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SUZUKI RH413 RH416 LIANA SERVICE MANUAL – PDF DOWNLOAD
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The Suzuki RH413 RH416 Liana Service Manual provides detailed guidance for maintenance and repairs, offering comprehensive instructions to ensure optimal performance and longevity of the vehicles.
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SUZUKI RH413 RH416 LIANA SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI RH413 RH416 LIANA SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 1233
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI RH413 RH416 LIANA SERVICE MANUAL – PDF DOWNLOAD
Bookcove............................................................................................................ 1 99500_54G00_01E_1................................................................................................... 2 Top............................................................................................................. 0 Manual List..................................................................................................... 0 IMPORTANT....................................................................................................... 2 WARNING/CAUTION/NOTE........................................................................................ 2 FOREWORD........................................................................................................ 3 TABLE OF CONTENTS............................................................................................... 5 SECTION 0A...................................................................................................... 7 How To Use This Manual...................................................................................... 8 Precautions................................................................................................. 9 Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System......................... 9 Diagnosis........................................................................................... 9 Servicing and handling.............................................................................. 10 General Precautions..................................................................................... 12 Precautions for Catalytic Converter..................................................................... 15 Precaution for Installing Mobile Communication Equipment................................................ 15 Precaution for Vehicle Tie-Down Hooks................................................................... 16 Precaution in Servicing Full-Time 4WD Vehicle........................................................... 16 Precautions for Electrical Circuit Service.............................................................. 17 Electrical Circuit Inspection Procedure................................................................. 20 Open circuit check.................................................................................. 20 Short circuit check (wire harness to ground)........................................................ 22 Intermittent and Poor Connection........................................................................ 23 Identification Information.................................................................................. 25 Vehicle Identification Number........................................................................... 25 Engine Identification Number............................................................................ 25 Transmission Identification Number...................................................................... 25 Warning, Caution and Information Labels..................................................................... 26 Vehicle Lifting Points...................................................................................... 27 Abbreviations and Symbols May Be Used in This Manual........................................................ 29 Fastener Information........................................................................................ 32 Metric Fasteners........................................................................................ 32 Fastener Strength Identification........................................................................ 32 Standard Tightening Torque.............................................................................. 32 SECTION 0B...................................................................................................... 35 Maintenance Schedule........................................................................................ 36 Maintenance Schedule Under Normal Driving Conditions.................................................... 36 Maintenance Recommended under Severe Driving Conditions................................................. 38 Maintenance Service......................................................................................... 39 Engine.................................................................................................. 39 Drive belt.......................................................................................... 39 Valve lash (clearance).............................................................................. 40 Engine oil and oil filter........................................................................... 40 Engine coolant...................................................................................... 42 Exhaust system...................................................................................... 42 Ignition System......................................................................................... 42 Spark plugs......................................................................................... 42 Fuel System............................................................................................. 43 Air cleaner filter.................................................................................. 43 Fuel lines and connections.......................................................................... 43 Fuel filter......................................................................................... 43 Fuel tank........................................................................................... 44 Emission Control System................................................................................. 44 PCV valve........................................................................................... 44 Fuel evaporative emission control system............................................................ 44 Brake................................................................................................... 44 Brake discs and pads (front)........................................................................ 44 Brake drums and shoes (rear)........................................................................ 45 Brake hoses and pipes............................................................................... 45 Brake fluid......................................................................................... 45 Brake lever and cable............................................................................... 45 Chassis and Body........................................................................................ 46 Clutch.............................................................................................. 46 Tires / Wheels...................................................................................... 46 Suspension system................................................................................... 47 Steering system..................................................................................... 47 Drive shaft (axle) boots / Propeller shafts (4WD)................................................... 48 Manual transaxle oil................................................................................ 49 Automatic transaxle fluid........................................................................... 49 Transfer oil (4WD A/T) and rear differential oil (4WD).............................................. 50 All latches, hinges and locks....................................................................... 51 Power steering (P/S) system (if equipped)........................................................... 51 Final Inspection........................................................................................ 52 Recommended Fluids and Lubricants........................................................................... 54 SECTION 1A...................................................................................................... 55 General Description......................................................................................... 56 Wiring Circuit.......................................................................................... 57 Diagnosis................................................................................................... 58 Diagnosis Table......................................................................................... 58 On-Vehicle Service.......................................................................................... 59 Blower Unit............................................................................................. 59 Blower Motor............................................................................................ 60 Blower Motor Resistor................................................................................... 61 Heater Unit............................................................................................. 62 Heater Controller....................................................................................... 63 Air Inlet Actuator...................................................................................... 65 Blower Motor and Blower Motor High Relays............................................................... 66 Center Ventilation Louver............................................................................... 67 Side Ventilation Louver................................................................................. 67 SECTION 1B...................................................................................................... 69 General Description......................................................................................... 71 Sub-cool System......................................................................................... 71 A/C Evaporator Inlet Air Temperature Sensor and A/C Evaporator Outlet Air Temperature Sensor............ 72 Refrigerant Type........................................................................................ 72 Major Components and Location........................................................................... 73 Diagnosis................................................................................................... 74 General Diagnosis Table................................................................................. 74 Abnormal Noise Diagnosis................................................................................ 76 Quickly Checking of Refrigerant Charge.................................................................. 78 Performance Diagnosis................................................................................... 79 Performance diagnosis table......................................................................... 81 Detail diagnosis table (ambient temperature at 30°C (86°F))......................................... 82 Electrical Diagnosis........................................................................................ 83 A/C System Inspection of ECM and Its Circuits........................................................... 83 Wiring diagram...................................................................................... 83 Voltage check....................................................................................... 84 Refrigerant Recovery, Evacuating and Charging............................................................... 86 Operation Procedure for Refrigerant Charging............................................................ 86 Recovery................................................................................................ 87 Replenishing Compressor Oil............................................................................. 87 Evacuating.............................................................................................. 88 Evacuating procedure................................................................................ 88 Checking system for pressure leaks.................................................................. 89 Charging................................................................................................ 90 Charging procedure.................................................................................. 90 Replacement of refrigerant container in charging procedure.......................................... 91 Leak Test............................................................................................... 92 Liquid leak detectors............................................................................... 92 On-vehicle Service.......................................................................................... 93 Service Precaution ..................................................................................... 93 Handling refrigerant HFC-134a (R-134a).............................................................. 93 Refrigerant Line........................................................................................ 93 Condenser Assembly...................................................................................... 94 Desiccant............................................................................................... 96 Condenser Cooling Fan................................................................................... 96 Heater and Cooling Unit................................................................................. 98 A/C Evaporator.......................................................................................... 100 A/C Evaporator Inlet and Outlet Air Temperature Sensors................................................. 102 Expansion Valve......................................................................................... 102 A/C Refrigerant Pressure Switch......................................................................... 103 A/C Switch and Defroster Switch in Heater Controller.................................................... 104 Compressor Relay and Condenser Cooling Fan Relay........................................................ 104 Compressor.............................................................................................. 105 Compressor Drive Belt................................................................................... 105 Magnet Clutch........................................................................................... 106 Required Service Material................................................................................... 109 Special Tool................................................................................................ 109 SECTION 3....................................................................................................... 111 CONTENTS.................................................................................................... 111 Diagnosis............................................................................................... 