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SUZUKI RH414D WITH 8HY ENGINE LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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“Suzuki RH414D with 8HY Engine Liana Supplementary Service Manual” offers specific instructions for model-specific maintenance, enhancing the main manual for thorough care and optimal performance.
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SUZUKI RH414D WITH 8HY ENGINE LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI RH414D WITH 8HY ENGINE LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 570
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI RH414D WITH 8HY ENGINE LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Bookcover.................................................................................................................................. 1 99501-73J00-01E............................................................................................................................ 2 TOP.................................................................................................................................... 2 MANUAL LIST............................................................................................................................ 2 IMPORTANT.............................................................................................................................. 2 FOREWORD............................................................................................................................... 3 TABLE OF CONTENTS...................................................................................................................... 4 Precautions............................................................................................................................ 6 Precautions........................................................................................................................ 7 Precautions.................................................................................................................... 7 General Precautions........................................................................................................ 7 Precaution for CAN Communication System.................................................................................... 9 General Information.................................................................................................................... 10 General Information................................................................................................................ 11 General Description............................................................................................................ 11 Fasteners Information...................................................................................................... 11 Engine Identification Number............................................................................................... 13 Transmission Identification Number......................................................................................... 13 Component Location............................................................................................................. 13 Warning, Caution and Information Labels Location........................................................................... 13 Maintenance and Lubrication........................................................................................................ 15 Precautions.................................................................................................................... 15 Precautions for Maintenance and Lubrication................................................................................ 15 Scheduled Maintenance.......................................................................................................... 15 Normal Condition Schedule.................................................................................................. 15 Maintenance Recommended under Severe Driving Conditions.................................................................... 16 Repair Instructions............................................................................................................ 16 Engine Accessory Drive Belt Replacement.................................................................................... 16 Engine Camshaft Timing Belt Replacement.................................................................................... 16 Engine Oil and Oil Filter Replacement...................................................................................... 17 Engine Coolant Inspection.................................................................................................. 18 Engine Coolant Change...................................................................................................... 18 Exhaust System Inspection.................................................................................................. 18 Air Cleaner Filter Replacement............................................................................................. 18 Fuel Lines and Connections Inspection...................................................................................... 19 Fuel Filter Replacement.................................................................................................... 19 Water Draining of Fuel Filter.............................................................................................. 19 Fuel Tank Inspection....................................................................................................... 19 Manual Transaxle Oil Inspection............................................................................................ 19 Power Steering (P/S) System Inspection..................................................................................... 19 Specifications................................................................................................................. 20 Tightening Torque Specifications........................................................................................... 20 Special Tools and Equipment.................................................................................................... 20 Recommended Fluids and Lubricants.......................................................................................... 20 Engine................................................................................................................................. 22 Precautions........................................................................................................................ 26 Precautions.................................................................................................................... 26 Precautions for Engine..................................................................................................... 26 Engine General Information and Diagnosis........................................................................................... 27 Precautions.................................................................................................................... 27 Precautions on Engine Service.............................................................................................. 27 Precautions in Diagnosing Trouble.......................................................................................... 27 General Description............................................................................................................ 28 Statement on Cleanliness and Care.......................................................................................... 28 Engine Diagnosis General Description....................................................................................... 28 On-Board Diagnostic System Description..................................................................................... 28 Schematic and Routing Diagram.................................................................................................. 30 Air Intake System Diagram.................................................................................................. 30 Electronic Control System Diagram.......................................................................................... 31 Engine and Emission Control System Diagram................................................................................. 34 Component Location............................................................................................................. 35 Electronic Control System Components Location.............................................................................. 35 Diagnostic Information and Procedures.......................................................................................... 36 Engine and Emission Control System Check................................................................................... 36 Malfunction Indicator Lamp (MIL) Check..................................................................................... 38 DTC Check.................................................................................................................. 38 DTC Clearance.............................................................................................................. 39 DTC Table.................................................................................................................. 39 Scan Tool Data............................................................................................................. 43 Visual Inspection.......................................................................................................... 46 Engine Basic Inspection.................................................................................................... 47 Engine Symptom Diagnosis................................................................................................... 47 Malfunction Indicator Lamp Does Not Come ON at Ignition Switch ON (But Engine at Stop)..................................... 65 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................. 66 DTC P0001 / P0003 / P0004: Fuel Volume Regulator Circuit................................................................... 67 DTC P0002: Fuel Volume Regulator Control Circuit Performance............................................................... 68 DTC P0069 / P0235 / P0236 / P0237 / P0238: Turbo Charger Boost Sensor Circuit.............................................. 69 DTC P0089: Fuel Pressure Regulator Performance............................................................................. 71 DTC P0101 / P0102 / P0103: Mass Air Flow Circuit........................................................................... 72 DTC P0106 / P0107 / P0108: Barometric Pressure Circuit..................................................................... 73 DTC P0111 / P0112 / P0113: Intake Air Temperature Sensor Circuit........................................................... 74 DTC P0115 / P0116 / P0117 / P0118: Engine Coolant Temperature Circuit...................................................... 75 DTC P0181 / P0182 / P0183: Fuel Temperature Sensor Circuit................................................................. 76 DTC P0190 / P0192 / P0193: Fuel Rail Pressure.............................................................................. 77 DTC P0201 / P0202 / P0203 / P0204: Injector Circuit Cylinder............................................................... 78 DTC P0215: Engine Shutoff Solenoid......................................................................................... 79 DTC P0222 / P0223 / P0227 / P0228 / P2137: Throttle Position Sensor Circuit................................................ 80 DTC P0234 / P0299: Turbo Charger Boost Condition........................................................................... 81 DTC P0243 / P0245 / P0246: Turbo Charger Wastegate Solenoid................................................................ 82 DTC P0261 / P0264 / P0267 / P0270: Cylinder Circuit Low.................................................................... 83 DTC P0262 / P0265 / P0268 / P0271: Cylinder Circuit High................................................................... 84 DTC P0263 / P0266 / P0269 / P0272: Cylinder Balance........................................................................ 