Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 2 When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
Page 4 Table of Contents GENERAL INFORMATION General Information Maintenance and Lubrication STEERING AND SUSPENSION Electrical Power Steering (EPS) System (If Equipped) 3B1 BRAKE SYSTEM Antilock Brake System (ABS) ENGINE Engine Engine and Emission Control System Ignition System (Electronic Ignition System) TRANSMISSION AND Automatic Transmission (4 A/T) DIFFERENTIAL ELECTRICAL SYSTEM...
Page 6: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION NOTE: For descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual. CONTENTS Precautions............0A-2 Diagnosis ..........0A-2 Servicing and handling......0A-3 Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System..0A-2 Warning, Caution and Information Labels..0A-6...
Page 7: Precautions
• If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
Page 8: Servicing And Handling
GENERAL INFORMATION 0A-3 Servicing and handling WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger and Side Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise.
Page 9 0A-4 GENERAL INFORMATION WARNING: • For handling and storage of a SDM, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise. • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM.
Page 10 GENERAL INFORMATION 0A-5 CAUTION: • Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys- tem parts and other related parts according to instructions under “REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT” in Section 10B as well as when air bag is deployment. •...
Page 11: Warning, Caution And Information Labels
0A-6 GENERAL INFORMATION Warning, Caution and Information Labels 1. Air bag caution label on back side of engine hood 6. Air bag caution label on combination switch and contact coil assembly 2. Air bag caution label on sun visor (for vehicle with air bag system) 7.
Page 12 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 13 0B-2 MAINTENANCE AND LUBRICATION Maintenance Schedule Maintenance Recommended under Severe Driving Conditions If the vehicle is usually used under the conditions corresponding to any severe condition code given below, IT IS RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the following table.
Page 14: Maintenance And Lubrication 0B
MAINTENANCE AND LUBRICATION 0B-3 NOTE: • “R” : Replace or change • “I” : Inspect and correct or replace if necessary • *1 : Inspect or replace more frequently if necessary. • *2 : Clean or replace more frequently if the air from the ventilator decreases.
Page 15 0B-4 MAINTENANCE AND LUBRICATION...
Page 16 However, bear the following in mind when checking DTC (Diagnostic Trouble Code). Be sure to use SUZUKI scan tool whenever checking DTC because this vehicle has no monitor con- nector for Electrical power steering system and DTC can not be displayed by EPS warning lamp flash-...
Page 17 3B1-2 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED)
Page 18 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 19 DTC C1045 – Left-Front Inlet Solenoid Precautions..........5E-31 Circuit............5E-26 ABS Hydraulic Unit Operation Check DTC C1051 – Right-Rear Inlet Solenoid (Using SUZUKI Scan Tool)......5E-31 Circuit............5E-26 ABS Hydraulic Unit/Control Module DTC C1055 – Left-Rear Inlet Solenoid Assembly ............ 5E-32 Circuit............
Page 20: General Description
ANTILOCK BRAKE SYSTEM (ABS) 5E-3 General Description Components and Parts Location The ABS (Antilock Brake System) controls the fluid pressure applied to the Wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This ABS has also the following function.
Page 21: System Schematic
5E-4 ANTILOCK BRAKE SYSTEM (ABS) System Schematic INPUT OUTPUT Wheel speed sensor (LF) Hydraulic unit Wheel speed sensor (LR) Pump motor Pump motor Wheel speed sensor (RF) relay ABS control Wheel speed sensor (RR) module Stop lamp switch Fail-safe G sensor relay Battery Voltage LF inlet solenoid...
Page 22: Abs Hydraulic Unit/Control Module Assembly
ANTILOCK BRAKE SYSTEM (ABS) 5E-5 ABS Hydraulic Unit/Control Module Assembly ABS control module is a component of ABS hydraulic unit/control module assembly and has the following functions. Self-diagnosis function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the ABS warning lamp (1) as described below.
Page 23: System Circuit
5E-6 ANTILOCK BRAKE SYSTEM (ABS) System Circuit...
Page 24 ANTILOCK BRAKE SYSTEM (ABS) 5E-7 1. Battery 9. ABS hydraulic unit/control module assembly 17. Left-rear wheel speed sensor 2. Main fuses 10. Terminal arrangement of ABS hydraulic unit/con- 18. Right-front wheel speed sensor trol module assembly 3. Ignition switch 11. ABS fail-safe relay (Solenoid valve relay) 19.
Page 25: Diagnosis
5E-8 ANTILOCK BRAKE SYSTEM (ABS) Diagnosis To ensure that the trouble diagnosis is done accurately and smoothly, observe “PRECAUTIONS IN DIAGNOSING TROU- BLES” and follow “ABS DIAGNOSTIC FLOW TABLE”. Precaution in Diagnosing Troubles • If the vehicles was operated in any of the following ways, ABS warning lamp may light momentarily but this does not indicate anything abnormal in ABS.
Page 26: Abs Diagnostic Flow Table
ANTILOCK BRAKE SYSTEM (ABS) 5E-9 ABS Diagnostic Flow Table Refer to the following pages for the details of each step. Step Action 1) Perform “Customer Complaint Analysis”. Go to Step 2. Go to Step 5. 2) Perform “Problem Symptom Confirmation”. 3) Perform “Diagnostic Trouble Code Check, Record and Clearance”.
Page 27 5E-10 ANTILOCK BRAKE SYSTEM (ABS) 1) MALFUNCTION ANALYSIS a) Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 28 ANTILOCK BRAKE SYSTEM (ABS) 5E-11 c) Diagnostic Trouble Code (DTC) Check, Record and Clearance Perform “DIAGNOSTIC TROUBLE CODE CHECK” procedure in this section, record it and then clear it referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section. If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again when the ignition switch is turned ON, attempt to diagnose the trouble based on the DTC recorded in this step may mislead the diagnosis or make diagnosing difficult.
Page 29: Abs Warning Lamp Check
5E-12 ANTILOCK BRAKE SYSTEM (ABS) ABS Warning Lamp Check 1) Turn ignition switch ON. 2) Check that ABS warning lamp (1) comes ON for about 2 sec- onds and then goes off. If any faulty condition is found, advance to Diagnostic Flow Table-A, B, or C.
Page 30: Ignition Switch
ANTILOCK BRAKE SYSTEM (ABS) 5E-13 Table – A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON 1. Main fuse 5. ABS warning lamp 9. Brake fluid level switch 2. Ignition switch 6. Brake warning lamp 10.
Page 31: Table – B Abs Warning Lamp Circuit Check – Lamp Comes "On" Steady
Action Perform diagnostic trouble code check. Is there Go to Step 2. Go to Step 3. any DTC (NO CODES on SUZUKI scan tool) exists? Does malfunction DTC exist at Step 1? Go to Step 7 of “ABS Go to Step 3.
Page 32: While Ignition Switch Is
ANTILOCK BRAKE SYSTEM (ABS) 5E-15 Table – C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously While Ignition Switch is ON 1. “ABS” warning lamp in combination meter 3. ABS hydraulic unit/control module connector 2. ABS hydraulic unit/control module assembly INSPECTION Step Action...
Page 33: On" Steady
5E-16 ANTILOCK BRAKE SYSTEM (ABS) Table – D EBD Warning Lamp (Brake Warning Lamp) Check – Lamp Comes “ON” Steady CIRCUIT DESCRIPTION EBD warning lamp (Brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS control module/hydraulic unit assembly through lamp driver module in combination meter.
Page 34: Diagnostic Trouble Code (Dtc) Check (Using Suzuki Scan Tool)
(A) : SUZUKI scan tool 2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. NOTE: If SUZUKI scan tool cannot display DTC, perform “SERIAL DATA LINK CIRCUIT CHECK”...
Page 35: Serial Data Link Circuit Check
5E-18 ANTILOCK BRAKE SYSTEM (ABS) Serial Data Link Circuit Check CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table. 1. “ABS” warning lamp in combination meter 3. Data link connector (DLC) 5. To ECM, TCM, P/S control module and SDM 2.
Page 36 Go to Step 2. Go to “ABS DIAGNOSTIC TABLE” performed? CHECK FLOW TABLE” in this section. 1) Make sure that SUZUKI scan tool is free Go to Step 3. Properly connect SUZUKI from malfunction and correct cartridge for scan tool to DLC.
Page 37: Diagnostic Trouble Code (Dtc) Table
5E-20 ANTILOCK BRAKE SYSTEM (ABS) Diagnostic Trouble Code (DTC) Table CAUTION: Be sure to perform “ABS DIAGNOSTIC FLOW TABLE” before starting diagnosis. DIAGNOSTIC ITEMS (displayed on SUZUKI scan tool) NO DTC Normal C1013 ABS control module C1015 G sensor circuit...
Page 38: Dtc C1013 - Incorrect Abs Control Module Installed
ANTILOCK BRAKE SYSTEM (ABS) 5E-21 DTC C1013 – Incorrect ABS Control Module Installed DESCRIPTION When abnormal signal is inputted to a no-used terminal of control module while running or incorrect ABS hydraulic unit/control module assembly is installed, this DTC will be set. NOTE: When ABS hydraulic unit/control module assembly for 2WD vehicle is installed to 4WD vehicle, this DTC is set.
Page 39 5E-22 ANTILOCK BRAKE SYSTEM (ABS) INSPECTION Step Action Is G sensor installed floor securely? Go to Step 2. Tighten sensor or bracket screw securely. If not, using new screw. 1) Ignition switch OFF. Go to Step 3. Replace G sensor. 2) Remove G sensor with bracket.
Page 40: Dtc C1021, Dtc C1022 - Right-Front Wheel Speed Sensor Circuit Or Sensor Ring
