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Suzukiswiftservicemanual2017

OwnershandbookfortheJapaneseImportmodelSuzukiSwiftHybrid.Brandnewitem.This400pagehandbookhasbeentranslatedfromtheoriginalJapanesehandbookintoEnglishandisveryprofessionalwithfullillustrations.ThesehandbooksaregreattocomplimentyourvehicleandaddvalueforresaleModelNumber:A2LmodelsEngineModel:1242ccK12CDualjetI4(HybridElectricengine:WA05A(MHEV),PB05A(Hybrid)2and4WDmodelsYearsofManufacture:2017–currentmodelPages:400ISBN:978-1-86976-514-9Unfortunately,nomanualscouldbefound.Tryanotherpage,orgototheHomepage.ServiceManualsServiceManuals(CurrentModels)Lumen(only)-DiagnosticGuides&FormsAPVRearParkAssist(RPA)Celerio(AVK310)FrontParkAssist(FPA)GrandVitara(JB)416/420/419/424/627/632TrailerWiringHarness(TWA)Ignis(ATK412)BluetoothDiag.Jimny(A6G415)BluetoothCompatibility,A2DPCapableKitKizashi(A6B)BluetoothCompatibility,NONA2DPCapableKitS-Cross(AKK)414/416BluetoothOwnerManualSwift(AZH)ReverseCameraSwift(A2L)Vitara(APK)414/416/416DBaleno(A1K)310/414ServiceManuals(OlderModels)StorageandPre-DeliveryManualsAlto(AMF310)New–Vehicle,StorageManualBaleno(SY)PreDeliveryCheckSheet&InspectionManualGrandVitara(SQ)andXL-7(JA)XL-7(JSAHTX92V00200001~)Vision(only)-ImmobiliserandRKE(OlderModels)Ignis(RG)VisionImmobiliserManualsJimny(SN413)Liana(RH)Swift(AZFThailandproduction)Swift(RS)SX4(RW420)BodyRepairInformationSoftwarePossiblyRequiredSX4BodyRepairManualFirefox3.6RSSwiftBodyRepairManualSVGViewerJBGrandVitaraBodyRepairManualBodyRepairFlatRateManualWe'vedetectedsomesuspiciousactivitycomingfromyourIPaddressandhavetemporarilyblockeditasasecurityprecaution.Pleasechecktheboxtoletusknowyou'rehuman(sorry,norobotsallowed).TheSwiftisasubcompactcarproducedbySuzuki.Itisfourgenerationsinandstillgoingstrong.Nodoubtrepairswillneedtobemadeandwhetheritisyourcar,oryouareaworkshopowner,makingsuretheyaredoneproperlyisimportant.OurSuzukiSwiftworkshopmanualcanhelpguaranteethatyougetitdoneright.OureManualwillhelpguideyouthroughtheprocessstepbysteptoensurethatyoucanmakerepairscorrectly.GetyoureManualtodaytogetstarted.ThefirstgenerationSuzukiSwiftwasproducedfrom2000to2004.Itwasofferedinbothathreeandafivedoorhatchbackoption.TheSwiftwaspoweredbyanewgenerationofSuzukienginecalledtheMfamily.Itwasaninline-fourenginewithbotha1.3and1.5literoption.Theycamewiththeoptionofafivespeedmanualtransmissionorafourspeedautomatic.Therewasalsotheoptionoffrontorfourwheeldrive.Thethreedoorversionwasslightlyshorter,ThesecondgenerationSuzukiSwiftwasproducedfrom2004until2010.Thissporty,subcompactcarwasalowpricealternativetoothervehiclesinitsclassanddidamazinglywellinthecarmarketduetothoseexactreasons.Ithasarefinedchassisandexcelledinroadtestingprograms.ItreceivedafourstarratingintheEuroNCAPcrashtests.In2006itreceivedtheSemperitIrishCaroftheYearAward.The1.3literengineoffered91horsepowerandthe1.5literoffered101horsepower.TherewereseveralotheroptionsoftheSwiftavailableaswellincludingtheSuzukiSwiftSport.ThethirdgenerationSwiftwasproducedfrom2010until2017.Duringthisperioditreceivedsomeprettyimpressiveupgrades.Ithadalongerandmoreroundedshapeandanewenginedesign.Itcamewitha1.4literenginewith95horsepowerwithavailablemanualorautomatictransmission.Antilockbrakeswerenowstandard.TherewerealsoafewtrimlevelsintroducingincludingtheGLandtheGX.Thecarwasverymodernandsleeklooking.TheS-Conceptcamewitha1.6liter4cylinderenginewithasixspeedmanualtransmission.TheSportversionwasalsoavailable.ThecurrentfourthgenerationSwiftwasintroducedin2017.Theallnew2019Swiftisbackandbetterthanever.Itoffersasleeker,sharperdesignandimprovedperformance.Itcomeswitha1.0literBoosterJetTurboEngine.Itisthemostpowerfulinitsclasswith109horsepower.Theinteriorhousesallofthemoderncomfortandtechnologythatconsumersdesiretoday.ItalsocomeswitharacecarlikedesigninsideandDshapedsteeringwheel.Safetyfeatureshavebeenupgradedtoincludeanadvancedairbagsystem,antilockbrakesystem,electronicstabilitycontrol,andmanymore.KeepingupserviceontheSwiftdoesn’thavetobehard.OurSuzukiSwiftservicemanualcontainseasytoread,stepbystepinstructionsforyoutofollowalongwith.JustreadyourwaythroughandservicingtheSwiftshouldbeabreeze.GetyourcopyoftheeManualtodaytogetstarted.Page1Eitherofthesetwoconditionsmayresultinsevereinjury.•Iftheairbagsystemandanothervehiclesystembothneedrepair,Suzukirecommendsthattheairbagsystemberepairedfirst,tohelpavoidunintendedairbagsystemactivation.Page3Strictobservanceofthesospecifieditemswillenableonetoobtainthefullperformanceofthevehicle.Whenreplacingpartsorservicingbydisassembling,itisrecommendedtouseSUZUKIgenuineparts,toolsandservicematerialsasspecifiedineachdescription.Page5TABLEOFCONTENTSVolume1Volume2Precautions...............00-iPrecautions...............00-iPrecautions............00-1Precautions............00-1GeneralInformation...........0-iTransmission/Transaxle..........5-iGeneralInformation..........0A-1Precautions..............5-1MaintenanceandLubrication.........0B-1AutomaticTransmission.........5A-1ManualTransmission..........5B-1Engine.................Page7TableofContents00-iSection00PrecautionsCONTENTSPrecautions..........00-1AirBagWarning..........00-9AirBagSystemServiceWarning......00-9Precautions............00-1FastenerCaution..........00-9PrecautionsforVehiclesEquippedwithSuspensionCaution..........00-9aSupplementalRestraint(AirBag)System..00-1WheelsandTiresCaution........Page8(driverandpassenger).Itis•Iftheairbagsystemandanothervehicleverydangerousastheelectriccurrentfromsystembothneedrepair,SUZUKIthetestermaydeploytheairbagoractivaterecommendsthattheairbagsystembethepretensioner.Page9Precautions:00-2ServicingandHandlingWARNING:Manyofserviceproceduresrequiredisconnectionof“A/BAG”fuseandallairbag(inflator)module(s)frominitiatorcircuittoavoidanaccidentaldeployment.Driver,Passenger,SideandCurtainAirBag(Inflator)Modules•Forhandlingandstorageofaliveairbag(inflator)module,selectaplacewheretheambienttemperaturebelow65C(150F),withouthighhumidityandawayfrom...Page1000-3Precautions:WARNING:•Whenservicingpartsotherthanairbagsystem,ifshocksmaybeappliedtoairbagsystemcomponentparts,removethosepartsbeforehand.•ForhandlingandstorageofaSDM,select•Whenhandlingtheairbag(inflator)modules(driver,aplacewheretheambienttemperaturepassenger,sideandcurtain),seatbeltpretensionersbelow65C(150F),withouthighhumidity...Page11Precautions:00-4WARNING:–Donotswallowanyoftheseservicematerials.Itwouldcausediarrheaor•Wheneverraisingavehicleforservice,benausea.suretofollowtheinstructionsunder–Keepallthesematerialsoutofchildren’s“VehicleLiftingPoints:inSection0A”.Page1200-5Precautions:•Whenremovingthebattery,besuretodisconnectthe•Makesurethatallpartsusedinreassemblyarenegativecablefirstandthenthepositivecable.Whenperfectlyclean.reconnectingthebattery,connectthepositivecableWhenuseofacertaintypeoflubricant,bondorfirstandthenthenegativecable,andreplacethesealantisspecified,besuretousethespecifiedtype.Precautions:00-6•Afterservicingfuel,oil,coolant,vacuum,exhaustor•Alwaysbecarefulnottohandleelectricalpartsbrakesystems,checkalllinesrelatedtothesystem(computer,relay,etc.)inaroughmannerordropforleaks.them.00-7Precautions:PrecautionforCANCommunicationSystem•Whendisconnectingandconnectingcoupler,makeS4RS0A0000014suretoturnignitionswitchOFF,orelectronicparts•Theloose(1)inthewireharnessestwistoftheCANmaygetdamaged.linesexceptaroundtheconnector(3)shouldbewithin100mm(3.9in.).Page15Precautions:00-8•Wheninstallingvehicleparts,becarefulsothatthe•Whentakingmeasurementsatelectricalconnectorswiringharnessisnotinterferedwithorcaughtbyanyusingatesterprobe,besuretoinserttheprobe(2)otherpart.Page16IfthecorrectonlybyanauthorizedSUZUKIdealer.Referpartnumberfastenerisnotavailable,ato“AirBagSystemComponents,Wiringfastenerofequalsizeandstrength(orandConnectorsLocation:inSection8B”...Page17Precautions:00-10BrakeCautionS4RS0A0000013CAUTION:Allbrakefastenersareimportantattachingpartsinthattheycouldaffecttheperformanceofvitalpartsandsystems,and/orcouldresultinmajorrepairexpense.Theymustbereplacedwithoneofsamepartnumberorwithanequivalentpartifreplacementbecomesnecessary.Page1800-11Precautions:2)Disconnecttheconnectorincludedinthecircuit(connector-Binthefigure)andmeasureresistancebetweenterminals“A-1”and“B-1”.Ifnocontinuityisindicated,thatmeansthatthecircuitisopenbetweenterminals“A-1”and“B-1”.Ifcontinuityisindicated,thereisanopencircuitbetweenterminals“B-1”...Precautions:00-12IntermittentandPoorConnectionInspectionS4RS0A0006002Mostintermittentarecausedbyfaultyelectricalconnectionsorwiring,althoughastickingrelayorsolenoidcanoccasionallybeatfault.Whencheckingitforproperconnection,performcarefulcheckofsuspectcircuitsfor:•...Page2000-13Precautions:•Poorterminal-to-wireconnection.Checkeachwireharnessinproblemcircuitsforpoorconnectionbyshakingitbyhandlightly.Ifanyabnormalconditionisfound,repairorreplace.I2RH01010059-•Wireinsulationwhichisrubbedthrough,causinganintermittentshortasthebareareatouchesotherwiringorpartsofthevehicle.TableofContents0-iSection0GeneralInformationCONTENTSGeneralInformation........0A-1FuelFilterReplacement........0B-7FuelTankInspection...........0B-7GeneralDescription..........0A-1PCVValveInspection.........0B-7Abbreviations............0A-1FuelEvaporativeEmissionControlSystemSymbols..............0A-2Inspection............0B-7WireColorSymbols..........Page220A-1GeneralInformation:GeneralInformationGeneralDescriptionAbbreviationsS4RS0A0101001GEN:GeneratorGND:GroundABS:Anti-lockBrakeSystemATDC:AfterTopDeadCenterHC:HydrocarbonsAPI:AmericanPetroleumInstituteHO2S:HeatedOxygenSensorATF:AutomaticTransmissionFluid,AutomaticHAVC:Heating,VentilatingandAirConditioningTransaxleFluidALR:AutomaticLockingRetractorIACValve:IdleAirControlValve(IdleSpeedControl...Page23WU-TWC:WarmUpThreeWayCatalyticConverterCatalyst)SymbolsS4RS0A0101002SymbolDefinitionSymbolDefinitionTighteningtorqueApplySUZUKIBONDNO.1216B99000-31230Applyoil(engine,transmission,transfer,ApplySILICONESEALANTdifferential)99000-31120Applyfluid(brake,powersteeringorApplySEALINGCOMPOUND366Eautomatictransmissionfluid)Page240A-3GeneralInformation:I2RH01010010-FastenersInformationMetricbolts:IdentificationclassnumbersormarksS4RS0A0101004correspondtoboltstrength(increasingnumbersMetricFastenersrepresentincreasingstrength).Mostofthefastenersusedforthisvehiclearemetric.Whenreplacinganyfasteners,itismostimportantthatreplacementfastenersbethecorrectdiameter,threadpitchandstrength.Page25GeneralInformation:0A-4Threaddiameter(Nominaldiameter)(mm)StrengthUnitAequivalentof6.8strengthfastenerwithoutflangekg-m0.240.470.8412.519.3lb-ft14.530.558.090.5139.5202.5I2RH01010013-01Aequivalentof6.8strengthfastenerwithflangekg-m0.240.490.88...Page260A-5GeneralInformation:WhenUsingFrameContactHoistI4RS0A010001-1.Vehiclefront3.Floorjackposition2.Supportpositionforframecontacthoistandsafetystand4.BodymountingstayWhenUsingFloorJackWARNING:Ifthevehicletobejackeduponlyatthefrontorrearend,besuretoblockthewheelsongroundinordertoensuresafety.Page27GeneralInformation:0A-6EngineSupportingPointsS4RS0A0101008WARNING:Whenusingenginesupportingdevice(1),besuretoobservethefollowings.Otherwise,notonlydeformationofvehiclebodybutalsopersonalinjurymayresult.•Applysupportingdeviceatthespecifiedpositions(2)indicatedinfigure•...Page280A-7GeneralInformation:VehicleIdentificationNumberEngineIdentificationNumberS4RS0A0101006S4RS0A0101007ThenumberispunchedclosebytherightsidestrutThenumberispunchedoncylinderblock.support(1)inengineroom.I3RM0A010005-TransmissionIdentificationNumberS4RS0A0101009Theautomatictransmissionidentificationnumberislocatedontransmissioncase.Page29GeneralInformation:0A-8I4RS0A010007-1.Airbaglabelonsunvisor(ifequipped)4.Steeringshaftjointcoverlabel(ifequipped)2.Radiatorcaplabel5.Jacklabel3.EnginecoolingfanlabelI4RS0A010009-1.Airbaglabelondriverairbag(inflator)module5.0B-1MaintenanceandLubrication:MaintenanceandLubricationPrecautionsPrecautionsforMaintenanceandLubricationS4RS0A0200001AirBagWarningReferto“AirBagWarning:inSection00”.ScheduledMaintenanceMaintenanceScheduleunderNormalDrivingConditionsS4RS0A0205001NOTE:•Thisintervalshouldbejudgedbyodometerreadingormonths,whichevercomesfirst.•...Page31MaintenanceandLubrication:0B-2Km(x1,000)IntervalMiles(x1,000)MonthsSteeringsystem(tightness,damage,breakage,rattle)(I:———Driveshaft(axle)boots(I:————Manualtransaxleoil(leakage,level)(I:1st15,000kmonly)(R:—...Page320B-3MaintenanceandLubrication:SevereMaintenanceMaintenanceMaintenanceintervalconditioncodeoperationFirsttimeonly:15,000km(9,000miles)or12monthsSecondtimeandafter:–B––E––HManualtransaxleoilEvery30,000km(18,000miles)or24monthsreckoningfrom0km(0mile)or0monthEvery30,000km(18,000miles)or24...Page33MaintenanceandLubrication:0B-4NOTE:EngineOilandFilterChangeS4RS0A0206004Whenreplacingbeltwithanewone,adjustWARNING:belttensionto6–7mm(0.24–0.28in.).•Newandusedengineoilcanbehazardous.Besuretoread“WARNING”...Page340B-5MaintenanceandLubrication:NOTE:EngineoilspecificationOilpancapacity:About3.7liters(7.8/6.5US/Beforefittingnewoilfilter,besuretooilitslmppt.)O-ring.Useengineoilforthispurpose.Oilfiltercapacity:About0.2liter(0.4/0.3US/lmppt.)Others:About0.3liter(0.6/0.5US/lmppt.)Total:About4.2liters(8.9/7.4US/lmppt.)Page35MaintenanceandLubrication:0B-6ExhaustSystemInspectionS4RS0A0206006WARNING:Toavoiddangerofbeingburned,donottouchexhaustsystemwhenitisstillhot.Anyserviceonexhaustsystemshouldbeperformedwhenitiscool.Whencarryingoutperiodicmaintenance,orthevehicleisraisedforotherservice,checkexhaustsystemasfollows:I2RH01140007-...Page360B-7MaintenanceandLubrication:FuelFilterReplacementBrakeDiscsandPads(Front)InspectionS4RS0A0206042S4RS0A0206015WARNING:1)Removewheelandcaliperbutdon’tdisconnectbrakehosefromcaliper.Thisworkmustbeperformedinawell2)Checkfrontdiscbrakepadsanddiscsforexcessiveventilatedareaandawayfromanyopenwear,damageanddeflection.Page37MaintenanceandLubrication:0B-8BrakeHosesandPipesInspection3)CheckparkingbrakeleverforproperoperationandS4RS0A0206017stroke,andadjustitifnecessary.PerformthisinspectionwheretheseisenoughlightandForcheckingandadjustingprocedures,refertouseamirrorasnecessary.Page380B-9MaintenanceandLubrication:TiresInspectionSuspensionSystemInspectionS4RS0A0206021S4RS0A02060241)Checktiresforunevenorexcessivewear,or•Inspectfrontstrutsandrearshockabsorbersforevidenceofoilleakage,dentsoranyotherdamageondamage.Ifdefective,replace.Referto“Irregularand/orPrematureWearsleeves;...Page39MaintenanceandLubrication:0B-104)Checkboots(1)and(2)ofsteeringlinkageandsteeringgearcasefordamage(leak,detachment,tear,etc.).Ifdamageisfound,replacedefectivebootwithnewone.Ifanydentisfoundonsteeringgearcaseboots,correctittooriginalshapebyturningsteeringwheeltotherightorleftasfarasitstopsandholdingitforafewseconds.Page400B-11MaintenanceandLubrication:AutomaticTransaxleFluidLevelInspectionAutomaticTransaxleFluidCoolerHoseS4RS0A0206039Inspection1)Inspecttransaxlecaseforevidenceoffluidleakage.S4RS0A0206041CheckautomatictransaxlefluidcoolerhoseforfluidRepairleakypoint,ifany.leakage,cracks,damageanddeterioration.2)MakesurethatvehicleisplacedlevelforfluidlevelReplacehoseand/orclampifanyfaultyconditionischeck.Page41MaintenanceandLubrication:0B-12AirConditioningFilter(IfEquipped)InspectionEngineStartS4RS0A0206036Checkenginestartforreadiness.1)RemovetheairconditioningfilterfromtheHVACunitWARNING:referringto“AirFilterRemovalandInstallation:inSection7A”.Beforeperformingthefollowingcheck,be2)Checkfordirtanddust.Page420B-13MaintenanceandLubrication:WARNING:•Checkthatengineisfreefromabnormalnoiseandabnormalvibration.Withvehicleparkedonafairlysteepslope,makesurenothingisinthewaydownhilltoBody,WheelsandPowerTransmittingSystemavoidanypersonalinjuryorpropertyCheckthatbody,wheelsandpowertransmittingsystemdamage.Page43TableofContents1-iSection1EngineCONTENTSPrecautions..........1-1DTCP0011/P0012:CamshaftPosition-TimingOver-AdvancedorSystemPerformancePrecautions.............1-1/-Retarded............1A-44PrecautionsforEngine..........1-1DTCP0031/P0032:HO2SHeaterControlEngineGeneralInformationandCircuitLow/High(Sensor-1)......1A-46DTCP0037/P0038:HO2SHeaterControlDiagnosis..........Page441-iiTableofContentsDTCP0171/P0172:FuelSystemTooLeanRadiatorcoolingfanHighSpeedControl/Rich.............1A-103SystemCheck..........1A-195DTCP0300/P0301/P0302/P0303/RepairInstructions..........1A-198P0304:RandomMisfireDetected/CylinderIdleSpeed/IdleAirControl(IAC)Duty1/Cylinder2/Cylinder3/Cylinder4Inspection............1A-198...Page45TableofContents1-iiiVehicleSpeedSensor(VSS)InspectionCamshaft,TappetandShimRemovaland(M/Tmodel)............1C-8Installation............1D-29KnockSensorRemovalandInstallation.....1C-8Camshaft,TappetandShimInspection....1D-31MainRelay,FuelPumpRelay,StartingValvesandCylinderHeadComponents...1D-34MotorControlRelayandThrottleActuatorValvesandCylinderHeadRemovalandControlRelayInspection........1C-9...Page461-ivTableofContentsEngineCoolingSystem......1F-1FuelInjectorRemovalandInstallation....1G-9FuelInjectorInspection........1G-10GeneralDescription..........1F-1FuelFillerCapInspection........1G-11CoolingSystemDescription........1F-1FuelTankInletValveRemovalandCoolantDescription..........Page47TableofContents1-vSpecifications............1I-9GeneratorComponents........1J-7CrankingSystemSpecifications......1I-9GeneratorInspection...........1J-8TighteningTorqueSpecifications......1I-9Specifications.............1J-10SpecialToolsandEquipment......1I-9ChargingSystemSpecifications.......1J-10RecommendedServiceMaterial......1I-9TighteningTorqueSpecifications......1J-10ChargingSystem........1J-1ExhaustSystem........Page481-1Precautions:PrecautionsPrecautionsPrecautionsforEngineS4RS0A1000001AirBagWarningReferto“AirBagWarning:inSection00”.PrecautionsonEngineServiceReferto“PrecautionsonEngineService:inSection1A”.PrecautionsinDiagnosingTroubleReferto“PrecautionsinDiagnosingTrouble:inSection1A”.PrecautionsofECMCircuitInspectionReferto“PrecautionsofECMCircuitInspection:inSection1A”.Page49CANcommunicationlinewithcarereferringto•DiagnosticinformationstoredinECMmemorycanbe“PrecautionforCANCommunicationSystem:inclearedaswellascheckedbyusingSUZUKIscanSection00”.toolorOBDgenericscantool.Beforeusingscantool,•...Page501A-2EngineGeneralInformationandDiagnosis:connectorsattheharnessside,andthenmeasureconnectorsissameastheoneoftheECMvoltage,resistanceand/orpulsesignal.Or,ECMandconnectors.Therefore,measurecircuitvoltageanditscircuitsmaybedamagedbywater.resistancebyidentifyingtheterminallocationsubjecttothemeasurement.Page51•ItispossibletocommunicatebyusingnotonlyTherefore,itispossibletoknowengineanddrivingSUZUKIscantool(2)butalsoOBDgenericscantool.conditions(e.g.,whethertheenginewaswarmornot,(Diagnosticinformationcanbeaccessedbyusingawherethevehiclewasrunningorstopped,whereair/fuelscantool.)Page52OBDserialdataline(3)(KlineofISO9141)isusedforSUZUKIscantoolorOBDgenericscantooltocommunicatewithECM,AirbagSDM,immobilizercontrolmodule(inECM),BCM(BodyelectricalControlModule),TCM(TransmissionControlModule)andABScontrolmodule.Page53EngineGeneralInformationandDiagnosis:1A-5EngineandEmissionControlSystemDescriptionS4RS0A1101004Theengineandemissioncontrolsystemisdividedinto4majorsub-systems:airintakesystem,fueldeliverysystem,electroniccontrolsystemandemissioncontrolsystem.Airintakesystemincludesaircleaner,throttlebody,IACvalveandintakemanifold.Fueldeliverysystemincludesfuelpump,deliverypipe,etc.Page541A-6EngineGeneralInformationandDiagnosis:NOTE:IncommunicationbetweenECMandcombinationmeter,dataistransmittedonlyfromECMtocombinationmeter.(CombinationmeterdoesnottransmitdatatoECM.)ECMReceptionDataTorquedownignitiondelayrequestCoastslipcontrolsignalVehiclespeedpulseTCMdatavalidityTransmissiongear...Page55EngineGeneralInformationandDiagnosis:1A-7ElectronicControlSystemDescriptionS4RS0A1101006Theelectroniccontrolsystemconsistsof1)varioussensorswhichdetectthestateofengineanddrivingconditions,2)ECMwhichcontrolsvariousdevicesaccordingtothesignalsfromthesensorsand3)variouscontrolleddevices.Functionally,itisdividedintothefollowingsubsystems:•...Page561A-8EngineGeneralInformationandDiagnosis:EngineandEmissionControlSystemFlowDiagramI4RS0A110006-...Page57EngineGeneralInformationandDiagnosis:1A-9ECMInput/OutputCircuitDiagramRED/YELC37-20C37-1BLU/YELC37-2BLU/WHTC37-21BLK/ORNBLU/REDC37-16BLU/ORNC37-17GRN/BLKC37-26C37-27BLU/BLKC37-29BLK/YELC37-25C37-4GRN/REDGRN/ORNC37-3GRY/REDC37-14WHT/REDC37-19C37-54GRY/BLUC37-18BRN/YEL...Page581A-10EngineGeneralInformationandDiagnosis:4.MAPsensor26.IACvalve48.Barometricpressuresensor5.Knocksensor27.EVAPcanisterpurgevalve49.Oilcontrolvalve(Camshaftpositioncontrol)6.TPsensor28.Fuelpumprelay50.Engineground7.Page59EngineGeneralInformationandDiagnosis:1A-11TerminalWirecolorCircuitTerminalWirecolorCircuitHeateroutputofheatedBLU/REDFuelinjectorNo.3outputBLK/REDoxygensensor-1HeateroutputofheatedBLU/ORNFuelinjectorNo.4outputRED/BLUoxygensensor-2EGRvalve(steppermotorcoilBRN/YELYEL/GRNStartingmotorsignal...Page601A-12EngineGeneralInformationandDiagnosis:TerminalWirecolorCircuitTerminalWirecolorCircuit————YEL/REDFuellevelsensorsignalGroundforsensorsVehiclespeedsignaloutputforA/CrefrigerantpressureEPScontrolmodulesensorsignalRED/BLUEPSsignal—...Page61EngineGeneralInformationandDiagnosis:1A-13EngineandEmissionControlInput/OutputTableS4RS0A1101007ELECTRICCONTROLDEVICEOUTPUTINPUTFordetectingfuellevelFUELLEVELSENSORBAROMETRICPRESSURESENSORSTOPLAMPSWITCHSTARTSWITCHIGNITIONSWITCHA/CREFRIGERANTPRESSURESENSORBLOWERSWITCHA/CSWITCHA/CEVAPOUTLETAIRTEMP.Page621A-14EngineGeneralInformationandDiagnosis:SchematicandRoutingDiagramEngineandEmissionControlSystemDiagramS4RS0A1102001I4RS0A110011-...Page63EngineGeneralInformationandDiagnosis:1A-151.Aircleaner15.ECTsensor29.ECM2.EVAPcanisterpurgevalve16.CMPsensor30.Barometricpressuresensor3.MAFandIATsensor17.CKPsensor31.Battery4.TPsensor18.Radiatorcoolingfan32.Page641A-16EngineGeneralInformationandDiagnosis:InformationsensorsControldevicesOthers6.VSSg:IACvalveG:TCM(A/T)7.Batteryh:Ignitioncoilassembly(withignitor)H:BCM(includedinjunctionblockassembly)8.CMPsensori:MainrelayI:Immobilizercoilantenna9.Page65EngineGeneralInformationandDiagnosis:1A-17StepActionIntermittentproblemscheckRepairorreplaceGotoStep11.malfunctionpart(s),and1)Checkforintermittentproblemsreferringto“IntermittentgotoStep11.ProblemsCheck”.Isthereanyfaultycondition?FinalconfirmationtestGotoStep6.Page661A-18EngineGeneralInformationandDiagnosis:Customerprobleminspectionform(Example)I2RH01110010-NOTE:Theformisastandardsample.Itshouldbemodifiedaccordingtoconditionscharacteristicofeachmarket.Page67ECMorotherpartandrepairorreplacefaultyparts.1)PrepareOBDgenericscantoolorSUZUKIscantool.Step10:IntermittentProblemsCheckCheckpartswhereanintermittenttroubleiseasytooccur(e.g.,wireharness,connector,etc.),referringto...Page68(A):SUZUKIscantoolDTCClearanceS4RS0A11040041)ConnectOBDgenericscantoolorSUZUKIscantooltodatalinkconnectorinthesamemanneraswhenmakingthisconnectionforDTCcheck.2)TurnignitionswitchOFFandthenON.Page69EngineGeneralInformationandDiagnosis:1A-21DetectingconditionDTCNo.Detectingitem(DTCwillsetwhendetecting:)HO2Sheatercontrolcircuitlow2driving*P0037HeatercurrentislessthanspecificationwhileheaterON.(Sensor-2)cyclesHO2Sheatercontrolcircuithigh2driving*P0038HeatercurrentismorethanspecificationwhileheaterON.Page701A-22EngineGeneralInformationandDiagnosis:DetectingconditionDTCNo.Detectingitem(DTCwillsetwhendetecting:)Totalfueltrimissmallerthanspecificationforspecified2driving*P0172Systemtoorichtimeorlonger.(Fueltrimtowardleansideislarge.)cyclesMisfireofsuchlevelastocausedamagetothreeway*2driving...Page71EngineGeneralInformationandDiagnosis:1A-23DetectingconditionDTCNo.Detectingitem(DTCwillsetwhendetecting:)TransmissionerrorthatisinconsistentbetweenCANcommunication(bussoff1driving*P1674transmissiondataandtransmissionmonitor(CANbuserror)cyclemonitor)dataisdetectedmorethan7timescontinuously.CANcommunicationTransmissionerrorofcommunicationdataforECMis1driving...Page721A-24EngineGeneralInformationandDiagnosis:Fail-SafeTableS4RS0A1104006WhenanyofthefollowingDTCsisdetected,ECMentersfail-safemodeaslongasmalfunctioncontinuestoexistbutthatmodeiscanceledwhenECMdetectsnormalconditionafterthat.DTCNo.Page73EngineGeneralInformationandDiagnosis:1A-25Normalcondition/ScantooldataVehicleconditionreferencevaluesAcceleratorpedalreleased0.5–1.0VTPSENSORVOLTIgnitionswitchON/(THROTTLEPOSITIONwarmedupengineAcceleratorpedaldepressedLessthan4.8VSENSOROUTPUTstoppedfully...Page741A-26EngineGeneralInformationandDiagnosis:Normalcondition/ScantooldataVehicleconditionreferencevalues1350–1650kPaFormoredetails,refertoA/CON(A/Cisoperating)atpressureofhighpressureambienttemperature:30Cgageunder“A/CSystem(86F)andhumidity:50%PerformanceInspection:inA/CPRESSURE(A/C...Page75EngineGeneralInformationandDiagnosis:1A-27ScanToolDataDefinitionsCALCLOAD(CALCULATEDLOADVALUE,%)EngineloaddisplayedasapercentageofmaximumCOOLANTTEMP(ENGINECOOLANTpossibleload.ValueiscalculatedmathematicallyusingTEMPERATURE,C,F)theformula:actual(current)intakeairvolumeItisdetectedbyenginecoolanttemp.Page761A-28EngineGeneralInformationandDiagnosis:CLOSEDTHROTTLEPOS(CLOSEDTHROTTLEBRAKESW(ON/OFF)POSITION,ON/OFF)Thisparameterindicatesthestateofthebrakeswitch.ThisparameterreadsONwhenthrottlevalveisfullyclosed,orOFFwhenitisnotfullyclosed.RADIATORCOOLINGFAN(RADIATORCOOLINGFANCONTROLRELAY,ON/OFF)CANISTPRGDUTY(EVAPCANISTERPURGEFLOW...Page77EngineGeneralInformationandDiagnosis:1A-29InspectionitemReferencesection•Tachometer–Operation•Abnormalairbeinginhaledfromairintakesystem•Exhaustsystem–leakageofexhaustgas,noise•OtherpartsthatcanbecheckedvisuallyEngineBasicInspectionS4RS0A1104009ThischeckisveryimportantfortroubleshootingwhenECMhasdetectednoDTCandnoabnormalityhasbeenfound...Page78CheckignitiontimingGoto“EngineSymptomCheckignitioncontrolDiagnosis:”.relatedpartsreferringto1)UsingSUZUKIscantool,select“MiscTest”modeon“IgnitionTimingSUZUKIscantoolandfixignitiontimingtoinitialone.Inspection:inSection1H”.Page79EngineGeneralInformationandDiagnosis:1A-31StepActionCheckfuelpumpforoperationGoto“FuelPressureGoto“FuelPumpandCheck:”.ItsCircuitCheck:”.Wasfuelpumpoperatingsoundheardfromfuelfillerforabout3secondsafterignitionswitchONandstop?10CheckignitionsparkGotoStep11.Page801A-32EngineGeneralInformationandDiagnosis:EngineSymptomDiagnosisS4RS0A1104010PerformtroubleshootingreferringtothefollowingswhenECMhasdetectednoDTCandnoabnormalityhasbeenfoundin“VisualInspection:”and“EngineBasicInspection:”.ConditionPossiblecauseCorrection/ReferenceItemHardstarting(EngineFaultysparkplug...Page81EngineGeneralInformationandDiagnosis:1A-33ConditionPossiblecauseCorrection/ReferenceItemEnginenoise–Piston,Wornpiston,ringandcylinderbore“Cylinders,PistonsandPistonRingsringandcylindernoiseInspection:inSection1D”NOTE:Beforecheckingmechanicalnoise,makesurethat:•...Page821A-34EngineGeneralInformationandDiagnosis:ConditionPossiblecauseCorrection/ReferenceItemPoorgasolinemileageLeaksorlooseconnectionofhigh-“High-TensionCordRemovalandInstallation:tensioncordinSection1H”Faultysparkplug(impropergap,heavy“SparkPlugInspection:inSection1H”depositsandburnedelectrodes,etc.)MalfunctioningEGRvalve“EGRValveInspection:inSection1B”...Page83EngineGeneralInformationandDiagnosis:1A-35ConditionPossiblecauseCorrection/ReferenceItemSurge–EnginepowerLeakyorlooselyconnectedhigh-tension“High-TensionCordRemovalandInstallation:variationundersteadycordinSection1H”throttleorcruise.FeelsFaultysparkplug(excesscarbon“SparkPlugInspection:inSection1H”...Page841A-36EngineGeneralInformationandDiagnosis:ConditionPossiblecauseCorrection/ReferenceItemEnginehasnopowerFaultysparkplug“SparkPlugInspection:inSection1H”Faultyignitioncoilwithignitor“IgnitionCoilAssembly(Includingignitor)Inspection:inSection1H”Leaks,looseconnectionor“High-TensionCordRemovalandInstallation:disconnectionofhigh-tensioncord...Page85EngineGeneralInformationandDiagnosis:1A-37ConditionPossiblecauseCorrection/ReferenceItemExcessivehydrocarbonFaultysparkplug“SparkPlugInspection:inSection1H”(HC)emissionorcarbonLeakyordisconnectedhigh-tensioncord“High-TensionCordRemovalandInstallation:monoxide(CO)inSection1H”...Page861A-38EngineGeneralInformationandDiagnosis:MalfunctionIndicatorLampDoesNotComeONwithIgnitionSwitchONandEngineStop(butEngineCanBeStarted)S4RS0A1104011WiringDiagramE23-3E23-18G28-31BLK/ORNRED/BLKG28-16BLK/WHTE23-29C37-58BLK/ORNC37-15C37-30BLK/YELBLK/YELBRN/WHT...Page87EngineGeneralInformationandDiagnosis:1A-39TroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.StepActionMILpowersupplycheck...Page881A-40EngineGeneralInformationandDiagnosis:MalfunctionIndicatorLampRemainsONafterEngineStartsS4RS0A1104012WiringDiagramE23-3E23-18G28-31BLK/ORNRED/BLKG28-16BLK/WHTE23-29C37-58BLK/ORNC37-15C37-30BLK/YELBLK/YELBRN/WHTE23-60BLK/REDBLK/REDE23-1BLK/YELE23-16BLK/RED3938323139383231...Page89EngineGeneralInformationandDiagnosis:1A-41CircuitDescriptionWhentheignitionswitchisturnedON,ECMcausesthemainrelaytoturnON(closethecontactpoint).Then,ECMbeingsuppliedwiththemainpower,transmitsindicationONsignalofmalfunctionindicatorlamp(MIL)tocombinationmeterinordertoturnMILON.Page901A-42EngineGeneralInformationandDiagnosis:DTCP0010:CamshaftPositionActuatorCircuitS4RS0A1104014SystemandWiringDiagramC37-60YEL/REDC37-58BLK/ORNC37-59YEL/GRNC37-15C37-30[A]:39383231393832315453474654534746I4RS0A110018-[A]:Oilflow...Page91EngineGeneralInformationandDiagnosis:1A-43DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page921A-44EngineGeneralInformationandDiagnosis:StepActionOilcontrolvalveelectricalcircuitcheckGotoStep9.“YEL/RED”wireor“YEL/GRN”wirecircuit1)DisconnectconnectorfromoilcontrolvalvewithignitionisopenorhighswitchturnedOFF.resistance.Page931)Drivevehicleunderfollowingconditions.•Vehiclespeedat80km/h(50mile/h).•Gearpositionat5thorDrange.2)Checkthat“VVTGAP”displayedonSUZUKIscantoolis0–5.IsitOK?OilcontrolcircuitvisualinspectionGotoStep6.Page941A-46EngineGeneralInformationandDiagnosis:StepActionOilcontrolvalvecheckReplacecamshaftReplaceoilcontroltimingsprocket.valve.1)Checkoilcontrolvalvereferringto“OilControlValveInspection:inSection1D”.Isitingoodcondition?DTCP0031/P0032:HO2SHeaterControlCircuitLow/High(Sensor-1)S4RS0A1104029WiringDiagramBLK/WHT...Page95EngineGeneralInformationandDiagnosis:1A-47DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page961A-48EngineGeneralInformationandDiagnosis:StepActionHO2S-1heatercheckGotoStep8.ReplaceHO2S-1.1)DisconnectHO2S-1connectorwithignitionswitchturnedOFF.2)CheckHO2S-1heaterresistancereferringto“HeatedOxygenSensor(HO2S-1andHO2S-2)HeaterOn-VehicleInspection:inSection1C”.Page97EngineGeneralInformationandDiagnosis:1A-49DTCConfirmationProcedure1)WithignitionswitchturnedOFF,connectscantool.2)TurnONignitionswitchandclearDTCusingscantool.3)Startengineandwarmuptonormaloperatingtemperature.4)Runengineatidlespeedfor1min.5)CheckDTCandpendingDTC.Page981A-50EngineGeneralInformationandDiagnosis:StepActionHO2S-2heatercheckGotoStep8.ReplaceHO2S-2.1)DisconnectHO2S-2connectorwithignitionswitchturnedOFF.2)CheckHO2S-2heaterresistancereferringto“HeatedOxygenSensor(HO2S-1andHO2S-2)HeaterOn-VehicleInspection:inSection1C”.Page99EngineGeneralInformationandDiagnosis:1A-51DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroublearea•MAFvolumeisgreaterthan20g/secevenifengine•Airintakesystem(clogorleakage)revolutionislessthan900rpmandintakemanifold•...Page1001A-52EngineGeneralInformationandDiagnosis:StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:”.VisualinspectionGotoStep3.Repairorreplace.CheckMAFsensorandairintakesystemfor:•...Page101EngineGeneralInformationandDiagnosis:1A-53StepActionGroundcircuitcheck“GRY”wireisopenorECMgrounds“C37-58”,highresistancecircuit.“C37-15”and/or“C37-1)Measureresistancebetween“C37-27”terminalofECM30”circuitisopenorconnectorandvehiclebodyground.highresistance.Page1021A-54EngineGeneralInformationandDiagnosis:DTCP0102:MassAirFlowCircuitLowInputS4RS0A1104017WiringDiagramBLK/WHTE23-29C37-58BLK/ORNC37-15C37-30BLK/YELBLK/YELBRN/WHTE23-60BLK/REDBLK/REDE23-1BLK/YELBLK/REDE23-16BLK/REDGRN/BLKC37-26C37-27BLK/YELC37-25C37-55393832313938...Page103EngineGeneralInformationandDiagnosis:1A-55DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page1041A-56EngineGeneralInformationandDiagnosis:StepActionMAFsensorsignalcircuitcheckGotoStep9.“GRN/BLK”wireisopenorhighresistance1)Measureresistancebetween“GRN/BLK”wireterminalcircuit.ofMAFandIATsensorconnectorand“C37-26”terminalofECMconnector.Page105EngineGeneralInformationandDiagnosis:1A-57DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDTCwillbesetwhenalloffollowingconditionsaredetectedfor0.5seconds•OpenorshortinMAFsensorcircuitcontinuously.•...Page1061A-58EngineGeneralInformationandDiagnosis:StepActionMAFsensorsignalcircuitcheckGotoStep7.“GRY/BLK”wireisshortedtoothercircuit.1)DisconnectconnectorsfromECMwithignitionswitchturnedOFF.2)Measurevoltagebetween“GRY/BLK”wireterminalofMAFandIATsensorconnectorandengineground.Page107EngineGeneralInformationandDiagnosis:1A-59DTCConfirmationProcedureNOTE:Checktomakesurethatthefollowingconditionsaresatisfiedwhenusingthis“DTCConfirmationProcedure”.•Intakeairtemperatureatenginestart:–10C(14F)to80C(176F)•...Page1081A-60EngineGeneralInformationandDiagnosis:DTCP0107:ManifoldAbsolutePressureCircuitLowInputS4RS0A1104050WiringDiagramGRY/REDGRY/REDC37-14RED/BLKC37-53C37-58BLK/ORNC37-55C37-15C37-3039383231393832315453474654534746I4RS0A110049-1.Page109EngineGeneralInformationandDiagnosis:1A-61StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:”.MAPsensoranditscircuitcheckGotoStep3.Intermittenttrouble.Checkforintermittent1)ConnectscantooltoDLCwithignitionswitchturnedreferringto“Intermittent...Page1101A-62EngineGeneralInformationandDiagnosis:DTCP0108:ManifoldAbsolutePressureCircuitHighInputS4RS0A1104051WiringDiagramGRY/REDGRY/REDC37-14RED/BLKC37-53C37-58BLK/ORNC37-55C37-15C37-3039383231393832315453474654534746I4RS0A110049-1.Page111EngineGeneralInformationandDiagnosis:1A-63DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page1121A-64EngineGeneralInformationandDiagnosis:StepActionGroundcircuitcheck“ORN”wireisopenorECMgrounds“C37-58”,highresistancecircuit.