85 DTC P0016 / P0335 / P0336 / P0337 / P0339: Crankshaft Position Sensor Circuit.............................................. 86 DTC P0341 / P0343 / P0344: Camshaft Position Sensor Circuit................................................................ 88 DTC P0400 / P0401 / P0402: Exhaust Gas Recirculation Flow.................................................................. 89 DTC P0461 / P0462 / P0463: Fuel Level Sensor Circuit....................................................................... 90 DTC P0480 / P0485: Fan No.1 Control Circuit................................................................................ 91 DTC P0481: Fan 2 Control Circuit Malfunction............................................................................... 92 DTC P0500 / P0501 / P0502: Vehicle Speed Sensor............................................................................ 93 DTC P0532 / P0533: A/C Refrigerant Pressure Sensor Circuit................................................................. 94 DTC P0562 / P0563: System Voltage.......................................................................................... 95 DTC P0603 / P0604 / P0605 / P0606 / P1600 / P1613: ECM Internal Control Module Error....................................... 96 DTC P0650: Malfunction Indicator Lamp (MIL) Circuit........................................................................ 97 DTC P0658 / P0659: Actuator Supply Voltage Circuit......................................................................... 98 DTC P0704: Clutch Switch Input Circuit Malfunction......................................................................... 99 DTC P1110: A/C Cut Signal Circuit Malfunction..............................................................................100 DTC P1160: MAF Sensor Circuit Plausibility.................................................................................101 DTC P1163 / P1363: Knock Sensor Fault......................................................................................102 DTC P1164: Fuel Pressure Sensor Signal Fault...............................................................................103 DTC P1166: Fuel Rail Pressure Error........................................................................................104 DTC P1207: Fuel Rail Pressure Regulator Circuit Malfunction................................................................105 DTC P1349 / P1350: Pre/Post Heater Relay...................................................................................106 DTC P1351 / P1352: Pre/Post Heater Relay Circuit...........................................................................107 DTC P1536: Brake Information Fault.........................................................................................108 DTC P1601: Main Relay Control Circuit Malfunction..........................................................................109 DTC P1602: Glow Indicator Lamp Circuit Malfunction.........................................................................110 DTC P1603: Engine Coolant Temperature Output Circuit.......................................................................111 DTC P1605: Fuel Level Output Circuit.......................................................................................112 DTC P1608: ECT Warning Lamp Circuit Malfunction............................................................................113 DTC P1609: Engine Speed Output Circuit.....................................................................................114 DTC P2143 / P2144 / P2145: EGR Vent Control Circuit........................................................................115 DTC P2147 / P2148 / P2150 / P2151: Fuel Injector Circuit...................................................................116 DTC P2299: Brake Pedal Position / Accelerator Pedal Position Incompatible..................................................117 DTC P2670 / P2671: Power Supply Voltage....................................................................................118 DTC P3007 / P3008: MAF Plausibility........................................................................................119 System Check Table.........................................................................................................120 Special Tools and Equipment....................................................................................................122 Special Tool...............................................................................................................122 Aux. Emission Control Devices......................................................................................................123 Repair Instructions............................................................................................................123 Vacuum Hose and Solenoid Valves Components.................................................................................123 EGR Solenoid Valve Removal and Installation................................................................................123 EGR Solenoid Valve Inspection..............................................................................................124 Boost Pressure Control Solenoid Valve Inspection...........................................................................124 Boost Pressure Control Solenoid Valve Removal and Installation.............................................................124 Vacuum Pump Removal and Installation.......................................................................................125 Vacuum Tank Removal and Installation.......................................................................................126 Vacuum Tank Inspection.....................................................................................................126 Vacuum Hose Inspection.....................................................................................................127 EGR Valve Inspection.......................................................................................................127 Specifications.................................................................................................................128 Tightening Torque Specifications...........................................................................................128 Special Tools and Equipment....................................................................................................128 Special Tool...............................................................................................................128 Engine Electrical Devices..........................................................................................................129 Repair Instructions............................................................................................................129 Idle Speed Inspection......................................................................................................129 Engine Control Module (ECM) Removal and Installation.......................................................................129 ECM Registration...........................................................................................................129 Registration Data Check....................................................................................................130 Pre/Post Heating Control Unit Removal and Installation.....................................................................131 Glow Plug Removal and Installation.........................................................................................131 Glow Plug Inspection.......................................................................................................132 MAF Sensor Assembly with IAT Sensor Removal and Installation...............................................................132 IAT Sensor Inspection......................................................................................................133 Turbo Pressure Sensor Removal and Installation.............................................................................133 Turbo Pressure Sensor Inspection...........................................................................................134 TP Sensor Inspection.......................................................................................................134 TP Sensor Removal and Installation.........................................................................................134 ECT Sensor Removal and Installation........................................................................................135 ECT Sensor Inspection......................................................................................................135 Knock Sensor Removal and Installation......................................................................................135 Knock Sensor Inspection....................................................................................................136 CMP Sensor Removal and Installation........................................................................................136 CMP Sensor Inspection......................................................................................................136 CKP Sensor Removal and Installation........................................................................................137 CKP Sensor Inspection......................................................................................................137 Double Relay Removal and Installation......................................................................................137 Double Relay Inspection....................................................................................................138 Specifications.................................................................................................................139 Tightening Torque Specifications...........................................................................................139 Special Tools and Equipment....................................................................................................139 Special Tool...............................................................................................................139 Engine Mechanical..................................................................................................................140 Precautions....................................................................................................................140 Precaution on Crankshaft Timing Pulley.....................................................................................140 Diagnostic Information and Procedures..........................................................................................140 Compression Check..........................................................................................................140 Repair Instructions............................................................................................................142 Air Cleaner Components.....................................................................................................142 Air Cleaner Element Removal and Installation...............................................................................143 Air Cleaner Element Inspection and Cleaning................................................................................143 Air Cleaner Assembly Removal and Installation..............................................................................144 Accelerator Cable Adjustment...............................................................................................144 Intercooler Components.....................................................................................................145 Intercooler Removal and Installation.......................................................................................146 Intercooler Inspection and Cleaning........................................................................................146 Turbocharger Assembly Components...........................................................................................147 Turbocharger Assembly Removal and Installation.............................................................................148 Turbocharger Assembly Inspection...........................................................................................149 Heat Exchanger and Oil Filter Block Components.............................................................................150 Heat Exchanger and Oil Filter Block Removal and