Suzuki Wagon R Plus RB310, Wagon R Plus RB413 Service Manual

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by
these signal words.

WARNING:

Indicates a potential hazard that could result in death or injury.

CAUTION:

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

WARNING:

This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.

WARNING:

For vehicles equipped with a Supplemental Restraint (Air Bag) System:

• 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 ser­vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser­vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. 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.

• Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components beforehand to avoid component damage or unin­tended activation.

The circle with a slash or a cross on illustllation in this manual means “Do not do this” or “Do not let this happen”.

Foreword

This SUPPLEMENTARY SERVICE MANUAL is a supplement to RB413 SERVICE MANUAL. It has been pre­pared exclusively for the following applicable model.

Applicable model: RB410/RB413 of and after the vehicle identification number below.

TSM MMA93S00 280001
TSM MMA33S00 280001
TSM MMB33S00 280001
TSM MMA33S40 280001

If describes only different service information of the above applicable model as compared with RB413 SERVICE
MANUAL. Therefore, whenever servicing the above applicable model, consult this supplement first. And for any
section, item or description not found in this supplement, refer to the related service manual below.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials (lubricant, sealants, etc.) as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest product infor­mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually
serviced.
The right is reserved to make changes at any time without notice.

RELATED MANUAL:

Manual Name Manual No.
RB413 SERVICE MANUAL 99500-83E00-01E
Wagon R+ (RB413) SUPPLEMENTARY SERVICE MANUAL 99501-83E00-01E
RB310 SERVICE MANUAL 99500-83E10-01E
Wagon R+ (RB310/RB413) SUPPLEMENTARY SERVICE MANUAL 99501-83E10-01E
Wagon R+ (RB310/RB413) SUPPLEMENTARY SERVICE MANUAL 99501-83E20-01E
RB310/413 WIRING DIAGRAM MANUAL 99512-83E30-669

© COPYRIGHT SUZUKI MOTOR CORPORATION 2003

Table of Contents

GENERAL INFORMATION

General Information 0A
Maintenance and Lubrication 0B Engine and Emission Control System

HEATING AND AIR CONDITIONING

Heater and Ventilation
Air Conditioning (Optional) 1B Ignition System (M13 Engine) 6F2

STEERING, SUSPENSION, WHEELS
AND TIRES

Steering, Suspension, Wheels and Tires
Front Wheel Alignment 3A
Manual Rack and Pinion 3B Charging System (G10/M13 Engines) 6H
Electrical Power Steering (EPS) System
(If Equipped)
Steering Wheel and Column
Front Suspension 3D
Rear Suspension 3E
Wheels and Tires 3F Manual Transaxle (M13 Engine) 7A2
DRIVE SHAFT AND PROPELLER SHAFT Automatic Transaxle (M13 Engine) 7B1
Front Drive Shaft (G10/M13 Engines) 4A Clutch (G10/M13 Engines) 7C
Propeller Shafts 4B Transfer 7D
BRAKES 5 Rear Differential 7F
Brakes Pipe/Hose/Master Cylinder 5A
Front Brake 5B
Parking and Rear Brake 5C Lighting System 8B
Antilock Brake System (ABS)

ENGINE

General Information and Engine
Diagnosis (G10 Engine)
Engine General Information and
Diagnosis (M13 Engine)
Engine Mechanical (G10 Engine)
Engine Mechanical (M13 Engine) 6A2
Engine Cooling (G10 Engine)
Engine Cooling (M13 Engine) 6B2
Engine Fuel (G10/M13 Engine)

1A

3

3B1

3C TRANSMISSION, CLUTCH AND

5E1 Instrumentation/Driver Information 8C 6-1 9

6-1

6-2

6A

6B

6C

Engine and Emission Control System
(G10 Engine)

(M13 Engine)
Ignition System (G10 Engine)

Cranking System (0.9 kw Reduction
Ty p e )
Cranking System (0.9 kw No-Reduction
Ty p e )

Exhaust System (G10 Engine)
Exhaust System (M13 Engine) 6K2

DIFFERENTIAL

Manual Transaxle (G10 Engine)

BODY ELECTRICAL SERVICE 8 5C 8D

Wiring Diagram

Windows, Mirrors, Security and Locks
Immobilizer Control System (G10/M13
Engines)

BODY SERVICE 9
RESTRAINT SYSTEM 10 6B2

Seat Belt
Air Bag System

6E1

6E2

6F1 1B 6G

6G

6G1

6K1 3D 7A2

7A 4A 7F

8A 5E1 8G

8D 6-2 10

8G

10A 6C
10B

0A 6E1
0B 6E2

6F1

1A 6F2

6G1

3 6H

3A 6K1
3B 6K2

3B1

3C 7A

3E 7B1
3F 7C

7D

4B

8

5 8A
5A 8B
5B 8C

6A 10A

6A2 10B

6B

NOTE:

For the screen toned sections in the above table, refer to the same section of Service Manual men­tioned in FOREWORD of this manual.

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

How to Use This Manual.................................0A-2

Precautions......................................................0A-3

Precaution for Vehicles Equipped with a

Supplemental Restraint (Air Bag) System.....0A-3

Diagnosis...................................................0A-4

Servicing and handling..............................0A-5

General Precautions .....................................0A-7

Precaution for CAN Communication

System ........................................................0A-10

Precaution for Wheel (with Tire) Removal...0A-10

Precautions for Catalytic Converter............. 0A-10

Precaution for Installing Mobile

Communication Equipment ......................... 0A-10

Precaution in Servicing Full-Time 4WD

Vehicle ........................................................0A-11

Precautions for Electrical Circuit Service .... 0A-12

Electrical Circuit Inspection Procedure........ 0A-15

Open circuit check...................................0A-15

Continuity check ...................................... 0A-16

Voltage check..........................................0A-16

Short circuit check (wire harness to

ground)....................................................0A-17

0A

CONTENTS

Intermittent and Poor Connection ............... 0A-17

Identification Information.............................0A-19

Vehicle Identification Number ..................... 0A-19

Engine Identification Number...................... 0A-19

Transmission Identification Number............ 0A-19

Warning, Caution and Information Labels.. 0A-20

Vehicle Lifting Points ...................................0A-21

When using frame contact hoist.............. 0A-21

When using floor jack.............................. 0A-22

Abbreviations and Symbols May be

Used in This Manual .....................................0A-23

Abbreviations .............................................. 0A-23

Symbols ...................................................... 0A-25

Wire Color Symbols .................................... 0A-25

Fastener Information.................................... 0A-26

Metric Fasteners Information ...................... 0A-26

Fastener Strength Identification.................. 0A-27

Standard Tightening Torque ....................... 0A-27

0A-2 GENERAL INFORMATION

How to Use This Manual

1) There is a “Table of Contents” on the third page of this manual, whereby you can easily find the section that
offers the information you need. Also, there is a “Contents” on the first page of each section, where the main
items in that section are listed.

2) Each section of this manual has its own pagination. It is indicated at the top of each page along with the Sec­tion name.

3) The special tool usage and torque specification are given as shown in the figure.

4) A number of abbreviations and symbols are used in the text. For their full explanations, refer to “Abbrevia-
tions and Symbols May Be Used In This Manual” in this section.

5) The SI, metric and foot-pound systems are used as units in this manual.

6) “Diagnosis” are included in each section as necessary.

7) At the end of each section, there are descriptions of “Special Tool”, “Required Service Material” and “Tight-
ening Torque Specification” that should be used for the servicing work described in that section.

GENERAL INFORMATION 0A-3

Precautions

Precaution for Vehicles Equipped with a Sup­plemental Restraint (Air Bag) System

WARNING:

• The configuration of air bag system parts are as shown
in the figure. When it is necessary to service (remove,
reinstall and inspect) these parts, be sure to follow
procedures described in Section 10B. Failure to follow
proper procedures could result in possible air bag sys­tem activation, personal injury, damage to parts or air

6

2

1

5

3

8

7

4

8

7

4

bag system being unable to activate when necessary.

• 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.

