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Suzuki Rg 413 Service Repair Manual 2000 – PDF Download
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Description
Suzuki Rg 413 Service Repair Manual 2000 – PDF Download
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SUZUKI RG 413 SERVICE REPAIR MANUAL 2000 – PDF DOWNLOAD:
Suzuki Rg 413 Service Repair Manual 2000 – PDF Download
DESCRIPTION:
Suzuki Rg 413 Service Repair Manual 2000 – PDF Download
This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul). Applicable model: RG413
- The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki Rg 413 Service Repair Manual 2000 – PDF Download
TOP............................................................................................................. 0 MANUAL LIST..................................................................................................... 0 IMPORTANT....................................................................................................... 1 WARNING/CAUTION/NOTE........................................................................................ 1 FOREWORD........................................................................................................ 2 TABLE OF CONTENTS............................................................................................... 3 SECTION 0A...................................................................................................... 4 HOW TO USE THIS MANUAL...................................................................................... 5 PRECAUTIONS................................................................................................. 6 PRECAUTION FOR VEHICLES EQUIPPED WITH A SUPPLEMENTAL RESTRAINT (AIR BAG) SYSTEM......................... 6 DIAGNOSIS........................................................................................... 6 SERVICING AND HANDLING.............................................................................. 7 GENERAL PRECAUTIONS..................................................................................... 9 PRECAUTIONS FOR CATALYTIC CONVERTER..................................................................... 12 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT................................................ 12 PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE........................................................... 13 PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE.............................................................. 14 ELECTRICAL CIRCUIT INSPECTION PROCEDURE................................................................. 16 OPEN CIRCUIT CHECK.................................................................................. 16 CONTINUITY CHECK.................................................................................... 17 VOLTAGE CHECK....................................................................................... 18 SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)........................................................ 19 INTERMITTENT AND POOR CONNECTION........................................................................ 19 IDENTIFICATION INFORMATION.................................................................................. 21 VEHICLE IDENTIFICATION NUMBER........................................................................... 21 ENGINE IDENTIFICATION NUMBER............................................................................ 21 TRANSMISSION IDENTIFICATION NUMBER...................................................................... 21 WARNING, CAUTION AND INFORMATION LABELS..................................................................... 22 VEHICLE LIFTING POINTS...................................................................................... 23 ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL........................................................ 25 FASTENER INFORMATION........................................................................................ 28 METRIC FASTENERS........................................................................................ 28 FASTENER STRENGTH IDENTIFICATION........................................................................ 28 STANDARD TIGHTENING TORQUE.............................................................................. 28 SECTION 0B...................................................................................................... 30 MAINTENANCE SCHEDULE........................................................................................ 31 MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS.................................................... 31 MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS................................................. 33 MAINTENANCE SERVICE......................................................................................... 34 ENGINE.................................................................................................. 34 DRIVE BELT.......................................................................................... 34 VALVE LASH (CLEARANCE).............................................................................. 35 ENGINE OIL AND OIL FILTER........................................................................... 35 ENGINE COOLANT...................................................................................... 37 EXHAUST SYSTEM...................................................................................... 39 IGNITION SYSTEM......................................................................................... 39 SPARK PLUGS......................................................................................... 39 FUEL SYSTEM............................................................................................. 39 AIR CLEANER FILTER.................................................................................. 39 FUEL LINES AND CONNECTIONS.......................................................................... 40 FUEL FILTER......................................................................................... 40 FUEL TANK........................................................................................... 41 EMISSION CONTROL SYSTEM................................................................................. 41 PCV VALVE........................................................................................... 41 FUEL EVAPORATIVE EMISSION CONTROL SYSTEM............................................................ 41 BRAKE................................................................................................... 41 BRAKE DISCS AND PADS (FRONT)........................................................................ 41 BRAKE DRUMS AND SHOES (REAR)........................................................................ 42 BRAKE HOSES AND PIPES............................................................................... 42 BRAKE FLUID......................................................................................... 42 BRAKE LEVER AND CABLE............................................................................... 42 CHASSIS AND BODY........................................................................................ 43 CLUTCH.............................................................................................. 43 TIRES / WHEELS...................................................................................... 43 SUSPENSION SYSTEM................................................................................... 44 STEERING SYSTEM..................................................................................... 44 DRIVE SHAFT (AXLE) BOOTS / PROPELLER SHAFTS (4WD)................................................... 45 MANUAL TRANSMISSION OIL............................................................................. 46 AUTOMATIC TRANSMISSION FLUID........................................................................ 46 TRANSFER OIL (4WD) AND REAR DIFFERENTIAL OIL (4WD).................................................. 47 ALL LATCHES, HINGES AND LOCKS....................................................................... 48 FINAL INSPECTION............................................................................................ 48 RECOMMENDED FLUIDS AND LUBRICANTS........................................................................... 50 SECTION 1A...................................................................................................... 52 GENERAL DESCRIPTION......................................................................................... 53 DIAGNOSIS................................................................................................... 54 DIAGNOSIS TABLE......................................................................................... 54 WIRING CIRCUIT.......................................................................................... 55 ON-VEHICLE SERVICE.......................................................................................... 56 HEATER UNIT............................................................................................. 56 BLOWER FAN MOTOR........................................................................................ 