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SUZUKI RH413 RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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The Suzuki RH413 RH416 Liana Supplementary Service Manual provides additional instructions for specific model maintenance, complementing the main manual for comprehensive care and optimal performance.
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Description
SUZUKI RH413 RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI RH413 RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 495
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI RH413 RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Bookcove............................................................................................................ 1 99501_54G00_01E..................................................................................................... 2 Top............................................................................................................. 0 Manual List..................................................................................................... 0 IMPORTANT....................................................................................................... 2 WARNING/CAUTION/NOTE........................................................................................ 2 FOREWORD........................................................................................................ 3 TABLE OF CONTENTS............................................................................................... 5 SECTION 0A...................................................................................................... 7 Warning, Caution and Information Labels..................................................................... 8 Vehicle Lifting Points...................................................................................... 9 SECTION 0B...................................................................................................... 11 Maintenance Schedule........................................................................................ 12 Maintenance Schedule Under Normal Driving Conditions.................................................... 12 Maintenance Recommended under Severe Driving Conditions................................................. 14 Maintenance Service......................................................................................... 15 Chassis and Body........................................................................................ 15 Automatic transaxle fluid........................................................................... 15 Recommended Fluids and Lubricants........................................................................... 16 SECTION 3....................................................................................................... 17 Specifications.............................................................................................. 20 Specification and Service Data.......................................................................... 20 On-Vehicle Service.......................................................................................... 22 Driver Air Bag (Inflator) Module........................................................................ 22 Centering Contact Coil.................................................................................. 24 General Description......................................................................................... 25 Construction............................................................................................ 25 On-vehicle Service.......................................................................................... 26 Strut Assembly.......................................................................................... 26 Tightening Torque Specifications............................................................................ 29 General Description......................................................................................... 31 Construction............................................................................................ 31 On-vehicle Service.......................................................................................... 32 Rear Strut Assembly..................................................................................... 32 Control Rod............................................................................................. 36 Trailing Rod............................................................................................ 38 Suspension Frame........................................................................................ 39 Knuckle................................................................................................. 41 Tightening Torque Specifications............................................................................ 44 Required Service Material................................................................................... 44 General Description......................................................................................... 46 Construction............................................................................................ 46 On-vehicle Service.......................................................................................... 47 Rear Suspension Frame................................................................................... 47 SECTION 4A...................................................................................................... 49 On-Vehicle Service.......................................................................................... 50 Drive Shaft Assembly.................................................................................... 51 Tightening Torque Specification............................................................................. 58 Required Service Material................................................................................... 58 Special Tool................................................................................................ 58 SECTION 5....................................................................................................... 59 Diagnosis................................................................................................... 60 Brake Pedal Free Height Inspection...................................................................... 60 Brake Pedal Play Inspection............................................................................. 60 Stop Light Switch Adjustment............................................................................ 60 Excessive Pedal Travel Inspection....................................................................... 61 On-Vehicle Service.......................................................................................... 62 Front Brake............................................................................................. 62 Brake pad........................................................................................... 62 Brake Booster........................................................................................... 65 SECTION 6....................................................................................................... 69 Engine Diagnosis............................................................................................ 71 Engine Diagnostic Flow Table............................................................................ 71 Diagnostic trouble code (DTC) table................................................................. 71 Scan Tool Data.......................................................................................... 75 Inspection of ECM and Its Circuits...................................................................... 80 Component Location...................................................................................... 88 Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come “ON” at Ignition Switch O....... 89 Table A-2 Malfunction Indicator Lamp Circuit Check - Lamp Remains “ON” after Engine Starts.............. 90 Table A-3 MIL Check - MIL Flashes at Ignition Switch ON (Vehicle without Immobilizer Indicator Lamp).... 90 Table A-4 MIL Check - MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch ....... 91 Table A-5 ECM Power and Ground Circuit Check - MIL Does Not Light at Ignition Switch ON and Engin....... 91 DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunction.............................. 94 DTC P0110 (DTC No.18) Intake Air Temp. (IAT) Circuit Malfunction........................................ 97 DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunction.............................. 