• Do not modify the steering wheel, dashboard, or any
other air bag system components. Modifications can
adversely affect air bag system performance and lead
to injury.

• If the vehicle will be exposed to temperatures over
93°C (200°F) (for example, during a paint baking pro­cess), remove the air bag system components before­hand to avoid component damage or unintended air
bag system activation.

1. Air bag wire harness
(in instrument panel harness)

2. Passenger air bag (inflator) module
(if equipped)

3. SDM 7. Side air bag (inflator) module

4. Seat belt pretensioner 8. Side sensor (if equipped)

5. Contact coil

6. Driver air bag (inflator) module

(if equipped)

0A-4 GENERAL INFORMATION

Diagnosis

• When troubleshooting air bag system, be sure to follow
“Diagnosis” in Section 10B. Bypassing these procedures

may result in extended diagnostic time, incorrect diagnosis,
and incorrect parts replacement.

• Never use electrical test equipment other than that specified
in this manual.

WARNI NG:

Never attempt to measure the resistance of the air bag
(inflator) modules (driver, passenger and side) and seat
belt pretensioners (driver and passenger). It is very dan­gerous as the electric current from the tester may deploy
the air bag or activate the pretensioner.

[A]

[B]

[C]

GENERAL INFORMATION 0A-5

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.

• When carrying a live air bag (inflator) module, make
sure the bag opening is pointed away from you. In case
of an accidental deployment, the bag will then deploy
with minimal chance of injury. Never carry the air bag
(inflator) module by the wires or connector on the
underside of the module. When placing a live air bag
(inflator) module on a bench or other surface, always
face the bag up, away from the surface. As the live pas­senger air bag (inflator) module must be placed with its
bag (trim cover) facing up, place it on the workbench
with a slit (1) or use the workbench vise (2) to hold it
securely at its lower mounting bracket (3). The front
seat back with the live air bag (inflator) module must
be placed with its frontal seat cover facing up. It is also
prohibited to place anything on top of the trim cover
and stack air bag (inflator) modules. This is necessary
so that a free space is provided to allow the air bag to
expand in the unlikely event of accidental deployment.
Otherwise, personal injury may result.

• Never dispose of live (undeployed) air bag (inflator)
modules (driver, passenger and side). If disposal is
necessary, be sure to deploy them according to
deployment procedures described in Section 10B
before disposal.

• The air bag (inflator) module immediately after deploy­ment is very hot. Wait for at least half an hour to cool it
off before proceeding the work.

• After an air bag (inflator) module has been deployed,
the surface of the air bag may contain a powdery resi­due. This powder consists primarily of cornstarch
(used to lubricate the bag as it inflates) and by-prod­ucts of the chemical reaction. As with many service
procedures, gloves and safety glasses should be worn.

[A]: Always carry air bag (inflator) module with trim cover (air bag opening) away from

body.

[B]: Always place air bag (inflator) module on workbench with trim cover (air bag open-

ing) up, away from loose objects.

[C]: Always place with its frontal seat cover facing up, away from loose objects.

0A-6 GENERAL INFORMATION

WARNING:

SDM

• 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.

• Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and
mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the
front of the vehicle to ensure proper operation of the air bag system.
The SDM could be activated when powered while not rigidly attached to the vehicle which could
cause deployment and result in personal injury.

WARNING:

Driver and Passenger Seat Belt Pretensioners (If equipped)

• For handling and storage of a live seat belt pretensioner, select a place where the ambient tempera­ture below 65°C (150°F), without high humidity and away from electric noise.

• Never carry seat belt pretensioner by wire or connector of pretensioner. When placing a live seat
belt pretensioner on the workbench or some place like that, never put something on seat belt pre­tensioner. Otherwise, personal injury may result.

• Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If disposal is nec­essary, be sure to activate them according to activation procedures described in Section 10B before
disposal.

• The seat belt pretensioner immediately after activation is very hot. Wait for at least half an hour to
cool it off before proceeding the work.

• With many service procedures, gloves and safety glasses should be worn to prevent any possible
irritation of the skin or eyes.

• Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys­tem parts and other related parts according to instructions under “Repair and Inspection Required
After an Accident” in Section 10B.

• When servicing parts other than air bag system, if shocks may be applied to air bag system compo­nent parts, remove those parts beforehand.

• When handling the air bag (inflator) modules (driver, passenger and side), seat belt pretensioners
(driver and passenger), side sensors or SDM, be careful not to drop it or apply an impact to it. If an
excessive impact was applied, never attempt disassembly or repair but replace it with a new one.

• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver, passen­ger and side) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth.

• Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire harness
branched off from floor and instrument panel wire harnesses can be identified easily as it is covered
with a yellow protection tube and it has yellow connectors. Be very careful when handling it.

• When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.

• Do not apply power to the air bag system unless all components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code.

• Never use air bag system component parts from another vehicle.

• When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pre-

tensioner connectors from air bag wire harness respectively.

• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.

GENERAL INFORMATION 0A-7

• WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to fol­low the instructions.

• After vehicle is completely repaired, perform “Air Bag Diagnostic System Check” in Section 10B.

General Precautions

The WARNING and CAUTION below describe some general precautions that you should observe when servic­ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and
they will not necessarily be repeated with each procedure to which they apply.

WARNING:

• Whenever raising a vehicle for service, be sure to follow the instructions under “Vehicle Lifting
Points” in this section.

• When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto­matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.

• When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

• Do not perform service work in areas where combustible materials can come in contact with a hot

exhaust system. When working with toxic or flammable materials (such as gasoline and refriger­ant), make sure that the area you work in is well-ventilated.

• To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail
pipe, muffler, etc.

• New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani­mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.

• Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.

• Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g, buttons) may cause damage to the vehicle’s
finish.

• When performing service to electrical parts that does
not require use of battery power, disconnect the nega­tive cable of the battery.

• When disconnecting the battery negative cable, record
displayed contents of clock and audio system before
disconnecting and reset them as before after connect­ing.

0A-8 GENERAL INFORMATION

• When removing the battery, be sure to disconnect the
negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first
and then the negative cable, and replace the terminal
cover.

• When removing parts that are to be reused, be sure to
keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and position.

• Whenever you use oil seals, gaskets, packing, O-rings,
locking washers, split pins, self-locking nuts, and cer­tain other parts as specified, be sure to use new ones.
Also, before installing new gaskets, packing, etc., be
sure to remove any residual material from the mating
surfaces.

• Make sure that all parts used in reassembly are perfectly
clean.
When use of a certain type of lubricant, bond or sealant
is specified, be sure to use the specified type.

“A”: Sealant 99000-31250

• Be sure to use special tools when instructed.

Special tool
(A): 09917-98221
(B): 09916-58210

GENERAL INFORMATION 0A-9

• When disconnecting vacuum hoses, attach a tag
describing the correct installation positions so that the
hoses can be reinstalled correctly.

• After servicing fuel, oil, coolant, vacuum, exhaust or
brake systems, check all lines related to the system for
leaks.

• For vehicles equipped with fuel injection systems, never
disconnect the fuel line between the fuel pump and
injector without first releasing the fuel pressure, or fuel
can be sprayed out under pressure.

• When performing a work that produces a heat exceeding
80°C (176°F) in the vicinity of the electrical parts, remove
the heat sensitive electrical part(s) beforehand.

• Use care not to expose connectors and electrical parts
to water which will be a cause of a trouble.

• Always be careful not to handle electrical parts (com­puter, relay, etc.) in a rough manner or drop them.

0A-10 GENERAL INFORMATION

33

2

Precaution for CAN Communication System

• The loose (1) in the wire harnesses twist of the CAN lines
except around the connector (3) should be within 100 mm
(3.9 in.) Refer to the wiring diagram for the CAN line discrim­ination. Excessive loosed lines may be influenced by the
electric noise.

2. Controller

1

2

• Do not connect terminals of the CAN line using a bypass

1

wire (1). Otherwise, the CAN line may be influenced by the
electric noise.