“C37-15”and/or“C37-1)Measureresistancebetween“C37-55”terminalofECM30”circuitareopenorconnectorandvehiclebodyground.highresistance.Page113EngineGeneralInformationandDiagnosis:1A-65DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDifferenceofmaximumIATminusminimumIATislessthan0.3C•Highresistancecircuit(32.5F)whileECTisover70C(158F)after10minfromcold•...Page1141A-66EngineGeneralInformationandDiagnosis:StepActionWireharnesscheckGotoStep8.GotoStep4.1)DisconnectMAFandIATsensorconnector(1)withignitionswitchturnedOFF.2)CheckforproperconnectiontoMAFandIATsensorconnector(1)at“BLK/YEL”...Page115EngineGeneralInformationandDiagnosis:1A-67StepActionGroundcircuitcheckGotoStep10.GotoStep9.1)ConnectconnectorstoECM.2)CheckforproperconnectionofMAFandIATsensorconnectorat“ORN”wireterminal.3)Measureresistancebetween“ORN”wireterminalofMAFandIATsensorconnectorandvehiclebodygroundwithignitionswitchturnedOFF.Page1161A-68EngineGeneralInformationandDiagnosis:DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDTCwillbesetwhenalloffollowingconditionsaredetectedfor•IATsensorcircuit0.5secondscontinuously.•IATsensor•Engineisrunning•...Page117EngineGeneralInformationandDiagnosis:1A-69StepActionECMvoltagecheckGotoStep6.GotoStep4.1)DisconnectconnectorfromMAFandIATsensorwithignitionswitchturnedOFF.2)CheckforproperconnectiontoMAFandIATsensorat“BLK/YEL”...Page1181A-70EngineGeneralInformationandDiagnosis:DTCP0113:IntakeAirTemperatureSensorCircuitHighS4RS0A1104020WiringDiagramBLK/REDGRN/BLKC37-26C37-27C37-25BLK/YELC37-5539383231393832315453474654534746I4RS0A110024-1.Page119EngineGeneralInformationandDiagnosis:1A-71StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:”.IATsensoranditscircuitcheckGotoStep3.Intermittenttrouble.Checkforintermittent1)ConnectscantooltoDLCwithignitionswitchturnedreferringto“Intermittent...Page1201A-72EngineGeneralInformationandDiagnosis:StepActionWirecircuitcheckGotoStep7.“BLK/YEL”wireishighresistancecircuit.1)Measureresistancebetween“C37-25”terminalofECMconnectorand“BLK/YEL”wireterminalofMAFandIATsensorconnectorwithignitionswitchturnedOFF.Isresistancebelow5GroundcircuitcheckGotoStep9.Page121EngineGeneralInformationandDiagnosis:1A-73DTCP0116:EngineCoolantTemperatureCircuitRange/PerformanceS4RS0A1104069WiringDiagramLTGRNC37-24C37-5539383231393832315453474654534746I4RS0A110025-1.ECTsensor2.Page1221A-74EngineGeneralInformationandDiagnosis:DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page123EngineGeneralInformationandDiagnosis:1A-75StepActionECMvoltagecheck“LTGRN”wireisopenGotoStep7.circuit.1)TurnOFFignitionswitch.Ifwireandconnection2)RemoveECMfromitsbracketwithECMconnectorsareOK,gotoStep7.connected.Page1241A-76EngineGeneralInformationandDiagnosis:DTCP0117:EngineCoolantTemperatureCircuitLowS4RS0A1104021WiringDiagramLTGRNC37-24C37-5539383231393832315453474654534746I4RS0A110025-1.ECTsensor2.Page125EngineGeneralInformationandDiagnosis:1A-77DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page1261A-78EngineGeneralInformationandDiagnosis:DTCP0118:EngineCoolantTemperatureCircuitHighS4RS0A1104022WiringDiagramLTGRNC37-24C37-5539383231393832315453474654534746I4RS0A110025-1.ECTsensor2.Page127EngineGeneralInformationandDiagnosis:1A-79StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:”.ECTsensoranditscircuitcheckGotoStep3.Intermittenttrouble.1)ConnectscantoolwithignitionswitchturnedOFF.Page1281A-80EngineGeneralInformationandDiagnosis:StepActionECTsensorgroundcircuitcheckGotoStep9.GotoStep8.1)ConnectconnectorstoECM.2)CheckforproperconnectionofECTsensorconnectorat“ORN”wireterminal.3)Measureresistancebetween“ORN”wireterminalofECTsensorconnectorandvehiclebodyground.Page129EngineGeneralInformationandDiagnosis:1A-81DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDifferencebetweenactualthrottleopening(detectedfromTP•Throttlebodysensor)andopeningcalculatedbyECM(obtainedonthebasisof•TPsensorenginespeedandmassairflow)isoutofspecifiedrange(–20•...Page130TPsensoranditscircuitcheckGotoStep14.GotoStep3.1)TurnOFFignitionswitchandconnectSUZUKIscantooltoDLC.2)TurnONignitionswitchandcheckTPsensoroutputvoltagewhenthrottlevalveisatidlepositionandfullyopened.Page131EngineGeneralInformationandDiagnosis:1A-83StepActionWireharnesscheckFaultyMAPsensorand/GotoStep6.orA/Crefrigerant1)TurnignitionswitchtoOFFposition.pressuresensor,check2)DisconnectconnectorsfromMAPsensorandA/CMAPsensorand/orA/Crefrigerantpressuresensor.Page1321A-84EngineGeneralInformationandDiagnosis:StepAction10WirecircuitcheckGotoStep11.“GRY/RED”and/or“GRY/BLU”wireare1)Measureresistancebetween“C37-14”terminalofECMhighresistancecircuit.connectorand“GRY/RED”wireterminalofTPsensorconnector,between“C37-54”...Page133EngineGeneralInformationandDiagnosis:1A-85DTCP0122:ThrottlePositionSensorCircuitLowS4RS0A1104024WiringDiagramC37-14GRY/REDGRY/REDGRY/BLUC37-54C37-5539383231393832315453474654534746I4RS0A110027-1.TPsensor3.Page1341A-86EngineGeneralInformationandDiagnosis:DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page135EngineGeneralInformationandDiagnosis:1A-87StepActionWireharnesscheckFaultyMAPsensorand/GotoStep5.orA/Crefrigerant1)TurnignitionswitchtoOFFposition.pressuresensor,check2)DisconnectconnectorsfromMAPsensorandA/CMAPsensorand/orA/Crefrigerantpressuresensor.Page1361A-88EngineGeneralInformationandDiagnosis:DTCP0123:ThrottlePositionSensorCircuitHighS4RS0A1104025WiringDiagramC37-14GRY/REDGRY/REDGRY/BLUC37-54C37-5539383231393832315453474654534746I4RS0A110027-1.TPsensor3.Page137EngineGeneralInformationandDiagnosis:1A-89StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:”.TPsensoranditscircuitcheckGotoStep3.Intermittenttrouble.1)ConnectscantooltoDLCwithignitionswitchturnedCheckforintermittentOFFandthenturnONignitionswitch.Page1381A-90EngineGeneralInformationandDiagnosis:StepActionWirecircuitcheckGotoStep7.“GRY/BLU”wireisshortedtopowercircuit.1)DisconnectconnectorsfromECMwithignitionswitchturnedOFF.IfwireisOK,substituteaknown-goodECMand2)TurnONignitionswitch.Page139EngineGeneralInformationandDiagnosis:1A-91DTCP0131/P0132:O2Sensor(HO2S)CircuitLowVoltage/HighVoltage(Sensor-1)S4RS0A1104026WiringDiagramBLK/WHTE23-29BLK/WHTBLK/REDC37-46C37-10C37-5739383231393832315453474654534746...Page1401A-92EngineGeneralInformationandDiagnosis:NOTE:Checktomakesurethatfollowingconditionsaresatisfiedwhenusingthis“DTCConfirmationProcedure”.•Intakeairtemperatureatenginestart:–10C(14F)to80C(176F)•Intakeairtemperature:–10C(14F)to70C(158F)•...Page141EngineGeneralInformationandDiagnosis:1A-93StepActionWirecircuitcheckGotoStep6.“WHT”wireishighresistancecircuitor1)TurnOFFignitionswitch.opencircuit.Poor“C37-2)RemoveECMfromitsbracketwithECMconnectors10”...Page1421A-94EngineGeneralInformationandDiagnosis:DTCP0133:O2Sensor(HO2S)CircuitSlowResponse(Sensor-1)S4RS0A1104027WiringDiagramBLK/WHTE23-29BLK/WHTBLK/REDC37-46C37-10C37-5739383231393832315453474654534746I4RS0A110029-1.Page143EngineGeneralInformationandDiagnosis:1A-955)Keepabovevehiclespeedfor6min.ormore.(Throttlevalveopeningiskeptconstantinthisstep.)6)Releaseacceleratorpedalandwithenginebrakeapplied,keepvehiclecoasting(withfuelcutfor3sec.ormore)andthenstopvehicle.Page1441A-96EngineGeneralInformationandDiagnosis:DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaHO2Svoltageishigherthan0.6Vformorethan1min•HO2S-1continuouslyafterwarmingupengineorHO2Svoltageislower•...Page145EngineGeneralInformationandDiagnosis:1A-97StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:”.HO2S-1outputvoltagecheckIntermittenttrouble,GotoStep3.checkforintermittent1)ConnectscantooltoDLCwithignitionswitchturnedreferringto“IntermittentOFF.Page1461A-98EngineGeneralInformationandDiagnosis:StepActionAirintakesystemcheckCheckHO2S-1referringRepairorreplaceairto“HeatedOxygenintakesystem.1)Checkairintakesystemforclogorleak.Sensor(HO2S-1andIsitOK?HO2S-2)HeaterOn-VehicleInspection:inSection1C”.Page147EngineGeneralInformationandDiagnosis:1A-99DTCConfirmationProcedureWARNING:•Whenperformingaroadtest,selectaplacewherethereisnotrafficorpossibilityofatrafficaccidentandbeverycarefulduringtestingtoavoidoccurrenceofanaccident.•...Page1481A-100EngineGeneralInformationandDiagnosis:StepActionHO2S-2groundcheckGotoStep5.“YEL”wireisopenorhighresistancecircuit.1)DisconnectconnectorfromHO2S-2withignitionswitchPoor“C37-57”terminalturnedOFF.connection.FaultyECM2)CheckforproperconnectiontoHO2S-2connectoratground.Page149EngineGeneralInformationandDiagnosis:1A-101DTCP0140:O2Sensor(HO2S)CircuitNoActivityDetected(Sensor-2)S4RS0A1104030WiringDiagramBLK/WHTE23-29BLK/WHTRED/BLUC37-47C37-11C37-5739383231393832315453474654534746I4RS0A110030-1.Page1501A-102EngineGeneralInformationandDiagnosis:DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page151EngineGeneralInformationandDiagnosis:1A-103DTCP0171/P0172:FuelSystemTooLean/RichS4RS0A1104032DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDTCP0171:•VacuumleakageTotalfueltrimishigherthan35%orshorttermfueltrimishigher•...Page1521A-104EngineGeneralInformationandDiagnosis:DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page153EngineGeneralInformationandDiagnosis:1A-105DTCP0300/P0301/P0302/P0303/P0304:RandomMisfireDetected/Cylinder1/Cylinder2/Cylinder3/Cylinder4MisfireDetectedS4RS0A1104033SystemDescriptionECMmeasurestheangleofthecrankshaftbasedonthepulsesignalfromtheCKPsensorandCMPsensorforeachcylinder.Page1541A-106EngineGeneralInformationandDiagnosis:DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page155EngineGeneralInformationandDiagnosis:1A-107DTCP0327/P0328:KnockSensorCircuitLow/HighS4RS0A1104034WiringDiagramC37-5639383231393832315453474654534746I4RS0A110031-1.Knocksensor2.Page1561A-108EngineGeneralInformationandDiagnosis:DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page157EngineGeneralInformationandDiagnosis:1A-109StepActionKnocksensorcircuitforhighresistancecheckFaultyknocksensor.“RED”wireishighresistancecircuit.1)TurnOFFignitionswitch,measureresistancebetween“C37-56”terminalofECMconnectorand“RED”wireterminalofknocksensorharnessconnector.Page1581A-110EngineGeneralInformationandDiagnosis:DTCConfirmationProcedure1)WithignitionswitchturnedOFF,connectscantool.2)TurnONignitionswitchandclearDTCusingscantool.3)Crankenginefor3–5sec.4)CheckDTCandpendingDTC.DTCTroubleshootingNOTE:•...EngineGeneralInformationandDiagnosis:1A-111StepActionGroundcircuitcheckGotoStep6.“BLK/ORN”wireisopenorhighresistance.1)TurnignitionswitchtoOFFposition.2)Measureresistancebetween“BLK/ORN”wireterminalofCKPsensorconnectorandengineground.Ismeasuredresistancevaluelessthan3?Wasterminal“B+”...Page1601A-112EngineGeneralInformationandDiagnosis:SystemDescriptionTheCMPsensorlocatedonthetransmissionsideofcylinderheadconsistsofthesignalgenerator(magneticsensor)andsignalrotor(intakecamshaftportion).ThesignalgeneratorgeneratesReferencesignalthroughslitsintheslitplatewhichturnstogetherwiththecamshaft.ReferencesignalTheCMPsensorgenerates6pulsesofsignalseachofwhichhasadifferentwaveformlengthwhilethecamshaftmakesonefullrotation.Page161EngineGeneralInformationandDiagnosis:1A-113StepActionWireharnessandconnectioncheckGotoStep7.GotoStep4.1)DisconnectconnectorfromCMPsensor.2)CheckforproperconnectiontoCMPsensorat“BLK/RED”,“RED/YEL”and“BLK/ORN”wireterminals.3)IfOK,turnONignitionswitchandcheckvoltageat“BLK/RED”,“RED/YEL”...Page1621A-114EngineGeneralInformationandDiagnosis:DTCP0401/P0402:ExhaustGasRecirculationFlowInsufficientDetected/ExcessiveDetectedS4RS0A1104037SystemandWiringDiagramI4RS0A110035-1.EGRvalve4.Sensedinformation7.“IGCOIL”fuse10.Mainrelay2.Intakemanifold5.Page163EngineGeneralInformationandDiagnosis:1A-115DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDTCP0401:•EGRvalveDifferenceinintakemanifoldabsolutepressurebetweenopenedEGRvalve•EGRpassageandclosedEGRvalveissmallerthanspecifiedvalue.•...Page164GotoStep5.EGRvalveoperationcheckGotoStep4.GotoStep5.1)WithignitionswitchturnedOFF,installSUZUKIscantooltoDTC.2)CheckEGRsystemreferringto“EGRSystemInspection:inSection1B”.Page165EngineGeneralInformationandDiagnosis:1A-117DTCP0403:ExhaustGasRecirculationControlCircuitS4RS0A1104071WiringDiagramBLK/WHTE23-29C37-58BLK/ORNC37-15C37-30BLK/YELBLK/YELBRN/WHTE23-60BLK/REDBLK/REDE23-1BLK/YELBLK/REDBLK/REDE23-16GRN/REDC37-4BLK/REDC37-3GRN/ORNBLK/REDC37-19WHT/REDC37-18BRN/YEL...Page1661A-118EngineGeneralInformationandDiagnosis:DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page167EngineGeneralInformationandDiagnosis:1A-119DTCP0420:CatalystSystemEfficiencybelowThresholdS4RS0A1104039SystemandWiringDiagramC37-10C37-57C37-11BLUWHTI4RS0A110037-1.HO2S-13.Warmupthreewaycatalyticconverter5.ECM2.HO2S-24.ThreewaycatalyticconverterCircuitDescriptionECMmonitorsoxygenconcentrationintheexhaustgaswhichhaspassedthewarmupthreewaycatalyticconverterbyHO2S-2.Page1681A-120EngineGeneralInformationandDiagnosis:DTCConfirmationProcedureWARNING:•Whenperformingaroadtest,selectaplacewherethereisnotrafficorpossibilityofatrafficaccidentandbeverycarefulduringtestingtoavoidoccurrenceofanaccident.•...Page169EngineGeneralInformationandDiagnosis:1A-121DTCP0443:EvaporativeEmissionSystemPurgeControlValveCircuitS4RS0A1104040WiringDiagramBLK/WHTE23-29C37-58BLK/ORNC37-15C37-30BLK/YELBLK/YELBRN/WHTE23-60BLK/REDBLK/REDE23-1BLK/YELE23-16BLK/REDBLK/REDC37-29BLU/BLK39383231393832315453...Page1701A-122EngineGeneralInformationandDiagnosis:DTCTroubleshootingWARNING:Inordertoreduceriskoffireandpersonalinjury,thisworkmustbeperformedinawellventilatedareaandawayfromanyopenflamessuchasgaswaterheater.NOTE:•...Page171EngineGeneralInformationandDiagnosis:1A-123DTCP0462:FuelLevelSensorCircuitLowS4RS0A1104072WiringDiagram12VYEL/REDE23-24BLK/ORN39383231393832315453474654534746I4RS0A110039-1.Fuellevelsensor(gauge)2.Page172FuellevelsensoroutputsignalcheckwithSUZUKIscanGotoStep5.IntermittenttroubleortoolfaultyECM.1)ConnectSUZUKIscantooltoDLCwithignitionswitchCheckforintermittentturnedOFF.referringto“IntermittentandPoorConnection...Page173SystemCheck:”.Doesfuellevelmeterincombinationmeterindicate“E”ReplenishfueltankwithGotoStep3.(empty)?fuelandgotoStep3.DoyouhaveSUZUKIscantool?GotoStep4.GotoStep5.Page174FuellevelsensoroutputsignalcheckwithSUZUKIscanGotoStep6.IntermittenttroubleortoolfaultyECM.1)ConnectSUZUKIscantooltoDLCwithignitionswitchCheckforintermittentturnedOFF.referringto“IntermittentandPoorConnection...Page175EngineGeneralInformationandDiagnosis:1A-127StepActionHighresistancecircuitcheckforfuellevelsensorcircuitGotoStep12.“YEL/RED”wireishighresistancecircuit.1)DisconnectconnectorsfromECM.2)Measureresistancebetween“YEL/RED”wireterminaloffuelpumpconnectorand“E23-24”...Page1761A-128EngineGeneralInformationandDiagnosis:DTCConfirmationProcedure1)TurnOFFignitionswitchturned.2)ClearDTCwithignitionswitchturnedON.3)Runengineatidlespeed.4)CheckpendingDTCin“ONBOARDTEST”or“PENDINGDTC”modeandDTCin“DTC”mode.DTCTroubleshootingStepAction...Page177EngineGeneralInformationandDiagnosis:1A-129StepActionWirecircuitcheckGotoStep8.GotoStep5.1)ConnectradiatorcoolingfanrelayNo.1torelayboxwithignitionswitchturnedOFF.2)RemoveECMfromitsbracketwithECMconnectorsconnected.Page1781A-130EngineGeneralInformationandDiagnosis:StepActionRadiatorcoolingfancontrolcheckGotoStep10.“BLU/RED”wireisopencircuit.1)DisconnectradiatorcoolingfanrelayNo.2(2)andNo.3(3)fromrelaybox(1)withignitionswitchturnedOFF.2)RunengineuntilECTisover97.5C,207.5F.Page179EngineGeneralInformationandDiagnosis:1A-131StepAction14RadiatorcoolingfanrelayNo.2andNo.3check“GRN”wireisopenReplacerelay.circuit.1)CheckradiatorcoolingfanrelayNo.2andNo.3referringto“RadiatorCoolingFanRelayInspection:inSection1F”.Page1801A-132EngineGeneralInformationandDiagnosis:DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroublearea•Vehiclespeedsignalisnotinputwhilefueliscutat•“BLK/ORN”circuitopendecelerationfor4secondscontinuouslyat3600rpmor•...Page181EngineGeneralInformationandDiagnosis:1A-133StepActionPowersupplycircuitcheckGotoStep6.“BLK/RED”wireisopencircuit.1)WithignitionswitchturnedOFF,disconnectconnectorfromVSS.2)Checkforproperconnectionto“BLK/RED”,“PPL”and“BLK/ORN”...Page1821A-134EngineGeneralInformationandDiagnosis:StepActionVSScheckSubstituteaknown-ReplaceVSSorsignalgoodECMandrecheck.rotor.1)CheckVSSandsignalrotortoothreferringto“VehicleSpeedSensor(VSS)Inspection(M/Tmodel):inSection1C”.Page183EngineGeneralInformationandDiagnosis:1A-135DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page1841A-136EngineGeneralInformationandDiagnosis:StepActionIdleaircontrolvalvecircuitcheckGotoStep9.“BLK”wireisopencircuit.1)Measureresistancebetween“BLK”wireterminalofidleaircontrolvalveconnectorandvehiclebodygroundwithignitionswitchturnedOFF.Page185EngineGeneralInformationandDiagnosis:1A-137DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaA/Crefrigerantpressuresensorsignalvoltageislessthan•A/Crefrigerantpressuresensorcircuit0.15Vfor0.5sec.continuously.•A/Crefrigerantpressuresensor(1drivingdetectionlogicbutMILdoesnotlightup)•...Page1861A-138EngineGeneralInformationandDiagnosis:StepActionA/CrefrigerantpressuresensorsignalcircuitcheckGotoStep7.GotoStep6.1)ConnectconnectorstoECM.2)TurnONignitionswitch,measurevoltagebetweenenginegroundand“RED”wireterminalofA/Crefrigerantpressuresensorconnector.Page187EngineGeneralInformationandDiagnosis:1A-139DTCConfirmationProcedure1)ConnectscantooltoDLCwithignitionswitchturnedOFF.2)TurnONignitionswitchandclearDTCusingscantool.3)CheckDTCandpendingDTC.TroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•...Page1881A-140EngineGeneralInformationandDiagnosis:StepActionECMgroundcircuitcheck“ORN”wireisopenorECMgrounds“C37-58”,highresistancecircuit.“C37-15”and/or“C37-1)RemoveECMfromitsbracketwithECMconnectors30”isopenorhighconnected.Page189EngineGeneralInformationandDiagnosis:1A-141DTCP0616:StarterRelayCircuitLowS4RS0A1104077WiringDiagramBLK/WHTE23-29RED/WHTGRN/WHTE23-30[A]:YELC37-48YEL/GRN[B]:YEL/GRNC37-58BLK/ORNYEL/GRNC37-15C37-3039383231393832315453474654534746...Page1901A-142EngineGeneralInformationandDiagnosis:StepActionSignalcircuitcheckPoor“C37-48”“YEL/GRN”wireisopenconnectionororhighresistance1)TurnOFFignitionswitch.intermittenttrouble.circuit.2)RemoveECMfromitsbracketwithECMconnectorsCheckforintermittentconnected.Page191EngineGeneralInformationandDiagnosis:1A-143DTCTroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page1921A-144EngineGeneralInformationandDiagnosis:DTCP1510:ECMBack-UpPowerSupplyMalfunctionS4RS0A1104053WiringDiagramWHT/REDE23-239383231393832315453474654534746I4RS0A110051-1.ECM2.“RADIO”fuse3.Page193EngineGeneralInformationandDiagnosis:1A-145StepActionBatteryvoltagesupplycircuitcheckPoor“E23-2”“RADIO”fuseblown,connectionor“WHT”or“WHT/RED”1)TurnOFFignitionswitch.intermittenttrouble.wireisopenorshort2)RemoveECMfromitsbracketwithECMconnectorscircuit.1A-146EngineGeneralInformationandDiagnosis:StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:”.DTCcheckGotoapplicableDTCSubstituteaknown-diag.flow.goodECMandrecheck.Page195EngineGeneralInformationandDiagnosis:1A-147TroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page1961A-148EngineGeneralInformationandDiagnosis:StepActionDTCcheckinECMGotoStep9.Substituteaknown-goodcombinationmeter1)Disconnectconnectorfromcombinationmeterwithandrecheck.ignitionswitchturnedOFF.2)CheckECMforDTC.IsthereDTCP1674?CANcommunicationlinecircuitinsulationcheckGotoStep10.Page197EngineGeneralInformationandDiagnosis:1A-149StepAction13CANcommunicationlinecircuitgroundshortcheckGotoStep14.RepairshorttogroundofCANcommunication1)Measureresistanceatfollowingconnectorterminals.linecircuitreferringto•Between“E23-3”terminalofECMconnectorand“PrecautionforCANvehiclebodygroundCommunication...1A-150EngineGeneralInformationandDiagnosis:DTCP1675:CANCommunication(TransmissionError)S4RS0A1104081WiringDiagramE23-3E46-1E46-2E23-18G28-8G37-4G28-10G37-2C34-17C37-13C37-12C34-739383231393832315453474654534746161514131211109...Page199EngineGeneralInformationandDiagnosis:1A-151TroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.•...Page2001A-152EngineGeneralInformationandDiagnosis:StepActionCombinationmeteroperationcheckSubstituteaknown-Substituteaknown-goodECMandrecheck.goodBCM(includedin1)Checkcombinationmeteroperationforseatbeltwarningjunctionblocklamp(fasteningandunfasteningdriversideseatbelt)assembly),TCMandshiftpositionindicatorlamp(equippedwithA/T)with(equippedwithA/T)and...Page201EngineGeneralInformationandDiagnosis:1A-153StepAction13CheckforshortcircuitofCANcommunicationlinetoSubstituteaknown-RepairshorttopowerpowercircuitgoodECMandrecheck.supplyofCANcommunicationline1)MeasurevoltageatfollowingconnectorterminalswithcircuitreferringtoignitionswitchturnedON.Page2021A-154EngineGeneralInformationandDiagnosis:DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaReceptionerrorofcommunicationdataforTCMis•ECMdetectedforlongerthanspecifiedtimecontinuously•TCM(1drivingdetectionlogic)•...Page203EngineGeneralInformationandDiagnosis:1A-155StepActionCANcommunicationlinecircuitcontinuitycheckGotoStep9.RepairopenorhighresistanceofCAN1)DisconnectconnectorsfromECMandTCMwithignitioncommunicationlineswitchturnedOFF.circuitreferringto2)Measureresistanceatfollowingconnectorterminals.Page2041A-156EngineGeneralInformationandDiagnosis:DTCP1678:CANCommunication(ReceptionErrorforBCM)S4RS0A1104083WiringDiagramE23-3E46-1E46-2E23-18G28-8G37-4G28-10G37-2C34-17C37-13C37-12C34-739383231393832315453474654534746161514131211...Page205EngineGeneralInformationandDiagnosis:1A-157StepActionDTCcheckGotoapplicableDTCGotoStep3.diag.flow.1)ConnectscantooltoDLCwithignitionswitchturnedOFF.2)CheckECM,TCM(equippedwithA/T)andBCMforDTC.Page2061A-158EngineGeneralInformationandDiagnosis:StepAction10CheckforshortcircuitofCANcommunicationlinetoGotoStep11.RepairshorttopowerpowercircuitsupplyofCANcommunicationline1)MeasurevoltageatfollowingconnectorterminalswithcircuitreferringtoignitionswitchturnedON.Page207EngineGeneralInformationandDiagnosis:1A-159DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDTCP2227:•Manifoldabsolute

pressuresensorDifferenceofbarometricpressurevalueandintakemanifoldperformanceproblempressurevalueishigherthanspecifiedvaluewhileengineis•...Page2081A-160EngineGeneralInformationandDiagnosis:InspectionofECMandItsCircuitsS4RS0A1104055ECManditscircuitscanbecheckedbymeasuringvoltage,pulsesignalandresistancewithspecialtoolconnected.CAUTION:ECMcannotbecheckedbyitself.ItisstrictlyprohibitedtoconnectvoltmeterorohmmetertoECMwithECMconnectorsdisconnectedfromit.Page209EngineGeneralInformationandDiagnosis:1A-161TerminalWireCircuitNormalvoltageConditionRemarkscolor10–14VIgnitionswitchturnedON.—*0–0.6V10–14VOutputsignalisactivelowBLU/FuelinjectorNo.1(“ReferenceC37-1Enginerunningatidle...Page2101A-162EngineGeneralInformationandDiagnosis:TerminalWireCircuitNormalvoltageConditionRemarkscolor0–1VIgnitionswitchturnedON.*Deflectsbetweenover0.5VandunderOxygensignalof0.45VWhileenginerunningatC37-10heatedoxygen—...Page211EngineGeneralInformationandDiagnosis:1A-163TerminalWireCircuitNormalvoltageConditionRemarkscolor0–1Vor4–5VIgnitionswitchturnedON.—*0–0.6VSensorsignalispulse.PulsefrequencyvariesRED/4–...Page2121A-164EngineGeneralInformationandDiagnosis:TerminalWireCircuitNormalvoltageConditionRemarkscolorC37-43—————C37-44—————C37-45—————10–14VIgnitionswitchturnedON.—...Page213EngineGeneralInformationandDiagnosis:1A-165TerminalWireCircuitNormalvoltageConditionRemarkscolorYEL/OilcontrolvalveC37-59Below1.3VIgnitionswitchturnedON.—ground*0–0.6VOutputsignalisactive10–14VYEL/OilcontrolvalveAtthemomentofignition...Page2141A-166EngineGeneralInformationandDiagnosis:TerminalWireCircuitNormalvoltageConditionRemarkscolorE23-17—————CANcommunicationlineCAN(low)signalispulse.Pulsecommunicationline*0.5–2.5VIgnitionswitchturnedONsignaldisplayedwithaE23-18(activelowsignal)(“Reference...Page215EngineGeneralInformationandDiagnosis:1A-167TerminalWireCircuitNormalvoltageConditionRemarkscolorE23-43—————E23-44—————E23-45—————IgnitionswitchturnedON,enginecoolanttemp.:below95C(203F),or10–...Page2161A-168EngineGeneralInformationandDiagnosis:TerminalWireCircuitNormalvoltageConditionRemarkscolorEnginerunning,A/CswitchOFFandblower1.38–1.52VselectoratOFFposition,A/Crefrigerantpressure:800kPa(116psi)Enginerunning,A/CswitchONandblowerA/Crefrigerantselectorat1stpositionor2.15–...Page217EngineGeneralInformationandDiagnosis:1A-169ReferencewaveformNo.2ReferencewaveformNo.4No.1fuelinjectorsignal(2)withengineidlingEGRvalvesignalMeasurementCH1:“C37-20”to“C37-58”CH1:“C37-4”to“C37-58”terminalCH2:“C37-1”to“C37-58”MeasurementCH2:“C37-3”to“C37-58”OscilloscopeCH1:5V/DIV,CH2:20V/DIVterminal...Page2181A-170EngineGeneralInformationandDiagnosis:ReferencewaveformNo.6ReferencewaveformNo.8Ignitioncoilsignal(1)withengineidlingVSSsignalat30km/h(19mph)(forM/Tmodel)MeasurementMeasurementCH1:“C37-9”to“C37-58”CH1:“C37-6”to“C37-58”terminalterminalCH2:“E23-25”...Page219EngineGeneralInformationandDiagnosis:1A-171ReferencewaveformNo.12ReferencewaveformNo.10Heatedoxygensensor-1heatersignal(2)withengineCANcommunicationlinesignalfromTCM(forA/ToridlingAMTmodel)withignitionswitchturnedONMeasurementCH1:“C37-10”to“C37-57”MeasurementCH1:“C37-13”...Page2201A-172EngineGeneralInformationandDiagnosis:ReferencewaveformNo.14ReferencewaveformNo.16No.4fuelinjectorsignal(2)withengineidlingCMPsensorsignalwithengineidlingMeasurementCH1:“C37-20”to“C37-58”MeasurementCH1:“C37-20”to“C37-58”terminalCH2:“C37-17”to“C37-58”terminalCH2:“C37-21”...Page221EngineGeneralInformationandDiagnosis:1A-173ReferencewaveformNo.20ReferencewaveformNo.18EVAPcanisterpurgevalvesignalIACvalvesignalMeasurementMeasurementCH1:“C37-29”to“C37-58”CH1:“C37-49”to“C37-58”terminalterminalOscilloscopeCH1:10V/DIVOscilloscopeCH1:5V/DIVsettingTIME:40ms/DIVsetting...Page2221A-174EngineGeneralInformationandDiagnosis:ReferencewaveformNo.22ReferencewaveformNo.24Manifoldabsolutepressuresensorsignal(1)withengineKnocksensorsignalatenginespeed4000r/min.racingMeasurementCH1:“C37-56”to“C37-58”MeasurementCH1:“C37-53”to“C37-55”terminalterminalCH2:“C37-54”...Page223EngineGeneralInformationandDiagnosis:1A-175ReferencewaveformNo.28ReferencewaveformNo.26Oilcontrolvalvesignalwithengineracing(forM15Ignitionpulse(enginerevolution)signal(2)withengineenginemodel)idlingMeasurementMeasurementCH1:“C37-20”to“C37-58”CH1:“C37-60”to“C37-59”terminalterminalCH2:“E23-4”...Page2241A-176EngineGeneralInformationandDiagnosis:ReferencewaveformNo.30IgnitioncoilsignalandfuelinjectorsignalwithenginecrankingCH1:“C37-20”to“C37-58”MeasurementCH2:“C37-6”to“C37-58”terminalCH3:“C37-1”to“C37-58”CH4:“C37-48”to“C37-58”CH1:5V/DIV,CH2:5V/DIVOscilloscopeCH3:50V/DIV,CH4:10V/DIVsetting...Page225EngineGeneralInformationandDiagnosis:1A-177TerminalsCircuitStandardresistanceConditionC37-4toE23-1/16EGRvalve(steppingmotorNo.1coil)20–31—C37-29toE23-1/16EVAPcanisterpurgevalve28–35—C37-2toE23-1/16No.2fuelinjector10.8–...Page2261A-178EngineGeneralInformationandDiagnosis:TroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.StepActionCircuitfusecheck...Page227EngineGeneralInformationandDiagnosis:1A-179StepActionECMgroundcircuitcheckSubstituteaknown-“BLK/ORN”or“BLK”goodECMandrecheck.wireisopenorhigh1)TurnignitionswitchtoOFFposition.resistancecircuit.2)DisconnectconnectorsfromECM.3)Measureresistancebetweeneach“C37-58”,“C37-15”...Page2281A-180EngineGeneralInformationandDiagnosis:StepActionSensorpowersourcecircuitcheckECMpowerandgroundGotoStep12.circuitisingood1)ConnectconnectorstoECMwithignitionswitchturnedcondition.OFF.2)TurnONignitionswitch,measureeachvoltagebetween“C37-14”...Page229EngineGeneralInformationandDiagnosis:1A-181TroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.StepActionFuelinjectorcheckforoperatingsound...Page2301A-182EngineGeneralInformationandDiagnosis:FuelPumpandItsCircuitCheckS4RS0A1104057WiringDiagramBLK/WHTBLK/WHTE23-29BLK/WHTE23-15GRN/WHTBLK/YELC37-58BLK/ORNBLK/REDC37-15C37-30BLK/REDE23-1BLK/YELBLK/REDBLK/REDE23-16E23-60BRN/WHTBLK/YEL39383231393832315453...Page231EngineGeneralInformationandDiagnosis:1A-183StepActionFuelpumpcontrolsystemcheckforoperationFuelpumpcircuitisinGotoStep2.goodcondition.Isfuelpumpheardtooperate3sec.afterignitionswitchisturnedON?I2RH01110132-FuelpumprelaypowersupplycheckGotoStep3.Page2321A-184EngineGeneralInformationandDiagnosis:StepActionWirecircuitcheckGotoStep8.“PNK”wireisshortedtoground.1)TurnOFFignitionswitch.2)Detachfueltankreferringto“FuelTankRemovalandInstallation:inSection1G”.3)Disconnectconnectorfromfuelpump.Page233EngineGeneralInformationandDiagnosis:1A-185FuelPressureCheckS4RS0A1104058SystemDiagramSpecialtool(A):09912–58442(B):09912–58432(C):09912–58490I3RM0A110081-1.Injector2.Deliverypipe3.FuelfilterandfuelpumpTroubleshootingNOTE:Beforeusingthefollowingflow,checktomakesurethatbatteryvoltageishigherthan11V.Ifbatteryvoltageislow,pressurebecomeslowerthanspecificationeveniffuelpumpandlineareingoodcondition.Page2341A-186EngineGeneralInformationandDiagnosis:StepActionFuellinecheckFaultyfuelpressureRepairorreplaceregulator.damagedordeformed1)Checkfuelpipe,fuelhoseandjointfordamageorpart.deform.Aretheyingoodcondition?WasfuelpressurehigherthanspecificationinStep1?GotoStep6.Page235EngineGeneralInformationandDiagnosis:1A-187TroubleshootingNOTE:•Beforeperformedtroubleshooting,besuretoreadthe“PrecautionsofECMCircuitInspection:”.•Whenmeasuringcircuitvoltage,resistanceand/orpulsesignalatECMconnector,connectthespecialtooltoECMand/ortheECMconnectorsreferringto“InspectionofECMandItsCircuits:”.StepAction1)CheckengineidlespeedandIACdutyreferringto“Idle...Page2361A-188EngineGeneralInformationandDiagnosis:StepActionIdleaircontrolvalvecircuitcheckReplaceIACvalve.RepairIACvalvecircuit.1)CheckidleaircontrolvalvecircuitreferringtoStep4to10of“DTCP0505:IdleAirControlSystem:”.Iscircuitingoodcondition?A/CSystemCircuitsCheckS4RS0A1104060...Page237EngineGeneralInformationandDiagnosis:1A-1891.Blowerfanmotor8.Radiatorcoolingfanmotorrelay15.BCM22.“IGACC”fuseNo.12.Blowerfanswitch9.Radiatorcoolingfanmotorrelay16.Evaporatoroutletairtemp.23.“RDTRFAN”fuseNo.2sensor3.Page2381A-190EngineGeneralInformationandDiagnosis:StepActionA/Cevaporatoroutletairtemp.sensorcheckGotoStep7.FaultyA/Cevaporatoroutletairtemp.sensor1)DisconnectconnectorsfromECMwithignitionswitchoritscircuit.turnedOFF.2)Checkforproperconnectionto“E23-57”and“E23-54”wireterminalsofECMconnector.Page239EngineGeneralInformationandDiagnosis:1A-191StepActionA/CcompressorrelaycircuitcheckGotoStep12.GotoStep13.1)Measurevoltagebetween“E23-47”wireterminalofECMconnectorandvehiclebodygroundunderfollowingconditionsrespectively.Voltagebetween“E23-47”terminalofECMconnectorandgroundWhileenginerunningandA/CswitchturnedOFF:10–...Page240ElectricloadsignalcircuitcheckElectricloadsignal“BLU/WHT”wireisopencircuitisingoodcircuitorshortcircuit,or1)ConnectSUZUKIscantooltoDLCwithignitionswitchcondition.blowercircuitturnedOFF.malfunction.2)Startengineandselect“DATALIST”modeonscantool.Page241EngineGeneralInformationandDiagnosis:1A-193StepActionElectricloadsignalcircuitcheckElectricloadsignal“BLU/WHT”wireisopencircuitisingoodcircuitorshortcircuit,or1)TurnONignitionswitch.condition.electricloadcircuit2)Checkvoltageatterminal“E23-19”ofECMconnectormalfunction.Page2421A-194EngineGeneralInformationandDiagnosis:TroubleshootingWARNING:Keephands,tools,andclothingawayfromenginecoolingfantohelppreventpersonalinjury.Thisfaniselectricandcancomeonwhetherornottheengineisrunning.ThefancanstartautomaticallyinresponsetotheECTsensorwiththeignitionswitchatthe“ON”...Page243EngineGeneralInformationandDiagnosis:1A-195RadiatorcoolingfanHighSpeedControlSystemCheckS4RS0A1104084WiringDiagramBLK/YELBLK/YELBRN/WHTE23-60BLK/REDBLK/REDE23-1BLK/YELBLK/REDBLK/REDE23-16LTGRNE23-46BLU/REDBLU/REDC37-58BLK/ORNC37-15C37-30BLU/BLKL–H–E23-48BLUWHTLTGRN...Page2441A-196EngineGeneralInformationandDiagnosis:StepActionIsthereDTC(s)ofECTsensorcircuit(DTCP0116/P0117/GotocorrespondingGotoStep2.P0118)and/orradiatorcoolingfancircuit(DTCP0480)?DTCflow.LowspeedradiatorcoolingfancontrolcircuitcheckGotoStep3.Page245EngineGeneralInformationandDiagnosis:1A-197StepActionRadiatorcoolingfancontrolNo.2checkGotoStep10.GotoStep9.1)ConnectradiatorcoolingfancontrolrelayNo.2torelayboxwithignitionswitchturnedOFF.2)RunenginewhenECTisover102.5C,216.5F.Page246“Neutral”(shiftselectorleverto“P”rangeforA/Tvehicle),andsetparkingbrakeandblockdrivewheels.1)ConnectSUZUKIscantooltoDLC(1)withignitionswitchturnedOFF.Specialtool(A):SUZUKIscantool...Page24758413).58413).09912–5849009930–764203-wayjoint&hoseTiming-light(drycelltype)SUZUKIscantool—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.DLCcable,4.SAE16/19adapter,5.Cigarettecable,6.DLCloopbackadapter,7.Page248Aux.EmissionControlDevicesDiagnosticInformationandProceduresEGRSystemInspectionS4RS0A12040011)ConnectSUZUKIscantooltodatalinkconnector(DLC)withignitionswitchturnedOFF.2)TurnONignitionswitchanderaseDTCusing“CLEARDTC”in“TROUBLECODES”menu.Page249“MISCTEST”modeonSUZUKIscanpassageforclogwhenvalveisswitchedONandtool.OFFbyusingSUZUKIscantoolorservicewire.Ifcheckresultisnotsatisfactory,checkvacuumSpecialtoolhoses,EVAPcanisterpurgevalve,wireharnessand(A):SUZUKIscantoolconnections.Page2501B-3Aux.EmissionControlDevices:VacuumHoseInspectionWARNING:S4RS0A1206004Checkhosesforconnection,leakage,clogandDonotsucktheairthroughvalve.Fuelvapordeterioration.insidevalveisharmful.Replaceasnecessary.Specialtool(A):09917–47011I4RS0A120005-EVAPCanisterPurgeValveInspectionS4RS0A1206005WARNING:Donotapplyvacuumbymouth;...Page251Aux.EmissionControlDevices:1B-4EGRValveRemovalandInstallationPCVHoseInspectionS4RS0A1206007S4RS0A1206009RemovalNOTE:1)Disconnectnegativecableatbattery.BesuretocheckthatthereisnoobstructioninPCVvalveoritshosesbeforechecking2)Removeairintakepipe.Page2521B-5Aux.EmissionControlDevices:SpecialToolsandEquipmentSpecialToolS4RS0A120800109917–47011SUZUKIscantoolVacuumpumpgauge—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.DLCcable,4.SAE16/19adapter,5.Cigarettecable,6.Page253S4RS0A1306002UsingSUZUKIscantool1)RemoveIACvalvereferringto“IdleAirControl(IAC)1)ConnectSUZUKIscantooltoDLC(1)withignitionValveRemovalandInstallation:”.switchturnedOFF.2)ConnecteachconnectortoIACvalve(1)andTPsensor.Page2541C-2EngineElectricalDevices:IdleAirControl(IAC)ValveRemovaland3)DisconnectconnectorsfromECMasfollows.Installationa)Pushlock(1)toreleaselockingoflocklever(2).S4RS0A1306003b)Turnlocklevertoarrowdirectionuntilitstops.Removal1)Removethrottlebodyreferringto“ThrottleBodyRemovalandInstallation:inSection1D”.Page255EngineElectricalDevices:1C-35)InstallMAPsensorsecurely.6)ConnectMAPsensorconnectorsecurely.7)Installaircleanerassembly.ThrottlePosition(TP)SensorOn-VehicleInspectionS4RS0A13060061)Disconnectnegativecableatbattery.2)DisconnectTPsensorconnector.3)Usingohmmeter,checkresistancebetweenterminalsundereachcondition.Page2561C-4EngineElectricalDevices:ThrottlePosition(TP)SensorRemovalandEngineCoolantTemperature(ECT)SensorInstallationRemovalandInstallationS4RS0A1306007S4RS0A1306008RemovalRemoval1)Disconnectnegativecableatbattery.1)Disconnectnegativecableatbattery.2)Draincoolantreferringto“CoolingSystemDraining:2)DisconnectTPsensorconnectorandremoveTPinSection1F”.Page257EngineElectricalDevices:1C-5EngineCoolantTemperature(ECT)SensorViewedfromterminalsideInspectionS4RS0A1306009ImmersetemperaturesensingpartofECTsensor(1)inwater(orice)andmeasureresistancebetweensensorterminalswhileheatingwatergradually.Ifmeasuredresistancedoesn’tshowsuchcharacteristicasshown,replaceECTsensor.Page2581C-6EngineElectricalDevices:InstallationReverseremovalprocedurenotingthefollowing.