear Shock Absorber And Rear Coil Spring Components

    2C-4 Rear Suspension: Reference Information Side slip limit When checked with side slip tester, side slip should satisfy following specification. Side slip limit IN 5.5 – IN 9.5 mm/m (IN 0.2166 – IN 0.3740 in/3.3 ft) If side slip exceeds the limit, toe or wheel alignment may not be correct. Rear Shock Absorber and Rear Coil Spring Components S5JB0A2306005 I5JB0A230006-04...

  • Page 601: Rear Shock Absorber Removal And Installation

    Rear Suspension: 2C-5 Rear Shock Absorber Removal and Installation Installation S5JB0A2306006 Install shock absorber by reversing removal procedure, noting the following instructions. Removal • Tighten all fasteners to specified torque. 1) Hoist vehicle, allowing rear suspension to hang free. Tightening torque 2) Remove wheel.

  • Page 602: Shock Absorber Check

    2C-6 Rear Suspension: Shock Absorber Check Rear Coil Spring and Bump Stopper Removal S5JB0A2306026 and Installation • Inspect for deformation or damage. S5JB0A2306027 Removal • Inspect bushings for wear or damage. 1) Hoist vehicle, allowing rear suspension to hang free. •...
  • Page 603 Rear Suspension: 2C-7 9) Remove bump stopper (1) from suspension upper 3) Installing coil spring on lower arm and place coil arm (2) by using special tool (A). spring end (1) onto lower arm (2) as shown. Special tool CAUTION (A): 09941–66010 •...

  • Page 604: Rear Coil Spring Check

    2C-8 Rear Suspension: 6) With marks (1) on lower arm washer (2) and rear 11) Tighten lower arm outer bolt and lower arm mount suspension frame (3) marked before remove aligned nut, shock absorber bolts to specified torque with to each other, tighten lower arm mount nut (4) vehicle weight on suspension.

  • Page 605: Rod And Arm Components

    Rear Suspension: 2C-9 Rod and Arm Components S5JB0A2306009 I5JB0A230017-02 1. Upper arm 8. Lower arm inner bolt 15. Control rod mount nut F: Forward 2. Upper arm bolt 9. Lower arm washer 16. Trailing rod : 135 N⋅m (13.5 kgf-m, 98.0 lb-ft) 3.

  • Page 606: Control Rod Removal And Installation

    2C-10 Rear Suspension: Control Rod Removal and Installation 4) Put match marks (1) on control rod washer (2) and S5JB0A2306010 on suspension frame (3) to install the bolts correctly in position. Removal 5) Remove control rod inner bolt (4) and control rod 1) Hoist vehicle and remove rear wheels.
  • Page 607 Rear Suspension: 2C-11 e) The marks (5) on control rod washer (3) and rear 3) Lower jack and remove floor jack (2) from lower arm suspension frame marked before its removal (1). must be aligned and, tighten bolt and nut temporarily by hand.

  • Page 608: Control Rod / Bushing Disassembly And Assembly

    2C-12 Rear Suspension: Control Rod / Bushing Disassembly and 2) Press-fit bushing so that dimensions “A” and “B” in figure become equal. Assembly S5JB0A2306029 Disassembly 1) Push out control rod bushing by using hydraulic press (1) and special tool. Special tool (A): 09913–84510 I5JB0A230024-01 Control Rod Check...

  • Page 609: Trailing Rod Removal And Installation

    Rear Suspension: 2C-13 Trailing Rod Removal and Installation 5) Remove trailing rod mount bracket bolt (1) and then S5JB0A2306012 trailing rod mount bracket (2). Removal 1) Hoist vehicle and remove rear wheels. 2) Support lower arm (1) with jack (2). I5JB0A230028-02 Installation 1) Install trailing rod mount bracket and then tighten...

  • Page 610: Trailing Rod / Bushing Disassembly And Assembly

    2C-14 Rear Suspension: 2) Install trailing rod (4). 7) Tighten trailing rod mount nut and trailing rod rear bolt to specified torque with vehicle weight on a) Install trailing rod and insert trailing rod front bolt suspension. (1) from the body inside. b) Insert trailing rod rear bolt (2).

  • Page 611: Trailing Rod Check

    Rear Suspension: 2C-15 Trailing Rod Check Assembly S5JB0A2306013 1) Press-fit trailing rod bushing (2) by using press (1) • Inspect for cracks, deformation or damage. and special tool. • Inspect bushing for wear and breakage. CAUTION If any faulty condition is found, replace. •...

  • Page 612: Lower Arm / Bushing Disassembly And Assembly

    2C-16 Rear Suspension: Installation 5) Tighten lower arm outer bolt and lower arm mount nut, shock absorber bolts to specified torque with 1) Install lower arm. vehicle weight on suspension. a) Install lower arm (1) to rear suspension frame. b) Insert suspension lower arm inner bolt (2) from CAUTION the vehicle rearward.

  • Page 613: Lower Arm Check

    Rear Suspension: 2C-17 Lower Arm Check Assembly S5JB0A2306033 1) Press-fit suspension lateral link bushing (2) by using • Inspect for cracks, deformation or damage. press (1) and special tool. • Inspect bushing for wear and breakage. CAUTION If any faulty condition is found, replace. Be sure to use new bushing.
  • Page 614 2C-18 Rear Suspension: Installation 9) Tighten each bolts and nuts to specified torque with vehicle weight on suspension. 1) Install upper arm. a) Install upper arm (2) to rear suspension frame. CAUTION b) Insert upper arm bolt (1) from the upper arm •...

  • Page 615: Upper Arm / Bushing Disassembly And Assembly

    Rear Suspension: 2C-19 Upper Arm / Bushing Disassembly and Assembly Assembly CAUTION S5JB0A2306035 Apply grease (included in the repair kit) to Disassembly ball joint and inside of ball stud boot when 1) Cut rubber (1) of flange of upper arm bushing. the ball stud boot is replaced.

  • Page 616: Rear Suspension Frame Components

    2C-20 Rear Suspension: Rear Suspension Frame Components S5JB0A2306014 I5JB0A230046-03 F: Forward 4. Rear suspension frame mount stopper 8. Stiffener 1. Rear suspension frame 5. Upper mount stopper washer : 135 N⋅m (13.5 kgf-m, 98.0 lb-ft) 2. Rear suspension frame mount bolt 6.

  • Page 617: Rear Suspension Frame Removal And Installation

    Rear Suspension: 2C-21 Rear Suspension Frame Removal and 12) Remove wheel sensor bolt (1) and ABS wheel sensor harness clamp (2) (if equipped). Installation S5JB0A2306015 13) Disconnect rear height sensor connector (3) and Removal rear height sensor harness clamp (4) (if equipped) 1) Hoist vehicle and remove rear wheels.
  • Page 618 2C-22 Rear Suspension: Installation 4) Connect rear height sensor connector (3) and rear height sensor harness clamp (4) (if equipped) for left 1) Remounting rear differential to rear suspension fame side. referring to “Rear Differential Unit Components: Rear in Section 3B”. 5) Tighten wheel sensor bolt (1) to specified torque and then connect ABS wheel sensor harness clamp (2) 2) Support rear suspension frame with rear differential...

  • Page 619: Rear Suspension Frame / Bushing Disassembly And Assembly

    Rear Suspension: 2C-23 Rear Suspension frame / Bushing Disassembly 12) Install control rod referring to “Control Rod Removal and Installation: ”“Control Rod Removal and and Assembly Installation: ”. S5JB0A2306037 13) Install rear wheel hub assembly referring to “Rear Disassembly Wheel Hub Assembly Removal and Installation: ”. 1) Cut rubber (1) of flange of rear suspension frame 14) Connect rear propeller shaft to differential aligning bushing.

  • Page 620: Rear Suspension Frame, Bushing And Pad Check

    2C-24 Rear Suspension: NOTE Assembly 1) Press-fit rear suspension frame bushing (2) by using Use bearing installer in dimensions of outer press (1) and special tool. diameter 43.0 to 49.0 mm (1.69 to 1.92 in.), inner diameter 41.0 mm (1.61 in.) or more and CAUTION length 21.0 mm (0.82 in.) or more.

  • Page 621: Rear Wheel Hub Assembly Removal And Installation

    (3) onto CAUTION pipe to prevent fluid from spilling. Do not apply the grease to the encoder section to avoid the encoder malfunction. “A”: Grease 99000–25010 (SUZUKI Super Grease A) 2, "A" I5JB0A230059-01 6) Loosen parking cable cap nut (1).
  • Page 622 2C-26 Rear Suspension: 3) Install rear wheel assembly and back plate to rear 6) Install rear break shoe referring to “Rear Brake Shoe suspension knuckle and tighten rear wheel hub Removal and Installation: in Section 4C”. housing bolts (1) to specified torque. 7) Pull up parking brake lever fully and tighten new rear axle nut (1) to specified torque.

  • Page 623: Rear Wheel Hub Assembly, Wheel Bearing And Wheel Stud Inspection

    Rear Suspension: 2C-27 Rear Wheel Hub Assembly, Wheel Bearing and • Check wheel bearings for wear. When measuring thrust play, apply a dial gauge to spindle cap center. If Wheel Stud Inspection thrust play exceeds limit, replace bearing. S5JB0A2306020 • Wheel bearing and wheel hub form a solid unit. Thrust play limit •...

  • Page 624: Rear Suspension Knuckle Removal And Installation

    2C-28 Rear Suspension: Rear Suspension knuckle Removal and 5) Support lower arm (1) with jack (2). Installation S5JB0A2306040 Removal 1) Hoist vehicle and remove rear wheels. 2) Remove rear wheel hub assembly referring to “Rear Wheel Hub Assembly Removal and Installation: ”. 3) Remove ABS wheel sensor (1) (if equipped).
  • Page 625 Rear Suspension: 2C-29 8) Loosen lower arm outer bolt (1). Installation 1) Connect upper arm joint (2) to rear suspension knuckle (1). 2) Tighten new upper arm joint nut (3) to specified torque. CAUTION Do not reuse removed upper arm joint nut. Tightening torque Upper arm joint nut (a): 55 N·m (5.5 kgf-m, 40.0 lb-ft)
  • Page 626 2C-30 Rear Suspension: 4) Install trailing rod to rear suspension knuckle and 6) Remove floor jack from lower arm. then tighten trailing rod rear bolt (1) temporarily by 7) Install rear brake hose bracket (1) and then tighten hand. rear brake hose bracket bolt (2) to specified torque. CAUTION Tightening torque Rear brake hose bracket bolt (a): 11 N·m (1.1...

  • Page 627: Rear Suspension Knuckle Check

    Rear Suspension: 2C-31 Rear Suspension Knuckle Check 11) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to five times so S5JB0A2306024 as to obtain proper drum-to-shoe clearance. Adjust • Inspect for cracks, deformation or damage. parking brake cable.
  • Page 628 2C-32 Rear Suspension: Specifications Tightening Torque Specifications S5JB0A2307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Control rod mount nut 13.5 98.0 Lower arm mount nut 13.5 98.0 Shock absorber upper bolt 43.5 Shock absorber lower bolt 65.0 Wheel nut 10.0 72.5 Bump stopper...

  • Page 629: Special Tools And Equipment

    Rear Suspension: 2C-33 Special Tools and Equipment Recommended Service Material S5JB0A2308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 NOTE Required service material is also described in the following. “Rear Shock Absorber and Rear Coil Spring Components: ”...

  • Page 630: Wheels And Tires

    2D-1 Wheels and Tires: Wheels and Tires General Description Tires Description • High tire temperature S5JB0A2401001 • Reduced handling The tire is of tubeless type. The tire is designed to • High fuel consumption operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation Matched Tires and Wheels (Steel Type) pressures.

  • Page 631: Wheels Description

    Wheels and Tires: 2D-2 Wheel Runout WARNING Lateral runout Radial runout Do not mix different types of tires on the limit limit same vehicle such as radial, bias and bias- 1.20 mm 0.70 mm Steel wheel belted tires except in emergencies, because (0.047 in.) (0.027 in.) handling may be seriously affected and may...

  • Page 632: Wear Indicators Description

    2D-3 Wheels and Tires: • Wear is uneven across the tread of any front tire. Wear Indicators Description S5JB0A2401004 • Front tire treads have scuffed appearance with Original equipment tires have built-in tread wear “feather” edges on one side of tread ribs or blocks. indicators (1) to show when they need replacement.

  • Page 633: Radial Tire Lead / Pull Description

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

  • Page 634: Repair Instructions

    2D-5 Wheels and Tires: Repair Instructions General Balance Procedures Tire Rotation S5JB0A2406001 S5JB0A2406002 Deposits of mud, etc. must be cleaned from inside of rim. To equalize wear, rotate tires according to figure. Radial tires should be rotated periodically. Set tire pressure. WARNING NOTE Stones should be removed from the tread in...

  • Page 635: Wheel Removal And Installation

    Wheels and Tires: 2D-6 Wheel Removal and Installation Tire Mounting and Dismounting S5JB0A2406003 S5JB0A2406004 Removal Use a tire changing machine to mount or dismount tires. Follow equipment manufacturer’s instructions. Do not 1) Loosen wheel nuts by approximately 180 ° (half a use hand tools or tire irons alone to change tires as they rotation).

  • Page 636: Specifications

    2D-7 Wheels and Tires: Specifications Wheels and Tires Specifications S5JB0A2407001 Tire size (Standard) 225/70R16 102S or 225/65R17 101S Wheel size (Standard) 16 x 6 1/2 J (for 225/70R16) or 17 x 6 1/2 J (for 225/65R17) Tightening torque Wheel nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) NOTE •...

  • Page 637: Driveline / Axle

    Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Front Differential Dismounting and Remounting............3B-3 Precautions............. 3-1 Front Differential Components ......3B-4 Precautions for Driveline / Axle ......3-1 Front Differential Assembly Disassembly Drive Shaft / Axle ........3A-1 and Reassembly ..........3B-5 Front Differential Inspection ......3B-17 Front .................3A-1...
  • Page 638 3-ii Table of Contents Input / Output Signal Table of 4WD Control Transfer Assembly Dismounting and Module ............3C-12 Remounting.............3C-57 On-Board Diagnostic System Description..3C-12 Transfer Assembly Components .......3C-58 CAN Communication System Description..3C-13 Transfer Assembly Disassembly and Reassembly ............3C-59 Diagnostic Information and Procedures..3C-14 Transfer Assembly Inspection ......3C-67 4WD Control System Check ......3C-14 Input Gear Assembly, Counter Gear...
  • Page 639 Table of Contents 3-iii Repair Instructions ..........3D-2 Tightening Torque Specifications......3D-5 Propeller Shaft Joint Check ........3D-2 Special Tools and Equipment ......3D-6 Propeller Shaft Removal and Installation ....3D-2 Recommended Service Material ......3D-6 Propeller Shaft Disassembly and Assembly ..3D-3 Special Tool ............3D-6 Propeller Shaft Inspection ........3D-5 Specifications............3D-5...

  • Page 640: Precautions

    3-1 Precautions: Precautions Precautions Precautions for Driveline / Axle S5JB0A3000001 Differential Gear Oil Note Refer to “Differential Gear Oil Note: in Section 00”. Fastener Caution Refer to “Fastener Caution: in Section 00”. Precautions for Transfer Refer to “Precautions in Diagnosing Trouble: Motor-Shift Type (Transfer with Shift Actuator) in Section 3C”.

  • Page 641: Drive Shaft / Axle

    Drive Shaft / Axle: Front 3A-1 Drive Shaft / Axle Front General Description Front Drive Shaft Construction S5JB0A3111001 A constant velocity tripod joint is used on the differential side of both the right and left drive shaft assemblies. And, a constant velocity ball joint is used on the wheel side of both the right and left drive shaft assemblies.

  • Page 642: Repair Instructions

    3A-2 Drive Shaft / Axle: Front Repair Instructions Front Drive Shaft Boot and Joint Check S5JB0A3116001 • Check boot for tear. If even a small tear is found, replace with new one. I5JB0A311001-01 • Check drive shaft joint for wear, breakage, and any other damage. Replace if any abnormality is found. Front Drive Shaft Components S5JB0A3116002 I5JB0A311002-03...

  • Page 643: Front Drive Shaft Assembly Removal And Installation

    Drive Shaft / Axle: Front 3A-3 Front Drive Shaft Assembly Removal and Installation Installation CAUTION S5JB0A3116003 • Be careful not to damage oil seals and Removal boots when installing drive shaft. 1) Undo caulking (1) and remove drive shaft nut (2). •...
  • Page 644 3A-4 Drive Shaft / Axle: Front 2) Wipe off grease from shaft and take off snap ring (1) Assembly using snap ring plier (2). 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.
  • Page 645 Drive Shaft / Axle: Front 3A-5 5) Apply grease (including in spare parts) to inside of 9) Fasten differential side boot big band. tripod joint housing (1), joint it with tripod joint. • For differential side boot big band Fasten band (1) by drawing hooks (2) with special Grease color tool and engage hooks (3) in slot and window (4).