Installation...............................................................151 EGR Valve and EGR Valve Pipe Removal and Installation......................................................................152 Intake Manifold and Cylinder Head Cover Components.........................................................................153 Cylinder Head Cover Removal and Installation...............................................................................153 Intake Manifold Removal and Installation...................................................................................154 Engine Mountings Components................................................................................................156 Engine Assembly Removal and Installation...................................................................................157 Timing Belt and Belt Tensioner Components..................................................................................160 Timing Belt and Belt Tensioner Removal and Installation....................................................................160 Timing Belt and Belt Tensioner Inspection..................................................................................165 Camshaft Housing Components................................................................................................165 Camshaft Housing Assembly Removal and Installation.........................................................................166 Camshafts, Valve Rockers and Hydraulic Valve Adjuster Components...........................................................170 Camshafts, Valve Rockers and Hydraulic Valve Adjuster Removal and Installation.............................................171 Camshafts, Valve Rockers and Hydraulic Valve Adjuster Inspection...........................................................172 Valves and Cylinder Head Components........................................................................................173 Cylinder Head Assembly Removal and Installation............................................................................174 Valves and Cylinder Head Assembly Inspection...............................................................................177 Cylinder Head Assembly Disassembly and Assembly............................................................................177 Valves and Valve Guides Inspection.........................................................................................178 Cylinder Head Inspection...................................................................................................178 Cylinder Head Bolt Inspection..............................................................................................179 Lower Crankcase, Main Bearings, Crankshaft, Piston and Connecting Rod Assembly Components..................................179 Lower Crankcase, Main Bearings, Crankshaft, Piston and Connecting Rod Assembly Removal and Installation....................180 Piston and Connecting Rod Assembly Disassembly and Assembly................................................................184 Cylinders, Pistons and Piston Rings Inspection.............................................................................185 Piston Pins and Connecting Rods Inspection.................................................................................185 Crank Pin and Connecting Rod Bearings Inspection...........................................................................186 Main Bearings Inspection...................................................................................................186 Flywheel Inspection........................................................................................................186 Cylinder Block Inspection..................................................................................................186 Specifications.................................................................................................................187 Tightening Torque Specifications...........................................................................................187 Special Tools and Equipment....................................................................................................188 Recommended Service Material...............................................................................................188 Special Tool...............................................................................................................188 Engine Lubrication System..........................................................................................................191 General Description............................................................................................................191 Engine Lubrication Description.............................................................................................191 Diagnostic Information and Procedures..........................................................................................191 Oil Pressure Check.........................................................................................................191 Repair Instructions............................................................................................................192 Oil Pan and Oil Pump Strainer Components...................................................................................192 Oil Pan and Oil Pump Strainer Removal and Installation.....................................................................193 Oil Pan and Oil Pump Strainer Cleaning.....................................................................................194 Oil Pump Components........................................................................................................195 Oil Pump Removal and Installation..........................................................................................195 Oil Pressure Switch Removal and Installation...............................................................................197 Specifications.................................................................................................................198 Tightening Torque Specifications...........................................................................................198 Special Tools and Equipment....................................................................................................198 Recommended Service Material...............................................................................................198 Special Tool...............................................................................................................198 Engine Cooling System..............................................................................................................199 General Description............................................................................................................199 Cooling System Description.................................................................................................199 Coolant Description........................................................................................................199 Schematic and Routing Diagram..................................................................................................200 Coolant Circulation........................................................................................................200 Diagnostic Information and Procedures..........................................................................................201 Engine Cooling Symptom Diagnosis...........................................................................................201 Repair Instructions............................................................................................................202 Cooling System Components..................................................................................................202 Coolant Level Check........................................................................................................203 Engine Cooling System Inspection and Cleaning..............................................................................203 Coolant Replacement........................................................................................................204 Cooling Water Pipes or Hoses Removal and Installation......................................................................206 Thermostat Assembly Removal and Installation...............................................................................206 Radiator Cooling Fan Relay Inspection......................................................................................207 Radiator On-Vehicle Inspection and Cleaning................................................................................207 Radiator Removal and Installation..........................................................................................207 Radiator Cooling Fan On-Vehicle Inspection.................................................................................209 Radiator Cooling Fan Motor Removal and Installation........................................................................209 Water Pump Removal and Installation........................................................................................209 Water Pump Inspection......................................................................................................210 Specifications.................................................................................................................210 Tightening Torque Specifications...........................................................................................210 Fuel System........................................................................................................................211 Precautions....................................................................................................................211 Precautions on Fuel System Service.........................................................................................211 Precautions on Fuel System to Keep Clean...................................................................................212 Schematic and Routing Diagram..................................................................................................215 Fuel Delivery System Diagram...............................................................................................215 Repair Instructions............................................................................................................216 Fuel System Components.....................................................................................................216 Fuel Pressure Relief Confirmation Procedure................................................................................217 Fuel Leakage Check Procedure...............................................................................................217 Water Draining of Fuel Filter..............................................................................................217 Air Bleeding of Fuel System................................................................................................217 Fuel Filter and Fuel Heater Removal and Installation.......................................................................217 Fuel Heater Inspection.....................................................................................................219 Fuel Lines Inspection......................................................................................................219 Fuel Pipe Removal and Installation.........................................................................................219 High Pressure Pipes Removal and Installation...............................................................................220 Fuel Injector On-Vehicle Inspection........................................................................................224 Fuel Injector Removal and Installation.....................................................................................224 Fuel Temperature Sensor Assembly Removal and Installation..................................................................226 Fuel Temperature Sensor Inspection.........................................................................................227 Injection Pump Components..................................................................................................227 Injection Pump Removal and