•Tightenheatedoxygensensor(1)tospecifiedtorque.TighteningtorqueHeatedoxygensensor(a):45N·m(4.5kg-m,32.5lb-ft)•Installexhaustmanifoldreferringto“ExhaustManifoldRemovalandInstallation:inSection1K”,ifremoved.Page259EngineElectricalDevices:1C-7Installation1)Installcrankshaftpositionsensortocylinderblock.TightenCKPsensorbolttospecifiedtorque.TighteningtorqueCKPsensorbolt(a):10N·m(1.0kg-m,7.5lb-ft)I4RS0A130007-2)ConnectconnectortoCKPsensorsecurely.3)Adjustgeneratordrivebelttensionreferringto“WaterPump/GeneratorDriveBeltTensionInspectionandAdjustment:inSection1F”.Page2601C-8EngineElectricalDevices:PerformancecheckPerformancecheck1)RemovemetalparticlesonendfaceofCKPsensor,1)RemovemetalparticlesonendfaceofVSS,ifany.ifany.2)Arrange12Vbattery(1)andconnectitspositive2)Arrange12Vbattery(1)andconnectitspositiveterminalto“Vin”...Page261EngineElectricalDevices:1C-9MainRelay,FuelPumpRelay,StartingMotorControlRelayandThrottleActuatorControlRelayInspectionS4RS0A13060191)Disconnectnegativecableatbattery.2)Removemainrelay(1),fuelpumprelay(3)andstartingmotorcontrolrelay(2)fromrelaybox.3)CheckthatthereisnocontinuitybetweenterminalI3RB0A130009-“C”...Page2621C-10EngineElectricalDevices:MassAirFlow(MAF)andIntakeAirMassAirFlow(MAF)andIntakeAirTemperature(IAT)SensorRemovalandTemperature(IAT)SensorInspectionS4RS0A1306022InstallationS4RS0A1306021CAUTION:CAUTION:DonotheatupMAFandIATsensormorethan100C(212F).Page263Forthetighteningtorqueoffastenernotspecifiedinthissection,referto“FastenersInformation:inSection0A”.SpecialToolsandEquipmentSpecialToolS4RS0A1308001SUZUKIscantool—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.DLCcable,4.SAE16/19adapter,5.Page2641D-1EngineMechanical:EngineMechanicalGeneralDescriptionEngineConstructionDescriptionS4RS0A1401001Theengineiswater-cooled,inline4cylinders,4strokecyclegasolineunitwithitsDOHC(Doubleoverheadcamshaft)valvemechanismarrangedfor“V”typevalveconfigurationand16valves(4valves/onecylinder).Thedoubleoverheadcamshaftismountedoverthecylinderhead;...Page265EngineMechanical:1D-2Mostadvancedtiming60˚(variableangle)IntakevalveExhaustvalveMostretardedtimingCrankangleOverlapofvalvesI3RH0B140002-4.Oilpassagetochamberfortimingretarding8.Oilfilter10.Oilpan12.Oilflow5.Oilpassagetochamberfortimingadvancing9.Page2661D-3EngineMechanical:TimingHoldingCamTimingSprocketThecamtimingsprocketisequippedwiththechambersWhenthedutyratioofthesignaloutputfromtheECMfortimingadvancing(2)andretarding(3)whichareshowsthatofholding,thespoolvalveoftheoilcontrolseparatedbytherotor(5).Page267EngineMechanical:1D-4DrivingconditionValvetimingTargetofcontrolEffectLoworaverageToadvancetheclosingtimingoftheImprovementofgeneratingtheenginespeedrangeTotheadvancedintakevalveinordertoimprovetheenginetorqueatlowandwithheavyenginesidevolumetricefficiency.Page2681D-5EngineMechanical:NOTE:2)Stopengineandturnofftheallelectricswitches.3)Removeaircleanercase(1)andresonator(2).•Formeasuringcompressionpressure,crankengineatleast250r/min.byusingfullychargedbattery.•Ifmeasuredcompressionpressureislowerthanlimitvalue,checkinstallationconditionofspecialtool.Page269EngineMechanical:1D-6ValveLash(Clearance)InspectionS4RS0A14040031)Removenegativecableatbattery.2)Removecylinderheadcoverreferringto“CylinderHeadCoverRemovalandInstallation:”.3)Removerightsideengineundercover,ifnecessary.4)Using17mmwrench,turncrankshaftpulley(1)clockwiseuntilcamlobes(2)becomeperpendiculartoshimfaces(3)atvalves“1”...Page2701D-7EngineMechanical:WARNING:2)Liftdownthevalvebyturningcrankshaftto360.3)HoldtappetatthatpositionusingspecialtoolasNeverputinthehandbetweencamshaftandfollows.tappet.a)Removeitshousingbolts.b)CheckhousingNo.Page271EngineMechanical:1D-8Specialtool6)SelectnewshimNo.(1)withathicknessascloseaspossibletocalculatedvalue.(A):09916–67020(A):09916–67021AvailablenewshimsNo.ThicknessThicknessShimNo.ShimNo.mm(in.)mm(in.)2.175(0.0856)2.600(0.1024)2.200(0.0866)2.625(0.1033)Page2721D-9EngineMechanical:AirCleanerElementInspectionandCleaningS4RS0A1406002InspectionCheckaircleanerelementfordirt.Replaceexcessivedirtyelement.CleaningBlowoffdustbycompressedairfromairoutletsideofelement.I2RH0B140032-9)Removeoillevelgauge(1).10)DisconnectPCVhose(2)fromPCVvalve(3)anddisconnectbreatherhose(4)fromcylinderheadcover.Page273EngineMechanical:1D-103)Installcylinderheadcovertocylinderhead.NOTE:Wheninstallingcylinderheadcover,usecaresothatcylinderheadcovergasketorsparkplugholegasketswillnotgetoutofplaceorfalloff.4)Tighteningboltsinsuchorderasindicatedinthefigurealittleatatimetilltheyaretightenedtospecifiedtorque.Page2741D-11EngineMechanical:AcceleratorCableAdjustmentS4RS0A1406003Withacceleratorpedaldepressedfully(1),checkclearancebetweenthrottlelever(2)andleverstopper(3)ofthrottlebody.Ifmeasuredvalueisoutofspecification,adjustittospecificationwithcableadjustingnut(4),andthentightenacceleratorcablelockingnuttospecifiedtorque.Page275EngineMechanical:1D-12ThrottleBodyOn-VehicleInspectionNOTE:S4RS0A1406005WhiledisassemblingandassemblingthrottleCheckthatthrottlelever(1)movessmoothly.body,usespecialcarenottodeformleversonthrottlevalveshaftorcausedamagetoanyotherparts.Installation1)InstallIACvalvetothrottlebodyreferringto“IdleAirControl(IAC)ValveRemovalandInstallation:in...Page2761D-13EngineMechanical:ThrottleBodyCleaningS4RS0A1406008Cleanthrottlebodybore(1)andidleairpassage(2)byblowingcompressedair.NOTE:TPsensor,idleaircontrolvalveorothercomponentscontainingrubbermustnotbeplacedinasolventorcleanerboth.Achemicalreactionwillcausethesepartstoswell,hardenorgetdistorted.Page277EngineMechanical:1D-14ThrottleBodyandIntakeManifoldComponentsS4RS0A1406009I4RS0A140003-1.Intakemanifold7.EGRpipe13.EVAPcanisterpurgevalve19.ToPCVvalve2.IntakemanifoldO-ring8.O-ring14.EVAPcanisterpurgevalvehose20.Tocylinderheadcover3.Page2781D-15EngineMechanical:IntakeManifoldRemovalandInstallationInstallationS4RS0A1406010Reverseremovalprocedureforinstallationnotingthefollowings.Removal•UsenewintakemanifoldO-ring.1)Removethrottlebodyreferringto“ThrottleBody•UsenewEGRpipegasketandO-ring.RemovalandInstallation:”.Page279EngineMechanical:1D-16EngineMountingsComponentsS4RS0A1406012I4RS0A140006-[A]:A/Tmodel10.Enginerightmountingbolt21.Enginerearmountingbodybracketbolt[B]:M/Tmodel11.Engineleftmountingbushbolt22.EnginerearmountingNo.3bracketbolt1.Enginerightmountingbracket12.Page2801D-17EngineMechanical:EngineAssemblyRemovalandInstallation•Oilcontrolvalve(10)S4RS0A1406013•Engineoilpressureswitch(11)Removal•CKPsensor(12)1)Relievefuelpressureaccordingto“FuelPressure•Knocksensor(13)ReliefProcedure:inSection1G”.•...Page281EngineMechanical:1D-1820)Disconnectrightandleftdriveshaftjointsfromdifferentialgearreferringto“FrontDriveShaftAssemblyRemovalandInstallation:inSection3A”.NOTE:Forengineandtransaxleremoval,itisnotnecessarytoremovedriveshaftsfromsteeringknuckle.Page2821D-19EngineMechanical:28)Lowerenginewithtransaxlefromenginecompartment.CAUTION:Beforeloweringengine,toavoiddamagetoA/Ccompressorandclutchoperatingcylinder,makeclearancebyrisingthem.BesurenottodamagesuspendedA/C1,(a)compressorandclutchoperatingcylinder.2,(b)I4RS0A140010-5)Supportengineassemblebyusingsupporting...Page283EngineMechanical:1D-2015)AdjustA/Ccompressorbelttension(ifequipped)19)Refillenginewithengineoilreferringto“EngineOilreferringto“CompressorDriveBeltInspectionandandFilterChange:inSection0B”.Adjustment:inSection7B”.20)Refilltransaxlewithtransaxleoilreferringto“Manual16)AdjustacceleratorcableplayreferringtoTransaxleOilChange:inSection5B”...Page2841D-21EngineMechanical:TimingChainCoverRemovalandInstallation7)Removewaterpumppulley.S4RS0A14060158)RemoveA/Cbracketfromcylinderblock.CAUTION:9)RemoveoilgallerypipesNo.2(1)andNo.3(2).•Keepworkingtable,toolsandhandscleanwhileoverhauling.Page285EngineMechanical:1D-22NOTE:Beforeinstallingtimingchaincover,checkthatpinissecurelyfitted.TighteningtorqueTimingchaincoverbolt(a):25N·m(2.5kg-m,18.0lb-ft)Timingchaincovernut(b):25N·m(2.5kg-m,18.0lb-ft)6)ApplyengineoiltonewO-rings(2)andinstallthemtocap(3).Page2861D-23EngineMechanical:OilControlValveRemovalandInstallation13)Installcrankshaftpulley(1).Tightenbolt(2)tospecifiedtorque.Tolockcrankshaftpulley,useS4RS0A1406043specialtoolwithitasshowninthefigure.RemovalSpecialtoolRemoveoilgallerypipeNo.1(1)andoilcontrolvalve(2)(A):09917–68221fromtimingchaincover(3).Page287EngineMechanical:1D-24OilControlValveInspectionS4RS0A1406044OilControlValve1)Inspectstrainer(1)andmatingsurface(2)ofoilcontrolvalveforclogordamage.Cleanoilcontrolvalveifclogorforeignmatterispresentonstrainerormatingsurfaceofoilcontrolvalve.Page2881D-25EngineMechanical:TimingChainandChainTensionerRemovalInstallationandInstallationCAUTION:S4RS0A1406018Aftertimingchainisremoved,neverturnRemovalcrankshaftandcamshaftsindependentlymorethansuchanextent(“a”,“b”)asshownCAUTION:inthefigure.Aftertimingchainisremoved,neverturnIfturned,interferencemayoccurbetweencrankshaftandcamshaftsindependentlypistonandvalvesandvalvesthemselves,...Page289EngineMechanical:1D-266)Applyengineoiltoslidingsurfaceofchaintensioner3)Installtimingchainbyaligningdarkblueplate(1)oftimingchainandtrianglemark(2)oncamshaft(1)andinstallchaintensionerandspacer.timingsprocketasshowninthefigure.Tightentensionerbolttospecifiedtorque.Page2901D-27EngineMechanical:8)Screwinplunger(1)byturningbody(2)inarrowdirectionandinstallaretainer(3)(wire)toholdplungerinplace.I2RH0B140065-9)Installtimingchaintensioneradjusterassembly(1)witharetainer(2).Tightenadjusterboltstospecifiedtorqueandthenremovearetainerfromchaintensioneradjusterassembly.EngineMechanical:1D-28CrankshaftTimingSprocketTimingChainCheckteethofsprocketforwearordamage.Checktimingchainforwearordamage.I2RH01140077-TimingChainTensionerAdjusterCheckthattoothsurface(1)arefreefromdamage.I2RH0B140070-I2RH0B140071-Camshaft,TappetandShimComponentsS4RS0A1406020I4RS0A140013-1.Page2921D-29EngineMechanical:Camshaft,TappetandShimRemovaland5)Removecamshafthousings.Installation6)Removeintakeandexhaustcamshafts.S4RS0A14060217)Removecamshaftbearing(1).CAUTION:•Keepworkingtable,toolsandhandscleanwhileoverhauling.•Usespecialcaretohandlealuminumpartssoasnottodamagethem.Page293EngineMechanical:1D-30I2RH0B140078-I3RH0B140039-A:I:IntakesideorE:Exhaustside3)Installintakecamshaft(1)andexhaustcamshaft(2).B:PositionfromtimingchainsideAlignknockpin(3)andmatchmark(4)withnotchesC:Pointingtotimingchainside(5)asshowninthefigure.Page2941D-31EngineMechanical:12)PerformSteps3)to8)of“Installation”of“TimingCamshaftRunoutChainCoverRemovalandInstallation:”.Setcamshaftbetweentwo“V”blocks,andmeasureitsrunoutbyusingadialgauge.Ifmeasuredrunoutexceedslimit,replacecamshaft.Camshaft,TappetandShimInspectionS4RS0A1406022Camshaftrunoutlimit...Page295EngineMechanical:1D-326)TightencamshafthousingboltsinsuchorderasCamshaftjournaldiameter[A]indicatedinthefigurealittleatatimetilltheyareItemStandardtightenedtospecifiedtorque.IntakesideNo.126.940–26.955mmhousing(1.0606–...Page2961D-33EngineMechanical:Measurecylinderheadboreandtappetoutsidediametertodeterminecylinderhead-to-tappetclearance.Ifclearanceexceedslimit,replacetappetorcylinderhead.CylinderheadtotappetclearanceStandard:0.025–0.066mm(0.0010–0.026in.)Limit:0.15mm(0.0059in.)Tappetoutsidediameter[A]Standard:30.959–...Page297EngineMechanical:1D-34ValvesandCylinderHeadComponentsS4RS0A1406023I4RS0A140015-1.Valvecotters7.Exhaustvalve13.Cylinderheadbolt(M8):Besuretotightencylinderheadbolt(M8)aftersecuringtheothercylinderheadbolt(M10).2.Valvespringretainer8.Page2981D-35EngineMechanical:ValvesandCylinderHeadRemovalandInstallationInstallation1)CleanmatingsurfaceofcylinderheadandcylinderS4RS0A1406024block.Removeoil,oldgasketanddustfrommatingsurface.Removal2)Installknockpins(1)tocylinderblock.1)Removeengineassemblyfromvehiclereferringto3)Installnewcylinderheadgasket(2)tocylinderblock.Page299EngineMechanical:1D-36NOTE:BesuretotightenM8bolt“A”aftersecuring“A”“B”theotherbolts.TighteningtorqueCylinderheadboltforM8(a):25N·m(2.5kg-“a”m,18.0lb-ft)“b”CylinderheadboltforM10(b):20Nm(2.0kg-m,14.5lb-ft),40Nm(4.0kg-m,29.0lb-ft)andthenretightenbyturningthroughto60twice...Page3001D-37EngineMechanical:ValvesandCylinderHeadDisassemblyandNOTE:AssemblyDonotreusevalvestemsealonceS4RS0A1406025disassembled.Besuretousenewsealwhenassembling.Disassembly1)Foreaseinservicingcylinderhead,removeintakemanifold,injectors,exhaustmanifoldfromcylinderhead.Page301EngineMechanical:1D-38I2RH0B140096-I2RH0B140096-2)Installvalveguidetocylinderhead.4)Installvalvespringseattocylinderhead.Heatcylinderheaduniformlyatatemperatureof805)Installnewvalvestemseal(1)tovalveguide.to100C(176to212F)sothatheadwillnotbeAfterapplyingengineoiltosealandspindleofdistorted,anddrivenewvalveguideintoholewithspecialtool(Valveguideinstallerhandle),fitoilseal...Page3021D-39EngineMechanical:8)Usingspecialtools(Valvelifter),compressvalvespringandfittwovalvecotters(1)intogrooveinvalvestem.NOTE:Whencompressingthevalvespring,becarefullytofreefromdamageininsidefaceoftappetinstallinghole.Specialtool(A):09916–14510(B):09916–14521...Page303EngineMechanical:1D-40I3RM0A140035-ValvestemenddeflectionIfboregaugeisnotavailable,checkenddeflectionofvalvestemwithadialgaugeinstead.Movestemendindirections(1)and(2)tomeasureenddeflection.Ifdeflectionexceedsitslimit,replacevalvestemandvalveguide.Page3041D-41EngineMechanical:ValveheadradialrunoutValveseatrepairCheckeachvalveforradialrunoutwithadialgaugeandAvalveseatnotproducingauniformcontactwithits“V”block.Tocheckrunout,rotatevalveslowly.Ifrunoutvalveorshowingwidthofseatingcontactthatisoutofexceedsitslimit,replacevalve.Page305EngineMechanical:1D-42CylinderHeadInspectionS4RS0A1406027•Removeallcarbondepositsfromcombustionchambers.NOTE:Donotuseanysharp-edgedtooltoscrapeoffcarbondeposits.Becarefulnottoscuffornickmetalsurfaceswhendecarbonizing.Thesameappliestovalvesandvalveseats,too.I2RH0B140106-•...Page3061D-43EngineMechanical:ValvespringpreloadSpringSquarenessStandard:107–125N(10.7–12.5kg)for31.50mmUseasquareandsurfaceplatetocheckeachspringfor(23.6–27.6lb/1.240in.)squarenessintermsofclearancebetweenendofvalveLimit:102N(10.2kg)for31.50mm(22.5lb/1.240in.)springandsquare.Page307EngineMechanical:1D-44Pistons,PistonRings,ConnectingRodsand3)Wheninstallingpistonandconnectingrodassemblyintocylinderbore,pointfrontmark(1)onpistonheadCylindersRemovalandInstallationtocrankshaftpulleyside.S4RS0A1406030Removal1)Removeengineassemblyfromvehiclereferringto“EngineAssemblyRemovalandInstallation:”.Page3081D-45EngineMechanical:NOTE:b)Forcepistonpinout.Beforeinstallingbearingcap,makesurethatcheckingforconnectingrodboltdeformation.Referto“PistonPinsandConnectingRodsInspection:”.TighteningtorqueConnectingrodbearingcapnut(a):15Nm(1.5kg-m,11.0lb-ft)andthenretightenbyturningthrough45twiceI2RH0B140114-...Page309EngineMechanical:1D-46NOTE:Ifanyoneoffourcylindershastoberebored,reboreallfourtothesamenextoversize.Thisisnecessaryforthesakeofuniformityandbalance.I2RH0B140116-4)Afterinstallingthreerings(1st,2ndandoilrings),distributetheirendgapsasshowninthefigure.Page3101D-47EngineMechanical:PistonclearanceMeasurecylinderborediameterandpistondiametertofindtheirdifferencewhichispistonclearance.Pistonclearanceshouldbewithinspecificationasfollows.Ifitisoutofspecification,reborecylinderanduseoversizepiston.NOTE:Cylinderborediametersusedherearemeasuredinthrustdirectionattwopositions.Page311EngineMechanical:1D-48PistonPinsandConnectingRodsInspectionConnectingRodS4RS0A1406033Big-endsideclearancePistonPinCheckbig-endofconnectingrodforsideclearance,withrodfittedandconnectedtoitscrankpininthenormalVisualinspectionmanner.IfmeasuredclearanceisfoundtoexceeditsCheckpistonpin,connectingrodsmallendboreandlimit,replaceconnectingrod.Page3121D-49EngineMechanical:CrankPinandConnectingRodBearingsConnectingrodboltdeformation(Plasticdeformationtighteningbolt)InspectionMeasureeachthreaddiameterofconnectingrodbolt(2)S4RS0A1406034at“A”on32mm(1.25in.)fromboltmountingsurfaceCrankPinDiameterand“B”...Page313EngineMechanical:1D-50ConnectingRodBearingGeneralInformation4)Installrodbearingcap(1)toconnectingrod.ServiceconnectingrodbearingsareavailableinWheninstallingcap,besuretopointarrowmark(2)standardsizeand0.25mm(0.0098in.)undersizeoncaptocrankshaftpulleyside,asshowninthebearing,andstandardsizebearinghas5kindsoffigure.Page3141D-51EngineMechanical:SelectionofConnectingRodBearings2)Next,checkcrankshaftpindiameter.OncrankwebNo.3,fouralphabetsarestampedasshownintheNOTE:figure.Threekindsofalphabet(“A”,“B”and“C”)represent•Ifbearingisinmalcondition,orbearingthefollowingcrankshaftpindiameterrespectively.Page315EngineMechanical:1D-52I3RH0A140019-1.Paint4)FromnumberstampedonconnectingrodanditscapandalphabetsstampedoncrankwebNo.3,determinenewstandardbearingtobeinstalledtoconnectingrodbigendinside,byreferringtothetable.Page3161D-53EngineMechanical:MainBearings,CrankshaftandCylinderBlockComponentsS4RS0A1406035I4RS0A140016-...Page317EngineMechanical:1D-541.CKPsensor(ifequipped)11.Rearoilseal21.Oilfilteradapterbolt:See“A”2.Knocksensor12.Inputshaftbearing22.Springpin3.Cylinderblock13.Flywheel23.Sensorplatebolt4.Venturiplug14.Page3181D-55EngineMechanical:6)Installbearingcaptocylinderblock,makingsureto1)Installsensorplate(1)tocrankshaft(2)andtightenboltstospecifiedtorque.pointarrowmark(oneachcap)tocrankshaftpulleyside.Fitthemsequentiallyinascendingorder,1,2,NOTE:3,4and5,startingfrompulleyside.Page319EngineMechanical:1D-5610)Installflywheel(forM/T).Usingspecialtool,lockflywheel,andtightenflywheelboltstospecifiedtorque.NOTE:Usenewflywheelbolts.Specialtool(A):09924–17810TighteningtorqueFlywheelbolt(a):70N·m(7.0kg-m,51.0lb-ft)I4RS0A140017-8)Applysealanttomatingsurfaceofrearoilsealhousing(1).Page3201D-57EngineMechanical:CrankshaftThrustPlay3)Useadialgaugetoreaddisplacementinaxial(thrust)directionofcrankshaft.1)MeasurethisplaywithcrankshaftsetincylinderIfitslimitisexceeded,replacethrustbearingwithblockinthenormalmanner,thatiswiththrustnewstandardoneoroversizeonetoobtainstandardbearing(1)andjournalbearingcapsinstalled.Page321EngineMechanical:1D-58MainBearingsInspection4)TightenmainbearingcapNo.1bolts(1)–(10)andS4RS0A1406038mainbearingcapNo.2bolts(11)–(20)graduallyasfollows.GeneralInformationa)Tightenbolts(1)–(10)to30Nm(3.0kg-m,22.0•...Page3221D-59EngineMechanical:SelectionofMainBearings2)Next,checkbearingcapborediameterwithoutbearing.Onmatingsurfaceofcylinderblock,fiveStandardbearingalphabetsarestampedasshowninthefigure.Ifbearingisinmalcondition,orbearingclearanceisoutThreekindsofalphabets(“A”,“B”...Page323EngineMechanical:1D-60I2RH01140191-1.Paint4)FromnumberstampedoncrankwebNo.2andalphabetsstampedoncylinderblock,determinenewstandardbearingtobeinstalledtojournal,byreferringtothetableshown.Forexample,ifnumberstampedoncrankwebNo.2is“1”andalphabetstampedoncylinderblockis“B”,installanewstandardbearingpaintedin“Brown”...Page3241D-61EngineMechanical:6)Whenreplacingcrankshaftorcylinderblockduetoanyreason,selectnewstandardbearingstobeinstalledbyreferringtonumberstampedonnewcrankshaftoralphabetsstampedonnewcylinderblock.Undersizebearing(0.25mm(0.0098in.))•...Page325EngineMechanical:1D-62NewundersizecrankshaftmainbearingspecificationMeasuredjournaldiameter51.7320–51.7379mm51.7380–51.7439mm51.7440–51.7500mm(2.0367–2.0369in.)(2.0370–2.0371in.)(2.0372–2.0373in.)A(1)RedandGreenRedandBrownRedandPurpleAlphabetsstamped...Page3261D-63EngineMechanical:SensorPlateInspectionCylinderBlockInspectionS4RS0A1406039S4RS0A1406042Checksensorplateforcrackdamage.Ifmalconditionisfound,replaceit.DistortionofGasketedSurfaceUsingstraightedgeandthicknessgauge,checkgasketedsurfacefordistortionand,ifflatnessexceedsitslimit,correctIt.Page327EngineMechanical:1D-64SpecificationsTighteningTorqueSpecificationsS4RS0A1407001TighteningtorqueFasteningpartNotekg-mlb-ftCamshafthousingbolts(fortighteningofspecialtool)CamshafthousingboltCylinderheadcoverboltAcceleratorcablelockingnutEVAPcanisterpurgevalvebracketboltEngineleftmountingbracketnut40.0Enginerightmountingnut...Page3281D-65EngineMechanical:SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A1408001MaterialSUZUKIrecommendedproductorSpecificationNoteSealantSUZUKIBondNo.1207BP/No.:99000–31140SUZUKIBondNo.1217GP/No.:99000–31260WatertightsealantSUZUKIBondNo.1207FP/No.:99000–31250NOTE:Requiredservicematerialisalsodescribedinthefollowing.Page329EngineMechanical:1D-6609916–3455009916–37320ReamerhandleValveguideouterreamer(10.5mm)09916–4491009916–56011Valveguideinstaller&Valveguideinstallerremoverattachment(protrusion:11.509916–5821009916–67020ValveguideinstallerhandleTappetholder(Overseas)09916–6702109916–77310TappetholderPistonringcompressor(50-125mm)09916–8451109917–68221...Page3301E-1EngineLubricationSystem:EngineLubricationSystemGeneralDescriptionEngineLubricationDescriptionS4RS0A1501001Theoilpumpisofatrochoidtype,andmountedonthecrankshaft.Oilisdrawnupthroughtheoilpumpstrainerandpassedthroughthepumptotheoilfilter.Thefilteredoilflowsintotwopathsincylinderblock.Page331EngineLubricationSystem:1E-2I3RH0B150001-...Page3321E-3EngineLubricationSystem:DiagnosticInformationandProceduresOilPressureCheck3)Disconnectoilpressureswitchcoupler(1).S4RS0A15040014)Removeoilpressureswitch(2)fromcylinderblock.NOTE:Priortocheckingoilpressure,checkthefollowing.•OillevelinoilpanIfoillevelislow,addoiluptoFulllevelmark(hole)(1)onoillevelgaugereferringto“EngineOilandFilterChange:in...Page333EngineLubricationSystem:1E-410)Startengineandcheckoilpressureswitchforoil9)Beforereinstallingoilpressureswitch(2),besuretowrapitsscrewthreadswithsealingtape(1)andleakage.Ifoilleakageisfound,repairit.tightenswitchtospecifiedtorque.Page3341E-5EngineLubricationSystem:OilPanandOilPumpStrainerRemovalandInstallationInstallation1)InstallnewO-rings(2)inthepositionasshownintheS4RS0A1506002figureandinstalloilpumpstrainer(1).Tightenstrainerbolt(3)firstandthenbracketbolt(4)Removaltospecifiedtorque.Page335EngineLubricationSystem:1E-64)Installoilpantocylinderblocktemporarily.9)Installexhaustmanifoldstiffener(2)andexhaustNo.1pipe(1)andheatedoxygensensorNo.15)Insertknockpin(1)inhole(2)ofoilpaninorderto(connectorcolor:green)(3)referringto“Exhaustlocateoilpanprecisely.Page3361E-7EngineLubricationSystem:OilPumpComponentsS4RS0A1506004I4RS0A150010-1.Rotorplate6.Rotorplatebolt10.Circlip2.O-ring7.Reliefvalve:11Nm(1.1kg-mm8.0lb-ft)3.Outerrotor8.Spring:Donotreuse.4.Page337EngineLubricationSystem:1E-8OilPumpInspectionReassemblyS4RS0A15060071)Wash,cleanandthendryalldisassembledparts.2)Applythincoatofengineoiltoinnerandouterrotors,OilSealoilseallipportion,insidesurfacesofoilpumpcaseCheckoilseallipforfaultorotherdamage.Page3381E-9EngineLubricationSystem:RadialclearanceReliefvalvespringfreelengthandloadCheckradialclearancebetweenouterrotor(1)andcaseCheckreliefvalvespringfreelengthandloadasshown(2)usingthicknessgauge(3).inthefigure.IfthemeasuredvalvespringlengthislowerIfclearanceexceedsitslimit,replaceouterrotororcase.Page339Forthetighteningtorqueoffastenernotspecifiedinthissection,referto“FastenersInformation:inSection0A”.SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A1508001MaterialSUZUKIrecommendedproductorSpecificationNoteSealantSUZUKIBondNo.1217GP/No.:99000–31260NOTE:Requiredservicematerialisalsodescribedinthefollowing.1F-1EngineCoolingSystem:EngineCoolingSystemGeneralDescriptionCoolingSystemDescriptionThis50/50mixturecoolantsolutionprovidesfreezingS4RS0A1601001protectionto–36C(–33F).Thecoolingsystemconsistsoftheradiatorcap,radiator,•Maintaincoolingsystemfreezeprotectionat–36C(–coolantreservoir,hoses,waterpump,coolingfanand33F)toensureprotectionagainstcorrosionandlossthermostat.Page341EngineCoolingSystem:1F-2SchematicandRoutingDiagramCoolantCirculationS4RS0A1602001Whiletheengineiswarmedup(thermostatclosed),coolantcirculatesasfollows.I3RM0A160001-1.Radiatorinlethose5.Thermostat9.Heatercoreinlethose2.Radiatoroutlethose6.Waterpump10.Page3421F-3EngineCoolingSystem:DiagnosticInformationandProceduresEngineCoolingSymptomDiagnosisS4RS0A1604001ConditionPossiblecauseCorrection/ReferenceItemEngineoverheatsLooseorbrokenwaterpumpbeltAdjustorreplace.(Radiatorfanoperates)NotenoughcoolantCheckcoolantlevelandaddasnecessary.FaultythermostatReplace.Page343EngineCoolingSystem:1F-4RepairInstructionsCoolingSystemComponentsS4RS0A1606001I4RS0A160001-1.Radiator13.Thermostatcase25.HeateroutletNo.1hose2.Reservoir14.Thermostat26.Enginecoolingfanassembly3.Radiatorcap15.Thermostatcap27.WaterbypassNo.2hose4.Page3441F-5EngineCoolingSystem:CoolantLevelCheck3)Checkcoolantforproperlevelandfreezeprotection.S4RS0A16060024)Usingapressuretester(1),checksystemandWARNING:radiatorcap(2)forproperpressureholdingcapacity.Tohelpavoiddangerofbeingburned,donotIfreplacementofcapisrequired,useapropercapremoveradiatorcapwhileengineandforthisvehicle.Page345EngineCoolingSystem:1F-6CoolingSystemFlushandRefill13)Tightenairventilationbolt(4)tospecifiedtorque.S4RS0A1606004TighteningtorqueWARNING:Airventilationbolt(a):4.5N·m(0.45kg-m,3.5Tohelpavoiddangerofbeingburned,donotlb-ft)removeradiatorcapwhileengineand14)Fillradiatorwithcoolantuptobottomofradiatorfiller...Page3461F-7EngineCoolingSystem:CoolingWaterPipesorHosesRemovaland6)Removewaterinletpipewiththermostatcapfromthermostatcase.InstallationS4RS0A16060057)Removethermostatfromthermostatcase(3).Removal1)Draincoolantreferringto“CoolingSystemDraining:”.Page347EngineCoolingSystem:1F-8ThermostatInspectionRadiatorCoolingFanMotorOn-VehicleS4RS0A1606007Inspection•Makesurethatairbleedvalve(1)ofthermostatisS4RS0A1606010clean.1)ChecklowspeedoperationofradiatorcoolingfanasShouldthisvalvebeclogged,enginewouldtendtofollows.Page3481F-9EngineCoolingSystem:RadiatorCoolingFanRelayInspection3)Draincoolant.S4RS0A16060204)Removefrontbumper,frontbumperupperabsorber1)Disconnectnegative(–)cableatbattery.anduppermemberreferringto“FrontBumperand2)RemoveradiatorcoolingfanrelayNo.1(1),No.2(2)RearBumperComponents:inSection9K”.Page349EngineCoolingSystem:1F-10RadiatorRemovalandInstallationNOTE:S4RS0A1606014Whenreplacingbeltwithanewone,adjustbelttensionto3–4mm(0.12–0.16in.).Removal1)Disconnectnegativecableatbattery.2)DrainA/Tfluid.3)Draincoolant.Page3501F-11EngineCoolingSystem:WaterPump/GeneratorDriveBeltRemovalandWaterPumpRemovalandInstallationS4RS0A1606017InstallationRemovalS4RS0A1606016Removal1)Disconnectnegativecableatbattery.1)Disconnectnegativecableatbattery.2)Draincoolant.2)IfvehicleequippedwithA/C,removecompressor3)Removewaterpump/generatordrivebeltreferringdrivebelt(4)beforeremovingwaterpumpbelt(1).Page351Forthetighteningtorqueoffastenernotspecifiedinthissection,referto“FastenersInformation:inSection0A”.SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A1608001MaterialSUZUKIrecommendedproductorSpecificationNoteWatertightsealantSUZUKIBondNo.1207FP/No.:99000–31250...1G-1FuelSystem:FuelSystemPrecautionsPrecautionsonFuelSystemServiceS4RS0A1700001WARNING:Beforeattemptingserviceofanytypeonfuelsystem,thefollowingshouldbealwaysobservedinordertoreducetheriskorfireandpersonalinjury.•Disconnectnegativecableatbattery.•...Page353FuelSystem:1G-2FuelPumpDescriptionS4RS0A1701003Thefuelpump(1)isanin-tanktypeelectricpump.Incorporatedinthepumpassemblyare;afuelfilter(2)andafuelpressureregulator(3)areincludedandafuellevelgauge(4)isattached.AdditionofthefuelpressureregulatortothefuelpumpmakesitpossibletomaintainthefuelpressureatconstantlevelandECMcontrolscompensationfor...Page3541G-3FuelSystem:WARNING:3)Connectspecialtoolsandhosebetweenfuelfeedhose(1)andfueldeliverypipeasshownintheAsfuelfeedlineisstillunderhighfuelfigure,andclamphosessecurelyinordertoensurepressure,makesuretoreleasefuelpressurethatnoleaksoccurduringchecking.FuelSystem:1G-4RepairInstructionsFuelSystemComponentsS4RS0A1706001I4RS0A170003-1.Fueltank10.Fueltankbelt19.Fueldeliverypipeinsulator2.Fuelpumpassembly11.Fuelpumpgasket20.Wireharnessforfuelpump3.Breatherhose12.Fueltankbolt21.Page3561G-5FuelSystem:7.Fuelvaporline16.Fueldeliverypipebolt:11Nm(1.1kg-m,8.0lb-ft)8.Fueltankinletvalve17.Fuelinjector:25Nm(2.5kg-m,18.0lb-ft)9.Fueltankprotector18.Page357FuelSystem:1G-61.Pipe5.Vehicleleftward“d”30mm(1.18in.)2.Hose“a”3–7mm(0.12–0.28in.)“e”38mm(1.50in.)3.Clamp“b”5–12mm(0.20–0.48in.):2Nm(0.2kg-m,1.5lb-ft)4.Page3581G-7FuelSystem:FuelPressureReliefProcedureFuelLinesOn-VehicleInspectionS4RS0A1706002S4RS0A1706004CAUTION:CAUTION:ThisworkmustnotbedonewhenengineisDuetothefactthatfuelfeedline(1)isunderhot.Ifdoneso,itmaycauseadverseeffecttohighpressure,usespecialcarewhencatalyst.Page359FuelSystem:1G-8InstallationFuelInjectorRemovalandInstallationS4RS0A17060071)Installclampstomarkedlocationonpipes.Ifclampisdeformed,itsclawisbentorbroken,replaceitwithWARNING:newone.Beforestartingthefollowingprocedure,be2)Installpipeswithpipeclampstovehicle.Page3601G-9FuelSystem:FuelInjectorInspectionInstallationReverseremovalprocedureforinstallationnotingtheS4RS0A1706008following.WARNING:•ReplaceinjectorO-ring(1)withnewoneusingcareBeforestartingthefollowingprocedure,benottodamageit.suretoobserve“PrecautionsonFuelSystem•...Page3618)Checkfuelleakagefrominjectornozzle.Donotoperateinjectorforthischeck(butfuelpumpshouldSpecialtoolbeatwork).Iffuelleaks(1)morethanthefollowing(A):SUZUKIscantoolspecifications,replace.FuelleakageLessthan1drop/min.Page3621G-11FuelSystem:FuelTankInletValveRemovalandInstallation4)Removefueltankinletvalve(1)usingflatheadrodS4RS0A1706015(2)orthelike.WARNING:CAUTION:Beforestartingthefollowingprocedure,besuretoobserve“PrecautionsonFuelSystemBecarefulnottodamagefueltankinletvalveService:”...Page363FuelSystem:1G-12FuelTankInletValveInspection7)Disconnectfuelpipejointandfuelhoses(1)fromS4RS0A1706016fuelpipes(2)referringto“FuelHoseDisconnectingandReconnecting:”.WARNING:Beforestartingthefollowingprocedure,besuretoobserve“PrecautionsonFuelSystemService:”...Page3641G-13FuelSystem:Installation6)Installexhaustcenterpipereferringto“ExhaustPipeandMufflerRemovalandInstallation:inSectionCAUTION:1K”.•Whenconnectingjoint,cleanoutsidesurfacesofpipewherejointistobeinserted,pushjointintopipetilljointlockclicksandchecktoensurethatpipesareconnectedsecurely,orfuelleakmayoccur.Page365FuelSystem:1G-14FuelPumpOn-VehicleInspectionFuelPumpAssemblyRemovalandInstallationS4RS0A1706017S4RS0A1706019WARNING:WARNING:Beforestartingthefollowingprocedure,beBeforestartingthefollowingprocedure,besuretoobserve“PrecautionsonFuelSystemsuretoobserve“PrecautionsonFuelSystemService:”...Page3661G-15FuelSystem:FuelLevelSensorRemovalandInstallationS4RS0A1706022CAUTION:•Donottouchresisterplate(1)anddeformarm(2).Itmaycausefuellevelsensortofail.•Beverycarefulnottocausedamagetofueltubeinstalledsection(sealedsectioninbore).Page367FuelSystem:1G-16FuelPumpInspectionS4RS0A1706021•Checkfuelpumpassemblyfordamage.•Checkfuelsuctionfilter(1)forevidenceofdirtandcontamination.Ifpresent,replaceorcleanandcheckforpresenceofdirtinfueltank.•...Page36858413).58413).09912–5849009919–470203-wayjoint&hoseQuickjointremover09930–88530SUZUKIscantoolInjectortestlead—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.DLCcable,4.SAE16/19adapter,5.Cigarettecable,6.DLCloopbackadapter,7.1H-1IgnitionSystem:IgnitionSystemGeneralDescriptionIgnitionSystemConstructionS4RS0A1801001Theignitionsystemisanelectronic(distributorless)ignitionsystem.Itconsistsofthepartsasdescribedbelow.•ECMItdetectstheengineandvehicleconditionsthroughthesignalsfromthesensors,determinesthemostsuitableignitiontimingandtimeforelectricitytoflowtotheprimarycoilandsendsasignaltotheignitor(powerunit)intheignitioncoilassembly.Page370IgnitionSystem:1H-2SchematicandRoutingDiagramIgnitionSystemWiringCircuitDiagramS4RS0A1802001BLK/WHTGRN/WHTC37-5C37-6GRN/YELBLK/WHTE23-29BLK/YELBLK/YELBRN/WHTE23-60BLK/REDBLK/REDE23-1BLK/YELBLK/REDE23-16BLK/REDC37-58BLK/ORNRED/YELC37-20C37-15C37-30C37-21BLK/ORN3938323139383231...Page3711H-3IgnitionSystem:ComponentLocationIgnitionSystemComponentsLocationS4RS0A1803001I4RS0A180002-1.ECM7.ECTsensor13.Datalinkconnector2.IgnitioncoilassemblyforNo.1andNo.48.MAFandIATsensor14.Mainrelayboxsparkplugs3.IgnitioncoilassemblyforNo.2andNo.39.Page372IgnitionSystem:1H-4DiagnosticInformationandProceduresIgnitionSystemSymptomDiagnosisS4RS0A1804001ConditionPossiblecauseCorrection/ReferenceItemEnginecranks,butwillBlownfuseforignitioncoilReplace.notstartorhardtostartLooseconnectionordisconnectionofConnectsecurely.Page3731H-5IgnitionSystem:IgnitionSystemCheckS4RS0A1804003StepActionWas“EngineandEmissionControlSystemCheck”GotoStep2.Goto“Engineandperformed?EmissionControlSystemCheck:inSection1A”.IgnitionsparktestGotoStep11.GotoStep3.1)Checkallsparkplugsforconditionandtypereferringto“SparkPlugInspection:”.Page374IgnitionSystem:1H-6StepAction12KnocksensorcheckGotoStep13.Substituteaknown-goodknocksensorand1)Confirmthatknocksensorcircuitisingoodconditionrecheck.referringto“DTCP0327/P0328:KnockSensorCircuitLow/High:inSection1A”...Page3751H-7IgnitionSystem:RepairInstructionsHigh-TensionCordRemovalandInstallationS4RS0A1806001Removal1)Removeaircleanerassemblywithairintakepipeandcylinderheaduppercover.2)DisconnectNo.1cylinder(2)andNo.3cylinder(3)high-tensioncordsfromignitioncoilassemblies(1)whilegrippingeachcap.Page376IgnitionSystem:1H-8SparkPlugRemovalandInstallationIgnitionCoilAssembly(Includingignitor)S4RS0A1806003RemovalandInstallationRemovalS4RS0A1806005Removal1)Removeaircleanerassemblywithairintakepipeandcylinderheaduppercover.1)Disconnectnegativecableatbattery.2)Pullouthigh-tensioncordsbygrippingtheircaps2)Removeaircleanerassemblywithairintakepipeandthenremoveignitioncoilassembliesreferringto...Page377Inspectionspecification.S4RS0A1806006Measuresecondarycoilforresistance.Initialignitiontiming(fixedwithSUZUKIscanIfresistanceisoutofspecification,replaceignitioncoiltool)assembly.3BTDC(atspecifiedidlespeed)Page378Forthetighteningtorqueoffastenernotspecifiedinthissection,referto“FastenersInformation:inSection0A”.SpecialToolsandEquipmentSpecialToolS4RS0A180800109930–76420SUZUKIscantoolTiming-light(drycelltype)—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.1I-1StartingSystem:StartingSystemSchematicandRoutingDiagramCrankingSystemCircuitDiagramS4RS0A1902001I4RS0A190001-1.Piniondrivelever6.Magneticswitchcontacts11.Ignition&Starterswitch2.Pinion&Over-runningclutch7.Pull-incoil12.Battery3.Magneticswitch8.Page380StartingSystem:1I-2ConditionPossiblecauseCorrection/ReferenceItemMotornotrunning(NoShiftleverswitchisnotinPorN,ornotShiftinPorN,oradjustswitch.