  • Page 646: Specifications

    3A-6 Drive Shaft / Axle: Front Specifications Tightening Torque Specifications S5JB0A3117001 NOTE The specified tightening torque is also described in the following. “Front Drive Shaft Components: Front” Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3118001...

  • Page 647: Rear

    Drive Shaft / Axle: Rear 3A-7 Rear General Description Rear Drive Shaft Construction S5JB0A3121002 Refer to “Front Drive Shaft Construction: Front”. Repair Instructions Rear Drive Shaft Components S5JB0A3126007 I5JB0A312001-02 1. Differential side joint (Constant velocity tripod joint) 5. Boot band (Small) 9.

  • Page 648: Rear Drive Shaft Assembly Removal And Installation

    3A-8 Drive Shaft / Axle: Rear Rear Drive Shaft Assembly Removal and CAUTION Installation • Protect oil seals and boots from any S5JB0A3126008 Removal damage, preventing them form 1) Undo caulking (1) of drive shaft nut (2) and then unnecessary contact while installing drive remove drive shaft nut.

  • Page 649: Specifications

    Drive Shaft / Axle: Rear 3A-9 Specifications Tightening Torque Specifications S5JB0A3127001 NOTE The specified tightening torque is also described in the following. “Rear Drive Shaft Components: Rear” Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3128001...

  • Page 650: Differential

    3B-1 Differential: Front Differential Front General Description Front Differential Construction S5JB0A3211001 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.

  • Page 651: Repair Instructions

    7) Apply sealant to thread of level / filler plug, and then S5JB0A3216012 tighten it to specified torque. 1) Before changing or inspecting oil, be sure to stop “A”: Sealant 99000–31260 (SUZUKI Bond engine and lift vehicle horizontally. No.1217G) 2) With vehicle lifted up, check leakage.

  • Page 652: Front Differential Unit Components

    3B-3 Differential: Front Front Differential Unit Components S5JB0A3216007 I5JB0A321001-05 1. Front differential 8. Rear mounting bracket bolt 2. Right mounting bracket 9. Damper 3. Right mounting bolt 10. Damper bolt 4. Differential mounting bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 5.

  • Page 653: Front Differential Components

    Differential: Front 3B-4 Remounting Reverse dismounting procedure for remounting noting the following. • Tighten each bolts and nuts referring to “Front Differential Unit Components: Front”, “Front Drive Shaft Components: Front in Section 3A” and “Front Suspension Frame, Stabilizer Bar and/or Bushings Components: in Section 2B”. •...

  • Page 654: Front Differential Assembly Disassembly And Reassembly

    3B-5 Differential: Front 9. Differential carrier 25. Rear cover bolt No.2 bolt : Apply sealant 99000-31260 to mating surface of carrier and rear cover. 10. Differential pinion 26. Differential right case 11. Differential gear : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 12.
  • Page 655 Differential: Front 3B-6 5) Support differential side right retainer (1) with soft 8) Remove drive bevel gear (hypoid gear), differential jawed vise and remove oil seal (2) from differential gears, differential pinions and pinion shaft as follows. side right retainer using special tool, if necessary. a) With aluminum plates (2) placed on vise first, grip differential case with it and remove drive Special tool...
  • Page 656 3B-7 Differential: Front b) Make mating marks (1) on drive bevel pinion and e) Remove drive bevel pinion rear bearing (2) by companion flange. using bearing puller (3) and hydraulic press. CAUTION CAUTION Do not make mating mark on the coupling To avoid rear bearing from being damaged, surface of the flange.
  • Page 657 Differential: Front 3B-8 12) Drive out rear bearing outer race (1) in the same 2) After applying differential oil to differential gear (4), manner as Step 11). pinions (5), pinion shaft (6), pinion washer, thrust washer (2) and spring washer (1), install them in differential right case (3).
  • Page 658 3B-9 Differential: Front 5) Install special tool to differential case assembly (2) 7) Press-fit right side bearing (1) with special tools and and check that preload is within specification. If hydraulic press. preload exceeds specified value, check if foreign NOTE matter is caught or gear is damaged.
  • Page 659 Differential: Front 3B-10 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
  • Page 660 3B-11 Differential: Front 9) Install special tools with bearings (3) and flange (2) 11) Set dial gauge to mounting dummy and make 0 to differential carrier (1). (zero) adjustment on surface plate (1). NOTE NOTE This installation requires no spacer or oil •...
  • Page 661 14) Select adjusting shim(s) (2) closest to calculated Then apply grease “A” to oil seal lip. value from among the following available sizes and put it in place and then press-fit rear bearing (1). “A”: Grease 99000–25010 (SUZUKI Super Grease A) Special tool (G): 09913–85210 Special tool (H): 09940–53111...
  • Page 662 3B-13 Differential: Front 17) While tightening flange nut gradually with special 18) Select differential side bearing shim as follows. tool and power wrench (4 – 10 magnification) (1), set a) Measure dimension “a” and “b” using vernier preload of pinion to specification. caliper.
  • Page 663 Differential: Front 3B-14 19) To measure bevel gear backlash, set dial gauge (1) 22) As final step, check gear tooth contact as follows. at right angle to bevel gear tooth, fix drive bevel a) After cleaning 10 drive bevel gear teeth, paint pinion and read dial gauge while moving bevel gear.
  • Page 664 3B-15 Differential: Front Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
  • Page 665 (1) as shown in figure. Distance between retainer surface and oil seal “a”: 0.65 – 1.65 mm (0.026 – 0.065 in.) “A”: Grease 99000–25010 (SUZUKI Super Grease A) I5JB0A321042-01 Special tool 25) Assembly front drive shaft retainer as follows.

  • Page 666: Front Differential Inspection

    Rear mounting bracket bolt (a): 50 N·m (5.0 kgf- with carrier and rear cover, and then tighten bolts to m, 36.5 lb-ft) specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Retainer bolt: 50 N·m (5.0 kgf-m, 36.5 lb-ft) “A”...

  • Page 667: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3218001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
  • Page 668 3B-19 Differential: Front 09913–75510 09913–75520 Bearing installer Bearing installer 09913–75821 09913–85210 Bearing installer attachment Bearing installer 09922–66021 09922–75222 Flange holder Differential gear preload adjuster 09922–76520 09924–74510 Bevel pinion gauge block Bearing and oil seal handle 09924–84510–004 09924–84510–005 Bearing installer attachment Bearing installer attachment 09925–14520 09925–86010...
  • Page 669 Differential: Front 3B-20 09928–06510 09930–30104 Differential torque checking Sliding shaft tool 09940–53111 09941–64511 Differential side bearing Bearing and oil seal remover installer (30 mm Min.) 09951–16070 09951–16090 Shim adjuster attachment Oil seal installer 09951–18210 09951–46010 Oil seal remover & installer Drive shaft oil seal installer No.

  • Page 670: Rear

    3B-21 Differential: Rear Rear General Description Rear Differential Construction S5JB0A3221001 Refer to “Front Differential Construction: Front”. Diagnostic Information and Procedures Rear Differential Symptom Diagnosis S5JB0A3224001 Refer to “Front Differential Symptom Diagnosis: Front”. Repair Instructions Rear Differential Oil Change S5JB0A3226010 Refer to “Front Differential Oil Change: Front”. The point which is different from the front differential is described.

  • Page 671: Rear Differential Dismounting And Remounting

    Differential: Rear 3B-22 Rear Differential Dismounting and Remounting d. Remove rear suspension frame mount front S5JB0A3226012 bolts (1). Dismounting 1) Lift up vehicle and drain oil from rear differential. 2) Remove rear propeller shaft referring to “Propeller Shaft Removal and Installation: in Section 3D”. 3) Remove exhaust center pipe referring to “Exhaust System Components: in Section 1K”.

  • Page 672: Rear Differential Components

    3B-23 Differential: Rear • Tighten rear suspension frame front and rear bolts to Remounting Reverse dismounting procedure for remounting noting specified torque referring to “Rear Suspension the following. Construction: in Section 2C”. • Tighten rear differential mounting front and rear bolts •...

  • Page 673: Rear Differential Assembly Disassembly And Reassembly

    Differential: Rear 3B-24 8. Flange nut 25. Rear cover bolt No.2 bolt : After tightening nut so as rotation torque of bevel pinion shaft to be in specified value, caulk nut securely. 9. Differential carrier 26. Dynamic damper (if equipped) 10.
  • Page 674 3B-25 Differential: Rear 5) Disassembly rear drive left retainer in the same b) Remove pinion shafts (1), differential gears, manner at Step 4), if necessary. washers, differential pinions, spring washers, thrust washers and pinion joint. 6) Take out differential assembly (1), outer race and shim all at once.
  • Page 675 Differential: Rear 3B-26 I1JA01322006-01 I5JB0A321017-02 1. Drive bevel pinion d) Remove drive bevel pinion (1) with rear bearing, shim and spacer from carrier. 10) Remove oil seal (1) using special tool. If it is hard to remove, screw an used nut (2) into drive bevel pinion and hammer (3) on that nut Special tool with a plastic hammer but never directly on drive...
  • Page 676 3B-27 Differential: Rear Reassembly 2) After applying differential oil to differential gear (4), Judging from faulty conditions noted before disassembly pinions (5), pinion shafts (6), pinion washer, thrust and what is found through visual check of bearing and washer (2) and spring washer (1), install them in gear tooth etc.
  • Page 677 Differential: Rear 3B-28 5) Install special tool to differential case assembly (2) 7) Press-fit right side bearing (1) with special tools and and check differential gear for preload. If preload hydraulic press. exceeds specified value, check if foreign matter is NOTE caught or gear is damaged.
  • Page 678 3B-29 Differential: Rear 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
  • Page 679 Differential: Rear 3B-30 9) Install special tools with bearings (3) and flange (2) 11) Set dial gauge to mounting dummy and make 0 to differential carrier (1). (zero) adjustment on surface plate (1). NOTE NOTE This installation requires no spacer or oil •...
  • Page 680 102 mm / “a” + “b” Then apply grease “A” to oil seal lip. 4.0157 in. “A”: Grease 99000–25010 (SUZUKI Super 14) Select adjusting shim(s) (2) closest to calculated Grease A) value from among the following available sizes and Special tool put it in place and then press-fit rear bearing (1).
  • Page 681 Differential: Rear 3B-32 17) While tightening flange nut gradually with special 18) Select differential side bearing shim as follows. tool and power wrench (4 – 10 magnification) (1), set a) Measure dimension “a” and “b” using vernier preload of pinion to specification. caliper.
  • Page 682 3B-33 Differential: Rear 19) To measure bevel gear backlash, set dial gauge (1) 22) As final step, check gear tooth contact as follows. at right angle to bevel gear tooth, fix drive bevel a) After cleaning 10 drive bevel gear teeth, paint pinion and read dial gauge while moving bevel gear.
  • Page 683 Differential: Rear 3B-34 Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
  • Page 684 3B-35 Differential: Rear 23) Upon completion of gear tooth contact check in Step b) Install snap ring. 22), caulk flange nut (2) with caulking tool (1) and hammer. I5JB0A322010-01 c) Install oil seal using special tools as shown in figure. Distance between retainer surface and oil I1JA01322021-01 seal...
  • Page 685 27) Clean mating surface of right retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover “A”: Sealant 99000–31260 (SUZUKI Bond as shown in figure by such amount that its section is No.1217G) 1.5 mm (0.059 in.) in diameter, mate right retainer...

  • Page 686: Special Tools And Equipment

    3B-37 Differential: Rear Special Tools and Equipment Recommended Service Material S5JB0A3228001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
  • Page 687 Differential: Rear 3B-38 09924–84510–004 09924–84510–005 Bearing installer attachment Bearing installer attachment 09925–14520 09925–86010 Bearing and oil seal installer Bearing puller attachment (80 x 50 mm) 09925–88210 09926–78311–002 Bearing puller attachment Pinion mounting dummy 09926–78311 09926–78320 Differential bevel pinion Mounting dummy dummy 09928–06510 09930–30104...
  • Page 688 3B-39 Differential: Rear 09951–18210 09951–46010 Oil seal remover & installer Drive shaft oil seal installer No. 2...

  • Page 689: Transfer

    • Diagnostic information stored in 4WD control module memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its I5JB0A331107-03 3) Pour specified oil into transfer up to lever plug hole if Operator’s (Instruction) Manual carefully to have good...

  • Page 690: Transfer Shift Control System Components

    3C-2 Transfer: Motor-Shift Type (Transfer with Shift Actuator) The transfer has such a selective mechanism as to enable the shift actuator to make selection of high speed (direct connection with transmission output: main shaft), low speed (speed reduction by input gear, counter gear and low gear) or neutral by way of the reduction shift sleeve located between the input gear and low gear, and selection of center differential lock or not by way of the differential lock clutch sleeve located at the center of the rear output shaft.

  • Page 691: 4Wd Control System Description

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-3 1. Transfer switch 4. N indicator 7. Center differential lock switch 2. Differential lock indicator 5. 4WD control module 8. 4L/N switch 3. 4L indicator 6. Transfer actuator 4WD Control System Description S5JB0A3311002 Transfer Shift Control The 4WD control module controls the transfer shift actuator based on the signal from the transfer switch so that the...
  • Page 692 3C-4 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Operation Condition Indicator Buzzer • Ignition switch is OFF. — • Transfer is at 4H/N position. • Within 2 seconds after ignition switch is turn ON (checking indicator operation). — • Transfer is at 4H-lock/4L-lock position. Flashes at 0.25 Sounds at 1 seconds for 3...

  • Page 693: Function Of 4Wd Control System Component

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-5 Function of 4WD Control System Component S5JB0A3311003 Part Name Function Detects transfer shift position combining center differential lock 4L/N switch switch. Center differential lock switch Detects transfer shift position combining 4L/N switch. Transfer switch Shifts transfer shift position.
  • Page 694 3C-6 Transfer: Motor-Shift Type (Transfer with Shift Actuator) I5JB0A332003-02 [A]: Transfer position indicator 5. Shift cam 11. Front drive shaft [B]: Transfer switch 6. High / Low shift fork 12. Front drive sprocket 1. 4L/N switch 7. Differential lock shift fork 13.
  • Page 695 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-7 The driving force from the transmission is transmitted from the transfer input gear to the rear output shaft, as in the case of 4H position. Also, as the front drive shaft and front drive sprocket bush are engaged via differential lock clutch sleeve, the driving force from the input gear is locked and transmitted to the rear output shaft.
  • Page 696 3C-8 Transfer: Motor-Shift Type (Transfer with Shift Actuator) N (Neutral) Position When N position is selected from 4H position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “A”. The shift cam shifts the High / Low shift fork in the arrow direction “B”, and the reduction shift sleeve moves in the arrow direction “B”.
  • Page 697 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-9 [A]: Transfer position indicator 4. Shift fork pin 9. Reduction shift sleeve [B]: Transfer switch 5. Shift cam 10. Differential lock clutch sleeve 1. 4L/N switch 6. High / Low shift fork 11.
  • Page 698 3C-10 Transfer: Motor-Shift Type (Transfer with Shift Actuator) I5JB0A332006-02 [A]: Transfer position indicator 6. High / Low shift fork 13. Rear output shaft [B]: Transfer switch 7. Differential lock shift fork 14. Center LSD case 1. 4L/N switch 8. Input gear 15.

  • Page 699: 4Wd Control System Wiring Circuit Diagram

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-11 4WD Control System Wiring Circuit Diagram S5JB0A3311006 E91-18 LT GRN G59-2 C54-1 E91-2 E91-19 BLU/BLK G59-3 C54-4 E91-3 E91-20 BLU/ORN G59-4 C54-2 E91-25 C54-3 E91-26 RED/BLK C54-5 BLK/YEL E91-24 PNK/WHT E91-13 E91-14 RED/GRN BLK/ORN E91-7...

  • Page 700: Module

    3C-12 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Terminal Arrangement of 4WD Control Module S5JB0A3311007 I4JA01332038-01 [A]: Connector “E91” viewed from harness side Terminal Circuit Terminal Circuit E91-1 Ground E91-18 Transfer switch 1 E91-2 Transfer actuator motor 1 E91-19 Transfer switch 2 E91-3 Transfer actuator motor 2 E91-20...

  • Page 701: Module

    • DTC can be checked by either one of the following ways. – DTC can be checked by using SUZUKI scan tool (4) connected to DLC (5). – If equipped with diagnosis connector, DTC can be displayed on digital display odometer by shorting diagnosis connector (6).