Installation....................................................................................228 Fuel Flow Actuator Inspection..............................................................................................230 Fuel Flow Actuator Removal and Installation................................................................................230 Common Rail (High Pressure Fuel Injection Rail) Removal and Installation...................................................231 Fuel Presser Sensor Inspection.............................................................................................232 Fuel Filler Cap Inspection.................................................................................................232 Fuel Tank Removal and Installation.........................................................................................232 Fuel Tank Inspection.......................................................................................................234 Fuel Tank Purging Procedure................................................................................................234 Fuel Tank Inlet Valve Removal and Installation.............................................................................235 Fuel Tank Inlet Valve Inspection...........................................................................................235 Fuel Level Gauge Assembly Components.......................................................................................235 Fuel Level Gauge Assembly Removal and Installation.........................................................................236 Fuel Level Gauge Assembly Inspection.......................................................................................237 Specifications.................................................................................................................238 Tightening Torque Specifications...........................................................................................238 Special Tools and Equipment....................................................................................................238 Recommended Service Material...............................................................................................238 Special Tool...............................................................................................................238 Starting System....................................................................................................................240 Schematic and Routing Diagram..................................................................................................240 Cranking System Circuit Diagram............................................................................................240 Diagnostic Information and Procedures..........................................................................................240 Cranking System Symptom Diagnosis..........................................................................................240 Cranking System Test.......................................................................................................242 Repair Instructions............................................................................................................243 Starting Motor Dismounting and Remounting..................................................................................243 Specifications.................................................................................................................243 Tightening Torque Specifications...........................................................................................243 Charging System....................................................................................................................244 General Description............................................................................................................244 Generator Description......................................................................................................244 Diagnostic Information and Procedures..........................................................................................245 Generator Symptom Diagnosis................................................................................................245 Generator Test (Undercharged Battery Check)................................................................................245 Generator Test (Overcharged Battery Check).................................................................................246 Repair Instructions............................................................................................................247 Generator Dismounting and Remounting.......................................................................................247 Generator Components.......................................................................................................248 Generator Inspection.......................................................................................................248 Generator Drive Belt Removal and Installation..............................................................................250 Generator Drive Belt Inspection............................................................................................250 Generator Drive Belt Tensioner Removal and Installation....................................................................250 Specifications.................................................................................................................251 Charging System Specifications.............................................................................................251 Tightening Torque Specifications...........................................................................................251 Special Tools and Equipment....................................................................................................251 Special Tool...............................................................................................................251 Exhaust System.....................................................................................................................252 General Description............................................................................................................252 Exhaust System Description.................................................................................................252 Repair Instructions............................................................................................................252 Exhaust System Components..................................................................................................252 Exhaust Manifold Components................................................................................................253 Exhaust Manifold Removal and Installation..................................................................................253 Catalytic Converter and Exhaust Pipe Removal and Installation..............................................................254 Specifications.................................................................................................................254 Tightening Torque Specifications...........................................................................................254 Suspension.............................................................................................................................256 Front Suspension...................................................................................................................258 Repair Instructions............................................................................................................258 Front Suspension Frame Components..........................................................................................258 Front Suspension Frame Removal and Installation............................................................................259 Front Suspension Frame Check...............................................................................................260 Front Suspension Fasteners Check...........................................................................................260 Specifications.................................................................................................................261 Tightening Torque Specifications...........................................................................................261 Driveline / Axle.......................................................................................................................262 Drive Shaft / Axle.................................................................................................................263 General Description............................................................................................................263 Front Drive Shaft Construction.............................................................................................263 Diagnostic Information and Procedures..........................................................................................263 Front Drive Shaft Symptom Diagnosis........................................................................................263 Repair Instructions............................................................................................................264 Front Drive Shaft Components...............................................................................................264 Drive Shaft Boot On-Vehicle Inspection.....................................................................................265 Front Drive Shaft Assembly Removal and Installation........................................................................265 Front Drive Shaft Disassembly and Assembly.................................................................................267 Center Shaft Disassembly and Assembly......................................................................................273 Specifications.................................................................................................................275 Tightening Torque Specifications...........................................................................................275 Special Tools and Equipment....................................................................................................275 Recommended Service Material...............................................................................................275 Special Tool...............................................................................................................275 Brakes.................................................................................................................................276 Brake Control System and Diagnosis.................................................................................................278 Precautions....................................................................................................................278 Precautions on Brake.......................................................................................................278 General Description............................................................................................................279 Brakes Construction........................................................................................................279 Front Brake Hose / Pipe Construction.......................................................................................280 Repair Instructions............................................................................................................282 Master Cylinder Components.................................................................................................282 Master Cylinder Reservoir Removal and Installation.........................................................................283 Master Cylinder Assembly Removal and Installation..........................................................................283 Master Cylinder Assembly Disassembly and Assembly..........................................................................284 Master Cylinder Assembly Inspection........................................................................................285 Brake Booster Components...................................................................................................286 Booster Operation