58 BLOWER FAN MOTOR RESISTOR............................................................................... 59 HEATER CONTROL ASSEMBLY................................................................................. 60 AIR INLET BOX........................................................................................... 63 VENTILATION LOUVER...................................................................................... 64 REQUIRED SERVICE MATERIALS.................................................................................. 65 SECTION 1B...................................................................................................... 66 GENERAL DESCRIPTION......................................................................................... 68 REFRIGERANT CIRCULATION................................................................................. 68 REFRIGERANT TYPE........................................................................................ 68 MAJOR COMPONENTS AND LOCATION........................................................................... 69 DIAGNOSIS................................................................................................... 70 GENERAL DIAGNOSIS TABLE................................................................................. 70 ABNORMAL NOISE DIAGNOSIS................................................................................ 72 QUICKLY CHECKING OF REFRIGERANT CHARGE.................................................................. 74 PERFORMANCE DIAGNOSIS................................................................................... 75 PERFORMANCE DIAGNOSIS TABLE......................................................................... 77 DETAIL DIAGNOSIS TABLE (AMBIENT TEMPERATURE AT 30°C (86°F))......................................... 78 COMPRESSOR DRIVE BELT................................................................................... 80 ELECTRICAL DIAGNOSIS........................................................................................ 81 WIRING DIAGRAM.......................................................................................... 81 A/C SYSTEM INSPECTION OF ECM AND ITS CIRCUITS........................................................... 82 REFRIGERANT RECOVERY, EVACUATING AND CHARGING............................................................... 85 OPERATION PROCEDURE FOR REFRIGERANT CHARGING............................................................ 85 RECOVERY................................................................................................ 86 REPLENISHING COMPRESSOR OIL............................................................................. 86 EVACUATING.............................................................................................. 87 EVACUATING PROCEDURE................................................................................ 87 CHECKING SYSTEM FOR PRESSURE LEAKS.................................................................. 88 CHARGING................................................................................................ 89 CHARGING PROCEDURE.................................................................................. 89 REMOVING MANIFOLD GAUGE SET............................................................................. 91 LEAK TEST............................................................................................... 91 LIQUID LEAK DETECTORS............................................................................... 91 ON-VEHICLE SERVICE.......................................................................................... 92 SERVICE PRECAUTION...................................................................................... 92 REFRIGERANT LINE.................................................................................... 92 HANDLING REFRIGERANT HFC-134a (R-134a).............................................................. 93 REFRIGERANT RECOVERY................................................................................ 93 REFRIGERANT CHARGE.................................................................................. 93 CONDENSER ASSEMBLY...................................................................................... 93 RECEIVER/DRYER.......................................................................................... 95 RADIATOR/CONDENSER COOLING FAN MOTOR.................................................................... 96 COOLING UNIT (EVAPORATOR)............................................................................... 97 A/C EVAPORATOR TEMPERATURE SENSOR....................................................................... 99 EXPANSION VALVE......................................................................................... 99 A/C REFRIGERANT PRESSURE SWITCH.........................................................................100 A/C SWITCH..............................................................................................101 RADIATOR/CONDENSER COOLING FAN MOTOR RELAY No.1, No.2 and No.3..........................................101 COMPRESSOR..............................................................................................101 MAGNET CLUTCH...........................................................................................103 LIP TYPE SEAL...........................................................................................106 REQUIRED SERVICE MATERIAL...................................................................................108 SPECIAL TOOL................................................................................................109 SECTION 3.......................................................................................................110 DIAGNOSIS...................................................................................................111 GENERAL DIAGNOSIS.......................................................................................111 DIAGNOSIS TABLE.........................................................................................111 TIRE DIAGNOSIS..........................................................................................114 IRREGULAR AND/OR PREMATURE WEAR.....................................................................114 WEAR INDICATORS.....................................................................................114 RADIAL TIRE WADDLE..................................................................................115 RADIAL TIRE LEAD....................................................................................116 VIBRATION DIAGNOSIS.....................................................................................116 SECTION 3A......................................................................................................118 GENERAL DESCRIPTION.........................................................................................119 TOE SETTING.............................................................................................119 CAMBER..................................................................................................119 ALIGNMENT SERVICE DATA (REFERENCE)......................................................................119 DIAGNOSIS...................................................................................................120 DIAGNOSIS TABLE.........................................................................................120 PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT...................................................120 TOE ADJUSTMENT..........................................................................................120 CAMBER AND CASTER CHECK AND ADJUSTMENT..................................................................121 STEERING ANGLE CHECK AND ADJUSTMENT.....................................................................121 SIDE SLIP (REFERENCE)...................................................................................121 SECTION 3B......................................................................................................122 GENERAL DESCRIPTION.........................................................................................123 DIAGNOSIS...................................................................................................124 ON-VEHICLE SERVICE..........................................................................................125 LUBRICATION.............................................................................................125 TIE ROD END.............................................................................................127 MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE)....................................................128 RACK BOOT/TIE ROD.......................................................................................131 STEERING RACK PLUNGER...................................................................................133 STEERING PINION.........................................................................................135 STEERING