(A/T)operatingsoundofadjusted(A/T)magneticswitch)BatteryrundownRechargebattery.Page3811I-3StartingSystem:ConditionPossiblecauseCorrection/ReferenceItemStartingmotordoesnotFusedcontactpointsofmagneticswitchReplacemagneticswitch.stoprunningShort-circuitbetweenturnsofmagneticReplacemagneticswitch.switchcoil(layershort-circuit)FailureofreturningactioninignitionReplace.Page382StartingSystem:1I-4RepairInstructionsStartingMotorDismountingandRemountingS4RS0A1906001I4RS0A190002-:9.8Nm(0.98kg-m,7.0lb-ft)Dismounting1)Disconnectnegative(–)batteryleadatbattery.2)Disconnectmagneticswitchleadwire(1)andbatterycable(2)fromstartingmotorterminals.3)Detachshift&...Page3831I-5StartingSystem:StartingMotorComponentsS4RS0A1906002I4RS0A190003-1.Fronthousing8.Sealrubber15.Yoke:Donotreuse.2.Bush9.Magneticswitch16.Armature:Applygrease99000-25010toslidingsurfaceofeachpart.3.Pinionstopring10.Page384StartingSystem:1I-6StartingMotorInspectionS4RS0A1906003PlungerInspectplungerforwear.Replaceifnecessary.I2RH01190011-RearBracketBushInspectbushforwearordamage.Replaceifnecessary.I2RH01190008-MagneticSwitchPushinplungerandreleaseit.Theplungershouldreturnquicklytoitsoriginalposition.Page3851I-7StartingSystem:BrushHolder•Checkmovementofbrushinbrushholder.Ifbrushmovementwithinbrushholderissluggish,checkbrushholderfordistortionandslidingfacesforcontamination.Cleanorcorrectasnecessary.•Checkforcontinuityacrossinsulatedbrush(positiveside)andgroundedbrush(negativeside).Page386StartingSystem:1I-8•Checkthecommutatorandarmaturecore.Ifthereiscontinuity,thearmatureisgroundedandmustbereplaced.I2RH01190022-•Inspectthesplineteethforwearordamage.Replaceifnecessary.I2RH01190019-Inspectthepinionforsmoothmovement.•...Page3871I-9StartingSystem:SpecificationsCrankingSystemSpecificationsS4RS0A1907002Voltage12voltsOutput1.2kWRating30secondsDirectionofrotationClockwiseasviewedfrompinionsideBrushlengthStandard:12.3mm(0.48in.)Limit:7.0mm(0.28in.)NumberofpinionteethPerformanceConditionGuarantee...ChargingSystem:1J-1ChargingSystemGeneralDescriptionBatteryDescription•ClearorlightyellowS4RS0A1A01001ThismeansthatfluidlevelisbelowthebottomofThebatteryhasthreemajorfunctionsintheelectricalhydrometer.Itspossiblecauseisexcessiveorsystem.Page3891J-2ChargingSystem:•Whenkeepingbatteryonvehicleoveralong2)Keepthebatterycableconnectionsclean.periodoftime,followinstructionsgivenbelow.Thecableconnections,particularlyatthepositive(+)terminalpost,tendtobecomecorroded.Theproduct–...Page390ChargingSystem:1J-3I2RH0B1A0002-1.Pulley5.Statorcore9.RearendframeE:Ground2.Pulleynut6.Fieldcoil10.DriveendframeF:Fieldcoilterminal3.Rotorfan7.RegulatorB:Generatoroutput(Batteryterminal)IG:Ignitionterminal4.Page3911J-4ChargingSystem:ChargingIndicatorLampOperationConditionPossiblecauseCorrection/ReferenceItemChargelightdoesnotFuseblownCheckfuse.lightwithignitionONandIndicatorlamp(LED)faultyReplacecombinationmeter.engineoffWiringconnectionlooseTightenlooseconnection.ICregulatororfieldcoilfaultyCheckgenerator.Page392ChargingSystem:1J-5GeneratorTest(OverchargedBatteryCheck)3)Ground“F”terminalandstartengine,thenmeasurevoltageat“B”terminalasshowninthefigure.S4RS0A1A040041)Todeterminebatterycondition,referto“Battery•Voltageishigherthanstandardvalue.ItisDescription:”.Page3931J-6ChargingSystem:RepairInstructionsJumpStartinginCaseofEmergencyWithChargingEquipmentS4RS0A1A06001WithAuxiliary(Booster)BatteryCAUTION:WhenjumpstartingenginewithchargingCAUTION:equipment,besureequipmentusedis12-Ifvehicleismanualtransaxlemodelandhasvoltandnegativeground.Page394ChargingSystem:1J-7GeneratorDismountingandRemountingS4RS0A1A060031)Disconnectnegativecableatbattery.2)Removerightsidedriveshaftreferringto“FrontDriveShaftAssemblyRemovalandInstallation:inSection3A”3)Dismountinnumericalorderasshowninthefigure.4)Reversedismountingprocedureforremounting.Page3951J-8ChargingSystem:GeneratorComponentsS4RS0A1A06004I4RS0A1A0004-1.Pulleynut7.Bearingretainer13.Sealplate19.Brushholdercover:3.6Nm(0.36kg-m,3.0lb-ft)2.Pulley8.Rotor14.Rectifier20.Rearendcover:2.0Nm(0.2kg-m,1.5lb-ft)3.Page396ChargingSystem:1J-9GeneratorInspectionStatorS4RS0A1A060051)Usinganohmmeter,checkallleadsforcontinuity.Ifthereisnocontinuity,replacethestator.Rotor1)Usinganohmmeter,checkforcontinuitybetweenslipringsofrotor.Ifthereisnocontinuity,replacetherotor.Page3971J-10ChargingSystem:Rectifier1)Usinganohmmeter,connectonetesterprobetothe“B”terminal(1)andtheothertoeachrectifierterminal(2).I1JA011A0002-2)ReversethepolarityofthetesterprobesandrepeatStep1).3)Checkthatoneshowscontinuityandtheothershowsnocontinuity.Page398ChargingSystem:1J-11SpecificationsChargingSystemSpecificationsS4RS0A1A07002BatteryBatterytype46B24RRatedcapacityAH/5HR,12VoltsElectrolyteL(US/lmppt.)3.2(6.76/5.63)GeneratorType70AtypeRatedvoltage12VNominaloutput70APermissiblemax.ExhaustSystem:1K-1ExhaustSystemGeneralDescriptionExhaustSystemDescriptionS4RS0A1B01001Theexhaustsystemconsistsofanexhaustmanifold,three-waycatalyticconverter(TWC)incatalystcase,exhaustpipes,amufflerandseals,gasketandetc.Thethree-waycatalyticconverterisanemissioncontroldeviceaddedtotheexhaustsystemtolowerthelevelsofHydrocarbon(HC),CarbonMonoxide(CO),andOxidesofNitrogen(NOx)pollutantsintheexhaustgas.Page4001K-2ExhaustSystem:RepairInstructionsExhaustSystemComponentsS4RS0A1B06001WARNING:Toavoidthedangerofbeingburned,donottouchtheexhaustsystemwhenthesystemishot.Anyserviceontheexhaustsystemshouldbeperformedwhenthesystemiscool.I4RS0A1B0001-[A]:Installinglocationofexhaustmanifoldboldand11.Page401ExhaustSystem:1K-3ExhaustManifoldRemovalandInstallation9)Removeexhaustmanifold(1)anditsgasketfromS4RS0A1B06003cylinderhead.RemovalWARNING:Toavoiddangerofbeingburned,donotserviceexhaustsystemwhileitisstillhot.Serviceshouldbeperformedaftersystemcoolsdown.Page4021K-4ExhaustSystem:ExhaustPipeandMufflerRemovaland4)InstallnewsealringandconnectexhaustNo.1pipe(1)toexhaustNo.2pipe.TightenpipefastenerstoInstallationspecifiedtorque.S4RS0A1B06004Forreplacementofexhaustpipe,besuretohoistvehicleTighteningtorqueandobserveWARNINGunder“ExhaustSystemExhaustNo.2pipebolt(c):43N·m(4.3kg-m,...Page403ExhaustSystem:1K-5SpecificationsTighteningTorqueSpecificationsS4RS0A1B07001TighteningtorqueFasteningpartNotekg-mlb-ftExhaustmanifoldbolt36.5Exhaustmanifoldnut36.5ExhaustNo.1pipebolt36.5Exhaustmanifoldstiffenerbolt36.5ExhaustNo.2pipebolt31.0NOTE:Thespecifiedtighteningtorqueisalsodescribedinthefollowing.“ExhaustSystemComponents:”...Page4041K-6ExhaustSystem:...Page405TableofContents2-iSection2SuspensionCONTENTSPrecautions..........2-1SpecialToolsandEquipment......2B-20SpecialTool............2B-20Precautions.............2-1PrecautionsonSuspension........2-1RearSuspension........2C-1SuspensionGeneralDiagnosis....2A-1GeneralDescription..........2C-1RearSuspensionConstruction......2C-1DiagnosticInformationandProcedures....2A-1ComponentLocation...........2C-2Suspension,WheelsandTiresSymptom...Page4062-iiTableofContentsTireRotation............2D-5Specifications............2D-7WheelRemovalandInstallation......2D-6WheelsandTiresSpecifications......2D-7TireMountingandDismounting......2D-6TighteningTorqueSpecifications......2D-7TireRepair............2D-6...Page407Precautions:PrecautionsPrecautionsPrecautionsonSuspensionS4RS0A2000001SuspensionCautionReferto“SuspensionCaution:inSection00”.WheelsandTiresCautionReferto“WheelsandTiresCaution:inSection00”.GeneralPrecautionsReferto“GeneralPrecautions:inSection00”.VehicleLiftingPointsReferto“VehicleLiftingPoints:inSection0A”.Page4082A-1SuspensionGeneralDiagnosis:SuspensionGeneralDiagnosisDiagnosticInformationandProceduresSuspension,WheelsandTiresSymptomDiagnosisS4RS0A2104001ConditionPossiblecauseCorrection/ReferenceItemVehiclepulls(Leads)MismatchedoruneventiresReplacetire.TiresnotadequatelyinflatedAdjusttirepressure.BrokenorsaggingspringsReplacespring.Page409SuspensionGeneralDiagnosis:2A-2ConditionPossiblecauseCorrection/ReferenceItemBodyleansorswaysinLoosestabilizerbarTightenstabilizerbarboltsornuts,orreplacecornersbushes.Faultystruts(shockabsorbers)orReplacestrutortightenmounting.mountingsBrokenorsaggingspringsReplace.Page4102A-3SuspensionGeneralDiagnosis:SpecificationsWheelAlignmentSpecificationsS4RS0A2107001WheelalignmentspecificationsItemFrontRearFronttoe(“B”–“A”)(total)IN0+1.0/–0.5mm(IN0+IN5.25.2mm(0.205Reartoe(Nonadjustable,forreferenceonly)0.0394/–0.0197in.)0.205in.)Camber“C”...FrontSuspension:2B-1FrontSuspensionGeneralDescriptionFrontSuspensionConstructionS4RS0A2201001I4RS0A220001-1.Strutassembly7.Driveshaft:50Nm(5.0kg-m,36.5lb-ft):23Nm(2.3kg-m,17.0lb-ft)2.Stabilizerbar8.Tie-rod:105Nm(10.5kg-m,76.0lb-ft):85Nm(8.5kg-m,61.5lb-ft)3.Page4122B-2FrontSuspension:FrontWheelAlignmentConstruction•Checkforlooseofballjoints.Checktie-rodends;ifS4RS0A2201002excessiveloosenessisnoted,itmustbecorrectedAmongfactorsforfrontwheelalignment,onlytoesettingbeforeadjusting.canbeadjusted.Camberandcastercanbeadjusted.•...Page413FrontSuspension:2B-33)Afteradjustment,tightenlocknuts(1)tospecifiedtorque.TighteningtorqueTie-rodendlocknut(a):45N·m(4.5kg-m,32.5lb-ft)NOTE:Makesurethatrackbootsarenottwisted.I3RH0A220003-ReferenceInformationSideslipWhencheckedwithsidesliptester,sideslipshouldsatisfyfollowingspecification.Page4142B-4FrontSuspension:FrontStrutAssemblyComponentsS4RS0A2206005I4RS0A220002-1.Strutassembly6.Strutbearing11.Strutbracketnut:105Nm(10.5kg-m,76.0lb-ft)2.Coilspring7.Strutsupport12.Stabilizerjointnut:50Nm(5.0kg-m,36.5lb-ft)3.Page415FrontSuspension:2B-5NOTE:NOTE:WhenservicingcomponentpartsofstrutHoldstrutbyhandsothatitwillnotfalloff.assembly,removestrutrodcapandthenloosenstrutnutalittlebeforeremovingstrutassembly.Thiswillmakeserviceworkeasier.Note,however,nutmustnotberemovedatthispoint.Page4162B-6FrontSuspension:I4RS0A220009-WARNING:UseacommerciallyavailablespringcompressorandfollowtheoperationproceduredescribedintheInstructionManualsuppliedwiththatspringcompressor.2)Whilekeepingspringcompressedwithspecialtoolasshown,removestrutsupportlowernut.Specialtool(B):09900-00411(socket)(C):09900-00414(6mm)Page417FrontSuspension:2B-72)Installcompressingcoilspring,andmatespringend(2)withsteppedpartofspringlowerseat(1)asshown.CAUTION:Endofcoilspringmustnotinterferewithstepofspringlowerseat.I4RS0A220011-3)Installbumpstopperontostrutrod.Forinstallingdirection,refertothefigurein“FrontSuspensionConstruction:”.Page4182B-8FrontSuspension:5)Comparestrutresistanceandnumberofrebalance•Inspectspringseatforcracksordeformation.ontherightwiththoseontheleft.AndtheymustbeIfdefective,replace.equalinboth.Withproperstrut,vehiclebodyshould•...Page419FrontSuspension:2B-96)Pullbrakedisc(2)offbyusingtwo8mmbolts.I4RS0A220018-10)Loosenstrutbracketnuts(1).I2RH01220027-7)Pulloutwheelhub(1)withspecialtools.11)Removeballjointbolt(3)andnut(4).12)RemovestrutbracketboltsfromstrutbracketandSpecialtoolthensteeringknuckle(2).Page4202B-10FrontSuspension:15)Removewheelbearingoutsideinnerrace(1).Specialtool(C):09913-65810(D):09913-85230I4RS0A220021-2)Installcirclip(1).I3RH0A220006-16)Removehubbolts(1)withcopperhammerorhydraulicpress.I2RH01220037-3)Insertnewhubbolt(1)inhubhole.RotatehubboltCAUTION:slowlytoassurethatserrationsarealignedwithNeverremoveboltunlessreplacementis...Page421FrontSuspension:2B-115)Installballjointbolt(1)andnut(2)fromthedirectionasshowninfigure.6)Tightennewsuspensionarmballjointnut(2)tospecifiedtorque.TighteningtorqueSuspensionarmballjointnut(a):60N·m(6.0kg-m,43.5lb-ft)3,(a)CAUTION:...Page4222B-12FrontSuspension:FrontWheelHub,Disc,NutandBearingCheckS4RS0A2206012•Inspecteachwheeldiscfordents,distortionandcracks.Adiscinbadlydamagedconditionmustbereplaced.•Checkinstallationfaceinsideofwheeldiscforrust.Asrustaffectsadversely,removeitthoroughly.Page423FrontSuspension:2B-13SuspensionControlArm/BushingDisassemblyandAssemblyS4RS0A2206014Disassembly1)Cutoffbushingflange(rubber)(1)withknife.I4RS0A220027-2)Installsuspensioncontrolarmballjointtosteeringknuckle.AlignballstudgroovewithsteeringknuckleI4RS0A220029-bolthole.Page4242B-14FrontSuspension:NOTE:SuspensionControlArm/SteeringKnuckleCheck•Beforeinstallingbushing,applysoapS4RS0A2206015wateronitscircumferencetofacilitateInspectforcracks,deformationordamage.installation.Ifdefective,replace.I2RH01220005-I4RS0A220032-2)Press-fitbushing(1)sothatdimensionsandinfigureSuspensionControlArmBushingCheckbecomeequal.Page425FrontSuspension:2B-15FrontSuspensionFrame,StabilizerBarand/orBushingsComponentsS4RS0A2206018I4RS0A220037-1.Stabilizerbar5.Stabilizerjoint9.Suspensionframe:150Nm(15.0kg-m,108.5lb-ft)2.Stabilizerbushing6.Stabilizerjointnut10.Suspensionframemountingbolt:170Nm(17.0kg-m,123.0lb-ft)3.Page4262B-16FrontSuspension:WARNING:Whenremovingsuspensionframe,besuretoapplysomesupportingequipment(suchasjack)underitatwell-balancedpositioninthecentersectionsoastopreventsuspensionframedropping.I4RS0A220039-3.Suspensionframe6)DisconnectmufflerNo.1mounting(1)fromsuspensionframe(2).Page427FrontSuspension:2B-17NOTE:5)Alignlugs(1)(rightandleft)ofsuspensionframewithholes(2)invehiclebodyrespectively.Forcorrectinstallationofstabilizerbar,side-to-side,besurethatstopperring(4)onstabilizerbaralignswithmountbush,bothrightandleft,asshowninfigure.Page4282B-18FrontSuspension:9)ConnectmufflerNo.1mounting(1)tosuspensionframe(2).I4RS0A220040-10)InstallsteeringgearcaseNo.1bolts(a)andNo.2bolts(b)tospecifiedtorqueTighteningtorqueSteeringgearcaseNo.1bolt(a):55N·m(5.5kg-m,40.0lb-ft)SteeringgearcaseNo.2bolt(b):55N·m(5.5kg-I4RS0A220051-...Page429FrontSuspension:2B-19FrontStabilizerBar,Bushingand/orJointStabilizerJointCheck1)Checkforsmoothrotation.S4RS0A22060222)Inspectballstudfordamage.StabilizerBarInspectfordamageordeformation.3)Inspectdustcoverfordamage.Ifdefective,replace.NOTE:Stabilizerjoint(1)cannotbedisassembled.Page4302B-20FrontSuspension:NOTE:Thespecifiedtighteningtorqueisalsodescribedinthefollowing.“FrontSuspensionConstruction:”“FrontStrutAssemblyComponents:”“FrontWheelHubandSteeringKnuckleComponents:”“FrontSuspensionFrame,StabilizerBarand/orBushingsComponents:”Reference:Forthetighteningtorqueoffastenernotspecifiedinthissection,referto“FastenersInformation:inSection0A”.RearSuspension:2C-1RearSuspensionGeneralDescriptionRearSuspensionConstructionS4RS0A23010012WDVehicle

I4RS0A230001-1.Rearcoilspring6.Wheelbearing11.Rearshockabsorberlowernut16.Rearspindle2.Rearspringlowerseat7.Brakedrum12.Rearspindlebolt17.Page4322C-2RearSuspension:ComponentLocationRearSuspensionComponentLocationS4RS0A23030012WDVehicleI4RS0A230002-1.Rearcoilspring8.Circlip15.Spindlecap:90Nm(9.0kg-m,65.0lb-ft)2.Blank9.Reartrailingarmbolt16.Brakebackplate:75Nm(7.5kg-m,54.0lb-ft)3.Page433RearSuspension:2C-3RepairInstructionsRearShockAbsorberRemovalandInstallationS4RS0A2306028Removal1)Hoistvehicle.2)Removetailendmembertrim(1)andquarterinnertrim(2).I4RS0A230003-3.ClipI4RS0A230004-3)Supportrearaxlebyusingfloorjacktopreventit4)Installtailendmembertrim(1)andquarterinnertrimfromlowering.Page4342C-4RearSuspension:RearShockAbsorberInspectionRearShockAbsorberBushRemovalandS4RS0A2306029Installation•Inspectfordeformationordamage.S4RS0A2306040Removal•Inspectbushingsforwearordamage.1)Removerearshockabsorberreferringto“Rear•Inspectforevidenceofoilleakage.ShockAbsorberRemovalandInstallation:”.Page435RearSuspension:2C-5RearShockAbsorberBushInspectionInstallationS4RS0A23060411)Installcoilspring(1)onspringseat(2)ofrearaxleInspectforcracks,deformationordamage.Replaceanyandmatespringopenendwithsteppedpart(3)ofdefectivepart.Page4362C-6RearSuspension:SpringUpperSeatandLowerSeatRemovaland4)Installwheelsandtightenwheelnutstospecifiedtorque.InstallationS4RS0A2306033TighteningtorqueRemovalWheelnut(a):85N·m(8.5kg-m,61.5lb-ft)1)Removecoilspringreferringto“CoilSpringRemovalandInstallation:”.Page437RearSuspension:2C-7I4RS0A230017-A:Vehiclebodyside(Upperside)LH:LeftsideF:FrontsideRH:Rightside3.Steppedpart2)Installcoilspringreferringto“CoilSpringRemovalandInstallation:”.RearAxleRemovalandInstallationS4RS0A2306035Removal1)Hoistvehicleandremoverearwheels(right&...Page4382C-8RearSuspension:9)LowerrearaxlegraduallyasfardownaswherecoilInstallationsprings(1)(right&left)canberemoved.1)Installbrakepipestorearaxle.2)Placerearaxleonfloorjacks.CAUTION:Theninstalltrailingarmandnewtrailingarmbolts(1)Becarefulnottoletrearaxledowntoomuch.Page439RearSuspension:2C-9I4RS0A230024-6)Installbrakebackplates(1),spindles(2)andnewspindlebolts(a)andthentightenspindlebolts(a)toI4RS0A230027-specifiedtorque.9)Connectbrakeflexiblehoses(1)tobracketonrearaxlewithE-rings(3)(right&left)andtightenbrakeCAUTION:pipeflarenuts(a)tospecifiedtorque.Page4402C-10RearSuspension:13)Installwheelandtightenwheelnutstospecifiedtorque.TighteningtorqueWheelnut(a):85N·m(8.5kg-m,61.5lb-ft)I2RH01220009-14)Uponcompletionofalljobs,depressbrakepedalwithabout300N(30kg,66Ibs)loadthreetofivetimessoastoobtainproperdrum-to-shoeclearance.Page441RearSuspension:2C-11WheelBearingandWheelStudBoltRemovalInstallationandInstallation1)Installnewwheelbearing(1)byusingspecialtoolS4RS0A2306036andhydraulicpress.Removal1)Removerearbrakedrumreferringto“RearBrakeNOTE:DrumRemovalandInstallation:inSection4C”.Sealsideofbearingcomesbrakebackplate2)Removecirclip(1).Page4422C-12RearSuspension:RearWheelDisc,NutandBearingInspectionS4RS0A2306021•Checkwheelnutsfortightnessand,asnecessary,retightentospecification.•Checkwheelboltpress-fittedintobrakedrumforwear,damage,poorthreadcondition,andlooseness.Replacedefectiveboltwithanewone.Whenboltinstallationisfoundloose,replacebothboltandbrakedrumwithnewones.Page443RearSuspension:2C-13TighteningtorqueTighteningtorqueRearspindlebolt(a):75N·m(7.5kg-m,54.0lb-Wheelnut(a):85N·m(8.5kg-m,61.5lb-ft)I4RS0A230025-2)Connectwheelspeedsensor(1)andtightenwheelspeedsensorbolt(a)tospecifiedtorque.I2RH01220009-Tighteningtorque7)Uponcompletionofalljobs,depressbrakepedal...Page4442C-14RearSuspension:SpecificationsTighteningTorqueSpecificationsS4RS0A2307001TighteningtorqueFasteningpartNotekg-mlb-ftRearshockabsorberuppernut18.0Rearshockabsorberlowernut65.0Wheelnut61.5Rearspindlebolt54.0WheelspeedsensorboltBrakepipeflarenut11.5ParkingbrakecableclampboltReartrailingarmbolt...WheelsandTires:2D-1WheelsandTiresGeneralDescriptionTiresDescription•HightiretemperatureS4RS0A2401001•ReducedhandlingThetireisoftubelesstype.Thetireisdesignedto•HighfuelconsumptionoperatesatisfactorilywithloadsuptothefullratedloadcapacitywheninflatedtotherecommendedinflationMatchedTiresandWheels(SteelType)pressures.Page4462D-2WheelsandTires:WARNING:Lateralrunoutlimit“a”:1.40mm(0.055in.)DonotmixdifferenttypesoftiresontheRadialrunoutlimitsamevehiclesuchasradial,biasandbias-“b”:1.14mm(0.045in.)beltedtiresexceptinemergencies,becausehandlingmaybeseriouslyaffectedandmayresultinlossofcontrol.Page447WheelsandTires:2D-3•FronttiretreadshavescuffedappearancewithWearIndicatorsDescription“feather”edgesononesideoftreadribsorblocks.S4RS0A2401004Originalequipmenttireshavebuilt-intreadwearindicators(1)toshowwhentheyneedreplacement.Theseindicators(1)willappearas12mm(0.47in)widebandswhenthetiretreaddepthbecomes1.6mm(0.063in).Page4482D-4WheelsandTires:Equipmentmanufacture’srecommendationsInflatetirestorecommendedpressureRoadtestvehicleonlevelunrounedroadinbothdirectionsSwitchfronttiressidetosideandroadtestagainLeadcorrected,LeadsreversesdirectionLeadsinsamedirectionifroughnessresults,replacetiresPuttiresbackinoriginalpositionInstallaknown-goodtireononefrontside...Page449WheelsandTires:2D-5RepairInstructionsGeneralBalanceProceduresTireRotationS4RS0A2406001S4RS0A2406002Depositsofmud,etc.mustbecleanedfrominsideofrim.Toequalizewear,rotatetiresaccordingtofigure.Radialtiresshouldberotatedperiodically.Settirepressure.WARNING:NOTE:Stonesshouldberemovedfromthetreadin...Page4502D-6WheelsandTires:WheelRemovalandInstallationTireMountingandDismountingS4RS0A2406003S4RS0A2406004RemovalUseatirechangingmachinetomountordismounttires.Followequipmentmanufacturer’sinstructions.Donot1)Loosenwheelnutsbyapproximately180(halfausehandtoolsortireironsalonetochangetiresastheyrotation).Page451WheelsandTires:2D-7SpecificationsWheelsandTiresSpecificationsS4RS0A2407001Tiresize(Standard)185/60R1584HWheelsize(Standard)15x51/2JJ(for185/60R15)TighteningtorqueWheelnut:85N·m(8.5kg-m,61.5lb-ft)NOTE:•Tireinflationpressureshouldbecheckedwhentiresarecool.•...Page4522D-8WheelsandTires:...Page453TableofContents3-iSection3Driveline/AxleCONTENTSDriveShaft/Axle........3A-1FrontDriveShaftAssemblyRemovalandInstallation............3A-3GeneralDescription..........3A-1FrontDriveShaftDisassemblyandFrontDriveShaftConstruction......3A-1Assembly............3A-4ComponentLocation...........3A-1CenterShaftandCenterBearingFrontDriveShaftAssemblyComponentsSupportDisassemblyandAssembly....3A-7...Page4543A-1DriveShaft/Axle:DriveShaft/AxleGeneralDescriptionFrontDriveShaftConstructionS4RS0A3101001Aconstantvelocitytripodjointisusedonthedifferentialsideofbothrightandleftsidedriveshaftassemblies.Aconstantvelocityballjointisusedonthewheelsideofbothrightandleftsidedriveshaftassemblies.Thedriveshaftcanslidethroughthetripodjointintheextension/contractiondirection.Page455DriveShaft/Axle:3A-2DiagnosticInformationandProceduresFrontDriveShaftSymptomDiagnosisS4RS0A3104001ConditionPossiblecauseCorrection/ReferenceItemAbnormalnoiseWornorbreakageofthedriveshaftjointReplace.WornorbreakageofthecenterbearingReplace.RepairInstructionsFrontDriveShaftComponentsS4RS0A3106001...Page4563A-3DriveShaft/Axle:1.Circlip13.Centerbearing2.Differentialsidejoint(Constantvelocitytripodjoint)14.Centershaft:Applydarkgraygreaseincludedinspareparttojoint.3.Snapring15.Tripodjointspider4.Bootband(Large)16.Page457DriveShaft/Axle:3A-4FrontDriveShaftDisassemblyandAssembly10)Removedriveshaftassembly.S4RS0A310600711)Removecenterbearingsupportbolts(3)andremovecenterbearingsupport(2)withcentershaft(1)fromDisassemblydifferentialsidegear.CAUTION:•...Page4583A-5DriveShaft/Axle:3)Removetripodjointspider(1)using3armspuller(2).CAUTION:Topreventanyproblemcausedbywashingsolution,donotwashtripodjointexceptitshousing.Degreasingoftripodjointwithclothisallowed.I4RS0A310007-I3RH0A311004-[A]:Wheelside...Page459DriveShaft/Axle:3A-67)Fastenbootband(1)securelyusingspecialtool.10)Applygreaseinthesuppliedpartstoinsideoftripodjointhousing(1),jointitwithtripodjointandfitbootCAUTION:(2)totripodjointhousing.DonotsqueezeordistortbootwhenGreasecolorfasteningitwithbands.Page4603A-7DriveShaft/Axle:CAUTION:•Bendeachbootbandagainstforwardrotation.•Donotsqueezeordistortbootwhenfasteningitwithbands.Distortedbootcausedbysqueezingairmayreduceitsdurability.I3RH0A311005-4)Removecenterbearingfromcenterbearingsupport.AssemblyInstallcentershaftbyreversingremovalprocedureandnotingthefollowingpoints.Page461DriveShaft/Axle:3A-8•Press-fitcentershaft(1)fromleftoilseal(2)side.Assembly1)Installcenterbearing(1)tocenterbearingsupport(2),andtheninstallcirclip(3)intogrooveofbearingsupportasshowninfigure.I4RS0A310015-TypeBI4RS0A310016-...Page4623A-9DriveShaft/Axle:FrontDriveShaftInspection4)Installrightoilseal(1)tocenterbearingsupport(2)untilitbecomeflushwithbearingsupportusingS4RS0A3106005•Checkshaftandjointfordamage,wearorbend.specialtool,andthenapplygreasetooilseallip.Replacethemasnecessary.Page463DriveShaft/Axle:3A-10SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A3108001MaterialSUZUKIrecommendedproductorSpecificationNoteGreaseSUZUKISuperGreaseAP/No.:99000–25010NOTE:Requiredservicematerialisalsodescribedinthefollowing.“FrontDriveShaftAssemblyComponentsLocation:”...Page4643A-11DriveShaft/Axle:...Page465TableofContents4-iSection4BrakesCONTENTSPrecautions..........4-1FrontDiscBrakePadOn-VehicleInspection............4B-2Precautions.............4-1FrontDiscBrakePadRemovalandPrecautionsforBrakes..........4-1Installation............4B-2BrakeControlSystemandDiagnosis...4A-1FrontDiscBrakePadInspection......4B-3FrontDiscBrakeCaliperRemovalandPrecautions............4A-1Installation............4B-3...Page4664-iiTableofContentsABS............4E-1DTCC1041/C1045/C1051/C1055,DTCC1042/C1046/C1052/C1056:Right-FrontPrecautions............4E-1/Left-Front/Right-Rear/Left-RearInletPrecautionsinDiagnosingTroubles....4E-1SolenoidCircuit,Right-Front/Left-Front/PrecautionsinOn-VehicleService......Page467Precautions:PrecautionsPrecautionsPrecautionsforBrakesS4RS0A4000001SuspensionCautionReferto“SuspensionCaution:inSection00”.WheelsandTiresCautionReferto“WheelsandTiresCaution:inSection00”.BrakeCautionReferto“BrakeCaution:inSection00”.GeneralPrecautionsReferto“GeneralPrecautions:inSection00”.Page4684A-1BrakeControlSystemandDiagnosis:BrakeControlSystemandDiagnosisPrecautionsPrecautionsonBrakeS4RS0A4100001AirBagWarningReferto“AirBagSystemServiceWarning:inSection00”.BrakesDiagnosisNoteReferto“BrakesDiagnosisNote:”.GeneralDescriptionBrakesConstructionS4RS0A4101001Whenthefootbrakepedalisdepressed,hydraulicpressureisdevelopedinthemastercylindertoactuatepistons(two...Page469BrakeControlSystemandDiagnosis:4A-2FrontBrakeHose/PipeConstructionS4RS0A4101002ForVehiclewithABSI4RS0A410002-[A]:ForRHsteeringvehicle5.ABShydraulicunit10.4-wayjointtoleftrearbrakehose1.FrommastercylinderprimarytoABShydraulicunit6.Page4704A-3BrakeControlSystemandDiagnosis:RearBrakeHose/PipeConstructionS4RS0A4101003I4RS0A410003-1.4-wayjointtoleftrearbrakehose4:Rightrearbrakehose2.4-wayjointtorightrearbrakehose5:Leftrearbrakehosetoleftbrake3.Page471BrakeControlSystemandDiagnosis:4A-4BrakesSymptomDiagnosisS4RS0A4104002ConditionPossiblecauseCorrection/ReferenceItemNotenoughbrakingforceBrakeoilleakagefrombrakelinesLocateleakingpointandrepair.BrakediscorpadsstainedwithoilCleanorreplace.OverheatedbrakesDeterminecauseandrepair.Page4724A-5BrakeControlSystemandDiagnosis:ConditionPossiblecauseCorrection/ReferenceItemDraggingbrakes(AveryMastercylinderpistonsnotreturningReplacemastercylinder.lightdragispresentinallcorrectlybrakesimmediatelyafterRestrictedbrakepipesorhosesCheckforsofthosesordamagedpipesandpedalisreleased)replacewithnewhosesand/ornewbrake...Page473BrakeControlSystemandDiagnosis:4A-6RepairInstructionsBrakePedalFreeHeightInspectionS4RS0A41060011)Checkbrakepedalfreeheight.Ifitisnotwithinspecification,checkandadjustfollowingitem2)andBrakepedalfreeheight“a”fromfloorpanel130–...Page4744A-7BrakeControlSystemandDiagnosis:MasterCylinderandBrakeFluidLevelInspectionS4RS0A41060041)Checkmastercylinder,reservoirandreservoirhose(ifequipped)forcrack,damageandbrakefluidleakage.Ifanyfaultyconditionexists,correctorreplace.2)CheckthatbrakefluidlevelisbetweenMAXandMINmarksonreservoir.Page475BrakeControlSystemandDiagnosis:4A-8I2RH01410017-7)Thenattachbleederplugcap.I4RS0A410008-2)Removebleederplugcap.Attachavinyltube(1)to8)Aftercompletingbleedingoperation,applyfluidbleederplug,andinserttheotherendintocontainerpressuretopipelineandcheckforleakage.Page4764A-9BrakeControlSystemandDiagnosis:•Performbraketestandcheckinstalledpartforfluid•Wheninstallinghose,makesurethatithasnotwistorleakage.kink.RearBrakeHose/PipeRemovalandBrakeHoseandPipeInspectionS4RS0A4106009InstallationS4RS0A4106008...Page477BrakeControlSystemandDiagnosis:4A-101.Mastercylinderseal7.Secondarypistonstopperpin:15Nm(1.5kg-m,11.0lb-ft)2.Circlip8.Reservoirbolt“a”:Applysmallamountofsilicongrease(includedinspareparts)tomatingsurfacesofrodsealandprimarypiston.Page4784A-11BrakeControlSystemandDiagnosis:MasterCylinderAssemblyRemovaland7)Removemastercylinderandmastercylinderseal.InstallationInstallationS4RS0A41060121)Installnewmastercylinderseal.Removal2)InstallmastercylindertoboosterandtightenmasterCAUTION:cylinderfixingnuts(a)tospecifiedtorque.DonotallowbrakefluidtogetonpaintedTighteningtorquesurfaces.Page479BrakeControlSystemandDiagnosis:4A-12Assembly6)FillreservoirwithspecifiedbrakefluiduptoitsMAXmark.CAUTION:7)Aftercompletingthework,bleedairreferringto“AirBleedingofBrakeSystem:”.•Neveruseanymineraloilsuchaskeroseneoilandgasolinewhenwashing8)Checkeachinstalledpartsforfluidleakage.Page4804A-13BrakeControlSystemandDiagnosis:MasterCylinderAssemblyInspection5)Applysmallamountofrubbergrease(includedinspareparts)tomatingsurfaceof“a”(pistoncup(3)S4RS0A4106014Inspectalldisassembledpartsforwearordamage,andandpistonguide(1))and“b”(pistonguide(1)andO-replacepartsifnecessary.Page481BrakeControlSystemandDiagnosis:4A-14BoosterOperationInspectionCheckOperationS4RS0A41060161)Withenginestopped,depressbrakepedalseveralTherearetwowaystoperformthisinspection,withandtimeswiththesameloadandmakesurethatpedalwithoutatester.Page4824A-15BrakeControlSystemandDiagnosis:I4RS0A410020-I2RH01410010-5)Tightenbrakepedalbracketmountingbolt.H:HoldTighteningtorqueT:30secondsBrakepedalbracketmountingbolt(a):13N·m(1.3kg-m,9.5lb-ft)BrakeBoosterRemovalandInstallationS4RS0A4106017Removal1)RecoverrefrigerantfromA/Csystembyusing...Page483Forthetighteningtorqueoffastenernotspecifiedinthissection,referto“FastenersInformation:inSection0A”.SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A4108001MaterialSUZUKIrecommendedproductorSpecificationNoteBrakefluidDOT3—(DOT3)NOTE:Requiredservicematerialisalsodescribedinthefollowing.4B-1FrontBrakes:FrontBrakesRepairInstructionsFrontDiscBrakeComponentsS4RS0A4206001I4RS0A420001-1.Caliper9.Pistonseal17.Hosewasher:Applysmallamountofrubbergrease(includedinrepairkit)toallaroundpartofpistonseal.2.Caliperpinbolt10.Page485FrontBrakes:4B-2FrontDiscBrakePadOn-VehicleInspection4)Removebrakepads(3).S4RS0A4206002Inspectpadlinings(1)periodicallyaccordingtomaintenanceschedulewheneverwheelsareremoved(fortirerotationorotherreason).Takealookthrougheachend(orhole)ofcaliperandcheckliningthicknessofoutsideandinsidepads.Page4864B-3FrontBrakes:NOTE:3)Installcaliperandtightencaliperpinbolts(a)tospecifiedtorque.Whenpadsareremoved,visuallyinspectcaliperforbrakefluidleak.CorrectleakyTighteningtorquepoint,ifany.Caliperpinbolt(a):26N·m(2.6kg-m,19.0lb-ft)I4RS0A420002-4)Installwheelandlowerlift.Page487FrontBrakes:4B-44)Removecaliperfromcalipercarrier.6)Lowerhoist.5)Disconnectflexiblehosefromcaliperusingcarenot7)Torquewheelnutstospecifications.totwistit.AsthiswillallowbrakefluidtoflowoutofTighteningtorqueflexiblehose,haveacontainerreadybeforehand.Page4884B-5FrontBrakes:1)Replacewithanewpistonseal(1)ateveryoverhaul.3)Removepistonsealusingathinbladelikeathicknessgauge,etc.Afterapplyingrubbergrease(includedinrepairkit),fitpistonseal(1)intogrooveincylindertakingcareCAUTION:nottotwistit.Page489FrontBrakes:4B-6NOTE:Checkthatbootisfittedinbootgroovesecurelyallaroundpistonandcylinder.I2RH01420015-FrontBrakeDiscRemovalandInstallationS4RS0A4206008Removal1)Hoistvehicleandremovewheel.I2RH01420020-2)Removecaliperassemblybyremovingcaliper5)Toconfirmthatbootisfittedinitsgrooveincylindercarrierbolts(2pcs)properly,pullpistonoutofcylinderalittlebutdonot...Page4904B-7FrontBrakes:InstallationFrontBrakeDiscInspectionS4RS0A42060091)Installdisctowheelhub.•Installwheelnutstohubboltsandfastentofixthe2)Installcaliperassemblytosteeringknuckle.brakedisc.UsingmagneticstandandwithdialgaugepositionedCAUTION:atabout10mm(0.39in.)inwardfromperipheryofMakesurethatflexiblehoseisnottwisted...Page491FrontBrakes:4B-8SpecificationsTighteningTorqueSpecificationsS4RS0A4207001TighteningtorqueFasteningpartNotekg-mlb-ftCaliperpinbolt19.0Wheelnut61.5Flexiblehosejointbolt17.0BleederplugCalipercarrierbolt61.5NOTE:Thespecifiedtighteningtorqueisalsodescribedinthefollowing.“FrontDiscBrakeComponents:”...4C-1RearBrakes:RearBrakesRepairInstructionsRearDrumBrakeComponentsS4RS0A4306001I4RS0A430001-1.Rearbrakedrum9.Quadrantspring17.Brakebackplate2.Spindle10.Shoereturnspring18.Spindlebolt3.Spindlenut11.Antirattlespring:175Nm(17.5kg-m,126.5lb-ft)4.Page493RearBrakes:4C-23)Installbrakedrumaftermakingsurethatinsideofbrakedrumandbrakeshoesarefreefromdirtandoil.4)Installnewspindlenut(a).5)Tightenspindlenut(a)tospecifiedtorque.TighteningtorqueSpindlenut(a):175N·m(17.5kg-m,126.5lb-ft)I4RS0A430004-6)Removewheelbearingfrombrakedrumreferringto...Page4944C-3RearBrakes:NOTE:9)Installwheelandtightenwheelnutstospecifiedtorque.Whendrumisremoved,visuallyinspectwheelcylinderforbrakefluidleakage.TighteningtorqueCorrectleakypoint,ifany.Wheelnut(a):85N·m(8.5kg-m,61.5lb-ft)BrakeShoeMeasurethicknessofbrakeshoe(1).Page495RearBrakes:4C-4ABSSensorRingInspectionS4RS0A4306010•Checkringserration(teeth)forbeingmissing,damagedordeformed.•Checksensorring(1)forbeingdeformed(warped).