  • Page 702: Diagnostic Information And Procedures

    3C-14 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 4WD Control Module Reception Data ABS hydraulic unit / control module Engine speed Vehicle speed Brake pedal switch active Transmission gear selector position Wheel speed pulse (front right) control Receive DATA Wheel speed pulse module (front left) Wheel speed pulse...
  • Page 703 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-15 Step Action Rechecking and record of DTC / freeze frame data Go to Step 9. Go to Step 10. 1) Recheck for DTC referring to “DTC Check: Motor-Shift Type (Transfer with Shift Actuator)”. Is there any DTC(s)? 4WD control symptom diagnosis Go to Step 11.
  • Page 704 3C-16 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Customer questionnaire (Example) Customer’s name: Model: VIN: Date of issue: Date of Reg: Date of problem: Mileage: Transfer position indicator abnormal: fails to turn on / fails to turn off / flashes Abnormal noise while vehicle running: from transfer, from actuator, other Problem Symptoms...

  • Page 705: Transfer Position Indicator Operation Check

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-17 Step 5. Trouble symptom confirmation 4WD Control System Operation Inspection Check trouble symptoms based on information obtained S5JB0A3314038 NOTE in “Step 1: Customer complaint analysis: Motor-Shift Type (Transfer with Shift Actuator)” and “Step 2. DTC / •...

  • Page 706: Visual Inspection

    3C-18 Transfer: Motor-Shift Type (Transfer with Shift Actuator) e) Check that 4L indicator blink, and then e) Check that differential lock indicator blinks, and differential lock indicator and 4L indicator comes then not comes ON. ON steady. 5) Inspect shift operation from 4H to N as follows. 3) Inspect shift operation from 4L-lock to 4H-lock as a) Stop vehicle completely with engine running.

  • Page 707: Dtc Check

    I5JB0A332012-01 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between SUZUKI scan tool and...

  • Page 708: Dtc Clearance

    1) Turn ignition switch to OFF position. the following cases. Be careful not to clear 2) Connect SUZUKI scan tool to data link connector them before keeping their record. (DLC) (1) located on underside of instrument panel.

  • Page 709: Fail-Safe Table

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-21 Transfer Detecting condition DTC No. Detecting item position (DTC will set when detecting) indicators Though actuator position switch is “4L-lock” C1228 4L/N switch circuit short position, the OFF signal is not input from the 4L/ N switch.

  • Page 710: Scan Tool Data

    3C-22 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Scan Tool Data S5JB0A3314009 Normal Condition / Scan Tool Data Vehicle Condition Reference Value Vehicle speed At vehicle stop 0 km/h, 0 mph Engine speed At engine idle speed Engine idle speed is display Transfer shifted to 4H position Transfer being shifted between 4H-lock and 4H position 4H-lock –...

  • Page 711: 4Wd Control Symptom Diagnosis

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-23 Warning buzzer (OFF / N Pos / Error): Mode switch 2 (Transfer switch) (ON / OFF): ON: Transfer switch to other than 4L-lock position. This parameter indicates if buzzer is being OFF: Transfer switch to 4L-lock position. commanded by 4WD control module.

  • Page 712: Transfer Position Indicator Does Not Come On At Ignition Switch On But Engine Stops

    3C-24 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Condition Possible cause Correction / Reference Item Gear slipping out of mesh Worn control cover shift shaft Check control cover shift shaft referring to “Transfer Assembly Inspection: Motor-Shift Type (Transfer with Shift Actuator)”. Worn shift fork or sleeve Check shift fork or sleeve referring to “Transfer Assembly Inspection: Motor-Shift Type...
  • Page 713 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-25 [A]: 4WD control module connector “E91” (viewed from harness side) 4. 4L indicator [B]: Combination meter connector (viewed from harness side) 5. N indicator 1. 4WD control module 6. Junction block assembly 2.

  • Page 714: Transfer Position Indicator Remains On Steady At Ignition Switch

    3C-26 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Position Indicator Remains ON Steady at Ignition Switch ON S5JB0A3314040 Wiring Diagram G28-15 PPL/RED BLK/YEL G28-13 WHT/GRN G28-10 E91-22 G28-8 E91-23 2221201918 1615141312 I5JB0A332015-03 [A]: 4WD control module connector “E91” (viewed from harness side) 4.

  • Page 715: Dtc C1213: Transfer Switch Circuit Open

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-27 DTC C1213: Transfer Switch Circuit Open S5JB0A3314041 Wiring Diagram E91-18 LT GRN G59-2 E91-19 BLU/BLK G59-3 G59-4 E91-20 BLU/ORN I5JB0A332016-01 [A]: 4WD control module connector “E91” (viewed from harness side) 1. 4WD control module [B]: Transfer switch connector “G59”...

  • Page 716: Dtc C1214: Transfer Switch Circuit Short

    3C-28 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step Action Transfer switch check Substitute a known- Replace transfer switch. good 4WD control 1) Check transfer switch referring to “Transfer Switch module and recheck. Inspection: Motor-Shift Type (Transfer with Shift Actuator)”. Is switch in good condition? Wire harness check Substitute a known-...
  • Page 717 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-29 DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Select transfer switch to “4H” position and keep its position for 10 seconds. Similarly select transfer switch to “4H- lock”, “N” and “4L-lock” position. 3) Check DTC.

  • Page 718: Dtc C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open

    3C-30 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open S5JB0A3314043 Wiring Diagram C54-1 E91-2 C54-4 E91-3 C54-2 E91-25 C54-3 E91-26 RED/BLK...
  • Page 719 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-31 Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Transfer shift actuator motor position switch circuit Go to Step 3.

  • Page 720: Dtc C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short

    3C-32 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short S5JB0A3314044 Wiring Diagram C54-1 E91-2 C54-4 E91-3 C54-2 E91-25 C54-3 E91-26 RED/BLK...
  • Page 721 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-33 Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. Transfer shift actuator motor position switch circuit Go to Step 3.

  • Page 722: Dtc C1227: 4L/N Switch Circuit Open

    3C-34 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC C1227: 4L/N Switch Circuit Open S5JB0A3314045 Wiring Diagram PNK/WHT E91-13 E91-14 RED/GRN I5JB0A332018-01 [A]: 4WD control module connector “E91” (viewed from harness side) 3. 4L/N switch 1. 4WD control module 4. Center differential lock switch 2.

  • Page 723: Dtc C1228: 4L/N Switch Circuit Short

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-35 Step Action 4L/N switch check Substitute a known- Replace 4L/N switch. good 4WD control 1) Check 4L/N switch referring to “Transfer Assembly module and recheck. Inspection: Motor-Shift Type (Transfer with Shift Actuator)”. Is switch in good condition? Wire harness check Substitute a known-...
  • Page 724 3C-36 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check: Motor- Shift Type (Transfer with Shift Actuator)”. 4L/N switch circuit check Go to Step 3. Go to Step 4.

  • Page 725: Dtc C1230: Transfer Actuator Circuit Malfunction

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-37 DTC C1230: Transfer Actuator Circuit Malfunction S5JB0A3314047 Wiring Diagram C54-1 E91-2 E91-3 C54-4 C54-2 E91-25 C54-3 E91-26 RED/BLK C54-5 BLK/YEL E91-24 I5JB0A332017-01 [A]: 4WD control module connector “E91” (viewed from harness side) 2.

  • Page 726: Dtc C1237: Center Differential Lock Switch Circuit Open

    3C-38 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step Action Transfer shift actuator circuit check Go to Step 3. Go to Step 4. 1) Disconnect transfer shift actuator connector “C54” with ignition switch OFF. 2) Check for proper connection to “C54-1” and “C54-4” terminals of transfer shift actuator connector.
  • Page 727 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-39 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Though transfer shift actuator motor position switch is “4H” • Center differential lock switch position, the ON signal is not input from the center differential •...

  • Page 728: Dtc C1238: Center Differential Lock Switch Circuit Short

    3C-40 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC C1238: Center Differential Lock Switch Circuit Short S5JB0A3314049 Wiring Diagram PNK/WHT E91-13 E91-14 RED/GRN I5JB0A332018-01 [A]: 4WD control module connector “E91” (viewed from harness side) 3. 4L/N switch 1. 4WD control module 4.

  • Page 729: Dtc C1240: 4Wd Control Module Power Supply Circuit Malfunction

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-41 Step Action Center differential lock switch check Substitute a known- Replace center good 4WD control differential lock switch. 1) Check center differential lock switch referring to module and recheck. “Transfer Assembly Inspection: Motor-Shift Type (Transfer with Shift Actuator)”.

  • Page 730: Dtc C1243: Internal Circuit Malfunction Of 4Wd Control Module

    3C-42 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area 4WD control module power supply voltage is out of specification • 4WD control module power supply circuit while vehicle is running at 20 km/h (12 mph) or more. DTC Confirmation Procedure 1) Clear DTC using scan tool.

  • Page 731: Dtc C1246: Clutch Pedal Position (Cpp) Switch Circuit Short

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-43 DTC C1246: Clutch Pedal Position (CPP) Switch Circuit Short S5JB0A3314051 Wiring Diagram BLK/ORN E91-7 I5JB0A332020-01 [A]: 4WD control module connector “E91” (viewed from harness side) 2. 4WD control module 1. CPP switch DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
  • Page 732 3C-44 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step Action Wire harness check Substitute a known- “BLK/ORN” wire is good 4WD control shorted to ground 1) Disconnect connector from 4WD control module module and recheck. circuit. connector “E91” with ignition switch OFF. 2) Check for proper connection to “E91-7”...
  • Page 733 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-45 [A]: Keyless start control module connector (if equipped) (viewed from harness side) 1. BCM [B]: ECM connector (viewed from harness side) 2. 4WD control module [C]: TCM connector (for A/T model) (viewed from harness side) 3.
  • Page 734 3C-46 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step Action Check DTC Check 4WD control Check applicable module power and control module power 1) Turn ignition switch to OFF position. ground circuit. If circuits and ground circuit. If 2) Disconnect each connector. are OK, substitute a circuit is OK, substitute •...
  • Page 735 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-47 [A]: Keyless start control module connector (if equipped) (viewed from harness side) 1. BCM [B]: ECM connector (viewed from harness side) 2. 4WD control module [C]: TCM connector (for A/T model) (viewed from harness side) 3.

  • Page 736: Dtc U1101: Lost Communication With Tcm

    3C-48 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC U1101: Lost Communication with TCM S5JB0A3314054 Wiring Diagram G31-2 G31-4 G31-1 G31-3 WHT/RED E23-4 WHT/BLU E23-19 E91-22 E91-23 WHT/BLU E03-8 E03-10 WHT/RED E92-17 RED E03-12 E92-7 E03-6 G44-19 G28-10 G44-18 G28-8 2221201918 1615141312 34 33 32 31 30 29...
  • Page 737 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-49 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for TCM is detected for • CAN communication circuit longer than specified time continuously. • TCM •...

  • Page 738: Dtc U1121: Lost Communication With Abs Hydraulic Unit / Control Module

    3C-50 Transfer: Motor-Shift Type (Transfer with Shift Actuator) DTC U1121: Lost Communication with ABS Hydraulic Unit / Control Module S5JB0A3314055 Wiring Diagram G31-2 G31-4 G31-1 G31-3 WHT/RED E23-4 WHT/BLU E23-19 E91-22 E91-23 WHT/BLU E03-8 E03-10 WHT/RED E92-17 RED E03-12 E92-7 E03-6 G44-19 G28-10...

  • Page 739: Inspection Of 4Wd Control Module And Its Circuits

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-51 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ABS hydraulic unit / • CAN communication circuit control module is detected for longer than specified time •...
  • Page 740 3C-52 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Voltage and Signal Check 1) Check voltage using voltmeter (1) connected to each terminal of couplers. 2) Check signal using oscilloscope (2) connected to each terminal of couplers. NOTE • As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when ignition switch is turned ON.
  • Page 741 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-53 Terminal Wire Normal Circuit Condition Number Color Voltage E91-9 — — — — E91-10 Ground 0 – 1 V — Power source for E91-11 10 – 14 V — internal memory E91-12 BLK/WHT Ignition switch 10 –...

  • Page 742: Repair Instructions

    : 1.5 liters (3.2/2.6 US/lmp. pt) 7) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Transfer oil level / filler plug (b): 23 N·m (2.3 kgf- m, 17.0 lb-ft)

  • Page 743: Transfer Oil Seal Removal And Installation

    1) Install new oil seal using special tool and plastic 7A”, and then remove transfer switch (1) from center hammer, and then apply grease to oil seal lip. cluster (2). : Grease 99000–25010 (SUZUKI Super Grease Special tool (A): 09913–70123 I5JB0A331003-02 Installation Reverse removal procedure.
  • Page 744 3C-56 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Switch Inspection 4WD Control Module Removal and Installation S5JB0A3316039 S5JB0A3316038 Check continuity between following terminals when Removal transfer switch (1) operated at each position. 1) Disconnect negative (–) cable from battery. Switch position Terminal 2) If the vehicle is equipped with air bag system,...

  • Page 745: Transfer Assembly Dismounting And Remounting

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-57 Transfer Assembly Dismounting and 10) Remove gear shift control lever rear case from transfer (for M/T model). Remounting S5JB0A3316040 11) Remove transfer to transmission bolts (upper side), Dismounting and then install engine rear mounting member with 1) Shift transfer to 4H position operating transfer transmission and transfer.

  • Page 746: Transfer Assembly Components

    3C-58 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Transfer Assembly Components S5JB0A3316041 1217G 1217G 1217G 1322 1217G I5JB0A331009-06...

  • Page 747: Transfer Assembly Disassembly And Reassembly

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-59 1. Front oil seal No.1 20. Washer 39. Oil strainer : Apply grease 99000-25010 to oil seal lip. 2. Front case bolt 21. Shim 40. Oil strainer bolt 3. Front case 22. Reduction shift sleeve 41.
  • Page 748 3C-60 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 6) Remove front case (1) using plastic hammer. 9) Remove needle bearings (1) from center case (2) using special tools, if necessary. Special tool (A): 09913–76010 (B): 09925–98210 I5JB0A331014-01 7) Remove rear case bolts (1) and clamp (2) and then separate center case (3) using special tool.
  • Page 749 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-61 16) Remove snap ring (1), and then remove rear output 12) Remove needle bearings (1), front drive shaft (2) and thrust needle bearing (4) from rear output shaft shaft assembly (2) from rear case (3). (3).
  • Page 750 Input gear plate bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft) Reassembly 1) Install new front oil seal No.2 to front case (1) using special tool, and then apply grease to oil seal lip. 1, (a) : Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–85210 I5JB0A331035-03 I5JB0A331033-01...
  • Page 751 5) Install new rear oil seal (1) to rear case (2) using special tool as shown in figure, and then apply grease to oil seal lip. “A”: Grease 99000–25010 (SUZUKI Super Grease A) Distance between case and oil seal “a”...
  • Page 752 3C-64 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 11) Install low gear (3), center differential (4) and 13) Remove used snap ring, and then install new snap reduction shift sleeve (1) to rear output shaft (2). ring (2) and needle bearing (1) to rear output shaft (3).
  • Page 753 (2) to specified grease to oil seal lip. torque. Distance between case and oil seal “a” “A”: Sealant 99000–31260 (SUZUKI Bond : 3.5 – 4.5 mm (0.138 – 0.177 in.) No.1217G) “A”: Grease 99000–25010 (SUZUKI Super...
  • Page 754 1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolts (3) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Oil pump cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 “A”...

  • Page 755: Transfer Assembly Inspection

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-67 Transfer Assembly Inspection • Assemble front drive shaft (1), front drive sprocket (2) S5JB0A3316043 and differential lock clutch sleeve (3), check whether • Check needle bearing and bearing contacting surface differential lock clutch sleeve moves smoothly, and for damage.
  • Page 756 3C-68 Transfer: Motor-Shift Type (Transfer with Shift Actuator) • Check 4L/N switch and center differential lock switch • Operate the motor, and measure the resistance for continuity between “a” and “b” terminals of switch. between following terminals of transfer actuator when If check result is not as specified below, replace matching transfer actuator (1) to 4H-lock position and switch.

  • Page 757: Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly And Rear Output Shaft Assembly Components

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-69 Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components S5JB0A3316044 I5JB0A331061-02 1. Snap ring 6. Counter gear 2. Bearing 7. Front output shaft 3. Input gear plate : Do not reuse.

  • Page 758: Input Gear Assembly Disassembly And Reassembly

    3C-70 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Input Gear Assembly Disassembly and 2) Install input gear plate (1), and then press-fit bearing (2) using special tool, bearing puller (3) and press Reassembly (4). S5JB0A3316045 Disassembly NOTE 1) Remove snap ring (1) from input gear, and then Assemble bearing so that seal side (5) may remove bearing (2).

  • Page 759: Counter Gear Assembly Disassembly And Reassembly

    Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-71 Counter Gear Assembly Disassembly and 3) Install snap ring (1) to counter gear (2). Reassembly S5JB0A3316046 Disassembly 1) Remove snap ring (1) from counter gear (2). I5JB0A331068-01 Front Output Shaft Assembly Disassembly and Reassembly S5JB0A3316047 I5JB0A331068-01...