Precaution for Wheel (with Tire) Removal

Each wheel of this vehicle is installed using wheel bolts. When removing any of these wheels, never
remove all wheel bolts at the same time. Leave at least 1 bolt for each wheel as it is to prevent wheel
from dropping. When removing this remaining 1 bolt, hold wheel and tire so as not to allow them to
come off.

Precautions for Catalytic Converter

For vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a
large amount of unburned gasoline enter the converter or it can be damaged.

• Conduct a spark jump test only when necessary, make it as short as possible, and do not open the
throttle.

• Conduct engine compression checks within the shortest possible time.

• Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is

nearly empty.)

Precaution for Installing Mobile Communication Equipment

When installing mobile communication equipment such as CB (Citizens-Band) -radio or cellular-tele­phone, be sure to observe the following precautions.
Failure to follow cautions may adversely affect electronic control system.

• Keep the antenna as far away as possible from the vehicle’s electronic control unit.

• Keep the antenna feeder more than 20 cm (7.9 in) away from electronic control unit and its wire har-

nesses.

• Do not run the antenna feeder parallel with other wire harnesses.

• Confirm that the antenna and feeder are correctly adjusted.

GENERAL INFORMATION 0A-11

Precaution in Servicing Full-Time 4WD Vehicle

This full-time 4WD vehicle can not be converted to 2WD manually.
Observe the following caution in servicing. Otherwise, front wheels drive rear wheels or vise-versa and
vehicle accidents, drivetrain damage and personal injury may result.

• Never perform any of the following types of service
work.
[A]: Testing with 2-wheel chassis dynamometer, speed­ometer tester or brake tester.
[B]: Driving front wheels, which are jacked up.
[C]: Towing under the condition where either front or
rear wheels can not rotate.

• When testing with 2-wheel chassis dynamometer,
speedometer tester or brake tester, be sure to make the
vehicle as front wheel drive by removing propeller shaft.

• When using On-vehicle type wheel balancing equipment
(1), be sure to jack up all four wheels, off the ground
completely and support vehicle with safety stands (2).
Be careful of the other wheels, which will rotate at the
same time.

• This vehicle should be towed under one of the following
conditions:

– With all wheels on a flatbed truck.
– With front or rear wheels lifted and a dolly under the

other wheels.

0A-12 GENERAL INFORMATION

Precautions for Electrical Circuit Service

• When replacing a fuse, make sure to use a fuse of the
specified capacity. Use of a fuse with a larger capacity
will cause a damage to the electrical parts and a fire.

• When disconnecting and connecting coupler, make sure
to turn ignition switch OFF, or electronic parts may get
damaged.

• When disconnecting connectors, never pull the wiring
harness. Unlock the connector lock first and then pull
them apart by holding connectors themselves.

• When connecting connectors, also hold connectors and
put them together until they lock securely (a click is
heard).

GENERAL INFORMATION 0A-13

• When installing the wiring harness, fix it with clamps so
that no slack is left.

• When installing vehicle parts, be careful so that the wir­ing harness is not interfered with or caught by any other
part.

• To avoid damage to the harness, protect its part which
may contact against a part forming a sharp angle by
winding tape or the like around it.

• Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control unit
like as ECM, PCM, P/S controller, etc.). The static elec­tricity from your body can damage these parts.

• Never connect any tester (voltmeter, ohmmeter, or what­ever) to electronic control unit when its coupler is dis­connected. Attempt to do it may cause damage to it.

• Never connect an ohmmeter to electronic control unit
with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.

• Be sure to use a specified voltmeter/ohmmeter. Other­wise, accurate measurements may not be obtained or
personal injury may result. If not specified, use a voltme­ter with high impedance (M

/ V minimum) or a digital

Ω

type voltmeter.

0A-14 GENERAL INFORMATION

• When taking measurements at electrical connectors
using a tester probe, be sure to insert the probe (2) from
the wire harness side (backside) of the connector (1).

• When connecting meter probe (2) from terminal side of
coupler (1) because it can’t be connected from harness
side, use extra care not to bend male terminal of coupler
of force its female terminal open for connection.
In case of such coupler as shown connect probe as
shown to avoid opening female terminal.
Never connect probe where male terminal is supposed
to fit.

• When checking connection of terminals, check its male
half for bend and female half for excessive opening and
both for locking (looseness), corrosion, dust, etc.

• Before measuring voltage at each terminal, check to
make sure that battery voltage is 11 V or higher. Such
terminal voltage check at low battery voltage will lead to
erroneous diagnosis.

GENERAL INFORMATION 0A-15

Electrical Circuit Inspection Procedure

While there are various electrical circuit inspection methods,
described here is a general method to check its open and short
circuit by using an ohmmeter and a voltmeter.

Open circuit check

Possible causes for the open circuit are as follows. As the cause
is in the connector or terminal in many cases, they need to be
checked particularly carefully.

• Loose connection of connector

• Poor contact of terminal (due to dirt, corrosion or rust on it,

poor contact tension, entry of foreign object etc.)

• Wire harness being open

When checking system circuits including an electronic control unit
such as ECM, TCM, ABS control module, etc., it is important to
perform careful check, starting with items which are easier to
check.

1) Disconnect negative (–) cable from battery

2) Check each connector at both ends of the circuit being
checked for loose connection. Also check lock condition of
connector if equipped with connector lock.

3) Using a test male terminal, check both terminals of the circuit
being checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.

1. Check contact tension by inserting and removing just for once.

4) Using continuity check or voltage check the following proce­dure, check the wire harness for open circuit and poor con­nection with its terminals. Locate abnormality, if any.

1. Looseness of crimping

2. Open

3. Thin wire (single strand of wire)

0A-16 GENERAL INFORMATION

Continuity check

1) Measure resistance between connector terminals at both
ends of the circuit being checked (between A-1 and C-1 in
the figure). If no continuity is indicated (infinity or over limit),
that means that the circuit is open between terminals A-1
and C-1.

2) Disconnect the connector included in the circuit (connector-B
in the figure) and measure resistance between terminals A-1
and B-1.
If no continuity is indicated, that means that the circuit is
open between terminals A-1 and B-1. If continuity is indi­cated, there is an open circuit between terminals B-1 and C­1 or an abnormality in connector-B.

Voltage check

If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.

1) With all connectors connected and voltage applied to the cir­cuit being checked, measure voltage between each terminal
and body ground.

a) If measurements were taken as shown in the figure and

results were as listed below, it means that the circuit is open
between terminals B-1 and A-1.

Voltage between
C-1 and body ground: Approx. 5 V
B-1 and body ground: Approx. 5 V
A-1 and body ground: 0 V

b) Also, if measured values were as listed below, it means that

there is a resistance (abnormality) of such level that corre­sponds to the voltage drop in the circuit between terminals
A-1 and B-1.

Voltage between
C-1 and body ground: Approx. 5 V
B-1 and body ground: Approx. 5 V
A-1 and body ground: Approx. 3 V

GENERAL INFORMATION 0A-17

Short circuit check (wire harness to ground)

1) Disconnect negative (–) cable at battery.

2) Disconnect connectors at both ends of the circuit to be
checked.

NOTE:

If the circuit to be checked is connected to other parts
(1), disconnect all connectors of those parts.
Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit
(A-1 terminal in the figure) and body ground. If continuity is
indicated, it means that there is a short to ground between
terminals A-1 and C-1 of the circuit.

4) Disconnect the connector included in circuit (connector B)
and measure resistance between A-1 and body ground.
If continuity is indicated, it means that the circuit is shorted to
the ground between terminals A-1 and B-1.

1. To other parts

Intermittent and Poor Connection

Most intermittent are caused by faulty electrical connections or
wiring, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:

• Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).

• Dirt or corrosion on the terminals. The terminals must be
clean and free of any foreign material which could impede
proper terminal contact. However, cleaning the terminal with
a sand paper or the like is prohibited.

• Damaged connector body, exposing the terminals to mois­ture and dirt, as well as not maintaining proper terminal ori­entation with the component or mating connector.

0A-18 GENERAL INFORMATION

• Improperly formed or damaged terminals.
Check each connector terminal in problem circuits carefully
to ensure good contact tension by using the corresponding
mating terminal.
If contact tension is not enough, reform it to increase contact
tension or replace.