113 General Diagnosis................................................................................... 113 Diagnosis Table..................................................................................... 113 Specifications.......................................................................................... 117 On-Vehicle Service...................................................................................... 118 Front Wheel Alignment............................................................................... 118 Preliminary checks prior to adjustment front wheel alignment.................................... 118 Toe inspection and adjustment................................................................... 119 Steering angle check and adjustment............................................................. 120 Reference information........................................................................... 120 Rear Wheel Alignment................................................................................ 121 Toe inspection and adjustment................................................................... 121 Reference information........................................................................... 121 General Description..................................................................................... 123 P/S System Description.............................................................................. 123 Specifications.......................................................................................... 124 Specification and Service Data...................................................................... 124 Diagnosis............................................................................................... 125 Diagnosis Table..................................................................................... 125 Steering Wheel Play Check........................................................................... 126 Steering Force Check................................................................................ 127 Power Steering Fluid Level Check.................................................................... 127 Power Steering Belt Check........................................................................... 127 Power Steering Belt Tension Adjustment.............................................................. 128 Idle Up System Check................................................................................ 128 Fluid Leakage Check................................................................................. 129 Hydraulic Pressure in P/S Circuit Check............................................................. 130 Steering Rack Boot Check............................................................................ 131 Tie Rod End Boot Check.............................................................................. 132 Steering Shaft Joint Check.......................................................................... 132 Air Bleeding Procedure.............................................................................. 132 On-vehicle Service...................................................................................... 133 Power Steering Belt................................................................................. 133 Tie Rod End......................................................................................... 133 Power Steering Gear Box............................................................................. 136 Tie Rod/Rack Boot................................................................................... 139 Power Steering Pump................................................................................. 141 Tightening Torque Specification......................................................................... 148 Required Service Material............................................................................... 149 Special Tool............................................................................................ 149 General Description..................................................................................... 150 Steering Column..................................................................................... 150 Steering Wheel and Driver Air Bag (Inflator) Module................................................. 151 Diagnosis............................................................................................... 151 Inspection and Repair Required after Accident....................................................... 151 On-Vehicle Service...................................................................................... 152 Service Precautions................................................................................. 152 Service and diagnosis........................................................................... 152 Disabling air bag system........................................................................ 152 Enabling air bag system......................................................................... 152 Handling and storage............................................................................ 153 Disposal........................................................................................ 153 Driver Air Bag (Inflator) Module.................................................................... 153 Steering Wheel...................................................................................... 155 Centering Contact Coil.............................................................................. 156 Contact Coil and Combination Switch Assembly........................................................ 157 Steering Column Assembly............................................................................ 159 Steering Lock Assembly (Ignition Switch)............................................................ 164 Steering Lower Shaft................................................................................ 165 Checking Steering Column Assembly and Lower Shaft for Accident Damage................................... 167 Special Tool............................................................................................ 167 General Description..................................................................................... 168 Construction........................................................................................ 168 Diagnosis............................................................................................... 169 Diagnosis Table..................................................................................... 169 Stabilizer Bar and/or Bushing Check................................................................. 169 Strut Assembly Check................................................................................ 169 Suspension Control Arm/Steering Knuckle Check....................................................... 170 Suspension Control Arm Bushing Check................................................................ 170 Suspension Control Arm Joint Check.................................................................. 170 Front Suspension Frame Check........................................................................ 171 Front Suspension Fasteners Check.................................................................... 171 Wheel Disc, Nut and Bearing Check................................................................... 171 On-vehicle Service...................................................................................... 172 Strut Assembly...................................................................................... 172 Stabilizer Bar and/or Bushings...................................................................... 175 Wheel Hub and Steering Knuckle...................................................................... 177 Suspension Control Arm/Bushing...................................................................... 183 Front Suspension Frame.............................................................................. 186 Required Service Material............................................................................... 188 Special Tool............................................................................................ 189 General Description..................................................................................... 191 Construction........................................................................................ 191 Diagnosis............................................................................................... 192 Strut Assembly Check................................................................................ 192 Stabilizer Bar, Bushing and/or Joint Check.......................................................... 192 Suspension Knuckle Check............................................................................ 193 Control Rod Check................................................................................... 193 Trailing Rod Check.................................................................................. 194 Suspension Frame, Bushing and Pad Check............................................................. 194 Rear Suspension Fasteners........................................................................... 194 Wheel Disc, Nut and Bearing Check................................................................... 194 On-vehicle Service...................................................................................... 195 Rear Strut Assembly................................................................................. 195 Stabilizer Bar and/or Bushings...................................................................... 199 Control Rod......................................................................................... 201 Trailing Rod........................................................................................ 203 Suspension Frame.................................................................................... 204 Wheel Hub, Wheel Bearing and Wheel Stud............................................................. 206 Knuckle............................................................................................. 208 Tightening Torque Specifications........................................................................ 211 Required Service Material............................................................................... 211 Special Tool............................................................................................ 212 General Description..................................................................................... 214 Construction........................................................................................ 214 On-vehicle Service...................................................................................... 215 Rear Suspension Frame............................................................................... 215 Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Race.............................................. 217 Knuckle, Wheel Bearing/Oil Seal..................................................................... 219 Tightening Torque Specifications........................................................................ 220 Required Service Material............................................................................... 221 Special Tool............................................................................................ 221 General Description..................................................................................... 222 Tires............................................................................................... 222 Tire placard.................................................................................... 222 Inflation of tires.............................................................................. 222 Matched tires and wheels (steel type)........................................................... 223 Replacement tires............................................................................... 223 Wheels.............................................................................................. 224 Wheel maintenance............................................................................... 224 Replacement wheels.............................................................................. 224 How to measure wheel runout..................................................................... 224 Metric lug nuts and wheel studs................................................................. 224 Specifications.......................................................................................... 225 Diagnosis............................................................................................... 225 Diagnosis Table..................................................................................... 225 Irregular and/or Premature Wear..................................................................... 225 Wear Indicators..................................................................................... 226 Radial Tire Waddle.................................................................................. 226 Radial Tire Lead/Pull............................................................................... 227 Balancing Wheels.................................................................................... 227 General Balance Procedures.......................................................................... 228 On-Vehicle Service...................................................................................... 229 Wheel............................................................................................... 229 Tire................................................................................................ 230 SECTION 4A...................................................................................................... 231 General Description......................................................................................... 232 Component............................................................................................... 232 Diagnosis................................................................................................... 232 Diagnosis Table......................................................................................... 232 Drive Shaft Boot Check.................................................................................. 232 On-Vehicle Service.......................................................................................... 233 Drive Shaft Assembly.................................................................................... 234 Tightening Torque Specification............................................................................. 247 Required Service Material................................................................................... 247 Special Tool................................................................................................ 247 SECTION 4B...................................................................................................... 249 General Description......................................................................................... 249 On-Vehicle Service.......................................................................................... 250 Propeller Shafts........................................................................................ 250 Tightening Torque Specification............................................................................. 