Inspection...............................................................................................287 Brake Booster Removal and Installation.....................................................................................288 Brake Booster Inspection and Adjustment....................................................................................289 Specifications.................................................................................................................290 Tightening Torque Specifications...........................................................................................290 Special Tools and Equipment....................................................................................................290 Special Tool...............................................................................................................290 ABS................................................................................................................................291 Repair Instructions............................................................................................................291 ABS Hydraulic Unit / Control Module Assembly Components....................................................................291 ABS Hydraulic Unit / Control Module Assembly Removal and Installation......................................................292 Specifications.................................................................................................................293 Tightening Torque Specifications...........................................................................................293 Special Tools and Equipment....................................................................................................294 Special Tool...............................................................................................................294 Transmission / Transaxle...............................................................................................................296 Precautions........................................................................................................................297 Precautions....................................................................................................................297 Precautions on Transmission / Transaxle....................................................................................297 Manual Transmission/Transaxle......................................................................................................298 General Description............................................................................................................298 Manual Transaxle Construction..............................................................................................298 Diagnostic Information and Procedures..........................................................................................299 Manual Transaxle Symptom Diagnosis.........................................................................................299 Repair Instructions............................................................................................................300 Manual Transaxle Oil Change................................................................................................300 Differential Side Oil Seal Replacement.....................................................................................300 Gear Shift Control Lever and Cable Components..............................................................................301 Gear Shift Control Lever and Cable Removal and Installation................................................................302 Reverse Gear Switch Removal and Installation...............................................................................302 Reverse Gear Switch Inspection.............................................................................................302 Vehicle Speed Sensor (VSS) Removal and Installation........................................................................303 Vehicle Speed Sensor (VSS) Inspection......................................................................................303 Manual Transaxle Unit Components...........................................................................................304 Manual Transaxle Unit Dismounting and Remounting...........................................................................305 Manual Transaxle Assembly Components.......................................................................................306 Gear Shift Shaft and Fork Components.......................................................................................307 Gear Shift Shaft and Fork Inspection.......................................................................................308 Manual Transaxle Assembly Disassembly and Reassembly.......................................................................308 Manual Transaxle Assembly Inspection.......................................................................................315 Primary Shaft Left Outer Race Removal and Installation.....................................................................315 Primary Shaft Shim Adjustment..............................................................................................316 Primary Shaft and Secondary Shaft Components...............................................................................317 Primary Shaft Assembly Disassembly and Reassembly..........................................................................318 Primary Shaft Assembly Inspection..........................................................................................319 Secondary Shaft Assembly Disassembly and Reassembly........................................................................319 Secondary Shaft Assembly Inspection........................................................................................320 Differential Assembly Components...........................................................................................321 Differential Removal and Installation......................................................................................321 Differential Components....................................................................................................323 Differential Disassembly and Assembly......................................................................................323 Differential Shim Adjustment...............................................................................................324 Specifications.................................................................................................................325 Tightening Torque Specifications...........................................................................................325 Special Tools and Equipment....................................................................................................326 Recommended Service Material...............................................................................................326 Special Tool...............................................................................................................326 Clutch.............................................................................................................................328 General Description............................................................................................................328 Clutch Construction........................................................................................................328 Diagnostic Information and Procedures..........................................................................................328 Clutch System Symptom Diagnosis............................................................................................328 Repair Instructions............................................................................................................329 Clutch Pedal Inspection....................................................................................................329 Clutch Pedal Switch Removal and Installation...............................................................................329 Clutch Pedal Switch Inspection.............................................................................................330 Clutch Fluid Inspection....................................................................................................330 Clutch Fluid Pipe and Hose Components......................................................................................331 Clutch Fluid Pipe and Hose Removal and Installation........................................................................332 Clutch Fluid Pipe and Hose Inspection......................................................................................332 Clutch Master Cylinder Removal and Installation............................................................................332 Clutch Master Cylinder Components..........................................................................................333 Clutch Master Cylinder Inspection..........................................................................................334 Clutch Operating Cylinder Removal and Installation.........................................................................334 Clutch Operating Cylinder Inspection.......................................................................................334 Clutch Cover, Clutch Disc, Flywheel and Clutch Release System Components...................................................335 Clutch Cover, Clutch Disc and Flywheel Removal and Installation............................................................335 Clutch Cover, Clutch Disc and Flywheel Inspection..........................................................................337 Clutch Release System Removal and Installation.............................................................................337 Clutch Release Bearing Guide Replacement...................................................................................338 Clutch Release System Inspection...........................................................................................338 Specifications.................................................................................................................339 Tightening Torque Specifications...........................................................................................339 Special Tools and Equipment....................................................................................................339 Recommended Service Material...............................................................................................339 Special Tool...............................................................................................................339 Steering...............................................................................................................................340 Precautions........................................................................................................................341 Precautions....................................................................................................................341 Precautions on Steering....................................................................................................341 Steering General Diagnosis.........................................................................................................342 Precautions....................................................................................................................342 Precautions for Steering, Suspension, Wheels and Tires Diagnosis...........................................................342 Diagnostic Information and Procedures..........................................................................................342 Steering Symptom Diagnosis.................................................................................................342 Power Assisted Steering System.....................................................................................................343 Precautions....................................................................................................................343 P/S System Note............................................................................................................343 General Description............................................................................................................343 