1. Check contact tension by inserting and removing just once.

2. Check each terminal for bend and proper alignment.

• Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor con­nection by shaking it by hand lightly. If any abnormal condi­tion is found, repair or replace.

• Wire insulation which is rubbed through, causing an intermit­tent short as the bare area touches other wiring or parts of
the vehicle.

• Wiring broken inside the insulation. This condition could
cause continuity check to show a good circuit, but if only 1 or
2 strands of a multi-strand-type wire are intact, resistance
could be far too high.
If any abnormality is found, repair or replace.

Identification Information

Vehicle Identification Number

The number is punched on front dash panel in engine room and it
is also on the left side of instrument panel depending on the vehi­cle specification.

Engine Identification Number

The number is punched on cylinder block.

1. M13 engine

2. G10 engine

GENERAL INFORMATION 0A-19

Transmission Identification Number

The number is located on the transmission case.

[A]: M/T for G10 engine

[B]: A/T for M13 engine

0A-20 GENERAL INFORMATION

Warning, Caution and Information Labels

The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.

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. Air bag caution label on passenger air bag (inflator) module

3. Pretensioner label on seat belt retractor 8. Air bag caution label on SDM

4. Tire information placard 9. Air bag caution label on side air bag (inflator) module

5. Air bag caution label on driver air bag (inflator) module 10. Side sensor caution label

GENERAL INFORMATION 0A-21

Vehicle Lifting Points

WARNING:

• Before applying hoist to underbody, always take vehicle balance throughout service into consider­ation. Vehicle balance on hoist may change depending on what part to be removed.

• Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.

• When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by try­ing to move vehicle body in both ways. Work can be started only after this confirmation.

• Make absolutely sure to lock hoist after vehicle is hoisted up.

When using frame contact hoist

1. Front left tire 4. Support position for frame contact hoist and safety stand

2. Rear left tire 5. Floor jack position

3. Vehicle front

0A-22 GENERAL INFORMATION

When using floor jack

WARNI NG:

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.

CAUTION:

Never apply jack against suspension parts (i.e., stabilizer
(3), etc.), front bumper (4) or vehicle floor, or it may get
deformed.

When lifting front vehicle end with floor jack, be sure to put the
wooden block (5) on the jack against front jacking bracket (1).
When lifting rear vehicle end with floor jack, be sure to put the
jack against the center portion of rear axle (2) (2WD vehicle) or
rear axle housing (6) (4WD vehicle).

To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands (1) under vehicle body so that vehi­cle body is securely supported. And then check to ensure that
vehicle body does not slide on safety stands (1) and the vehicle is
held stable for safety’s sake.

[A]: Front

[B]: Rear

Abbreviations and Symbols May be Used in This Manual

Abbreviations

GENERAL INFORMATION 0A-23

ABS Anti-lock Brake System
ATDC After Top Dead Center
API American Petroleum Institute
ATF Automatic Transmission Fluid EPS Electronic Power Steering
ALR Automatic Locking Retractor EVAP Evaporative Emission
AC Alternating Current EVAP Canister Evaporative Emission Canister

A

A/T Automatic Transmission
A/C Air Conditioning F 4WD 4 Wheel Drive
ABDC After Bottom Dead Center
A/F Air Fuel Mixture Ratio GND Ground
A-ELR Automatic-Emergency Locking

Retractor

B+ Battery Positive Voltage

B

BTDC Before Top Dead Center
BBDC Before Bottom Dead Center
CAN Controller Area Network IAT Sensor Intake Air Temperature Sensor
CKT Circuit
CKP sensor Crankshaft Position Sensor ICM Immobilizer Control Module
CMP sensor Camshaft Position Sensor IG Ignition
CO Carbon Monoxide ISC Actuator Idle Speed Control Actuator

C

CPP switch Clutch Pedal Position Switch

(Clutch Switch, Clutch Start

Switch)
CPU Central Processing Unit
CRS Child Restraint System
DC Direct Current MAP Sensor Manifold Absolute Pressure Sen­DLC Data Link Connector (Assembly

Line Diag. Link, ALDL, Serial Data

Link, SDL)

D

DOJ Double Offset Joint MIN Minimum
DRL Daytime Running Light MIL Malfunction Indicator Lamp
DTC Diagnostic Trouble Code (Diag-

nostic Code)
EBCM Electronic Brake Control Module,

ABS Control Module
EBD Electronic Brake Force Distribu-

tion
ECM Engine Control Module O/D Overdrive
ECT sensor Engine Coolant Temperature Sen-

E

sor (Water Temp. Sensor, WTS)
EGR Exhaust Gas Recirculation
EGRT sensor EGR Temperature Sensor (Recir-

culated Exhaust Gas Temp. Sen-

sor, REGTS)

EFE Heater Early Fuel Evaporation Heater

(Positive Temperature Coeffi­cient, PTC Heater)

E

(Charcoal Canister)

GEN Generator

G

HC Hydrocarbons

H

HO2S Heated Oxygen Sensor
IAC Valve Idle Air Control Valve (Idle Speed

Control Solenoid Valve ISC Sole­noid Valve)

I

LH Left Hand

L

LSPV Load Sensing Proportioning Valve
MAF Sensor Mass Air Flow Sensor (Air Flow

Max Maximum
MFI Multiport Fuel Injection

M

M/T Manual Transmission

N NOx Nitrogen Oxides

OBD On-Board Diagnostic System

O

OHC Over Head Camshaft
O2S Oxygen Sensor
PNP Park/Neutral Position

P

P/S Power Steering

(Air temperature Sensor, ATS)

Sensor, AFS, Air Flow Meter,
AFM)

sor (Pressure Sensor, PS)

(Multipoint Fuel Injection)DOHC Double Over Head Camshaft

(“SERVICE ENGINE SOON”
Light)

(Self-Diagnosis Function)

0A-24 GENERAL INFORMATION

PSP Switch Power Steering Pressure Switch

P

PCM Powertrain Control Module

(P/S Pressure Switch)

PCV Positive Crankcase Ventilation

R RH Right Hand

SAE Society of Automotive Engineers
SDM Sensing and Diagnostic Module

S

(Air bag controller, Air bag control

module)
SFI Sequential Multiport Fuel Injection
SOHC Single Over Head Camshaft
TBI Throttle Body Fuel Injection (Sin-

gle-Point Fuel Injection, SPI)
TCC Torque Converter Clutch
TCM Transmission Control Module (A/T

Controller, A/T Control Module)
TP Sensor Throttle Position Sensor

T

TVV Thermal Vacuum Valve (Thermal

Vacuum Switching Valve, TVSV,

Bimetal Vacuum Switching Valve,

BVSV)
TWC Three Way Catalytic Converter

(Three Way Catalyst)
2WD 2 Wheel Drive
VIN Vehicle Identification Number

V

VSS Vehicle Speed Sensor
VVT Variable Valve Timing
WU-OC Warm Up Oxidation Catalytic

W

WU-TWC Warm Up Three Way Catalytic

Converter

Converter

GENERAL INFORMATION 0A-25

Symbols

SYMBOL DEFINITION SYMBOL DEFINITION

Tightening torque Apply SEALANT 1216B

99000-31230

Apply oil (engine, transmission, trans­fer, differential)

Apply fluid (brake, power steering or
automatic transmission fluid)

Apply GREASE A 99000-25010

Apply GREASE C 99000-25030 Apply THREAD LOCK 1322

Apply GREASE E 99000-25050 Apply THREAD LOCK 1333B

Apply GREASE H 99000-25120 Apply THREAD LOCK 1342

Apply GREASE I 99000-25210

Apply SEALANT 1215 99000-31110 Do not reuse

Apply SEALANT 1207F 99000-31250 Note on reassembly

Apply SILICONE SEALANT
99000-31120

Apply SEALING COMPOUND 366E
99000-31090

99000-32110

99000-32020

99000-32050

Wire Color Symbols

Symbol Wire Color Symbol Wire Color

B BLK Black O, Or ORN Orange

BlBLUBlue RREDRed

Br BRN Brown W WHT White

G GRN Green Y YEL Yellow

Gr GRY Gray P PNK Pink

Lbl LT BLU Light blue V PPL Violet

Lg LT GRN Light green

There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure).