RACK...........................................................................................136 PINION BEARING..........................................................................................138 RACK BUSHING............................................................................................139 REQUIRED SERVICE MATERIAL...................................................................................140 SPECIAL TOOL................................................................................................141 SECTION 3B1.....................................................................................................142 GENERAL DESCRIPTION.........................................................................................143 SYSTEM COMPONENTS.......................................................................................143 WIRING DIAGRAM..........................................................................................144 DIAGNOSIS...................................................................................................145 ON-BOARD DIAGNOSTIC SYSTEM..............................................................................145 PRECAUTIONS IN DIAGNOSING TROUBLES......................................................................145 SYSTEM CHECK FLOW TABLE.................................................................................146 MALFUNCTION INDICATOR LAMP (“EPS” WARNING LAMP) CHECK...................................................148 DTC CHECK...............................................................................................149 DTC CLEARANCE...........................................................................................150 SERIAL DATA LINK CIRCUIT CHECK..........................................................................151 DTC TABLE...............................................................................................152 TABLE A - MALFUNCTION INDICATOR LAMP DOES NOT COME ON AT IGNITION SWITCH ON BUT LEAVING ENGINE OFF......154 TABLE B - MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON......................................156 TABLE C - MALFUNCTION INDICATOR LAMP DOES NOT FLASH, JUST REMAINS ON OR JUST REMAINS OFF EVEN WIT.......156 DTC C1111 (DTC No.11) TORQUE SENSOR MAIN CIRCUIT FAILURE................................................157 DTC C1113 (DTC No.13) TORQUE SENSOR MAIN AND SUB CIRCUIT FAILURE........................................157 DTC C1115 (DTC No.15) TORQUE SENSOR SUB CIRCUIT FAILURE.................................................157 DTC C1114 (DTC No.14) TORQUE SENSOR 5V POWER SUPPLY CIRCUIT FAILURE.....................................158 DTC C1116 (DTC No.16) TORQUE SENSOR 8V POWER SUPPLY CIRCUIT FAILURE.....................................159 DTC C1121/C1123/C1124 (DTC No.21/23/24) VSS CIRCUIT FAILURE.............................................160 DTC C1122 (DTC No.22) ENGINE SPEED SIGNAL CIRCUIT FAILURE...............................................161 DTC C1141/C1142/C1143/C1144/C1145 (DTC No.41/42/43/44/45) MOTOR CIRCUIT FAILURE.........................162 DTC C1151 (DTC No.51) CLUTCH CIRCUIT FAILURE............................................................163 DTC C1153(DTC No.53) P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAILURE....................................165 DTC C1152/C1154/C1155 (DTC No.52/54/55) P/S CONTROL MODULE FAILURE......................................165 TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON BOARD DIAGNOSTIC SYSTEM).............................166 INSPECTION OF P/S CONTROL MODULE AND ITS CIRCUITS.......................................................167 STEERING WHEEL PLAY INSPECTION..........................................................................169 STEERING FORCE INSPECTION...............................................................................169 ON-VEHICLE SERVICE..........................................................................................170 P/S CONTROL MODULE......................................................................................170 TORQUE SENSOR...........................................................................................170 MOTOR AND CLUTCH........................................................................................171 STEERING COLUMN ASSEMBLY................................................................................172 SPECIAL TOOL................................................................................................172 SECTION 3C......................................................................................................174 GENERAL DESCRIPTION.........................................................................................175 STEERING COLUMN.........................................................................................175 STEERING WHEEL AND DRIVER AIR BAG (INFLATOR) MODULE.....................................................175 DIAGNOSIS...................................................................................................175 INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT...........................................................175 ON-VEHICLE SERVICE..........................................................................................176 SERVICE PRECAUTIONS.....................................................................................176 SERVICE AND DIAGNOSIS...............................................................................176 DISABLING AIR BAG SYSTEM............................................................................176 ENABLING AIR BAG SYSTEM.............................................................................176 HANDLING AND STORAGE................................................................................177 DISPOSAL............................................................................................177 DRIVER AIR BAG (INFLATOR) MODULE........................................................................177 STEERING WHEEL..........................................................................................179 CENTERING CONTACT COIL..................................................................................180 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY............................................................181 STEERING COLUMN ASSEMBLY................................................................................183 STEERING LOCK ASSEMBLY (IGNITION SWITCH)................................................................189 STEERING LOWER SHAFT....................................................................................190 CHECKING STEERING COLUMN ASSEMBLY AND LOWER SHAFT FOR ACCIDENT DAMAGE.......................................191 SPECIAL TOOL................................................................................................192 SECTION 3D......................................................................................................194 GENERAL DESCRIPTION.........................................................................................194 DIAGNOSIS...................................................................................................196 STABILIZER BAR AND/OR BUSHING CHECK.....................................................................196 STRUT ASSEMBLY CHECK....................................................................................196 SUSPENSION CONTROL ARM / STEERING KNUCKLE CHECK.........................................................197 SUSPENSION CONTROL ARM BUSHING CHECK....................................................................197 SUSPENSION CONTROL ARM JOINT CHECK......................................................................197 FRONT SUSPENSION FASTENERS CHECK........................................................................198 WHEEL DISC, NUT AND BEARING CHECK.......................................................................198 ON-VEHICLE SERVICE..........................................................................................199 STRUT ASSEMBLY..........................................................................................199 STABILIZER BAR AND/OR BUSHINGS..........................................................................202 WHEEL HUB AND STEERING KNUCKLE..........................................................................204 SUSPENSION CONTROL ARM / BUSHING........................................................................209 REQUIRED SERVICE MATERIAL...................................................................................212 SPECIAL TOOL................................................................................................212 SECTION 3E......................................................................................................214 GENERAL DESCRIPTION.........................................................................................215 DIAGNOSIS...................................................................................................217 REAR SHOCK ABSORBER CHECK...............................................................................217 TRAILING ARM, LATERAL ROD, REAR AXLE, PEAR AXLE HOUSING