251 SECTION 4C...................................................................................................... 253 General Description......................................................................................... 253 On-Vehicle Service.......................................................................................... 253 Tightening Torque Specifications............................................................................ 256 Required Service Material................................................................................... 256 SECTION 5....................................................................................................... 257 General Description......................................................................................... 258 Diagnosis................................................................................................... 260 Road Testing Brakes..................................................................................... 260 Brake Fluid Leaks....................................................................................... 260 Substandard or Contaminated Brake Fluid................................................................. 260 Diagnosis Table......................................................................................... 261 Brake Pedal Free Height Inspection...................................................................... 264 Brake Pedal Play Inspection............................................................................. 264 Stop Light Switch Adjustment............................................................................ 264 Excessive Pedal Travel Inspection....................................................................... 265 Front Brake Pad Inspection.............................................................................. 265 Brake Disc Inspection................................................................................... 265 Parking Brake Inspection and Adjustment................................................................. 266 Booster Operation Inspection............................................................................ 267 Fluid Pressure Test (If Equipped with LSPV)............................................................. 268 Master Cylinder and Brake Fluid Level Inspection........................................................ 270 Brake Hose and Pipe Inspection.......................................................................... 271 On-Vehicle Service.......................................................................................... 271 Air Bleeding of Brake System............................................................................ 271 Front Brake............................................................................................. 273 Brake pad........................................................................................... 273 Caliper assembly.................................................................................... 275 Brake disc.......................................................................................... 279 Rear Brake.............................................................................................. 281 Brake drum.......................................................................................... 281 Brake shoe.......................................................................................... 285 Wheel cylinder...................................................................................... 286 Brake back plate.................................................................................... 288 Master Cylinder......................................................................................... 290 Master cylinder reservoir........................................................................... 290 Master cylinder assembly............................................................................ 291 Brake Booster........................................................................................... 296 Brake Hose/Pipe......................................................................................... 299 Front brake hose/pipe............................................................................... 299 Rear brake hose/pipe................................................................................ 301 Parking brake cable................................................................................. 303 LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped).......................................... 305 Required Service Material................................................................................... 307 Special Tool................................................................................................ 308 SECTION 5B...................................................................................................... 309 General Description......................................................................................... 310 Components/Parts Location and Brake Hose/Pipe Routing................................................... 310 System Schematic........................................................................................ 312 ABS Hydraulic Unit/Control Module Assembly.............................................................. 313 Self-diagnosis function............................................................................. 313 Fail-safe function.................................................................................. 313 System Circuit.......................................................................................... 314 Diagnosis................................................................................................... 316 Precaution in Diagnosing Troubles....................................................................... 316 ABS Diagnostic Flow Table............................................................................... 317 ABS Warning Lamp Check.................................................................................. 320 EBD Warning Lamp (Brake Warning Lamp) Check............................................................. 320 Table-A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON.................. 321 Table-B ABS Warning Lamp Circuit Check – Lamp Comes “ON” Steady......................................... 322 Table-C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously While Ignition Switch Is ON...... 323 Table-D Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground............. 324 Table-E EBD Warning Lamp (Brake Warning Lamp) Check – Lamp Comes “On” Steady............................ 325 Diagnostic Trouble Code (DTC) Check (Using ABS Warning Lamp)............................................ 326 Diagnostic Trouble Code (DTC) Check..................................................................... 327 (Using SUZUKI Scan Tool)................................................................................ 327 Diagnostic Trouble Code (DTC) Clearance................................................................. 327 Diagnostic Trouble Code (DTC) Table..................................................................... 328 DTC C1013 (DTC 13) – System Specifications Different From ABS Control Module Specifications............. 330 DTC C1015 (DTC 15) -G Sensor Circuit.................................................................... 330 DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right-front Wheel Speed Sensor Circuit or Sensor Ring.......... 332 DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left-front Wheel Speed Sensor Circuit or Sensor Ring........... 332 DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right-rear Wheel Speed Sensor Circuit or Sensor Ring........... 332 DTC C1035 (DTC 35), DTC C1036 (DTC 36) – Left-rear Wheel Speed Sensor Circuit or Sensor Ring............ 332 DTC C1041 (DTC 41) – Right-front Inlet Solenoid Circuit................................................. 334 DTC C1045 (DTC 45) – Left-front Inlet Solenoid Circuit.................................................. 334 DTC C1051 (DTC 51) – Right-rear Inlet Solenoid Circuit.................................................. 334 DTC C1055 (DTC 55) – Left-rear Inlet Solenoid Circuit................................................... 334 DTC C1042 (DTC 42) – Right-front Outlet Solenoid Circuit................................................ 334 DTC C1046 (DTC 46) – Left-front Outlet Solenoid Circuit................................................. 334 DTC C1052 (DTC 52) – Right-rear Outlet Solenoid Circuit................................................. 334 DTC C1056 (DTC 56) – Left-rear Outlet Solenoid Circuit.................................................. 334 DTC C1057 (DTC 57) – Power Source Circuit............................................................... 335 DTC C1061 (DTC 61) – ABS Pump Motor Circuit............................................................. 336 DTC C1063 (DTC 63) – ABS Fail-safe Relay Circuit........................................................ 337 DTC C1071 (DTC 71) – ABS Control Module................................................................. 338 ON-Vehicle Service.......................................................................................... 339 Precautions............................................................................................. 339 ABS Hydraulic Unit Operation Check...................................................................... 339 (Using SUZUKI Scan Tool)................................................................................ 339 ABS Hydraulic Unit Operation Check...................................................................... 339 (Not Using SUZUKI Scan Tool)............................................................................ 339 ABS Hydraulic Unit/Control Module Assembly.............................................................. 341 Front Wheel Speed Sensor................................................................................ 343 Front Wheel Speed Sensor Ring........................................................................... 345 Rear Wheel Speed Sensor................................................................................. 346 Rear Wheel Speed Sensor Ring............................................................................ 349 G Sensor (For 4WD Vehicle Only)......................................................................... 349 Special Tool................................................................................................ 350 SECTION 6....................................................................................................... 351 General Information......................................................................................... 353 Statement on Cleanliness and Care....................................................................... 353 General Information on Engine Service................................................................... 353 Precaution on fuel system service................................................................... 354 Fuel pressure relief procedure...................................................................... 355 Fuel leakage check procedure........................................................................ 355 Engine Diagnosis............................................................................................ 355 General Description..................................................................................... 355 On-Board Diagnostic System (Vehicle with Immobilizer Indicator Lamp).................................... 356 On-Board Diagnostic System (Vehicle without Immobilizer Indicator Lamp)................................. 359 Precaution in Diagnosing Trouble........................................................................ 360 Engine Diagnostic Flow Table............................................................................ 361 Customer problem inspection form (example).......................................................... 363 Malfunction indicator lamp (MIL) check.............................................................. 364 Diagnostic trouble code (DTC) check................................................................. 364 Diagnostic Trouble Code (DTC) Clearance............................................................. 365 Diagnostic trouble code (DTC) table................................................................. 366 Fail-safe table..................................................................................... 369 Visual inspection................................................................................... 371 Engine basic inspection............................................................................. 372 Engine diagnosis table.............................................................................. 374 Scan Tool Data.......................................................................................... 379 Inspection of ECM and Its Circuits...................................................................... 384 Component Location...................................................................................... 389 Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come “ON” at Ignition Switch O....... 390 Table A-2 Malfunction Indicator Lamp Circuit Check - Lamp Remains “ON” after Engine Starts.............. 391 Table A-3 MIL Check - MIL Flashes at Ignition Switch ON (Vehicle without Immobilizer Indicator Lamp).... 391 Table A-4 MIL Check - MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch ....... 392 Table A-5 ECM Power and Ground Circuit Check - MIL Does Not Light at Ignition Switch ON and Engin....... 392 DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunction.............................. 395 DTC P0110 (DTC No.18) Intake Air Temp. (IAT) Circuit Malfunction........................................ 398 DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunction.............................. 400 DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction............................................. 402 DTC P0121 Throttle Position Circuit Range/Performance Problem........................................... 404 DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)........................ 406 DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1).................................. 408 DTC P0134 Heated Oxygen Sensor (HO2S) Circuit No Activity Detected (Sensor-1)........................... 409 DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1)................. 410 DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2).................................... 412 DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2)............................. 414 DTC P0171 Fuel System Too Lean.......................................................................... 416 DTC P0172 Fuel System Too Rich.......................................................................... 416 DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders)............................. 420 DTC P0301 Cylinder 1 Misfire Detected................................................................... 420 DTC P0302 Cylinder 2 Misfire Detected................................................................... 420 DTC P0303 Cylinder 3 Misfire Detected................................................................... 420 DTC P0304 Cylinder 4 Misfire Detected................................................................... 420 DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction.................................................. 424 DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction.............................. 