0A-26 GENERAL INFORMATION

Fastener Information

Metric Fasteners Information

Most of the fasteners used for this vehicle are JIS-defined and
ISO-defined metric fasteners. When replacing any fasteners, it is
most important that replacement fasteners be the correct diame­ter, thread pitch and strength.

CAUTION:

Even when the nominal diameter (1) of thread is the
same, the thread pitch (2) or the width across flats (3)
may vary between ISO and JIS. Refer to JIS-TO-ISO Main
Fasteners Comparison Table below for the difference.
Installing a mismatched bolt or nut will cause damage to
the thread.
Before installing, check the thread pitch for correct
matching and then tighten it by hand temporarily. If it is
tight, recheck the thread pitch.

JIS-TO-ISO Main Fasteners Comparison Table

Standard

JIS

ISO

Nominal diameter

Thread pitch 1.0 1.25 1.25 1.25 1.5
Width across flats 10 12 14 17 19
Thread pitch 1.0 1.25 1.5 1.5 1.5
Width across flats 10 13 16 18 21

M6 M8 M10 M12 M14

GENERAL INFORMATION 0A-27

Fastener Strength Identification

Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class
identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark
strength identification on the nut face. Figure shows the different strength markings.
When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the origi­nal fasteners (the same number marking or higher). It is likewise important to select replacement fasteners of
the correct diameter and thread pitch. Correct replacement bolts and nuts are available through the parts divi­sion.

Metric bolts: Identification class numbers or marks correspond to bolt strength (increasing numbers represent
increasing strength).

1. Nut strength identification

Standard Tightening Torque

Each fastener should be tightened to the torque specified in each section of this manual. If no description or
specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener.
When a fastener of greater strength than the original one is used, however, use the torque specified for the orig­inal fastener.

NOTE:

• For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening
torque given in the chart below.

• The chart below is applicable only where the fastened parts are made of steel light alloy.

0A-28 GENERAL INFORMATION

Tightening torque chart:

A equivalent of 4T strength
fastener

Thread Diameter (Nominal Diameter) (mm)

4 5 6 8 10 12 14 16 18

N·m 1.5 3.0 5.5 13 29 45 65 105 160

kg-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16

lb-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0

Strength

A equivalent of 6.8 strength
fastener without flange

A equivalent of 6.8 strength
fastener with flange

A equivalent of 7T strength
fastener

A equivalent of 8.8 strength
fastener without flange

N·m 2.4 4.7 8.4 20 42 80 125 193 280

kg-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28

lb-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5

N·m 2.4 4.9 8.8 21 44 84 133 203 298

kg-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8

lb-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5

N·m 2.3 4.5 10 23 50 85 135 210 240

kg-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24

lb-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0

N·m 3.1 6.3 11 27 56 105 168 258 373

A equivalent of 8.8 strength
fastener with flange

✱: Self-lock nut

kg-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3

lb-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0

N·m 3.2 6.5 12 29 59 113 175 270 395

kg-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5

lb-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

WARNING:

For vehicles equipped with a Supplemental Restraint (Air Bag) System:

• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “System Components and Wiring Location View and Connec-
tors” under “General Description” in air bag system section in order to confirm whether you are
performing service on or near the air bag system components or wiring. Please observe all WARN­INGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before per-
forming service on or around the air bag system components or wiring. Failure to follow
WARNINGS could result in unintentional activation of the system or could render the system inop­erative. Either of these two conditions may result in severe injury.

• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

0B

CONTENTS

Maintenance Schedule ...................................0B-3

Maintenance Schedule Under Normal

Driving Conditions .........................................0B-3

Maintenance Recommended Under

Severe Driving Conditions.............................0B-5

Maintenance Service.......................................0B-6

Drive Belt Inspection (M13 Engine)...............0B-6

Water pump and generator drive belt

inspection ..................................................0B-6

A/C Compressor drive belt (if equipped)

inspection ..................................................0B-6

Drive Belt Replacement (M13 Engine).......... 0B-6

Water pump and generator drive belt

replacement............................................... 0B-6

A/C Compressor drive belt (if equipped)

replacement............................................... 0B-6

Drive Belt Inspection (G10 Engine)...............0B-7

A/C compressor drive belt inspection (If

equipped) ..................................................0B-7

Water pump belt inspection.......................0B-7

Drive Belt Replacement (G10 Engine) ..........0B-8

A/C compressor drive belt replacement .... 0B-8

Water pump belt replacement ................... 0B-8

Camshaft Timing Belt Replacement

(G10 Engine).................................................0B-8

Valve Lash (Clearance) Inspection

(M13 Engine).................................................0B-8

Engine Oil and Oil Filter Replacement .......... 0B-9

Engine Coolant Replacement .....................0B-11

Exhaust System Inspection.........................0B-11

Spark Plugs Replacement...........................0B-11

Distributor Cap and Rotor Inspection

(G10 Engine)............................................... 0B-12

Air Cleaner Filter Inspection........................ 0B-12

Air Cleaner Filter Replacement................... 0B-12

Fuel Lines and Connections Inspection ...... 0B-12

Fuel Tank Inspection................................... 0B-13

PCV Valve Inspection ................................. 0B-13

Fuel Evaporative Emission Control

System Inspection....................................... 0B-13

Brake Discs and Pads (Front) Inspection ... 0B-13
Brake Drums and Shoes (Rear)

Inspection.................................................... 0B-14

Brake Hoses and Pipes Inspection ............. 0B-14

Brake Fluid Replacement............................ 0B-14

Brake Lever and Cable Inspection.............. 0B-14

Clutch Inspection ........................................ 0B-15

Tires Inspection........................................... 0B-15

Wheel Discs Inspection............................... 0B-16

Wheel Bearing Inspection........................... 0B-16

Suspension System Inspection................... 0B-16

Steering System Inspection ........................ 0B-16

Drive Shaft (Axle) Boots Inspection ............ 0B-17

Propeller Shafts (4WD) Inspection.............. 0B-17

Manual Transmission Oil Inspection ........... 0B-18

Manual Transmission Oil Replacement ...... 0B-18

Automatic Transmission Fluid Level

Inspection.................................................... 0B-18

Automatic Transmission Fluid

Replacement............................................... 0B-19

Automatic Transmission Fluid Cooler

Hose Inspection .......................................... 0B-19

0B-2 MAINTENANCE AND LUBRICATION

Transfer Oil (4WD) and Rear Differential

Oil (4WD) Inspection................................... 0B-19

Transfer Oil (4WD) and Rear Differential

Oil (4WD) Replacement.............................. 0B-20

All Latches, Hinges and Locks

Inspection.................................................... 0B-20

Doors ...................................................... 0B-20

Engine hood............................................ 0B-20

Ventilator Air Filter (If Equipped)................. 0B-20

Final Inspection ............................................ 0B-21

Recommended Fluids and Lubricants ....... 0B-23

MAINTENANCE AND LUBRICATION 0B-3

Maintenance Schedule

Maintenance Schedule Under Normal Driving Conditions

NOTE:

• This interval should be judged by odometer reading or months, whichever comes first.

• This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km

(54,000 miles), carry out the same services at the same intervals respectively.

Km (x 1,000) 15 30 45 60 75 90

Interval

ENGINE

Drive belt –– I ––R
Camshaft timing belt (G10 engine) Replace every 100,000 km (60,000 miles)
Valve lash (clearance) (M13 engine) – I – I – I

Engine oil and oil filter

Engine coolant – R – R – R
Exhaust system – I – I – I

IGNITION SYSTEM

When
unleaded

Spark plugs

✱

Distributor cap and rotor (G10 engine) –– I ––I

FUEL SYSTEM

Air cleaner filter

Fuel lines and connections – I – I – I
Fuel tank –– I –– I

EMISSION CONTROL SYSTEM

PCV valve ––––– I

✱

Fuel evaporative emission control system ––––– I

✱

fuel is used
When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Cond­tion” in this section.

Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72

When SG, SH, SJ, or SL grade oil
is used.

M13 engine Iridium plug

G10 engine ––R ––R

Paved-road I I R I I R

Dusty conditions

RRRRRR

Replace every 105,000 km (63,000 miles) or
84 months

Refer to “Maintenance Recommended
Under Severe Driving Conditions” in this
section.

NOTE:

•“R”: Replace or change

•“I”: Inspect and correct, replace or lubricate if necessary

• For Sweden, items with

• For spark plugs, replace every 50,000 km if the local law requires.

• Iridium spark plug: IFR6J11 (NGK)

• For camshaft timing belt (G10 engine), it may be replaced every 90,000 km (54,000 miles) according

to customer’s maintenance convenience.

(asterisk) should be performed by odometer reading only.

✱

0B-4 MAINTENANCE AND LUBRICATION

Km (x 1,000) 15 30 45 60 75 90

Interval

Miles (x 1,000) 9 1827364554
Months 12 24 36 48 60 72

BRAKE

Brake discs and pads (thickness, wear, damage) IIIIII
Brake drums and shoes (wear, damage) – I – I – I
Brake hoses and pipes (leakage, damage, clamp) – I – I – I
Brake fluid – R – R – R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles only)

CHASSIS AND BODY

Clutch (pedal height and travel) – I – I – I
Tires (wear, damage, rotation) / wheels (damage) IIIIII
Suspension system (tightness, damage, rattle, breakage) – I – I – I
Steering system (tightness, damage, breakage, rattle) – I – I – I
Drive shaft (axle) boots / Propeller shafts (4WD) –– I –– I
Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I – R ––R

Fluid level – I – I – I

Automatic transmission

Fluid change Replace every 165,000 km (99,000 miles)

Fluid hose ––– I ––
Transfer oil (4WD) (leakage, level) I – I – I –
Rear differential oil (4WD) (leakage, level) (R: 1st 15,000 km
only)

R or I – I – I –

All latches, hinges and locks – I – I – I
Ventilator air filter (if equipped) – IR– IR

NOTE:

•“R”: Replace or change

•“I”: Inspect and correct or replace if necessary

MAINTENANCE AND LUBRICATION 0B-5

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.

Severe condition code:

A: Repeated short trips E: Repeated short trips in extremely cold weather
B: Driving on rough and/or muddy roads F: Leaded fuel use
C: Driving on dusty roads G: – – – – –
D: Driving in extremely cold weather and/or salted roads H: Towing a trailer (if admitted)

Severe

Condition Code

Maintenance

Maintenance

Operation

– B C D – – – – Drive belt

A – C D E F – H Engine oil and oil filter R

1

– – C – – – – – Air cleaner filter

✱

Iridium spark plug

A B C – E F – H Spark plugs

of M13 engine

G10 engine R

– B C D – – – H Wheel bearings I

– B – D E – – H Drive shafts and propeller shafts (4WD) I

– B – – E – – H

– – CD – – – – Ventilator air filter

Manual transmission oil, transfer oil (4WD)
and differential oil (4WD)

2 (if equipped)

✱

– B – – E – – H Automatic transmission fluid R

Maintenance Interval

I

R

Every 15,000 km
(9,000 miles) or 12 months
Every 45,000 km
(27,000 miles) or 36 months
Every 5,000 km
(3,000 miles) or 4 months

I

R

R

Every 2,500 km
(1,500 miles)
Every 30,000 km
(18,000 miles) or 24 months
Every 30,000 km
(18,000 miles) or 24 months
Every 10,000 km
(6,000 miles) or 8 months
Every 15,000 km
(9,000 miles) or 12 months
Every 15,000 km
(9,000 miles) or 12 months
First time only: 15,000 km
(9,000 miles) or 12 months
Second time and after:

R

Every 30,000 km
(18,000 miles) or 24 months
reckoning from 0 km (0
miles) or 0 month

I

R

Every 15,000 km
(9,000 miles) or 12 months
Every 45,000 km
(27,000 miles) or 36 months
Every 30,000 km
(18,000 miles) or 24 months

NOTE:

•“I”: Inspect and correct or replace if necessary

•“R”: Replace or change

•

1: Inspect more frequently if the vehicle is used under dusty conditions.

✱

•

2: Clean or replace more frequently if the air from the ventilator decreases.

✱

0B-6 MAINTENANCE AND LUBRICATION

Maintenance Service

Drive Belt Inspection (M13 Engine)

WARNI NG:

All inspection and replacement are to be performed with
ENGINE NOT RUNNING.

Water pump and generator drive belt inspection

1) Disconnect negative (–) cable at battery.

2) Inspect belt for cracks, cuts, deformation, wear and cleanli­ness. If any defect exists, replace.
Check belt for tension.

Water pump and generator belt tension
“a”: 4.5 – 5.5 mm (0.18 – 0.22 in.) deflection under 100 N
(10 kg, 22 lb) pressure

NOTE:

When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.)

3) If belt is too tight or too loose, adjust it to specification by
adjusting alternator position.

4) Tighten alternator adjusting bolts and pivot bolt.

5) Connect negative (–) cable to battery.

A/C Compressor drive belt (if equipped) inspection

1) Disconnect negative (–) cable at battery.

2) Inspect belt for cracks, cuts, deformation, wear and cleanli­ness. If any defect exists, replace.
Check belt for tension.
If belt tension is out of specification, adjust it referring to “A/C
Compressor Driver Belt (M13 engine model)” in Section 1B.

A/C compressor drive belt tension
“a”: 3 – 5 mm (0.12 – 0.20 in.) deflection under 100 N
(10 kg, 22 lb) pressure

3) Connect negative (–) cable to battery.

Drive Belt Replacement (M13 Engine)

Water pump and generator drive belt replacement

Replace belt with new one referring to “Water Pump/Generator
Drive Belt Removal and Installation” in Section 6B2.

A/C Compressor drive belt (if equipped) replacement

Replace belt with new one referring to “A/C Compressor Drive
Belt (M13 engine model)” in Section 1B.

MAINTENANCE AND LUBRICATION 0B-7

Drive Belt Inspection (G10 Engine)

WARNING:

Disconnect negative cable at battery before checking and
replacing belt.

A/C compressor drive belt inspection (If equipped)

1) Hoist vehicle and remove engine under cover of right side
from vehicle body.

2) Inspect belt for wear, deterioration and tension.
Replace or adjust, if necessary.

A/C compressor drive belt tension “a”:
7 – 9 mm (0.28 – 0.35 in.) deflection under 100 N, 10 kg or
22 lb pressure

1. A/C compressor pulley

2. Blank

3. Tension pulley

4. Crankshaft pulley

Water pump belt inspection

1) Inspect belt for cracks, cuts, deformation, wear and cleanli­ness.
Replace, if necessary.

2) Check pump belt for tension and adjust it as necessary.

Water pump belt tension “a”:
7 – 9 mm (0.27 – 0.35 in.) deflection under 100 N, 10 kg or
22 lb pressure

Drive Belt Replacement (G10 Engine)

A/C compressor drive belt replacement

1) Disconnect negative cable from battery.

2) Remove engine under cover of right side.

3) Loosen belt tension and replace belt with new one.

4) Adjust belt tension to specification.

5) Install engine under cover and connect negative cable to bat­tery.

Water pump belt replacement

Replace belt with a new one. Refer to Section 6B for replacement
procedure of pump belt.

NOTE:

When replacing belt with a new one, adjust belt tension
to 6 – 7 mm (0.24 – 0.27 in.).

0B-8 MAINTENANCE AND LUBRICATION

Camshaft Timing Belt Replacement (G10 Engine)

Replace belt with new one. Refer to Section 6A for replacement
procedure.

CAUTION:

• Do not bend or twist timing belt.

• Do not allow timing belt to come into contact with oil,

water, etc.