AND COIL SPRING CHECK...........................217 BUMP STOPPER/SPRING UPPER SEAT CHECK....................................................................218 REAR SUSPENSION FASTENERS...............................................................................218 WHEEL DISC, NUT AND BEARING CHECK.......................................................................218 ON-VEHICLE SERVICE..........................................................................................219 LATERAL ROD.............................................................................................219 REAR SHOCK ABSORBER.....................................................................................220 COIL SPRING.............................................................................................220 BUMP STOPPER............................................................................................223 SPRING UPPER SEAT.......................................................................................224 TRAILING ARM............................................................................................224 REAR AXLE (2WD VEHICLE).................................................................................227 WHEEL BEARING AND WHEEL STUD (2WD VEHICLE)..............................................................232 REAR AXLE SHAFT AND WHEEL BEARING (4WD VEHICLE).........................................................234 REAR AXLE SHAFT OIL SEAL (4WD VEHICLE)..................................................................238 REAR AXLE HOUSING (4WD VEHICLE).........................................................................239 REQUIRED SERVICE MATERIAL...................................................................................245 SPECIAL TOOL................................................................................................245 SECTION 3F......................................................................................................246 GENERAL DESCRIPTION.........................................................................................247 TIRES...................................................................................................247 WHEELS..................................................................................................247 REPLACEMENT TIRES.......................................................................................247 REPLACEMENT WHEELS......................................................................................247 HOW TO MEASURE WHEEL RUNOUT.........................................................................248 METRIC LUG NUTS AND WHEEL STUDS.....................................................................248 DIAGNOSIS...................................................................................................248 DIAGNOSIS TABLE.........................................................................................248 BALANCING WHEELS........................................................................................248 GENERAL BALANCE PROCEDURES..............................................................................249 OFF-VEHICLE BALANCING...............................................................................249 ON-VEHICLE BALANCING................................................................................249 MAINTENANCE AND MINOR ADJUSTMENTS...........................................................................250 WHEEL MAINTENANCE.......................................................................................250 WHEEL ATTACHING STUDS...............................................................................250 MATCHED TIRES AND WHEELS............................................................................250 TIRE MAINTENANCE........................................................................................250 TIRE PLACARD........................................................................................250 INFLATION OF TIRES..................................................................................251 TIRE ROTATION.......................................................................................251 ON-VEHICLE SERVICE..........................................................................................252 WHEEL...................................................................................................252 TIRE....................................................................................................253 MOUNTING AND DISMOUNTING............................................................................253 REPAIR..............................................................................................253 SECTION 4A......................................................................................................254 GENERAL DESCRIPTION.........................................................................................255 COMPONENT...............................................................................................255 DIAGNOSIS...................................................................................................255 DIAGNOSIS TABLE.........................................................................................255 DRIVE SHAFT BOOT CHECK..................................................................................255 ON-VEHICLE SERVICE..........................................................................................256 DRIVE SHAFT ASSEMBLY....................................................................................257 TIGHTENING TORQUE SPECIFICATION.............................................................................269 REQUIRED SERVICE MATERIAL...................................................................................269 SPECIAL TOOL................................................................................................269 SECTION 4B......................................................................................................270 GENERAL DESCRIPTION.........................................................................................270 DIAGNOSIS...................................................................................................270 DIAGNOSIS TABLE.........................................................................................270 PROPELLER SHAFT JOINT CHECK.............................................................................271 ON-VEHICLE SERVICE..........................................................................................271 TIGHTENING TORQUE SPECIFICATION.............................................................................273 SECTION 5.......................................................................................................274 GENERAL DESCRIPTION.........................................................................................275 DIAGNOSIS...................................................................................................277 ROAD TESTING BRAKES.....................................................................................277 BRAKE FLUID LEAKS.......................................................................................277 SUBSTANDARD OR CONTAMINATED BRAKE FLUID.................................................................277 DIAGNOSIS TABLE.........................................................................................278 BRAKE PEDAL FREE HEIGHT ADJUSTMENT......................................................................281 BRAKE PEDAL PLAY INSPECTION.............................................................................281 STOP LIGHT SWITCH ADJUSTMENT............................................................................281 EXCESSIVE PEDAL TRAVEL INSPECTION.......................................................................282 FRONT BRAKE PAD INSPECTION..............................................................................282 BRAKE DISC INSPECTION...................................................................................282 PARKING BRAKE INSPECTION AND ADJUSTMENT.................................................................283 BOOSTER OPERATION INSPECTION............................................................................284 FLUID PRESSURE TEST (IF EQUIPPED WITH LSPV).............................................................285 MASTER CYLINDER AND BRAKE FLUID LEVEL INSPECTION........................................................287 BRAKE HOSE AND PIPE INSPECTION..........................................................................288 HOSE................................................................................................288 PIPE................................................................................................288 ON-VEHICLE SERVICE..........................................................................................288 AIR BLEEDING OF BRAKE SYSTEM............................................................................288 FRONT BRAKE.............................................................................................290 BRAKE