P/S System Description.....................................................................................................343 Diagnostic Information and Procedures..........................................................................................344 P/S System Symptom Diagnosis...............................................................................................344 Hydraulic Pressure in P/S Circuit Check....................................................................................345 Repair Instructions............................................................................................................347 P/S Fluid Leakage Check....................................................................................................347 P/S Pump Drive Belt Removal and Installation...............................................................................347 P/S Pump Drive Belt Inspection.............................................................................................347 P/S Gear Box Components....................................................................................................348 P/S Gear Box Removal and Installation......................................................................................349 Tie-Rod / Rack Boot Removal and Installation...............................................................................350 P/S Pump Components........................................................................................................352 P/S Pump Removal and Installation..........................................................................................353 P/S Pump Disassembly and Assembly..........................................................................................353 P/S Pump Inspection........................................................................................................355 Specifications.................................................................................................................356 P/S System Specification and Service Data..................................................................................356 Tightening Torque Specifications...........................................................................................357 Special Tools and Equipment....................................................................................................357 Recommended Service Material...............................................................................................357 Special Tool...............................................................................................................357 HVAC...................................................................................................................................358 Precautions........................................................................................................................361 Precautions....................................................................................................................361 Precautions on HVAC........................................................................................................361 Heater and Ventilation.............................................................................................................362 Precautions....................................................................................................................362 Precautions in Diagnosing Trouble..........................................................................................362 General Description............................................................................................................363 Additional Heater Assembly Description.....................................................................................363 On-Board Diagnostic System Description.....................................................................................364 Schematic and Routing Diagram..................................................................................................365 Heater and Ventilation Wiring Circuit Diagram..............................................................................365 Diagnostic Information and Procedures..........................................................................................366 Heater and Ventilation Symptom Diagnosis...................................................................................366 DTC Check..................................................................................................................367 DTC Clearance..............................................................................................................368 DTC Table..................................................................................................................369 Fail-Safe Table............................................................................................................371 Scan Tool Data.............................................................................................................371 DTC B1501 (No.01): Outside Air Temperature Sensor and/or its Circuit Malfunction...........................................372 DTC B1510 (No.10): Engine Coolant Temperature (ECT) Sensor and/or its Circuit Malfunction..................................372 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction...........................372 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or its Circuit malfunction..............................372 DTC B1513 (No.13): Temperature Control Actuator and/or its Circuit malfunction.............................................372 DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction................................................372 DTC B1523 (No.23): Additional Heater and/or its Circuit Malfunction........................................................372 DTC B1524 (No.24): Engine Speed Signal Circuit Malfunction.................................................................373 Inspection of HVAC Control Module and its Circuit..........................................................................373 Repair Instructions............................................................................................................377 Outside Air Temperature Sensor Removal and Installation....................................................................377 Outside Air Temperature Sensor Inspection..................................................................................377 Additional Heater Assembly Removal and Installation........................................................................377 Additional Heater Assembly On-Vehicle Inspection...........................................................................377 Additional Heater Relays Inspection........................................................................................378 Specifications.................................................................................................................378 Tightening Torque Specifications...........................................................................................378 Special Tools and Equipment....................................................................................................378 Special Tool...............................................................................................................378 Air Conditioning System............................................................................................................379 Manual Type....................................................................................................................379 Precautions................................................................................................................379 Precaution in Diagnosing Trouble.......................................................................................379 Precautions on Servicing A/C System....................................................................................379 General Description........................................................................................................381 A/C Evaporator Outlet Air Temperature Sensor Construction..............................................................381 On-Board Diagnostic System Description.................................................................................381 Schematic and Routing Diagram..............................................................................................382 Major Components of A/C System.........................................................................................382 A/C System Wiring Diagram..............................................................................................383 Diagnostic Information and Procedures......................................................................................384 A/C System Symptom Diagnosis...........................................................................................384 DTC Check..............................................................................................................386 DTC Clearance..........................................................................................................386 DTC Table..............................................................................................................387 Fail-Safe Table........................................................................................................389 Scan Tool Data.........................................................................................................389 DTC B1501 (No.01): Outside Air Temperature Sensor and/or its Circuit Malfunction.......................................390 DTC B1503 (No.03): A/C Evaporator Air Temperature Sensor and/or its Circuit Malfunction................................390 DTC B1510 (No.10): Engine Coolant Temperature (ECT) Sensor and/or its Circuit Malfunction..............................390 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction.......................391 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or its Circuit malfunction..........................391 DTC B1513 (No.13): Temperature Control Actuator and/or its Circuit malfunction.........................................391 DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction............................................391 DTC B1523 (No.23): Additional Heater and/or its Circuit Malfunction....................................................391 DTC B1524 (No.24): Engine Speed Signal Circuit Malfunction.............................................................391 Inspection of HVAC Control Module and its Circuit......................................................................391 Repair Instructions........................................................................................................395 Operation Procedure for Refrigerant Charging...........................................................................395 Heater and Cooling Unit Components.....................................................................................400 Heater and Cooling Unit Removal and Installation.......................................................................400 Condenser Assembly Removal and Installation............................................................................401 Desiccant Removal and Installation.....................................................................................402 A/C Evaporator Removal and Installation................................................................................402 A/C Evaporator Outlet Air Temperature Sensor Removal and Installation..................................................403 A/C Evaporator Outlet Air Temperature Sensor Inspection................................................................404 A/C Refrigerant Pressure Sensor Removal and Installation...............................................................404 A/C Refrigerant Pressure Sensor Inspection.............................................................................404 Outside Air Temperature Sensor Removal and Installation................................................................405 Outside Air Temperature Sensor Inspection..............................................................................405 Compressor Relay