•CheckthatnoforeignmaterialisattachedIfanymalfunctionisfound,repairorreplace.I4RS0A430009-Installation1)Installnewsensorring(1)tobrakedrum(2)byusing...Page4964C-5RearBrakes:WheelCylinderRemovalandInstallation5)Removepushnut(1).S4RS0A43060066)Removeparkingbrakeshoelever(2)fromshoerim(3).Removal1)Removebrakedrumreferringto“RearBrakeDrumRemovalandInstallation:”.2)Removebrakeshoereferringto“RearBrakeShoeRemovalandInstallation:”.Page497RearBrakes:4C-6BrakeBackPlateRemovalandInstallation4)Installbleederplugcap(4)takenofffrompipebacktobleederplug.S4RS0A4306008Removal1)Removebrakedrumreferringto“RearBrakeDrumRemovalandInstallation:”.2)Removebrakeshoereferringto“RearBrakeShoeRemovalandInstallation:”.Page4984C-7RearBrakes:Installation5)Installwheelcylinderandconnectbrakepipeflarenut,andthentightenwheelcylinderboltsandflare1)Installbrakebackplate(1)andspindle(2),andnuttospecifiedtorquereferringto“WheelCylindertightenspindlebolts(3)byhand.Page499RearBrakes:4C-8SpecificationsTighteningTorqueSpecificationsS4RS0A4307001TighteningtorqueFasteningpartNotekg-mlb-ftSpindlenut17.5126.5Wheelnut61.5WheelcylindermountingboltRearbrakepipeflarenut11.5RearwheelspeedsensorboltSpindlebolt53.0ParkingcablecapnutNOTE:Thespecifiedtighteningtorqueisalsodescribedinthefollowing.4D-1ParkingBrake:ParkingBrakeGeneralDescriptionParkingBrakeCableConstructionS4RS0A4401001I4RS0A440001-T:Topside4.Parkingcablebracket10.Parkingcableclampbolt[D]:View[D]F:Frontside5.Parkingcablebracketbolt11.Rearwheelspeedsensorbolt[E]:View[E]R:Rightside6.Page501ParkingBrake:4D-2RepairInstructionsParkingBrakeInspectionandAdjustmentAdjustmentS4RS0A4406001InspectionNOTE:HoldcenterofparkingbrakelevergripandpullitupwithMakesureforthefollowingconditionsbefore200N(20kg,44lbs)force.cableadjustment.Page5024D-3ParkingBrake:ParkingBrakeCableRemovalandInstallationParkingBrakeLeverRemovalandInstallationS4RS0A4406002S4RS0A4406003RemovalRemoval1)Disconnectnegative(–)cableatbattery.NOTE:2)Removeconsolebox.Whenitisnecessarytoremovebothright3)Blockvehiclewheelsandreleaseparkingbrakeandleftparkingbrakecables,repeatbelowlever.Page503ParkingBrake:4D-4Installation1)Installinreverseorderofremovalprocedure.Checkequalizerinclinedangle.TighteningtorqueParkingbrakeleverbolt(a):25N·m(2.5kg-m,18.0lb-ft)I4RS0A440006-2)Afterallpartsareinstalled,parkingbrakeleverneedstobeadjusted.Referto“ParkingBrakeInspectionandAdjustment:”.Page5044E-1ABS:PrecautionsPrecautionsinDiagnosingTroublesPrecautionsinOn-VehicleServiceS4RS0A4500001S4RS0A4500002ToensurethatthetroublediagnosisisdoneaccuratelyWhenconnectorisconnectedtoABShydraulicunit/andsmoothly,observethefollowingandfollow“ABScontrolmoduleassembly,donotdisconnectconnectorsCheck:”.Page505ABS:4E-2GeneralDescriptionABSDescriptionABSHydraulicUnit/ControlModuleAssemblyS4RS0A4501001DescriptionTheABS(AntilockBrakeSystem)controlsthefluidS4RS0A4501002pressureappliedtothewheelcylinderofeachbrakeABScontrolmoduleisacomponentofABShydraulicfromthemastercylindersothateachwheelisnotlockedunit/controlmoduleassemblyandhasthefollowingevenwhenhardbrakingisapplied.Page5064E-3ABS:SchematicandRoutingDiagramABSSchematicS4RS0A4502001INPUTOUTPUTABScontrolmoduleHydraulicunitWheelspeedsensor(LF)PumpmotorWheelspeedsensor(LR)Pumpmotordriver(transistor)Wheelspeedsensor(RF)Solenoidvalvepowersupplydriver(transistor)Wheelspeedsensor(RR)StoplampswitchLFinletsolenoidvalve...Page507ABS:4E-41.ABShydraulicunit/controlmoduleassembly8.Pumpmotor15.Wheelspeedsensor(Right-front)2.ABScontrolmodule9.Stoplampswitch16.Wheelspeedsensor(Left-front)3.ABShydraulicunit10.ABSwarninglamp17.Wheelspeedsensor(Right-rear)4.Page5084E-5ABS:TerminalWirecolorCircuitWHT/REDABSpumpmotordriver(Transistor)——GRN/WHTBrakelightswitch——Darklinkconnector——GRN/ORNIgnitionswitch——————————GroundWHT/BLUSolenoidvalvepowersupplydriver(Transistor)LTGRNLeft–rearwheelspeedsensor(+)Page509ABS:4E-6FrontWheelSpeedSensorComponentsLocationS4RS0A4503002I4RS0A450005-[A]:OK1.Frontwheelspeedsensor3.Connector25Nm(2.5kg-m,18.0lb-ft)[B]:NG2.Grommet4.Sensorring11Nm(1.1kg-m,8.0lb-ft)RearWheelSpeedSensorComponentsLocationS4RS0A4503003I4RS0A450006-...Page5104E-7ABS:DiagnosticInformationandProceduresABSCheckS4RS0A4504001Refertothefollowingitemsforthedetailsofeachstep.StepActionMalfunctionanalysisGotoStep4.GotoStep2.1)Perform“Customercomplaintanalysis:”.2)Perform“Problemsymptomconfirmation:”.3)Perform“DTCcheck,recordandclearance:”...Page511ABS:4E-8Customerquestionnaire(Example)I2RH01450014-ProblemsymptomconfirmationCheckifwhatthecustomerclaimedin“CustomerQuestionnaire”isactuallyfoundinthevehicleandifthatsymptomisfound,whetheritisidentifiedasafailure.(Thisstepshouldbesharedwiththecustomerifpossible.)Checkwarninglampsrelatedtobrakesystemreferringto“EBDWarningLamp(BrakeWarningLamp)Check:”...Page5124)ReadDTCaccordingtoinstructionsdisplayedonIfitdoesn’tgooff,goto“EBDWarningLamp(BrakeSUZUKIscantoolandprintitorwriteitdown.ReferWarningLamp)ComesONSteady:”.toSUZUKIscantooloperator’smanualforfurther...Page513BrakepedalreleasedbyperformingthefollowingprocedureorusingSUZUKIscantool.1)ConnectSUZUKIscantooltodatalinkconnectorinthesamemanneraswhenmakingthisconnectionforDTCcheck.2)TurnignitionswitchtoONposition.Page5144E-11ABS:RFWheelSpeed,LFWheelSpeed,RRWheelSpeedScanToolDataDefinitionBatteryVolt(V):BatteryVoltageisananaloginputandLFWheelSpeed(km/h,MPH):WheelspeedsignalreadbytheABScontrolmodule.CertainABSisanABScontrolmoduleinternalparameter.Page515ABS:4E-12StepAction1)RemovecombinationmeterwithignitionswitchturnedGotoStep6.“RED/BLU”circuitOFF.shortedtoground.2)Measureresistancebetween“RED/BLU”wireofcombinationmeterconnectorandvehiclebodyground.Isitinfinite()?IsCircuitfuseforcombinationmeteringoodcondition?GotoStep5.Page5164E-13ABS:TroubleshootingStepAction1)Performdiagnostictroublecodecheck.GotoStep7of“ABSGotoStep2.Check:”.IsthereanyDTC(s)?AremainfusesforABSpumpmotorandABSsolenoidinGotoStep3.Replacefuseandcheckgoodcondition?circuitforshortto...Page517ABS:4E-14ABSWarningLampFlashesContinuouslywhileIgnitionSwitchIsONS4RS0A4504010WiringDiagramI4RS0A450011-[A]:ABShydraulicunit/controlmoduleconnectorE035.Combinationmeter1.Battery6.ABSwarninglamp2.Mainfusebox7.EBDwarninglamp(brakewarninglamp)3.Page5184E-15ABS:EBDWarningLamp(BrakeWarningLamp)ComesONSteadyS4RS0A4504012WiringDiagramI4RS0A450010-[A]:ABShydraulicunit/controlmoduleconnectorE034.Circuitfusebox8.Lampdrivermodule1.Battery5.Combinationmeter9.ABShydraulicunit/controlmoduleassembly2.Page519ABS:4E-16SerialDataLinkCircuitCheckS4RS0A4504013I4RS0A450012-[A]:ABShydraulicunit/controlmoduleconnectorE031.Battery4.Circuitfusebox7.Lampdrivermodule10.ABShydraulicunit/controlmoduleassembly2.Mainfusebox5.Page5204E-17ABS:StepAction1)TurnignitionswitchtoOFFposition.GotoStep6.GroundcircuitforABShydraulicunit/control2)CheckforproperconnectiontoABShydraulicunit/moduleopenorhighcontrolmoduleconnectoratterminals“E03-13”andresistance.Page521ABS:4E-18DTCC1021,C1022/C1025,C1026/C1031,C1032/C1035,C1036:Right-Front/Left-Front/Right-Rear/Left-RearWheelSpeedSensorCircuitorSensorRingS4RS0A4504015WiringDiagramI4RS0A450014-[A]:ABShydraulicunit/controlmoduleconnectorE033.Page5224E-19ABS:StepAction1)TurnignitionswitchOFF.GotoStep4.ABSwheelspeedsensorcircuitshortedto2)ConnectapplicableABSwheelspeedsensorcoupler.power.3)DisconnectABShydraulicunit/controlmoduleconnector.4)CheckforproperconnectiontoABScontrolmoduleateachsensorterminal.Page523ABS:4E-20DTCC1041/C1045/C1051/C1055,DTCC1042/C1046/C1052/C1056:Right-Front/Left-Front/Right-Rear/Left-RearInletSolenoidCircuit,Right-Front/Left-Front/Right-Rear/Left-RearOutletSolenoidCircuitS4RS0A4504016WiringDiagramI4RS0A450015-[A]:ABShydraulicunit/controlmoduleassembly3.Page5244E-21ABS:DTCC1057:PowerSourceCircuitS4RS0A4504017WiringDiagramI4RS0A450016-[A]:ABShydraulicunit/controlmoduleconnectorE032.Mainfusebox1.Battery3.ABShydraulicunit/controlmoduleassemblyDTCDetectingConditionTheABScontrolmodulemonitorsthepowersourcevoltageatterminal“E03-14”.Whenthepowersourcevoltagebecomesextremelyhighorlowwhilevehicleisrunningatmorethan20km/h(13MPH),thisDTCwillbeset.Page525ABS:4E-22StepAction1)Measurevoltagebetweenterminals“E03-14”and“E03-PoorconnectionofCheckchargingsystem13”withenginerunning.“E03-14”and/or“E03-referringto“Generator13”terminals.IftheTest(OverchargedIsvoltage181.0Vorless?terminalsareingoodBatteryCheck):incondition,substitutea...Page5264E-23ABS:DTCC1063:SolenoidValvePowerSupplyDriverCircuitS4RS0A4504019WiringDiagramI4RS0A450018-[A]:ABShydraulicunit/controlmoduleconnectorE035.Solenoidvalvepowersupplydriver(transistor)1.Battery6.ABShydraulicunit/controlmoduleassembly2.Page527ABS:4E-24DTCC1071:ABSControlModuleS4RS0A4504020WiringDiagramI4RS0A450019-[A]:ABShydraulicunit/controlmoduleconnectorE032.Mainfusebox4.ABShydraulicunit/controlmoduleassembly1.Battery3.ABSpowercontrolmoduleDTCDetectingConditionThisDTCwillbesetwhenaninternalmalfunctionisdetectedintheABScontrolmodule.Page528Brakepedal(1)shouldbedepressedandthenselectgoodcondition.testingwheelbySUZUKIscantoolandthewheel(2)shouldbeturnedbyanotherperson’shand.Atthis2)Checkthatbatteryvoltageis11Vorhigher.Page529ABS:4E-26I4RS0A450021-1.ABShydraulicunit/controlmoduleassembly3.Connector9Nm(0.9kg-m,6.5lb-ft)2.Bracket16Nm(1.6kg-m,11.5lb-ft)25Nm(2.5kg-m,18.0lb-ft)ABSHydraulicUnit/ControlModuleAssemblyABSHydraulicUnit/ControlModuleAssemblyOn-VehicleInspectionRemovalandInstallation...Page5304E-27ABS:5)RemoveboltandpulloutABShydraulicunit/control3)Usingspecialtool,loosenflarenuts(1)anddisconnectbrakepipes(2)fromABShydraulicunit/moduleassembly(1)frombracket(3)usingflatendcontrolmoduleassembly(3).Page531ABS:4E-282)Bleedairfrombrakesystemreferringto“AirBleedingofBrakeSystem:inSection4A”.3)Checkeachinstalledpartforfluidleakageandperform“ABSHydraulicUnitOperationCheck:”.NOTE:FornewABShydraulicunit/controlmoduleassembly,if“ABSHydraulicUnitOperationCheck:”...Page5324E-29ABS:InstallationFrontWheelSpeedSensorInspectionS4RS0A45060071)Checkthatnoforeignmaterialisattachedtosensor•Checksensorfordamage.(1)andsensorring(2).•Measureresistanceofsensor.2)Installitbyreversingremovalprocedure.Betweenbothterminals(1)ofsensorTighteningtorque1.2–...Page533ABS:4E-30Reference6)DetachABSwheelsensorwireharness(1).Whenusingoscilloscopeforthischeck,checkifpeak-to-NOTE:peakvoltage(1)meetsspecificationandwaveformiscomplete.DonotdetachclipofrearwheelspeedsensorconnectorfromvehiclebodyunlessPeak-to-peakvoltageat1/2to1rotationpersecondreplacementisnecessary.Page5344E-31ABS:RearWheelSpeedSensorInspection•Besuretoinstallwheelspeedsensor(2)anditsboltatthecorrect(upper)positionasshowninfigure.S4RS0A4506010•Checksensorfordamage.Tightensensorbolt(1)andharnessclampboltstospecifiedtorque.Page535ABS:4E-32FrontWheelSpeedSensorRingRemovaland•Checkthatnoforeignmaterialisattached.Ifanyfaultyisfound,repairorreplace.InstallationS4RS0A4506012NOTE:Thefrontwheelsensorringcannotberemovedorreplacedalone.Iffrontwheelsensorringneedstobereplaced,replaceitasawheelsidejointassemblyofdriveshaft.Page5364E-33ABS:SpecialToolsandEquipmentSpecialToolS4RS0A450800109950–78220SUZUKIscantoolFlarenutwrench(10mm)—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.DLCcable,4.SAE16/19adapter,5.Cigarettecable,6.DLCloopbackadapter,7.Page537TableofContents5-iSection5Transmission/TransaxleCONTENTSPrecautions..........5-1DTCP0712:TransmissionFluidTemperatureSensorCircuitLow....5A-47Precautions.............5-1DTCP0713:TransmissionFluidPrecautionsonTransmission/Transaxle.....5-1TemperatureSensorCircuitHigh....5A-48AutomaticTransmission......5A-1DTCP0717:Input/TurbineSpeedSensorCircuitMalfunction...........5A-49Precautions............5A-1...Page5385-iiTableofContentsInspectionofTCMandItsCircuits....5A-86DirectClutchAssemblyDisassemblyTCMPowerandGroundCircuitCheck.....5A-90andReassembly...........5A-127BrakeInterlockSystemInspection....5A-91DirectClutchAssemblyInspection....5A-129ForwardandReverseClutchAssemblyRepairInstructions..........5A-92Components..........5A-130LearningControlInitialization......5A-92...Page539TableofContents5-iiiVehicleSpeedSensor(VSS)RemovalRecommendedServiceMaterial.......5B-35andInstallation..........5B-7SpecialTool............5B-35BackUpLampSwitchRemovalandClutch............5C-1Installation............5B-7BackUpLampSwitchInspection.......5B-8GeneralDescription..........5C-1ManualTransaxleUnitComponents....Page5405-1Precautions:PrecautionsPrecautionsPrecautionsonTransmission/TransaxleS4RS0A5000001AirBagWarningReferto“AirBagSystemServiceWarning:inSection00”.•DiagnosticinformationstoredinTCMmemorycanbemayoccurandoftentimewouldbewasted.clearedaswellascheckedbyusingSUZUKIscanAstheautomatictransaxleconsistsofhighprecisiontoolorgenericscantool.Beforeusingscantool,readcomponent,thefollowingcautionsshouldbestrictlyitsOperator’s(Instruction)Manualcarefullytohave...Page5425A-2AutomaticTransmission:CAUTION:PartInspectionandCorrectionTablePartInspectforCorrection•KeepcomponentpartsingroupforeachCastedpart,Smallflaw,burrRemovewithoilsubassemblyandavoidmixingthemup.machinedpartstone.•CleanallpartswithcleaningsolventDeeporgroovedReplacepart.Page543AutomaticTransmission:5A-3GeneralDescriptionA/TDescriptionS4RS0A5101001Thisautomatictransaxleiselectroniccontrolfullautomatictransaxlewithforward3-speedplusoverdrive(O/D)andreverse1-speed.Thetorqueconverterisa3-element,1-stepand2-phasetypeandisequippedwithanautomaticallycontrolledlock-upmechanism.Page5445A-4AutomaticTransmission:202122I3RM0B510001-1.Driveplate11.1standreversebrake21.Rearsungear2.Torqueconverterclutch(TCC)12.Ringgear22.Frontsungear3.Torqueconverter13.Longplanetpinion23.Shortplanetpinion4.Page545Wettypemultiple-discbrake...3setsOne-wayclutch...2setsReductiongearratio1.023Finalgearreductionratio4.052LubricationLubricationsystemForcefeedsystembyoilpumpCoolingCoolingsystemRadiatorassistedcooling(water-cooled)FluidusedSUZUKIATF3317orMobilATF3309...Page5465A-6AutomaticTransmission:Clutch/Brake/PlanetaryGearFunctionofAutomaticTransaxleS4RS0A5101002I4RS0A510001-1.Inputshaftandintermediateshaft8:One-wayNo.2clutch15.Frontsungear2:Directclutch9:2ndbrake16.Rearsungear3.Reductiondrivegear10:One-wayNo.1clutch17.Page547AutomaticTransmission:5A-7PartSelectorGearShiftsolenoidShiftsolenoidTCCsolenoidForwardReversepositionpositionDirectclutchvalve-A(No.1)valve-B(No.2)valveclutchclutchPartSelectorGearO/Dand2nd1standOne-wayNo.1One-wayNo.2positionposition2ndbrakecoastbrakereversebrakeclutch...Page5485A-8AutomaticTransmission:DrivingCycle(MIL)doesnotlightatthistime.ItlightsupatthesecondA“DrivingCycle”consistsofenginestartup,drivingdetectionofsamemalfunctionalsointhenextdrivingmodewhereamalfunctionwouldbedetectedifpresent,cycle.Page549AutomaticTransmission:5A-9SchematicandRoutingDiagramTransmissionControlModule(TCM)WiringDiagramS4RS0A5102001C35-6C34-11LTGRNC35-162.5VC34-12BLK/REDC35-25C34-16YEL/BLKC34-15BLK/YELC34-14BLU/BLKC34-7C34-17C34-5WHT/BLUC34-3WHT/BLKC34-4C34-2LTGRN/BLKC34-24WHT/REDLTGRNYEL/BLK...Page5505A-10AutomaticTransmission:OperationofShiftSolenoidValves,TimingSolenoidValveandTCCSolenoidValveSolenoidShiftShiftSelectorGearTimingsolenoidsolenoidConditionpositionpositionsolenoidsolenoidvalve-Avalve-Bvalvevalve(No.1)(No.2)ParkingWhenvehicleistravelingforwardsinlessthan9km/h,6mile/hvehiclespeedReverseWhenvehicleistravelingforwardsin9...Page551AutomaticTransmission:5A-11AutomaticGearShiftTableS4RS0A5102002Automaticgearshiftscheduleisshowninthefollowingtable.Test-drivethevehicleonaflatroadintheDposition.1.ShiftPointinD,3and/or2positionThrottleopening(%)ShiftVehiclespeedkm/h(mph)Remark...Page5525A-12AutomaticTransmission:ComponentLocationElectronicShiftControlSystemComponentsLocationS4RS0A5103001I4RS0A510006-1.Engine8.TCCpressurecontrolsolenoidvalve15.ECM2.Transaxle9.Transmissionfluidtemperaturesensor16.TCM3.MIL10.Timingsolenoidvalve17.ATrelay4.Page553AutomaticTransmission:5A-13TorqueconverterwithPlanetarygearFinalgearEngineunittorqueconverterclutchreductionunitClutchesandRegulatorvalvesbrakesOilpumpinvalvebodyControlvalvesinvalvebodyPressurecontrolsolenoidvalveShiftsolenoidvalves,TCCpressurecontrolsolenoidvalveandTimingsolenoidvalveTransmissioncontrolmodule(TCM)Page5545A-14AutomaticTransmission:DiagnosticInformationandProceduresA/TSystemCheckS4RS0A5104001Refertothefollowingitemsforthedetailsofeachstep.StepActionCustomercomplaintanalysisGotoStep2.Performcustomercomplaintanalysis.1)Performcustomercomplaintanalysis.Wascustomercomplaintanalysisperformed?DTC/freezeframedatacheck,recordandclearancePrintDTCorwritethem...Page555AutomaticTransmission:5A-15Customerprobleminspectionform(Example)I2RH01510008-NOTE:Theformisastandardsample.Itshouldbemodifiedaccordingtoconditionscharacteristicofeachmarket.Page5565A-16AutomaticTransmission:Step2.DTC/FreezeFrameDataCheck,RecordandStep8.A/TBasicCheckandA/TSymptomClearanceDiagnosisFirst,referringto“DTCCheck:”,checkDTCandPerformbasiccheckofA/Taccordingto“A/TBasicpendingDTC.Page557AutomaticTransmission:5A-17VisualInspectionS4RS0A5104002Visuallycheckthefollowingpartsandsystems.InspectionitemReferring•A/Tfluid-----level,leakage,color“AutomaticTransaxleFluidLevelInspection:inSection0B”•A/Tfluidhoses-----disconnection,looseness,deterioration“A/TFluidCoolerHosesReplacement:”•...Page5585A-18AutomaticTransmission:DetectingconditionDrivingcycleDTCNo.Detectingitem(DTCwillsetwhendetecting)whenMILlightedInput/TurbinespeedsensorNosensorsignalisdetectedalthoughoutputP07171drivingcyclecircuitnosignalspeedsensorsignalisinputted.OutputspeedsensorcircuitnoNosensorsignalisinputtedalthoughinputP0722...Page559ECMandTCMisreadanddisplayed1)ConnectSUZUKIscantooltodatalinkconnectorinatatime.Incaseusinggenericscantool,thesamemanneraswhenmakingthisconnectionreferto“DTCTable:inSection1A”.Page5605A-20AutomaticTransmission:Fail-SafeTableS4RS0A5104008Thisfunctionisprovidedbythesafemechanismthatassuressafedriveabilityevenwhenthesolenoidvalve,sensororitscircuitfails.Thefollowingtableshowsthefail-safefunctionforeachfailconditionofsensor,solenoidoritscircuit.DTCNo.Page561AutomaticTransmission:5A-21DTCNo.TroubleareaFail-safeoperationIncaseofthrottlepositionsignalmalfunction:•Throttleopeningusedforlinepressurecontrolisassumedtobe100%.•Throttleopeningusedforgearshiftingcontrolisassumedtobe0%.•...Page5625A-22AutomaticTransmission:DTCNo.TroubleareaFail-safeoperation•Throttleopeningusedforlinepressurecontrolisassumedtobe100%.•Throttleopeningusedforgearshiftingcontrolisassumedtobe0%.•Enginerevolutionisassumedtobe0RPM.•...Page563AutomaticTransmission:5A-23Normalcondition/referenceScantooldataVehicleconditionvaluesAfterdrivingat60km/h(37.5mile/h)for15minutesormore,andA/Tfluidtemperaturearoundsensor70–80C(158–176F)TEMPERATUREreaches70–...Page5645A-24AutomaticTransmission:Normalcondition/referenceScantooldataVehicleconditionvaluesEnginerunningatidlespeedandselectorleverisin0RPM“P”rangeSLIPRPMEnginerunning,vehiclestopandselectorleverisinEnginespeedisdisplayed“D”...Page565AutomaticTransmission:5A-25TORQUEREDUCTIONSIGNALENGINETORQUESIGNAL(Nm)ON:SignalwhichTCMrequireECMtoreduceoutputEnginetorquecomputedbydutypulsesignaloutputtedtorqueatshiftinggearfromECM.OFF:SignalwhichTCMdoesnotrequireECMtoreduceoutputtorqueSLIPRPM(RPM)Thisparameterindicatesslippingrotationinthetorque...Page5665A-26AutomaticTransmission:RoadTestS4RS0A5104011Thistestistocheckifupshift,downshiftandlock-uptakeplaceatspecifiedspeedswhileactuallydrivingvehicleonalevelroad.WARNING:•Carryouttestinverylittletrafficareatopreventanaccident.•...Page567AutomaticTransmission:5A-27ConditionPossiblecauseCorrection/ReferenceItem4upshiftfailstoMalfunctionofshiftsolenoidvalve-BInspect.IfNG,replace.occurMalfunctionof“3”positionswitchInspect.IfNG,replace.MalfunctionofenginecoolantInspect.IfNG,replace.temperaturesensorMalfunctionofoutputshaftspeedInspect.Page5685A-28AutomaticTransmission:ConditionPossiblecauseCorrection/ReferenceItemTCC(lock-up)functionMalfunctionofTCCpressurecontrolInspect.IfNG,replace.pressurecontroldoesnotsolenoidvalveoperateMalfunctionofshiftsolenoidvalve-AInspect.IfNG,replace.and/or-BMalfunctionofbrakelightswitchInspect.Page569AutomaticTransmission:5A-29TroubleshootingConditionPossiblecauseCorrection/ReferenceItemOperatedgearisnotFaultyvalvebodycomponentReplacevalvebodyassembly.correctFaultyclutchorbrakeInspectclutchandbrake.Ifanypartsarefaulty,replacethem.EngineBrakeTestS4RS0A5104016WARNING:Beforetest,makesurethatthereisnovehiclebehindsoastopreventrear-endcollision.Page5705A-30AutomaticTransmission:TroubleshootingConditionPossiblecauseCorrection/ReferenceItemLowerthanstandardlevelEngineoutputtorquefailureInspectandrepairengine.inboth“D”and“R”rangeFaultyone-wayclutchoftorqueReplacetorqueconverter.converterHigherthanstandardMalfunctionofpressurecontrolsolenoidInspect.Page571AutomaticTransmission:5A-31TimeLagTestS4RS0A5104014Thistestistocheckconditionsofclutch,brakeandfluidpressure.“Timelag”meanstimeelapsedsinceselectleverisshiftedwithengineidlingtillshockisfelt.1)Withchocksplacedbeforeandbehindfrontandrearwheelsrespectively,depressbrakepedal.2)Startengine.Page5725A-32AutomaticTransmission:LinePressureTestS4RS0A5104015Purposeofthistestistocheckoperatingconditionsofeachpartbymeasuringfluidpressureinfluidpressureline.Linepressuretestrequiresthefollowingconditions.•Automaticfluidisatnormaloperatingtemperature(70–80C/158–176F).•...Page573AutomaticTransmission:5A-33“P”RangeTestS4RS0A51040171)Stopvehicleonaslopeof5degreesormore,shiftselectleverto“P”rangeandatthesametimeapplyparkingbrake.2)Afterstoppingengine,depressbrakepedalandreleaseparkingbrake.3)Then,releasebrakepedalgraduallyandcheckthatvehicleremainsstationary.Page5745A-34AutomaticTransmission:ConditionPossiblecauseCorrection/ReferenceItemPoor12shiftShiftsolenoidvalve-BcircuitfaultyInspectcircuitforopen,shortandintermittent.IfNG,repair.Outputshaftspeedsensor(VSS)circuitInspectcircuitforopen,shortandintermittent.faultyIfNG,repair.Page575AutomaticTransmission:5A-35ConditionPossiblecauseCorrection/ReferenceItemPoor34shiftShiftsolenoidvalve-BcircuitfaultyInspectcircuitforopen,shortandintermittent.IfNG,repair.PressurecontrolsolenoidvalvecircuitInspectcircuitforopen,shortandintermittent.faultyIfNG,repair.Page5765A-36AutomaticTransmission:ConditionPossiblecauseCorrection/ReferenceItemPoor32shiftShiftsolenoidvalve-AcircuitfaultyInspectcircuitforopen,shortandintermittent.IfNG,repair.Outputshaftspeedsensor(VSS)circuitInspectcircuitforopen,shortandintermittent.faultyIfNG,repair.Page577AutomaticTransmission:5A-37ConditionPossiblecauseCorrection/ReferenceItemNonoperateTCC(lock-TCCpressurecontrolsolenoidvalveInspectcircuitforopen,shortandintermittent.up)systemcircuitfaultyIfNG,repair.Shiftsolenoidvalve-Aand/or-BcircuitInspectcircuitforopen,shortandintermittent.faultyIfNG,repair.Page5785A-38AutomaticTransmission:TroubleDiagnosis2On-vehiclerepairConditionPossiblecauseCorrection/ReferenceItemUnabletoruninallrangeFaultyvalvebodycomponentReplacevalvebodyassembly.ExcessiveshiftshockEngineabnormalconditionInspectandrepairengine.Malfunctionofshiftsolenoidvalve-AInspect.Page579AutomaticTransmission:5A-39ConditionPossiblecauseCorrection/ReferenceItemPoor34shiftMalfunctionofshiftsolenoidvalve-BInspect.IfNG,replace.MalfunctionoftimingsolenoidvalveInspect.IfNG,replace.MalfunctionofoutputshaftspeedInspect.IfNG,replace.sensor(VSS)MalfunctionofinputshaftspeedsensorInspect.Page5805A-40AutomaticTransmission:ConditionPossiblecauseCorrection/ReferenceItemNonoperateTCC(lock-MalfunctionofTCCsolenoidvalveInspect.IfNG,replace.up)systemMalfunctionofshiftsolenoidvalve-AInspect.IfNG,replace.and/or-BMalfunctionofoutputshaftspeedInspect.Page581AutomaticTransmission:5A-41ConditionPossiblecauseCorrection/ReferenceItemPoor21shift,Faulty2ndbrakeInspect.IfNG,replace.excessiveshockorFaultyone-wayNo.2clutchInspect.IfNG,replace.slippageNonoperateTCC(lock-FaultytorqueconverterReplace.Page5825A-42AutomaticTransmission:StepAction1)PerformrunningtestunderthefollowingconditionsandFaultyshiftsolenoid“BRN”circuitshortedtomeasurevoltagebetweenterminal“C39-16”ofTCMvalve,circuitorpowercircuitoropen,orconnectorandground,terminal“C39-15”ofTCMtransaxle.Page5834)Keepenginerunningatidlespeedfor25secondsormore.5)StopvehicleandcheckDTC.DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.DoyouhaveSUZUKIscantool?GotoStep3.GotoStep4.Page584GotoStep5.operationCheckforintermittentCheckbyusingSUZUKIscantool:referringto“Intermittent1)ConnectSUZUKIscantooltoDLCwithignitionswitchandPoorConnectionOFF.Inspection:inSection00”.2)TurnignitionswitchONandchecktransmissionrangesignal(“P”,“R”,“N”,“D”,“2”...Page5856)RepeatStep3)to4)onetime.7)StopvehicleandcheckDTC.DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.DoyouhaveSUZUKIscantool?GotoStep3.GotoStep4.Page586GotoStep5.operationCheckforintermittentCheckbyusingSUZUKIscantool:referringto“Intermittent1)ConnectSUZUKIscantooltoDLCwithignitionswitchandPoorConnectionOFF.Inspection:inSection00”.2)TurnignitionswitchONandchecktransmissionrangesignal(P,R,N,D,2orL)ondisplaywhenshiftingselectlevertoeachrange.Page587AutomaticTransmission:5A-47DTCP0712:TransmissionFluidTemperatureSensorCircuitLowS4RS0A5104046WiringDiagramLTGRNC34-11C34-121211I4RS0A510011-1.TCM3.A/T2.Transmissionfluidtemperaturesensor4.TerminalarrangementofTCMconnector(viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroublearea...Page5885A-48AutomaticTransmission:DTCP0713:TransmissionFluidTemperatureSensorCircuitHighS4RS0A5104023WiringDiagramLTGRNC34-11C34-121211I4RS0A510011-1.TCM3.A/T2.Transmissionfluidtemperaturesensor[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroublearea...Page589AutomaticTransmission:5A-49StepActionChecktransmissionfluidtemperaturecircuitforIG“LTGRN”circuitshortedIntermittenttroubleorshorttopowercircuit.faultyTCM.1)CooldownA/TfluidtemperatureunderambientIfcircuitisOK,gotoCheckforintermittenttemperature.Page5905A-50AutomaticTransmission:DTCConfirmationProcedureWARNING:•Whenperformingaroadtest,selectaplacewherethereisnotrafficorpossibilityofatrafficaccidentandbeverycarefulduringtestingtoavoidoccurrenceofanaccident.•Roadtestshouldbecarriedoutwith2persons,adriverandatester,onalevelroad.1)ConnectscantooltoDLCwithignitionswitchOFF,ifavailable.Page591AutomaticTransmission:5A-51DTCP0722:OutputSpeedSensor(VSS)CircuitNoSignalS4RS0A5104025WiringDiagramBLK/REDC35-25YEL/BLKI4RS0A510013-1.TCM3.ToECM2.Outputshaftspeedsensor(VSS)[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroublearea...Page5925A-52AutomaticTransmission:StepActionCheckoutputshaftspeedsensor(VSS)groundcircuitGotoStep4.“YEL/BLK”wireopen.1)TurnignitionswitchOFF.2)Checkcontinuitybetween“YEL/BLK”wireterminalofdisconnectedoutputshaftspeedsensorharnesssideconnectorandground.Page593AutomaticTransmission:5A-53DTCP0741/P0742:TCCCircuitPerformanceorStuckOFF/TCCCircuitStuckONS4RS0A5104027DTCDetectingConditionandTroubleAreaDTCP0741DTCdetectingconditionTroubleareaWhendrivingvehiclewith3rdor4thgearin“D”range,•...Page5945A-54AutomaticTransmission:DTCP0751/P0752/P0756/P0757:ShiftSolenoidMalfunctionS4RS0A5104030DTCP0751:ShiftSolenoid-A(No.1)PerformanceorStuckOFFDTCP0752:ShiftSolenoid-A(No.1)StuckONDTCP0756:ShiftSolenoid-B(No.2)PerformanceorStuckOFFDTCP0757:ShiftSolenoid-B(No.2)StuckONDTCDetectingConditionandTroubleAreaDTCP0751...Page595AutomaticTransmission:5A-554)Shiftselectleverto“N”and“D”rangefor10seconds.5)Startvehicleandincreasevehiclespeedto65km/h(40mile/h)withthrottleposition10%ormore.6)StopvehicleandturnignitionswitchOFF.7)RepeatStep3)to5)onetime.Page5965A-56AutomaticTransmission:DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.ChecktimingsolenoidvalveresistanceGotoStep3.Replacetimingsolenoidvalveorleadwire.1)TurnignitionswitchOFF.2)Disconnectvalvebodyharnessconnector(1),(2)ontransaxle.Page597AutomaticTransmission:5A-57DTCP0788:Shift/TimingSolenoidControlCircuitHighS4RS0A5104050WiringDiagramBLU/BLKC34-14I4RS0A510014-1.TCM3.A/T2.Timingsolenoidvalve[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaVoltageoftimingsolenoidvalveTCMterminalishigh...Page5985A-58AutomaticTransmission:StepActionChecktimingsolenoidvalveresistance“BLU/BLK”circuitopen.Replacetimingsolenoidvalveorleadwire.1)TurnignitionswitchOFF.2)Disconnectvalvebodyharnessconnector(1),(2)ontransaxle.3)Checkforproperconnectiontosolenoidvalveat“BLU/BLK”...Page599AutomaticTransmission:5A-59DTCP0962:PressureControlSolenoidControlCircuitLowS4RS0A5104032WiringDiagramC34-4C34-2LTGRN/BLKI4RS0A510015-1.TCM3.A/T2.Pressurecontrolsolenoidvalve[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaPressurecontrolsolenoidvalveoutputvoltageistoolow...Page6005A-60AutomaticTransmission:DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.CheckpressurecontrolsolenoidvalveresistanceGotoStep3.Replacepressurecontrolsolenoidvalveor1)TurnignitionswitchOFF.valvebodyharness.Page601AutomaticTransmission:5A-61StepActionCheckpressurecontrolsolenoidvalvecircuitforopen“GRY”or“LTGRN/BLK”Intermittenttroubleorcircuitopen.faultyTCM.1)Checkresistancecontinuitybetweenterminals“C34-2”and“C34-4”ofdisconnectedharnesssideTCMCheckforintermittentconnector.Page6025A-62AutomaticTransmission:DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.CheckpressurecontrolsolenoidcircuitforIGshortGotoStep3.“BRN/YEL”or“LTGRN”circuitshortedtopower1)Connectvalvebodyharnessconnector.Page603AutomaticTransmission:5A-63DTCP0973/P0976:ShiftSolenoid-A(No.1)ControlCircuitLow/ShiftSolenoid-B(No.2)ControlCircuitLowS4RS0A5104051WiringDiagramC34-16BLK/YELC34-151615I4RS0A510016-1.TCM3.Shiftsolenoidvalve-B(No.2)2.Shiftsolenoidvalve-A(No.1)[A]:TerminalarrangementofTCMconnector(Viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingcondition...Page6045A-64AutomaticTransmission:DTCTroubleshootingStepActionWas“AutomaticTransaxleDiagnosticFlowTable”GotoStep2.Goto“A/TSystemperformed?Check:”.CheckshiftsolenoidvalveresistanceGotoStep3.Replaceapplicableshiftsolenoidvalveorvalve1)TurnignitionswitchOFF.Page605AutomaticTransmission:5A-65DTCP0974/P0977:ShiftSolenoid-A(No.1)/ShiftSolenoid-B(No.2)ControlCircuitHighS4RS0A5104048WiringDiagramC34-16BLK/YELC34-151615I4RS0A510016-1.TCM3.Shiftsolenoidvalve-B(No.2)[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)2.Page6065A-66AutomaticTransmission:DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.CheckshiftsolenoidvalvecircuitforIGshortGotoStep3.DTCP0974:“BRN”circuitshortedtopower1)Connectvalvebodyharnessconnector.Page607AutomaticTransmission:5A-67DTCP1702:InternalControlModuleMemoryCheckSumErrorS4RS0A5104033DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaCalculationofcurrentdatastoredinTCMisnotcorrectcomparingwithpre-storedcheckingdatainTCM.DTCConfirmationProcedure1)ConnectscantooltoDLCwithignitionswitchOFF.Page608Substituteaknown-GotoStep3.goodTCMandrecheck.1)ConnectSUZUKIscantooltoDLCwithignitionswitchOFF.2)TurnignitionswitchONandcheck“3”positionswitchsignalonscantooldatadisplaywhenshiftingselectlevertoeachrange.Page609AutomaticTransmission:5A-69StepAction“3”positionswitchsignalinspectionSubstituteaknown-GotoStep4.WithignitionswitchON,checkvoltagebetween“L01-8”goodBCMandrecheck.terminalofBCMcouplerandground.“3”positionswitchspecificationsShiftselectorleverto“3”or“2”range:BatteryvoltageShiftselectorlevertootheraboverange:0VIstheresultasspecified?Check“3”...Page6105A-70AutomaticTransmission:DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.CheckDTCGotoapplicableDTCGotoStep3.diag.flow.1)ConnectscantooltoDLCwithignitionswitchturnedOFF.Page611AutomaticTransmission:5A-71StepActionCheckCANcommunicationlinecircuitinsulationGotoStep10.RepairinsulationofCANcommunication1)DisconnectconnectorsfromECM,BCM,TCMandlinecircuitreferringtocombinationmeterwithignitionswitchOFF.“PrecautionforCAN2)Measureresistanceatthefollowingconnectorterminals.Page6125A-72AutomaticTransmission:StepAction12CheckCANcommunicationlinecircuitpowersupplySubstituteaknown-RepairshortedtopowershortgoodBCM(includedinsupplyofCANjunctionblockcommunicationline1)Measurevoltageatthefollowingconnectorterminalsassembly)andrecheck.Page613AutomaticTransmission:5A-73DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaTransmissionerrorofcommunicationdataforTCMisdetectedmore•ECMthanspecifiedtimecontinuously.•BCM•TCM•Combinationmeter•CANcircuitDTCConfirmationProcedure1)ConnectscantooltoDLCwithignitionswitchOFF.Page6145A-74AutomaticTransmission:StepActionCheckCANcommunicationlinecircuitinsulationGotoStep9.RepairinsulationofCANcommunication1)Measureresistancebetween“C34-17”and“C34-7”linecircuitreferringtoterminalsofTCMconnector.“PrecautionforCANIsresistanceinfinity?CommunicationSystem:inSection00”.Page615AutomaticTransmission:5A-75DTCP1777:TCMLostCommunicationwithECM(ReceptionError)S4RS0A5104055WiringDiagramE46-1E23-3E46-2E23-18G28-8G37-4G28-10G37-2C34-17C37-13C37-12C34-73938323139383231545347465453474617161514...Page6165A-76AutomaticTransmission:DTCTroubleshootingStepActionWas“A/TSystemCheck”performed?GotoStep2.Goto“A/TSystemCheck:”.CheckDTCGotoapplicableDTCGotoStep3.diag.flow.1)ConnectscantooltoDLCwithignitionswitchturnedOFF.Page617AutomaticTransmission:5A-77StepAction10CheckCANcommunicationlinecircuitpowersupplyGotoStep11.RepairshortedtopowershortsupplyofCANcommunicationline1)MeasurevoltageatthefollowingconnectorterminalscircuitreferringtowithignitionswitchturnedON.“PrecautionforCAN•...Page6185A-78AutomaticTransmission:DTCP1778:TCMLostCommunicationwithBCM(ReceptionError)S4RS0A5104056WiringDiagramE46-1E23-3E46-2E23-18G28-8G37-4G28-10G37-2C34-17C37-13C37-12C34-73938323139383231545347465453474617161514...Page619AutomaticTransmission:5A-79StepActionCheckTCMforCANcommunicationerrorGoto“DTCP1774:GotoStep4.ControlModule1)CheckDTCinTCM.CommunicationBusIsthereDTCP1774?Off:”.CheckECM,TCMandBCMconnectorsGotoStep5.Page6205A-80AutomaticTransmission:StepAction10CheckCANcommunicationlinecircuitgroundshortGotoStep11.RepairshortedtogroundofCAN1)Measureresistanceatthefollowingconnectorterminals.communicationline•Between“E23-3”terminalofECMconnectorandcircuitreferringtovehiclebodyground“PrecautionforCAN...Page621AutomaticTransmission:5A-81DTCP1878:TorqueConverterClutchShudderS4RS0A5104057DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaTheaccelerationslipcontrolfunctionstopswhenthevariationinthe•MismatchingATFoutputrevolutionspeedofthespecifiedamplitudeandspecifiedcycle•...Page6225A-82AutomaticTransmission:DTCP2763:TorqueConverterClutch(TCC)PressureControlSolenoidControlCircuitHighS4RS0A5104037WiringDiagramC34-5WHT/BLUC34-3WHT/BLKI4RS0A510019-1.TCClock-uppressurecontrolsolenoidvalve3.A/T2.TCM[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroublearea...Page623AutomaticTransmission:5A-83StepActionCheckTCCsolenoidvalvecircuitforIGshortGotoStep3.