PAD...........................................................................................290 CALIPER ASSEMBLY....................................................................................292 BRAKE DISC..........................................................................................296 REAR BRAKE..............................................................................................298 BRAKE DRUM..........................................................................................299 BRAKE SHOE..........................................................................................302 WHEEL CYLINDER......................................................................................303 BRAKE BACK PLATE (FOR 2WD VEHICLE)..................................................................304 BRAKE BACK PLATE (FOR 4WD VEHICLE)..................................................................306 MASTER CYLINDER.........................................................................................306 MASTER CYLINDER RESERVOIR...........................................................................306 MASTER CYLINDER ASSEMBLY............................................................................307 BRAKE BOOSTER...........................................................................................311 BRAKE HOSE/PIPE.........................................................................................314 FRONT BRAKE HOSE/PIPE...............................................................................314 REAR BRAKE HOSE/PIPE................................................................................317 PARKING BRAKE CABLE.....................................................................................319 LSPV (LOAD SENSING PROPORTIONING VALVE) ASSEMBLY (IF EQUIPPED)..........................................321 REQUIRED SERVICE MATERIAL...................................................................................323 SPECIAL TOOL................................................................................................323 SECTION 5E......................................................................................................326 GENERAL DESCRIPTION.........................................................................................327 COMPONENTS/PARTS LOCATION AND BRAKE HOSE/PIPE ROUTING...................................................327 SYSTEM SCHEMATIC........................................................................................329 ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY..............................................................330 SELF-DIAGNOSIS FUNCTION.............................................................................330 FAIL-SAFE FUNCTION..................................................................................330 SYSTEM CIRCUIT..........................................................................................331 DIAGNOSIS...................................................................................................333 PRECAUTION IN DIAGNOSING TROUBLES.......................................................................333 ABS DIAGNOSTIC FLOW TABLE...............................................................................334 ABS WARNING LAMP CHECK..................................................................................337 EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK.............................................................337 TABLE – A ABS WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON................338 TABLE – B ABS WARNING LAMP CIRCUIT CHECK – LAMP COMES “ON” STEADY.......................................339 TABLE – C ABS WARNING LAMP CIRCUIT CHECK – THE LAMP FLASHES CONTINUOUSLY WHILE IGNITION SWITCH IS ON....340 TABLE – D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAGNOSIS SWITCH TERMINAL CONNECTED TO GROUND...........341 TABLE – E EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK – LAMP COMES “ON” STEADY..........................342 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (USING ABS WARNING LAMP)............................................343 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (USING SUZUKI SCAN TOOL)............................................344 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE.................................................................344 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.....................................................................345 DTC C1013 (DTC 13) – SYSTEM SPECIFICATIONS DIFFERENT FROM ABS CONTROL MODULE SPECIFICATIONS.............347 DTC C1015 (DTC 15) – G SENSOR CIRCUIT...................................................................347 DTC C1021 (DTC 21), DTC C1022 (DTC 22) – RIGHT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING..........349 DTC C1025 (DTC 25), DTC C1026 (DTC 26) – LEFT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING...........349 DTC C1031 (DTC 31), DTC C1032 (DTC 32) – RIGHT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING...........349 DTC C1035 (DTC 35), DTC C1036 (DTC 36) – LEFT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING............349 DTC C1041 (DTC 41) – RIGHT-FRONT INLET SOLENOID CIRCUIT.................................................351 DTC C1045 (DTC 45) – LEFT-FRONT INLET SOLENOID CIRCUIT..................................................351 DTC C1051 (DTC 51) – RIGHT-REAR INLET SOLENOID CIRCUIT..................................................351 DTC C1055 (DTC 55) – LEFT-REAR INLET SOLENOID CIRCUIT...................................................351 DTC C1042 (DTC 42) – RIGHT-FRONT OUTLET SOLENOID CIRCUIT................................................351 DTC C1046 (DTC 46) – LEFT-FRONT OUTLET SOLENOID CIRCUIT.................................................351 DTC C1052 (DTC 52) – RIGHT-REAR OUTLET SOLENOID CIRCUIT.................................................351 DTC C1056 (DTC 56) – LEFT-REAR OUTLET SOLENOID CIRCUIT..................................................351 DTC C1057 (DTC 57) – POWER SOURCE CIRCUIT...............................................................352 DTC C1061 (DTC 61) – ABS PUMP MOTOR CIRCUIT.............................................................353 DTC C1063 (DTC 63) – ABS FAIL-SAFE RELAY CIRCUIT........................................................354 DTC C1071 (DTC 71) – ABS CONTROL MODULE.................................................................355 ON-VEHICLE SERVICE..........................................................................................356 PRECAUTIONS.............................................................................................356 ABS HYDRAULIC UNIT OPERATION CHECK (USING SUZUKI SCAN TOOL).............................................356 ABS HYDRAULIC UNIT OPERATION CHECK (NOT USING SUZUKI SCAN TOOL).........................................356 ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY..............................................................358 FRONT WHEEL SPEED SENSOR................................................................................360 FRONT WHEEL SPEED SENSOR RING...........................................................................362 REAR WHEEL SPEED SENSOR.................................................................................363 REAR WHEEL SPEED SENSOR RING (FOR 2WD VEHICLE)..........................................................366 REAR WHEEL SPEED SENSOR RING (FOR 4WD VEHICLE)..........................................................367 G SENSOR (FOR 4WD VEHICLE ONLY).........................................................................368 SPECIAL TOOL................................................................................................369 SECTION 6.......................................................................................................370 GENERAL INFORMATION.........................................................................................373 STATEMENT ON CLEANLINESS AND CARE.......................................................................373 GENERAL INFORMATION ON ENGINE SERVICE...................................................................373 PRECAUTION ON FUEL SYSTEM SERVICE...................................................................374 FUEL PRESSURE RELIEF PROCEDURE......................................................................375 FUEL LEAKAGE CHECK PROCEDURE........................................................................375 ENGINE DIAGNOSIS............................................................................................375 GENERAL DESCRIPTION.....................................................................................375 ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITH IMMOBILIZER INDICATOR LAMP)....................................376 ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP).................................379 PRECAUTION IN DIAGNOSING TROUBLE........................................................................380 ENGINE DIAGNOSTIC FLOW TABLE............................................................................381 CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)..........................................................383 