99 DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction.............................................101 DTC P0121 Throttle Position Circuit Range/Performance Problem...........................................103 DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)........................105 DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)..................................107 DTC P0134 Heated Oxygen Sensor (HO2S) Circuit No Activity Detected (Sensor-1)...........................108 DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1).................109 DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)....................................111 DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2).............................113 DTC P0171 Fuel System Too Lean..........................................................................115 DTC P0172 Fuel System Too Rich..........................................................................115 DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders).............................119 DTC P0301 Cylinder 1 Misfire Detected...................................................................119 DTC P0302 Cylinder 2 Misfire Detected...................................................................119 DTC P0303 Cylinder 3 Misfire Detected...................................................................119 DTC P0304 Cylinder 4 Misfire Detected...................................................................119 DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction..................................................124 DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction..............................126 DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction................................129 DTC P0400 Exhaust Gas Recirculation Flow Malfunction....................................................132 DTC P0420 Catalyst System Efficiency below Threshold....................................................135 DTC P0443 Purge Control Valve Circuit Malfunction.......................................................138 DTC P0480 Radiator Cooling Fan Control System Malfunction...............................................139 DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction............................................143 DTC P0505 (DTC No.26) Idle Control System Malfunction...................................................146 DTC P1500 Engine Starter Signal Circuit Malfunction.....................................................148 DTC P1510 ECM Back-Up Power Supply Malfunction..........................................................149 DTC P1600 Serial Communication Problem Between ECM and TCM..............................................150 DTC P1717 A/T Drive Range (Park/Neutral Position) Signal Circuit Malfunction............................152 Table B-1 Fuel Injector Circuit Check...................................................................154 Table B-2 Fuel Pump and Its Circuit Check...............................................................155 Table B-4 Idle Air Control System Check.................................................................157 Table B-5 A/C Signal Circuits Check (Vehicle with A/C)..................................................160 Table B-6 Electric Load Signal Circuit Check............................................................164 TAble B-7 Radiator Fan Control System Check.............................................................166 Table B-8 Power Steering Pressure (PSP) Switch Signal Circuit Check.....................................169 Table B-9 Generator Control Signal Circuit Check........................................................170 SECTION 6A1.....................................................................................................171 On-Vehicle Service..........................................................................................172 Cylinder Head Cover.....................................................................................172 Exhaust Manifold........................................................................................175 Engine Mountings........................................................................................177 Unit Repair Overhaul........................................................................................178 Timing Chain and Chain Tensioner........................................................................178 Required Service Material...................................................................................182 Tightening Torque Specification.............................................................................183 Special Tool................................................................................................184 SECTION 6E1.....................................................................................................187 General Description.........................................................................................189 ECM input / output circuit diagram......................................................................189 Terminal arrangement of ECM coupler (viewed from harness side)..........................................191 On-Vehicle Service..........................................................................................192 Idle speed / idle air control (IAC) duty inspection.....................................................192 Electronic Control System...............................................................................194 Engine control module (ECM).........................................................................194 Heated oxygen sensor (HO2S-1 and HO2S-2)............................................................195 Vehicle speed sensor (VSS)..........................................................................197 Emission Control System.................................................................................197 EGR system..........................................................................................197 SECTION 6K......................................................................................................199 On-Vehicle Service..........................................................................................200 Components..............................................................................................200 SECTION 7A1.....................................................................................................201 Transaxle for 4WD model.....................................................................................204 General Description.........................................................................................202 Construction and Servicing..............................................................................202 Transaxle for 2WD model.............................................................................203 Unit Repair Overhaul........................................................................................205 Transaxle Unit..........................................................................................205 Transaxle Case..........................................................................................206 Input & Counter Shaft...................................................................................207 Gear Shifter............................................................................................208 Transaxle Unit..........................................................................................209 Disassembling Unit......................................................................................211 Gear shift and select shaft assembly and fifth gears................................................211 Sub Assembly Service....................................................................................213 Counter shaft assembly..............................................................................213 Gear shift & select shaft assembly..................................................................217 Assembling Unit.........................................................................................218 Fifth gears.........................................................................................218 Gear shift and select shaft assembly................................................................222 Tightening Torque Specification.............................................................................223 SECTION 7B1.....................................................................................................225 General Description.........................................................................................227 2WD.....................................................................................................228 4WD.....................................................................................................229 Specifications..........................................................................................230 Clutch/Brake/Planetary Gear.............................................................................231 Functions...........................................................................................231 Table of Component Operation............................................................................232 Electronic Shift Control System.........................................................................233 Transmission Control Module (TCM).......................................................................235 Operation of shift solenoid valves, timing solenoid valve and TCC solenoid valve....................236 Automatic gear shift diagram for 2WD................................................................237 Automatic gear shift diagram for 4WD................................................................238 Diagnosis...................................................................................................239 General Description.....................................................................................239 On-board Diagnostic System..............................................................................239 2 driving cycle detection logic.....................................................................240 Freeze frame data...................................................................................240 Precaution in Diagnosing Trouble........................................................................242 Automatic Transaxle Diagnostic Flow Table...............................................................243 Malfunction Indicator Lamp (MIL) Check..................................................................247 “O/D OFF” Lamp Check....................................................................................247 Diagnostic Trouble Code (DTC) Check.....................................................................247 Reading DTC from ECM using SUZUKI scan tool – method-1..............................................247 Reading DTC from TCM using SUZUKI scan tool – method-2..............................................248 Displaying DTC on odometer – method-3...............................................................248 Diagnostic Trouble Code (DTC) Clearance.................................................................249 To clear DTC stored in ECM with scan tool – method- 1...............................................249 To clear DTC stored in TCM with scan tool – method-2................................................249 To clear DTC stored in TCM without scan tool – method-3.............................................249 Diagnostic Trouble Code (DTC) Table.....................................................................250 Fail Safe Table.........................................................................................253 Visual Inspection.......................................................................................255 Automatic Transaxle Basic Check.........................................................................256 Trouble Diagnosis Table.................................................................................257 Trouble diagnosis table-1...........................................................................257 Trouble diagnosis table-2...........................................................................260 Trouble diagnosis table-3...........................................................................262 Road Test...............................................................................................263 Manual Road Test........................................................................................266 Engine Brake Test.......................................................................................267 Stall Test..............................................................................................268 Time Lag Test...........................................................................................269 Line Pressure Test......................................................................................270 “P” Range Test..........................................................................................271 Diagnostic Flow Table A-1: No Gear Shift to O/D.........................................................272 Diagnostic Flow Table A-2: No Lock-Up Occurs............................................................273 Diagnostic Flow Table A-3: “O/D OFF” Lamp Circuit Check.................................................274 Diagnostic Flow Table A-4: TCM Power and Ground Circuit Check...........................................276 DTC P0705/DTC No.34 Transmission Range Sensor Circuit Malfunction.......................................277 DTC P0710/DTC No.36 or 38 Transmission Fluid Temperature Sensor Circuit Malfunction.....................280 DTC P0715/DTC No.14 Input/Turbine Speed Sensor Circuit Malfunction......................................282 DTC P0720/DTC No.31 Output Speed Sensor/VSS Circuit Malfunction.........................................284 DTC P0725/DTC No.35 Engine Speed Input Circuit Malfunction..............................................287 DTC P0741/DTC No.29 TCC Circuit Performance or Stuck Off................................................289 DTC P0743/DTC No.25 or No.26 TCC Circuit Electrical.....................................................290 DTC P0748/DTC No.41 or No.42 Pressure Control Solenoid Electrical.......................................291 DTC P0751/DTC No.17 Shift Solenoid-A/No.1 Performance or Stuck Off......................................293 DTC P0756/DTC No.28 Shift Solenoid-B/No.2 Performance or Stuck Off......................................293 DTC P0753/DTC No.21 or No.22 Shift Solenoid-A/No.1 Electrical...........................................294 DTC P0758/DTC No.23 or No.24 Shift Solenoid-B/No.2 Electrical...........................................294 DTC P0785/DTC No.13 Timing Solenoid.....................................................................296 DTC P1700/DTC No.32 or No.33 Throttle Position Signal Circuit Malfunction...............................298 DTC P1702/DTC No.52 Internal Malfunction of TCM.........................................................300 DTC P1705/DTC No.51 Engine Coolant Temperature Signal Circuit Malfunction...............................301 DTC P1730/DTC No.64 Engine Torque Signal Circuit Malfunction............................................303 DTC P1895/DTC No.27 Torque Reduction Signal Circuit Malfunction.........................................305 Scan Tool Data..........................................................................................307 Inspection of TCM and Its Circuits......................................................................311 On-Vehicle Service..........................................................................................314 Maintenance Service.....................................................................................314 Fluid level check at normal operating temperature – Hot check.......................................314 Fluid level check at room temperature – Cold check..................................................315 Fluid change........................................................................................316 A/T fluid cooler hoses..............................................................................316 Selector Lever..........................................................................................317 Select Cable............................................................................................318 Transmission Range Sensor...............................................................................320 Output Shaft Speed Sensor/VSS...........................................................................321 Input Shaft Speed Sensor................................................................................322 Throttle Position Sensor................................................................................322 Engine Coolant Temperature Sensor.......................................................................322 O/D OFF Switch..........................................................................................323 Shift Solenoid Valves, TCC Solenoid Valve and Timing Solenoid Valve.....................................323 Pressure Control Solenoid Valve.........................................................................327 Transmission Control Module (TCM).......................................................................329 Learning control initialization.....................................................................330 Brief learning......................................................................................331 Transmission Fluid Temperature Sensor...................................................................332 Differential Side Oil Seal..............................................................................333 Shift Lock Solenoid, If Equipped........................................................................334 Brake Interlock System, If Equipped.....................................................................335 Key Interlock Cable, If Equipped........................................................................336 Automatic Transmission Assembly.........................................................................339 Components..........................................................................................339 Unit Repair.................................................................................................344 