Inspection............................................................................................405 Compressor Drive Belt Removal and Installation.........................................................................405 Compressor Drive Belt Inspection.......................................................................................405 Compressor Removal and Installation....................................................................................405 Compressor Inspection..................................................................................................406 Magnet Clutch Components...............................................................................................406 Magnet Clutch Removal and Installation.................................................................................407 Specifications.............................................................................................................408 Tightening Torque Specifications.......................................................................................408 Special Tools and Equipment................................................................................................409 Recommended Service Material...........................................................................................409 Special Tool...........................................................................................................409 Automatic Type.................................................................................................................410 Precautions................................................................................................................410 Precautions in Diagnosing Trouble......................................................................................410 Precautions on Servicing A/C System....................................................................................410 General Description........................................................................................................410 A/C System Introduction................................................................................................410 On-Board Diagnostic System Description.................................................................................411 Schematic and Routing Diagram..............................................................................................412 Major Components of A/C System.........................................................................................412 A/C System Wiring Diagram..............................................................................................413 Diagnostic Information and Procedures......................................................................................414 A/C System Symptom Diagnosis...........................................................................................414 DTC Check..............................................................................................................417 DTC Clearance..........................................................................................................418 DTC Table..............................................................................................................419 Fail-Safe Table........................................................................................................422 Scan Tool Data.........................................................................................................422 DTC B1501 (No.01): Outside Air Temperature Sensor and/or its Circuit Malfunction.......................................424 DTC B1502 (No.02): Inside Air Temperature Sensor and/or its Circuit Malfunction........................................425 DTC B1503 (No.03): A/C Evaporator Air Temperature Sensor and/or its Circuit Malfunction................................426 DTC B1504 (No.04): Sunload Sensor and/or its Circuit Malfunction.......................................................427 DTC B1510 (No.10): Engine Coolant Temperature (ECT) Sensor and/or its Circuit Malfunction..............................428 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction.......................430 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or its Circuit malfunction..........................431 DTC B1513 (No.13): Temperature Control Actuator and/or its Circuit malfunction.........................................433 DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction............................................435 DTC B1523 (No.23): Additional Heater and/or Its Circuit Malfunction....................................................438 DTC B1524 (No.24): Engine Speed Signal Circuit Malfunction.............................................................440 Inspection of HVAC Control Module and its Circuit......................................................................442 Repair Instructions........................................................................................................446 Operation Procedure for Refrigerant Charging...........................................................................446 Heater and Cooling Unit Removal and Installation.......................................................................446 Condenser Assembly Removal and Installation............................................................................446 Desiccant Removal and Installation.....................................................................................446 A/C Evaporator Removal and Installation................................................................................446 A/C Evaporator Outlet Air Temperature Sensor Removal and Installation..................................................446 A/C Evaporator Outlet Air Temperature Sensor Inspection................................................................446 A/C Refrigerant Pressure Sensor Removal and Installation...............................................................446 A/C Refrigerant Pressure Sensor Inspection.............................................................................446 Compressor Relay Inspection............................................................................................446 Compressor Drive Belt Removal and Installation.........................................................................446 Compressor Drive Belt Inspection.......................................................................................446 Compressor Removal and Installation....................................................................................446 Compressor Inspection..................................................................................................446 Magnet Clutch Components...............................................................................................446 Magnet Clutch Removal and Installation.................................................................................446 Special Tools and Equipment................................................................................................447 Special Tool...........................................................................................................447 Body, Cab and Accessories..............................................................................................................448 Precautions........................................................................................................................452 Precautions....................................................................................................................452 Precautions on Body, Cab and Accessories...................................................................................452 Precautions for Body Service...............................................................................................452 Fastener Caution for Body Service..........................................................................................452 Wiring Systems.....................................................................................................................453 Precautions....................................................................................................................453 Cautions in Body Electrical System Servicing...............................................................................453 Precautions for Wiring System..............................................................................................453 General Description............................................................................................................454 Abbreviations..............................................................................................................454 Wire / Connector Color Symbols.............................................................................................454 Symbols and Marks..........................................................................................................455 How to Read Connector Layout Diagram.......................................................................................457 How to Read Connector Codes and Terminal Nos...............................................................................458 How to Read Ground Point...................................................................................................460 How to Read Power Supply Diagram...........................................................................................461 How to Read System Circuit Diagram.........................................................................................461 Harness Routing and Connector Layout Diagram...................................................................................463 Connector Layout Diagram...................................................................................................463 Engine Compartment for Connector Layout Diagram............................................................................463 Instrument Panel for Connector Layout Diagram..............................................................................465 Door, Roof for Connector Layout Diagram....................................................................................467 Floor for Connector Layout Diagram.........................................................................................468 Rear for Connector Layout Diagram..........................................................................................471 Ground Point...................................................................................................................473 Ground (earth) Point.......................................................................................................473 Power Supply Diagram...........................................................................................................475 Power Supply Diagram.......................................................................................................475 Fuses and the Protected Parts..............................................................................................477 Fuses in Main Fuse Box.....................................................................................................477 Individual Circuit Fuse Box, Supplementary Fuse Box (No. 1), Supplementary Fuse Box (No. 2)................................477 System Circuit Diagram.........................................................................................................479 System Circuit Diagram.....................................................................................................479 A-1 Cranking System Circuit Diagram........................................................................................480 A-2 Charging System Circuit Diagram........................................................................................481 A-4 Cooling System Circuit Diagram.........................................................................................482 A-5 Engine and A/C Control System Circuit Diagram..........................................................................483 A-7 Immobilizer Control System Circuit Diagram.............................................................................487 B-1 Windshield Wiper and Washer Circuit Diagram............................................................................488 B-2 Rear Wiper and Washer Circuit Diagram (Instrument Panel Switch