MALFUNCTION INDICATOR LAMP (MIL) CHECK..............................................................384 DIAGNOSTIC TROUBLE CODE (DTC) CHECK.................................................................384 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE.............................................................385 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.................................................................386 FAIL-SAFE TABLE.....................................................................................389 VISUAL INSPECTION...................................................................................391 ENGINE BASIC INSPECTION.............................................................................392 ENGINE DIAGNOSIS TABLE..............................................................................395 SCAN TOOL DATA..........................................................................................400 INSPECTION OF ECM AND ITS CIRCUITS......................................................................405 ECM VOLTAGE VALUES TABLE............................................................................406 TERMINAL RESISTANCE TABLE...........................................................................412 COMPONENT LOCATION......................................................................................414 TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK - LAMP DOES NOT COME “ON” AT IGNITION SWITCH O.......415 TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK - LAMP REMAINS “ON” AFTER ENGINE STARTS..............416 TABLE A-3 MIL CHECK - MIL FLASHES AT IGNITION SWITCH ON (VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)....417 TABLE A-4 MIL CHECK - MIL DOES NOT FLASH OR JUST REMAINS ON EVEN WITH GROUNDING DIAGNOSIS SWITCH .......417 TABLE A-5 ECM POWER AND GROUND CIRCUIT CHECK - MIL DOESN’T LIGHT AT IGNITION SWITCH ON AND ENGINE.......418 DTC P0105 (DTC NO.11) MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT MALFUNCTION..............................421 DTC P0110 (DTC NO.18) INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION........................................424 DTC P0115 (DTC NO.19) ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT MALFUNCTION..............................426 DTC P0120 (DTC NO.13) THROTTLE POSITION CIRCUIT MALFUNCTION.............................................429 DTC P0121 THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROBLEM...........................................432 DTC P0130 (DTC NO.14) HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-1)........................435 DTC P0133 HEATED OXYGEN SENSOR (HO2S) CIRCUIT SLOW RESPONSE (SENSOR-1)..................................437 DTC P0134 HEATED OXYGEN SENSOR (HO2S) CIRCUIT NO ACTIVITY DETECTED (SENSOR-1)...........................438 DTC P0135 (DTC NO.14) HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-1).................439 DTC P0136 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2)....................................441 DTC P0141 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-2).............................443 DTC P0171 FUEL SYSTEM TOO LEAN..........................................................................445 DTC P0172 FUEL SYSTEM TOO RICH..........................................................................445 DTC P0300 RANDOM MISFIRE DETECTED (MISFIRE DETECTED AT 2 OR MORE CYLINDERS).............................450 DTC P0301 CYLINDER 1 MISFIRE DETECTED...................................................................450 DTC P0302 CYLINDER 2 MISFIRE DETECTED...................................................................450 DTC P0303 CYLINDER 3 MISFIRE DETECTED...................................................................450 DTC P0304 CYLINDER 4 MISFIRE DETECTED...................................................................450 DTC P0325 (DTC NO.17) KNOCK SENSOR CIRCUIT MALFUNCTION..................................................455 DTC P0335 (DTC NO.23) CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT MALFUNCTION..............................457 DTC P0340 (DTC NO.15) CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION................................460 DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION....................................................463 DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD....................................................466 DTC P0443 PURGE CONTROL VALVE CIRCUIT MALFUNCTION.......................................................469 DTC P0480 RADIATOR COOLING FAN CONTROL SYSTEM MALFUNCTION...............................................470 DTC P0500 (DTC NO.16) VEHICLE SPEED SENSOR (VSS) MALFUNCTION............................................472 DTC P0505 (DTC NO.26) IDLE CONTROL SYSTEM MALFUNCTION...................................................474 DTC P1450 BAROMETRIC PRESSURE SENSOR LOW/HIGH INPUT.....................................................477 DTC P1451 BAROMETRIC PRESSURE SENSOR PERFORMANCE PROBLEM................................................477 DTC P1500 ENGINE STARTER SIGNAL CIRCUIT MALFUNCTION.....................................................479 DTC P1510 ECM BACK-UP POWER SUPPLY MALFUNCTION..........................................................480 DTC P1600 SERIAL COMMUNICATION PROBLEM BETWEEN ECM AND TCM..............................................481 DTC P1717 A/T DRIVE RANGE (PARK/NEUTRAL POSITION) SIGNAL CIRCUIT MALFUNCTION............................483 TABLE B-1 FUEL INJECTOR CIRCUIT CHECK...................................................................486 TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK...............................................................487 TABLE B-3 FUEL PRESSURE CHECK...........................................................................489 TABLE B-4 IDLE AIR CONTROL SYSTEM CHECK.................................................................491 TABLE B-5 A/C SIGNAL CIRCUITS CHECK (VEHICLE WITH A/C)..................................................493 TABLE B-6 ELECTRIC LOAD SIGNAL CIRCUIT CHECK............................................................495 TABLE B-7 RADIATOR FAN CONTROL SYSTEM CHECK.............................................................497 SPECIAL TOOL................................................................................................499 SECTION 6A1.....................................................................................................502 GENERAL DESCRIPTION.........................................................................................503 ENGINE..................................................................................................503 ENGINE LUBRICATION......................................................................................504 DIAGNOSIS...................................................................................................505 DIAGNOSIS TABLE.........................................................................................505 COMPRESSION CHECK.......................................................................................505 ENGINE VACUUM CHECK.....................................................................................507 OIL PRESSURE CHECK......................................................................................508 VALVE LASH (CLEARANCE)..................................................................................510 ON-VEHICLE SERVICE..........................................................................................513 AIR CLEANER ELEMENT.....................................................................................513 AIR CLEANER ASSEMBLY AND RESONATOR......................................................................514 KNOCK SENSOR............................................................................................514 CYLINDER HEAD COVER.....................................................................................514 THROTTLE BODY AND INTAKE MANIFOLD.......................................................................517 EXHAUST MANIFOLD........................................................................................520 OIL PAN AND OIL PUMP STRAINER...........................................................................522 TIMING CHAIN COVER......................................................................................526 OIL PUMP................................................................................................531 TIMING CHAIN AND CHAIN TENSIONER........................................................................535 CAMSHAFT, TAPPET AND SHIM...............................................................................540 VALVES AND CYLINDER HEAD................................................................................545 PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS....................................................558 ENGINE MOUNTINGS........................................................................................568 UNIT REPAIR OVERHAUL........................................................................................569 