“WHT/BLU”or“WHT/BLK”circuitshortedto1)Connectvalvebodyharnessconnector.powercircuit.2)DisconnectTCMconnectors.3)CheckforproperconnectiontoTCMatterminal“C34-3”and“C34-5”.Page6245A-84AutomaticTransmission:DTCP2764:TorqueConverterClutch(TCC)CircuitPressureControlSolenoidControlCircuitLowS4RS0A5104036WiringDiagramC34-5WHT/BLUC34-3WHT/BLKI4RS0A510019-1.TCCpressurecontrolsolenoidvalve3.A/T2.TCM[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroublearea...Page625AutomaticTransmission:5A-85StepActionCheckTCClock-uppressurecontrolsolenoidvalveGotoStep3.ReplaceTCClock-upresistancepressurecontrolsolenoidvalveorlead1)TurnignitionswitchOFF.wire.2)Disconnectvalvebodyharnessconnector(1),(2)onautomatictransaxle.Page6265A-86AutomaticTransmission:InspectionofTCMandItsCircuitsS4RS0A5104038TCManditscircuitscanbecheckedatTCMwiringconnectorsbymeasuringvoltage,pulsesignalandresistance.CAUTION:TCMcannotbecheckedbyitself,itisstrictlyprohibitedtoconnectvoltmeterorohmmetertoTCMwithconnectordisconnectedfromit.Page627AutomaticTransmission:5A-87StandardTerminalWirecolorCircuitConditionvoltage*0–0.6VEnginerunningatidling(Outputsignalisdutypulse.TCCpressurecontrol10–14VWHT/BLUDutyratiovariesdependingontorqueconverterclutchsolenoidvalve(+)(“Referenceoperatingcondition).Page6285A-88AutomaticTransmission:StandardTerminalWirecolorCircuitConditionvoltage8–14VIgnitionswitchON,selectorleverat“D”rangeTransmissionrangeIgnitionswitchON,selectorleveratotherthan“D”sensor(“D”range)0–1Vrange8–...Page629AutomaticTransmission:5A-89ReferencewaveformNo.2ReferencewaveformNo.4TCCpressurecontrolsolenoidvalvesignalatengineInputshaftspeedsensorsignalatengineidling.idling.MeasurementCH1:“C35-6”to“C34-1”MeasurementterminalCH1:“C34-5”to“C34-1”terminalOscilloscopeCH1:2V/DIVOscilloscope...Page6305A-90AutomaticTransmission:TCMPowerandGroundCircuitCheckS4RS0A5104039WiringDiagramC34-24WHT/REDYEL/BLKYEL/BLUC34-6LTGRN/BLKC34-1C34-232423I4RS0A510023-1.TCM3.Ignitionswitch2.A/Trelay[A]:TerminalarrangementofTCMconnector(viewedfromharnessside)TroubleshootingStepAction...Page631AutomaticTransmission:5A-91StepActionCheckTCMgroundcircuitTCMpowerandground“BLK”circuitforTCMcircuitsareingoodgroundopen.1)TurnignitionswitchOFF.condition.2)WithTCMconnectorsdisconnected,checkforproperconnectiontoTCMat“C34-1”/“C34-23”terminal.3)IfOK,checkresistancebetween“C34-1”...Page632FULLHOT(2)andLOWHOT(3).IfitisFluidlevelcheckatroom(cold)temperaturebelowLOWHOT,addSUZUKIATF3317orMobilisrecommendedonlyforpreparationoflevelATF3309uptoFULLHOT.Page6333.Connector2.Selectorleverassembly4.“3”positionswitchI3RM0B510033-4)LowervehicleandpourproperamountofSUZUKIATF3317orMobilATF3309.5)Checkfluidlevelreferringto“A/TFluidLevelCheck:”.Automatictransaxlefluid...Page6345A-94AutomaticTransmission:SelectLeverAssemblyInstallationCAUTION:S4RS0A5106068Wheninstallingselectleverknob,donotturnNotethefollowingwheninstallingselectleverassembly:morethanspecifiednumbersofrotation.•Afterinstallingselectleverassembly,adjustselectOtherwiseselectleverknobisdamaged.cablereferringto“SelectCableAdjustment:”.Page635AutomaticTransmission:5A-951.Selectorleverassembly6.Clip11.Lock2.Selectcable7.Selectcableretainerbolt(a):23Nm(2.0kg-m,17.0lb-ft)3.Selectcableretainer8.Manualselectleverpin(b):5.0Nm(0.55kg-m,4.0lb-ft):Applylithiumgrease99000-25010toallaroundpin(0.15g)4.Page6365A-96AutomaticTransmission:TransmissionRangeSensor(ShiftSwitch)OutputShaftSpeedSensor(VSS)RemovalandInspectionandAdjustmentInstallationS4RS0A5106008S4RS0A5106009Removal1)Shiftmanualselectlever(4)to“N”range.1)Disconnectnegativecableatbattery.2)Checkthatneedledirectionshapedonlockwasher(2)and“N”...Page637AutomaticTransmission:5A-97OutputShaftSpeedSensor(VSS)InspectionInstallationS4RS0A51060101)ApplyA/TfluidtoinputshaftspeedsensorO-ring.1)Connectpositivecableof12voltbatteryto“A”2)Installinputshaftspeedsensor(1)toA/Tcaseandterminalofsensorandgroundcableto“C”...Page6385A-98AutomaticTransmission:TransmissionFluidTemperatureSensorRemovalandInstallationS4RS0A5106059Removal1)Disconnectnegativecableatbattery.2)Liftupvehicle.3)Withengineiscool,removedrainpluganddrainA/Tfluid.4)Installdrainplug.Referto“A/TFluidChange:”.5)RemoveA/Toilpan.Page639AutomaticTransmission:5A-99“3”PositionSwitchInspectionS4RS0A51060141)Removeconsoleboxreferringto“ConsoleBoxComponents:inSection9H”.2)Disconnect“3”positionswitchconnector(1).3)Checkcontinuitybetween“3”positionswitchterminals.“3”positionswitchspecificationShiftselectorleverto“3”or“2”range:ContinuityShiftotheraboverange:NocontinuityI2RH0B510054-...Page6405A-100AutomaticTransmission:Installation1)Installshiftsolenoidvalve-A(No.1)(1),shiftsolenoidvalve-B(No.2)(2)andtimingsolenoidvalve(3).TighteningtorqueShiftsolenoidbolt(a):11N·m(1.1kg-m,8.0lb-I2RH0B510059-5)Installnewoilpangasket(1)andoilpan(2).6)Tightenoilpanboltstospecifiedtorquediagonallyandlittlebylittle.Page641AutomaticTransmission:5A-101OperationCheckTimingsolenoidvalveCAUTION:Shiftsolenoidvalve-A(No.1)and-B(No.2)•DonotinsertairgunagainststrainerCAUTION:installedoninletofsolenoidvalvetoo•Donotinsertairgunagainststrainerdeeply,whenblowingairintosolenoidinstalledoninletofsolenoidvalvetoovalve.Page6425A-102AutomaticTransmission:PressureControlSolenoidValves(Pressure10)RemovepressurecontrolsolenoidvalveandTCCpressurecontrolsolenoidvalvereferringto“ValveControlSolenoidandTCCPressureControlBodyAssemblyDisassemblyandReassembly:”.Solenoid)RemovalandInstallationS4RS0A5106060RemovalInstallation1)Disconnectnegativecableatbattery.Page643AutomaticTransmission:5A-103UsingregulatedDCpowersupply1)Connectpressurecontrolsolenoidvalve(1)withregulatedDCpowersupply(2)asshowninfigure.2)TurnregulatedDCpowersupplyswitchONandincreasevoltageofpowersupplykeepingcurrentwithin1.0A.Page6445A-104AutomaticTransmission:InstallationDifferentialSideOilSealReplacementReverseremovalprocedurenotingthefollowing.S4RS0A51060191)Liftupvehicleanddrainautomatictransaxlefluid.•ConnectTCMconnectorssecurely.2)Removedriveshaftjointsfromdifferentialgearof•Ifthevehicleisequippedwithairbagsystem,besuretransaxle.Page645AutomaticTransmission:5A-105ShiftLockSolenoidInspectionS4RS0A5106064Checkthatshiftlocksolenoid(1)actuatewhenbatteryvoltageisconducted.I4RS0A510034-ShiftLockSolenoidReplacementS4RS0A51060651)Removeconsoleboxreferringto“ConsoleBoxComponents:inSection9H”.2)Replaceshiftlocksolenoid(1)usingflatheadorlike.3)Installcoversastheywere.Page6465A-106AutomaticTransmission:KeyInterlockCableRemovalandInstallationS4RS0A5106066NOTE:Don’tbendinterlockcableexcessivelywhenremovingandinstallingit,orsystemwillnotoperatecorrectly.Removal1)Ifthevehicleisequippedwithairbagsystem,disconnectnegativecableatbatteryanddisableairbagsystem,referringto“DisablingAirBagSystem:inSection8B”.Page647AutomaticTransmission:5A-10711)Ifthevehicleisequippedwithairbagsystem,connectnegativecableatbatteryandenableairbagsystem,referringto“EnablingAirBagSystem:inSection8B”.A/TFluidCoolerHosesReplacementS4RS0A5106022TherubberhosesfortheA/Tfluidcoolershouldbecheckedatspecifiedinterval.Page6485A-108AutomaticTransmission:AutomaticTransaxleUnitDismountingandNOTE:RemountingWhendetachingtransaxlefromengine,moveS4RS0A5106024itinparallelwithcrankshaftandusecaresoasnottoapplyexcessiveforcetodriveplateDismountingandtorqueconverter.1)Takedowntransaxlewithengine.Foritsprocedure,referto“EngineAssemblyRemovalandInstallation:inSection1D”.Page649AutomaticTransmission:5A-1093)Tightendriveplatetotorqueconverterbolts.Alignboltholeofdriveplateandtorqueconverterthentightenboltsthroughtorqueconverterhousinglowerplateopening.Lockdriveplate(1)byengagingflatheadrodorthelike(2)withdriveplategear.Page6505A-110AutomaticTransmission:AutomaticTransaxleAssemblyComponentsS4RS0A5106025I3RM0B510053-...Page651AutomaticTransmission:5A-1111.Torqueconverter33.Oilpan65.2ndbrakeretainingplate2.Torqueconverterhousing34.A/Tfluiddrainplug66.2ndbrakedisc:Applysealant99000-31230tomatingsurfacetotransaxlecase.3.Oilstrainerassembly35.Page6525A-112AutomaticTransmission:AutomaticTransaxleUnitDisassembly4)Uncaulklockwasher(1),thenremovelocknut(2)S4RS0A5106026andlockwasher.CAUTION:•Thoroughlycleantransaxleexteriorbeforeoverhaulingit.•Keepworkingtable,toolsandhandscleanwhileoverhauling.•...Page653AutomaticTransmission:5A-11312)Disconnectconnectors(2)fromsolenoidvalvesandtransmissionfluidtemperaturesensor(1).I4RS0A510027-13)Removevalvebodyassemblybolts.CAUTION:I3RM0B510059-Becarefulnottoletmanualvalvefalloff10)Removeoilpan(1)andoilpangasket(2).whenremovingvalvebodyassembly.Page6545A-114AutomaticTransmission:18)Removeaccumulatorpistonsandsprings.15)Removevalvebodyharness(1).ToremoveC2(1),C1(2)andB1(3)accumulatorCAUTION:pistonsandsprings,positionragonpistonstocatcheachpiston.Toremovepistons,forcelow-pressureWhenpullingvalvebodyharnessoutofcompressedair(1kg/cm,15psi,100kPa,max)into...Page655AutomaticTransmission:5A-11519)Removetransaxlecaseplug(1).I2RH0B510098-25)Removeoilpumpassembly(1).I2RH0B510095-20)Removetorqueconverterhousingbolts.21)Removetorqueconverterhousing(1)while

tappingarounditlightlywithplastichammer.I2RH0B510099-26)Removedirectclutchassembly(1).I3RM0B510060-22)Removebreatherhose(1).Page6565A-116AutomaticTransmission:28)Removeinputshaftrearthrustbearing(1)andthrust31)RemovegovernorapplyNo.2gasket(1).bearingrace(2).NOTE:Ifinputshaftrearthrustbearingisnotfound,itmayhavebeentakenoutwithdirectclutchassembly.Page657AutomaticTransmission:5A-11735)Remove2ndbrakegasket(1).37)Removeforwardandreverseclutchassembly(1).I2RH0B510109-I2RH0B510111-36)MeasureO/Dand2ndcoastbrakepistonstroke.38)RemoveintermediateshaftthrustbearingfrontraceIfpistonstrokeexceedsspecification,inspectand(1),thrustbearing(2)andrearrace(3)fromforwardreplaceplatesanddiscs.Page6585A-118AutomaticTransmission:40)Removeforwardclutchhub(1).I2RH0B510117-I2RH0B510114-44)Removeplanetarygearthrustbearing(1).41)Removerearsungearthrustbearing(1)fromNOTE:forwardclutchhub(2).IfplanetarygearthrustbearingisnotfoundNOTE:onone-wayclutchNo.1assembly,itmayIfrearsungearthrustbearingisnotfoundon...Page659AutomaticTransmission:5A-119I2RH0B510124-I2RH0B510120-51)Remove2ndbrakepistonassembly(1).48)Removefrontplanetarysungear(1).52)Remove2ndbrakereturnspringsubassembly(2).I2RH0B510121-I4RS0A510038-49)Removefrontsungearthrustbearingrace(2)from53)Remove2ndbrakeseparatorplates(1),discs(2)frontplanetarysungear(1).Page6605A-120AutomaticTransmission:55)Removeone-wayclutchouterraceretainer(1).I2RH0B510132-59)Measure1standreversebrakepistonstroke.I2RH0B510129-Ifpistonstrokeexceedsspecifiedvalue,56)Checkone-wayclutchNo.2asfollows.disassemble,inspectandreplacediscsandplates.•...Page661AutomaticTransmission:5A-121I2RH0B510134-61)Remove1standreversebrakeretainingplate,discsI2RH0B510137-65)Usingspecialtoolsandhydraulicpress,removeandseparatorplates.planetaryringgearsubassembly(1).62)Remove1standreversebrakereturnspringsubassembly(1).CAUTION:Donotreuseplanetaryringgearsubassembly.Page6625A-122AutomaticTransmission:67)Screwing3bolts(1),removereductiondrivegear(2).CAUTION:Screw3boltsintoreductiondrivegearuniformly,orreductiondrivegear,bearingandtransaxlecasemaybedamaged.Boltlength30mm(1.20in.)I2RH0B510142-70)Withslottedscrewdriver,cutandunfoldmanualvalveleverspacer(1)andproceedtoremovemanualvalveleverspacer.Page663AutomaticTransmission:5A-123I2RH0B510146-I2RH0B510147-75)Removemanualshiftshaftoilseal(1).OilPumpAssemblyComponentsS4RS0A5106027I2RH0B510148-1.Oilseal5.Oilpumpdrivegear:Applyautomatictransaxlefluid.:Applygrease99000-25030tooilseallip.2.Page6645A-124AutomaticTransmission:OilPumpAssemblyDisassemblyand2)InstalldrivengearanddrivegeartooilpumpbodyafterapplyingA/Tfluid.ReassemblyS4RS0A51060283)Installstatorshaftassemblytooilpumpbodyandtighten8pumpsubassemblybolts(1)toDisassemblyspecification.Page665AutomaticTransmission:5A-1252)Checktipclearanceofbothdriveanddrivengears.Usingafeelergauge,measureclearancebetweendriveanddrivengeartips.Ifclearanceexceedsitsstandardvalue,replaceoilpumpassembly.TipclearancebetweenoilpumpdrivegearandoilpumpdrivengearStandard:0.07–...Page6665A-126AutomaticTransmission:DirectClutchAssemblyComponentsS4RS0A5106030I2RH0B510160-1.Inputshaftfrontthrustbearing6.OuterO-ring11.Directclutchretainingplate2.Inputshaftsealring7.Directclutchreturnspringsubassembly12.Platesnapring3.Inputshaftsubassembly8.Page667AutomaticTransmission:5A-127DirectClutchAssemblyDisassemblyandReassemblyS4RS0A5106032Disassembly1)Removeplatesnapring(1)thenremovedirectclutchretainingplate,discsandseparatorplates.I2RH0B510165-2.Directclutchpiston6)RemoveinnerO-ring(2).I2RH0B510162-2)Usingspecialtoolandhydraulicpress,removeshaftsnapring(1).Page6685A-128AutomaticTransmission:ReassemblyReversedisassemblyprocedureforassembly,notingthefollowingpoints.•UsenewsealringandO-ring.ApplyA/Tfluidbeforeinstallation.•Donotdamagedirectclutchreturnspringsubassembly(1)andpistonbypressingindirectclutchreturnspringsubassemblypassingthroughitsoriginalinstallingpositionover0.7mm(0.027in.).Page669AutomaticTransmission:5A-129DirectClutchAssemblyInspectionDirectClutchPistonS4RS0A5106033Shakedirectclutchpistonlightlyandcheckthatcheckball(1)isnotstuck.ClutchDiscs,PlatesandRetainingPlateBlowinlowpressureair(Max.100kPa,1kg/cm,15psi)Checkthatslidingsurfacesofdiscs,separatorplatestocheckballtocheckthatthereisnoleakage.Page6705A-130AutomaticTransmission:ForwardandReverseClutchAssemblyComponentsS4RS0A5106034I3RM0B510061-1.Forwardclutchbalancer8.Intermediateshaftsealring15.Forwardclutchretainingplate2.Forwardclutchreturnspring9.Reverseclutchplatesnapring16.Forwardclutchdiscsubassembly3.Page671AutomaticTransmission:5A-131I2RH0B510178-2)Removeforwardclutchplatesnapring(1)andtakeoutforwardclutchretainingplate,discsandI2RH0B510176-separatorplatesfromforwardclutchdrum.2)Blowcompressedair(400–800kPa,4–8kg/cm57–...Page6725A-132AutomaticTransmission:5)Removeforwardclutchreturnspringsubassembly(1).I2RH0B510184-9)RemoveforwardclutchdrumO-ring(1)fromforwardclutchdrum(2).I2RH0B510181-2.Intermediateshaftsubassembly6)Installintermediateshaftsubassembly(1)totransaxlerearcover(2).Applycompressedair(400–...Page673AutomaticTransmission:5A-133•Measureforwardclutchpistonstrokeinthesamemanneras“ForwardandReverseClutchAssemblyPreliminaryCheck:”.Whenpistonstrokeisoutofspecification,selectforwardclutchretainingplatewithproperthicknessfromamongthefollowingtableandreplaceit.Specialtool(A):09900–20607(B):09900–20701...Page6745A-134AutomaticTransmission:•InstallreverseclutchplatesnapringsothatitsbothForwardandReverseClutchAssemblyendswouldbepositionedincorrectlocationsasInspectionshowninfigure.S4RS0A5106037Clutch,Discs,SeparatorPlatesandRetainingPlateCheckthatslidingsurfacesofdiscs,separatorplatesandretainingplatearenotwornhardorburnt.Page675AutomaticTransmission:5A-135I2RH0B510194-ForwardClutchDrumLipCheckeachlipforwear,deformation,cutand/orI2RH0B510195-hardening.Ifnecessary,replace.2ndBrakePistonAssemblyComponentsS4RS0A5106038I2RH0B510196-1.2ndbrakecylinder4.OuterO-ring2.2ndbrakepiston:Applyautomatictransaxlefluid.3.Page6765A-136AutomaticTransmission:•UsenewO-rings.ApplyA/TfluidtotheO-rings,2)RemoveinnerO-ring(1)andouterO-ring(2).beforeinstallation.•Install2ndbrakepiston(1)towhichA/Tfluidisappliedto2ndbrakecylinder(2).DonotdamageO-ringwheninstalling2ndbrakepiston.Page677AutomaticTransmission:5A-137TransaxleRearCover(O/Dand2ndCoastBrakePiston)AssemblyDisassemblyandReassemblyS4RS0A5106044Disassembly1)Removesnapringbyusingspecialtoolsandhydraulicpress.Specialtool(A):09926–96030(B):09946–06710I2RH0B510203-5)Removerearcoversealrings(1).CAUTION:DonotpressO/Dand2ndcoastbrakereturnspringsubassemblyinover1.0mm(0.039...Page6785A-138AutomaticTransmission:TransaxleRearCover(O/Dand2ndCoastBrake•Donotopenrearcoversealringtoowidetoattach.Piston)AssemblyInspectionS4RS0A5106045O/Dand2ndCoastBrakeReturnSpringSubassemblyMeasurefreelengthofO/Dand2ndcoastbrakereturnspring.Page679AutomaticTransmission:5A-139CountershaftAssemblyComponentsS4RS0A5106048I2RH0B510211-Reassembly1)InstallnewcountershaftRHbearing(1)byusingspecialtoolandhydraulicpress.Specialtool(A):09913–84510I2RH0B510209-NOTE:1.CountershaftRHbearing5.Bearingcap2.Countershaft6.CountershaftbearingshimReplacecountershaftRHbearingtogether3.Page6805A-140AutomaticTransmission:3)InstallcountershaftLHbearing(1)withspecialtoolsandhydraulicpress.Specialtool(A):09913–84510(B):09925–88210I2RH0B510214-ValveBodyAssemblyComponentsS4RS0A5106050I4RS0A510044-1.Pressurecontrolsolenoidvalve6.Temperaturesensorclamp:Applyautomatictransaxlefluid.2.Page681AutomaticTransmission:5A-141ValveBodyAssemblyDisassemblyandReassemblyS4RS0A5106051CAUTION:Whenreplacingpressurecontrolsolenoidvalveand/orTCCpressurecontrolsolenoidvalve,itisstrictlyrequiredtoreplaceittogetherwithvalvebodyassemblyasaset.Replacingpressurecontrolsolenoidvalveand/orTCCpressurecontrolsolenoidvalveindependentlymaycauseexcessiveshiftI2RH0B510219-...Page6825A-142AutomaticTransmission:ReassemblyReversedisassemblyprocedureforassembly,notingthefollowingpoints.•Shiftsolenoidvalve-Aand-Bareidentical•AfterapplyingA/TfluidtonewO-rings,fitthemtosolenoidvalves,theninstallsolenoidvalvestovalvebody.Page683AutomaticTransmission:5A-143DifferentialAssemblyDisassemblyandSpecialtool(A):09926–37610Reassembly(B):09926–37610–001S4RS0A5106053(C):09926–37610–003Disassembly(D):09926–37610–0021)Removefinalgearbolts(1),andthenfinalgear(2).I2RH0B510225-2)RemovedifferentialsideRHbearingbyusingspecialI2RH0B510228-tools.Page6845A-144AutomaticTransmission:2)Asshowninfigure,facinggroove(2)sideupward,installfinaldrivengear(1)todifferentialcase.I2RH0B510233-6)InstallnewdifferentialsideLHbearing(1)byusingI2RH0B510230-specialtoolandhydraulicpress.3)Tightenfinalgearbolts(1)tospecifiedtorque.NOTE:NOTE:ReplacedifferentialsideLHbearingtogether...Page685AutomaticTransmission:5A-145TorqueConverterHousingDisassemblyandReassemblyS4RS0A5106055Disassembly1)RemovefluidreservoirRHplate(1)andlubricationtubeclamp(2).I2RH0B510239-5)RemovedifferentialsideRHbearingcupbyusingspecialtools.Specialtool(A):09944–96011(B):09942–15511I2RH0B510236-2)RemovelubricationLHtube(1)andRHtube(2).Page6865A-146AutomaticTransmission:DifferentialsideoilsealinstallingdepthReassembly“a”:2.6–3.6mm(0.10–0.14in.)1)AfterapplyingA/TfluidtonewO-rings,fitthemtohousingplugs.Finallyinstallplugstotorque5)Applygreasetooilseallip.converterhousing.Page687AutomaticTransmission:5A-147TransaxleCaseDisassemblyandReassemblyReassemblyS4RS0A51060571)Usingspecialtools,assembleshimanddifferentialsideLHbearingcup.Disassembly1)Removedifferentialsideoilseal(1).NOTE:Useshimwithsamethicknessastheremovedone.Specialtool(A):09924–74510(B):09944–88220...Page6885A-148AutomaticTransmission:4)Applygreasetooilseallip.:Grease99000–25030I2RH0B510253-BrakereturnspringsubassemblyMeasurebrakereturnsprings.Evidenceofextremeheatorburningintheareaofclutchmayhavecausedspringstotakeheatsetandwouldrequiretheirreplacement.Page689AutomaticTransmission:5A-149AdjustmentAvailableshimthicknessThicknessIdentificationmarkDifferentialsidebearingpreload1.80mm(0.070in.)1.85mm(0.072in.)1)AfterapplyingA/Tfluidtodifferentialassembly,fitit1.90mm(0.074in.)totransaxlecase.1.95mm(0.076in.)2)Installtorqueconverterhousingtotransaxlecase,2.00mm(0.078in.)thentightenbolts(1)tospecifiedtorque.Page690•Applyautomatictransaxlefluidonslidingorrotatingsurfacesofthepartsbeforeassembly.•UseSuzukiSuperGrease“C”toretainI3RM0B510067-partsinplace.4)Ifbearingpreloadisoutofspecification,selectshim•Besuretoinstallthrustbearingsandraceswithsuitablethicknessfromamongthelistbelowincorrectdirectionandposition.Page691AutomaticTransmission:5A-151TighteningtorqueTighteningtorqueManualdetentspringbolt(a):10N·m(1.0kg-m,Parkinglockpawlbracketbolt(a):7.5N·m(0.757.5lb-ft)kg-m,5.5lb-ft)I2RH0B510262-I2RH0B510259-7)AfterapplyingA/TfluidtonewO-rings,installthem3)Installparkinglockpawlrod(2)tomanualvalveleverto1standreversebrakepiston(3).Page6925A-152AutomaticTransmission:9)Install1standreversebrakereturnspringsubassembly(1)totransaxlecase(2).I2RH0B510265-10)ApplyA/Tfluidto1standreversebrakediscs(2),separatorplates(3)andretainingplate(1),theninstallthemtotransaxlecase.I2RH0B510268-[A]:Correct[B]:Incorrect...Page693AutomaticTransmission:5A-153NOTE:Specialtool(A):09951–18210Whenreplacingreductiondrivegear,replace(B):09944–78210ittogetherwithreductiondrivengearasaset.Specialtool(A):09951–18210(B):09944–78210I2RH0B510272-2.Standthatcanslightlylifttransaxlecase.17)Usingasmalltorquewrench,whileturningtocounterdrivegear100rpmandmeasurethepreload.Page6945A-154AutomaticTransmission:18)Caulkreductiondrivegearnut(1).“a”I2RH0B510274-19)ApplyA/Tfluidtoplanetarygearassembly(1),thenfitittoplanetaryringgearassembly.I2RH0B510275-20)Checkforcorrectinstallationofplanetarygearassemblyasfollows.“a”...Page695AutomaticTransmission:5A-15523)ApplyA/Tfluidtonewbrakedrumgasket(1),thenCAUTION:installittotransaxlecase.Donotdamage2ndbrakepistonassembly,returnspringsubassembly,platesanddiscsbypressingin2ndbrakeassemblypassingthroughitsoriginalinstallingpositionover0.4mm(0.016in.).Page6965A-156AutomaticTransmission:30)InstallO/Dand2ndcoastbrakeretainingplatesnapring(1).CAUTION:BesuretoinstallO/Dand2ndcoastbrakeretainingplatesnapringcorrectlyingrooveoftransaxlecase.I2RH0B510290-35)AfterapplyingA/Tfluidtorearsungearthrustbearingrace(1),installittorearplanetarysungear(2).Page697AutomaticTransmission:5A-157BearingracedimensionFrontraceRearraceOutside30.6mm(1.20in.)28.2mm(1.11in.)diameter“a”Thickness2.0mm(0.08in.)2.0mm(0.08in.)“a”I2RH0B510294-39)ApplyA/Tfluidtoforwardandreverseclutchassembly(1).Page6985A-158AutomaticTransmission:AvailableO/Dand2ndcoastbrakerearplate45)Removesealantattachedtomatingsurfaceofthicknesstransaxlerearcover(1)completely.ThicknessIdentificationmark46)Applysealanttomatingsurfaceoftransaxlerear1.8mm(0.071in.)cover(1)byusinganozzle(2)asshowninfigureby2.0mm(0.079in.)suchamountthatitssectionis1.2mm(0.047in.)in...Page699AutomaticTransmission:5A-15954)AfterapplyingA/Tfluidtoinputshaftrearthrustbearing(1)andthrustbearingrace(2),installthemintodirectclutchhub(3).I2RH0B510304-52)AfterapplyingA/Tfluidtodifferentialassembly(1)andcountershaftassembly(2),installthemtoI2RH0B510307-transaxlecase.Page7005A-160AutomaticTransmission:57)Checkforcorrectinstallationofdirectclutchassemblyasfollows.Measuredistance“a”byusingmicrometercaliper(1)andstraightedge(2).Ifoutofspecification,removedirectclutchassembly,directclutchhubandreinstallthemproperly.Distancebetweendirectclutchassemblyandmatingsurfaceoftransaxlecase“a”:10.5–...Page701AutomaticTransmission:5A-16163)Wipeoffandcleanmatingsurfacebetweentransaxlecase(1)andtorqueconverterhousing.64)Applysealanttotorqueconverterhousingbyusinganozzle(2)asshowninfigurebysuchamountthatitssectionis1.2mm(0.047in.)indiameter.“A”:Sealant99000–31230I2RH0B510317-“A”...Page7025A-162AutomaticTransmission:71)AfterapplyingA/TfluidtonewO-ring,fitittovalvebodyharnessconnector(3),theninstallvalvebodyharnesstotransaxlecase.CAUTION:Whenputvalvebodyharness(1)intotransaxlecase,takecarenottodamagetransmissionfluidtemperaturesensor(2)atnarrowentranceofcase.Page703AutomaticTransmission:5A-163TighteningtorqueBoltLength“a”PiecesOilstrainerbolt(a):10N·m(1.0kg-m,7.5lb-ft)B(2)28mm(1.10in.)C(3)49mm(1.93in.)D(4)36mm(1.42in.)E(5)40mm(1.58in.)I2RH0B510325-76)Installoilcleanermagnets(1)inoilpan(2).Page7045A-164AutomaticTransmission:80)Installnewgaskets(2)andtheninstallfluidcoolerpipes.TighteningtorqueFluidcoolerpipeunionbolt(b):22N·m(2.2kg-m,16.0lb-ft)Fluidcoolerpipebracketbolt(c):10N·m(1.0kg-m,7.5lb-ft)81)AfterapplyingA/TfluidtonewO-ring,fitittofluidfillertube.Page705AutomaticTransmission:5A-16594)Installtorqueconverter(3)notingthefollowingpoints.CAUTION:•Beforeinstallingconverter,makesurethatitspumphubportionisfreefromnicks,burrsordamagewhichmaycauseoilsealtoleak.•Beverycarefulnottodropconverteronoilpumpgear.Page7065A-166AutomaticTransmission:SpecificationsTighteningTorqueSpecificationsS4RS0A5107001TighteningtorqueFasteningpartNotekg-mlb-ftA/Tfluiddrainplug12.5Transmissionrangesensorbolt0.55Outputshaftspeedsensor(VSS)boltInputshaftspeedsensorbolt0.55Valvebodyharnessconnectorbolt0.55ShiftsolenoidboltOilstrainerbolt...Page707AutomaticTransmission:5A-167SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A5108001MaterialSUZUKIrecommendedproductorSpecificationNoteGreaseSUZUKISuperGreaseAP/No.:99000–25010SUZUKISuperGreaseCP/No.:99000–25030SealantSUZUKIBondNo.1216BP/No.:99000–31230NOTE:Requiredservicematerialisalsodescribedinthefollowing.Page7085A-168AutomaticTransmission:09923–7821009924–74510BearinginstallerBearingandoilsealhandle09925–37811–00109925–88210OilpressuregaugeBearingpullerattachment09925–9821009925–98221InputshaftbearinginstallerBearinginstaller09926–37610–00109926–37610–002BearingpullerBearingpullerattachment09926–37610–00309926–37610BearingremoverattachmentBearingremover09926–5801009926–96030...Page709Transferbearingdummy09951–1821009952–06020Oilsealremover&installerDialgaugeplateNo.2No.2SUZUKIscantool—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.DLCcable,4.SAE16/19adapter,5.Cigarettecable,6.Page7105B-1ManualTransmission:ManualTransmissionGeneralDescriptionManualTransaxleConstructionandServicingS4RS0A5201001Thetransaxleprovidesfiveforwardspeedsandonereversespeedbymeansofthreesynchromeshsandthreeshafts(inputshaft,countershaftandreversegearshaft).Allforwardgearsareinconstantmesh,andreverseusesaslidingidlergeararrangement.Page711ManualTransmission:5B-2I3RM0B521001-1.5thspeedsleeve&hub8.Reverseidlergear15.Countershaft3rdgear2.Inputshaft5thgear9.Inputshaft16.Countershaft2ndgear3.Inputshaft4thgear10.Rightcase17.Lowspeedsynchronizersleeve&hub4.Page7125B-3ManualTransmission:DiagnosticInformationandProceduresManualTransaxleSymptomDiagnosisS4RS0A5204001ConditionPossiblecauseCorrection/ReferenceItemGearsslippingoutofWornshiftforkshaftReplace.meshWornshiftforkorsynchronizersleeveReplace.WeakordamagedlocatingspringsReplace.Page713ManualTransmission:5B-4DifferentialSideOilSealReplacementS4RS0A52060021)Liftupvehicleanddraintransaxleoil.2)Removefrontdriveshaftand/orcentershaftreferringto“FrontDriveShaftAssemblyRemovalandInstallation:inSection3A”.3)Removeoilseal(1)usingspecialtool.Specialtool(A):09913–50121I4RH01520003-...Page7145B-5ManualTransmission:GearShiftControlLeverandCableComponentsS4RS0A5206003I4RS0A520002-1.Gearshiftcontrolleverknob6.Gearshiftcontrolleverassemblymountingnut:10Nm(1.0kg-m,7.5lb-ft)2.Cablebracketbolt7.Gearshiftcontrolleverassembly:55Nm(5.5kg-m,40.0lb-ft)3.Page715ManualTransmission:5B-6GearShiftControlLeverandCableRemovalandInstallationS4RS0A5206004Removal1)Removeconsolebox.2)Disconnectcableends(5)frompivot(6)ofgearshiftcontrolleverassembly.3)Disconnectgearshiftandselectcontrolcables(1)fromgearshiftcontrolleverassembly(2)whilepullingquickjoint(4)asshowninfigure.Page7165B-7ManualTransmission:VehicleSpeedSensor(VSS)RemovalandTighteningtorqueCablebracketbolt(a):55N·m(5.5kg-m,40.0lb-InstallationS4RS0A5206027Removal1)Removebatteryandtraywithcoolantreservoir.2)Disconnectgearshiftandselectcontrolcables(1)fromtransaxle.Page717ManualTransmission:5B-8BackUpLampSwitchInspectionInstallationS4RS0A52060081)ApplyoiltonewO-ring(1)andtightenbackuplampCheckbackuplampswitchforfunctionusingohmmeter.switch(2)tospecifiedtorque.BackuplampswitchspecificationTighteningtorqueSwitchON(Push):ContinuityBackuplampswitch(a):23N·m(2.3kg-m,17.0...Page7185B-9ManualTransmission:3.Enginerearmountingandbracket10.Transaxletoenginenut:85Nm(8.5kg-m,61.5lb-ft)4.Backuplampswitchconnector11.Groundcable:55Nm(5.5kg-m,40.0lb-ft)5.VSSconnector12.Page719ManualTransmission:5B-1016)Removeengineundercovers.Remounting17)Supporttransaxlewithtransmissionjack.CAUTION:18)Removetransaxletoengineboltsandnutoflower•Careshouldbetakennottoscratchoilside.seallipwithdriveshaftwhileraising19)Removeengineleftmounting(1)withbracket(2).Page7205B-11ManualTransmission:GearShiftandSelectShaftAssemblyComponentsS4RS0A5206029I4RS0A520014-1.Gearshift&selectshaft7.Gearshiftguidecasebolt13.Selectleverboss:Applysealant99000-31260toboltthread.:Applygrease99000-25010tointernalandexternaldiameter.Page721ManualTransmission:5B-12NOTE:4)Installwasherandgearshiftinterlockbolt(2)towhichsealanthavebeenappliedandthentightenit•Setnewgearshift&selectleverinnerpintospecifiedtorque.(8)andouterpin(9)facingeachgap(“a”,“B”:Sealant99000–31260“b”)intheoppositedirectionasshowninfigure.Page7225B-13ManualTransmission:ManualTransaxleAssemblyComponentsS4RS0A5206028I4RS0A520013-...Page723ManualTransmission:5B-141.Transaxlerightcase25.5thgearshiftfork2.Transaxleleftcase26.Needlebearing(Separatedsteelcagetype.):Applysealant99000-31260tomatingsurfaceofleftcaseandrightcase.3.Gearshiftandselectshaftassembly27.Page7245B-15ManualTransmission:6)Removeinputshaft5thgear,needlebearingandNOTE:thencountershaft5thgear(1).Gearpuller(2)would•AlignprotrusionAof5thspeedbenecessaryifsplinefittingofcountershaft5thgearsynchronizerlevers(1)withgrooveofhubistight.Page725ManualTransmission:5B-162,(a),“A”2,(a)I3RM0B521016-5)Fit5thgearshiftfork(1)tosynchronizersleeve(2)andhub(3)assemblyandinstallthemintoinputI4RS0A520030-shaftandgearshiftshaftaligningpunchmark(4)4.Polishedsurfacewithmatchingmark(5)oninputshaft.Page7265B-17ManualTransmission:ManualTransaxleAssemblyDisassemblyandReassemblyS4RS0A5206034Disassembly1)Removegearshiftandselectshaftassemblyreferringto“GearShiftandSelectShaftAssemblyRemovalandInstallation:”.2)Removefifthgearreferringto“FifthGearDisassemblyandAssembly:”.3)Removeleftcaseplate.Page727ManualTransmission:5B-18I2RH01520036-3.VSSI4RH01520021-15)Removesidebearingretainerbolts.Installation16)Turnsidebearingretainer(1)counterclockwiseuntil1)Installdifferentialassembly(1)intorightcase(2).itstops,andremovesidebearingretainerusing2flatendrods(2)orthelike.Page7285B-19ManualTransmission:6)Cleanmatingsurfacesofbothrightandleftcases,3)Install5th&reversegearshiftshaft(1)with5th&reversegearshiftguideshaft(2)intorightcase(5).applysealanttorightcase(2)asshowninthefigureReversegearshiftarm(4)hastobejoinedwithbysuchamountthatitssectionis1.5mm(0.059in.)reversegearshiftlever(3)atthesametime.Page729ManualTransmission:5B-20iii)Calculateclearancea–b,andselectdifferentialshimaccordingtothefollowingtable.BearingshimspecificationThicknessofbearingClearance“a”–“b”shimtobeinstalled0.636–0.665mm0.75mm(0.030in.)(0.0250–...Page7305B-21ManualTransmission:c)Installdifferentialsidebearingshimtoleftcase(4).d)ApplyoiltonewO-ringofsidebearingretainer(3),andinstallsidebearingretainerwithnewO-ringtoleftcase.e)Tightensidebearingretainerbolts(1)tospecifiedtorque.Page731ManualTransmission:5B-2215)ByrepeatingStep14),selectasuitableshimwhichadjustsclearance“a”tospecificationandputitonbearingouterrace.NOTE:Insert0.15mm(0.0059in.)feelertoknowwhetherornotashimfulfillsspecificationquickly.Page7325B-23ManualTransmission:3)Removeinputshaftoilseal(1)usingspecialtools,ifnecessary.Specialtool(A):09930–30104(B):09923–745104)Pulloutcountershaftrightbearingouterrace(2)usingspecialtools,ifnecessary.Specialtool(A):09930–30104(C):09941–64511I3RM0A520047-4)Installdifferentialsidebearingouterracetorightcaseusingspecialtoolandhammer.Page733ManualTransmission:5B-24Assembly1)Ifinputoilgutter(1)hasbeenremoved,installitwithbolttowhichthreadlockcementhasbeenapplied.“A”:Threadlockcement99000–32110TighteningtorqueOilgutterbolt(a):10N·m(1.0kg-m,7.5lb-ft)I3RM0A520048-2)Ifdifferentialsideoilsealisremoved,installittoleftcasereferringto“DifferentialSideOilSeal...Page7345B-25ManualTransmission:8.Highspeedsynchronizersleeve&hub19.Lowspeedsynchronizerspring30.Countershaftleftbearing9.Highspeedsynchronizerkey20.Lowspeedsynchronizersleeve&hub:Donotreuse.10.Circlip21.Lowspeedsynchronizerkey:Applytransaxleoil.Page735ManualTransmission:5B-263)Fithighspeedsynchronizersleeve(4)tohub(3),6)Driveinhighspeedsynchronizersleeve&hubinsert3keys(2)initandthensetsprings(1)asassembly(3)usingspecialtoolandhammer,facingshowninthefigure.Page7365B-27ManualTransmission:8)Press-fitleftbearing(2)usingspecialtoolandCAUTION:hammer.•Ifcompressionexceeds5ton(11,000lb),Specialtoolreleasecompressiononce,resetbearing(A):09913–70123pullersupportandthencontinuepressworkagain.9)UsingthesamespecialtoolatStep8),drivein5thgearspacer(1).Page737ManualTransmission:5B-286)Disassemblelowspeedsynchronizersleeve&hubassembly.7)Takeout1stgearneedlebearingofresincagetypefromshaft.8)Removerightbearingcone(2)usingbearingpuller(3),metalstick(1)andhydraulicpress.I2RH01520058-Assembly1)Cleanallcomponentsthoroughly,inspectthemfor...Page7385B-29ManualTransmission:NOTE:CAUTION:Press-fitspacer(1)and3rdgear(2)first,and•Supportshaftwithspecialtoolasshowninthen4thgearlaterseparatelysothatthefiguresothatretainerofbearingconecountershaftwillnotbecompressed(4)willbefreefromcompression.Page739ManualTransmission:5B-30SynchronizerPartsInspectionPutthe2ndgearsynchronizerouterring(1),innerringS4RS0A5206036(3)andthecone(2)togetherandthenmeasurethestepCheckclearance“a”betweensynchronizerring(2)anddifferencebetweentheouterringandtheinnerring.Andgear(1),eachchamferedtoothofgear,synchronizeralsocheckeachchamferedtoothofgearandringandsleeve,thendeterminepartsreplacement.Page7405B-31ManualTransmission:5thandReverseGearShiftShaftsDisassemblyGearShiftShaftandForkInspectionS4RS0A5206037andAssemblyUsingfeelergauge,checkclearancebetweenfork(1)S4RS0A5206024andsleeve(2)andreplacethosepartsifitexceedslimit.DisassemblyNOTE:DisassemblecomponentpartsusingspecialtoolandForcorrectjudgementofpartsreplacement,...Page741ManualTransmission:5B-32DifferentialComponentsS4RS0A5206032I4RS0A520016-1.Differentialpinionwasher8.Finalgear2.Differentialsidepiniongear9.Finalgearbolt3.Differentialsidegear10.Differentialpinionshaft4.Sidegearwasher11.Differentialpinionshaftpin5.Page7425B-33ManualTransmission:AssemblyJudgingfromabnormalitynotedbeforedisassemblyandwhatisfoundthroughvisualcheckofcomponentpartsafterdisassembly,preparereplacingpartsandproceedtoreassembly.Makesurethatallpartsareclean.1)Assembledifferentialgearandmeasurethrustplayofdifferentialgearasfollows.Page743ManualTransmission:5B-34I3RM0B521025-7)Holddifferentialassemblywithsoftjawedvise(3),installfinalgear(2)asshowninthefigureandthentightenbolts(1)tospecifiedtorque.CAUTION:Useofanyotherboltsthanspecifiedonesisprohibited.Page744Forthetighteningtorqueoffastenernotspecifiedinthissection,referto“FastenersInformation:inSection0A”.SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A5208001MaterialSUZUKIrecommendedproductorSpecificationNoteGreaseSUZUKISuperGreaseAP/No.:99000–25010SealantSUZUKIBondNo.1217G...Page745ManualTransmission:5B-3609913–7601009913–80113BearinginstallerBearinginstaller09913–8451009913–85210BearinginstallerBearinginstaller09922–8581109923–74510Springpinremover(4.5mm)Bearingpuller(20-35mm)09923–7821009924–07710BearinginstallerSynchronizerhubinstaller09924–0773009924–74510BearinginstallerBearingandoilsealhandle09924–84510–00409925–15410Bearinginstallerattachment...Page7465B-37ManualTransmission:09927–7606009930–30104GearholderSlidingshaft09940–5171009940–54910BearinginstallerFrontforkoilsealinstalldriver09941–6451109951–16060BearingandoilsealremoverControlarmbushremover(30mmMin.)09951–16080Bearinginstaller...Page747Clutch:5C-1ClutchGeneralDescriptionClutchConstructionS4RS0A5301001Theclutchisadiaphragmspringclutchofadrysingledisctype.Thediaphragmspringisofatapering-fingertype,whichisasolidringintheouterdiameterpart,withaseriesoftaperedfingerspointinginward.Thedisc,carryingfourtorsionalcoilsprings,ispositionedonthetransaxleinputshaftwithaninvolutesplinefit.Page7485C-2Clutch:DiagnosticInformationandProceduresClutchSystemSymptomDiagnosisS4RS0A5304001ConditionPossiblecauseCorrection/ReferenceItemSlippingImproperclutchpedalfreetravelReplacemastercylinderorclutchpedalarm.WornoroilyclutchdiscfacingReplacedisc.Warpeddisc,pressureplateorflywheelReplacedisc,clutchcoverorflywheel.Page749Clutch:5C-3RepairInstructionsClutchPedalInspectionS4RS0A5306019ClutchPedalFreeTravel“A”1)Depressclutchpedal(1),stopthemomentclutchresistanceisfelt,andmeasurehowmuchpedalhasmoved(clutchpedalfreetravel)asrepresentedby“A”inthefigure.Thencheckitsconformancetospecificationshownbelow.Page7505C-4Clutch:ClutchFluidLevelInspectionS4RS0A5306020Referto“MasterCylinderandBrakeFluidLevelInspection:inSection4A”.AirBleedingofClutchSystemS4RS0A5306021CAUTION:I4RS0A530004-Brakefluidisextremelydamagingtopaint.If4)Whenfluidpressureincylinderisalmostdepleted,fluidshouldaccidentallytouchpaintedpushpipeconnector.Page751Clutch:5C-5ClutchFluidPipeandHoseComponentsS4RS0A5306022I4RS0A530005-1.Mastercylinder5.Clamp:Applygrease99000-25100topushrodend.2.Pipe6.Clutchreservoirhose3.Operatingcylinder:23Nm(2.3kg-m,17.0lb-ft):Applygrease99000-25100torodtip.Page7525C-6Clutch:InstallationReverseremovalprocedureforinstallationnotingthefollowing.CAUTION:•Donotallowfluidtogetonpaintedsurface.