  • Page 760: Rear Output Shaft Assembly Disassembly And Reassembly

    3C-72 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Rear Output Shaft Assembly Disassembly and Reassembly Reassembly 1) Clean all components thoroughly, inspect them for S5JB0A3316048 any abnormality and replace with new ones as necessary. Disassembly 2) Press-fit bearing (1) to front output shaft using 1) Remove snap ring (1) from rear output shaft (2).
  • Page 761 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3318001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
  • Page 762 Bearing installer 09928–36510 09940–54910 Transfer cap Front fork oil seal install driver SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7.

  • Page 763: Non-Shift Type (Transfer Without Shift Actuator)

    Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-75 Non-Shift Type (Transfer without Shift Actuator) Precautions Transfer Warning S5JB0A3320001 Refer to “Transfer Warning: Motor-Shift Type (Transfer with Shift Actuator)”. General Description Transfer Construction S5JB0A3321001 The aluminum transfer case directly connected to the back of the transmission contains the input gear, rear output shaft, front output shaft and drive chain.

  • Page 764: Diagnostic Information And Procedures

    3C-76 Transfer: Non-Shift Type (Transfer without Shift Actuator) Diagnostic Information and Procedures Transfer Symptom Diagnosis S5JB0A3324001 Before attempting to repair the transfer or related components for any reason other than mechanical failure, the condition and possible causes should be identified. When any of these conditions occur, the following inspections should be made before disassembling the transfer.

  • Page 765: Repair Instructions

    Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-77 Repair Instructions Transfer Oil Change S5JB0A3326002 Refer to “Transfer Oil Change: Motor-Shift Type (Transfer with Shift Actuator)”. Transfer Oil Level Check S5JB0A3326003 Refer to “Transfer Oil Level Check: Motor-Shift Type (Transfer with Shift Actuator)”. Transfer Oil Seal Removal and Installation S5JB0A3326004 Refer to “Transfer Oil Seal Removal and Installation: Motor-Shift Type (Transfer with Shift Actuator)”.

  • Page 766: Transfer Assembly Components

    3C-78 Transfer: Non-Shift Type (Transfer without Shift Actuator) Transfer Assembly Components S5JB0A3326006 1217G 1217G 1217G 1217G I5JB0A331084-05...
  • Page 767 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-79 1. Front oil seal No.1 17. Differential lock clutch sleeve 33. Oil drain plug : Apply grease 99000-25010 to oil seal lip. : Apply sealant 99000-31260 to plug thread. 2. Front case bolt 18.

  • Page 768: Transfer Assembly Disassembly And Reassembly

    3C-80 Transfer: Non-Shift Type (Transfer without Shift Actuator) Transfer Assembly Disassembly and 5) Remove rear case bolts (1), and then separate center case (2) using special tool. Reassembly S5JB0A3326007 Special tool Disassembly (A): 09912–34510 1) Remove differential lock shift lever case (1). I5JB0A331087-01 I5JB0A331085-01 2) Remove oil pump cover (1).
  • Page 769 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-81 8) Remove needle bearing (1), snap ring (2), washer 12) Remove front drive sprocket bush (1) from rear (3) and shim(s) (4) from rear output shaft (5). output shaft (2). I5JB0A331089-01 I5JB0A331023-01 9) Remove reduction shift sleeve (1) and center 13) Take out front drive sprocket (1), front output shaft differential (3) from rear output shaft (2).
  • Page 770 I5JB0A331036-02 5) Install new rear oil seal (1) to rear case (2) using : Grease 99000–25010 (SUZUKI Super Grease A) special tool as shown in figure, and then apply Special tool grease to oil seal lip.
  • Page 771 Transfer: Non-Shift Type (Transfer without Shift Actuator) 3C-83 9) Install differential lock clutch sleeve (1) to rear output shaft (2) as shown in figure. “a” 1, “A” I5JB0A331094-04 6) Install rear output shaft assembly (2) to rear case (3), I5JB0A331040-01 and then install snap ring (1).
  • Page 772 Distance between case and oil seal “a” : 3.5 – 4.5 mm (0.138 – 0.177 in.) “A”: Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–70123...
  • Page 773 (0.047 in.) in diameter, mate front case (3) with case and then tighten bolts (2) to specified torque. center case and then tighten bolts (2) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Rear case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)

  • Page 774: Input Gear Assembly Disassembly And Reassembly

    1.2 mm (0.047 in.) in diameter, mate oil pump cover with rear case and then tighten bolts (3) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Oil pump cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 “A”...

  • Page 775: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0A3328001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...

  • Page 776: Propeller Shafts

    3D-1 Propeller Shafts: Propeller Shafts Precautions Propeller Shaft Caution S5JB0A3400001 CAUTION • All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.

  • Page 777: Diagnostic Information And Procedures

    • Clean and inspect sliding portion of propeller shaft end (where oil seal contacts) before installation and if even small dent or scratch exists, correct end clean it again. Then apply grease inside splines of propeller shaft. “B”: Grease 99000–25010 (SUZUKI Super Grease IYSQ01521009-01...
  • Page 778 3D-3 Propeller Shafts: • Install propeller shaft aligning match marks. Propeller Shaft Disassembly and Assembly Otherwise, vibration may occur during driving. S5JB0A3406005 • Use the following specification to torque universal joint CAUTION flange nuts and bolts. For front propeller shaft flange Never disassemble each joint.
  • Page 779 Propeller Shafts: 3D-4 NOTE • Take care not to lose rollers in spider bearing race when removing it. • Fit removed bearings temporarily in spider so that they can be reinstalled in their original positions. IYSQ01340008-01 I5JB0A340006-01 Assembly 4) Tapping yoke with a hammer, completely remove bearing race.
  • Page 780 4) Insert bearing races on the flange yoke side in the 1) Make sure to apply grease to spider bearing race. same way as described in Step 1) and 2). “A”: Grease 99000–25030 (SUZUKI Super 5) Securely fit 4 circlips to shaft and flange yoke. Grease C) NOTE •...
  • Page 781 Propeller Shafts: 3D-6 Special Tools and Equipment Recommended Service Material S5JB0A3408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 SUZUKI Super Grease C P/No.: 99000–25030 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
  • Page 782 3D-7 Propeller Shafts:...

  • Page 783: Brakes

    Table of Contents 4- i Section 4 Brakes CONTENTS Precautions ..........4-1 Repair Instructions ..........4B-2 Front Disc Brake Components ......4B-2 Precautions............. 4-1 Front Disc Brake Pad On-Vehicle Check ....4B-3 Precautions for Brakes.......... 4-1 Front Disc Brake Pad Removal and Brake Control System and Diagnosis ... 4A-1 Installation ............4B-3 Front Brake Disc and Pad Inspection....4B-4 General Description ..........4A-1...
  • Page 784 4-ii Table of Contents ABS............4E-1 DTC C1057: Power Source Circuit ....4E-23 DTC C1061: ABS Pump Motor and/or Precautions............4E-1 Motor Driver Circuit .........4E-24 Precautions in Diagnosing Troubles ....4E-1 DTC C1063: Solenoid Valve Power Supply Precautions in On-Vehicle Service...... 4E-1 Driver Circuit ...........4E-25 General Description ..........

  • Page 785: Precautions

    Precautions: Precautions Precautions Precautions for Brakes S5JB0A4000001 Suspension Caution Refer to “Suspension Caution: in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution: in Section 00”. Brake Caution Refer to “Brakes Caution and Note: in Section 00”. General Precautions Refer to “General Precautions: in Section 00”.

  • Page 786: Brake Control System And Diagnosis

    4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis General Description Brakes Construction S5JB0A4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder (2) to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder.

  • Page 787: Front Brake Hose / Pipe Construction

    Brake Control System and Diagnosis: 4A-2 Front Brake Hose / Pipe Construction S5JB0A4101006 I5JB0A410002-02 [A]: For LH steering vehicle 4. From ABS hydraulic unit to left front brake 9. Master cylinder fixing nut [B]: For RH steering vehicle 5. ABS hydraulic unit / control module assembly 10.

  • Page 788: Rear Brake Hose / Pipe Construction

    4A-3 Brake Control System and Diagnosis: Rear Brake Hose / Pipe Construction S5JB0A4101007 I5JB0A410003-02 1. To left rear brake hose 3. Left rear brake hose 2. To right rear brake hose 4. Right rear brake hose Master Cylinder Assembly Construction S5JB0A4101003 The master cylinder has two pistons, two pressure seal (3) and two separating seal (4).

  • Page 789: Booster Assembly Construction

    Brake Control System and Diagnosis: 4A-4 I5JB0A410004-01 2. Secondary piston 6. Secondary piston return spring 8. O-ring 5. Primary piston return spring 7. Grommet 9. Master cylinder body Booster Assembly Construction S5JB0A4101004 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.

  • Page 790: Brakes Symptom Diagnosis

    4A-5 Brake Control System and Diagnosis: Substandard or contaminated brake fluid If deterioration of rubber is evident, disassemble all hydraulic parts and wash with alcohol. Dry these parts CAUTION with compressed air before assembly to keep alcohol out of the system. Replace all rubber parts in the system, Improper brake fluid, mineral oil or water in including hoses.
  • Page 791 Brake Control System and Diagnosis: 4A-6 Condition Possible cause Correction / Reference Item Dragging brakes Master cylinder pistons not returning Replace master cylinder. (A very light drag is correctly present in all disc brakes Restricted brake pipes or hoses Check for soft hoses or damaged pipes and immediately after pedal is replace with new hoes and/or new brake pipes.

  • Page 792: Repair Instructions

    4A-7 Brake Control System and Diagnosis: Repair Instructions Excessive Pedal Travel Check Brake Pedal Play Check S5JB0A4106001 S5JB0A4106002 Pedal play should be within specification. If out of 1) Start engine. specification, check brake light switch for proper 2) Depress brake pedal a few times. installation position and adjust if necessary.

  • Page 793: Air Bleeding Of Brake System

    Brake Control System and Diagnosis: 4A-8 Air Bleeding of Brake System 3) Depress brake pedal several times, and then while S5JB0A4106004 holding it depressed, loosen bleeder plug about one- CAUTION third to one half turn. Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface.

  • Page 794: Brake Pedal Free Height Adjustment

    4A-9 Brake Control System and Diagnosis: Brake Pedal Free Height Adjustment Adjustment should be made as follows when installing S5JB0A4106005 switch (1). Pull up brake pedal toward you and while Measure brake pedal free height between pedal and holding it there, adjust switch position so that clearance carpet installed on dash panel.

  • Page 795: Flushing Brake Hydraulic System

    Brake Control System and Diagnosis: 4A-10 4) If pedal travel doesn’t change, air tightness isn’t obtained. NOTE If defective, inspect vacuum lines and sealing parts, and replace any faulty part. When this has been done, repeat the entire test. I5JB0A410005-01 Flushing Brake Hydraulic System S5JB0A4106009 It is recommended that entire hydraulic system be...

  • Page 796: Front Brake Hose / Pipe Removal And Installation

    4A-11 Brake Control System and Diagnosis: Check air tightness under load Installation Reverse brake flexible hose removal procedure, noting 1) With engine running, depress brake pedal. Then the following. stop engine while holding brake pedal depressed. • Make sure that steering wheel is in straight-forward position and flexible hose has not twist or kink.

  • Page 797: Master Cylinder Components

    Brake Control System and Diagnosis: 4A-12 Master Cylinder Components S5JB0A4106026 CAUTION Never disassemble master cylinder. Disassembly will spoil its original function. If faulty condition is found, replace it with new one as an assembly. I5JB0A410010-01 [A]: A/T vehicle 2. Grommet 5.

  • Page 798: Master Cylinder Reservoir Removal And Installation

    4A-13 Brake Control System and Diagnosis: Master Cylinder Reservoir Removal and Installation Installation 1) When using new grommets (3), lubricate them with S5JB0A4106013 the same fluid as the one to fill reservoir (1) with. CAUTION Then press-fit grommets (3) to master cylinder (2). Grommets (3) must be seated in place.

  • Page 799: Master Cylinder Assembly Removal And Installation

    Brake Control System and Diagnosis: 4A-14 Master Cylinder Assembly Removal and 6) Loosen master cylinder fixing nuts (1) and then remove master cylinder (2) with reservoir (3) from Installation brake booster (4). S5JB0A4106014 CAUTION • Never disassemble master cylinder. Disassembly will spoil its original function. If faulty condition is found, replace it with new one as an assembly.

  • Page 800: Master Cylinder Assembly Inspection

    4A-15 Brake Control System and Diagnosis: Master Cylinder Assembly Inspection 4) Connect brake pipes to master cylinder and tighten brake pipe flare nuts (1) to specified torque. S5JB0A4106017 • Check master cylinder for corrosion and smooth Tightening torque operation. Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0 •...

  • Page 801: Brake Booster Components

    Brake Control System and Diagnosis: 4A-16 Brake Booster Components S5JB0A4106018 NOTE The difference between RH steering vehicle and LH steering vehicle booster components is the location of vacuum hose. I5JB0A410023-02 1. Brake master cylinder assembly 5. Clevis pin lock nut 9.

  • Page 802: Brake Booster Removal And Installation

    4A-17 Brake Control System and Diagnosis: Brake Booster Removal and Installation S5JB0A4106020 Removal 1) Disconnect brake pipes from ABS actuator if equipped. 6,(a) 2) Remove master cylinder assembly, referring to “Master Cylinder Assembly Removal and Installation: ”. 3) Disconnect brake vacuum hose from brake booster. 4) Remove clip (2) and the disconnect clevis pin (3).

  • Page 803: Special Tool

    Brake Control System and Diagnosis: 4A-18 Specifications Tightening Torque Specifications S5JB0A4107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Front brake caliper bleeder plug Rear wheel cylinder bleeder plug Master cylinder fixing nut 13.0 Brake pipe flare nut 12.0 Booster attaching nut Clevis pin lock nut 19.0 NOTE...

  • Page 804: Front Brakes

    4B-1 Front Brakes: Front Brakes General Description Front Disc Brake Caliper Assembly Construction S5JB0A4201001 This caliper is mounted to the brake caliper carrier with two caliper pin bolts. 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 805: Repair Instructions

    Front Brakes: 4B-2 Repair Instructions Front Disc Brake Components S5JB0A4206010 I5JB0A420001-01 1. Caliper 10. Piston seal 19. Brake disc : Apply small amount of brake fluid to all around part of piston seal. Caliper pin bolt 11. Cylinder boot F: Forward : Apply small amount of brake fluid.

  • Page 806: Front Disc Brake Pad On-Vehicle Check

    4B-3 Front Brakes: Front Disc Brake Pad On-Vehicle Check 3) Remove caliper (1) from caliper carrier. S5JB0A4206001 Inspect pad linings periodically according to NOTE maintenance schedule whenever wheels are removed Hang removed caliper (1) with a wire hook (2) (for tire rotation or other reason). Take a look through or the like so as to prevent brake hose from hole of caliper and check lining thickness of outside and bending and twisting excessively or being...

  • Page 807: Front Brake Disc And Pad Inspection

    Front Brakes: 4B-4 2) Install caliper and tighten caliper (slide) pin bolts (1) Front disc brake pad thickness (lining thickness) to specification. Standard: 11.0 mm (0.43 in.) Limit: 2.0 mm (0.08 in.) NOTE Make sure that boots are fit into groove securely.

  • Page 808: Front Disc Brake Caliper Removal And Installation

    4B-5 Front Brakes: Front brake disc deflection Limit: 0.1 mm (0.004 in.) I5JB0A420006-01 3) Remove caliper pin bolts (1). 4) Remove caliper (2). IYSQ01420009-01 Slide Pin Bolt / Cylinder Slide Pin Check slide pin (bolt) for smooth movement as shown in the figure.

  • Page 809: Front Disc Brake Caliper Disassembly And Assembly

    Front Brakes: 4B-6 3) Install brake flexible hose as shown and tighten flexible hose joint bolt (1) to specification. Tightening torque Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft) I2RH01420011-01 2) Remove cylinder boot. CAUTION 1,(a) Be careful not to damage inside (bore side) of cylinder.

  • Page 810: Front Disc Brake Caliper Inspection

    4B-7 Front Brakes: Piston seal NOTE Piston seal is used to seal piston and cylinder and to Boot’s face (1) should be at the same level adjust clearance between pad and disc. Replace with a from cylinder’s face (2) all around. new one at every overhaul.

  • Page 811: Front Brake Disc Removal And Installation

    Front Brakes: 4B-8 Piston Seal Installation Excessive or uneven wear of pad lining may indicate 1) Install disc to wheel hub. unsmooth return of the piston. In such a case, replace 2) Install caliper assembly to steering knuckle. rubber seal. 3) Tighten caliper carrier bolts (1) to specification.

  • Page 812: Specifications

    4B-9 Front Brakes: Specifications Tightening Torque Specifications S5JB0A4207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Caliper pin bolt 26.0 Wheel nut 10.0 72.5 Flexible hose joint bolt 17.0 Caliper carrier bolt 61.5 NOTE The specified tightening torque is also described in the following. “Front Disc Brake Components: ”...