ANTILOCK BRAKE SYSTEM (ABS) 5E-23 DTC C1021, DTC C1022 – Right-Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1025, DTC C1026 – Left-Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1031, DTC C1032 – Right-Rear Wheel Speed Sensor Circuit or Sensor Ring DTC C1035, DTC C1036 –...
Page 41 5E-24 ANTILOCK BRAKE SYSTEM (ABS) NOTE: When the vehicle was operated in any of the following ways, one of these DTCs may be set even when the sensor is in good condition. If such possibility is suspected, repair the trouble (dragging of brake, etc.) of the vehicle, clear DTC once and then after performing the driving test as described in Step 2 of “ABS DIAGNOSIS FLOW TABLE”, check whether or not any abnormality exists.
Page 42 ANTILOCK BRAKE SYSTEM (ABS) 5E-25 Step Action 1) Install ABS wheel speed sensor to knuckle. Go to Step 7. Replace ABS wheel 2) Tighten sensor bolt to specified torque and check that speed sensor. there is no clearance between sensor and knuckle. Is it OK? Referring to “Reference”...
Page 43: Dtc C1041 - Right-Front Inlet Solenoid Circuit
5E-26 ANTILOCK BRAKE SYSTEM (ABS) DTC C1041 – Right-Front Inlet Solenoid Circuit DTC C1045 – Left-Front Inlet Solenoid Circuit DTC C1051 – Right-Rear Inlet Solenoid Circuit DTC C1055 – Left-Rear Inlet Solenoid Circuit DTC C1042 – Right-Front Outlet Solenoid Circuit DTC C1046 –...
Page 44: Dtc C1057 - Power Source Circuit
ANTILOCK BRAKE SYSTEM (ABS) 5E-27 DTC C1057 – Power Source Circuit 1. Ignition switch 3. ABS hydraulic unit/control module assembly 2. Main fuse 4. ABS hydraulic unit/control module connector DESCRIPTION The ABS control module monitors the power source voltage at terminal “E20-18”. When the power source volt- age becomes extremely high or low, this DTC will be set.
Page 45: Dtc C1061 - Abs Pump Motor Circuit
5E-28 ANTILOCK BRAKE SYSTEM (ABS) DTC C1061 – ABS Pump Motor Circuit 1. ABS hydraulic unit/control module assembly 3. ABS pump motor 5. ABS hydraulic unit/control module connector 2. ABS pump motor relay 4. ABS fail safe relay DESCRIPTION The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the igni- tion switch turned ON.
Page 46: Dtc C1063 - Abs Fail-Safe Relay Circuit
ANTILOCK BRAKE SYSTEM (ABS) 5E-29 DTC C1063 – ABS Fail-Safe Relay Circuit 1. Ignition switch 3. ABS hydraulic unit/control module connector 5. To pump motor relay 2. ABS hydraulic unit/control module assembly 4. To solenoid valves 6. Fail-safe relay DESCRIPTION ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned ON.
Page 47: Dtc C1071 - Abs Control Module
5E-30 ANTILOCK BRAKE SYSTEM (ABS) DTC C1071 – ABS Control Module 1. ABS hydraulic unit/control module assembly 3. ABS pump motor 5. ABS hydraulic unit/control module connector 2. ABS pump motor relay 4. ABS fail safe relay DESCRIPTION This DTC will be set when an internal malfunction is detected in the ABS control module. INSPECTION Step Action...
Page 48: On-Vehicle Service
5) Turn each wheel gradually by hand to check if brake drag- ging occurs. If it does, correct. 6) Remove steering column hole cover. 7) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool...
Page 49: Abs Hydraulic Unit/Control Module Assembly
5E-32 ANTILOCK BRAKE SYSTEM (ABS) ABS Hydraulic Unit/Control Module Assembly CAUTION: Never disassemble ABS hydraulic unit/control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit/ control module assembly. 1.
Page 50 ANTILOCK BRAKE SYSTEM (ABS) 5E-33 3) Disconnect ABS hydraulic unit/control module assembly con- nector (1) by pulling up lock (2). 4) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit/control module assembly (3). Special tool : 09950-78220 NOTE:...
Page 51: Front Wheel Speed Sensor
5E-34 ANTILOCK BRAKE SYSTEM (ABS) Front Wheel Speed Sensor 1. Left front wheel speed sensor 3. Grommet 5. Sensor ring 2. Clamp bolt 4. Connector OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch OFF. 2) Hoist vehicle a little. 3) Disconnect wheel speed sensor connector. 4) Disconnect wheel speed sensor grommet from vehicle body.
Page 52 ANTILOCK BRAKE SYSTEM (ABS) 5E-35 Reference When using oscilloscope for this check, check if peak-to-peak voltage (1) meets specification and waveform is complete. Peak-to-peak voltage at 1 to 1 1/3 rotation per second : 280 mV or more at 43 – 57 Hz REMOVAL 1) Disconnect negative cable at battery.
Page 53: Front Wheel Speed Sensor Ring
5E-36 ANTILOCK BRAKE SYSTEM (ABS) INSTALLATION 1) Check that no foreign material is attached to sensor (1) and sensor ring (2). 2) Install it by reversing removal procedure. Tightening torque Front wheel speed sensor bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) CAUTION: Do not pull or twist wire harness more than necessary when installing front wheel speed sensor.
Page 54: Rear Wheel Speed Sensor
ANTILOCK BRAKE SYSTEM (ABS) 5E-37 Rear Wheel Speed Sensor 1. Left rear wheel sensor 3. Sensor ring 5. Right rear wheel sensor 7. Forward [A] : For 2WD 2. Trailing arm 4. Sensor coupler 6. Rear axle housing 8. Vehicle inside [B] : For 4WD OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch OFF.
Page 55 5E-38 ANTILOCK BRAKE SYSTEM (ABS) Reference When using oscilloscope for this check, check if peak-to-peak voltage (1) meets specification and waveform is complete. Peak-to-peak voltage at 1 to 1 1/3 rotation per second 280 mV or more at 20 Hz REMOVAL 1) Disconnect negative cable from battery.
Page 56: Rear Wheel Speed Sensor Ring (For 2Wd Vehicle)
ANTILOCK BRAKE SYSTEM (ABS) 5E-39 INSTALLATION 1) Check that no foreign material is attached to sensor (1) and ring. 2) Reverse removal procedure for installation noting the follow- ing. • There is another bolt hole (2) that is fit for wheel speed sen- sor bolt by proper bolt hole (3).
Page 57: G Sensor (For 4Wd Vehicle Only)
5E-40 ANTILOCK BRAKE SYSTEM (ABS) G Sensor (For 4WD Vehicle Only) REMOVAL 1) Turn ignition switch OFF and disconnect battery negative cable. 2) Remove center console box. 3) Remove G sensor (1) from floor. 4) Disconnect connector from sensor. CAUTION: Sensor must not be dropped or shocked.
Page 58: Special Tool
ANTILOCK BRAKE SYSTEM (ABS) 5E-41 Special Tool 09931-76011 09931-76030 09950-78220 Tech 1A kit (SUZUKI scan Mass storage cartridge for 16/14 pin DLC cable for Flare nut wrench (10 mm) tool) See NOTE “A” Tech 1A Tech 1A below. Tech 2 kit (SUZUKI scan tool) See NOTE “B”...
Page 59 5E-42 ANTILOCK BRAKE SYSTEM (ABS)
Page 60 However, bear the following in mind when checking DTC (Diagnostic Trouble Code). Be sure to use SUZUKI scan tool whenever checking DTC because this vehicle has no monitor con- nector for Engine and emission control system and DTC can not be displayed by malfunction indica-...
Page 61 6-2 ENGINE...
Page 62 However, bear the following in mind when checking DTC (Diagnostic Trouble Code). Be sure to use SUZUKI scan tool whenever checking DTC because this vehicle has no monitor con- nector for Engine and emission control system and DTC can not be displayed by malfunction indica-...
Page 63 6E-2 ENGINE AND EMISSION CONTROL SYSTEM...
Page 64 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 65: General Description
6F1-2 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) General description The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 66: Diagnosis
IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-3 SYSTEM WIRING DIAGRAM 1. Ignition switch 7. No.1 spark plug 2. Main relay 8. No.2 spark plug 3. Ignition coil assembly for No.1 and No.4 spark plugs 9. No.3 spark plug 4. Ignition coil assembly for No.2 and No.3 spark plugs 10.
Page 67 6F1-4 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) IGNITION SYSTEM DIAGNOSTIC FLOW TABLE Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in section Ignition Spark Test Go to Step 11. Go to Step 3. 1) Check all spark plugs for condition and type referring to “Spark Plugs”...
Page 68: On-Vehicle Service
IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-5 On-vehicle service Ignition spark test 1) Disconnect all injector couplers (1) from injectors. WARNING: Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room. 2) Remove spark plug and check it for condition and type refer- ring to “Spark Plugs”...
Page 69: Spark Plugs
6F1-6 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 5) Install high-tension cords (2) to spark plugs and ignition coil assemblies (1) while gripping each cap. CAUTION: • Never attempt to use metal conductor high-tension cords as replacing parts. • Insert each cap portion fully when installing high-ten- sion cords.
Page 70: Ignition Coil Assembly (Including Ignitor)
IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-7 Ignition coil assembly (including ignitor) Inspection 1) Disconnect negative cable at battery. 2) Pull out ignition coil cover (4). 3) Disconnect ignition coil coupler. 4) Disconnect high-tension cord (3) from ignition coil assembly (2). 5) Remove ignition coil bolts (1) and then pull out ignition coil assembly.
Page 71 6F1-8 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) INSPECTION 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. Special tool (A): SUZUKI scan tool 2) Start engine and warm it up to normal operating tempera- ture. 3) Make sure that all of electrical loads except ignition are switched off.
Page 72: Special Tools
Special tools 09931-76011 09931-76030 Tech 1A kit (SUZUKI scan Mass storage cartridge for 16/14 pin DLC adapter for Tech 2 kit (SUZUKI scan tool) tool) (See NOTE “A”.) Tech 1A Tech 1A (See NOTE “B”.) NOTE: • “A” : This kit includes the following items and substitutes for the Tech 2 kit.
Page 73 6F1-10 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