426 DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction................................ 429 DTC P0400 Exhaust Gas Recirculation Flow Malfunction.................................................... 432 DTC P0420 Catalyst System Efficiency below Threshold.................................................... 435 DTC P0443 Purge Control Valve Circuit Malfunction....................................................... 438 DTC P0480 Radiator Cooling Fan Control System Malfunction............................................... 439 DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction............................................ 441 DTC P0505 (DTC No.26) Idle Control System Malfunction................................................... 443 DTC P1450 Barometric Pressure Sensor Low/High Input..................................................... 445 DTC P1451 Barometric Pressure Sensor Performance Problem................................................ 445 DTC P1500 Engine Starter Signal Circuit Malfunction..................................................... 447 DTC P1510 ECM Back-Up Power Supply Malfunction.......................................................... 448 DTC P1600 Serial Communication Problem Between ECM and TCM.............................................. 449 DTC P1717 A/T Drive Range (Park/Neutral Position) Signal Circuit Malfunction............................ 451 Table B-1 Fuel Injector Circuit Check................................................................... 453 Table B-2 Fuel Pump and Its Circuit Check............................................................... 454 Table B-3 Fuel Pressure Check........................................................................... 456 Table B-4 Idle Air Control System Check................................................................. 458 Table B-5 A/C Signal Circuits Check (Vehicle with A/C).................................................. 461 Table B-6 Electric Load Signal Circuit Check............................................................ 465 TAble B-7 Radiator Fan Control System Check............................................................. 467 Table B-8 Power Steering Pressure (PSP) Switch Signal Circuit Check (If equipped)....................... 469 Table B-9 Generator Control Signal Circuit Check........................................................ 470 Special Tool................................................................................................ 471 SECTION 6A1..................................................................................................... 473 General Description......................................................................................... 474 Engine.................................................................................................. 474 Engine Lubrication...................................................................................... 475 Diagnosis................................................................................................... 476 Diagnosis Table......................................................................................... 476 Compression Check....................................................................................... 476 Engine Vacuum Check..................................................................................... 478 Oil Pressure Check...................................................................................... 479 Valve Lash (Clearance).................................................................................. 481 On-Vehicle Service.......................................................................................... 484 Air Cleaner Element..................................................................................... 484 Knock Sensor............................................................................................ 485 Cylinder Head Cover..................................................................................... 485 Throttle Body and Intake Manifold....................................................................... 487 Exhaust Manifold........................................................................................ 490 Oil Pan and Oil Pump Strainer........................................................................... 492 Engine Mountings........................................................................................ 495 Unit Repair Overhaul........................................................................................ 496 Engine Assembly......................................................................................... 496 Timing Chain Cover...................................................................................... 500 Oil Pump................................................................................................ 503 Timing Chain and Chain Tensioner........................................................................ 507 Camshaft, Tappet and Shim............................................................................... 511 Valves and Cylinder Head................................................................................ 517 Pistons, Piston Rings, Connecting Rods and Cylinders.................................................... 528 Main Bearings, Crankshaft and Cylinder Block............................................................ 538 Required Service Material................................................................................... 552 Tightening Torque Specification............................................................................. 553 Special Tool................................................................................................ 554 SECTION 6B...................................................................................................... 557 General Description......................................................................................... 558 Cooling System Circulation.............................................................................. 558 Coolant................................................................................................. 559 Diagnosis................................................................................................... 560 Diagnosis Table......................................................................................... 560 System Circuit.......................................................................................... 561 System Circuit Inspection............................................................................... 561 Maintenance................................................................................................. 562 Coolant Level Check..................................................................................... 562 Engine Cooling System Inspection and Service............................................................ 563 Cooling System Flush and Refill......................................................................... 563 Water Pump/Generator Drive Belt Tension Inspection and Adjustment....................................... 565 On-Vehicle Service.......................................................................................... 566 System Components....................................................................................... 566 Cooling Water Pipes or Hoses............................................................................ 567 Thermostat.............................................................................................. 567 Radiator................................................................................................ 569 Radiator Cooling Fan.................................................................................... 570 Radiator Cooling Fan Relay.............................................................................. 571 Water Pump/Generator Drive Belt......................................................................... 571 Water Pump.............................................................................................. 572 ECT Sensor.............................................................................................. 573 Required Service Material................................................................................... 574 Tightening Torque Specification............................................................................. 574 SECTION 6C...................................................................................................... 575 General Description......................................................................................... 575 On-Vehicle Service.......................................................................................... 576 Components.............................................................................................. 576 Precautions............................................................................................. 577 Fuel Lines.............................................................................................. 578 Fuel Pipe............................................................................................... 578 Fuel Filler Cap......................................................................................... 579 Fuel Tank............................................................................................... 579 Fuel Tank Inlet Valve................................................................................... 583 Fuel Pump Assembly...................................................................................... 584 Special Tool................................................................................................ 588 Tightening Torque Specification............................................................................. 588 SECTION 6E1..................................................................................................... 589 General Description......................................................................................... 590 Air Intake System....................................................................................... 593 Fuel Delivery System.................................................................................... 594 Fuel pump........................................................................................... 594 Electronic Control System............................................................................... 595 Engine & emission control input/output table........................................................ 596 On-vehicle Service.......................................................................................... 600 Accelerator cable adjustment............................................................................ 600 Idle speed/idle air control (IAC) duty inspection....................................................... 600 Idle mixture inspection / adjustment (vehicle without heated oxygen sensor)............................. 602 Air Intake System....................................................................................... 603 Throttle body....................................................................................... 603 Idle air control valve (IAC valve).................................................................. 605 Fuel Delivery System.................................................................................... 606 Fuel pressure inspection............................................................................ 606 Fuel pump........................................................................................... 607 Fuel pressure regulator............................................................................. 608 Fuel injector....................................................................................... 609 Electronic Control System............................................................................... 613 Engine control module (ECM)......................................................................... 613 Manifold absolute pressure sensor (MAP sensor)...................................................... 613 Throttle position sensor (TP sensor)................................................................ 614 Intake air temperature sensor (IAT sensor).......................................................... 615 Engine coolant temperature sensor (ECT sensor)...................................................... 616 Heated oxygen sensor (HO2S-1 and HO2S-2)............................................................ 617 Camshaft position sensor............................................................................ 618 Crankshaft position sensor.......................................................................... 618 Vehicle speed sensor (VSS).......................................................................... 619 Fuel level sensor (gauge)........................................................................... 619 Knock sensor (if equipped).......................................................................... 619 Main relay, fuel pump relay, A/C compressor relay and A/C condenser fan relay....................... 619 Fuel cut operation.................................................................................. 620 Radiator fan control system......................................................................... 620 Radiator fan relay No. 1, No. 2 and No.3............................................................ 620 Output signals of throttle valve opening and engine coolant temp. (vehicle with A/T only)........... 622 Emission Control System................................................................................. 622 EGR system.......................................................................................... 622 Evaporative emission control system................................................................. 623 PCV system.......................................................................................... 625 Special Tool................................................................................................ 626 Tightening Torque Specification............................................................................. 627 SECTION 6F1..................................................................................................... 629 General Description......................................................................................... 630 System Components....................................................................................... 630 System Wiring Diagram................................................................................... 631 Diagnosis................................................................................................... 631 On-vehicle Service.......................................................................................... 633 Ignition Spark Test..................................................................................... 633 High-tension Cords...................................................................................... 633 Spark Plugs............................................................................................. 634 Ignition Coil Assembly (Including Igniter).............................................................. 635 Crankshaft Position Sensor (CKP Sensor)................................................................. 635 Ignition Timing......................................................................................... 