ENGINE ASSEMBLY.........................................................................................569 MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK............................................................574 REQUIRED SERVICE MATERIAL...................................................................................586 TIGHTENING TORQUE SPECIFICATION.............................................................................587 SPECIAL TOOL................................................................................................588 SECTION 6B......................................................................................................590 GENERAL DESCRIPTION.........................................................................................591 COOLING SYSTEM CIRCULATION..............................................................................591 COOLANT.................................................................................................592 DIAGNOSIS...................................................................................................593 DIAGNOSIS TABLE.........................................................................................593 SYSTEM CIRCUIT..........................................................................................594 SYSTEM CIRCUIT INSPECTION...............................................................................594 MAINTENANCE.................................................................................................595 COOLANT LEVEL CHECK.....................................................................................595 ENGINE COOLING SYSTEM INSPECTION AND SERVICE............................................................596 COOLING SYSTEM FLUSH AND REFILL.........................................................................596 WATER PUMP/GENERATOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT.......................................598 ON-VEHICLE SERVICE..........................................................................................599 SYSTEM COMPONENTS.......................................................................................599 COOLING SYSTEM DRAINING.................................................................................600 COOLING SYSTEM REFILL...................................................................................600 COOLING WATER PIPES OR HOSES............................................................................601 THERMOSTAT..............................................................................................601 RADIATOR................................................................................................603 RADIATOR AND CONDENSER COOLING FAN......................................................................604 RADIATOR AND CONDENSER COOLING FAN RELAY................................................................604 WATER PUMP/GENERATOR DRIVE BELT.........................................................................604 WATER PUMP..............................................................................................605 ECT SENSOR..............................................................................................607 REQUIRED SERVICE MATERIAL...................................................................................607 TIGHTENING TORQUE SPECIFICATION.............................................................................607 SECTION 6C......................................................................................................608 GENERAL DESCRIPTION.........................................................................................608 ON-VEHICLE SERVICE..........................................................................................609 COMPONENTS..............................................................................................609 PRECAUTIONS.............................................................................................610 FUEL LINES..............................................................................................611 FUEL PIPE...............................................................................................611 FUEL FILLER CAP.........................................................................................612 FUEL TANK INLET VALVE...................................................................................613 FUEL TANK...............................................................................................614 FUEL PUMP ASSEMBLY......................................................................................617 DISASSEMBLY AND REASSEMBLY..........................................................................619 SPECIAL TOOL................................................................................................621 TIGHTENING TORQUE SPECIFICATION.............................................................................621 SECTION 6E1.....................................................................................................622 GENERAL DESCRIPTION.........................................................................................623 AIR INTAKE SYSTEM.......................................................................................626 FUEL DELIVERY SYSTEM....................................................................................627 FUEL PUMP...........................................................................................627 ELECTRONIC CONTROL SYSTEM...............................................................................628 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE........................................................629 ECM INPUT/OUTPUT CIRCUIT DIAGRAM....................................................................630 ECM TERMINAL ARRANGEMENT TABLE......................................................................634 ON-VEHICLE SERVICE..........................................................................................636 ACCELERATOR CABLE ADJUSTMENT............................................................................636 IDLE SPEED/IDLE AIR CONTROL (IAC) DUTY INSPECTION.......................................................636 IDLE MIXTURE INSPECTION / ADJUSTMENT (VEHICLE WITHOUT HEATED OXYGEN SENSOR).............................638 AIR INTAKE SYSTEM.......................................................................................639 THROTTLE BODY.......................................................................................639 IDLE AIR CONTROL VALVE (IAC VALVE)..................................................................641 FUEL DELIVERY SYSTEM....................................................................................642 FUEL PRESSURE INSPECTION............................................................................642 FUEL PUMP WITH PRESSURE REGULATOR...................................................................643 FUEL INJECTOR.......................................................................................644 ELECTRONIC CONTROL SYSTEM...............................................................................648 ENGINE CONTROL MODULE (ECM).........................................................................648 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP SENSOR)......................................................648 THROTTLE POSITION SENSOR (TP SENSOR)................................................................649 INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR)..........................................................650 ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR)......................................................651 HEATED OXYGEN SENSOR (HO2S-1 AND HO2S-2)............................................................652 CAMSHAFT POSITION SENSOR............................................................................653 CRANKSHAFT POSITION SENSOR..........................................................................653 VEHICLE SPEED SENSOR (VSS)..........................................................................654 FUEL LEVEL SENSOR (GAUGE)...........................................................................654 KNOCK SENSOR (IF EQUIPPED)..........................................................................654 MAIN RELAY, FUEL PUMP RELAY AND RADIATOR FAN RELAY NO.1.............................................654 FUEL CUT OPERATION..................................................................................655 RADIATOR FAN CONTROL SYSTEM.........................................................................655 RADIATOR FAN RELAY NO. 2 AND NO.3...................................................................655 OUTPUT SIGNALS OF THROTTLE VALVE OPENING AND ENGINE COOLANT TEMP. (VEHICLE WITH A/T ONLY)...........657 EMISSION CONTROL SYSTEM.................................................................................657 EGR SYSTEM..........................................................................................657 EVAPORATIVE EMISSION CONTROL SYSTEM.................................................................658 