Page 74 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 75 7B-2 AUTOMATIC TRANSMISSION (4 A/T) DTC P1709 Engine coolant Fluid level at room temperature ....7B-52 temperature/barometric pressure Fluid change ........... 7B-52 signal circuit ..........7B-47 Transmission Control Module (TCM)..7B-53 DTC P0702/P1702 Transmission Learning control initialization....7B-55 control system electrical or internal Tightening Torque Specification....
Page 76: General Description
AUTOMATIC TRANSMISSION (4 A/T) 7B-3 General Description This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type equipped with lock-up mechanism. The gear shift device consists of 2 sets of planetary gear units, sets of 3 disc type clutches, 3sets of disc type brakes and one- way clutch.
Page 77: Specifications
7B-4 AUTOMATIC TRANSMISSION (4 A/T) Specifications Item Specifications Torque Type 3-element, 1-step, 2-phase type converter Stall torque ratio 1.65 – 1.85 Type Internal gear type oil pump Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type “P”...
Page 78: Functions
AUTOMATIC TRANSMISSION (4 A/T) 7B-5 Functions NOTE: For operation of each part, refer to TABLE OF COMPONENT OPERATION. PART NAME FUNCTION Rear clutch Meshes input shaft and rear sun gear through one-way clutch. Front clutch Meshes input shaft and front internal gear and rear carrier. Overdrive brake Fixes rear sun gear.
Page 79: Electronic Shift Control System
20. Suzuki scan tool J. Blank sensor) 7. TCC solenoid (Lock-up solenoid) 21. Ignition switch K. Serial communication with Suzuki scan tool 8. Shift solenoid-A (Shift solenoid No.1) 22. Battery L. Power supply 9. Shift solenoid-B (Shift solenoid No.2) 23. A/T relay M.
Page 80: Transmission Control Module (Tcm)
AUTOMATIC TRANSMISSION (4 A/T) 7B-7 Transmission control module (TCM) TCM is an electronic circuit component that controls gear shift, idle-up according to the signal from each sensor. Also it has learning control function for performing optimum control. It is a microcomputer consisting of an IC, transistor, diode, etc.
Page 81: Fail Safe Function
7B-8 AUTOMATIC TRANSMISSION (4 A/T) Fail safe function This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The table below shows the fail safe function for each fail condition of sensor, solenoid or its circuit. Area Detecting condition Fail safe function...
Page 82 AUTOMATIC TRANSMISSION (4 A/T) 7B-9 Area Detecting condition Fail safe function “P” range → P, “R” range → R, “N” range → N, A/T hardware itself Difference in detected (DTC P0730) revolution between “D”/“2”/“L” range “To be controlled as follows : input shaft speed 1) When detecting trouble at first, gear is selected well-suited sensor and output...
Page 83: Operation Of Shift Solenoid Valves And Tcc Solenoid Valve
7B-10 AUTOMATIC TRANSMISSION (4 A/T) Area Detecting condition Fail safe function Throttle position No or abnormal throt- • Scheduling of automatic gear shift is performed as throttle signal circuit tle opening signal is valve opening is 0%. (DTC P1700) inputted •...
Page 84: Automatic Gear Shift Diagram
AUTOMATIC TRANSMISSION (4 A/T) 7B-11 Automatic gear shift diagram Automatic shift schedule as a result of shift control is shown below. Shift Throttle opening 1→2 2→3 3→4 4→3 3→2 2→1 Full throttle (km/h) – Closed throttle (km/h) Gear Shift Diagram TCC Lock-up Diagram...
Page 85: Diagnosis
7B-12 AUTOMATIC TRANSMISSION (4 A/T) Diagnosis This vehicle is equipped with an electronic transmission control system, which controls the automatic shift up and shift down timing, etc. suitably to vehicle driving conditions. When diagnosing a trouble in the transmission including this system, follow “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE”...
Page 86 AUTOMATIC TRANSMISSION (4 A/T) 7B-13 Step Action Automatic Transmission Basic Check and Trou- Go to Step 11. 1) Check repair ble Diagnosis Table malfunction part(s). 1) Check and repair according to “A/T BASIC 2) Go to Step 11. CHECK” and “TROUBLE DIAGNOSIS TABLE”...
Page 87 7B-14 AUTOMATIC TRANSMISSION (4 A/T) 1. Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 88 DTC in this step may mislead the diagnosis or make diagnosing difficult. Even after checking the DTC with the SUZUKI scan tool, diagnosis should be performed according to this flow chart to check TCM for proper self- diagnosis function.
Page 89 7B-16 AUTOMATIC TRANSMISSION (4 A/T) 8. Automatic Transmission Basic Check and Trouble Diagnosis Table Perform basic automatic transmission check according to the list below first. When the end of the list has been reached, check the part of system suspected as a possible cause referring to “TROUBLE DIAGNOSIS TABLE” and based on symptoms appearing on vehicle (symptoms obtained through steps of customer complaint analy- sis, trouble symptom confirmation and/or A/T basic check) and repair or replace faulty parts, if any.
Page 90: Trouble Diagnosis Table
AUTOMATIC TRANSMISSION (4 A/T) 7B-17 Trouble Diagnosis Table NOTE: For the inspection of throttle position sensor, refer to “TP SENSOR” in Section 6E. Trouble diagnosis table-1 Electrical Repair Condition Possible Cause Correction 1st → 2nd • Output shaft speed sensor or its circuit faulty Inspect output shaft speed sen- 2nd →...
Page 91: Trouble Diagnosis Table-2
7B-18 AUTOMATIC TRANSMISSION (4 A/T) Trouble diagnosis table-2 Mechanical Repair Condition Possible Cause Correction Vehicle does not move • Manual valve faulty Clean or replace. at any range • Primary regulator valve faulty Clean or replace. 1st ↔ 2nd • Shift solenoid -D (No.4) and/or -E (No.5) stuck Clean or replace. 2nd ↔...
Page 92: Stall Test
AUTOMATIC TRANSMISSION (4 A/T) 7B-19 Stall test This test is to check overall performance of automatic transmis- sion and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transmission fluid is at nor- mal operating temperature and its level is between FULL and LOW marks.
Page 93: Time Lag Test
7B-20 AUTOMATIC TRANSMISSION (4 A/T) Time lag test This test is to check conditions of clutch, reverse brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) With chocks placed in front and behind front and rear wheels respectively, depress brake pedal.
Page 94: Line Pressure Test
AUTOMATIC TRANSMISSION (4 A/T) 7B-21 Line pressure test Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following conditions. • Automatic fluid is at normal operating temperature (70 – 80°C /158 –...
Page 95: Engine Brake Test
7B-22 AUTOMATIC TRANSMISSION (4 A/T) Engine brake test WARNING: Before test, make sure that there is no vehicle behind so as to pre- vent rear-end collision. 1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake operates.
Page 96: Electronic Control System Diagnosis
(MIL) (1) does not come on although TCM detects malfunction of automatic transmission system. • Using SUZUKI scan tool (3), diagnostic trouble code (DTC) stored in TCM memory can be checked and cleared as well. Before its use, be sure to read Operator’s (instruction) Man- ual supplied with it carefully to have good understanding of its functions and usage.
Page 97: Dtc Check
3) Turn ignition switch ON. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. 5) After completing the check, turn ignition switch OFF and dis- connect SUZUKI scan tool from data link connector (DLC) (1).
Page 98: Dtc Table
AUTOMATIC TRANSMISSION (4 A/T) 7B-25 DTC table DTC NO. DETECTING ITEMS Vehicle equipped Vehicle equipped with EGR valve without EGR valve P0715 Input/Turbine speed sensor circuit malfunction 1 driving cycle Not applicable P0730 Incorrect gear ratio 2 driving cycles Not applicable P0753 Shift solenoid-A (No.1) electrical 1 driving cycle...
Page 99: Tcm Power And Ground Circuit Check
7B-26 AUTOMATIC TRANSMISSION (4 A/T) TCM power and ground circuit check 1. Battery 4. Circuit fuse (IG) 7. TCM 2. Main fuse 5. Ground 3. Ignition switch 6. A/T relay DTC DETECTING CONDITION • Automatic transmission doesn’t shift to 1st gear at vehicle start in “D” range. Step Action 1) Disconnect TCM coupler with ignition switch...
Page 100: Dtc P0715 Input/Turbine Speed Sensor Circuit Malfunction
AUTOMATIC TRANSMISSION (4 A/T) 7B-27 DTC P0715 Input/turbine speed sensor circuit malfunction 1. Input shaft speed sensor 2. TCM couplers (viewed from harness side) 3. TCM DTC DETECTING CONDITION • Input shaft speed sensor signal voltage too high or too low. Step Action Was “AUTOMATIC TRANSMISSION DIAGNOSTIC...
Page 101 7B-28 AUTOMATIC TRANSMISSION (4 A/T) Figure for Step 2 1. Output shaft speed sensor - Input shaft speed sensor coupler 2. Input shaft speed sensor terminal Figure for Step 4...
Page 102: Dtc P0730 Incorrect Gear Ratio
AUTOMATIC TRANSMISSION (4 A/T) 7B-29 DTC P0730 Incorrect gear ratio 1. Input shaft speed sensor 4. Shield wire 2. Output shaft speed sensor 5. TCM couplers (viewed from harness side) 3. TCM DTC DETECTING CONDITION • Difference in detected revolution between input shaft speed sensor and output shaft speed sensor too wide. Step Action Check if DTC P0730 displayed with DTC...
Page 103 7B-30 AUTOMATIC TRANSMISSION (4 A/T) Figure for Step 2 Figure for Step 3 1. Output shaft speed sensor 2. Input shaft speed sensor...
Page 104: Dtc P0753 Shift Solenoid-A (No.1) Electrical
AUTOMATIC TRANSMISSION (4 A/T) 7B-31 DTC P0753 Shift solenoid-A (No.1) electrical DTC P0758 Shift solenoid-B (No.2) electrical DTC P0743 TCC (lock-up) system electrical 1. Shift solenoid-A (No.1) 4. TCM 2. Shift solenoid-B (No.2) 5. TCM couplers (viewed from harness side) 3.