Precautions.............................................................................................344 Part Inspection and Correction Table....................................................................345 Unit Disassembly........................................................................................346 Components..........................................................................................346 Disassembly/Assembly of Subassembly.....................................................................368 Oil pump assembly...................................................................................369 Direct clutch assembly..............................................................................373 Forward and reverse clutch assembly.................................................................378 2nd brake piston assembly...........................................................................386 Transaxle rear cover and O/D and 2nd coast brake piston assembly....................................388 Differential Assembly...................................................................................391 Countershaft assembly...............................................................................396 Valve body assembly.................................................................................397 Torque converter housing............................................................................399 Transaxle case......................................................................................402 Adjustment before unit assembly.....................................................................404 Unit Assembly...........................................................................................407 Tightening Torque Specification.............................................................................431 Special Tool................................................................................................432 Required Service Material...................................................................................435 SECTION 8.......................................................................................................437 Diagnosis...................................................................................................439 Interior Light (Dome, Front Spot or Luggage Compartment Light)..........................................439 Power Door Lock System with Keyless Entry System (If Equipped)..........................................439 On-Vehicle Service..........................................................................................441 Interior Light (Dome, Front Spot or Luggage Compartment Light)..........................................441 Interior light system location......................................................................441 Trunk lid switch....................................................................................441 Rear Window Defogger....................................................................................442 Defogger wire.......................................................................................442 Wipers and Washers......................................................................................445 Front wiper and washer switch.......................................................................445 Power Door Lock System with Keyless Entry System (If Equipped)..........................................448 Power door lock system with keyless entry system component location.................................448 Power door lock system operation inspection.........................................................448 Power door lock system circuit inspection...........................................................449 Keyless entry system operation inspection...........................................................451 Keyless entry system circuit inspection.............................................................451 Transmitter.........................................................................................453 Power door lock switch..............................................................................454 Door key cylinder switch (driver and passenger side)................................................454 Power door lock actuator............................................................................454 Door switch.........................................................................................454 SECTION 9.......................................................................................................455 Glass, Windows and Mirrors..................................................................................457 Quarter Window (For Wagon Model)........................................................................457 Back Door Glass (For Wagon Model).......................................................................457 Back Window (For Sedan Model)...........................................................................458 Body Structure..............................................................................................459 Back Door Assembly (For Wagon Model)....................................................................459 Trunk Lid (For Sedan Model).............................................................................459 Body Dimensions.........................................................................................462 Back door (For Wagon Model).........................................................................462 Trunk room (For Sedan Model)........................................................................462 Side body (For Wagon Model).........................................................................462 Side body (For Sedan Model).........................................................................463 Seats.......................................................................................................465 Rear Seat (For Wagon Model).............................................................................465 Rear Seat (For Sedan Model).............................................................................465 Security and Locks..........................................................................................466 Back Door Lock Assembly (For Wagon Model)...............................................................466 Trunk Lid Lock Assembly (For Sedan Model)...............................................................466 Exterior and Interior Trim..................................................................................468 Head Lining.............................................................................................468 Roof Molding............................................................................................470 Paint and Coatings..........................................................................................471 Sealant Application Areas (For Wagon Model).............................................................471 Sealant Application Areas (For Sedan Model).............................................................471 Under Coating Application Areas.........................................................................473 Anti-Corrosion Compound Application Area (For Wagon Model)..............................................475 Anti-Corrosion Compound Application Area (For Sedan Model)..............................................475 SECTION 10B.....................................................................................................477 General Description.........................................................................................479 System Components and Wiring Location View and Connectors...............................................479 System Wiring Diagram...................................................................................480 Diagnosis...................................................................................................482 DTC B1015 - Passenger Air Bag Initiator Circuit Resistance High.........................................482 DTC B1016 - Passenger Air Bag Initiator Circuit Resistance Low..........................................482 DTC B1018 - Passenger Air Bag Initiator Circuit Short to Ground.........................................482 DTC B1019 - Passenger Air Bag Initiator Circuit Short to Power Circuit..................................482 DTC B1021 – Driver Air Bag Initiator Circuit Resistance High............................................487 DTC B1022 – Driver Air Bag Initiator Circuit Resistance Low.............................................487 DTC B1024 – Driver Air Bag Initiator Circuit Short to Ground............................................487 DTC B1025 – Driver Air Bag Initiator Circuit Short to Power Circuit.....................................487 Copylight.......................................................................................................495 Bookcover....................................................................................................... 0
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