636 Special Tool................................................................................................ 637 SECTION 6G...................................................................................................... 639 Specification............................................................................................... 650 1.0 kW type............................................................................................. 650 1.2 kW type............................................................................................. 650 1.4 kW type............................................................................................. 650 Required Service Material................................................................................... 651 General Description......................................................................................... 640 Cranking Circuit........................................................................................ 640 Diagnosis................................................................................................... 640 Diagnosis Table......................................................................................... 640 Performance Test........................................................................................ 642 Pull-in test........................................................................................ 642 Hold-in test........................................................................................ 642 Plunger and pinion return test...................................................................... 642 No-load performance test............................................................................ 643 ON-Vehicle Service.......................................................................................... 643 Starting Motor.......................................................................................... 643 Dismounting......................................................................................... 643 Remounting.......................................................................................... 643 Disassembly and reassembly.......................................................................... 644 Inspection.......................................................................................... 646 SECTION 6H...................................................................................................... 653 General Description......................................................................................... 654 Battery................................................................................................. 654 Carrier and hold-down............................................................................... 654 Electrolyte freezing................................................................................ 654 Sulfation........................................................................................... 654 Built-in indicator (if equipped).................................................................... 654 Care of battery..................................................................................... 655 Generator............................................................................................... 656 Diagnosis................................................................................................... 657 Battery................................................................................................. 657 Visual inspection................................................................................... 657 Hydrometer test..................................................................................... 657 Generator............................................................................................... 658 Charging indicator lamp operation................................................................... 658 Undercharged battery................................................................................ 659 Overcharged battery................................................................................. 660 On-Vehicle Service.......................................................................................... 661 Battery................................................................................................. 661 Jump starting in case of emergency.................................................................. 661 Dismounting......................................................................................... 662 Handling............................................................................................ 662 Remounting.......................................................................................... 662 Generator............................................................................................... 662 Generator belt...................................................................................... 662 Dismounting and remounting.......................................................................... 663 Disassembly and reassembly.......................................................................... 663 Inspection.......................................................................................... 664 Specification............................................................................................... 666 Battery................................................................................................. 666 Generator............................................................................................... 666 Tightening Torque Specification............................................................................. 666 SECTION 6K...................................................................................................... 667 General Description......................................................................................... 667 On-Vehicle Service.......................................................................................... 668 Exhaust Manifold........................................................................................ 669 Exhaust Pipe............................................................................................ 669 SECTION 7A1..................................................................................................... 5 SECTION 7B1..................................................................................................... 65 SECTION 7C1..................................................................................................... 241 SECTION 7D...................................................................................................... 263 SECTION 7F...................................................................................................... 289 SECTION 8....................................................................................................... 317 SECTION 8G...................................................................................................... 361 SECTION 9....................................................................................................... 393 SECTION 10...................................................................................................... 449 SECTION 10B..................................................................................................... 459 Copyright....................................................................................................... 671 Bookcover....................................................................................................... 0 99500_54G00_01E_2................................................................................................... 672 Top............................................................................................................. 0 Manual List..................................................................................................... 0 IMPORTANT....................................................................................................... 672 WARNING/CAUTION/NOTE........................................................................................ 672 FOREWORD........................................................................................................ 673 TABLE OF CONTENTS............................................................................................... 675 SECTION 0A...................................................................................................... 5 SECTION 0B...................................................................................................... 33 SECTION 1A...................................................................................................... 53 SECTION 1B...................................................................................................... 67 SECTION 3....................................................................................................... 109 SECTION 4A...................................................................................................... 229 SECTION 4B...................................................................................................... 247 SECTION 4C...................................................................................................... 251 SECTION 5....................................................................................................... 255 SECTION 5B...................................................................................................... 307 SECTION 6....................................................................................................... 349 SECTION 6A1..................................................................................................... 471 SECTION 6B...................................................................................................... 555 SECTION 6C...................................................................................................... 573 SECTION 6E1..................................................................................................... 587 SECTION 6F1..................................................................................................... 627 SECTION 6G...................................................................................................... 637 SECTION 6H...................................................................................................... 651 SECTION 6K...................................................................................................... 665 SECTION 7A1..................................................................................................... 677 Gear shift mechanism........................................................................................ 680 5th & reverse gear shift cam................................................................................ 680 Diagnosis................................................................................................... 682 General Description......................................................................................... 678 Construction and Servicing.............................................................................. 678 Transaxle for 2WD model............................................................................. 678 Transaxle for 4WD model............................................................................. 679 On-Vehicle Service.......................................................................................... 683 Oil Change.............................................................................................. 683 Differential Side Oil Seal.............................................................................. 684 Gear Shift Control Lever and Cable...................................................................... 686 Vehicle Speed Sensor (VSS).............................................................................. 688 Unit Repair Overhaul........................................................................................ 689 Transaxle Unit.......................................................................................... 689 Transaxle Case.......................................................................................... 690 Input & Counter Shaft................................................................................... 691 Gear Shifter............................................................................................ 692 Differential............................................................................................ 693 Transfer................................................................................................ 694 Transaxle Unit.......................................................................................... 695 Disassembling Unit...................................................................................... 697 Transfer and differential (for 4WD model)........................................................... 697 Gear shift and select shaft assembly and fifth gears................................................ 697 Main shaft and countershaft......................................................................... 698 Right case.......................................................................................... 699 Sub Assembly Service.................................................................................... 700 Right case.......................................................................................... 700 Left case........................................................................................... 700 Input shaft assembly................................................................................ 701 Counter shaft assembly.............................................................................. 704 Gear shift & select shaft assembly.................................................................. 708 High speed and low speed gear shift shafts.......................................................... 709 5th & rev gear shift shafts......................................................................... 710 Transfer assembly................................................................................... 710 Differential assembly............................................................................... 721 Assembling Unit......................................................................................... 724 Differential to left case (for 4WD model)........................................................... 724 Left case........................................................................................... 725 Fifth gears......................................................................................... 726 Gear shift and select shaft assembly................................................................ 730 Installation of transfer & differential (for 4WD model)............................................. 731 Tightening Torque Specification............................................................................. 733 Required Service Material................................................................................... 734 Special Tool................................................................................................ 734 SECTION 7B1..................................................................................................... 737 General Description......................................................................................... 739 Specifications.......................................................................................... 