Page 105 7B-32 AUTOMATIC TRANSMISSION (4 A/T) Step Action Turn ignition switch ON then measure voltage Poor connection at termi- “B/R”, “B/O” or “Br” wire or between terminal “E13-10”, “E13-23” or “E13- nal “E13-10”, “E13-23” or shift solenoid lead wire 22” of the disconnected harness side TCM cou- “E13-22”...
Page 106: Dtc P0741 Tcc (Lock-Up) Solenoid Performance Or Stuck Off
AUTOMATIC TRANSMISSION (4 A/T) 7B-33 DTC P0741 TCC (lock-up) solenoid performance or stuck OFF Step Action Was “AUTOMATIC TRANSMISSION DIAG- Go to Step 2. Go to “AUTOMATIC NOSTIC FLOW TABLE” performed? TRANSMISSION DIAG- NOSTIC FLOW TABLE”. Check TCC (lock-up) solenoid referring to Go to Step 3.
Page 107: Dtc P0720 Output Shaft Speed Sensor Circuit Malfunction
7B-34 AUTOMATIC TRANSMISSION (4 A/T) DTC P0720 Output shaft speed sensor circuit malfunction 1. Output shaft speed sensor (A/T VSS) 4. TCM 2. Coupler 5. TCM couplers (viewed from harness side) 3. Shield wire DTC DETECTING CONDITION • Output shaft speed sensor signal voltage too high or too low. Step Action 1) Turn ignition switch OFF and disconnect...
Page 108 AUTOMATIC TRANSMISSION (4 A/T) 7B-35 Step Action 1) Disconnect output shaft speed sensor – Replace output shaft Go to Step 4. input shaft speed sensor coupler. (See fig- speed sensor. ure.) 2) Measure resistance between terminal “3” (of disconnected sensor side coupler) and body ground then terminal “4”...
Page 109 7B-36 AUTOMATIC TRANSMISSION (4 A/T) Figure for Step 2, 5 1. “E12-14” terminal 2. “E12-6” terminal 3. “E12-13” terminal 4. TCM couplers Figure for Step 4 1. “E12-14” terminal 2. “E12-6” terminal 3. TCM couplers...
Page 110: Dtc P1700 Throttle Position Signal Input Malfunction
AUTOMATIC TRANSMISSION (4 A/T) 7B-37 DTC P1700 Throttle position signal input malfunction 1. Throttle position (TP) sensor 4. TCM couplers (viewed from harness side) 2. ECM 5. ECM couplers (viewed from harness side) 3. TCM DTC DETECTING CONDITION • NO or abnormal throttle opening signal inputted. Step Action Check DTC of “ENGINE DIAGNOSIS”...
Page 111 7B-38 AUTOMATIC TRANSMISSION (4 A/T) Step Action Check continuity between terminal “E12-8” of “Y/B” wire shorted to Go to Step 4. disconnected harness side TCM coupler and ground. ground. Is continuity indicated? 1) Connect TCM couplers. Intermittent trouble or Faulty TCM. 2) Turn ignition switch ON.
Page 112: Dtc P0705 Transmission Range Sensor (Switch) Circuit Malfunction
AUTOMATIC TRANSMISSION (4 A/T) 7B-39 DTC P0705 Transmission range sensor (switch) circuit malfunction 1. Transmission range sensor (shift switch) 3. TCM couplers (viewed from harness side) 2. TCM 4. Power source DTC DETECTING CONDITION • No shift switch signal inputted or two or more shift switch signals inputted at the same time. Step Action 1) Turn ignition switch OFF, disconnect TCM...
Page 113 7B-40 AUTOMATIC TRANSMISSION (4 A/T) Step Action While ignition switch ON, check voltage Go to Step 6. Go to Step 7. between terminal “E12-10” and “E13-15” of dis- connected harness side TCM coupler. Is it 10 – 14 V at “2” range and 0 V at the other range? While ignition switch ON, check voltage Intermittent trouble or...
Page 114: Dtc P0725 Engine Speed Input Circuit Malfunction
AUTOMATIC TRANSMISSION (4 A/T) 7B-41 DTC P0725 Engine speed input circuit malfunction 1. ECM 3. TCM couplers (viewed from harness side) 2. TCM 4. ECM couplers (viewed from harness side) DTC DETECTING CONDITION • Inputted engine rev. signal too low or too high. Step Action Check DTC of “ENGINE DIAGNOSIS”...
Page 115 7B-42 AUTOMATIC TRANSMISSION (4 A/T) Step Action 1) Turn ignition switch OFF and connect ECM Intermittent trouble or Faulty ECM. couplers. faulty ECM or TCM. Substitute a known-good 2) Turn ignition switch ON and measure volt- Check for intermittent ECM and recheck. age between terminal “E12-5”...
Page 116: Dtc P0710 Transmission Fluid Temperature Sensor Circuit Malfunction
AUTOMATIC TRANSMISSION (4 A/T) 7B-43 DTC P0710 Transmission fluid temperature sensor circuit malfunction 1. Transmission fluid temperature sensor 3. TCM 2. Coupler 4. TCM couplers (viewed from harness side) DTC DETECTING CONDITION • A/T fluid temperature signal input voltage too low. •...
Page 117 7B-44 AUTOMATIC TRANSMISSION (4 A/T) Step Action 1) Connect TCM couplers. Intermittent trouble or “Bl” wire shorted to power 2) Disconnect solenoid wire harness coupler. faulty TCM. circuit or poor connection 3) Turn ignition switch ON then measure volt- Check for intermittent of terminal “E13-3”.
Page 118: Dtc P0763 Shift Solenoid-C (No.3) Electrical
AUTOMATIC TRANSMISSION (4 A/T) 7B-45 DTC P0763 Shift solenoid-C (No.3) electrical DTC P0768 Shift solenoid-D (No.4) electrical DTC P0773 Shift solenoid-E (No.5) electrical E13-11 E13-12 Y/Bl E13-13 W/Bl E13-24 E13-25 Y/Bl W/Bl E13-26 E13-15 1. Dropping resistor 4. Shift solenoid valve-D (No.4) 7.
Page 119 7B-46 AUTOMATIC TRANSMISSION (4 A/T) Step Action Check continuity between terminal of discon- Circuit between Go to Step 5. nected body side solenoid coupler and transmis- TCM and transmis- sion ground with TCM, dropping resister and sion shorted to solenoid couplers disconnected. ground.
Page 120: Dtc P1709 Engine Coolant Temperature/Barometric Pressure Signal Circuit
AUTOMATIC TRANSMISSION (4 A/T) 7B-47 DTC P1709 Engine coolant temperature/barometric pressure signal circuit 1. ECM 3. TCM couplers (viewed from harness side) 2. TCM 4. ECM couplers (viewed from harness side) DTC DETECTING CONDITION • Engine coolant temperature/barometric pressure signal voltage too low although A/T fluid temperature is normal operating temperature and engine revolution is standard.
Page 121: Dtc P0702/P1702 Transmission Control System Electrical Or Internal Malfunction Of Tcm
7B-48 AUTOMATIC TRANSMISSION (4 A/T) DTC P0702/P1702 Transmission control system electrical or internal malfunction of TCM 1. TCM 3. A/T relay 2. Ignition switch 4. TCM couplers (viewed from harness side) DTC DETECTING CONDITION • Relay output voltage too high although TCM orders the relay to turn OFF or relay output voltage too low although TCM orders the relay to turn on.
Page 122: Inspection Of Tcm And Its Circuits
AUTOMATIC TRANSMISSION (4 A/T) 7B-49 Inspection of TCM and ITS circuits TCM and its circuits can be checked at TCM wiring couplers by measuring voltage and resistance. CAUTION: TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with coupler disconnected from it.
Page 123 7B-50 AUTOMATIC TRANSMISSION (4 A/T) STANDARD TERMINAL CIRCUIT CONDITION VOLTAGE Serial data link (SUZUKI scan 10 – 14 V IG switch ON tool) Output shaft speed sensor – – shield Output shaft speed sensor(–) – – Input shaft speed sensor(–) –...
Page 124: On-Vehicle Service
AUTOMATIC TRANSMISSION (4 A/T) 7B-51 On-Vehicle Service Maintenance Service Fluid level at normal operating temperature INSPECTION 1) Stop vehicle and place it level. 2) Apply parking brake and place chocks against wheels. 3) With selector at P position, start engine. 4) Warm up engine till fluid temperature reaches normal operat- ing temperature (70 –...
Page 125: Fluid Level At Room Temperature
7B-52 AUTOMATIC TRANSMISSION (4 A/T) Fluid level at room temperature INSPECTION The fluid level check at room temperature performed after repair or fluid change before test driving is just preparation for level check of normal operation temperature. The checking procedure itself is the same as that described previously.
Page 126: Transmission Control Module (Tcm)
AUTOMATIC TRANSMISSION (4 A/T) 7B-53 4) Lower vehicle and fill proper amount of an equivalent of ® DEXRON -III. 5) Check fluid level according to procedure described under “FLUID LEVEL AT NORMAL OPERATING TEMPERATURE. A/T fluid specification ® : An equivalent of DEXRON -III A/T fluid capacity When draining from drain plug hole :...
Page 127 7B-54 AUTOMATIC TRANSMISSION (4 A/T) 4) Disconnect couplers from TCM (1). 5) Loosen 2 nuts (2) and remove TCM from vehicle. INSTALLATION Reverse removal procedure noting the following. • Connect ECM and TCM couplers securely. • If the vehicle is equipped with air bag system, be sure to enable air bag system after TCM and ECM are back in place.
Page 128: Learning Control Initialization
AUTOMATIC TRANSMISSION (4 A/T) 7B-55 Learning control initialization When one or more operations such as shown below are per- formed, all learned contents which are stored in TCM memory should be erased after the operations. • Replacing transmission with new or used one. •...
Page 129: Tightening Torque Specification
7B-56 AUTOMATIC TRANSMISSION (4 A/T) Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft A/T fluid drain plug 16.5 Transmission rage sensor bolt 13.0 Output shaft speed sensor bolt Input shaft speed sensor bolt Dropping resistor bolts 14.5 Shift solenoid bolts Transmission temperature sensor bolt Transmission to engine bolts and nut 61.5...
Page 130: Special Tool
AUTOMATIC TRANSMISSION (4 A/T) 7B-57 Special Tool 09900-06108 09900-20606 09900-20701 09913-75510 Snap ring plier Dial gauge Magnetic stand Bearing installer (Closing type) 09913-80112 09913-85210 09922-85811 09923-74510 Bearing installer Bearing installer Spring pin remover Bearing remover (6 mm) 09924-74510 09925-37811-001 09925-88210 09926-26030 Installer handle Oil pressure gauge...
Page 131 Sliding shaft 16/14 pin DLC cable for No.7 No.8 Tech 1A 09931-76011 09941-64511 09944-68510 09951-16060 Tech 1A kit (SUZUKI scan Bearing remover Bearing installer Bush remover tool) (See NOTE “A”.) 09952-06010 09952-06020 09926-26050 Dial gauge plate No.1 Dial gauge plate No.2 Mass storage cartridge for Air installer No.3...