Valve Lash (Clearance) Inspection (M13 Engine)

1) Inspect intake and exhaust valve lash and adjust as neces­sary.
Refer to “Valve Lash (Clearance) Inspection” in Section 6A2
for valve lash inspection and adjustment procedure.

1. Camshaft

2. Thickness gauge

MAINTENANCE AND LUBRICATION 0B-9

Engine Oil and Oil Filter Replacement

WARNING:

• New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.

• Step 1) – 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

Before draining engine oil, check engine for oil leakage. If any evi­dence of leakage is found, make sure to correct defective part
before proceeding to the following work.

1) Drain engine oil by removing drain plug.

2) After draining oil, wipe drain plug clean. Reinstall drain plug,
and tighten it securely as specified below.

Tightening torque
Engine oil drain plug (a): 50 N·m (5.0 kg-m, 36.5 lb-ft)

3) Loosen oil filter by using oil filter wrench (special tool).

Special tool
(A): 09915-47330

NOTE:

Before fitting new oil filter, be sure to oil its O-ring. Use
engine oil for this purpose.

4) Screw new filter on oil filter stand by hand until the filter O­ring contacts the mounting surface.

CAUTION:

To tighten oil filter properly, it is important to accurately
identify the position at which filter O-ring first contacts
the mounting surface.

0B-10 MAINTENANCE AND LUBRICATION

5) Tighten the filter (1) 3/4 turn from the point of contact with
the mounting surface using an oil filter wrench (2).

Tightening torque
Oil filter (b): 14 N·m (1.4 kg-m, 10.5 lb-ft) (for reference)

6) Replenish oil until oil level is brought to FULL level mark on
dipstick. (oil pan and oil filter capacity). The filler inlet is at
the top of the cylinder head cover.
It is recommended to use engine oil of SG, SH, SJ or SL
grade. Select the appropriate oil viscosity according to the
proper engine oil viscosity chart [A].

Engine oil specification

M13 Engine G10 Engine

Oil pan capacity

About 3.6 liters
(7.6/6.3 US/lmp pt.)

A bout 3.1 liters

(6.5/5.5 US/lmp pt.)
Oil filter capacity About 0.2 liter (0.4/0.3 US/lmp pt.)
Others About 0.3 liter (0.6/0.5 US/lmp pt.)

To t a l

About 4.1 liters
(8.7/7.2 US/lmp pt.)

A bout 3.6 liters

(7.5/6.3 US/lmp pt.)

NOTE:

Engine oil capacity is specified. However, note that the
amount of oil required when actually changing oil may
somewhat differ from the data in the table depending on
various conditions (temperature, viscosity, etc.)

7) Check oil filter and drain plug for oil leakage.

8) Start engine and run it for 3 minutes. Stop it and wait 5 min­utes before checking oil level. Add oil, as necessary, to bring
oil level to FULL level mark on dipstick.

1. Full level mark (hole)

2. Low level mark (hole)

MAINTENANCE AND LUBRICATION 0B-11

Engine Coolant Replacement

WARNING:

To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot. Scald­ing fluid and steam can be blown out under pressure if
cap is taken off too soon.

CAUTION:

When changing engine coolant, use mixture of 50% spec­ified water and 50% ANTIFREEZE / ANTICORROSION
COOLANT for the purpose of corrosion protection and
lubrication.

Change engine coolant with new one referring to “Cooling System
Flush and Refill” in Section 6B or 6B2.

Exhaust System Inspection

WARNING:

To avoid danger of being burned, do not touch exhaust
system when it is still hot. Any service on exhaust sys­tem should be performed when it is cool.

When carrying out periodic maintenance, or the vehicle is raised
for other service, check exhaust system as follows:

• Check rubber mountings for damage, deterioration, and out
of position.

• Check exhaust system for leakage, loose connections, dents
and damages.
If bolts or nuts are loose, tighten them to specification.

• Check nearby body areas for damaged, missing, or misposi­tioned parts, open seams, holes, loose connections or other
defects which could permit exhaust fumes to seep into the
vehicle.

• Make sure that exhaust system components have enough
clearance from the underbody to avoid overheating and pos­sible damage to the floor carpet.

• Any defects should be fixed at once.

Spark Plugs Replacement

Replace spark plugs with new ones referring to “Spark Plugs
Removal and Installation” in Section 6F or 6F2.

0B-12 MAINTENANCE AND LUBRICATION

Distributor Cap and Rotor Inspection (G10 Engine)

• Check distributor cap and rubber caps for cracks.

• Clean dusty and stained parts using a dry, soft cloth.

• Check center electrode and terminals for wear.

• Check rotor for cracks and its electrode for wear.

Repair or replace any component which is found to be in
malcondition.

Air Cleaner Filter Inspection

1) Unclamp air cleaner case clamps.

2) Take air cleaner filter out of case.

3) Check that filter is not excessively dirty, damaged or oily,
clean filter with compressed air from air outlet side of filter.

4) Install air cleaner filter and clamp upper case securely.

Air Cleaner Filter Replacement

Replace air cleaner filter with new one according to steps 1), 2)
and 4) of inspection procedure.

Fuel Lines and Connections Inspection

Visually inspect fuel lines and connections for evidence of fuel
leakage, hose cracking and damage. Make sure all clamps are
secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.

MAINTENANCE AND LUBRICATION 0B-13

Fuel Tank Inspection

Check fuel tank damage, cracks, fuel leakage, corrosion and tank
bolts looseness.
If a problem is found, repair or replace.

PCV Valve Inspection

Check crankcase ventilation hose and PCV hose for leaks, cracks
or clog, and PCV valve for stick or clog. Refer to “PCV valve”
under “PCV System Inspection” of Section 6E1 or 6E2 for PCV
valve checking procedure.

Fuel Evaporative Emission Control System Inspection

1) Visually inspect hoses for cracks, damage, or excessive
bends. Inspect all clamps for damage and proper position.

2) Check EVAP canister for operation and clog, referring to
“EVAP Canister” under “EVAP Control System Inspection” in
Section 6E1 or 6E2.

If a malfunction is found, repair or replace.

Brake Discs and Pads (Front) Inspection

1) Remove wheel and caliper but don’t disconnect brake hose
from caliper.

2) Check front disc brake pads and discs for excessive wear,
damage and deflection. Replace parts as necessary. For
details, refer to “Front Disc Brake Pad Inspection” and “Front
Brake Disc Inspection” in Section 5B.
Be sure to torque caliper pin bolts to specification.

0B-14 MAINTENANCE AND LUBRICATION

Brake Drums and Shoes (Rear) Inspection

1) Remove wheel and brake drum.

2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed. At the
same time, check wheel cylinders for leaks. Replace these
parts as necessary.

Brake Hoses and Pipes Inspection

Perform this inspection where there is enough light and use a mir­ror as necessary.

• Check brake hoses and pipes for proper hookup, leaks,
cracks, chafing and other damage.

• Check that hoses and pipes are clear of sharp edges and
moving parts.

Repair or replace any of these parts as necessary.

CAUTION:

After replacing any brake pipe or hose, be sure to carry
out air purge operation.

Brake Fluid Replacement

Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
specified fluid and carry out air purge operation.
For air purging procedure, refer to “Bleeding Brake” in Section 5.

Brake Lever and Cable Inspection

1) Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition.

MAINTENANCE AND LUBRICATION 0B-15

2) Check tooth tip of each notch for damage or wear. If any
damage or wear is found, replace parking lever.

3) Check parking brake lever for proper operation and stroke,
and adjust it if necessary.
For checking and adjusting procedures, refer to “Parking
Brake Inspection and Adjustment” in Section 5.

Parking brake lever stroke
“a”: 4 – 9 notches (with 20 kg (44 lbs) of pull pressure)

Clutch Inspection

Check clutch pedal for height and free travel (1) referring to
“Clutch Pedal Height Check” and “Clutch Pedal Free Travel
Check” in Section 7C. Adjust or correct if necessary.

Tires Inspection

1) Check tires for uneven or excessive wear, or damage.
If defective, replace.
Refer to “Tire Diagnosis” in Section 3 for details.