742 Clutch/Brake/Planetary Gear............................................................................. 743 Functions............................................................................................... 743 Table of Component Operation............................................................................ 744 Electronic Shift Control System......................................................................... 745 Transmission Control Module (TCM)....................................................................... 746 Operation of shift solenoid valves and TCC solenoid valve........................................... 747 Automatic gear shift diagram........................................................................ 748 Diagnosis................................................................................................... 749 General Description..................................................................................... 749 On-board Diagnostic System.............................................................................. 749 2 driving cycle detection logic..................................................................... 750 Freeze frame data................................................................................... 750 Precaution in Diagnosing Trouble........................................................................ 752 Automatic Transaxle Diagnostic Flow Table............................................................... 753 Malfunction Indicator Lamp (MIL) Check.................................................................. 757 “O/D OFF” Lamp Check.................................................................................... 757 Diagnostic Trouble Code (DTC) Check..................................................................... 757 Reading DTC from ECM using SUZUKI scan tool – method-1.............................................. 757 Reading DTC from TCM using SUZUKI scan tool – method-2.............................................. 758 Displaying DTC on odometer – method-3............................................................... 758 Diagnostic Trouble Code (DTC) Clearance................................................................. 759 To clear DTC stored in ECM with scan tool – method- 1............................................... 759 To clear DTC stored in TCM with scan tool – method-2................................................ 759 To clear DTC stored in TCM without scan tool – method-3............................................. 759 Diagnostic Trouble Code (DTC) Table..................................................................... 760 Fail Safe Table......................................................................................... 762 Visual Inspection....................................................................................... 764 Automatic Transaxle Basic Check......................................................................... 765 Trouble Diagnosis Table................................................................................. 766 Trouble diagnosis table-1........................................................................... 766 Trouble diagnosis table-2........................................................................... 769 Trouble diagnosis table-3........................................................................... 770 Road Test............................................................................................... 771 Manual Road Test........................................................................................ 773 Engine Brake Test....................................................................................... 773 Stall Test.............................................................................................. 774 Time Lag Test........................................................................................... 775 Line Pressure Test...................................................................................... 776 “P” Range Test.......................................................................................... 777 Diagnostic Flow Table A-1: No Gear Shift to O/D......................................................... 778 Diagnostic Flow Table A-2: No Lock-Up Occurs............................................................ 779 Diagnostic Flow Table A-3: “O/D OFF” Lamp Circuit Check................................................. 780 Diagnostic Flow Table A-4: TCM Power and Ground Circuit Check........................................... 782 DTC P0705/DTC No.34 Transmission Range Sensor Circuit Malfunction....................................... 783 DTC P0710/DTC No.36 or 38 Transmission Fluid Temperature Sensor Circuit Malfunction..................... 786 DTC P0715/DTC No.37 Input/Turbine Speed Sensor Circuit Malfunction...................................... 788 DTC P0720/DTC No.31 Output Speed Sensor Circuit Malfunction............................................. 790 DTC P0725/DTC No.35 Engine Speed Input Circuit Malfunction.............................................. 792 DTC P0741/DTC No.29 TCC System Performance or Stuck Off................................................. 794 DTC P0743/DTC No.25 or No.26 TCC System Electrical...................................................... 795 DTC P0748/DTC No.41 or No.42 Pressure Control Solenoid Electrical....................................... 797 DTC P0751/DTC No.17 Shift Solenoid-A (No.1) Performance or Stuck Off.................................... 799 DTC P0756/DTC No.28 Shift Solenoid-B (No.2) Performance or Stuck Off.................................... 799 DTC P0753/DTC No.21 or No.22 Shift Solenoid-A (No.1) Electrical......................................... 801 DTC P0758/DTC No.23 or No.24 Shift Solenoid-B (No.2) Electrical......................................... 801 DTC P1700/DTC No.32 or No.33 Throttle Position Signal Circuit........................................... 803 DTC P1702/DTC No.52 Internal Malfunction of TCM......................................................... 805 DTC P1705/DTC No.51 Engine Coolant Temperature Signal Circuit Malfunction............................... 806 DTC P1895/DTC No.27 Torque Reduction Signal Circuit Malfunction......................................... 808 Scan Tool Data.......................................................................................... 810 Inspection of TCM and Its Circuits...................................................................... 813 On-Vehicle Service.......................................................................................... 816 Maintenance Service..................................................................................... 816 Fluid level check................................................................................... 816 Fluid change........................................................................................ 817 A/T fluid cooler hoses.............................................................................. 818 Selector Lever.......................................................................................... 819 Select Cable............................................................................................ 820 Transmission Range Sensor (Shift Switch)................................................................ 822 Output Shaft Speed Sensor............................................................................... 823 Input Shaft Speed Sensor................................................................................ 824 Vehicle Speed Sensor (VSS).............................................................................. 824 Throttle Position Sensor................................................................................ 824 Engine Coolant Temperature Sensor....................................................................... 825 O/D OFF Switch.......................................................................................... 825 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Pressure Control Solenoid Valve)......... 825 Solenoid valves (shift solenoid valves and TCC solenoid valve)...................................... 826 Pressure control solenoid valve..................................................................... 828 Transmission Control Module (TCM)....................................................................... 831 Transmission Fluid Temperature Sensor................................................................... 832 Differential Side Oil Seal.............................................................................. 833 Shift Lock Solenoid (If Equipped)....................................................................... 834 Brake Interlock System (If Equipped).................................................................... 835 Key Interlock Cable (If Equipped)....................................................................... 836 Automatic Transmission Assembly......................................................................... 839 Components.......................................................................................... 839 Unit Repair................................................................................................. 843 Precautions............................................................................................. 843 Part Inspection and Correction Table.................................................................... 844 Automatic Transaxle Assembly............................................................................ 845 Components.......................................................................................... 845 Unit Disassembly........................................................................................ 846 Subassembly............................................................................................. 855 Oil pump............................................................................................ 855 Forward Clutch...................................................................................... 858 Overdrive clutch and coast clutch................................................................... 863 Planetary gear...................................................................................... 868 Reverse clutch...................................................................................... 875 Counter drive gear.................................................................................. 881 Counter driven gear................................................................................. 884 Valve body assembly................................................................................. 887 Differential........................................................................................ 889 Transaxle housing................................................................................... 893 Transaxle case...................................................................................... 894 Unit Assembly........................................................................................... 895 Tightening Torque Specification............................................................................. 907 Special Tool................................................................................................ 908 Required Service Material................................................................................... 911 SECTION 7C1..................................................................................................... 913 General Description......................................................................................... 914 Diagnosis................................................................................................... 915 Clutch pedal............................................................................................ 916 Clutch fluid............................................................................................ 917 On-Vehicle Service.......................................................................................... 918 Clutch Fluid Pipe and Hose.............................................................................. 918 Clutch Master Cylinder.................................................................................. 920 Clutch Operating Cylinder............................................................................... 921 Unit Repair Overhaul........................................................................................ 923 Clutch Master Cylinder.................................................................................. 923 Clutch Operating Cylinder............................................................................... 925 Clutch Cover, Clutch Disc, Flywheel and Clutch Release System........................................... 927 Clutch cover, clutch disc and flywheel.............................................................. 927 Clutch release system............................................................................... 930 Tightening Torque Specification............................................................................. 933 Required Service Material................................................................................... 933 Special Tool................................................................................................ 934 SECTION 7D...................................................................................................... 935 General Description......................................................................................... 936 Diagnosis................................................................................................... 937 On-Vehicle Service.......................................................................................... 937 Oil Change.............................................................................................. 937 Unit Repair Overhaul........................................................................................ 938 Unit Dismounting........................................................................................ 939 Unit Disassembly........................................................................................ 941 Transfer assembly................................................................................... 941 Reduction drive gear, reduction idler gear and reduction driven gear................................ 942 Transfer right case and left case................................................................... 942 Transfer output retainer assembly................................................................... 943 Component Inspection.................................................................................... 944 Unit Assembly........................................................................................... 944 Reduction drive gear, reduction idler gear and reduction driven gear................................ 945 Transfer output retainer assembly................................................................... 945 Transfer right case................................................................................. 949 Transfer left case.................................................................................. 950 Transfer assembly................................................................................... 950 Unit Installation....................................................................................... 957 Tightening Torque Specification............................................................................. 