  • Page 813: Rear Brakes

    Rear Brakes: 4C-1 Rear Brakes General Description Rear Drum Brake Assembly Construction S5JB0A4301001 The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is depressed and when parking brake is applied on level road.

  • Page 814: Repair Instructions

    4C-2 Rear Brakes: Repair Instructions Rear Drum Brake Assembly Components S5JB0A4306001 I5JB0A430001-03 1. Brake back plate 9. Shoe return lower spring 17. Rear wheel hub assembly 2. Brake shoe 10. Shoe hold down spring 18. Rear wheel hub housing bolt 3.

  • Page 815: Rear Brake Drum Removal And Installation

    Rear Brakes: 4C-3 Rear Brake Drum Removal and Installation 2) Install brake drum after making sure that inside of S5JB0A4306003 brake drum and brake shoes are free from dirt and Removal oil. 1) Hoist vehicle and remove rear wheel. 3) Upon completion of all jobs, depress brake pedal 2) Release parking brake lever.

  • Page 816: Rear Brake Drum And Shoe Inspection

    4C-4 Rear Brakes: Rear Brake Drum and Shoe Inspection S5JB0A4306004 “a” Brake Drum Inspect brake drum for wear. If drum inner diameter is exceeds the limit or uneven or stepped wear is excessive, replace the drum. Rear brake drum inner diameter “a” Standard: 254 mm (10.00 in.) Limit: 256 mm (10.07 in.) I5JB0A430004-02...

  • Page 817: Rear Brake Shoe Removal And Installation

    Rear Brakes: 4C-5 Rear Brake Shoe Removal and Installation 6) Disconnect parking brake shoe lever (1) from S5JB0A4306006 parking brake cable (2). WARNING Use special care when installing brake shoe return spring. Failure in its proper installation may allow it to springback and cause personal injury.

  • Page 818: Rear Brake Shoe Inspection

    4C-6 Rear Brakes: 4) Install brake adjuster (2) and upper shoe return Springs spring (1). Inspect for damage or weakening. Inspect each part with arrow for rust. If found defective, 5) Install adjuster pawl lever (3) and adjuster spring. replace. I5JB0A430012-02 I5JB0A430006-01 4.

  • Page 819: Wheel Cylinder Inspection

    Rear Brakes: 4C-7 Wheel Cylinder Inspection Installation S5JB0A4306009 1) Fit wheel cylinder to brake back plate, take off Inspect wheel cylinder disassembled parts for wear, bleeder plug cap from brake pipe and connect pipe cracks, corrosion or damage. to wheel cylinder just enough to prevent fluid from leaking.
  • Page 820 4C-8 Rear Brakes: 4) Remove brake drum referring to “Rear Brake Drum 2) Tighten rear axle nut (1) temporarily by hand at this Removal and Installation: ”. step. 5) Remove brake shoe referring to “Rear Brake Shoe Removal and Installation: ”. 6) Remove wheel cylinder referring to “Wheel Cylinder Removal and Installation: ”.
  • Page 821 Rear Brakes: 4C-9 8) Install wheel and tighten wheel nuts to specified 9) Check to ensure that brake drum is free from torque. dragging and proper braking is obtained. Remove vehicle from hoist and perform brake test (foot brake and parking brake). Specifications Tightening Torque Specifications S5JB0A4307001...

  • Page 822: Parking Brake

    4D-1 Parking Brake: Parking Brake Component Location Parking Brake Cable Location S5JB0A4403001...
  • Page 823 Parking Brake: 4D-2 I5JB0A440001-02 T: Top side 3. Equalizer 8. Parking brake shoe lever [a]: For 5door model F: Front side 4. Parking cable bracket 9. Parking cable clamp nut [b]: For 3door model R: Right side 5. Parking cable bracket bolt 10.

  • Page 824: Repair Instructions

    4D-3 Parking Brake: Repair Instructions Parking Brake Check and Adjustment Adjustment S5JB0A4406001 Check NOTE Hold center of parking brake lever grip and pull it up with Make sure for the following conditions before 200 N (20 kg, 44 lbs) force. cable adjustment.

  • Page 825: Parking Brake Lever Removal And Installation

    Parking Brake: 4D-4 Parking Brake Lever Removal and Installation S5JB0A4406002 Removal 1) Disconnect negative (–) cable at battery. 2) Block vehicle wheels and release parking brake lever. 3) Remove console box. 4) Disconnect lead wire of parking brake switch at coupler.

  • Page 826: Specifications

    4D-5 Parking Brake: • Tighten bolts and nuts to specified torque referring to Installation Install it by reversing removal procedure, noting the “Parking Brake Cable Location: ”. following points. • Adjust parking brake cable. Refer to “Parking Brake • Install clamps properly referring to “Parking Brake Check and Adjustment: ”.

  • Page 827: Abs

    ABS: 4E-1 Precautions Precautions in Diagnosing Troubles When connecting, set the connector on ABS hydraulic S5JB0A4500001 unit / control module assembly and pull up the lock To ensure that the trouble diagnosis is done accurately lever (2) until it locks. and smoothly, observe the following and follow “ABS Check: ”.

  • Page 828: Abs Hydraulic Unit / Control Module Assembly Description

    4E-2 ABS: This ABS is equipped with Electronic Brake force Distribution (EBD) system that controls a fluid pressure of rear wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sensor independently of change of load due to load capacity and so on.

  • Page 829: Schematic And Routing Diagram

    ABS: 4E-3 Schematic and Routing Diagram ABS Schematic S5JB0A4502001 INPUT OUTPUT ABS control module Hydraulic unit Wheel speed sensor (LF) Pump motor Wheel speed sensor (LR) Pump motor driver (transistor) Wheel speed sensor (RF) Solenoid valve power supply driver (transistor) Wheel speed sensor (RR) LF inlet solenoid valve Stop lamp switch...

  • Page 830: Abs Wiring Circuit Diagram

    4E-4 ABS: 5. Solenoid valve driver (transistor) 13. Data link connector 21. ECM 6. Pump motor driver (transistor) 14. Wheel speed sensor (Right-front) 22. 4 way joint 7. Solenoid valve 15. Wheel speed sensor (Left-front) 8. Pump motor 16. Wheel speed sensor (Right-rear) ABS Wiring Circuit Diagram S5JB0A4502002 WHT/BLU...
  • Page 831 ABS: 4E-5 4. Circuit fuse box 16. Right-front wheel speed sensor 28. Brake fluid level switch 5. Combination meter 17. Left-front wheel speed sensor 29. Parking brake switch 6. ABS warning lamp 18. Data link connector 30. CAN junction 7. EBD warning lamp (Brake warning lamp) 19.

  • Page 832: Component Location

    4E-6 ABS: Component Location ABS Components Location S5JB0A4503001 NOTE As for the difference of RH steering vehicle and LH steering vehicle, the location of the combination meter, data link connector, stop lamp switch and the brake master cylinder assembly only changes. I5JB0A450006-01 1.

  • Page 833: Diagnostic Information And Procedures

    ABS: 4E-7 Diagnostic Information and Procedures ABS Check S5JB0A4504001 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”. 3) Perform “DTC check, record and clearance: ”...
  • Page 834 4E-8 ABS: Customer questionnaire (Example) I2RH01450014-01 Problem symptom confirmation Check if what the customer claimed in “Customer Questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check: ”...

  • Page 835: Abs Warning Lamp Check

    Ignition Switch Is ON: ”. BRAKE I5JB0A450007-01 DTC Check S5JB0A4504004 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (1). Special tool (A): SUZUKI scan tool I5JB0A450001-01 EBD Warning Lamp (Brake Warning Lamp)

  • Page 836: Dtc Table

    3) Turn ignition switch to ON position. S5JB0A4504006 4) Read DTC according to instructions displayed on WARNING SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further When performing a driving test, select a safe details.

  • Page 837: Ignition Switch

    ABS: 4E-11 Pump Motor Driver (V): This parameter indicates the Scan Tool Standards Condition operational condition of the pump motor driver Data (transistor). LF Wheel 0 km/h, 0.0 MPH Vehicle stop RF Wheel Speed, LF Wheel Speed, RR Wheel Speed Speed and LF Wheel Speed (km/h, MPH): Wheel speed RR Wheel...
  • Page 838 4E-12 ABS: Circuit Description Operation (ON/OFF) of ABS warning lamp is controlled by ABS control module through lamp driver module in combination meter. If the antilock brake system is in good condition, ABS control module turns ABS warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF.

  • Page 839: Abs Warning Lamp Comes On Steady

    ABS: 4E-13 ABS Warning Lamp Comes ON Steady S5JB0A4504009 Wiring Diagram WHT/BLU E03-1 E03-14 WHT/RED WHT/GRN BLK/YEL GRN/ORN E03-7 PPL/RED E03-12 E03-6 E03-13 E03-26 I5JB0A450009-02 [A]: ABS hydraulic unit / control module connector 4. Circuit fuse (in junction block assembly) 8.
  • Page 840 4E-14 ABS: Troubleshooting Step Action 1) Perform diagnostic trouble code check. Go to Step 7 of “ABS Go to Step 2. Check: ”. Is there any DTC(s)? Are main fuses for ABS pump motor and ABS solenoid in Go to Step 3. Replace fuse and check good condition? circuit for short to...
  • Page 841 ABS: 4E-15 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON S5JB0A4504010 Wiring Diagram WHT/BLU E03-1 E03-14 WHT/RED WHT/GRN BLK/YEL GRN/ORN E03-7 PPL/RED E03-20 E03-12 E03-6 E03-13 E03-26 I5JB0A450010-02 [A]: ABS hydraulic unit / control module connector 4. Circuit fuse (in junction block assembly) 8.

  • Page 842: Ebd Warning Lamp (Brake Warning Lamp) Comes On Steady

    4E-16 ABS: EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady S5JB0A4504011 Wiring Diagram WHT/BLU E03-1 WHT/RED E03-14 BLK/YEL GRN/ORN E03-7 WHT/GRN PPL/RED E03-12 E03-6 E03-13 RED/BLK E03-26 RED/BLK I5JB0A450011-02 [A]: ABS hydraulic unit / control module connector 5. Combination meter 10.

  • Page 843: Serial Data Link Circuit Check

    ABS: 4E-17 Serial Data Link Circuit Check S5JB0A4504012 WHT/BLU E03-1 WHT/RED E03-14 BLK/YEL GRN/ORN E03-7 WHT/GRN PPL/RED E03-12 E03-6 PPL/WHT E03-5 E03-13 E03-26 I5JB0A450012-02 ABS hydraulic unit / control module connector 5. Combination meter 10. CAN junction [A]: (viewed from terminal side) 1.
  • Page 844 4E-18 ABS: Step Action 1) Turn ignition switch to OFF position. Go to Step 5. “WHT/RED” and/or “WHT/BLU” wire circuit 2) Check for proper connection to ABS hydraulic unit / open. control module connector at terminals “E03-1” and “E03- 14”. 3) If OK then turn ignition switch to ON position and measure voltage between each terminal of “E03-1”, “E03-14”...

  • Page 845: Dtc C1015: G Sensor Circuit

    ABS: 4E-19 Step Action 1) Turn ignition switch to OFF position. Substitute a known- Repair high resistance good ABS hydraulic unit or open in “PPL/WHT” 2) Check proper connection at “E03-5” (“PPL/WHT” wire) / control module and wire circuit for anti lock terminal for serial data circuit.

  • Page 846: Dtc C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit Or Encoder

    4E-20 ABS: DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder S5JB0A4504013 Wiring Diagram BLK/YEL GRN/ORN E03-7 E03-22 BLU/BLK E03-21 E03-18 GRN/BLK E03-19 E03-16 YEL/BLK E03-15...
  • Page 847 ABS: 4E-21 Step Action 1) Disconnect applicable ABS wheel speed sensor coupler Go to Step 4. Circuit open or short to with ignition switch OFF. ground. 2) Measure resistance between the following points. • Both ABS hydraulic unit / control module connector (1) terminals a pair of applicable sensor terminals.
  • Page 848 4E-22 ABS: DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit S5JB0A4504014 Wiring Diagram WHT/RED E03-14 E03-13...

  • Page 849: Dtc C1057: Power Source Circuit

    ABS: 4E-23 DTC C1057: Power Source Circuit S5JB0A4504015 Wiring Diagram WHT/RED E03-14 E03-13 E03-26 I5JB0A450016-02 [A]: ABS hydraulic unit / control module connector 2. Main fuse box (viewed from terminal side) 1. Battery 3. ABS hydraulic unit / control module assembly DTC Detecting Condition The ABS control module monitors the power source voltage at terminal “E03-14”.

  • Page 850: Dtc C1061: Abs Pump Motor And/Or Motor Driver Circuit

    4E-24 ABS: Step Action 1) Measure voltage between terminals “E03-14” and “E03- Poor connection of Check charging system 13” with engine running. “E03-14” and/or “E03- referring to “Generator 13” terminals. If the Test (Overcharged ± Is voltage 18 1.0 V or less? terminals are in good Battery Check): in condition, substitute a...

  • Page 851: Dtc C1063: Solenoid Valve Power Supply Driver Circuit

    ABS: 4E-25 DTC C1063: Solenoid Valve Power Supply Driver Circuit S5JB0A4504017 Wiring Diagram WHT/GRN BLK/YEL GRN/ORN E03-7 WHT/RED E03-14 I5JB0A450018-02 [A]: ABS hydraulic unit / control module connector 5. Solenoid valve power supply driver (transistor) (viewed from terminal side) 1. Battery 6.

  • Page 852: Dtc C1071: Abs Control Module

    4E-26 ABS: DTC C1071: ABS Control Module S5JB0A4504018 Wiring Diagram WHT/BLU E03-1 E03-14 WHT/RED E03-13 E03-26 I5JB0A450019-02 [A]: ABS hydraulic unit / control module connector 2. Main fuse box 4. ABS hydraulic unit / control module assembly (viewed from terminal side) 1.

  • Page 853: Dtc U1073: Control Module Communication Bus Off

    ABS: 4E-27 DTC U1073: Control Module Communication Bus Off S5JB0A4504020 Wiring Diagram E03-1 WHT/BLU E92-17 E92-7 E03-14 WHT/RED GRN/ORN E03-7 E03-13 E03-26 E91-22 E91-23 BLK/YEL E03-12 E03-6 G44-19 E03-10 WHT/RED G44-18 WHT/BLU E03-8 WHT/GRN E23-19 WHT/BLU E23-4 WHT/RED G28-10 G28-8 G31-1 G31-3 18 17...
  • Page 854 4E-28 ABS: DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check: ”. 1) Check connection of connectors of all control modules Go to Step 3. Intermittent trouble. communicating by means of CAN. Check for intermittent referring to “Intermittent 2) Recheck DTC.

  • Page 855: Dtc U1100: Lost Communication With Ecm (Reception Error)

    ABS: 4E-29 Step Action 1) Turn ignition switch to OFF position. Check ABS power and Check combination ground circuit. If circuit meter power and 2) Disconnect connectors from combination meter. is OK, substitute a ground circuit. If circuit 3) Recheck DTC for ABS. known-good ABS is OK, substitute a hydraulic unit / control...

  • Page 856: Repair Instructions

    Brake pedal (1) should be depressed and then select good condition. testing wheel by SUZUKI scan tool and the wheel (2) should be turned by another person’s hand. At this 2) Check that battery voltage is 11 V or higher.

  • Page 857: Abs Hydraulic Unit / Control Module Assembly Components

    ABS: 4E-31 ABS Hydraulic Unit / Control Module Assembly Components S5JB0A4506002 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.

  • Page 858: Abs Hydraulic Unit / Control Module Assembly Removal And Installation

    4E-32 ABS: ABS Hydraulic Unit / Control Module Assembly 5) Disconnect harness clamps (4) from bracket (5). Removal and Installation S5JB0A4506004 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.
  • Page 859 ABS: 4E-33 Installation 1) Install hydraulic unit / control module assembly by reversing removal procedure. Tightening torque Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5 lb-ft) ABS hydraulic unit / control module assembly bolt (b): 9 N·m (0.9 kgf-m, 6.5 lb-ft) ABS hydraulic unit / control module assembly bracket bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft) ABS hydraulic unit / control module assembly bracket nut (d): 25 N·m (2.5 kgf-m, 18.0 lb-ft) I5JB0A450025-01...

  • Page 860: Front Wheel Speed Sensor On-Vehicle Inspection

    4E-34 ABS: Front Wheel Speed Sensor On-Vehicle 7) Measure voltage at resistance with wheel rotation and confirm voltage alternately changes between Inspection high and low voltages. S5JB0A4506005 Output Voltage Inspection If voltage does not change with wheel rotation, check 1) Disconnect negative cable from battery. sensor, mating encoder and their installation conditions.

  • Page 861: Front Wheel Speed Sensor Removal And Installation

    ABS: 4E-35 Front Wheel Speed Sensor Removal and Installation Installation 1) Check that no foreign material is attached to sensor S5JB0A4506006 (1) and mating encoder (2). 2) Install it by reversing removal procedure. Removal 1) Disconnect negative cable from battery. Tightening torque Front wheel speed sensor bolt (a): 11 N·m (1.1 2) Disconnect front wheel speed sensor coupler (1).