Type)...................................................489 B-2 Rear Wiper and Washer Circuit Diagram (Column Lever Switch Type).......................................................490 B-3 Rear Defogger Circuit Diagram..........................................................................................491 B-4 Power Window Circuit Diagram...........................................................................................492 B-5 Power Door Lock Circuit Diagram........................................................................................494 B-6 Power Mirror Circuit Diagram...........................................................................................496 B-7 Horn Circuit Diagram...................................................................................................497 B-8 Seat Heater Circuit Diagram............................................................................................498 C-1 Combination Meter Circuit Diagram (Meter)..............................................................................499 C-2 Combination Meter Circuit Diagram (Indicator)..........................................................................500 C-3 Combination Meter Circuit Diagram (Warning Light)......................................................................501 D-1 Headlight System Circuit Diagram.......................................................................................503 D-2 Position, Tail and Licence Plate Light Circuit Diagram.................................................................504 D-3 Fog Light Circuit Diagram..............................................................................................505 D-4 Illumination Light Circuit Diagram.....................................................................................506 D-5 Interior Light Circuit Diagram.........................................................................................507 D-6 Turn Signal and Hazard Warning Light Circuit Diagram...................................................................508 D-7 Brake Light Circuit Diagram............................................................................................509 D-8 Back-Up Light Circuit Diagram..........................................................................................510 D-9 Headlight Beam Leveling System Circuit Diagram.........................................................................511 D-10 Rear fog light Circuit Diagram........................................................................................512 E-2 Auto A/C System Circuit Diagram........................................................................................513 E-3 PTC Heater.............................................................................................................515 F-1 Air-Bag Control System Circuit Diagram.................................................................................516 F-2 Anti-Lock Brake System Circuit Diagram.................................................................................518 G-1 Radio / Cigar Lighter Circuit Diagram..................................................................................520 G-2 Clock Circuit Diagram..................................................................................................522 List of Connectors.............................................................................................................523 List of Connectors.........................................................................................................523 C Connector................................................................................................................523 D Connector................................................................................................................524 E Connector................................................................................................................524 G Connector................................................................................................................526 J Connector................................................................................................................527 K Connector................................................................................................................528 L Connector................................................................................................................528 M Connector................................................................................................................530 O Connector (for 5 Door)...................................................................................................530 Instrumentation / Driver Info. / Horn..............................................................................................531 Schematic and Routing Diagram..................................................................................................531 Combination Meter Circuit Diagram..........................................................................................531 Diagnostic Information and Procedures..........................................................................................532 Speedometer and VSS Symptom Diagnosis......................................................................................532 Fuel Meter Symptom Diagnosis...............................................................................................532 Low Fuel Warning Light Symptom Diagnosis...................................................................................533 Oil Pressure Warning Light Symptom Diagnosis...............................................................................533 High Engine Coolant Temperature Warning Light Symptom Diagnosis............................................................533 Information Display (If Equipped) Symptom Diagnosis........................................................................534 Repair Instructions............................................................................................................535 Fuel Level Sensor Removal and Installation.................................................................................535 Fuel Level Sensor Inspection...............................................................................................535 Oil Pressure Switch Removal and Installation...............................................................................535 Oil Pressure Switch On-Vehicle Inspection..................................................................................535 VSS Removal and Installation...............................................................................................535 VSS Inspection.............................................................................................................535 Engine Coolant Temperature (ECT) Sensor Inspection.........................................................................535 Body Structure.....................................................................................................................536 Specifications.................................................................................................................536 Body Dimensions............................................................................................................536 Control systems........................................................................................................................546 Immobilizer Control System.........................................................................................................547 Precautions....................................................................................................................547 Precautions in Diagnosing Troubles.........................................................................................547 Precautions in Replacing ECM or Immobilizer Control Module.................................................................547 Precautions in Handling Immobilizer Control System.........................................................................547 General Description............................................................................................................548 Immobilizer Control System Introduction....................................................................................548 Immobilizer Control System Components Location.............................................................................549 On-Board Diagnostic System Description (Self- diagnosis Function)..........................................................549 Schematic and Routing Diagram..................................................................................................550 Immobilizer Control System Wiring Circuit Diagram..........................................................................550 Diagnostic Information and Procedures..........................................................................................551 Immobilizer Control System Check...........................................................................................551 Diagnostic Trouble Code (DTC) Check........................................................................................551 Diagnostic Trouble Code (DTC) Table........................................................................................552 Scan Tool Data.............................................................................................................552 Communication Error between Immobilizer Control Module and SUZUKI Scan Tool................................................553 DTC B1000: Transponder EEPROM Malfunction..................................................................................555 DTC B1001: Transponder Code Error..........................................................................................555 DTC B4002: Transponder Antenna Malfunction.................................................................................557 DTC B1003: Coil Antenna Malfunction........................................................................................559 DTC B1004: Immobilizer Control Module EEPROM Malfunction:..................................................................560 DTC B3005: Short to Ground Circuit in Wire Connection Between Immobilizer Indicator Lamp and Immobilizer Control Module....561 DTC B4005: Open in Wire Connection Between Immobilizer Indicator Lamp and Immobilizer Control Module.......................561 DTC B4006: Open in Wire Connection Between Standby LED and Immobilizer Control Module......................................562 DTC U1007: CAN Communication Error between Immobilizer Control Module and ECM..............................................563 DTC U1008: Open or Short in CAN Communication Lines between Immobilizer Control Module and ECM.............................564 Inspection of Immobilizer Control Module and Its Circuit...................................................................565 Repair Instructions............................................................................................................566 Immobilizer Control Module Removal and Installation........................................................................566 Coil Antenna Removal and Installation......................................................................................566 Coil Antenna Inspection....................................................................................................567 Registration of Transponder Code in Ignition Key...........................................................................567 Procedure after Immobilizer Control Module Replacement.....................................................................567 Procedure after ECM Replacement............................................................................................567 Special Tools and Equipment....................................................................................................568 Special Tool...............................................................................................................568 COPYRIGHT..............................................................................................................................569 BOOKCOVER..............................................................................................................................570
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