958 Required Service Material................................................................................... 958 Special Tool................................................................................................ 959 SECTION 7F...................................................................................................... 961 General Description......................................................................................... 962 Diagnosis................................................................................................... 963 On-Vehicle Service.......................................................................................... 964 Maintenance Service..................................................................................... 964 Oil change.......................................................................................... 964 Differential Mountings.................................................................................. 965 Differential front mounting......................................................................... 965 Differential rear mounting.......................................................................... 966 Rear Differential Assembly.............................................................................. 968 Unit Repair Overhaul........................................................................................ 970 Tightening Torque Specification............................................................................. 985 Required Service Material................................................................................... 985 Special Tool................................................................................................ 986 SECTION 8....................................................................................................... 989 Diagnosis................................................................................................... 991 Headlight............................................................................................... 991 Headlights with Leveling System (If Equipped)........................................................... 991 Turn Signal and Hazard Warning Light.................................................................... 991 Clearance, Tail and License Plate Light................................................................. 992 Back-Up Light........................................................................................... 992 Brake Light............................................................................................. 992 Front Fog Light (If Equipped)........................................................................... 992 Rear Fog Light (If Equipped)............................................................................ 992 Interior Light.......................................................................................... 993 Combination Meter....................................................................................... 993 Speedometer and VSS..................................................................................... 993 Fuel Meter and Fuel Gauge Unit.......................................................................... 993 Engine Coolant Temperature (ECT) Meter and Sensor....................................................... 994 Oil Pressure Warning Light.............................................................................. 994 Brake and Parking Brake Warning Light................................................................... 994 Seat Belt Warning Light (If Equipped)................................................................... 994 Ignition Key Remainder and Light Remainder Warning Buzzer............................................... 995 A/T Shift Position Display (A/T Vehicle Only)........................................................... 995 O/D Off Display (A/T Vehicle Only)...................................................................... 995 Rear Window Defogger.................................................................................... 995 Wipers and Washers (Front/Rear)......................................................................... 996 Power Window Control System............................................................................. 996 Cigarette Lighter....................................................................................... 996 Power Door Lock Control System (If Equipped)............................................................ 997 Power Door Mirror Control System (If Equipped).......................................................... 998 Front Seat Heater (If Equipped)......................................................................... 998 Horn.................................................................................................... 998 On-Vehicle Service.......................................................................................... 999 Cautions in Servicing................................................................................... 999 Headlight............................................................................................... 999 Headlight system location........................................................................... 999 Headlight switch (in lighting switch)............................................................... 999 Headlight assembly..................................................................................1000 Headlight bulb......................................................................................1001 Headlight aiming adjustment with screen.............................................................1001 Headlight leveling switch (if equipped).............................................................1002 Turn Signal and Hazard Warning Lights...................................................................1003 Turn signal and hazard warning system location......................................................1003 Turn signal light switch (in lighting switch).......................................................1003 Turn signal and hazard relay........................................................................1004 Hazard switch.......................................................................................1004 Front Fog Lights (If Equipped)..........................................................................1005 Front fog light system location.....................................................................1005 Front fog light switch..............................................................................1005 Rear Fog Light (If Equipped)............................................................................1006 Rear fog light system location......................................................................1006 Rear fog light switch...............................................................................1006 Rear fog light operation inspection.................................................................1007 Licence Lamp............................................................................................1008 Licence lamp assembly...............................................................................1008 Interior Light..........................................................................................1009 Interior light system location......................................................................1009 Door switch (front/rear door).......................................................................1009 Back door switch....................................................................................1009 Ignition switch.........................................................................................1010 Combination Meter.......................................................................................1011 Circuit.............................................................................................1011 Fuel level sensor (gauge unit)......................................................................1012 Speed Meter and VSS.....................................................................................1013 VSS.................................................................................................1013 Engine Coolant Temperature (ECT) Sensor.................................................................1013 Oil Pressure Warning Light..............................................................................1013 Oil pressure switch.................................................................................1013 Brake Fluid Level and Parking Brake Warning Light.......................................................1014 Brake fluid level switch............................................................................1014 Parking brake switch................................................................................1014 Rear Window Defogger....................................................................................1014 Defogger switch.....................................................................................1014 Defogger wire.......................................................................................1015 Wipers and Washers......................................................................................1017 Components..........................................................................................1017 Front wiper and washer switch.......................................................................1017 Front wiper motor...................................................................................1020 Washer tank and washer pump.........................................................................1020 Rear wiper and washer switch........................................................................1021 Rear wiper motor....................................................................................1022 Power Window Control System.............................................................................1023 Power window control system location................................................................1023 Power window main switch............................................................................1023 Power window sub switch.............................................................................1024 Stop (Brake) Lamp.......................................................................................1024 Stop (brake) lamp switch............................................................................1024 Power Door Lock System (If Equipped)....................................................................1025 Power door lock system location.....................................................................1025 Power door lock system (with dead lock system)......................................................1025 Power door lock controller (without dead lock system)...............................................1027 Power door lock switch..............................................................................1027 Door key cylinder switch (driver and passenger side)................................................1027 Power door lock actuator............................................................................1028 Power Door Mirror Control System (If Equipped)..........................................................1029 Mirror switch.......................................................................................1029 Door mirror actuator................................................................................1029 Door Mirror Heater (If Equipped)........................................................................1030 Mirror heater switch................................................................................1030 Mirror heater (if equipped).........................................................................1030 Front Seat Heater (If Equipped).........................................................................1031 Seat heater switch (driver and passenger side)......................................................1031 Seat heater wire....................................................................................1031 SECTION 8G......................................................................................................1033 General Description.........................................................................................1034 Wiring Circuit..........................................................................................1036 On-board Diagnostic System (Self-diagnosis Function)....................................................1037 Diagnosis...................................................................................................1039 Precautions in Diagnosing Troubles......................................................................1039 Precautions in identifying diagnostic trouble code..................................................1039 Diagnostic Flow Table...................................................................................1040 Diagnostic Trouble Code (DTC) Check (Immobilizer Control Module)........................................1043 Diagnostic Trouble Code (DTC) Check (ECM)...............................................................1044 Diagnostic Trouble Code Table...........................................................................1046 Table A - Immobilizer Indicator Lamp Check: Immobilizer Indicator Lamp Does Not Light at Ignition.......1047 Table B - Immobilizer Indicator Lamp Check: Immobilizer Indicator Lamp Remains ON after Engine St.......1048 Table C - DTC Is Not Output from Immobilizer Control Module.............................................1049 DTC11/32 Transponder Code Not Matched...................................................................1050 DTC31 Transponder Code Not Registered...................................................................1051 DTC12 Fault in Immobilizer Control Module...............................................................1051 DTC13 No Transponder Code Transmitted or Coil Antenna Opened/Shorted....................................1052 DTC21 ECM/Immobilizer Control Module Code Not Matched (Immobilizer Control Module Side).................1053 DTC81 (P1623) ECM/Immobilizer Control Module Code Not Matched (ECM Side)................................1053 DTC84 (P1620) ECM/Immobilizer Control Module Code Not Registered........................................1053 DTC82 (P1622) Fault in ECM..............................................................................1053 DTC22 Ignition Switch Circuit Open/Short................................................................1054 DTC23 No ECM/Immobilizer Control Module Code Transmitted from ECM or DLC Circuit Opened/Shorted.........1055 DTC83 (P1621) No ECM/Immobilizer Control Module Code Transmitted from Immobilizer Control Module .......1055 Inspection of ECM, Immobilizer Control Module and Its Circuit...........................................1057 On-vehicle Service..........................................................................................1058 Precautions in Handling Immobilizer Control System......................................................1058 Immobilizer Control Module..............................................................................1059 How to Register Ignition Key................................................................................1061 Procedure after Immobilizer Control Module Replacement......................................................1062 Procedure after ECM