  • Page 862: Front Wheel Speed Sensor Inspection

    4E-36 ABS: Front Wheel Speed Sensor Inspection Installation S5JB0A4506007 Reverse removal procedure for installation noting the Check sensor for damage. following. If any malcondition is found, replace. • Check that no foreign material is attached to sensor (1) and mating encoder (2). •...

  • Page 863: Rear Wheel Speed Sensor Inspection

    ABS: 4E-37 Rear Wheel Speed Sensor Inspection Front Wheel Encoder Removal and Installation S5JB0A4506010 S5JB0A4506012 Refer to “Front Wheel Speed Sensor Inspection: ” since CAUTION rear wheel speed sensor is the same as front wheel speed sensor. Front wheel encoder is included in front wheel hub assembly.

  • Page 864: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Special Tool S5JB0A4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.

  • Page 865: Transmission / Transaxle

    Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 No Gear Shift to 4th Gear .........5A-43 No Lock-Up Occurs...........5A-44 Precautions............. 5-1 Transmission Warning Light Circuit Check – Precautions for Transmission / Transaxle..... 5-1 Light Does Not Come “ON” at Ignition Automatic Transmission/Transaxle..
  • Page 866 5-ii Table of Contents DTC P1777: TCM Lost Communication with Automatic Transmission Assembly ECM (Reception Error) ........5A-66 Dismounting and Remounting......5A-97 DTC P1778: TCM Lost Communication with Automatic Transmission Unit Disassembly ..5A-98 BCM (Reception Error) ........5A-67 Oil Pump Components ........5A-103 DTC P1874 4L Switch Circuit Malfunction Oil Pump Disassembly and Assembly ....5A-104 Oil Pump Inspection ........5A-104 (Short) .............5A-68...
  • Page 867 Table of Contents 5-iii Back Up Light Switch Removal and Clutch ............5C-1 Installation ............5B-11 General Description ..........5C-1 Back Up Light Switch Inspection....... 5B-11 Clutch (Hydraulic Type) Construction ....5C-1 Gear Shift Control Lever Rear Case Component Location ...........5C-2 Assembly Removal and Installation ....5B-11 Clutch Fluid Pipe and Hose Location ....5C-2 Gear Shift Control Lever Rear Case Diagnostic Information and Procedures ....5C-2...

  • Page 868: Precautions

    5-1 Precautions: Precautions Precautions Precautions for Transmission / Transaxle S5JB0A5000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00”. Fastener Caution Refer to “Fastener Caution: in Section 00”. Precautions in Diagnosing Trouble (for A/T) Refer to “Precautions in Diagnosing Trouble: in Section 5A”. Precautions for Disassembly and Reassembly (for A/T) Refer to “Precautions for Disassembly and Reassembly: in Section 5A”.

  • Page 869: Automatic Transmission/Transaxle

    TCM memory can be are in good condition. Also, the power circuit of cleared as well as checked by using SUZUKI scan these sensors is not shorted to the ground. tool or OBD generic scan tool. Before using scan tool, •...
  • Page 870 5A-2 Automatic Transmission/Transaxle: • Wash the disassembled parts in ATF (Automatic • Select a clean place free from dust and dirt for overhauling. Transmission Fluid) or kerosene (using care not to allow ATF or kerosene to get on your face, etc.) and •...

  • Page 871: General Description

    Automatic Transmission/Transaxle: 5A-3 General Description Automatic Transmission Description S5JB0A5101001 This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up mechanism.
  • Page 872 One-way clutch ... 3 sets Transfer Hi: 1.000 Lo: 1.970 Final gear reduction ratio 5.125 Lubrication Lubrication system Forced feed system by oil pump Cooling Cooling system Radiator assisted cooling (water-cooled) Fluid used SUZUKI ATF 3317 or Mobil ATF 3309...

  • Page 873: Clutch / Brake Functions Of Automatic Transmission

    Automatic Transmission/Transaxle: 5A-5 Clutch / Brake Functions of Automatic Transmission S5JB0A5101002 I5JB0A510005-01 1. Overdrive clutch 5. Second coast brake 9. One-way clutch No.1 13. Intermediate shaft 2. Overdrive brake 6. Second brake 10. Overdrive one-way clutch 3. Forward clutch 7. Reverse brake 11.

  • Page 874: Table Of A/T System Component Operation

    5A-6 Automatic Transmission/Transaxle: Table of A/T System Component Operation S5JB0A5101003 Solenoid Solenoid Direct clutch Forward valve valve Inner Outer O/D brake clutch clutch No. 1–A No. 1–B piston piston — — — — R (V ≤ 7 km/h) — — R (V>...

  • Page 875: Can Communication System Description

    Automatic Transmission/Transaxle: 5A-7 CAN Communication System Description S5JB0A5101008 Refer to “CAN Communication System Description: in Section 1A” for CAN communication system description. TCM communicates control data with each control module as follows. TCM Transmission Data Combination 4WD control Meter module Torque reduction request Slip control signal Transmission malfunction...

  • Page 876: Electronic Shift Control Input / Output Table

    5A-8 Automatic Transmission/Transaxle: Electronic Shift Control Input / Output Table S5JB0A5101004 OUTPUT INPUT -Accelerator pedal position -Torque red. request -Coolant temperature -Slip control signal (*1) Gear shift control -Engine torque -Shift position signal -Engine speed -A/C ON/OFF 4th gear inhibit control -Brake light switch -Vehicle speed -Cruise control signal...
  • Page 877 Automatic Transmission/Transaxle: 5A-9 CONTROL INPUT / OUTPUT Accelerator effective position Throttle position Coolant temperature Engine torque Engine speed A/C ON/OFF Brake light switch Vehicle speed Cruise control signal P/N mode switch "3" position switch Input shaft speed sensor Output shaft speed sensor ATF temperature sensor 4L/N switch Shift switch...
  • Page 878 5A-10 Automatic Transmission/Transaxle: Electronic Shift Control System Wiring Diagram E93-5 E93-14 2.5V YEL/BLK E92-11 E93-6 E92-12 E93-16 2.5V E92-16 E92-15 GRN/RED GRN/YEL E92-5 E92-3 PPL/WHT E92-4 YEL/RED E92-7 E92-2 BRN/RED E92-17 E93-12 PNK/BLK E93-23 PPL/WHT E92-24 YEL/RED E92-20 YEL/BLK E92-10 E92-6 BLK/WHT E93-20...

  • Page 879: Brake Interlock System Description

    • It is possible to communicate through DLC (2) by on main harness or not. using not only SUZUKI scan tool (3) but also OBD generic scan tool. (Diagnostic information can be checked and erased by using a scan tool.)
  • Page 880 (1) and stores malfunction DTC in its memory. • It is possible to communicate with TCM through data link connector (DLC) (3) by using SUZUKI scan tool (2). Diagnostic information can be checked and erased by using SUZUKI scan tool.

  • Page 881: Schematic And Routing Diagram

    Automatic Transmission/Transaxle: 5A-13 2 Driving cycle detection logic Pending DTC The malfunction detected in the first driving cycle is Pending DTC means a DTC detected and stored stored in TCM memory (in the form of pending DTC and temporarily at 1 driving cycle of the DTC which is freeze frame data) but the malfunction indicator lamp detected in the 2 driving cycle detection logic.
  • Page 882 5A-14 Automatic Transmission/Transaxle: 3. Slip lock-up point in D and/or 3 position *1 Slip lock-up Vehicle speed km/h clutch status Throttle opening (%) (mph) Remark Slip ON 10 – 15% 29 – 34 (18 – 21) gear Slip OFF 10 – 15% 25 –...
  • Page 883 Automatic Transmission/Transaxle: 5A-15 2. Lock-up point in D position and power mode Lock-up clutch Vehicle speed km/h status Throttle opening (%) (mph) Remark 106 – 111 (66 – 69) gear 20 – 30% 56 – 61 (35 – 38) lock-up 76 –...

  • Page 884: Bearing And Race Installation Diagram

    5A-16 Automatic Transmission/Transaxle: Bearing and Race Installation Diagram S5JB0A5102002 10 11 14 15 I5JB0A510013-01 Bearing and Race Dimension Bearing and race Inside diameter Outside diameter Baring assy, O/D FR 24.32 mm (0.957 in.) 43.20 mm (1.701 in.) Race, thrust O/D FR 24.32 mm (0.957 in.) 39.20 mm (1.543 in.) Bearing, assy, thrust O/D case...

  • Page 885: Component Location

    Automatic Transmission/Transaxle: 5A-17 Component Location Electronic Shift Control System Components Location S5JB0A5103001 I5JB0A510014-01...

  • Page 886: Diagnostic Information And Procedures

    5A-18 Automatic Transmission/Transaxle: 1. Engine 6. Transmission warning light (vehicle is 11. 4L/N low switch 16. Shift solenoid valve-B equipped with engine diagnosis connector) 2. Transmission 7. MIL (vehicle is not equipped with engine 12. Pressure control solenoid valve 17. Valve body assembly diagnosis connector) 3.
  • Page 887 Automatic Transmission/Transaxle: 5A-19 Step Action Check for intermittent problem Repair or replace Go to Step 11. malfunction part(s). 1) Check for intermittent problem. Go to Step 11. Is there any faulty condition? Final confirmation test Go to Step 6. End. 1) Clear DTC if any.

  • Page 888: Malfunction Indicator Lamp (Mil) Check

    5A-20 Automatic Transmission/Transaxle: NOTE The form is a standard sample. It should be modified according to conditions characteristic of each market. Step 2. DTC / Freeze Frame Data Check, Record and Step 10. Check for Intermittent Problem Clearance Check parts where an intermittent trouble is easy to First, referring to “DTC Check: ”, check DTC (including occur (e.g., wire harness, connector, etc.), referring to pending DTC).

  • Page 889: Dtc Table

    Confirmation available table of automatic transmission related DTC is shown below. Vehicle is not equipped with engine Vehicle is equipped with engine diagnosis connector diagnosis connector SUZUKI scan tool Generic scan tool Not using scan tool (if equipped with A/T monitor connector) : Available-DTC can be confirmed...

  • Page 890: Dtc Check

    Reading DTC Using SUZUKI Scan Tool S5JB0A5104006 1) Turn ignition switch OFF. NOTE 2) Connect SUZUKI scan tool to data link connector For vehicle without engine diagnosis (DLC). connector, the MIL is turned on when the ECM and/or TCM detect malfunction(s). Each...

  • Page 891: Dtc Clearance

    Automatic Transmission/Transaxle: 5A-23 DTC Clearance 3) Read DTC according to instructions displayed on SUZUKI scan tool and write it down. Refer to S5JB0A5104007 Automatic transmission DTC can be cleared using any SUZUKI scan tool operator’s manual for further one of the following 2 methods.

  • Page 892: Fail Safe Table

    5A-24 Automatic Transmission/Transaxle: DTC Clearance Using Monitor Connector (If Equipped) 1) Remove steering column hole cover (1). 2) Turn ignition switch ON. 3) After 6 seconds or more, repeat connecting and disconnecting diagnosis switch terminal (3) of monitor connector (2) and body ground 5 times at about 1 second interval within 10 seconds, using service wire.
  • Page 893 Automatic Transmission/Transaxle: 5A-25 Trouble Area Fail Safe Operation Pressure Control Solenoid “A” Control • Power supply for all solenoid valves is cut. Circuit Low • Gear position is fixed according to select lever position as shown Pressure Control Solenoid “A” Control in the following.

  • Page 894: Scan Tool Data

    5A-26 Automatic Transmission/Transaxle: Trouble Area Fail Safe Operation CAN communication problem-TCM • Throttle opening used for line pressure control is assumed to be 100%. TCM Lost Communication with ECM • Throttle opening used for gear shifting control is assumed to be (Reception Error) •...
  • Page 895 Automatic Transmission/Transaxle: 5A-27 Scan Tool Data Vehicle Condition Normal Condition / Reference Values Vehicle Speed 1 At vehicle stop 0 km/h, 0 MPH Battery Voltage Ignition switch ON and engine stop Battery voltage is displayed (8 – 16 V) ATF Temp After driving at 60 km/h (37.5 mile/h) for 15 minutes 70 –...
  • Page 896 5A-28 Automatic Transmission/Transaxle: Scan Tool Data Vehicle Condition Normal Condition / Reference Values D Range Signal Ignition switch ON Select lever is in “P” position P/N range Select lever is in “R” position D range Select lever is in “N” position P/N range Select lever is in “D”...

  • Page 897: Visual Inspection

    Automatic Transmission/Transaxle: 5A-29 4WD Low Switch (ON, OFF): Inputted signal from 4L/ A/C Switch (ON, OFF): ON: Signal which inform that N switch on transfer case. air conditioner compressor is turned ON. ON: Transfer gear position is 4L OFF: Signal which inform that air conditioner OFF: Transfer gear position is 4H compressor is turned OFF.

  • Page 898: Road Test

    5A-30 Automatic Transmission/Transaxle: Step Action Perform “Time Lag Test” Go to Step 7. Proceed to “Troubleshooting” in Is it OK? “Time Lag Test: ”. Perform “Line Pressure Test” Go to Step 8. Proceed to “Troubleshooting” in Is it OK? “Line Pressure Test: ”. 1) Proceed to “Trouble Diagnosis 1”...

  • Page 899: Manual Road Test

    Automatic Transmission/Transaxle: 5A-31 Condition Possible cause Correction / Reference Item Incorrect gear shift point Malfunction of throttle position sensor Inspect. If NG, replace. Malfunction of input shaft speed sensor Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor Malfunction of power mode switch Inspect, If NG, replace.

  • Page 900: Stall Test

    5A-32 Automatic Transmission/Transaxle: Troubleshooting Condition Possible cause Correction / Reference Item Selected gear is incorrect Faulty valve body component Replace valve body assembly. Faulty clutch or brake Inspect clutch and brake. If any parts are faulty, replace them. Stall Test S5JB0A5104014 This test is to check overall performance of automatic transmission and engine by measuring stall speed at “D”...

  • Page 901: Time Lag Test

    Automatic Transmission/Transaxle: 5A-33 Condition Possible cause Correction / Reference Item Higher than standard Malfunction of pressure control solenoid Inspect. If NG, replace valve body assembly. level in both “D” and “R” valve (Low line pressure) range Malfunction of primary regulator valve Replace valve body assembly.
  • Page 902 5A-34 Automatic Transmission/Transaxle: 1) Apply parking brake securely and place chocks against wheels. 2) Remove fluid pressure check hole plug bolt. 3) Attach oil pressure gauge to fluid pressure check hole in transmission case. Special tool (A): 09925–37811–001 CAUTION After attaching oil pressure gauge, check that no fluid leakage exists. I5JB0A510019-01 4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D”...

  • Page 903: Engine Brake Test

    Automatic Transmission/Transaxle: 5A-35 Condition Possible cause Correction / Reference Item Lower than standard level Fluid leakage from direct clutch Inspect. If NG, replace. in “D” range Defective O/D clutch Inspect. If NG, replace. Leakage from “D” range fluid pressure Inspect. If NG, replace valve body assembly. circuit Lower than standard level Fluid leakage from direct clutch...

  • Page 904: A/T Symptom Diagnosis

    5A-36 Automatic Transmission/Transaxle: A/T Symptom Diagnosis S5JB0A5104019 Trouble Diagnosis 1 Electrical repair Condition Possible cause Correction / Reference Item Excessive shift shock Shift solenoid valve No.1 and/or No.2 Inspect circuit for open, short and intermittent. circuit faulty If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent.
  • Page 905 Automatic Transmission/Transaxle: 5A-37 Condition Possible cause Correction / Reference Item → Poor 2 3 shift Shift solenoid valve No.1 circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent. If NG, repair.
  • Page 906 5A-38 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → Poor O/D 3 shift Shift solenoid valve No.2 circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
  • Page 907 Automatic Transmission/Transaxle: 5A-39 Condition Possible cause Correction / Reference Item Incorrect gear shift point Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
  • Page 908 5A-40 Automatic Transmission/Transaxle: Trouble Diagnosis 2 On-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Excessive shift shock Engine abnormal condition Inspect and repair engine. Malfunction of shift solenoid valve No.1 Inspect.
  • Page 909 Automatic Transmission/Transaxle: 5A-41 Condition Possible cause Correction / Reference Item → Poor 3 O/D shift Malfunction of shift solenoid valve No.2 Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor Malfunction of transmission range Inspect. If NG, replace. sensor Malfunction of “3”...
  • Page 910 5A-42 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item Incorrect shift point Engine abnormal condition Inspect and repair engine Malfunction of output shaft speed Inspect. If NG, replace. sensor Malfunction of accelerator pedal position Inspect referring to “DTC P0122: Throttle sensor Position Sensor (Main) Circuit Low: in Section 1A”, “DTC P0123: Throttle Position Sensor...