Page 132: Required Service Material
Automatic transmission fluid ® • Automatic transmission An equivalent of DEXRON -III • Parts lubrication when installing Sealant SUZUKI BOND No. 1215 • Case housing star-shaped recess (99000-31110) bolts (3 pcs only) Lithium grease SUZUKI SUPER GREASE C • Retaining parts in place when...
Page 133 7B-60 AUTOMATIC TRANSMISSION (4 A/T)
Page 134 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 135 8C-2 INSTRUMENTATION/DRIVER INFORMATION General Description Combination Meter ABS/EBD circuit (if equipped) if equipped if equipped Voltage SPEEDO TACHO FUEL TEMP. METER regurator METER METER METER Interface circuit 1. To ground 12. Blank – 23. To generator 2. To ignition switch 13.
Page 136 INSTRUMENTATION/DRIVER INFORMATION 8C-3 Diagnosis Low Fuel Warning Lamp Condition Possible Cause Correction Low fuel warning light Bulb blown Check bulb. does not come ON IG METER fuse blown Check fuse. after ignition switch Combination meter internal circuit faulty Check combination meter. turns to ON position Wiring or grounding faulty Repair.
Page 137 8C-4 INSTRUMENTATION/DRIVER INFORMATION 4) Connect fuel pump connector (1) to fuel pump (2). 5) Connect negative (-) cable to battery. 6) Turn ignition switch to ON position. 7) After 4 seconds, check for low fuel warning lamp operation under the following each float position (1) of fuel pump (2). If faulty condition is found, replace combination meter.
Page 138 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 139: Diagnosis
8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS Diagnosis NOTE: Fuse name (“ ”) in the table below is shown on the fuse box cover. Power Door Lock System (If Equipped) Condition Possible Cause Correction All doors are not “DOOR LOCK” fuse blown Replace fuse to check for short.
Page 140: On-Vehicle Service
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-3 Condition Possible Cause Correction Interior light does not Power door lock controller faulty Check system referring to KEY- turn ON when doors are Wiring or grounding faulty LESS ENTRY SYSTEM CIRCUIT unlocked by keyless INSPECTION in this section.
Page 141: Power Door Lock System Circuit Inspection
8D-4 WINDOWS, MIRRORS, SECURITY AND LOCKS c) For vehicle equipped dead lock system: When the driver side door key cylinder is turned LOCK twice within 2 seconds, check all doors lock and not pulled up all door lock knobs by hand. If check result is not satisfied, go to “Power Door Lock System Circuit Inspection”...
Page 142: Power Door Lock System Circuit Check
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-5 5) Check that the voltage and resistance between the following terminals and body ground are specifications under each conditions. If check result is OK, replace door lock controller. If check 12 13 14 15 17 18 result is not as specified, repair circuit.
Page 143: Keyless Entry System (If Equipped)
8D-6 WINDOWS, MIRRORS, SECURITY AND LOCKS (If Equipped) Keyless Entry System Keyless entry system operation inspection 1) Confirm that power door lock system is good condition. 2) Confirm that all doors are closed and unlocked. 3) Check the following operation: a) When pushing “LOCK”...
Page 144: Keyless Entry System Circuit Check
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-7 Keyless entry system circuit check Terminal Wire Circuit Specification Condition Push “LOCK” button on transmitter Figure “A” once. Hazard waning signal circuit Push “UNLOCKI” button on transmit- G02-7 GRN/YEL Figure “B” (right side) ter once. Push “LOCK”...
Page 145: Transmitter
8D-8 WINDOWS, MIRRORS, SECURITY AND LOCKS Transmitter REPLACEMENT OF TRANSMITTER BATTERY If transmitter becomes unreliable, replace transmitter battery as follows. 1) Remove screw (1), and remove cover (2) from ignition key (3). 2) Unhook tabs (4) and remove transmitter (5). 3) Replace battery (lithium disc-type CR1616 or equivalent bat- tery) (6) so its + terminal faces “+”...
Page 146 However, bear the following in mind when checking DTC (Diagnostic Trouble Code). Be sure to use SUZUKI scan tool whenever checking DTC because this vehicle has no monitor con- nector for lmmobilizer control system and DTC can not be displayed by malfunction indicator lamp (MIL) flashing.
Page 147: On-Vehicle Service
ON (II) position. Trouble Code Registration 4) Select vehicle, “immobilizer” and “Registration” at each menu screen. SUZUKI -->Other than Notrht America--> Passenger Car -->WAGON R+(RB310/413)--> Immobilizer 5) Select “Register New Ig Key (Fix code)” to register fix code Immobilizer registration menu...
Page 148: Procedure After Immobilizer Control Module Replacement
IMMOBILIZER CONTROL SYSTEM 8G-3 Procedure after immobilizer control module replace- ment [When using Tech 1A] For the procedure, refer to “Procedure after immobilizer control module replacement” in the same section of the Service manual mentioned in FOREWORD of this manual. [When using Tech 2] 1) Perform IMMOBILIZER SYSTEM COMPONENTS REGIS- TRATION FLOW TABLE.
Page 149: Special Tools
Special Tools 09931-76011 09931-76030 Tech 1A kit (SUZUKI scan Mass storage cartridge for 16/14 pin DLC adapter for Tech 2 kit (SUZUKI scan tool) tool) (See NOTE “A”.) Tech 1A Tech 1A (See NOTE “B”.) NOTE: • “A” : This kit includes the following items and substitutes for the Tech 2 kit.
Page 150 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 151 9-2 BODY SERVICE Seats Front Seat WARNING: For vehicle equipped with side air bags: • Never attempt to disassemble front seat back. Do not remove side air bag (inflator) module from front seat back. If any abnormality is found, be sure to replace front seat back with new one as an assembly.
Page 152 BODY SERVICE 9-3 REMOVAL 1) Disable air bag system referring to “DISABLEING AIR BAG SYSTEM” in Section 10B. 2) Disconnect side air bag coupler (1), if equipped. 3) Remove center console box (1). 4) Remove 4 mounting bolts to remove front seat from vehicle floor.
Page 153 9-4 BODY SERVICE Rear Seat 1. Seat cushion 4. Seat cushion bolt 2. Seat back 5. Folding bolt 3. Seat back bolt REMOVAL/INSTALLATION For removal and Installation of rear seat, refer to above figure.
Page 154 • Service on or around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On- Vehicle Service” in this section before performing service on or around the air bag system compo- nents or wiring.
Page 155 10B-2 AIR BAG SYSTEM DTC B1044 – Driver Pretensioner DTC B1084 – Side Air Bag (Driver Side) Initiator Circuit Short to Power Circuit ..10B-36 Intiator Circuit Short to Power Circuit..10B-57 DTC B1045 – Passenger Pretensioner DTC B1085 – Side Air Bag Initiator Circuit Resistance High....
Page 156: General Description
AIR BAG SYSTEM 10B-3 General Description With the air bag system which includes front air bags and side air bags for both the driver’s and passenger’s sides as well as the seat belt pretensioners, the sag of the seat belt is taken up (for seat belt with pretensioner), the driver air bag (inflator) module is deployed from the center of the steering column and the passen- ger air bag (inflator) module from the top of the instrument panel...
Page 157: System Components And Wiring Location View And Connectors
10B-4 AIR BAG SYSTEM System Components and Wiring Location View and Connectors CONNECTOR “X01” CONNECTOR “G65” CONNECTOR “G74” CONNECTOR “X02”, “X03” CONNECTOR “G69“, “G70” CONNECTOR “Q08” CONNECTOR “G67“, “G72” CONNECTOR “G66” CONNECTOR “G68“, “G71” 1. Air bag harness (in instrument panel harness) 5.
Page 158: System Wiring Diagram
AIR BAG SYSTEM 10B-5 System Wiring Diagram “G66” “G65” “Q08” +12V GRN/RED G66-27 “G66” “G25” “G25” G66-26 BLK/RED G66-30 “G74” “X01” +12V YEL/RED G66-31 G66-24 G66-23 BLU/RED G66-32 “G67” +12V WHT/RED WHT/BLU G66-28 +30V G66-33 G66-34 WHT/RED “G72” +12V G66-36 “G68”...
Page 159: Diagnosis
The AIR BAG DIAGNOSTIC SYSTEM CHECK must always be the starting point of any air bag system diagno- sis. The AIR BAG DIAGNOSTIC SYSTEM CHECK checks for proper “AIR BAG” warning lamp operation and checks for air bag diagnostic trouble codes (DTCs) using SUZUKI scan tool.
Page 160: Use Of Special Tool
AIR BAG SYSTEM 10B-7 Use of Special Tool WARNING: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equip- ment other than that specified in this manual.
Page 161 10B-8 AIR BAG SYSTEM Special tool (B) : 09932-75010 (Air Bag Driver/Passenger Load Tool) This tool is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag (inflator) module deployment.
Page 162: Intermittents And Poor Connections
AIR BAG SYSTEM 10B-9 Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diagnostic flow table, perform careful check of suspect circuits for: • Check connector for loose connection. •...
Page 163: Air Bag Diagnostic System Check
10B-10 AIR BAG SYSTEM Air Bag Diagnostic System Check WARNING: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equip- ment other than that specified in this manual.
Page 164: Air Bag Diagnostic System Check Flow Table
OFF, after flashing 6 times? circuit is good condition. good condition. Go to step 4. Go to step 5. 1) Check DTC using SUZUKI scan Air bag system is in good An intermittent trouble has occurred tool. Refer to DTC CHECK in this condition.
Page 165: Dtc Check
3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between scan tool and SDM is not possi- ble, proceed to SDM Can not Communicate through the Serial Data Circuit in this section.