•Donotallowpipetocontacthardagainstvehiclebodyorotherparts.I4RS0A530008-•Installeachclampsecurely.3.Page753Clutch:5C-7•TightenclutchoperatingcylinderbolttospecifiedInstallationReverseremovalprocedureforinstallationnotingthetorque.following.Tighteningtorque•Applygreasetopushrodtip.Clutchoperatingcylinderbolt:23N·m(2.3kg-m,17.0lb-ft)“A”:Grease99000–25100“A”...5C-8Clutch:ClutchCover,ClutchDiscandFlywheelComponentsS4RS0A5306014I4RS0A530013-1.Flywheel9.Clutchdisc2.Flywheelbolt10.Clutchcoverbolt3.Clutchreleaseshaftseal11.Releasearm:Applygrease99000-25010toseallip.(0.3g(0.01oz))4.Page755Clutch:5C-94)Removeflywheel(1)fromcrankshaftusingspecialtool.Specialtool(A):09924–17810I4RS0A530016-3)Aligningclutchdisctoflywheelcenterusingspecialtool,installclutchcover(1)andbolts(2).Thentightenbolts(2)tospecification.NOTE:•...Page7565C-10Clutch:NOTE:ClutchCover1)Checkdiaphragmspring(1)forabnormalwearorWheninsertingtransaxleinputshafttoclutchdamage.disc,turncrankshaftlittlebylittletomatchthesplines.2)Inspectpressureplate(2)forwearorheatspots.3)Ifabnormalityisfound,replaceclutchcover.Page757Clutch:5C-114)Coatgreasetoreleaseshaftseal(2)lipandthen5)Installtap(M16X1.5)(1)toclutchreleaseshaftNo.1bush.installittillitisflushwithcasesurface.Usespecialtoolforthisinstallationandfaceseallipdownward(inside).Page7585C-12Clutch:ClutchReleaseSystemInspectionS4RS0A5306018ClutchReleaseBearingCheckclutchreleasebearingforsmoothrotation.Ifabnormalityisfound,replaceit.CAUTION:Donotwashreleasebearing.Washingmaycausegreaseleakageandconsequentialbearingdamage.I3RM0A530020-I4RS0A530021-8)Setreleasearm(1)toreleaseshaft(2)aligningClutchReleaseShaftpunchmark(4)ofreleasearmandpunchmark(3)of...Page759Clutch:5C-13SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A5308001MaterialSUZUKIrecommendedproductorSpecificationNoteBrakefluidDOT3—(DOT3)GreaseSUZUKISuperGreaseAP/No.:99000–25010SUZUKISiliconeGreaseP/No.:99000–25100SUZUKISuperGreaseIP/No.:99000–...Page7605C-14Clutch:...Page761TableofContents6-iSection6SteeringCONTENTSPrecautions..........6-1DTCTable............6C-6ScanToolData...........6C-8Precautions.............6-1P/SSystemSymptomDiagnosis......6C-9PrecautionsonSteering........6-1SerialDataLinkCircuitCheck......6C-9SteeringGeneralDiagnosis....6A-1“EPS”WarningLampDoesNotComeONatIgnitionSwitchONbutEngineStop....6C-11Precautions............6A-1“EPS”...Page7626-iiTableofContentsSpecialTool............6C-38...Page763Precautions:PrecautionsPrecautionsPrecautionsonSteeringS4RS0A6000001AirBagWarningReferto“AirBagWarning:inSection00”.AirBagSystemServiceWarningReferto“AirBagSystemServiceWarning:inSection00”.PrecautionsforSteeringDiagnosisReferto“PrecautionsforSteeringDiagnosis:inSection6A”.ServicePrecautionsofSteeringWheelandColumnReferto“ServicePrecautionsofSteeringWheelandColumn:inSection6B”.Page7646A-1SteeringGeneralDiagnosis:SteeringGeneralDiagnosisPrecautionsPrecautionsforSteeringDiagnosisS4RS0A6100001Sincetheproblemsinsteeringinvolveseveralsystems,theymustallbeconsideredwhendiagnosingacomplaint.Toavoidusingthewrongsymptom,alwaysroadtestthevehiclefirst.Proceedwiththefollowingpreliminaryinspectionandcorrectanydefectswhicharefound.Page765SteeringGeneralDiagnosis:6A-2DiagnosticInformationandProceduresSteeringSymptomDiagnosisS4RS0A6104001ConditionPossiblecauseCorrection/ReferenceItemHardsteeringTirenotadequatelyinflatedInflatetirestoproperpressure.MalfunctionofpowersteeringsystemCheckandcorrect.Bindintie-rodendballstudsorlowerReplacetie-rodendorfrontsuspensionarm.Page7666B-1SteeringWheelandColumn:SteeringWheelandColumnPrecautionsServicePrecautionsofSteeringWheelandEnablingAirBagSystemForenablingairbagsystem,referto“EnablingAirBagColumnSystem:inSection8B”.S4RS0A6200001Forserviceprecautions,referto“PrecautionsonServiceandDiagnosisofAirBagSystem:inSection8B”.Page767SteeringWheelandColumn:6B-25)Checksteeringshaftandsteeringcolumnforbend,4)Checksteeringshaftforsmoothrotation.Iffounddefective,replaceassteeringcolumncracksordeformation.assembly.Iffounddefective,replace.RepairInstructionsSteeringWheelandColumnConstructionS4RS0A6206009I4RS0A620004-1.Page7686B-3SteeringWheelandColumn:3)Removedriverairbag(inflator)modulefromsteeringwheel.Referto“DriverAirBag(Inflator)ModuleRemovalandInstallation:inSection8B”.4)Disconnecthornconnectorandaudiocontrolswitchconnector,ifequipped.5)Removesteeringshaftnutandthenmakealignmentmarks(1)onsteeringwheelandshaftforaguideduringreinstallation.Page769SteeringWheelandColumn:6B-4I4RS0A620008-I4RS0A620011-5)Removecontactcoilcableassembly(1)from4)Installsteeringwheeltosteeringcolumn.Refertosteeringcolumn.“SteeringWheelRemovalandInstallation:”.5)Connectbatterynegative(–)cable.6)Enableairbagsystemreferringto“EnablingAirBagSystem:inSection8B”.Page7706B-5SteeringWheelandColumn:NOTE:4)Fromthepositionwherecontactcoilbecameunabletoturnanyfurther(itstopped),turnitbackclockwiseWhenservicingsteeringcolumnoranyabouttwoandahalfrotationsandaligncentermarkcolumn-mountedcomponent,removewithalignmentmark(1).Page771SteeringWheelandColumn:6B-63)Alignflatpart“A”ofsteeringlowershaft(1)withbolthole“B”ofshaftjoint(2)ofcolumnasshown.Theninsertlowershaftintoshaftjointofsteeringcolumnwithmatchingmarks(4).4)Insertlowershaft(1)intopinionshaft(3)withmatchingmarks(4).Page7726B-7SteeringWheelandColumn:SteeringColumnInspectionInstallationS4RS0A62060061)BesurethatfrontwheelsareinstraightforwardChecksteeringcolumnfordamageandoperationstate.referringto“CheckingSteeringColumnforAccident2)Alignflatpart“A”ofsteeringlowershaft(1)withboltDamage:”.Page773SteeringWheelandColumn:6B-8SpecificationsTighteningTorqueSpecificationsS4RS0A6207001TighteningtorqueFasteningpartNotekg-mlb-ftSteeringshaftnut24.0Steeringcolumnnut10.5Steeringshaftjointbolt18.5NOTE:Thespecifiedtighteningtorqueisalsodescribedinthefollowing.“SteeringWheelandColumnConstruction:”...Page7746C-1PowerAssistedSteeringSystem:PowerAssistedSteeringSystemPrecautionsSteeringSystemNote•TakeanoteofDTCindicatedontheSUZUKIscanS4RS0A6300001tool.NOTE:•Beforeinspection,besuretoread“PrecautionsforAllsteeringgearfastenersareimportantElectricalCircuitService:inSection00”...Page775PowerAssistedSteeringSystem:6C-2I4RS0A630001-2.Steeringcolumn6.Steeringgearcaseassembly7.Battery9.ECMEPSDiagnosisGeneralDescriptionS4RS0A6301003TheP/SsysteminthisvehicleiscontrolledbytheP/Scontrolmodule.TheP/Scontrolmodulehasanon-boarddiagnosticsystemwhichdetectsamalfunctioninthissystem.Page7766C-3PowerAssistedSteeringSystem:SchematicandRoutingDiagramEPSSystemWiringCircuitDiagramS4RS0A6302001E49-2E51-1E49-1E51-2LTGRN/BLKE52-1RED/BLKE52-18G28-31G28-25E52-5E52-6E52-8E52-4E52-20E52-9E52-16RED/BLUE52-14E52-19E52-12PPL/WHTE52-1112131415161718192016151413121110987654321323130292827...Page777PowerAssistedSteeringSystem:6C-4[A]:Connector“E52”(viewedfromharnessside)3.Junctionblockassembly11.P/Scontrolmodule[B]:Connector“E49”(viewedfromharnessside)4.Fuse12.P/Smotor[C]:Connector“E51”(viewedfromharnessside)5.VSS13.Page7786C-5PowerAssistedSteeringSystem:NOTE:•Asexecutionof“DTCClearance:”willclearallDTCs,besuretorecordallDTCsbeforeservice.•DTCC1122isindicatedwhenignitionswitchisatONpositionandengineisnotrunning,itmeansthatnothingisabnormal.Page7791)TurnignitionswitchtoOFFposition.1)TurnignitionswitchtoOFFposition.2)ConnectSUZUKIscantooltodatalinkconnector2)ConnectSUZUKIscantooltodatalinkconnector(DLC)(1)locatedonundersideofinstrumentpanel(DLC)(1)locatedonundersideofinstrumentpanelatdriver’sseatside.Page7806C-7PowerAssistedSteeringSystem:DetectingconditionDTCNo.Detectingitem(DTCwillsetwhendetecting)Voltageat“E52-16”terminalishigherthan1drivingTorquesensorfailure(signalvoltagelow)upperlimitvoltageforP/ScontrolmoduleC1118cyclediagnosisforspecifiedperiodorlongerVoltageat“E52-8”...Page781PowerAssistedSteeringSystem:6C-8DetectingconditionDTCNo.Detectingitem(DTCwillsetwhendetecting)Batteryvoltageishigherthanupperlimit1drivingC1155P/ScontrolmodulefailurevoltageforP/ScontrolmodulediagnosiscycleorinternalfailureofcontrollerScanToolDataASSISTTORQUES4RS0A6304011...Page7826C-9PowerAssistedSteeringSystem:P/SSystemSymptomDiagnosisS4RS0A6304001ThissectiondescribestroublediagnosisoftheP/Ssystempartswhosetroubleisnotindicatedbytheon-boarddiagnosticsystem(self-diagnosticfunction).Whennomalfunctionisindicatedbytheon-boarddiagnosticsystem(self-diagnosisfunction)andassuredlythosesteeringbasicpartsasdescribedin“SteeringSymptomDiagnosis:inSection6A”...Page783Was“EPSSystemCheck”performed?GotoStep2.Goto“EPSSystemCheck:”.1)MakesurethatSUZUKIscantoolisfreefromGotoStep3.ConnectSUZUKIscanmalfunctionandthatcorrectprogramcard(software)fortooltoDLCproperly.Page7846C-11PowerAssistedSteeringSystem:“EPS”WarningLampDoesNotComeONatIgnitionSwitchONbutEngineStopS4RS0A6304013WiringDiagramE49-2121314151617181920E49-1LTGRN/BLKE52-1RED/BLK1615141312111098765432132313029282726252423222120191817...Page785PowerAssistedSteeringSystem:6C-12StepAction1)CheckforproperconnectiontoP/ScontrolmoduleatGotoStep5.“BLK”or“GRN”wire“E49-1”terminal.circuitopenorshorttoground.2)IfOK,checkforvoltagebetween“E49-1”(“GRN”wire)terminalandbodygroundwithignitionswitchON.Page7861)PerformDTCcheck.GotoStep5of“EPSGotoStep2.SystemCheck:”.IsthereanyDTC(NOCODESonSUZUKIscantool)?1)WithignitionswitchOFF,disconnectP/ScontrolmoduleConnectP/ScontrolReplacetheP/Scontrolconnector(“E52”).Page787PowerAssistedSteeringSystem:6C-14DTCC1113/C1117/C1118:TorqueSensorCircuitFailureS4RS0A6304015DTCC1113:TorqueSensorMainandSubCircuitVoltageDifferenceHighDTCC1117:TorqueSensorFailure(SignalVoltageHigh)DTCC1118:TorqueSensorFailure(SignalVoltageLow)WiringDiagramE49-2E52-18...Page7886C-15PowerAssistedSteeringSystem:DTCTroubleshootingStepActionWas“EPSSystemCheck”performed?GotoStep2.Goto“EPSSystemCheck:”.IsDTCC1114and/orDTCC1119indicated,too?Goto“DTCC1114:GotoStep3.TorqueSensor5VPowerSupplyCircuitFailure:”...Page789PowerAssistedSteeringSystem:6C-16DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaVoltageat“E52-20”terminal(5V)differsfromspecified•Highresistance,openorshortintorquesensorcircuitvoltageforP/Scontrolmodulediagnosisforspecified•...Page7906C-17PowerAssistedSteeringSystem:DTCC1119:TorqueSensor12VPowerSupplyCircuitFailureS4RS0A6304020WiringDiagramE49-2E52-18E52-6E52-8E49-1E52-20E52-9LTGRN/BLKE52-1E52-16E52-19121314151617181920I4RS0B630006-[A]:Connector“E52”...Page791PowerAssistedSteeringSystem:6C-18StepAction1)Removeconsolebox.GotoStep4.Repairhighresistance,openorshorttopower2)CheckP/Scontrolmoduleconnector(“E52”)forpropercircuitorgroundin12Vconnection.powersupply(“GRN”3)IfOK,turnignitionswitchON.Page7926C-19PowerAssistedSteeringSystem:DTCC1121/C1123/C1124:VSSCircuitFailureS4RS0A6304017DTCC1121:VSSCircuitSignalNotInput(60SecondsorMore)DTCC1123:VSSCircuitSignalNotInput(30SecondsorMore)DTCC1124:VSSCircuitFailure(AbnormalDeceleration)WiringDiagramE49-2121314151617181920...Page793PowerAssistedSteeringSystem:6C-20DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaDTCC1121:•Highresistance,openorshortinVSScircuitNovehiclespeedsignalisinputtedtoP/Scontrolmodule•VSSineitheroneofthefollowingtwoconditions•...Page7946C-21PowerAssistedSteeringSystem:DTCC1122:EngineSpeedSignalCircuitFailureS4RS0A6304018WiringDiagramE49-2E49-1LTGRN/BLKE52-1121314151617181920RED/BLUE52-14E52-12I4RS0B630008-[A]:Connector“E52”(viewedfromharnessside)2.Page795PowerAssistedSteeringSystem:6C-22DTCC1141/C1142/C1143/C1145:MotorCircuitFailureS4RS0A6304019DTCC1141:MotorCircuitVoltageAbnormalDTCC1142:MotorCircuitCurrentHighCommandwithP/SControlModuleTargetCurrentDTCC1143:MotorCircuitCurrentExcessiveDTCC1145:MotorCircuitCurrentLowCommandwithP/SControlModuleTargetCurrentWiringDiagramE49-1...Page7966C-23PowerAssistedSteeringSystem:DTCTroubleshootingStepActionWas“EPSSystemCheck”performed?GotoStep2.Goto“EPSSystemCheck:”.IsDTCC1153and/orDTCC1155indicated,too?Goto“DTCC1153:P/SGotoStep3.ControlModulePowerSupplyCircuitFailure:”...Page797PowerAssistedSteeringSystem:6C-24DTCDetectingConditionandTroubleAreaDTCdetectingconditionTroubleareaBatteryvoltageislowerthanlowerlimitvoltageforP/S•Highresistance,openorshortinP/Scontrolmodulecontrolmodulediagnosispowersupplycircuit(1drivingcycledetectionlogic)•...Page7986C-25PowerAssistedSteeringSystem:DTCC1155:P/SControlModuleFailureS4RS0A6304022WiringDiagramE49-1LTGRN/BLKE52-1121314151617181920E49-2I4RS0B630010-[A]:Connector“E52”(viewedfromharnessside)2.Ignitionswitch5.P/Scontrolmodule[B]:Connector“E49”...Page799PowerAssistedSteeringSystem:6C-26VoltageCheck1)Removeconsolebox.2)CheckforvoltageateachterminalwithconnectorsconnectedtotheP/Scontrolmodule.NOTE:Aseachterminalvoltageisaffectedbythebatteryvoltage,confirmifthebatteryvoltageis11VormorewhenignitionswitchisON.Page8006C-27PowerAssistedSteeringSystem:TerminalWirecolorCircuitNormalvoltageCondition•IgnitionswitchONandsteeringwheelatstraightpositionE52-6Torquesensor(Sub)About2.5V•Checkvoltagebetween“E52-6”and“E52-9”terminalsE52-7———...Page801PowerAssistedSteeringSystem:6C-28SteeringWheelPlayCheckSteeringForceCheckS4RS0A6304002S4RS0A6304003•Checksteeringwheelforloosenessorrattleby1)Placevehicleonlevelroadandsetsteeringwheelatmovingitinitsshaftdirectionandlateraldirection.straight-aheadposition.Page8026C-29PowerAssistedSteeringSystem:RepairInstructionsSteeringGearCaseAssemblyComponentsS4RS0A6306020I4RS0A630025-1.Steeringgearcase10.SteeringgearcasemountingNo.1bolt19.Heatinsulatorbolt2.Tie-rodlockwasher11.Steeringgearcasegrommet:93Nm(9.3kg-m,67.5lb-ft)3.Page803PowerAssistedSteeringSystem:6C-30Tie-RodEndBootOn-VehicleInspectionS4RS0A6306008Inspecteachbootfortear.Ifevanasmalltearisnoted,replaceitwithanewone.I4RS0A630041-Installation1)Installtie-rodendlocknut(1)andtie-rodend(2)toI3RM0A630024-tie-rod(3).Page8046C-31PowerAssistedSteeringSystem:SteeringGearCaseAssemblyRemovaland4)Afterconfirmingpropertoe,tightentie-rodendlocknuttospecifiedtorque.InstallationS4RS0A6306013TighteningtorqueTie-rodendlocknut(a):45N·m(4.5kg-m,32.5Removallb-ft)CAUTION:Besuretosetfrontwheels(tires)instraightdirectionandremoveignitionkeyfromkey...Page805PowerAssistedSteeringSystem:6C-324,(b)3,(a)I4RS0A630030-2)Installfrontsuspensionframewithsteeringgearcaseassemblyreferringto“FrontSuspensionI4RS0A630040-Frame,StabilizerBarand/orBushingsRemovaland7)Toremovethesteeringgearcaseassemblyeasily,Installation:inSection2B”.lowertheenginewithtransmission,butdon’tremove.Page8066C-33PowerAssistedSteeringSystem:SteeringRackBootInspection7)Tightensteeringshaftjointlowerbolt(1)andupperbolt(2)tospecifiedtorque(LowersidefirstandthenS4RS0A6306014Hoistvehicle.upperside).Inspecteachbootfortear.AtornbootallowsentryofTighteningtorquedustandwaterwhichcancauseweartosteeringrackSteeringshaftjointbolt(a):25N·m(2.5kg-m,...Page807PowerAssistedSteeringSystem:6C-347)Holdrackwithsoftjawedvise(3)andremovetie-rodfromrack(2).I3RM0A630050-5)Fastenbootwithnewbandandclipsecurely.Specialtool(A):09943–55010I3RM0A630051-I4RS0A630033-6)Installtie-rodendlocknutandtie-rodendtotie-rod.InstallationPositionlocknuttomarking(1)madeinremoval.Page8086C-35PowerAssistedSteeringSystem:SteeringRackPlungerRemovalandInstallationSpecialtoolS4RS0A6306030(A):09944–18310TighteningtorqueRemovalRotationtorquerofpinion(a):2.0N·m(0.2kg-1)Removegearcaseassemblyreferringto“Steeringm,1.5lb-ft)GearCaseAssemblyRemovalandInstallation:”.2)Loosenlocknut(1)withholdingdamperscrew(2).Page809PowerAssistedSteeringSystem:6C-36MotorAssemblyInspectionS4RS0A63060291)Removeconsolebox.2)Disconnectmotorconnector(“E51”)fromP/ScontrolmodulewithignitionswitchOFF.3)Checkforresistancebetweenterminalsofmotorconnector(“E51”).Ifcheckresultisnotasspecified,replacesteeringgearcaseassembly.Page8106C-37PowerAssistedSteeringSystem:SpecificationsTighteningTorqueSpecificationsS4RS0A6307001TighteningtorqueFasteningpartNotekg-mlb-ftTie-rodendnut32.5Tie-rodendlocknut32.5Wheelbolt61.5SteeringgearcasemountingNo.1bolt40.0SteeringgearcasemountingNo.3bolt29.0EnginerearmountingbracketboltSteeringshaftjointbolt...Page811PowerAssistedSteeringSystem:6C-38SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A6308001MaterialSUZUKIrecommendedproductorSpecificationNoteGreaseSUZUKISuperGreaseEP/No.:99000–25050SealantSiliconeSealantP/No.:99000–31120ThreadlockcementThreadLockCementSuper1322P/No.:99000–32110...Page8126C-39PowerAssistedSteeringSystem:...Page813TableofContents7-iSection7HVACCONTENTSPrecautions..........7-1A/CSystemSymptomDiagnosis......7B-7AbnormalNoiseSymptomDiagnosisofA/CPrecautions.............7-1System..............7B-9PrecautionsonHVAC...........7-1A/CSystemPerformanceInspection....7B-10HeaterandVentilation......7A-1A/CSystemInspectionatECM......7B-15RepairInstructions..........7B-17GeneralDescription..........7A-1...Page8147-1Precautions:PrecautionsPrecautionsPrecautionsonHVACS4RS0A7000001AirBagWarningReferto“AirBagWarning:inSection00”.A/CSystemCautionReferto“A/CSystemCaution:inSection7B”.PrecautionsonServicingA/CSystemReferto“PrecautionsonServicingA/CSystem:inSection7B”.Page815HeaterandVentilation:7A-1HeaterandVentilationGeneralDescriptionHeaterandVentilationConstructionS4RS0A7101001I4RS0A710001-1.HVACunit6.Footair11.Centerventilationair2.Ventilatorduct7.Frontdefrosterair12.Airintakedoor3.Defrosternozzle8.Sidedefrosterair13.Page8167A-2HeaterandVentilation:SchematicandRoutingDiagramHeaterandVentilationWiringCircuitDiagramS4RS0A7102001BLK/YELBLK/WHTG19-6G19-7RED/BLKG19-1BLU/WHTG19-3G19-2RED/BLKG18-14G18-13G18-9G18-10BLK/ORNG18-8BLK/REDG18-7RED/YELG18-4G18-3E23-19BLU/WHTI4RS0A710002-1.Ignitionswitch4.Page817HeaterandVentilation:7A-3DiagnosticInformationandProceduresHeaterandVentilationSymptomDiagnosisS4RS0A7104001ConditionPossiblecauseCorrection/ReferenceItemBlowermotordoesnotFuseblownCheckrelatedfuses,andthencheckforshortoperatewithblowercircuittoground.speedselectorON.Page8187A-4HeaterandVentilation:RepairInstructionsHVACUnitComponentsS4RS0A7106001I4RS0A710003-1.Freshairinletduct6.Footduct11.Blowermotor16.Drainhose2.Bloweruppercase7.Airflowcontroldoorassembly12.Heaterunitlowercase17.Packing3.Page819HeaterandVentilation:7A-5HVACUnitRemovalandInstallationS4RS0A7106002Removal1)Disconnectnegative(–)cablefrombattery.2)Disableairbagsystemreferringto“DisablingAirBagSystem:inSection8B”.3)Removecowltoppanelfromvehiclebodyreferringto“CowlTopComponents:inSection9K”.Page8207A-6HeaterandVentilation:BlowerMotorResistorRemovalandInstallationInstallationS4RS0A7106005ReverseremovalprocedurenotingthefollowingRemovalinstruction.1)Disconnectnegative(–)cablefrombattery.•Enableairbagsystemreferringto“EnablingAirBag2)Disableairbagsystemreferringto“DisablingAirSystem:inSection8B”.Page821HeaterandVentilation:7A-7HVACControlUnitComponentsS4RS0A7106008I4RS0A710012-1.Heatercontrolbodyassembly4.Bulb7.Airintakeswitch10.Reardefoggerswitch2.Airflowselector5.Temperaturecontrolcable8.Temperatureselector3.Blowerspeedselector6.Airflowcontrolcable9.Page8227A-8HeaterandVentilation:InstallationReverseremovalprocedurenotingthefollowinginstructions.•ConnecttemperaturecontrolcableandairflowcontrolcableofHVACcontrolunittolinksofHVACunit.a.Setairflowselector(1)to“VENT”positionandtemperatureselector(2)to“MAXCOOL”position.I4RS0A710016-b.Page823HeaterandVentilation:7A-9AirIntakeSwitchInspectionInstallationS4RS0A7106018Reverseremovalprocedurenotingthefollowing•Checkthatthereiscontinuitybetweenterminal(1)instruction.andterminal(2)whenairintakeswitchisatfresh•Besuretoinsertthelinkagepin(1)intothegroove(2)position.Page8247A-10HeaterandVentilation:CenterVentilationLouverRemovalandSideVentilationLouverRemovalandInstallationInstallationS4RS0A7106014S4RS0A7106015RemovalRightsideventilationlouver1)Disconnectnegative(–)cablefrombattery.Removal2)Disableairbagsystemreferringto“DisablingAir1)Disconnectnegative(–)cablefrombattery.HeaterandVentilation:7A-114)RemovepassengerairbagmodulefrominstrumentInstallationpanelreferringto“PassengerAirBag(Inflator)ReverseremovalprocedurenotingthefollowingModuleRemovalandInstallation:inSection8B”.instructions.5)Separateleftsideventilationlouver(1)and•...Page8267B-1AirConditioningSystem:AirConditioningSystemPrecautionsA/CSystemCautionS4RS0A7200001CAUTION:TheairconditioningsystemofthisvehicleusesrefrigerantHFC-134a(R-134a).Noneofrefrigerant,compressoroilandcomponentpartsisinterchangeablebetweentwotypesofA/C:oneusingrefrigerantHFC-134a(R-134a)andtheotherusingrefrigerantCFC-12(R-12).Besuretocheckwhichrefrigerantisusedbeforeanyserviceworkincludinginspectionandmaintenance.Page827AirConditioningSystem:7B-2I4RS0A720001-1.Suctionhose4.Expansionvalve:Applycompressoroil(refrigerantoil)toO-ring.:Applycompressoroil(refrigerantoil)toO-ring.2.Dischargehose5.A/Crefrigerantpressuresensor:Applycompressoroil(refrigerantoil)toO-ring.:Applycompressoroil(refrigerantoil)toO-ring.Page8287B-3AirConditioningSystem:GeneralDescriptionRefrigerantTypeConstructionS4RS0A7201002WhethertheA/CsysteminthevehicleusesHFC-134a(R-134a)orCFC-12(R-12)isindicatedonlabel(1)onthecompressor.Also,itcanbecheckedbytheshapeoftheservice(charge)valve(2).I4RS0A720002-[A]:HFC-134a(R-134a)[B]:CFC-12(R-12)Page829AirConditioningSystem:7B-4:[A]:[B]:[C]I4RS0A720051-[A]:Liquid2.Magnetclutch6.Expansionvalve10.Desiccant[B]:Vapor3.Condenser7.A/Cevaporator11.Filter[C]:Superheatedvapor4.Receiver/dryer8.Condensationpart12.Vaporrefrigerant1.Page8307B-5AirConditioningSystem:SchematicandRoutingDiagramMajorComponentsofA/CSystemS4RS0A7202001AirflowdiagramI4RS0A720003-MajorcomponentsofA/CsystemI4RS0A720004-1.HVAC5.Dischargehose9.Sideventilationair13.Sidedefrosterair2.Compressor6.Suctionhose10.Page831AirConditioningSystem:7B-6A/CSystemWiringDiagramS4RS0A7202002BLK/YELBLK/WHTG19-6G19-7RED/BLKG19-1BLU/WHTG19-3G19-2G19-5BRN/WHTG18-6G18-5GRN/WHTRED/BLKG18-14G18-13G18-9G18-10BLK/ORNG18-8BLK/REDG18-7RED/YELG18-4G18-3BLU/WHTE23-19BLK/YELBLK/YELBRN/WHTE23-60BLK/REDBLK/RED...Page8327B-7AirConditioningSystem:DiagnosticInformationandProceduresA/CSystemSymptomDiagnosisS4RS0A7204001ConditionPossiblecauseCorrection/ReferenceItemNocoolaircomesout(A/NorefrigerantPerformrecovery,evacuationandchargeCsystemdoesnotreferringto“OperationProcedureforoperate)RefrigerantCharge:”.Page833AirConditioningSystem:7B-8ConditionPossiblecauseCorrection/ReferenceItemCoolairdoesnotcomeInsufficientorexcessivechargeofChecktheamountofrefrigerantandsystemoutorinsufficientcoolingrefrigerantforleaks.(A/CsystemnormalCondensercloggedCheckcondenserreferringto“Condenseroperation)AssemblyOn-VehicleInspection:”.Page8347B-9AirConditioningSystem:ConditionPossiblecauseCorrection/ReferenceItemInsufficientairflowofA/CevaporatorcloggedorfrostedCheckA/Cevaporatorandevaporatorcooledairthermistor(evaporatortemperaturesensor)referringto“EvaporatorInspection:”and“EvaporatorThermistor(EvaporatorTemperatureSensor)Inspection:”.AirleakingfromHVACunitorairductRepairasnecessary.Page835AirConditioningSystem:7B-10AbnormalNoisefromTensionPulleyConditionPossiblecauseCorrection/ReferenceItemClatteringnoiseisheardWornordamagedbearingReplacetensionpulley.frompulleyPulleycranksuponCrackedorloosebracketReplaceorretightenbracket.contactAbnormalNoisefromA/CEvaporatorCondition...Page8367B-11AirConditioningSystem:8)Openfrontwindows,frontdoorsandenginefood.9)Withabout20mm(0.8in.)ofdrybulbthermometer(1)putrightinfrontofcenterventilationlouverandawetanddrybulbthermometer(2)nearairinletofHVACunit.Page837AirConditioningSystem:7B-12HighpressuregaugeConditionPossiblecauseCorrectionPressureishigherthanRefrigerantoverchargedRecharge.acceptablerangeExpansionvalvefrozenorcloggedCheckexpansionvalve.(“A”area)CloggedrefrigerantpassageofhighpressuresideCleanorreplace.Radiatorcoolingfanmalfunction(InsufficientCheckradiatorcoolingfan.Page8387B-13AirConditioningSystem:˚F˚C82.480.678.877.0“E”75.273.471.669.868.066.264.462.660.859.057.255.453.6“F”51.850.048.246.4˚C˚FTemp.nearAirInletofHVACunitI4RS0A720009-ThermometeratcenterductConditionPossiblecauseCorrection...Page839AirConditioningSystem:7B-14ConditionManifoldgaugeMPa(kg/cm)(psi)PossiblecauseCorrectionDetailNormal:Normal:DuringA/Coperation,theExpansionvalveisReplaceexpansion0.23–0.361.24–1.52lowpressuresidefrozenduetomoisturevalve.(2.3–...Page8407B-15AirConditioningSystem:A/CSystemInspectionatECMS4RS0A7204004VoltageCheckECManditscircuitscanbecheckedatECMwiringcouplersbymeasuringvoltage.CAUTION:•ECMconnectorsarewaterproofed.EachterminaloftheECMconnectorsissealedupwiththegrommet.Page841AirConditioningSystem:7B-16ECMVoltageValuesTableforRelationofA/CControlTerminalWireColorCircuitNormalValueConditionOutputof5VC37-14GRY/RED4.5–5.5VIgnitionswitchturnedONpowersourceEnginecoolant3.3–3.6VIgnitionswitchturnedON,ECTat0C(32F)C37-24LTGRN...Page8427B-17AirConditioningSystem:RepairInstructionsOperationProcedureforRefrigerantChargeS4RS0A7206002WARNING:•Youreyesshouldnotbeexposedtorefrigerant(liquid).AnyliquidHFC-134a(R-134a)escapingbyaccidentshowsatemperatureaslowasapproximately–6C(21.2F)belowfreezingpoint.ShouldliquidHFC-134a(R-134a)isexposedtoyoureyes,itmaycauseaseriousinjury.Page843AirConditioningSystem:7B-18RecoveryWhenchargingrefrigerantonlyWhendischargingrefrigerantoutofA/Csystem,alwaysWhenchargingrefrigerantwithoutreplacinganyrecoveritbyusingrefrigerantrecoveryandrecyclingcomponent,replenishthesameamountofmeasuredoilequipmentbecausedischargingrefrigerantHFC-134awhenrecoveringrefrigerant(ifnotmeasure,replenish30(R-134a)intoatmospherewouldcauseadverseeffectto...Page8447B-19AirConditioningSystem:EvacuationCAUTION:DonotevacuatebeforerecoveringrefrigerantinA/Csystem.NOTE:Onceairconditioningsystemcircuitisopened(exposed)toatmosphericair,systemmustbeevacuatedbyusingavacuumpump.TheA/Csystemshouldbeattachedwithamanifoldgaugeset,andshouldbeevacuatedforapproximately15minutes.Page845AirConditioningSystem:7B-20ChargeTheinitialchargeoftheA/Csystemisperformedthroughthehighpressuresidewiththeenginestopped.CAUTION:Andnext,thismethodmustbefollowedbychargingfromthelowpressuresidewiththeenginerunning.•...Page8467B-21AirConditioningSystem:b)Replaceemptycontainerwitharefrigerant8)Afterthesystemhasbeenchargedwithspecifiedcontainerwhichhasbeenchargedwithamount(37020g)ofrefrigerantorwhenlowrefrigerant.Whenusingrefrigerantcontainertappressuregauge(1)andhighpressuregauge(2)valve(2),usethefollowingprocedureforhaveindicatedthefollowingspecifiedvalue,close...Page847AirConditioningSystem:7B-22CheckA/CSystemforRefrigerantLeaksCondenserAssemblyRemovalandInstallationWheneverarefrigerantleakissuspectedinthesystemS4RS0A7206007CAUTION:oranyserviceoperationhasbeenperformedwhichmayresultinmalfunctionoflinesandconnections,itisDonotdamagecondenserfins.Page8487B-23AirConditioningSystem:DesiccantRemovalandInstallationInstallationReversetheremovalproceduretoinstallcondenserS4RS0A7206009Removalnotingthefollowinginstructions.1)Removecondenserassemblyreferringto•Replenishspecifiedamountofcompressoroilto“CondenserAssemblyRemovalandInstallation:”.compressorsuctionsidereferringto“Replenishing2)Removecap(1)fromreceiver/dryertank.Page849AirConditioningSystem:7B-24HVACUnitComponentsS4RS0A7206003I4RS0A720021-1.Freshairinletduct7.Airflowcontroldoorassembly13.Heatercore19.Evaporatorthermistor(evaporatortemperaturesensor)2.Bloweruppercase8.Temperaturecontroldoor14.Temperaturecontrollever20.Page8507B-25AirConditioningSystem:6.Footduct12.Heaterunitlowercase18.Expansionvalve:Donotreuse.HVACUnitRemovalandInstallationS4RS0A7206012Removal1)Disconnectnegative(–)cablefrombattery.2)Disableairbagsystemreferringto“DisablingAirBagSystem:inSection8B”.Page851AirConditioningSystem:7B-26I4RS0A720052-InstallationReversetheremovalprocedurenotingthefollowinginstruction.•Installevaporatorthermistor(evaporatortemperaturesensor)(1)ontoevaporator(2)asshown.I4RS0A720027-[A]:Resistance(k)[B]:TemperatureExpansionValveRemovalandInstallationS4RS0A7206015Removal1)RecoverrefrigerantfromtheA/CsystemwithI4RS0A720053-...Page8527B-27AirConditioningSystem:InstallationReverseremovalprocedurenotingthefollowinginstructions.•ApplycompressoroiltoO-ringofexpansionvalveandpipes.•EvacuateandchargetheA/Csystemreferringto“Evacuation”and“Charge”in“OperationProcedureforRefrigerantCharge:”.ExpansionValveInspectionS4RS0A7206016I4RS0A720029-...Page853AirConditioningSystem:7B-28CompressorDriveBeltInspectionandAdjustmentS4RS0A7206021Inspection•Checkcompressordrivebelt(1)forwear,crack,deformationandcleanliness.Ifanydefectisfound,replacethebeltwithnewonereferringto“CompressorDriveBeltRemovalandInstallation:”.•...Page8547B-29AirConditioningSystem:CompressorDriveBeltRemovalandNOTE:InstallationCapopenfittingsimmediatelytokeepS4RS0A7206036moistureoutofthesystem.Removal1)Loosentensionpulleynut(1).2)Loosenbelttensionbylooseningtensionpulleyadjustingbolt(2).3)Removecompressordrivebelt(3).Page855AirConditioningSystem:7B-30CompressorAssemblyComponentsS4RS0A7206024I4RS0A720037-1.Armatureplatebolt4.Circlip7.Magnetclutchpulley:Donotreuse.2.Compressor5.Shim8.Armatureplate:15Nm(1.5kg-m,11.0lb-ft)3.Reliefvalve6.Page8567B-31AirConditioningSystem:4)Removeshimsfromshaft.Installation5)Removecirclip(1)usingspecialtool.1)Installmagnetclutchcoil(2)fittingprotrusion(4)ofmagnetclutchcoilontohole(5)ofcompressor(3).Specialtool2)Installnewcirclip(1)directingchamferside(6)(B):09900–06107downward.Page857AirConditioningSystem:7B-32ReliefValveInspectionS4RS0A7206031Byusingspecialtool,checkifthereisrefrigerantleakage.Ifthereisrefrigerantleakage,replacethereliefvalve.Specialtool(A):09990–86011I4RS0A720045-8)Adjustclearancebetweenmagnetclutchplate(1)andmagnetclutchpulleybyputtingshim(s)oncompressorshaft.Page8587B-33AirConditioningSystem:InstallationReverseremovalprocedurenotingthefollowinginstructions.•UsenewO-ring.•ApplycompressoroiltoO-ring.•Tightenrelivevalvetothespecifiedtorque.TighteningtorqueReliefvalve(a):8N·m(0.8kg-m,6.0lb-ft)I4RS0A720049-•...Page859AirConditioningSystem:7B-34SpecialToolsandEquipmentRecommendedServiceMaterialS4RS0A7208001MaterialSUZUKIrecommendedproductorSpecificationNoteCompressoroilCompressoroilP/No.:99000–99015–(MATSUSHITADENKI)-DomesticNOTE:Requiredservicematerialisalsodescribedinthefollowing.“PrecautionsonServicingA/CSystem:”...Page8607B-35AirConditioningSystem:...Page861TableofContents8-iSection8RestraintCONTENTSPrecautions..........8-1“AIRBAG”WarningLampDoesNotComeON..............8B-15Precautions.............8-1“AIRBAG”WarningLampFlashes....8B-17PrecautionsonRestraint........8-1DTCB1013:SDMfault........8B-18SeatBelts..........8A-1DTCB1014:“AIRBAG”WarningLampCircuitFailure..........8B-18Precautions............8A-1DTCB1016:PowerSourceVoltageHigh..8B-19...Page8628-iiTableofContentsDTCB1064/B1068:Driver/PassengerRepairInstructions..........8B-105Side-AirBagInitiatorCircuitShorttoPowerDisablingAirBagSystem........8B-105Circuit..............8B-82EnablingAirBagSystem........8B-105DTCB1071:Forward-SensorPerformanceSDMRemovalandInstallation......8B-106Problem............Page863Precautions:PrecautionsPrecautionsPrecautionsonRestraintS4RS0A8000001AirBagSystemServiceWarningReferto“AirBagSystemServiceWarning:inSection00”.FastenerCautionReferto“FastenerCaution:inSection00”.PrecautionsonServiceandDiagnosisofSeatBeltReferto“PrecautionsonServiceandDiagnosisofSeatBelt:inSection8A”.PrecautionsonServiceandDiagnosisofAirBagSystemReferto“PrecautionsonServiceandDiagnosisofAirBagSystem:inSection8B”.Replacedefectiveassemblieswithconditionmaybecomeunreliable.Forthisnewreplacementparts.reason,SUZUKIwillsupplyonlythespare•Keepbeltsdryandcleanatalltimes.buckleandseatbeltassemblyinasetpart.Page865SeatBelts:8A-2SeatBeltwithELRSeatBeltwithELRandPretensionerTheseatbeltwithemergencylockingretractor(ELR)isTheseatbeltwithELRandapretensionerhasadesignedsothatitlocksimmediately(topreventthepretensionermechanismwhichoperatesinlinkagewithwebbingfrombeingpulledoutoftheretractoranytheairbaginadditiontothedescribedELR.Page8668A-3SeatBelts:RepairInstructionsFrontSeatBeltComponentsS4RS0A8106001WARNING:•Neverattempttodisassembleorrepairtheseatbeltpretensioner(retractorassembly).Ifanyabnormalityisfound,besuretoreplaceitwithnewoneasanassembly.•...Page867SeatBelts:8A-4FrontSeatBeltInspectionS4RS0A8106003WARNING:•Neverattempttodisassembleorrepairtheseatbeltpretensioner(retractorassembly).Ifanyabnormalityisfound,besuretoreplaceitwithnewoneasanassembly.•Besuretoread“PrecautionsonServiceI2RH01810003-andDiagnosisofSeatBelt:”,before5)Removefrontseatbeltsfromthevehicle.Page8688A-5SeatBelts:SeatBeltAnchorBolt•Theseatbeltwebbingorstrapshouldbefreefrom•Anchorboltsshouldbetorquedtospecification.damage.BeltLatchRetractorAssembly(withSeatBeltPretensioner)•Itshouldbesecurewhenlatched.1)Lettheseatbeltretractfullytoconfirmitseasyretraction.Page869SeatBelts:8A-6RearSeatBeltComponentsS4RS0A8106006WARNING:Besuretoread“PrecautionsonServiceandDiagnosisofSeatBelt:”beforestartingtoworkandobserveeveryprecautionduringwork.I4RS0A810003-1.Upperanchor4.Rearcenterseatbelt7.Page8708A-7SeatBelts:RearSeatBeltRemovalandInstallationInstallationS4RS0A8106004ReverseremovalprocedureforinstallationnotingtheWARNING:following.Besuretoread“PrecautionsonServiceand•SeatbeltanchorboltsshouldhaveanunifiedfineDiagnosisofSeatBelt:”beforestartingtothread(7/16-20UNF).Page871•Iftheairbagsystemandanothervehicle•Whenusingelectricwelding,besuretodisconnectairsystembothneedrepair,SUZUKIbag(inflator)moduleconnectors(driver,passenger,recommendsthattheairbagsystembe...Page8728B-2AirBagSystem:I5RH01820001-•IfSDMhasbeendropped,replaceitwithanewone.•IfSDMinstallationpartoffloorwasdamaged,repairthatpartcompletelybeforereinstallation.•AllSDMandmountingbracketfastenersmustbecarefullytorquedandthearrowmustbepointedtowardthefrontofthevehicletoensureproperoperationoftheairbagsystem.Page873AirBagSystem:8B-3WARNING:WARNING:Whenplacingaliveairbag(inflator)module•Forhandlingandstorageofaliveairbagonbenchorothersurface,alwaysfacethe(inflator)module,selectaplacewherethebagup,awayfromthesurface.Astheliveambienttemperaturebelow65C(150F),passengerairbag(inflator)modulemustbewithouthighhumidityandawayfrom...Page8748B-4AirBagSystem:WARNING:Neverattempttomeasuretheresistanceoftheseatbeltpretensioners.Itisverydangerousastheelectriccurrentfromthetestermayactivatepretensioner.I2RH01820048-DeployedAirBag(Inflator)ModuleandActivatedSeatBeltPretensionerWARNING:•...Page875AirBagSystem:8B-5Donotdisposeofthelive(undeployed)airbag(inflator)•Makesureairbagsystemgroundingpoint(2)iscleanandgroundissecurelyfastenedforoptimummetal-to-modulesandthelive(inactivated)seatbeltmetalcontact.Page8768B-6AirBagSystem:Theairbagsystemisdesignedtoactivateonlyinseverefrontalandsidewardcollisions.Itisnotdesignedtoactivateinrearimpacts,rollovers,orminorfrontalandsidewardcollisions,sinceitwouldoffernoprotectioninthosetypesofaccidents.Page877AirBagSystem:8B-7SchematicandRoutingDiagramAirBagSystemWiringCircuitDiagramS4RS0A8202001“L29”“G04”“G26”“L32”L29-3“G28”BLU/ORNL29-2“G34”“L29”RED/BLK“G33”“L04”YEL/REDYEL/REDL29-4BLU/ORNL29-1YEL/GRNYEL/GRNL29-5L29-26“G32”“L10”