PCV SYSTEM..........................................................................................660 SPECIAL TOOL................................................................................................661 TIGHTENING TORQUE SPECIFICATION.............................................................................662 SECTION 6F1.....................................................................................................663 GENERAL DESCRIPTION.........................................................................................664 SYSTEM COMPONENTS.......................................................................................664 SYSTEM WIRING DIAGRAM...................................................................................665 DIAGNOSIS...................................................................................................665 ON-VEHICLE SERVICE..........................................................................................667 IGNITION SPARK TEST.....................................................................................667 HIGH-TENSION CORDS......................................................................................667 SPARK PLUGS.............................................................................................668 IGNITION COIL ASSEMBLY (INCLUDING IGNITOR)..............................................................669 CRANKSHAFT POSITION SENSOR (CKP SENSOR).................................................................669 IGNITION TIMING.........................................................................................670 SPECIAL TOOL................................................................................................671 SECTION 6G......................................................................................................673 GENERAL DESCRIPTION.........................................................................................674 CRANKING CIRCUIT........................................................................................674 DIAGNOSIS...................................................................................................674 DIAGNOSIS TABLE.........................................................................................674 PERFORMANCE TEST........................................................................................676 PULL-IN TEST........................................................................................676 HOLD-IN TEST........................................................................................676 PLUNGER AND PINION RETURN TEST......................................................................676 NO-LOAD PERFORMANCE TEST............................................................................677 ON-VEHICLE SERVICE..........................................................................................677 STARTING MOTOR..........................................................................................677 DISMOUNTING.........................................................................................677 REMOUNTING..........................................................................................677 DISASSEMBLY AND REASSEMBLY..........................................................................678 SPECIFICATION...............................................................................................680 1.0 kW TYPE.............................................................................................680 1.2 kW TYPE.............................................................................................680 REQUIRED SERVICE MATERIAL...................................................................................680 SECTION 6H......................................................................................................681 GENERAL DESCRIPTION.........................................................................................682 BATTERY.................................................................................................682 CARRIER AND HOLD-DOWN...............................................................................682 ELECTROLYTE FREEZING................................................................................682 SULFATION...........................................................................................682 BUILT-IN INDICATOR (IF EQUIPPED)....................................................................682 CARE OF BATTERY.....................................................................................683 GENERATOR...............................................................................................684 DIAGNOSIS...................................................................................................685 BATTERY.................................................................................................685 VISUAL INSPECTION...................................................................................685 HYDROMETER TEST.....................................................................................685 GENERATOR...............................................................................................686 CHARGING INDICATOR LAMP OPERATION...................................................................686 UNDERCHARGED BATTERY................................................................................687 OVERCHARGED BATTERY.................................................................................688 ON-VEHICLE SERVICE..........................................................................................689 BATTERY.................................................................................................689 JUMP STARTING IN CASE OF EMERGENCY..................................................................689 DISMOUNTING.........................................................................................690 HANDLING............................................................................................690 REMOUNTING..........................................................................................690 GENERATOR...............................................................................................690 GENERATOR BELT......................................................................................690 DISMOUNTING AND REMOUNTING..........................................................................691 DISASSEMBLY AND REASSEMBLY..........................................................................691 INSPECTION..........................................................................................692 SPECIFICATION...............................................................................................694 BATTERY.................................................................................................694 GENERATOR...............................................................................................694 TIGHTENING TORQUE SPECIFICATION.............................................................................694 SECTION 6K......................................................................................................695 GENERAL DESCRIPTION.........................................................................................696 MAINTENANCE.................................................................................................696 ON-VEHICLE SERVICE..........................................................................................697 EXHAUST MANIFOLD........................................................................................698 EXHAUST PIPE............................................................................................698 SECTION 7A...................................................................................................... 0 SECTION 7B...................................................................................................... 42 SECTION 7C......................................................................................................182 SECTION 7D......................................................................................................198 SECTION 7F......................................................................................................222 SECTION 8.......................................................................................................244 SECTION 8G......................................................................................................278 SECTION 9.......................................................................................................304 SECTION 10......................................................................................................366 SECTION 10B.....................................................................................................374 COPYRIGHT.......................................................................................................446 BOOKCOVER....................................................................................................... 0
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