Page 166: Dtc Table
AIR BAG SYSTEM 10B-13 DTC Table Diagnosis – Normal – B1015 Resistance high B1016 Resistance low Passenger air bag circuit B1018 Short to ground B1019 Short to power circuit B1021 Resistance high B1022 Resistance low Driver air bag circuit B1024 Short to ground B1025 Short to power circuit...
Page 167 No. B1086 Resistance low Side air bag circuit B1087 (passenger side) Short to ground B1088 Short to power circuit NOTE: • When 2 or more codes are indicated by SUZUKI scan tool (Tech-1A), the lowest numbered code will appear first.
Page 168: Air Bag" Warning Lamp Comes On Steady
AIR BAG SYSTEM 10B-15 “AIR BAG” Warning Lamp Comes ON Steady “AIR BAG” Warning Lamp Does Not Come ON “AIR BAG” Warning Lamp Flashes WIRING DIAGRAM “G66” “G25” “G25” BLK/RED G66-30 G66-31 BLU/RED G66-32 WHT/BLU +30V+5V WHT/RED WHT/RED G66-28 1. From main fuse 5.
Page 169 10B-16 AIR BAG SYSTEM TABLE TEST DESCRIPTION “AIR BAG” Warning Lamp Comes ON Steady: STEP 1 : Check for “AIR BAG” fuse blown. STEP 2 : Check for loose connection between SDM connector and SDM. STEP 3 : Check for power supply circuit. STEP 4 : Check for short circuit between “AIR BAG”...
Page 170 AIR BAG SYSTEM 10B-17 “G66-32” “G66-30” [A] : Fig. for Step 3 [B] : Fig. for Step 4 1. SDM connector “G66” Special tool (A) : 09932-76010 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. •...
Page 171 10B-18 AIR BAG SYSTEM “G66-30” “G66-30” “G25-13” [A] : Fig. for Step 3 1. SDM connector “G66” [B] : Fig. for Step 4 2. “G25” connector for combination meter Special tool (A) : 09932-76010 NOTE: Upon completion of inspection and repair work, perform the following items. •...
Page 172: Sdm Cannot Communicate Through The Serial Data Circuit
STEP 5 : This test checks for an open in A/B serial data circuit. DIAGNOSTIC FLOW TABLE Step Action 1) Make sure that SUZUKI scan tool is free from malfunc- Go to step 2. Properly connect SUZUKI tion and set correctly for air bag system is used. scan tool to DLC.
Page 173 10B-20 AIR BAG SYSTEM Step Action 1) Check if communication is possible by trying communi- Go to step 3. Repair open in common cation with other control module (ECM or ABS control section of serial data circuit module (if equipped)). (“WHT/RED”...
Page 174 AIR BAG SYSTEM 10B-21 “G09-16” “G09-7” “G66-28” “G09-04” “G09-05” [A] : Fig. for Step 1 and 2 1. DLC “G09” [B] : Fig. for Step 3 2. Scan tool [C] : Fig. for Step 4 3. SDM connector “G66” [D] : Fig. for Step 5 Special tool (A) : 09932-76010 NOTE:...
Page 175: Dtc B1015 - Passenger Air Bag Initiator Circuit Resistance High
10B-22 AIR BAG SYSTEM DTC B1015 – Passenger Air Bag Initiator Circuit Resistance High DTC B1016 – Passenger Air Bag Initiator Circuit Resistance Low DTC B1018 – Passenger Air Bag Initiator Circuit Short to Ground DTC B1019 – Passenger Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM “G66”...
Page 176 AIR BAG SYSTEM 10B-23 DIAGNOSTIC FLOW TABLE DTC B1015 : Passenger Air Bag Initiator Circuit Resistance High Step Action 1) With ignition switch OFF, disconnect passenger air Go to step 2. Ignition switch OFF. bag (inflator) module connector “G74” behind the Replace passenger air glove box.
Page 177 10B-24 AIR BAG SYSTEM DTC B1016 : Passenger Air Bag Initiator Circuit Resistance Low Step Action 1) With ignition switch OFF, disconnect passenger air Go to step 2. Ignition switch OFF. bag (inflator) module connector “G74” behind the Replace passenger air glove box.
Page 178 AIR BAG SYSTEM 10B-25 DTC B1018 : Passenger Air Bag Initiator Circuit Short to Ground Step Action 1) With ignition switch OFF, disconnect passenger air Go to step 2. Ignition switch OFF. bag (inflator) module connector “G74” behind the Replace passenger air glove box.
Page 179 10B-26 AIR BAG SYSTEM DTC B1019 : Passenger Air Bag Initiator Circuit Short to Power Circuit Step Action 1) With ignition switch OFF, disconnect passenger Go to step 2. Ignition switch OFF. air bag (inflator) module connector “G74” behind Replace passenger air the glove box.
Page 180: Dtc B1021 - Driver Air Bag Initiator Circuit Resistance High
AIR BAG SYSTEM 10B-27 DTC B1021 – Driver Air Bag Initiator Circuit Resistance High DTC B1022 – Driver Air Bag Initiator Circuit Resistance Low DTC B1024 – Driver Air Bag Initiator Circuit Short to Ground DTC B1025 – Driver Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM “G66”...
Page 181 10B-28 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1021 : Driver Air Bag Initiator Circuit Resistance High Step Action 1) With ignition switch OFF, disconnect contact coil con- Go to step 2. Go to step 3. nector “G65” behind steering wheel. 2) Check proper connection to contact coil at terminals in “G65”...
Page 182 AIR BAG SYSTEM 10B-29 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to DTC CLEARANCE), if any. •...
Page 183 10B-30 AIR BAG SYSTEM “GRN/RED” “G66-26” “G66-27” “GRN” “Q08” [A] : Fig. for STEP 1 and 2 1. Release tool [B] : Fig. for STEP 2 2. SDM connector “G66” [C] : Fig. for STEP 3 3. Contact coil connector “G65” Special tool (A) : 09932-76010 (B) : 09932-75010...
Page 184 AIR BAG SYSTEM 10B-31 Step Action 1) With ignition switch OFF, disconnect Special Tools Ignition switch OFF. Ignition switch OFF. (B) and (C) from “G65” connector, then reconnect Replace contact coil Replace driver air bag contact coil connector “G65” as it was. assembly (Refer to (inflator) module 2) Remove driver air bag (inflator) module from steer-...
Page 185 10B-32 AIR BAG SYSTEM Step Action 1) With ignition switch OFF, disconnect Special Substitute a known-good Repair short from “GRN/ Tools (B) and (C) from “G65” connector. SDM and recheck. RED” or “GRN” wire cir- 2) Disconnect SDM connector “G66” from cuit to power circuit.
Page 186: Dtc B1031 - Power Source Voltage High
AIR BAG SYSTEM 10B-33 DTC B1031 – Power Source Voltage High DTC B1032 – Power Source Voltage Low WIRING DIAGRAM “G66” BLU/RED G66-32 G66-31 +30V+5V 1. From main fuse 3. “AIR BAG” fuse 5. Ground for air bag system 2. Ignition switch 4.
Page 187 10B-34 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1031 : Power Source Voltage High Step Action 1) With ignition switch OFF, disconnect SDM Go to step 2. Check Charging System connector “G66” and repair as necessary. 2) Check proper connection to SDM at “G66- (Refer to DIAGNOSIS in 32”...
Page 188 AIR BAG SYSTEM 10B-35 1) With ignition switch OFF, disconnect SDM Go to Step 3. Check Charging System connector “G66”. and repair as necessary. 2) Check proper connection to SDM at “G66- (Refer to DIAGNOSIS in 32” terminal. Section 6H.) 3) If OK, then ignition switch ON, and then check voltage from “G66-32”...
Page 189: Dtc B1041 - Driver Pretensioner Initiator Circuit Resistance High
10B-36 AIR BAG SYSTEM DTC B1041 – Driver Pretensioner Initiator Circuit Resistance High DTC B1042 – Driver Pretensioner Initiator Circuit Resistance Low DTC B1043 – Driver Pretensioner Initiator Circuit Short to Ground DTC B1044 – Driver Pretensioner Initiator Circuit Short to Power Circuit DTC B1045 –...
Page 190 AIR BAG SYSTEM 10B-37 DTC WILL SET WHEN DTC B1041 or B1045 : The resistance of driver or passenger seat belt pretensioner initiator circuit is above a specified value for speci- fied time. DTC B1042 or B1046 : The resistance of driver or passenger seat belt pretensioner initiator circuit is below a specified value for speci- fied time.
Page 191 10B-38 AIR BAG SYSTEM Step Action 1) With ignition switch OFF, disconnect SDM Substitute a known- DTC B1041 : connector “G66”. good SDM and recheck. Repair high resistance or 2) Check proper connection to SDM at termi- open in “PNK” or “WHT” wire nals “G66-33”...
Page 192 AIR BAG SYSTEM 10B-39 DTC B1042 : Driver Pretensioner Initiator Circuit Resistance Low DTC B1046 : Passenger Pretensioner Initiator Circuit Resistance Low Step Action 1) With ignition switch OFF, remove center pil- Go to step 2. Ignition switch OFF. lar inner garnish of applicable side then dis- Replace seat belt preten- connect seat belt pretensioner connector sioner (Refer to Front...
Page 193 10B-40 AIR BAG SYSTEM Special tool (A) : 09932-76010 (B) : 09932-75010 (C) : 09932-78310 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. •...
Page 194 AIR BAG SYSTEM 10B-41 “G67”, “G72” (A) “G66-35” “G66-36” “G66-33” “G66-34” STEERING WHEEL [A] : Fig. for STEP 1 and 2 [B] : Fig. for STEP 2 [C] : For DTC B1043 [D] : For DTC B1047 1. Release tool 2.
Page 195 10B-42 AIR BAG SYSTEM Step Action 1) With ignition switch OFF, disconnect Spe- Substitute a known- DTC B1044 : cial Tools (A) and (B) and (C) from “G67” good SDM and recheck. Repair short “PNK” or “WHT” or “G72” connector. wire circuit to power circuit.
Page 196: Dtc B1051 - Frontal Crash Detected (System Activation Command Outputted)
AIR BAG SYSTEM 10B-43 DTC B1051 – Frontal Crash Detected (System Activation Command Output- ted) CAUTION: Be sure to perform Air Bag Diagnostic System Check before starting diagnosis according to flow table. DTC WILL SET WHEN The SDM detects a frontal crash of sufficient force to warrant activation of the air bag system. (SDM outputs a deployment command.) TABLE TEST DESCRIPTION STEP 1 : Check that DTC B1051 has been set although air bag has not been deployed.
Page 197: Dtc B1056 - Sideward Crash (Driver Side) Detected (Side Air Bag System Activation Command Outputted)