  • Page 911: No Gear Shift To 4Th Gear

    Automatic Transmission/Transaxle: 5A-43 Condition Possible cause Correction / Reference Item ↔ Poor 3 O/D shift, Faulty O/D clutch Inspect. If NG, replace. excessive shock or Faulty O/D brake Inspect. If NG, replace. slippage → Poor 3 2 shift, excessive Faulty direct clutch Inspect.

  • Page 912: No Lock-Up Occurs

    5A-44 Automatic Transmission/Transaxle: Step Action “3” position switch signal inspection Go to Step 5. Faulty “3” position switch or its circuit. If 1) With ignition switch ON, check voltage between terminal OK, substitute a known- “E92-20” of TCM connector and ground under the good TCM and recheck.

  • Page 913: Transmission Warning Light Circuit Check - Light Does Not Come "On" At Ignition Switch On (Vehicle Is Equipped With Engine Diagnosis Connector)

    Automatic Transmission/Transaxle: 5A-45 Step Action 4L/N switch signal inspection Go to Step 5. Faulty “4L” switch or its circuit. If OK, substitute 1) With ignition switch ON, check voltage between terminal a known-good TCM and “E92-4” of TCM connector and ground. recheck.

  • Page 914: Dtc P0705 Transmission Range Sensor Circuit Malfunction

    5A-46 Automatic Transmission/Transaxle: “POWER” Light Circuit Check – Light Does Not Come “ON” at Ignition Switch ON S5JB0A5104065 Troubleshooting Step Action Combination Meter Power Supply Check Go to Step 2. Repair combination meter power supply 1) Turn ignition switch ON. circuit referring to Does other indicator / warning lights in combination meter “Combination Meter...
  • Page 915 Check for intermittent Check by using SUZUKI scan tool: trouble referring to “Intermittent and Poor 1) Connect SUZUKI scan tool to DLC with ignition switch Connection Inspection: OFF. in Section 00”. 2) Turn ignition switch ON and check transmission range sensor signal (“P”, “R”, “N”, “D”, “2”...

  • Page 916: Dtc P0707 Transmission Range Sensor Circuit Low

    Check for intermittent Check by using SUZUKI scan tool: trouble referring to “Intermittent and Poor 1) Connect SUZUKI scan tool to DLC with ignition switch Connection Inspection: OFF. in Section 00”. 2) Turn ignition switch ON and check transmission range sensor signal (“P”, “R”, “N”, “D”, “2”...
  • Page 917 Check transmission range sensor (switch) circuit for Intermittent trouble. Go to Step 5. operation Check for intermittent Check without using SUZUKI scan tool: trouble referring to “Intermittent and Poor 1) Turn ignition switch ON. Connection Inspection: 2) Check voltage at terminals “E93-1”, “E93-7”, “E93-8”, in Section 00”.

  • Page 918: Dtc P0712 Transmission Fluid Temperature Sensor "A" Circuit Low

    5A-50 Automatic Transmission/Transaxle: DTC P0712 Transmission Fluid Temperature Sensor “A” Circuit Low S5JB0A5104029 Wiring Diagram E92-11 YEL/BLK E92-12 16 15 14 13 12 11 10 9 17 16 15 14 13 12 11 10 9 21 20 19 26 25 23 22 24 23 18 17...

  • Page 919: Dtc P0713 Transmission Fluid Temperature Sensor "A" Circuit High

    Automatic Transmission/Transaxle: 5A-51 DTC P0713 Transmission Fluid Temperature Sensor “A” Circuit High S5JB0A5104030 Wiring Diagram Refer to “DTC P0712 Transmission Fluid Temperature Sensor “A” Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Transmission temperature sensor terminal voltage is less than •...

  • Page 920: Dtc P0717 Input / Turbine Speed Sensor Circuit No Signal

    5A-52 Automatic Transmission/Transaxle: DTC P0717 Input / Turbine Speed Sensor Circuit No Signal S5JB0A5104031 Wiring Diagram E93-6 E93-16 2.5V 16 15 14 13 12 11 10 9 17 16 15 14 13 12 11 10 9 21 20 19 26 25 23 22 24 23 18 17...

  • Page 921: Dtc P0722 Output Speed Sensor Circuit No Signal

    Automatic Transmission/Transaxle: 5A-53 Step Action Inspection input shaft speed sensor Input shaft speed Go to Step 4. Inspect input shaft speed sensor referring to “Input Shaft sensor circuit is Speed Sensor Inspection: ”. malfunction. Is check result satisfactory? Check visually input shaft speed sensor and clutch Intermittent trouble.

  • Page 922: Dtc P0741 / P0742 Tcc Circuit Performance Or Stuck Off / Tcc Circuit Stuck

    5A-54 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Check input shaft speed sensor circuit Go to Step 4. Go to Step 3. 1) Disconnect TCM connectors with ignition switch OFF. 2) Check for proper connection to input shaft speed sensor at “E93-5”...

  • Page 923: Dtc P0751 / P0752 Shift Solenoid-A Performance Or Stuck Off / Shift Solenoid-A Stuck

    Automatic Transmission/Transaxle: 5A-55 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF.

  • Page 924: Dtc P0756 / P0757 Shift Solenoid-B Performance Or Stuck Off / Shift Solenoid-B Stuck

    5A-56 Automatic Transmission/Transaxle: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF.

  • Page 925: Dtc P0962 Pressure Control Solenoid "A" Control Circuit Low

    Automatic Transmission/Transaxle: 5A-57 Table for detecting condition TCM output gear position Actual gear position Stuck OFF (DTC P0756) 1st *1 4th *2 Stuck ON (DTC P0757) 2nd *3 3rd *4 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.

  • Page 926: Dtc P0963 Pressure Control Solenoid "A" Control Circuit High

    5A-58 Automatic Transmission/Transaxle: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Pressure control solenoid valve output voltage is too low • Pressure control solenoid valve circuit open or comparing with TCM command value. shorted to ground. (1 driving cycle detection logic) •...

  • Page 927: Dtc P0973 / P0976 Shift Solenoid "A" Control Circuit Low / Shift Solenoid "B" Control Circuit Low

    Automatic Transmission/Transaxle: 5A-59 DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF. 2) Clear DTCs in TCM and ECM memories by using scan tool. 3) Start engine. 4) Keep engine running at idle speed for 10 seconds or more. 5) Check DTC, pending DTC and freeze-frame data.
  • Page 928 5A-60 Automatic Transmission/Transaxle: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Voltage of shift solenoid valve TCM terminal is low although TCM • Shift solenoid valve circuit shorted to ground. is commanding shift solenoid to turn ON. •...

  • Page 929: Dtc P0974 / P0977 Shift Solenoid "A" Control Circuit High / Shift Solenoid "B" Control Circuit High

    Automatic Transmission/Transaxle: 5A-61 DTC P0974 / P0977 Shift Solenoid “A” Control Circuit High / Shift Solenoid “B” Control Circuit High S5JB0A5104042 Wiring Diagram Refer to “DTC P0973 / P0976 Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low: ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...

  • Page 930: Dtc P1702 Internal Control Module Memory Check Sum Error

    5A-62 Automatic Transmission/Transaxle: Step Action Inspection solenoid valve Intermittent trouble or Replace defective faulty TCM. Check for solenoid valve referring 1) Inspection solenoid valve referring to “Solenoid Valves intermittent trouble to “Solenoid Valves (Shift Solenoid-A, Shift Solenoid-B, TCC Pressure referring to “Intermittent (Shift Solenoid-A, Shift Control Solenoid and Pressure Control Solenoid and Poor Connection...

  • Page 931: Dtc P1723 Range Select Switch Malfunction

    Automatic Transmission/Transaxle: 5A-63 DTC P1723 Range Select Switch Malfunction S5JB0A5104056 Wiring Diagram E92-20 YEL/RED YEL/BLK E92-10 16 15 14 13 12 11 10 9 17 16 15 14 13 12 11 10 9 21 20 19 26 25 23 22 24 23 18 17 I5JB0A510001-01...

  • Page 932: Dtc P1774: Can Communication Bus Off

    5A-64 Automatic Transmission/Transaxle: DTC P1774: CAN Communication Bus Off S5JB0A5104057 Wiring Diagram G31-2 G31-4 G31-1 8 7 6 5 4 3 2 1 G31-3 WHT/RED E23-4 WHT/BLU E23-19 E91-22 E91-23 WHT/BLU E03-8 E03-10 WHT/RED E92-17 RED E03-12 E92-7 E03-6 G44-19 G28-10 G44-18 G28-8...
  • Page 933 Automatic Transmission/Transaxle: 5A-65 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Transmission error that is inconsistent between transmission data • ECM and transmission monitor (CAN bus monitor) data is detected more • TCM than 7 times continuously. •...

  • Page 934: Dtc P1777: Tcm Lost Communication With Ecm (Reception Error)

    5A-66 Automatic Transmission/Transaxle: DTC P1777: TCM Lost Communication with ECM (Reception Error) S5JB0A5104058 Wiring Diagram Refer to “DTC P1774: CAN Communication Bus Off: ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Reception error of communication data for ECM is detected for •...

  • Page 935: Dtc P1778: Tcm Lost Communication With Bcm (Reception Error)

    Automatic Transmission/Transaxle: 5A-67 DTC P1778: TCM Lost Communication with BCM (Reception Error) S5JB0A5104059 Wiring Diagram Refer to “DTC P1774: CAN Communication Bus Off: ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Reception error of communication data for BCM is detected for •...

  • Page 936: Dtc P1874 4L Switch Circuit Malfunction (Short)

    C1026, C1031, C1032, C1035 and/or C1036 in ABS hydraulic unit / control module? Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Do you have SUZUKI scan tool? Go to Step 4. Go to Step 5.

  • Page 937: Dtc P1875 4L Switch Circuit Malfunction (Open)

    Action 4L switch and its circuit check Intermittent trouble or Go to Step 6. faulty TCM. Check for 1) Connect SUZUKI scan tool to DLC with ignition switch intermittent trouble OFF. referring to “Intermittent 2) Turn ignition switch ON. and Poor Connection 3) Select “DATA LIST”...
  • Page 938 Go to Step 5. 4L switch and its circuit check Intermittent trouble or Go to Step 6. faulty TCM. Check for 1) Connect SUZUKI scan tool to DLC with ignition switch intermittent trouble OFF. referring to “Intermittent 2) Turn ignition switch ON.

  • Page 939: Dtc P1878 Torque Converter Clutch Shudder

    Automatic Transmission/Transaxle: 5A-71 DTC P1878 Torque Converter Clutch Shudder S5JB0A5104060 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area The acceleration slip control function stops when the • Mismatching ATF variation in the output revolution speed of the specified •...
  • Page 940 5A-72 Automatic Transmission/Transaxle: DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Voltage of TCC pressure control solenoid valve TCM terminal is • TCC pressure control solenoid valve circuit high although TCM is commanding TCC pressure control solenoid shorted to power circuit.

  • Page 941: Dtc P2764 Torque Converter Clutch (Tcc) Circuit Low

    Automatic Transmission/Transaxle: 5A-73 DTC P2764 Torque Converter Clutch (TCC) Circuit Low S5JB0A5104052 Wiring Diagram Refer to “DTC P2763 Torque Converter Clutch (TCC) Circuit High: ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Voltage of TCC pressure control solenoid valve TCM terminal is •...

  • Page 942: Inspection Of Tcm And Its Circuits

    5A-74 Automatic Transmission/Transaxle: Inspection of TCM and Its Circuits S5JB0A5104061 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance. CAUTION TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it.
  • Page 943 Automatic Transmission/Transaxle: 5A-75 Connector “E92” Standard Terminal Wire color Circuit Condition voltage BLK/ORN Ground 0 – 1 V Ignition switch ON Pressure control BRN/RED 0.6 – 1.0 V Ignition switch ON solenoid valve (–) TCC pressure control PPL/WHT 0.6 – 1.0 V Ignition switch ON solenoid valve (–) *0 –...
  • Page 944 5A-76 Automatic Transmission/Transaxle: Connector “E93” Standard Terminal Wire color Circuit Condition voltage 8 – 14 V Ignition switch ON, selector lever at “R” range Transmission range Ignition switch ON, selector lever at other than “R” sensor (“R” range) 0 – 1 V range —...
  • Page 945 Automatic Transmission/Transaxle: 5A-77 Reference Waveform No. 1 Reference Waveform No. 3 Pressure control solenoid valve signal at engine idling. CAN communication line (High & Low) signal at engine idling. Measurement CH1: “E92-4” to “E92-1” terminal Measurement CH1: “E92-7” to “E92-1” Oscilloscope CH1: 5 V/DIV terminal...

  • Page 946: Tcm Power And Ground Circuit Check

    5A-78 Automatic Transmission/Transaxle: Reference Waveform No. 5 Input shaft speed sensor signal at engine speed 3000 rpm. Measurement CH1: “E93-6” to “E92-1” terminal Oscilloscope CH1: 2 V/DIV setting TIME: 10 ms/DIV • After warmed up to normal operating temperature Measurement condition •...
  • Page 947 Automatic Transmission/Transaxle: 5A-79 Troubleshooting Step Action Check TCM back-up power circuit Go to Step 2. “WHT” circuit open or shorted to ground. 1) Disconnect TCM connector with ignition switch OFF. 2) Check for proper connection to TCM at “E92-24” terminal. 3) If OK, check voltage at terminal “E92-24”...

  • Page 948: Repair Instructions

    4. “FULL COLD” 3. “LOW HOT” 5. “LOW COLD” A/T fluid specification SUZUKI ATF 3317 or Mobil ATF 3309 At Room Temperature The fluid level check at room temperature performed NOTE after repair or fluid change before test driving is just •...

  • Page 949: A/T Fluid Change

    5) Check fluid level referring to “At Normal Operating Temperature” under “A/T Fluid Level Check: ”. I5JB0A510033-01 A/T fluid specification SUZUKI ATF 3317 or Mobil ATF 3309 1. Manual lever assembly 2. Select indicator assembly A/T fluid capacity reference value 3.

  • Page 950: Manual Selector Assembly Removal And Installation

    5A-82 Automatic Transmission/Transaxle: Manual Selector Assembly Removal and CAUTION Installation When installing select lever knob, do not turn S5JB0A5106044 more than specified numbers of rotation. Removal Otherwise select lever knob is damaged. 1) Disconnect negative cable at battery. 2) Remove front console box. 3) Disconnect shift lever switch connector.

  • Page 951: Select Cable Component

    Automatic Transmission/Transaxle: 5A-83 Select Cable Component S5JB0A5106047 I5JB0A510035-01 1. Manual selector assembly 6. Manual select cable nut : 13 N⋅m (1.3 kgf-m, 9.5lb-ft) 2. Manual selector assembly mounting bolt 7. Manual select lever nut : 12.5 N⋅m (1.25 kgf-m, 9.0 lb-ft) 3.

  • Page 952: Transmission Range Sensor Removal And Installation

    5A-84 Automatic Transmission/Transaxle: Transmission Range Sensor Removal and Tightening torque Transmission range sensor bolt (b): 5.3 N·m ( Installation 0.53 kgf-m, 4.0 lb-ft) S5JB0A5106049 Removal 1) Disconnect negative cable at battery. 4, (b) 2) Hoist vehicle. 3) Disconnect transmission range sensor connector (1).

  • Page 953: Key Interlock Cable Removal And Installation

    Automatic Transmission/Transaxle: 5A-85 3) Check that engine starts in “N” and “P” ranges but it 7) Pull out key interlock cable (1) from key cylinder doesn’t start in “D”, “3”, “2”, “L” or “R” range. Also, cover (2) while pressing checkhook with slotted check that back-up lamp lights in “R”...
  • Page 954 5A-86 Automatic Transmission/Transaxle: 4) Pass and connect interlock cable as shown in the figure. I5JB0A510065-02 1-1. Interlock cable for LH steering vehicle 2-1. Key cylinder for LH steering vehicle 1-2. Interlock cable for RH steering vehicle 2-2. Key cylinder for RH steering vehicle 5) Pull out lock button (1) of selector side cable end (2).

  • Page 955: Brake And Key Interlock System Inspection

    Automatic Transmission/Transaxle: 5A-87 Brake and key Interlock System Inspection • For RH steering vehicle, with shift lock solenoid S5JB0A5106052 release button (1) pushed and ingition key turned 1) Check that selector lever cannot be moved to any to LOCK position, selector lever can not be shifted other range from “P”...

  • Page 956: Mode Select Switch Inspection

    5A-88 Automatic Transmission/Transaxle: Mode Select Switch Inspection Installation S5JB0A5106053 1) Check that sensor is free from any metal particles 1) Pull out mode select switch from front center console and damage. box. 2) Apply A/T fluid to new O-ring and then install input 2) Disconnect mode select switch connector.