“G10”L29-31L29-7“G35”...Page8788B-8AirBagSystem:TerminalarrangementofSDM(viewedfromharnessside)I5RH01820003-1.SDMConnector“L29”Connector“L29”(SDMconnector)TerminalTerminalTerminalCircuitTerminalCircuitsymbolsymbolL29-1“AIRBAG”warninglampL29-26Ignitionswitch(powersource)L29-2D1–...Page879AirBagSystem:8B-9ComponentLocationAirBagSystemComponents,WiringandConnectorsLocationS4RS0A8203001I4RS0A820007-...Page8808B-10AirBagSystem:1.Passengerairbag(inflator)module8.Side-airbag(inflator)module(ifequipped)15.“AIRBAG”warninglamp2.Driverairbag(inflator)module9.Groundforairbagsystem:23Nm(2.3kg-m,16.5lb-ft)3.Page881AirBagSystem:8B-11StepAction1)CheckDTCusingSUZUKIscantoolreferringto“DTCAirbagsystemisinAnintermittenttroubleCheck:”.goodcondition.hasoccurredatsomeplace.Is“NOCODES”displayedonSUZUKIscantool?Checktheconnectorharness,etc.Page8824)ReadDTCaccordingtoinstructionsdisplayedonisdisplayedandnotmalfunctionDTC.SUZUKIscantoolandprintitorwriteitdown.Refer6)TurnignitionswitchtoOFFpositionanddisconnecttoSUZUKIscantooloperator’smanualforfurtherSUZUKIscantoolfromDLC.Page883AirBagSystem:8B-13ScanToolDataDrivA/BIniRes(Driverairbaginitiatorresistance)S4RS0A8204068(ohm):Thisparameterindicatestheresistanceofthedriverairbaginitiatorcircuit.DatalistofSDMPassA/BIniRes(PassengerairbaginitiatorNormalCondition/resistance)(ohm):ThisparameterindicatestheScanToolData...Page8848B-14AirBagSystem:CAUTION:•Besuretoperform“AirBagDiagnosticSystemCheck:”beforestartingdiagnosisaccordingtoflow.•Whenmeasurementofresistanceorvoltageisrequiredinthisflow,useatesteralongwithacorrectterminaladapterfromspecialtool(Connectortestadapterkit).Page885AirBagSystem:8B-15StepAction1)Disconnectcombinationmeterconnector“G28”referringSubstituteaknown-“BLU/ORN”wireto“CombinationMeterRemovalandInstallation:ingoodSDMandrecheck.(betweencombinationSection9C”.If“AIRBAG”warningmeterandSDMlampremainlighting,connector)openor2)Checkproperconnectiontocombinationmeterat“BLU/...Page8868B-16AirBagSystem:CAUTION:•Besuretoperform“AirBagDiagnosticSystemCheck:”beforestartingdiagnosisaccordingtoflow.•Whenmeasurementofresistanceorvoltageisrequiredinthisflow,useatesteralongwithacorrectterminaladapterfromspecialtool(Connectortestadapterkit).Page887AirBagSystem:8B-17“AIRBAG”WarningLampFlashesS4RS0A8204009WiringDiagram“G28”RED/BLKBLU/ORN“L29”“G33”“G34”“L04”BLU/ORNL29-1L29-26“G32”L29-31STL29-27“G32”I4RS0A820009-1.Frommainfuse5.“AIRBAG”warninglampincombinationmeter9.Page8888B-18AirBagSystem:DTCB1013:SDMfaultS4RS0A8204030DTCWillSetwhenAninternalSDMfaultisdetectedbySDM.NOTE:DTCB1013canneverbeclearedonceithasbeenset.DTCTroubleshooting1)TurnignitionswitchOFF.2)ReplaceSDM.Page889AirBagSystem:8B-19DTCTroubleshootingStepAction1)ThisDTCissetwhenthereisatroublein“AIRBAG”GotoStep2.Repair“AIRBAG”warninglampcircuit.Failuretoproperlyperform“AirBagwarninglampcircuit.DiagnosticSystemCheck”...Page8908B-20AirBagSystem:DTCWillSetwhenThepowersourcevoltagetoSDMisaboveanapprox.21Vforspecifiedtime.FlowTestDescriptionStep1:CheckifvoltageappliedtoSDMiswithinnormalrange.Step2:CheckifDTCB1016stillexists.DTCTroubleshootingStepAction...Page891AirBagSystem:8B-21DTCB1017:PowerSourceVoltageLowS4RS0A8204021WiringDiagram“L04”L29-26“G32”L29-27“L29”I4RS0A820011-1.Frommainfuse3.“A/BAG”fuse5.SDM2.Ignitionswitch4.Junctionblockassembly6.GroundforairbagsystemCAUTION:•...Page8928B-22AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectSDMconnector.GotoStep4.Gotostep3.2)CheckproperconnectiontoSDMat“L29-26”terminal.3)IfOK,turnignitionswitchONandthencheckvoltagebetween“L29-26”...Page893AirBagSystem:8B-23DTCB1021:FrontAirBagModuleDeployedS4RS0A8204028DTCWillSetwhenTheSDMdetectsafrontalcrashofsufficientforcetowarrantactivationoftheairbagsystem.(SDMoutputsadeploymentcommand.)FlowTestDescriptionStep1:CheckthatDTCB1021hasbeensetalthoughairbaghasnotbeendeployed.Page8948B-24AirBagSystem:DTCTroubleshootingStepAction1)TurnignitionswitchOFF.ReplacecomponentsGotoStep2.andperforminspectionsHasairbagdeployed?asdirectedin“RepairandInspectionRequiredafterAccident:”.1)InspectfrontofvehicleandundercarriageforsignsofReplacecomponentsSubstituteaknown-impact.Page895AirBagSystem:8B-25DTCB1027:ReusableNumberExceededS4RS0A8204071DTCWillSetwhenTheSDMhasnotbeenreplacedthoughtheside-airbagdevelopedseveraltimesinthepast.NOTE:DTCB1027canneverbeclearedonceithasbeenset.DTCTroubleshooting1)TurnignitionswitchOFF.Page8968B-26AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectcontactcoilGotoStep2.GotoStep4.connectorlocatedunderofthesteeringcolumn.2)Checkproperconnectiontocontactcoilatterminalin“G26”...Page897AirBagSystem:8B-27StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.Highresistanceoropenlocatedneartheglovebox.wirein“GRN”or“YEL”circuitininstrument2)Checkproperconnectiontofloorharnessconnectoratpanelharness.Page8988B-28AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-Highresistanceoropen“L29”.goodSDMandrecheck.wirein“GRN”or“YEL”circuitinfloorharness.2)CheckproperconnectiontoSDMatterminals“L29-2”and“L29-3”.Page899AirBagSystem:8B-29StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)TurnignitionswitchTurnignitionswitchand(C)from“G26”connectorandthenreconnectOFF.ReplacecontactOFF.Replacedriveraircontactcoilconnectorlocatedunderofthesteeringcoilassemblyreferringbag(inflator)modulecolumn.Page9008B-30AirBagSystem:DTCB1032:DriverAirBagInitiatorCircuitResistanceLowS4RS0A8204017WiringDiagram“L29”“L04”“L32”“G04”“G26”L29-26L29-3“G32”L29-2L29-27“L29”I4RS0A820013-[A]:Shortingbar3.“A/BAG”fuse6.Contactcoilassembly1.Frommainfuse5.Page901AirBagSystem:8B-31DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectcontactcoilGotoStep2.GotoStep4.connectorlocatedunderofthesteeringcolumn.2)Checkproperconnectiontocontactcoilatterminalin“G26”...Page9028B-32AirBagSystem:StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.“GRN”circuitshortedtolocatedneartheglovebox.“YEL”circuit,“GRN”circuitor“YEL”circuit2)Checkproperconnectiontofloorharnessconnectoratshortedtoothercircuitterminal“L32-1”...Page903AirBagSystem:8B-33StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-“GRN”circuitshortedto“L29”.goodSDMandrecheck.“YEL”circuit,“GRN”circuitor“YEL”circuit2)CheckproperconnectiontoSDMatterminals“L29-2”shortedtoothercircuitand“L29-3”.Page9048B-34AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)TurnignitionswitchTurnignitionswitchand(C)from“G26”connectorandreconnectcontactcoilOFF.ReplacecontactOFF.Replacedriverairconnectorlocatedunderofthesteeringcolumn.coilassemblyreferringbag(inflator)moduleto“ContactCoilCable...Page905AirBagSystem:8B-35DTCB1033:DriverAirBagInitiatorCircuitShorttoGroundS4RS0A8204018WiringDiagram“L29”“L04”“L32”“G04”“G26”L29-26L29-3“G32”L29-2L29-27“L29”I4RS0A820013-[A]:Shortingbar3.“A/BAG”fuse6.Contactcoilassembly1.Frommainfuse4.Page9068B-36AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectcontactcoilGotoStep2.GotoStep4.connectorlocatedunderofthesteeringcolumn.2)Checkproperconnectiontocontactcoilatterminalin“G26”...Page907AirBagSystem:8B-37StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.“GRN”circuitor“YEL”locatedneartheglovebox.circuitshortedtogroundininstrumentpanel2)Checkproperconnectiontofloorharnessconnectoratharness.Page9088B-38AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)Substituteaknown-“GRN”circuitor“YEL”and(D)from“L32”connectorandSDMconnector“L29”goodSDMandrecheck.circuitshortedtogroundfromSDMrespectively.infloorharness.Page909AirBagSystem:8B-39StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)TurnignitionswitchTurnignitionswitchand(C)from“G26”connectorandreconnectcontactcoilOFF.ReplacecontactOFF.Replacedriverairconnectorlocatedunderofthesteeringcolumn.coilassemblyreferringbag(inflator)moduleto“ContactCoilCable...Page9108B-40AirBagSystem:DTCB1034:DriverAirBagInitiatorCircuitShorttoPowerCircuitS4RS0A8204019WiringDiagram“L29”“L04”“L32”“G04”“G26”L29-26L29-3“G32”L29-2L29-27“L29”I4RS0A820013-[A]:Shortingbar3.“A/BAG”fuse6.Contactcoilassembly1.Page911AirBagSystem:8B-41DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectcontactcoilGotoStep2.GotoStep4.connectorlocatedunderofthesteeringcolumn.2)Checkproperconnectiontocontactcoilatterminalin“G26”...Page9128B-42AirBagSystem:StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.“GRN”circuitor“YEL”locatedneartheglovebox.circuitshortedtopowersupplycircuitin2)Checkproperconnectiontofloorharnessconnectoratinstrumentpanelterminal“L32-1”...Page913AirBagSystem:8B-43StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)Substituteaknown-“GRN”circuitor“YEL”and(D)from“L32”connectorandSDMconnector“L29”goodSDMandrecheck.circuitshortedtopowerfromSDMrespectively.supplycircuit.Page9148B-44AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)TurnignitionswitchTurnignitionswitchand(C)from“G26”connectorandreconnectcontactcoilOFF.ReplacecontactOFF.Replacedriverairconnectorlocatedunderofthesteeringcolumn.coilassemblyreferringbag(inflator)moduleto“ContactCoilCable...Page915AirBagSystem:8B-45DTCB1041:PassengerAirBagInitiatorCircuitResistanceHighS4RS0A8204012WiringDiagram“L29”“L04”“L32”“G04”“G10”L29-26YEL/REDYEL/REDL29-4“G32”YEL/GRNYEL/GRNL29-5L29-27“L29”I4RS0A820020-[A]:Shortingbar3.“A/BAG”fuse6.Passengerairbag(inflator)module1.Page9168B-46AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectpassengerairbagGotoStep2.Turnignitionswitch(inflator)moduleconnector.OFF.Replacepassengerairbag2)Checkproperconnectiontopassengerairbag(inflator)(inflator)modulemoduleatterminalsin“G10”...Page917AirBagSystem:8B-47StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.Highresistanceoropenlocatedneartheglovebox.wire“YEL/RED”or“YEL/GRN”circuitin2)Checkproperconnectiontofloorharnessconnectoratinstrumentpanelterminal“L32-3”...Page9188B-48AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-Highresistanceoropen“L29”.goodSDMandrecheck.wirein“YEL/RED”or“YEL/GRN”circuitin2)CheckproperconnectiontoSDMatterminals“L29-4”floorharness.Page919AirBagSystem:8B-49DTCB1042:PassengerAirBagInitiatorCircuitResistanceLowS4RS0A8204013WiringDiagram“L29”“L04”“L32”“G04”“G10”L29-26YEL/REDYEL/REDL29-4“G32”YEL/GRNYEL/GRNL29-5L29-27“L29”I4RS0A820020-[A]:Shortingbar3.“A/BAG”fuse6.Passengerairbag(inflator)module1.Page9208B-50AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectpassengerairbagGotoStep2.Turnignitionswitch(inflator)moduleconnector.OFF.Replacepassengerairbag2)Checkproperconnectiontopassengerairbag(inflator)(inflator)modulemoduleatterminalsin“G10”...Page921AirBagSystem:8B-51StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.“YEL/RED”circuitlocatedneartheglovebox.shortedto“YEL/GRN”circuit,“YEL/RED”2)Checkproperconnectiontofloorharnessconnectoratcircuitor“YEL/GRN”terminal“L32-3”...Page9228B-52AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-“YEL/RED”circuit“L29”.goodSDMandrecheck.shortedto“YEL/GRN”circuit,“YEL/RED”2)CheckproperconnectiontoSDMatterminals“L29-4”circuitor“YEL/GRN”and“L29-5”.Page923AirBagSystem:8B-53DTCB1043:PassengerAirBagInitiatorCircuitShorttoGroundS4RS0A8204014WiringDiagram“L29”“L04”“L32”“G04”“G10”L29-26YEL/REDYEL/REDL29-4“G32”YEL/GRNYEL/GRNL29-5L29-27“L29”I4RS0A820020-[A]:Shortingbar3.“A/BAG”fuse6.Passengerairbag(inflator)module1.Page9248B-54AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectpassengerairbagGotoStep2.Turnignitionswitch(inflator)moduleconnector.OFF.Replacepassengerairbag2)Checkproperconnectiontopassengerairbag(inflator)(inflator)modulemoduleatterminalsin“G10”...Page925AirBagSystem:8B-55StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.“YEL/RED”or“YEL/locatedneartheglovebox.GRN”circuitshortedtogroundininstrument2)Checkproperconnectiontofloorharnessconnectoratpanelharness.Page9268B-56AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)Substituteaknown-“YEL/RED”or“YEL/and(C)from“L32”connectorandSDMconnector“L29”goodSDMandrecheck.GRN”circuitshortedtofromSDMrespectively.groundinfloorharness.Page927AirBagSystem:8B-57DTCB1044:PassengerAirBagInitiatorCircuitShorttoPowerCircuitS4RS0A8204015WiringDiagram“L29”“L04”“L32”“G04”“G10”L29-26YEL/REDYEL/REDL29-4“G32”YEL/GRNYEL/GRNL29-5L29-27“L29”I4RS0A820020-[A]:Shortingbar3.“A/BAG”fuse6.Page9288B-58AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectpassengerairbagGotoStep3.Turnignitionswitch(inflator)moduleconnector.OFF.Replacepassengerairbag2)Checkproperconnectiontopassengerairbag(inflator)(inflator)modulemoduleatterminalsin“G10”...Page929AirBagSystem:8B-59StepAction1)WithignitionswitchOFF,disconnect“L32”connectorGotoStep3.“YEL/RED”or“YEL/locatedneartheglovebox.GRN”circuitshortedtopowersupplycircuitin2)Checkproperconnectiontofloorharnessconnectoratinstrumentpanelterminal“L32-3”...Page9308B-60AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)Substituteaknown-“YEL/RED”or“YEL/and(C)from“L32”connectorandSDMconnector“L29”goodSDMandrecheck.GRN”circuitshortedtofromSDMrespectively.powersupplycircuitinfloorharness.Page931AirBagSystem:8B-61DTCB1051/B1055:Driver/PassengerPretensionerInitiatorCircuitResistanceHighS4RS0A8204024WiringDiagram“L29”“L10”“L04”L29-7L29-26“G32”L29-6L29-8L29-27LTGRNL29-9“L29”“L36”I4RS0A820026-[A]:Shortingbar3.“A/BAG”fuse6.Page9328B-62AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,removecenterpillarlowertrimGotoStep2.TurnignitionswitchofdriverorpassengersideanddisconnectseatbeltOFF.Replaceseatbeltpretensionerconnector“L10”or“L36”(1).pretensionerreferringto“FrontSeatBelt2)Checkproperconnectiontoseatbeltpretensionerat...Page933AirBagSystem:8B-63StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1051:High“29”.goodSDMandrecheck.resistanceoropenwirein“PNK”or“WHT”2)CheckproperconnectiontoSDMatterminalsin“L29-6”circuit.Page9348B-64AirBagSystem:DTCB1052/B1056:Driver/PassengerPretensionerInitiatorCircuitResistanceLowS4RS0A8204025WiringDiagram“L29”“L10”“L04”L29-7L29-26“G32”L29-6L29-8L29-27LTGRNL29-9“L29”“L36”I4RS0A820026-[A]:Shortingbar3.“A/BAG”fuse6.Page935AirBagSystem:8B-65DTCTroubleshootingStepAction1)WithignitionswitchOFF,removecenterpillarlowertrimGotoStep2.TurnignitionswitchofdriverorpassengersideanddisconnectseatbeltOFF.Replaceseatbeltpretensionerconnector“L10”or“L36”(1).pretensionerreferringto“FrontSeatBelt2)Checkproperconnectiontoseatbeltpretensionerat...Page9368B-66AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1052:“PNK”“29”.goodSDMandrecheck.circuitshortedto“WHT”circuit,“PNK”circuitor2)CheckproperconnectiontoSDMatterminalsin“L29-6”“WHT”...Page937AirBagSystem:8B-67DTCB1053/B1057:Driver/PassengerPretensionerInitiatorCircuitShorttoGroundS4RS0A8204026WiringDiagram“L29”“L10”“L04”L29-7L29-26“G32”L29-6L29-8L29-27LTGRNL29-9“L29”“L36”I4RS0A820026-[A]:Shortingbar3.“A/BAG”fuse6.Page9388B-68AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,removecenterpillarlowertrimGotoStep2.IgnitionswitchOFF.ofdriverorpassengersideanddisconnectseatbeltReplaceseatbeltpretensionerconnector“L10”or“L36”(1).pretensionerreferringto“FrontSeatBelt2)Checkproperconnectiontoseatbeltpretensionerat...Page939AirBagSystem:8B-69NOTE:Uponcompletionofinspectionandrepairwork,performthefollowingitems.•Reconnectallairbagsystemcomponentsandensureallcomponentsareproperlymounted.•ClearDTCsreferringto“DTCClearance:”,ifany.•...Page9408B-70AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,removecenterpillarlowertrimGotoStep2.TurnignitionswitchofdriverorpassengersideanddisconnectseatbeltOFF.Replaceseatbeltpretensionerconnector“L10”and“L36”(1).pretensionerreferringto“FrontSeatBelt2)Checkproperconnectiontoseatbeltpretensionerat...Page941AirBagSystem:8B-71NOTE:Uponcompletionofinspectionandrepairwork,performthefollowingitems.•Reconnectallairbagsystemcomponentsandensureallcomponentsareproperlymounted.•ClearDTCsreferringto“DTCClearance:”,ifany.•...Page9428B-72AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectside-airbagGotoStep2.GotoStep3.(inflator)moduleconnectorunderfrontseatcushion.2)Checkproperconnectiontodriverorpassengerside-airbag(inflator)moduleatterminalsin“L25”...Page943AirBagSystem:8B-73StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1061:Repair“L29”.goodSDMandrecheck.highresistanceoropenin“WHT/RED”or“WHT/2)CheckproperconnectiontoSDMatterminals“L29-10”GRN”...Page9448B-74AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)DTCB1061:RepairReplaceside-airbagand(C)thenreconnectconnector“L25”or“L30”.highresistanceoropen(inflator)modulein“WHT/RED”or“WHT/referringto“Side-Air2)Disconnectside-airbag(inflator)moduleconnector(1)GRN”...Page945AirBagSystem:8B-75DTCB1062/B1066:Driver/PassengerSide-AirBagInitiatorCircuitResistanceLowS4RS0A8204073WiringDiagram“L29”“L25”“L04”WHT/REDL29-11L29-26WHT/GRN“G32”L29-10GRY/BLUL29-12L29-27LTGRN/REDL29-13“L29”“L30”I4RS0A820031-[A]:Shortingbar3.Page9468B-76AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectside-airbagGotoStep2.GotoStep3.(inflator)moduleconnectorunderfrontseatcushion.2)Checkproperconnectiontodriverorpassengerside-airbag(inflator)moduleatterminalsin“L25”...Page947AirBagSystem:8B-77StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1062:Repair“L29”.goodSDMandrecheck.shortfrom“WHT/RED”wirecircuitto“WHT/2)CheckproperconnectiontoSDMatterminals“L29-10”GRN”...Page9488B-78AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B)DTCB1062:RepairReplaceside-airbagand(C)thenreconnectconnector“L25”or“L30”.shortfrom“WHT/RED”(inflator)modulewirecircuitto“WHT/referringto“Side-Air2)Disconnectside-airbag(inflator)moduleconnector(1)GRN”...Page949AirBagSystem:8B-79DTCB1063/B1067:Driver/PassengerSide-AirBagInitiatorCircuitShorttoGroundS4RS0A8204074WiringDiagram“L29”“L25”“L04”WHT/REDL29-11L29-26WHT/GRN“G32”L29-10GRY/BLUL29-12L29-27LTGRN/REDL29-13“L29”“L30”I4RS0A820031-[A]:Shortingbar3.Page9508B-80AirBagSystem:DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectside-airbagGotoStep2.GotoStep3.(inflator)moduleconnectorunderfrontseatcushion.2)Checkproperconnectiontodriverorpassengerside-airbag(inflator)moduleatterminalsin“L25”...Page951AirBagSystem:8B-81StepAction1)WithignitionswitchOFF,disconnectspecialtoolsandSubstituteaknown-DTCB1063:RepairSDMconnector“L29”.goodSDMandrecheck.shortfrom“WHT/RED”or“WHT/GRN”wire2)ReleaseshortingbarinSDMconnectorinsertingreleasecircuittogroundinfloortool(1)includedinspecialtool(A).Page9528B-82AirBagSystem:NOTE:Uponcompletionofinspectionandrepairwork,performthefollowingitems.•Reconnectallairbagsystemcomponents,ensureallcomponentsareproperlymounted.•ClearDTCsreferringto“DTCClearance:”,ifany.•Repeat“AirBagDiagnosticSystemCheck:”toconfirmthatthetroublehasbeencorrected.DTCB1064/B1068:Driver/PassengerSide-AirBagInitiatorCircuitShorttoPowerCircuitS4RS0A8204075WiringDiagram...Page953AirBagSystem:8B-83DTCTroubleshootingStepAction1)WithignitionswitchOFF,disconnectside-airbagGotoStep2.GotoStep3.(inflator)moduleconnectorunderfrontseatcushion.2)Checkproperconnectiontodriverorpassengerside-airbag(inflator)moduleatterminalsin“L25”...Page9548B-84AirBagSystem:StepAction1)WithignitionswitchOFF,disconnectspecialtools(B),Substituteaknown-DTCB1064:Repair(C)andSDMconnector“L29”.goodSDMandrecheck.shortfrom“WHT/RED”or“WHT/GRN”wire2)ReleaseshortingbarinSDMconnectorinsertingreleasecircuittopowercircuitintool(1)includedinspecialtool(A).Page955AirBagSystem:8B-85NOTE:Uponcompletionofinspectionandrepairwork,performthefollowingitems.•Reconnectallairbagsystemcomponents,ensureallcomponentsareproperlymounted.•ClearDTCsreferringto“DTCClearance:”,ifany.•Repeat“AirBagDiagnosticSystemCheck:”toconfirmthatthetroublehasbeencorrected.DTCB1071:Forward-SensorPerformanceProblemS4RS0A8204022DTCWillSetwhen...Page9568B-86AirBagSystem:CAUTION:•Besuretoperform“AirBagDiagnosticSystemCheck:”beforestartingdiagnosisaccordingtoflow.•Whenmeasurementofresistanceorvoltageisrequiredinthisflow,useatesteralongwithacorrectterminaladapterfromspecialtool(Connectortestadapterkit).Page957AirBagSystem:8B-87NOTE:Uponcompletionofinspectionandrepairwork,performthefollowingitems.•Reconnectallairbagsystemcomponentsandensureallcomponentsareproperlymounted.•ClearDTCsreferringto“DTCClearance:”,ifany.•...Page9588B-88AirBagSystem:DTCTroubleshootingStepAction1)Disconnectforward-sensorconnector“E13”.GotoStep2.Highresistanceoropenwirein“GRY/RED”2)DisconnectSDMconnector“L29”.circuitor“GRY”circuit.3)CheckproperconnectiontoSDMconnectoratterminals“L29-49”...Page959AirBagSystem:8B-89NOTE:Uponcompletionofinspectionandrepairwork,performthefollowingitems.•Reconnectallairbagsystemcomponentsandensureallcomponentsareproperlymounted.•ClearDTCsreferringto“DTCClearance:”,ifany.•...Page9608B-90AirBagSystem:DTCWillSetwhenTheresistancemeasuredbetweenside-sensorcircuitandgroundcircuitisbelowaspecifiedvalueforspecifiedtime.FlowTestDescriptionStep1:Checkforshortcircuitbetweenside-sensorcircuitandground.Step2:Checkifmalfunctionisinside-sensor.DTCTroubleshootingStepAction...Page961AirBagSystem:8B-91DTCB1084/B1094:Driver/PassengerSide-SensorCircuitShorttoPowerCircuitorOpenS4RS0A8204081WiringDiagram“L29”“L11”“L04”GRN/WHTL29-45L29-26GRN/BLK“G32”L29-46GRN/YELL29-44L29-27GRN/ORNL29-43“L29”“L35”I4RS0A820041-1.Frommainfuse4.Page9628B-92AirBagSystem:DTCTroubleshootingStepAction1)Disconnectside-sensorconnector“L11”or“L35”.GotoStep2.DTCB1084:Highresistanceoropenwire2)DisconnectSDMconnector“L29”.in“GRN/WHT”circuitor3)CheckproperconnectiontoSDMconnectoratterminals“GRN/BLK”...Page963AirBagSystem:8B-93NOTE:Uponcompletionofinspectionandrepairwork,performthefollowingitems.•Reconnectallairbagsystemcomponentsandensureallcomponentsareproperlymounted.•ClearDTCsreferringto“DTCClearance:”,ifany.•...Page9648B-94AirBagSystem:DTCWillSetwhenThecombinedresistanceofthesidecurtain-airbag(inflator)module(driverorpassenger),harnesswiringandconnectorterminalcontactisaboveaspecifiedvalueforspecifiedtime.FlowTestDescriptionStep1:Checkwhethermalfunctionisinsidecurtain-airbag(inflator)module.Step2:Checksidecurtain-airbaginitiatorcircuit.Page965AirBagSystem:8B-95StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1361:Repair“L29”.goodSDMandrecheck.highresistanceoropenin“RED/BLU”or“YEL/2)CheckproperconnectiontoSDMatterminals“L29-18”BLK”...Page9668B-96AirBagSystem:CAUTION:•Besuretoperform“AirBagDiagnosticSystemCheck:”beforestartingdiagnosisaccordingtoflow.•Whenmeasurementofresistanceorvoltageisrequiredinthisflow,useatesteralongwithacorrectterminaladapterfromspecialtool(Connectortestadapterkit).Page967AirBagSystem:8B-97StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1362:Repair“L29”.goodSDMandrecheck.shortfrom“RED/BLU”wirecircuitto“YEL/BLK”2)CheckproperconnectiontoSDMatterminals“L29-18”wirecircuitorfromand“L29-19”...Page9688B-98AirBagSystem:CAUTION:•Besuretoperform“AirBagDiagnosticSystemCheck:”beforestartingdiagnosisaccordingtoflow.•Whenmeasurementofresistanceorvoltageisrequiredinthisflow,useatesteralongwithacorrectterminaladapterfromspecialtool(Connectortestadapterkit).Page969AirBagSystem:8B-99StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1363:Repair“L29”.goodSDMandrecheck.shortfrom“RED/BLU”or“YEL/BLK”wire2)ReleaseshortingbarinSDMconnectorinsertingreleasecircuittoground.Page9708B-100AirBagSystem:CAUTION:•Besuretoperform“AirBagDiagnosticSystemCheck:”beforestartingdiagnosisaccordingtoflow.•Whenmeasurementofresistanceorvoltageisrequiredinthisflow,useatesteralongwithacorrectterminaladapterfromspecialtool(Connectortestadapterkit).Page971AirBagSystem:8B-101StepAction1)WithignitionswitchOFF,disconnectSDMconnectorSubstituteaknown-DTCB1064:Repair“L29”.goodSDMandrecheck.shortfrom“RED/BLU”or“YEL/BLK”wire2)ReleaseshortingbarinSDMconnectorinsertingreleasecircuittopowercircuit.Page9728B-102AirBagSystem:RepairandInspectionRequiredafterAccidentS4RS0A8204033CAUTION:•Allairbagsystemcomponents,includingtheelectricalharness(componentmountingpoints),mustbeinspectedafteranaccident.Ifanycomponentsaredamagedorbent,theymustbereplacedevenifairbagsystemactivationdidnotoccur.Page973AirBagSystem:8B-103Whenside-airbagandsidecurtain-airbagaredeployed,thefollowingcomponentsmustbereplaced.•Deployedside-airbag(inflator)module•Deployedsidecurtain-airbag(inflator)module•Side-sensor•SDMAccidentwithorwithoutDeployment/Activation–ComponentInspectionsCertainairbagandrestraintsystemcomponentsmustbeinspectedafteranycrash,whethertheairbagsystem...Page9748B-104AirBagSystem:–Checkwireharnessclampsfortightness.•Seatbeltpretensioner–Forairbagharnessincludingininstrumentpanel–Checkfordents,cracks,damageorfitnessharnessreplacement,referto“PassengerAirBag–Checkharnessandconnectorfordamageor(Inflator)ModuleRepairHarnessInstallation:”.Page975AirBagSystem:8B-105RepairInstructionsDisablingAirBagSystemS4RS0A82060011)Turnsteeringwheelsothatvehicle’swheels(fronttires)arepointingstraightahead.2)Disconnectnegative(–)cableatbattery.3)Turnignitionswitchto“LOCK”positionandremovekey.Page9768B-106AirBagSystem:SDMRemovalandInstallationS4RS0A8206003WARNING:Duringserviceprocedures,beverycarefulwhenhandlingaSensingandDiagnosticModule(SDM).Besuretoread“PrecautionsonServiceandDiagnosisofAirBagSystem:”beforestartingtoworkandobserveeveryprecautionduringwork.Page977AirBagSystem:8B-107CAUTION:Installation1)Checkthatnoneofthefollowingfaultyconditions•Donotconnectatesterwhatevertypeitexists.maybe.•Bend,scratch,deformityinvehiclebodywhere•NeverrepairordisassembleSDM.SDMismounted.Page9788B-108AirBagSystem:TighteningtorqueDriverairbag(inflator)modulemountingbolt(a):9N·m(0.9kg-m,6.5lb-ft)I4RS0A820057-I5RH01820103-WARNING:6)Enableairbagsystem.Referto“EnablingAirBagSystem:”.Specialcareisnecessarywhenhandlingand7)Connectnegativecableatbattery.Page979AirBagSystem:8B-109PassengerAirBag(Inflator)ModuleRemovalandInstallationS4RS0A8206007WARNING:•Neverattempttodisassembleorrepairthepassengerairbag(inflator)module.Ifanyabnormalityisfound,besuretoreplaceitwithnewoneasanassembly.•...Page9808B-110AirBagSystem:Installation4)Connectpassengerairbag(inflator)moduleconnector(1)securelyasshowninfigure.1)Installpassengerairbag(inflator)moduletoairbagholecover(2).a)Connectconnector.b)Lockconnectorwithlockbutton(2).CAUTION:Confirmclaw(1)ofpassengerairbag(inflator)modulehangsinairbagholecover...Page981AirBagSystem:8B-111CAUTION:Ifairbag(Inflator)modulewasdroppedfromaheightof90cm(3ft)ormore,itshouldbereplaced.Checkairbag(inflator)moduleappearancevisuallyforthefollowingsymptomsandifanyoneofthemisfound,replacewithanewone.Page9828B-112AirBagSystem:Side-AirBag(Inflator)InspectionInstallationS4RS0A82060221)Confirmsleeve(1)issurelyinstalledinside-airbagWARNING:(inflator)module.•Neverattempttodisassembleorrepairthe2)Tightensleevelocknut(2)tospecifiedtorque.side-airbag(inflator)module.Page983AirBagSystem:8B-113SideCurtain-AirBag(Inflator)ModuleRemovalWARNING:andInstallation•Whencarryingaliveairbag(inflator)S4RS0A8206025WARNING:module,makesurethebagopeningispointedawayfromyou.•NeverattempttodisassembleorrepairtheNevercarryairbag(inflator)modulebysidecurtain-airbag(inflator)module.Page9848B-114AirBagSystem:CAUTION:Ifairbag(inflator)modulewasdroppedfromaheightof90cm(3ft)ormore,itshouldbereplaced.Checkairbag(inflator)moduleappearancevisuallyforthefollowingsymptomsandifanyoneofthemisfound,replacewithanewone.Page985AirBagSystem:8B-115Forward-SensorInspection4)Removeforward-sensorbolt(1)andforward-sensor(2).S4RS0A8206010WARNING:Duringserviceprocedures,beverycarefulwhenhandlingasensor.•Neverstrikeorjarasensor.•Asensorandmountingbracketboltsmustbecarefullytorquedtoassureproperoperation.Page9868B-116AirBagSystem:6)Disconnectside-sensorconnectorslidingconnectorouter(1)asshown.I4RS0A820106-4)Connectnegativecableatbattery.I4RS0A820109-5)Enableairbagsystem.Referto“EnablingAirBagSystem:”.InstallationCAUTION:Side-SensorInspectionS4RS0A8206024Properoperationofside-sensorrequiresWARNING:sensorberigidlyattachedtospecifiedDuringserviceprocedures,beverycareful...Page987AirBagSystem:8B-1171)Disableairbagsystem.Referto“DisablingAirBag•Checksensor(1)fordents,crack,deformation.System:”.•Checksensorconnector(sensorsideandharness2)Disconnect“L32”connectorfromfloorharnessside),lockmechanismorsensorleadwireforlocatedneartheglovebox.Page9888B-118AirBagSystem:AirBag(Inflator)ModuleandSeatBeltWARNING:PretensionerDisposalThefollowingprecautionsmustbeobservedS4RS0A8206013forthiswork.FailuretoobserveanyofthemWARNING:mayresultinpersonalinjury.Failuretofollowproperairbag(inflator)•...Page989AirBagSystem:8B-119WARNING:Deployment/ActivationOutsideofVehicleWhenyouintendtoreturnthevehicletoservice,deploy•Forhandingandstorageofliveairbagtheairbag(inflator)module(s)oractivateseatbelt(inflator)module,selectplacewherepretensioner(s)outsideofthevehicle.Page9908B-120AirBagSystem:I4JA01822118-6)Setairbag(inflator)moduleorseatbeltpretensionerasfollows.•Fordriverairbag(inflator)modulea.Clearspace(3)ongroundabout185cm(6ft)indiameterwheredriverairbag(inflator)module(1)issetfordeployment.Page991AirBagSystem:8B-121c.Fillplasticreservoirindeploymentfixture(A)e.Attachside-airbag(inflator)module(1)inwithwaterorsand.Thisisnecessarytodeploymentfixtureusingmountingprovidesufficientstabilizationoffixtureduringattachment,sleevelocknutandwasher(2).deployment.Page9928B-122AirBagSystem:Paved,outdoorlocationwherethereisnod.Tieseatbeltpretensioner(2)withwireactivityispreferred.Ifoutdoorlocationisnotharness(3)towheel-installedtire(4)asavailable,usespaceonshopfloorwhereshown.Page993AirBagSystem:8B-123•Forpassengerairbag(inflator)module[B]Checkthatpassengerairbag(inflator)moduleisfirmlyandproperlysecuredondeploymentfixture(specialtool),andconnectadaptercable(B)topassengerairbag(inflator)module.•...Page9948B-124AirBagSystem:12)Notifyallpeopleinimmediateareathatyouintendtodeploy/activateairbag(inflator)moduleorseatbeltpretensioner.NOTE:•Whenairbag(inflator)moduledeploysandseatbeltpretensioneractivates,rapidgasexpansionwillcreatesubstantialreport.Page995AirBagSystem:8B-12521)Washyourhandswithmildsoapandwaterafterward.NOTE:Remainingstepsaretobefollowedintheunlikelyeventthatairbag(inflator)moduledidnotdeployorseatbeltpretensionerdidnotactivate.22)Ensurethatdeploymentharnesshasbeendisconnectedfrom12voltsvehiclebatteryandthatitstwobananaplugshavebeenshortedtogetherby...Page9968B-126AirBagSystem:5)Checkthatthereisnoopen,shortordamageinspecialtools(deploymentharness(A),adaptercable(B)and(C)).Ifanyfaultyconditionisfound,donotuseitandbesuretousenewspecialtool.Andconnectadaptercable(B),(C)or(D)todeploymentharness(A)andlockconnectorswithlockslider.Page997AirBagSystem:8B-12712)Completelycoverwindshieldareaandfrontdoor15)Connectdeploymentharness(2)to12voltsvehiclewindowopeningswithdropcloth,ablanketoranybattery(3).Thiswillimmediatelydeployoractivatesimilaritem.Thisreducespossibilityofinjuryduetoairbag(inflator)moduleorseatbeltpretensioners.Page9988B-128AirBagSystem:NOTE:Remainingstepsaretobefollowedintheunlikelyeventthatairbag(inflator)moduledidnotdeployorseatbeltpretensionerdidnotactivate.24)Removeundeployedairbag(inflator)module(s)and/orinactivatedseatbeltpretensioner(s)fromvehicle.Fordriverairbag(inflator)module,referto“DriverAirBag(Inflator)ModuleRemovalandInstallation:”.Page999AirBagSystem:8B-129SpecificationsTighteningTorqueSpecificationsS4RS0A8207001TighteningtorqueFasteningpartNotekg-mlb-ftSDMboltDriverairbag(inflator)modulemountingboltPassengerairbag(inflator)moduleattaching16.5boltSleevelocknut0.25Sidecurtain-airbag(inflator)moduleattachingboltsForward-sensormountingboltSide-sensorbolt...Page1000(inflator)moduleanddriverandpassengerseatbeltpretensionersinstrumentpanelharnessfordriverandpassenger3.Notusedseatbeltpretensioners.RecommendedServiceMaterialS4RS0A8208004MaterialSUZUKIrecommendedproductorSpecificationNoteThreadlockcementThreadLockCementSuper1332BP/No.:99000–32100...Page1001AirBagSystem:8B-131SpecialToolS4RS0A820800509932–7501009932–75031AirbagloadtoolAirbagdeploymentharness09932–7504109932–76010Passengerairbag(inflator)ConnectortestadaptersetmoduledeploymentfixtureThissetincludesthefollowingitems.1.Connectortestadapterkit(09932-75020),2.Page10028B-132AirBagSystem:SUZUKIscantool—Thiskitincludesfollowingitems.1.Tech2,2.PCMCIAcard,3.DLCcable,4.SAE16/19adapter,5.Cigarettecable,6.DLCloopbackadapter,7.Batterypowercable,8.RS232cable,9.Page1003TableofContents9-iSection9Body,CabandAccessoriesCONTENTSPrecautions..........9-1BCMside...............9A-25Fuseside...............9A-26Precautions.............9-1JunctionBlockInnerCircuit(Overview)....9A-27PrecautionsonBody,CabandAccessories..9-1JunctionBlockInnerCircuit(Detail)....9A-28PrecautionsforBodyService........

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