10B-44 AIR BAG SYSTEM DTC B1056 – Sideward Crash (Driver Side) Detected (Side Air Bag System Activation Command Outputted) DTC B1057 – Sideward Crash (Passenger Side) Detected (Side Air Bag System Activation Command Outputted) CAUTION: Before starting diagnosis according to flow table, Air Bag Diagnostic System Check. DTC WILL SET WHEN DTC B1056 or B1057 : The SDM detects a sideward crash (driver or passenger side) of sufficient force to warrant activation of the side...
Page 198: Dtc B1058 - Frontal Crash Detected (Pretensioner Activation Command Outputted)
AIR BAG SYSTEM 10B-45 DTC B1058 – Frontal Crash Detected (Pretensioner Activation Command Out- putted) CAUTION: Be sure to perform Air Bag Diagnostic System Check before starting diagnosis according to flow table. DTC WILL SET WHEN The SDM detects a frontal crash of sufficient force to warrant activation of pretensioner. (SDM outputs a activa- tion command.) TABLE TEST DESCRIPTION STEP 1 : Check that DTC B1058 has been set although pretensioner has not been activated.
Page 199: Dtc B1061 - "Air Bag" Warning Lamp Circuit Failure
10B-46 AIR BAG SYSTEM DTC B1061 – “AIR BAG” Warning Lamp Circuit Failure WIRING DIAGRAM “G66” “G25” “G25” BLK/RED G66-30 G66-31 BLU/RED G66-32 WHT/RED WHT/BLU G66-28 +30V+5V 1. From main fuse 5. “AIR BAG” fuse 9. Ground for air bag system 2.
Page 200 AIR BAG SYSTEM 10B-47 DIAGNOSTIC FLOW TABLE Step Action 1) This DTC is set when there is a trouble in Go to step 2. Repair “AIR BAG” warn- “AIR BAG” warning lamp circuit. Check “AIR ing lamp circuit. BAG” warning lamp circuit referring to AIR BAG DIAGNOSTIC SYSTEM CHECK in this section.
Page 201: Dtc B1063 - Side Sensor (Driver Side) Circuit Short To Ground
10B-48 AIR BAG SYSTEM DTC B1063 – Side Sensor (Driver Side) Circuit Short to Ground DTC B1064 – Side Sensor (Driver Side) Circuit Short to Power Circuit Or Open DTC B1065 – Side Sensor (Passenger Side) Circuit Short to Ground DTC B1066 –...
Page 202 AIR BAG SYSTEM 10B-49 TABLE TEST DESCRIPTION DTC B1063, B1064, B1065 or B1066 : STEP 1 : Check side sensor (driver or passenger side) circuit in floor harness. STEP 2 : Check side sensor (driver or passenger side) circuit in floor harness. (for DTC B1064 and B1066 only) DIAGNOSTIC FLOW TABLE DTC B1063 : Side Sensor (Driver Side) Circuit Short to Ground DTC B1065 : Side Sensor (Passenger Side) Circuit Short to Ground...
Page 203: Dtc B1066 - Side Sensor (Passenger Side) Circuit Short To Power Circuit Or Open
10B-50 AIR BAG SYSTEM DTC B1064 : Side Sensor (Driver Side) Circuit Short to Power Circuit or Open DTC B1066 : Side Sensor (Passenger Side) Circuit Short to Power Circuit or Open Step Action 1) With ignition switch OFF, remove center pil- Got to Step 2.
Page 204 AIR BAG SYSTEM 10B-51 “G66-6” “G66-5” “G66-17” “G66-16” [A] : Fig. for STEP 2 (DTC B1064) [B] : Fig. for STEP 2 (DTC B1066) 1. SDM connector “G66” Special tool (A) : 09932-76010 NOTE: Upon completion of inspection and repair work, perform the following items. •...
Page 205: Dtc B1071 - Internal Sdm Fault
10B-52 AIR BAG SYSTEM DTC B1071 – Internal SDM Fault CAUTION: Be sure to perform Air Bag Diagnostic System Check before starting diagnosis according to flow table. DTC WILL SET WHEN An internal SDM fault is detected by SDM. NOTE: DTC B1071 can never be cleared once it has been set.
Page 206: Dtc B1073 - Side Sensor (Driver Side) Correspondence Abnormality
AIR BAG SYSTEM 10B-53 DTC B1073 – Side Sensor (Driver Side) Correspondence Abnormality DTC B1075 – Side Sensor (Passenger Side) Correspondence Abnormality WIRING DIAGRAM “G66” BLU/RED G66-32 “G68” GRN/WHT G66-17 GRN/BLK G66-6 “G71” GRN/YEL G66-16 GRN/ORN G66-5 G66-31 1. From main fuse 4.
Page 207 10B-54 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1073 : Side Sensor (Driver Side) Correspondence Abnormality DTC B1075 : Side Sensor (Passenger Side) Correspondence Abnormality Step Action 1) With ignition switch OFF, disconnect SDM Go to step 2. DTC B1073 : connector “G66”...
Page 208 AIR BAG SYSTEM 10B-55 Step Action 1) DTC B1073 : Go to step 4. DTC B1073 : Measure resistance between “G66-17” ter- Repair short from “GRN/ minal and body ground, and between “G66- WHT” or “GRN/BLK” wire 6” terminal and body ground with connected to body ground.
Page 209 10B-56 AIR BAG SYSTEM “G66-6” “G66-5” “G66-17” “G66-16” “G66-6” “G66-5” “G66-17” “G66-16” [A] : Fig. for STEP 1 [D] : Fig. for STEP 4 1. SDM connector “G66” [B] : Fig. for STEP 2 [E] : For DTC B1073 [C] : Fig. for STEP 3 [F] : For DTC B1075 Special tool (A) : 09932-76010...
Page 210: Dtc B1081 - Side Air Bag (Driver Side) Intiator Circuit Resistance High
AIR BAG SYSTEM 10B-57 DTC B1081 – Side Air Bag (Driver Side) Intiator Circuit Resistance High DTC B1082 – Side Air Bag (Driver Side) Intiator Circuit Resistance Low DTC B1083 – Side Air Bag (Driver Side) Intiator Circuit Short to Ground DTC B1084 –...
Page 211 10B-58 AIR BAG SYSTEM DTC WILL SET WHEN DTC B1081 or B1085 : The combined resistance of the side air bag (inflator) module (driver or passenger side), harness wiring and connector terminal contact is above a specified value for specified time. DTC B1082 or B1086 : The combined resistance of the side air bag (inflator) module (driver or passenger side), harness wiring and connector terminal contact is below a specified value for specified time.
Page 212 AIR BAG SYSTEM 10B-59 Step Action 1) With ignition switch OFF, disconnect SDM Substitute a known-good DTC B1081 : connector “G66”. SDM and recheck. Repair high resistance or 2) Check proper connection to SDM at termi- open in “WHT/RED” or nals “G66-19”...
Page 213 10B-60 AIR BAG SYSTEM DTC B1082 : Side Air Bag (Driver Side) Initiator Circuit Resistance Low DTC B1086 : Side Air Bag (Passenger Side) Initiator Circuit Resistance Low Step Action 1) With ignition switch OFF, disconnect side air Go to step 2. Ignition switch OFF.
Page 214 AIR BAG SYSTEM 10B-61 Special tool (A) : 09932-76010 (B) : 09932-75010 (C) : 09932-78310 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. •...
Page 215: Power Circuit
10B-62 AIR BAG SYSTEM “G69”, “G70” “G66-18” “G66-19” “G66-20” “G66-21” STEERING WHEEL [A] : Fig. for STEP 1 and 2 [B] : Fig. for STEP 2 [C] : For DTC B1083 [D] : For DTC B1087 1. Release tool 2. SDM connector “G66” Special tool (A) : 09932-76010 (B) : 09932-75010...
Page 216 AIR BAG SYSTEM 10B-63 Step Action 1) With ignition switch OFF, disconnect Special Substitute a known-good DTC B1084 : Tools (B) and (C) from “G69” or “G70” con- SDM and recheck. Repair short from “WHT/ nector. RED” or “WHT/GRN” wire 2) Disconnect SDM connector “G66”...
Page 217: On-Vehicle Service
Be sure to follow the instructions. WARNING: • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 218: Disabling Air Bag System
AIR BAG SYSTEM 10B-65 Disabling air bag system 1) Turn steering wheel so that vehicle's wheels (front tires) and pointing straight ahead. 2) Turn ignition switch to “LOCK” position and remove key. 3) Remove “AIR BAG” fuse from circuit fuse box referring to “System Components and Wiring Location View and Con- nectors”...
Page 219: Enabling Air Bag System
10B-66 AIR BAG SYSTEM Enabling air bag system 1) Turn ignition switch to “LOCK” position and remove key. 2) Connect contact coil connector (1) and combination switch assembly by pushing lock lever (2) as shown in figure securely. 3) Install steering column upper and lower covers. 4) If equipped with passenger air bag (inflator) module, connect Yellow connector (1) of passenger air bag (inflator) module by pushing connector till click is heard from it.
Page 220: Handling And Storage
AIR BAG SYSTEM 10B-67 Handling and storage WARNING: Never power up air bag system when SDM is not rigidly attached to the vehicle. Otherwise, personal injury may result. CAUTION: After detecting one time of such collision as to meet deployment conditions, the SDM must not be used. Refer to “AIR BAG DIAGNOSTIC SYSTEM CHECK”...
Page 221 10B-68 AIR BAG SYSTEM LIVE (UNDEPLOYED) AIR BAG (INFLATOR) MODULES Special care is necessary when handling and storing a live (unde- ployed) air bag (inflator) modules. The rapid gas generation produced during deployment of the air bag could cause the air bag (inflator) module, or an object in front of the air bag (inflator) module, to be thrown through the air in the unlikely event of an accidental deployment.
Page 222 AIR BAG SYSTEM 10B-69 WARNING: • For handing and storage of air bag (inflator) module and seat belt pretensioner, select place where ambient temperature below 65°C (150°F), without high humidity and away from electric noise. • Always carry live air bag (inflator) module with trim cover away from you.
Page 223 10B-70 AIR BAG SYSTEM WARNING: Never attempt to measure the resistance of the seat belt pretensioners. It is very dangerous as the electric current from the tester may activate pretensioner. • Never attempt to disassemble the seat belt pretensioner (retractor assembly). •...
Page 224 AIR BAG SYSTEM 10B-71 DEPLOYED AIR BAG (INFLATOR) MODULE AND ACTI- VATED SEAT BELT PRETENSIONER WARNING: • The air bag (inflator) module and seat belt pretensioner immediately after deployment/activation is very hot. Wait for at least 30 minutes to cool it off before pro- ceeding the work.
Page 225 10B-72 AIR BAG SYSTEM AIR BAG WIRE HARNESS AND CONNECTOR IN FLOOR WIRE HARNESS Air bag wire harness is included in instrument panel harness. The part of coupler side wire harness can be identified easily as it is covered with a yellow protection tube. Be very careful when han- dling it.
Page 226: Repairs And Inspections Required After An Accident
AIR BAG SYSTEM 10B-73 Repairs and Inspections Required after an Accident CAUTION: • All air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be replaced even if air bag system activation did not occur.