  • Page 957: Output Shaft Speed Sensor Removal And Installation

    Automatic Transmission/Transaxle: 5A-89 Output Shaft Speed Sensor Removal and Output Shaft Speed Sensor Inspection S5JB0A5106057 Installation 1) Disconnect negative cable at battery. S5JB0A5106056 Removal 2) Hoist vehicle. 1) Disconnect negative cable at battery. 3) Disconnect output shaft speed sensor connector. 2) Hoist vehicle.

  • Page 958: Oil Cooler Hose And Pipes Removal And Installation

    5A-90 Automatic Transmission/Transaxle: Oil Cooler Hose and Pipe Components S5JB0A5106058 I5JB0A510032-03 [A]: View from A side 3. Oil hose No.1 6. Oil pipe No.2 9. Oil pipe No.1 bolt : 10 N⋅m (1.0 kgf-m, 7.5 lb- 1. Radiator 4. Oil hose No.4 7.

  • Page 959: Solenoid Valves

    Automatic Transmission/Transaxle: 5A-91 Installation 6) Remove A/T oil strainer (1). When replacing them, be sure to note the followings. • To replace clamps at the same time • To insert hose as far as its limit mark • To clamp hose securely 1) Use new union gaskets and connect oil cooler pipes to oil outlet unions.
  • Page 960 5A-92 Automatic Transmission/Transaxle: Solenoid Valves (Shift Solenoid-A, Shift CAUTION Solenoid-B, TCC Pressure Control Solenoid and Do not insert air gun against strainer Pressure Control Solenoid Inspection installed on inlet of solenoid valve too deeply, S5JB0A5106061 when blowing air into solenoid valve. If not, Solenoid Valves (Shift Solenoid–A and Shift the strainer will be damaged.

  • Page 961: Removal And Installation

    Automatic Transmission/Transaxle: 5A-93 Operation check Check pressure control solenoid valves (Pressure control solenoid and TCC pressure control solenoid) (1) operation in either of the following methods. [Using regulated DC power supply] 1) Connect pressure control solenoid valve (1) with regulated DC power supply (2) as shown in the figure.

  • Page 962: Transmission Fluid Temperature Sensor Inspection

    5A-94 Automatic Transmission/Transaxle: 7) Disconnect shift solenoid–A connector (1), shift Transmission Fluid Temperature Sensor solenoid–B connector (2), TCC pressure control Inspection solenoid connector (4) and Pressure control solenoid S5JB0A5106063 Immerse transmission fluid temperature sensor (1) in connector (3). water or oil. Check transmission fluid temperature 8) Remove solenoid valves.

  • Page 963: Transmission Control Module (Tcm) Removal And Installation

    Automatic Transmission/Transaxle: 5A-95 Transmission Control Module (TCM) Removal A/T Relay Inspection S5JB0A5106092 and Installation 1) Disconnect negative cable at battery. S5JB0A5106064 CAUTION 2) Remove integration relay No.2 (1) from fuse box No.2 (2). TCM consists of highly precise parts, so when handling it, be careful not to expose it to excessive shock.

  • Page 964: Automatic Transmission Unit Components

    5A-96 Automatic Transmission/Transaxle: Automatic Transmission Unit Components S5JB0A5106065 I5JB0A510003-01...

  • Page 965: Automatic Transmission Assembly Dismounting And Remounting

    Automatic Transmission/Transaxle: 5A-97 1. Torque converter mounting bolt No.1 11. Transmission to engine bolt 21. Output shaft speed sensor 31. Engine earth cable bolt : After tightening torque converter mounting bolt No.1, tighten torque converter mounting bolt No.2. 2. Torque converter mounting bolt No.2 12.

  • Page 966: Automatic Transmission Unit Disassembly

    5A-98 Automatic Transmission/Transaxle: Automatic Transmission Unit Disassembly 5) Remove C-ring (1) and then remove speed sensor S5JB0A5106067 rotor (2). NOTE 1) Extract torque converter. And remove oil filler tube and dipstick. Use care not to loose rotor stop key. CAUTION Remove torque converter as much straight as possible.
  • Page 967 Automatic Transmission/Transaxle: 5A-99 10) Check dimensions of overdrive (O/D) case (1) 14) Remove oil strainer (1). surface and clutch cylinder (2) surface for reassembly. 11) Remove overdrive (O/D) clutch assembly by holding input shaft (3). 12) Remove O/D case, bearing and bearing race. NOTE Confirm direction of bearing and bearing race for reassembly.
  • Page 968 5A-100 Automatic Transmission/Transaxle: 18) Remove accumulator pistons (1) by blowing air into 20) Check top surface level of forward clutch (2) against holes (2) as shown in the figure. case (1) for reassembly. 21) Remove forward clutch. NOTE NOTE Hold accumulator piston (1) with shop cloth while blowing.
  • Page 969 Automatic Transmission/Transaxle: 5A-101 26) Remove center support assembly (1). 30) Remove reverse brake piston (1) by applying compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) to oil hole (2). IYSQ01510104-01 27) Remove retaining ring (1), planetary gear assembly leaf spring, bearing and bearing race.
  • Page 970 5A-102 Automatic Transmission/Transaxle: 33) Remove manual shift shaft and lever as follows. 34) Remove oil seal (1) from both sides of transmission case. a) Undo caulking of sleeve cover (1) by using flat end rod or the like and hammer. IYSQ01510111-01 35) Remove cover plate (1).

  • Page 971: Oil Pump Components

    Automatic Transmission/Transaxle: 5A-103 Oil Pump Components S5JB0A5106068 I5JB0A510090-01 1. Oil pump body oil seal 4. Seal ring : 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft) 2. Oil pump cover O-ring 5. Oil pump body : Do not reuse. 3. Oil pump cover 6.

  • Page 972: Oil Pump Disassembly And Assembly

    5A-104 Automatic Transmission/Transaxle: Oil Pump Disassembly and Assembly • When installing pump cover, use care so that its S5JB0A5106069 splined part will not cause damage to oil seal and use specified torque to tighten it to pump body. Disassembly Tightening torque 1) Remove 6 bolts, oil pump cover (1), drive gear and Oil pump bolt (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) driven gear in that order.
  • Page 973 Automatic Transmission/Transaxle: 5A-105 • Check tip clearance between inner gear (1) and outer • Measure inside diameter of oil pump body bushing. gear. If inside diameter exceeds limit, replace oil pump body. Tip clearance between inner gear and outer gear Standard: 0.11 –...

  • Page 974: Overdrive (Planetary Gear Side) Components

    5A-106 Automatic Transmission/Transaxle: Overdrive (Planetary Gear Side) Components S5JB0A5106071 I5JB0A510096-01 1. Bearing 5. O-ring 9. Clutch plate 13. One-way clutch : Apply A/T fluid. 2. Race 6. Return spring 10. Clutch disc 14. Thrust washer 3. Clutch cylinder 7. Snap ring 11.
  • Page 975 Automatic Transmission/Transaxle: 5A-107 6) With clutch piston return spring compressed with 2) Remove O/D planetary gear assembly (1). special tools, remove clutch piston return spring. Special tool (A): 09918–48211 (B): 09926–98320 (C): 09918–48220 IYSQ01510121-01 2. O/D clutch cylinder 3) With O/D clutch assembly (2) installed to oil pump, apply compressed air (400 –...

  • Page 976: Overdrive (Planetary Gear Side) Inspection

    5A-108 Automatic Transmission/Transaxle: Assembly • For installing cushion clutch plate (1), refer to the Assemble each component by reversing removal figure. procedure and noting the following points. • When installing thrust washer (1), bring its oil groove (3) to the front. •...

  • Page 977: Overdrive (Case Side) Components

    Automatic Transmission/Transaxle: 5A-109 • Measure inside diameter of planetary gear bushing. If • Measure free length of piston return spring. inside diameter exceeds limit, replace planetary gear. Standard free length of O/D clutch piston return spring Planetary gear bushing inside diameter standard 16.9 mm (0.665 in.) 11.200 –...

  • Page 978: Overdrive (Case Side) Disassembly And Assembly

    5A-110 Automatic Transmission/Transaxle: Overdrive (Case Side) Disassembly and 3) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm 57 – 113 psi) to oil hole (1) in O/D case (2) and Assembly remove brake piston. S5JB0A5106075 Disassembly 1) Remove retaining ring (1), brake backing plate (2), brake disc (3) and brake plate (4) in that order.

  • Page 979: Overdrive (Case Side) Inspection

    Automatic Transmission/Transaxle: 5A-111 Overdrive (Case Side) Inspection Assembly Install each component by reversing removal procedure S5JB0A5106076 • Measure free length of piston return spring. and noting the following points. • When installing rear seal ring, use care not to open it Standard free length of O/D brake piston return too wide.

  • Page 980: Forward Clutch Components

    5A-112 Automatic Transmission/Transaxle: Forward Clutch Components S5JB0A5106077 I5JB0A510108-01 1. Input shaft 5. Retaining ring 9. Clutch disc : Apply A/T fluid. 2. Piston 6. Bearing race 10. Froward clutch hub 3. Return spring 7. Bearing 11. Direct clutch hub 4. O-ring 8.
  • Page 981 Automatic Transmission/Transaxle: 5A-113 4) Using special tool and hydraulic press, compress Assembly forward clutch piston return spring and remove 1) Apply A/T fluid to forward input shaft O-rings, install retaining return spring. forward clutch piston and piston return spring (2) to forward input shaft and then install return spring ring Special tool with special tool and hydraulic press.

  • Page 982: Forward Clutch Inspection

    5A-114 Automatic Transmission/Transaxle: 4) Install forward clutch hub (3), direct clutch hub (2) Forward Clutch Piston Return Spring and retaining ring (1) in that order. • Measure free length. Standard free length of forward clutch piston return spring 24.81 mm (0.977 in.) IYSQ01510151-01 4.

  • Page 983: Direct Clutch Components

    Automatic Transmission/Transaxle: 5A-115 Direct Clutch Components S5JB0A5106080 I5JB0A510112-01 1. Bearing race 5. Clutch disc 9. Direct clutch piston : Apply A/T fluid. 2. Bearing 6. Clutch plate 10. Direct clutch inner piston 3. Retaining ring 7. Return spring 11. Direct clutch cylinder 4.
  • Page 984 5A-116 Automatic Transmission/Transaxle: 3) Using special tool and hydraulic press (1), compress Assembly direct clutch piston return spring (3) and remove Assemble each component by reversing disassembly retaining return spring ring (2). procedure and noting the following points. • Always use new O-ring and apply A/T fluid before Special tool installation.

  • Page 985: Direct Clutch Inspection

    Automatic Transmission/Transaxle: 5A-117 • Install direct clutch assembly (1) to center support (2) Direct Clutch Piston Return Spring and with compressed air (400 – 800 kPa, 4 – 8 kg/ • Measure free length. , 57 – 113 psi) applied to oil hole (3), measure Standard free length of direct clutch piston return stroke of direct clutch piston as shown in the figure.

  • Page 986: Center Support Components

    5A-118 Automatic Transmission/Transaxle: Center Support Components S5JB0A5106083 I5JB0A510116-01 1. Center support 6. Second coast brake plate 11. Second brake piston : Do not reuse. 2. O-ring 7. Second coast brake disc 12. Second brake plate : Apply A/T fluid. 3. Second coast brake piston 8.

  • Page 987: Center Support Disassembly And Assembly

    Automatic Transmission/Transaxle: 5A-119 Center Support Disassembly and Assembly 4) Remove retaining ring. S5JB0A5106084 Disassembly 1) Remove retaining ring. Special tool (A): 09920–76010 IYSQ01510168-01 5) After removing clutch backing plate (1), remove second coast brake plate (3) and second coast brake disc (2). IYSQ01510165-01 2) Pull out center support assembly (2) from planetary sun gear (1).
  • Page 988 5A-120 Automatic Transmission/Transaxle: 8) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm 11) After removing retaining back plate ring, remove 57 – 113 psi) to oil hole at the extreme left and clutch backing plate, second brake plates and remove second coast brake piston as shown in the second brake discs.
  • Page 989 Automatic Transmission/Transaxle: 5A-121 14) Blow air into the second air hole from the left and 17) Remove 2 sun gear seal rings (1) from planetary sun remove second brake piston. Then remove piston gear. inner O-ring and piston outer O-ring from second NOTE brake piston.

  • Page 990: Center Support Inspection

    5A-122 Automatic Transmission/Transaxle: • When installing brake discs, brake plates and clutch • Measure inside diameter of center support hub backing plate, refer to “Center Support Components: bushing. If inside diameter exceeds limit, replace ”. center support. • Install clutch backing plate (1) with its flat side facing Center support bushing inside diameter standard brake disc.

  • Page 991: Planetary Gears And Output Shaft Components

    Automatic Transmission/Transaxle: 5A-123 Planetary Gears and Output Shaft Components S5JB0A5106085 I5JB0A510125-01 1. Inner shaft 6. Front planetary gear 11. Front planetary ring gear 16. Bearing race 2. Retaining ring 7. Reverse brake plate 12. Rear planetary gear 17. Output shaft assembly 3.

  • Page 992: Planetary Gears And Output Shaft Disassembly And Assembly

    5A-124 Automatic Transmission/Transaxle: Planetary Gears and Output Shaft Disassembly 5) After removing retaining ring (1), remove front planetary ring gear (2), thrust bearing and bearing and Assembly race. S5JB0A5106086 Disassembly 1) Remove front planetary gear assembly (1) from output shaft assembly (2). IYSQ01510189-01 6) Remove thrust washer (1), rear planetary gear (2) and rear planetary sun gear (3).

  • Page 993: Planetary Gears And Output Shaft Inspection

    Automatic Transmission/Transaxle: 5A-125 NOTE Planetary Gears and Output Shaft Inspection S5JB0A5106090 A is longer than B. • Check that sliding surface of discs and plate are not worn or burnt. if necessary, replace them. NOTE • If disc lining is exfoliated, discolored or worn hardly, replace all discs.

  • Page 994: Valve Body Assembly Components

    5A-126 Automatic Transmission/Transaxle: Valve Body Assembly Components S5JB0A5106087 I5JB0A510127-01 1. Manual valve 5. Plate 9. Solenoid clamp 13. Valve body assembly 2. TCC control solenoid valve 6. Shift solenoid valve A 10. Solenoid clamp bolt : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft) 3.
  • Page 995 Automatic Transmission/Transaxle: 5A-127 6) Install thrust bearing (1) and thrust bearing race (2) 3) Measure free length of reverse brake piston return spring. after lubricating them with grease. Standard free length of reverse brake piston NOTE return spring Make sure that thrust bearing output shaft 16.84 mm (0.663 in.) race is installed in proper direction.
  • Page 996 5A-128 Automatic Transmission/Transaxle: 9) Remove reverse brake reaction plate of planetary gear assembly and align lugs of reverse brake plate, reverse brake disc and reverse brake backing plate. Install planetary gear assembly to transmission case so that aligned lugs fit in groove in transmission case.
  • Page 997 Automatic Transmission/Transaxle: 5A-129 13) After confirming that lugs of all brake plates and brake discs are in grooves securely, hold retaining ring (1) of planetary sun gear, install center support assembly by aligning bolt holes (2) in center support and transmission case. NOTE Unless retaining ring of planetary sun gear is held, brake valve gets off center support and...
  • Page 998 5A-130 Automatic Transmission/Transaxle: 21) Apply grease to thrust washers (1) and install them 18) When clutch disc and plate have been replaced, check height difference between forward clutch input to O/D planetary gear (2) and planetary ring gear (3), shaft and transmission case (1) by measuring as and then install O/D input shaft assembly to O/D shown in the figure.
  • Page 999 Automatic Transmission/Transaxle: 5A-131 23) Apply A/T fluid to new housing O-ring and install it to 26) Apply 2 – 4 kg/cm air pressure into fluid holes in the O/D case. Then install converter housing (1) and figure as numbered and check operation sound of tighten housing bolt to specified torque.
  • Page 1000 5A-132 Automatic Transmission/Transaxle: 35) Install parking lock pawl (2), parking pawl pin (1) and 29) Check that inner shaft runs smoothly. parking pawl spring (3). 30) Apply grease to lip of new oil lip seal and drive in oil lip seal with special tool till it contacts transmission case.
  • Page 1001 Automatic Transmission/Transaxle: 5A-133 38) Apply A/T fluid to new O-ring and spring and install 40) Fix valve body (1) by using bolts with each nominal them to accumulator piston and install accumulator length as indicated in the figure and tightening to piston to transmission case.
  • Page 1002 5A-134 Automatic Transmission/Transaxle: 43) Connect solenoid coupler to each solenoid. 47) Install adapter case (1) with new adapter gasket to transmission case and tighten adapter case bolts to 44) Install oil strainer (1) to valve body assembly. specified torque. Tightening torque Tightening torque Oil strainer bolt (a): 5.5 N·m (0.55 kgf-m, 4.0 lb- Adapter case bolt (a): 31 N·m (3.1 kgf-m, 30.0 lb-...

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2005-2010 grand vitaraGrand vitara jb416Grand vitara jb420Grand vitara 2005

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