Replacement.............................................................................1063 Special Tool................................................................................................1063 SECTION 9.......................................................................................................1065 Glass, Windows and Mirrors..................................................................................1067 Front Door Glass........................................................................................1067 Front Door Window Regulator.............................................................................1070 Door Mirror.........................................................................................1071 Rear Door Glass.....................................................................................1072 Rear Door Window Regulator..............................................................................1075 Windshield..............................................................................................1076 Front Pillar Window.....................................................................................1081 Quarter Window..........................................................................................1082 Back Door Glass.........................................................................................1083 Body Structure..............................................................................................1084 Front Door Assembly.....................................................................................1084 Rear Door Assembly......................................................................................1086 Back Door Assembly......................................................................................1087 Hood....................................................................................................1089 Front Fender............................................................................................1090 Front Bumper and Rear Bumper............................................................................1091 Body Dimensions.........................................................................................1092 Engine room.........................................................................................1092 Back door...........................................................................................1093 Side body...........................................................................................1094 Under body..........................................................................................1096 Instrumentation and Driver Information......................................................................1098 Instrument Panel........................................................................................1098 Seats.......................................................................................................1100 Front Seat..............................................................................................1100 Rear Seat...............................................................................................1101 Security and Locks..........................................................................................1102 Front Door Lock Assembly................................................................................1102 Rear Door Lock Assembly.................................................................................1104 Back Door Lock Assembly.................................................................................1105 Key Coding..............................................................................................1106 Key usage and identification........................................................................1106 Ignition switch lock cylinder.......................................................................1107 Exterior and Interior Trim..................................................................................1107 Floor Carpet............................................................................................1107 Head Lining.............................................................................................1108 Roof Molding............................................................................................1109 Paint and Coatings..........................................................................................1110 Anti-Corrosion Treatment................................................................................1110 Sealant Application Areas...............................................................................1111 Under Coating Application Areas.........................................................................1117 Anti-Corrosion Compound Application Area................................................................1119 Required Service Material...................................................................................1120 SECTION 10......................................................................................................1121 General Description.........................................................................................1122 System Specification....................................................................................1123 Seat Belt Pretensioner (If Equipped)....................................................................1123 Diagnosis...................................................................................................1123 Inspection and Repair Required after Accident...........................................................1123 On-Vehicle Service..........................................................................................1124 Service Precautions.....................................................................................1124 Service and diagnosis...............................................................................1124 Disabling air bag system............................................................................1124 Enabling air bag system.............................................................................1124 Handling and storage................................................................................1124 Disposal............................................................................................1124 Front Seat Belt.........................................................................................1125 Rear Seat Belt..........................................................................................1128 Tightening Torque Specification.............................................................................1129 SECTION 10B.....................................................................................................1131 General Description.........................................................................................1133 System Components and Wiring Location View and Connectors...............................................1134 System Wiring Diagram...................................................................................1135 Diagnosis...................................................................................................1136 Diagnostic Trouble Code (DTC)...........................................................................1136 Use of Special Tool.....................................................................................1137 Intermittents and Poor Connections......................................................................1139 Air Bag Diagnostic System Check......................................................................... 0 Air Bag Diagnostic System Check Flow Table..............................................................1141 DTC Check...............................................................................................1142 DTC Clearance...........................................................................................1143 DTC Table...............................................................................................1144 Table A - “AIR BAG” Warning Lamp Comes ON Steady........................................................1147 Table B - “AIR BAG” Warning Lamp Does Not Come ON.......................................................1147 Table C - “AIR BAG” Warning Lamp Flashes................................................................1147 Table D - “AIR BAG” Warning Lamp Cannot Indicate Flashing Pattern of DTC................................1147 Table E - SDM Cannot Communicate through the Serial Data Circuit........................................1153 DTC B1015 - Passenger Air Bag Initiator Circuit Resistance High.........................................1155 DTC B1016 - Passenger Air Bag Initiator Circuit Resistance Low..........................................1155 DTC B1018 - Passenger Air Bag Initiator Circuit Short to Ground.........................................1155 DTC B1019 - Passenger Air Bag Initiator Circuit Short to Power Circuit..................................1155 DTC B1021 – Driver Air Bag Initiator Circuit Resistance High............................................1160 DTC B1022 – Driver Air Bag Initiator Circuit Resistance Low.............................................1160 DTC B1024 – Driver Air Bag Initiator Circuit Short to Ground............................................1160 DTC B1025 – Driver Air Bag Initiator Circuit Short to Power Circuit.....................................1160 DTC B1031 – Power Source Voltage High...................................................................1167 DTC B1032 – Power Source Voltage Low....................................................................1167 DTC B1041 – Driver Pretensioner Initiator Circuit Resistance High.......................................1170 DTC B1042 – Driver Pretensioner Initiator Circuit Resistance Low........................................1170 DTC B1043 – Driver Pretensioner Initiator Circuit Short to Ground.......................................1170 DTC B1044 – Driver Pretensioner Initiator Circuit Short to Power Circuit................................1170 DTC B1045 – Passenger Pretensioner Initiator Circuit Resistance High....................................1170 DTC B1046 – Passenger Pretensioner Initiator Circuit Resistance Low.....................................1170 DTC B1047 – Passenger Pretensioner Initiator Circuit Short to Ground....................................1170 DTC B1048 – Passenger Pretensioner Initiator Circuit Short to Power Circuit.............................1170 DTC B1051 – Frontal Crash Detected (System Activation Command Outputted)................................1177 DTC B1056 – Sideward Crash (Driver Side) Detected (Side Air Bag System Activation Command Outputted)....1178 DTC B1057 – Sideward Crash (Passenger Side) Detected (Side Air Bag System Activation Command Outp.......1178 DTC B1058 – Frontal Crash Detected (Pretensioner Activation Command Outputted)..........................1179 DTC B1061 - “AIR BAG” Warning Lamp Circuit Failure......................................................1180 DTC B1063 – Side Sensor (Driver Side) Circuit Short to Ground...........................................1182 DTC B1064 – Side Sensor (Driver Side) Circuit Short to Power Circuit Or Open............................1182 DTC B1065 – Side Sensor (Passenger Side) Circuit Short to Ground........................................1182 DTC B1066 – Side Sensor (Passenger Side) Circuit Short to Power Circuit or Open.........................1182 DTC B1071 - Internal SDM Fault..........................................................................1186 DTC B1072 – Internal Side Sensor (Driver Side) Fault....................................................1186 DTC B1074 – Internal Side Sensor (Passenger Side) Fault.................................................1186 DTC B1073 – Side Sensor (Driver Side) Correspondence Abnormality........................................1187 DTC B1075 – Side Sensor (Passenger Side) Correspondence Abnormality.....................................1187 DTC B1081 – Side Air Bag (Driver Side) Intiator Circuit Resistance High.................................1191 DTC B1082 – Side Air Bag (Driver Side) Intiator Circuit Resistance Low..................................1191 DTC B1083 – Side Air Bag (Driver Side) Intiator Circuit Short to Ground.................................1191 DTC B1084 – Side Air Bag (Driver Side) Intiator Circuit Short to Power Circuit..........................1191 DTC B1085 – Side Air Bag (Passenger Side) Intiator Circuit Resistance High..............................1191 DTC B1086 – Side Air Bag (Passenger Side) Intiator Circuit Resistance Low...............................1191 DTC B1087 – Side Air Bag (Passenger Side) Intiator Circuit Short to Ground..............................1191 DTC B1088 – Side Air Bag (Passenger Side) Intiator Circuit Short to Power Circuit.......................1191 On-Vehicle Service..........................................................................................1199 Service Precautions.....................................................................................1199 Service and diagnosis...............................................................................1199 Disabling air bag system............................................................................1200 Enabling air bag system.............................................................................1201 Handling and storage................................................................................1202 Repairs and Inspections Required after an Accident......................................................1207 Accident with deployment/activation - component replacement.........................................1207 Accident with or without deployment/activation - component inspections..............................1207 SDM.....................................................................................................1210 Side Sensor.............................................................................................1211 Seat Belt Pretensioner..................................................................................1213 Passenger Air Bag (Inflator) Module.....................................................................1214 Side Air Bag (Inflator) Module (If Equipped)............................................................1216 Driver Air Bag (Inflator) Module........................................................................1216 Contact Coil and Combination Switch Assembly............................................................1216 Seat Belt Pretensioner..................................................................................1216 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal...............................................1217 Deployment/Activation Outside of Vehicle................................................................1218 Deployment/Activation Inside of Vehicle.................................................................1225 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal........................1230 Tightening Torque Specification.............................................................................1231 Special Tool................................................................................................1231 Copyright.......................................................................................................1233 Bookcover....................................................................................................... 0
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