Page 227 10B-74 AIR BAG SYSTEM • Steering wheel (1) and driver air bag (inflator) module (2) – Check for damage or air bag (inflator) module fitness. – Check trim cover (pad surface) for cracks. – Check wire harness and connector for damage or tight- ness.
Page 228 AIR BAG SYSTEM 10B-75 • Passenger air bag (inflator) module (1) (if equipped) – Check for dents, cracks, damage or fitness. – Check trim cover for cracks or deformities. – Check harness and connector for damage or tightness. If any faulty condition is found in above checks, replace. •...
Page 229: Sdm
10B-76 AIR BAG SYSTEM WARNING: During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Be sure to read “SERVICE PRECAUTIONS” before start- ing to work and observe every precaution during work. Neglecting them may result in personal injury or inactiva- tion of the air bag system when necessary.
Page 230: Side Sensor (If Equipped)
AIR BAG SYSTEM 10B-77 INSTALLATION For installation, reverse removal procedure nothing the following points. • Check none of the following conditions exists. – Bend, scratch, deformity in vehicle body which SDM is mounted. – Foreign matters or rusts on mating surface of vehicle body with SDM •...
Page 231 10B-78 AIR BAG SYSTEM 6) Disconnect side sensor connector sliding connector outer (1) as shown. INSPECTION CAUTION: • Never disassemble side sensor. • Sensor should be replaced when it was dropped from a height of 90 cm (3 ft) or more. •...
Page 232: Seat Belt Pretensioner
AIR BAG SYSTEM 10B-79 INSTALLATION CAUTION: Proper operation of side sensor requires sensor be rig- idly attached to vehicle structure. 1) Check that none of following faulty conditions exists. • Bend, deformity or rust of under body. • Foreign matter on mating surface of sensor. 2) Install side sensor (1) on under body (2) and tighten side sensor bolt (3) to specified torque.
Page 233: Passenger Air Bag (Inflator) Module (If Equipped)
10B-80 AIR BAG SYSTEM Passenger Air Bag (Inflator) Module (if equipped) WARNING: • Never attempt to disassemble or repair the passenger air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. •...
Page 234 AIR BAG SYSTEM 10B-81 INSTALLATION 1) Install passenger air bag (inflator) module (1) to instrument panel (2). 2) Tighten passenger air bag (inflator) module attaching bolts (3) to specified torque. Tightening torque Passenger air bag (inflator) module mounting bolt (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft) 3) Set glove box (4) to original position of instrument panel (2) and install clips (5).
Page 235: Side Air Bag (Inflator) Module (If Equipped)
10B-82 AIR BAG SYSTEM Side Air Bag (Inflator) Module (If Equipped) WARNING: • Never attempt to disassemble front seat back. It is impossible to remove side air bag (inflator) mod- ule from front seat back. If any abnormality is found, be sure to replace front seat back with new one as an assembly referring to “FRONT SEAT”...
Page 236: Air Bag (Inflator) Module And Seat Belt Pretensioner Disposal
AIR BAG SYSTEM 10B-83 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal WARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury. Do not dispose of live (undeployed) air bag (inflator) modules and seat belt pretensioners.
Page 237 10B-84 AIR BAG SYSTEM 1) Turn ignition switch to “LOCK” position and remove key. 2) Wear safety glasses during this deployment/activation proce- dure. 3) Check that there is no open, short or damage in special tools (deployment harness (A) and adapter cable (B)). If any faulty is found, do not use it and be sure to use new deployment harness.
Page 238 AIR BAG SYSTEM 10B-85 WARNING: • For handing and storage of air bag (inflator) module and seat belt pretensioner, select place where ambient temperature below 65°C (150°F), without high humidity and away from electric noise. • Always carry live air bag (inflator) module with trim cover away from you.
Page 239 10B-86 AIR BAG SYSTEM • For passenger air bag (inflator) module a) Clear space (1) on ground about 185 cm (6 ft) in diameter where passenger air bag (inflator) module for deployment. Paved, outdoor location where there is no activity is pre- ferred.
Page 240 AIR BAG SYSTEM 10B-87 • For seat belt pretensioner a) Cut webbing (1) at tongue plate stopper (2) of seat belt pre- tensioner (3) side as shown. NOTE: Hold seat belt pretensioner (3) vertically in the same con- dition as it is installed. Otherwise, webbing can’t be pulled out.
Page 241 10B-88 AIR BAG SYSTEM 7) Stretch deployment harness (A) from air bag (inflator) mod- ule or seat belt pretensioner to its full length 10 m (33 ft). Special tool (A): 09932-75030 8) Place 12 volts vehicle battery (1) near shorted end of deploy- 10 m (33 ft) ment harness (A).
Page 242 AIR BAG SYSTEM 10B-89 12) Notify all people in immediate area that you intend to deploy/ activate air bag (inflator) module or seat belt pretensioner. NOTE: • When air bag (inflator) module deploys and seat belt pretensioner activates, rapid gas expansion will create substantial report.
Page 243 10B-90 AIR BAG SYSTEM 18) Disconnect adapter cable (special tool) from air bag (inflator) module or seat belt pretensioner as soon as possible. This will prevent adapter cable (special tool) from damage due to possible contact with hot air bag (inflator) module or hot seat belt pretensioner.
Page 244: Deployment/Activation Inside Of Vehicle
AIR BAG SYSTEM 10B-91 Deployment/Activation Inside of Vehicle When vehicle will be destroyed, or salvaged for component parts, deploy air bag modules and/or activate seat belt pretensioners installed on vehicle. 1) Turn ignition switch to “LOCK” position, remove key and put on safety glasses.
Page 245 10B-92 AIR BAG SYSTEM 5) Check that there is no open, short or damage in special tools (deployment harness (A) and adapter cable (B)). If any faulty condition is found, do not use it and be sure to use new deployment harness (A) and/or adapter cable (B).
Page 246 AIR BAG SYSTEM 10B-93 7) Connect deployment harness (A) and/or adapter cable (B) to air bag (inflator) module or seat belt pretensioner as follows. Special tool (A) : 09932-75030 (B) : 09932-78320 • For driver air bag (inflator) module Connect adapter cable (B) to deployment harness (A) and lock connectors with lock slider.
Page 247 10B-94 AIR BAG SYSTEM 8) Route deployment harness (1) out of vehicle. 9) Verify that inside of vehicle and area surrounding vehicle are clear of all people and loose or flammable objects. 10) Stretch deployment harness (1) to its full length 10 m (33 ft). 11) Place 12 volts vehicle battery (2) near shorted end of deploy- ment harness (1).
Page 248 AIR BAG SYSTEM 10B-95 17) Repeat Steps 2) through 16) to deploy/activate air bag (infla- tor) modules and seat belt pretensioners which has not been deployed/activated, if any. 18) In the unlikely event that air bag (inflator) module and seat belt pretensioner after following these procedures, proceed immediately with Step 24) through 26).
Page 249 10B-96 AIR BAG SYSTEM • For passenger air bag (inflator) module : Remove passenger air bag (inflator) module from instrument panel referring to “Passenger Air Bag (inflator) Module” in this section. • For side air bag (inflator) module : Remove seat bag (side air bag (inflator) module) from front seat referring to “Front Seat and Rear Seat”...
Page 250: Deployed Air Bag (Inflator) Module And Activated Seat Belt Pretensioner Disposal
AIR BAG SYSTEM 10B-97 Deployed Air Bag (Inflator) Module and Acti- vated Seat Belt Pretensioner Disposal WARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury.
Page 251: Tightening Torque Specification
(See NOTE “A” and WARNING.) 09932-75041 09932-78310 09932-78320 09931-76011 Passenger air bag (infla- Adapter cable Deployment adapter cable SUZUKI scan tool (Tech tor) module deployment 1A) kit (See NOTE “C”.) fixture 09931-76030 09932-75420 16/14 pin DLC cable Mass storage cartridge for...
Page 252 AIR BAG SYSTEM 10B-99 WARNING: Be sure to use the specified digital multimeter. Otherwise, air bag deployment or personal injury may result. NOTE: • “A” : Digital multimeter for which the maximum test current is 10 mA or less at the minimum range of resistance measurement.
Page 253 Prepared by Service Department 1st Ed. November, 2001 Printed in Hungary...
Page 254 Prepared by Service Department 1st Ed. November, 2001 Printed in Hungary...

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Wagon r rb413

Suzuki Wagon R RB310 Supplementary Service Manual

General Information

Precautions

Warning, Caution and Information Labels

Section 5E Antilock Brake System (Abs)

General Description

Diagnosis

On-Vehicle Service

Special Tool

Section 6F1 Ignition System (Electronic Ignition System)

General Description

Diagnosis

On-Vehicle Service

Special Tools

Section 7B Automatic Transmission (4 A/T)

General Description

Diagnosis

Automatic Transmission (4 A/T)

On-Vehicle Service

Tightening Torque Specification

Special Tool

Required Service Material

Section 8D Windows, Mirrors, Security and Locks

Diagnosis

On-Vehicle Service

Section 8G Immobilizer Control System

On-Vehicle Service

Special Tools

Section 10B Air Bag System

General Description

Diagnosis

On-Vehicle Service

Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal

Tightening Torque Specification

Special Tool

Quick Links

Chapters

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Summary of Contents for Suzuki Wagon R RB310