1. Wear indicator

2) Check inflating pressure of each tire and adjust pressure to
specification as necessary.

NOTE:

• Tire inflation pressure should be checked when tires
are cool.

• Specified tire inflation pressure should be found on
tire placard or in owner’s manual which came with the
vehicle.

3) Rotate tires.
For details, refer to “Tire Rotation” in Section 3F.

0B-16 MAINTENANCE AND LUBRICATION

Wheel Discs Inspection

Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.

Wheel Bearing Inspection

1) Check front wheel bearing for wear, damage, abnormal
noise or rattles. For details, refer to “Wheel Disc, Nut and
Bearing Check” in Section 3D.

2) Check rear wheel bearing for wear, damage, abnormal noise
or rattles. For details, refer to “Wheel Disc, Nut and Bearing
Check” in Section 3E.

Suspension System Inspection

• Inspect front struts & rear shock absorbers for evidence of oil
leakage, dents or any other damage on sleeves; and inspect
anchor ends for deterioration.
Replace defective parts, if any.

• Check front and rear suspension systems for damaged,
loose or missing parts; also for parts showing signs of wear
or lack of lubrication.
Repair or replace defective parts, if any.

• Check front suspension arm ball joint stud dust seals for
leakage, detachment, tear or any other damage.
Replace defective boot, if any.

Steering System Inspection

1) Check steering wheel for play and rattle, holding vehicle
straight on ground.

Steering wheel play
“a”: 0 – 30 mm (0 – 1.1 in.)

2) Check bolts and nuts for tightness and retighten them as
necessary. Repair or replace defective parts, if any.

MAINTENANCE AND LUBRICATION 0B-17

3) Check steering linkage for looseness and damage. Repair or
replace defective parts, if any.

4) Check boots (1) and (2) of steering linkage and steering gear
case for damage (leak, detachment, tear, etc.). If damage is
found, replace defective boot with new one.
If any dent is found on steering gear case boots, correct it to
original shape by turning steering wheel to the right or left as
far as it stops and holding it for a few seconds.

5) Check universal joints (3) of steering shaft for rattle and dam­age. If rattle or damage is found, replace defective part with
a new one.

6) Check that steering wheel can be turned fully to the right and
left. Repair or replace defective parts, if any.

7) If equipped with power steering system, check also, in addi­tion to above check items, that steering wheel can be turned
fully to the right and left more lightly when engine is running
at idle speed than when it is stopped. Repair, if found faulty.

8) Check wheel alignment referring to “Front Wheel Alignment
Inspection and Adjustment” in Section 3A.

Drive Shaft (Axle) Boots Inspection

Check drive shaft boots (wheel side and differential side) for
leaks, detachment, tear or other damage.
Replace boot as necessary.

Propeller Shafts (4WD) Inspection

1) Check propeller shaft connecting bolts for looseness. If
looseness is found, tighten to specified torque.

2) Check propeller shaft joints for wear, play and damage.
If any defect is found, replace.

3) Check propeller shaft center support for biting of foreign mat­ter, crack, abnormal noise and damage. If any defect is
found, replace.

0B-18 MAINTENANCE AND LUBRICATION

Manual Transmission Oil Inspection

1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.

2) Make sure that vehicle is placed level for oil level check.

3) Remove oil filler/level plug (1) of transmission.

4) Check oil level.
Oil level can be checked roughly by means of filler/level plug
hole. That is, if oil flows out of level plug hole or if oil level is
found up to hole when level plug is removed, oil is properly
filled.
If oil is found insufficient, pour specified oil up to level hole.
For specified oil, refer to “Manual Transaxle Oil Change” in
Section 7A or 7A2.

5) Apply sealant to filler/level plug and tighten it to specified
torque.

Manual Transmission Oil Replacement

1) Place the vehicle level and drain oil by removing drain plug
(2).

2) Apply sealant to drain plug after cleaning it and tighten drain
plug to specified torque.

3) Pour specified oil up to level hole.

4) Tighten filler plug to specified torque.
For recommended oil, its amount and tightening torque data,
refer to “Manual Transaxle Oil Change” in Section 7A or 7A2.

Automatic Transmission Fluid Level Inspec­tion

1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.

2) Make sure that vehicle is placed level for fluid level check.

3) Pull out dipstick and check fluid level.
For fluid level checking procedure, refer to “Fluid Level
Check at Normal Operating (Hot) Temperature (Hot Check)”
in Section 7B and be sure to perform it under specified con­ditions. If fluid level is low, replenish specified fluid.

1. Dipstick

2. Clamp

3. FULL HOT mark

4. LOW HOT mark

MAINTENANCE AND LUBRICATION 0B-19

Automatic Transmission Fluid Replacement

1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.

2) Make sure that vehicle is placed level for fluid level check.

3) Change fluid. For its procedure, refer to “Fluid Change” in
Section 7B.

1. Drain plug

Automatic Transmission Fluid Cooler Hose Inspection

Check automatic transaxle fluid cooler hose for fluid leakage,
cracks, damage and deterioration.
Replace hose and/or clamp if any faulty condition is found.

Transfer Oil (4WD) and Rear Differential Oil (4WD) Inspection

1) Check transfer case or differential for evidence of oil leakage.
Repair leaky point if any.

2) Make sure that vehicle is placed level for oil level check.

3) Remove level plug of transfer or differential and check oil
level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found
up to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified
oil referring to “Transfer Oil Change” in Section 7D or “Rear
Differential Oil Change” in Section 7F.

[A]: Transfer

[B]: Rear differential

1. Oil level/filler plug

2. Drain plug

4) Tighten level plug to specified torque referring to “Tra n s fe r
Oil Change” in Section 7D or “Rear Differential Oil Change”
in Section 7F.

0B-20 MAINTENANCE AND LUBRICATION

Transfer Oil (4WD) and Rear Differential Oil (4WD) Replacement

Change transfer oil and differential oil with new specified oil refer­ring to “Transfer Oil Change” in Section 7D or “Rear Differential
Oil Change” in Section 7F.

All Latches, Hinges and Locks Inspection

Doors

Check that each door of front, rear and back doors opens and
closes smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair
door lock system.

Engine hood

Check that secondary latch operates properly (check that sec­ondary latch keeps hood from opening all the way even when
pulling hood release handle inside vehicle.) Also check that hood
opens and closes smoothly and properly and hood locks securely
when closed.
If any malfunction is found, lubricate hinge and latch, or repair
hood lock system.

Ventilator Air Filter (If Equipped)

Inspection

1) Remove air filter from air inlet box or cooling unit by remov­ing filter cover located on bottom of case.

2) Check filter for dirt. Replace excessively dirty filter.

3) Blow off dust by compressed air from air outlet side of filter.

4) Install filter to air inlet box or cooling unit.

Replacement

Replace ventilator air filter with new one.

MAINTENANCE AND LUBRICATION 0B-21

Final Inspection

WARNING:

When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to
prevent any accident.

SEATS

Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front
seat back allows it to be locked at any angle.

SEAT BELT

Inspect belt system including webbing, buckles, latch plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE BELT” label on front seat belt is visible, replace belt.

BATTERY ELECTROLYTE LEVEL CHECK

Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If bat­tery is equipped with built-in indicator, check battery condition by the indicator.

ACCELERATOR PEDAL OPERATION

Check that pedal operates smoothly without getting caught or interfered by any other part.

ENGINE START

Check engine start for readiness.

WARNING:

Before performing the following check, be sure to have enough room around the vehicle. Then, firmly
apply both the parking brake and the regular brakes. Do not use the accelerator pedal. If the engine
starts, be ready to turn off the ignition promptly. Take these precautions because the vehicle could
move without warning and possibly cause personal injury or property damage.

On automatic transmission vehicles, try to start the engine in each select lever position. The starting motor
should crank only in “P” (Park) or “N” (Neutral).
On manual transmission vehicles, place the shift lever in “Neutral,” depress clutch pedal fully any try to start.

EXHAUST SYSTEM CHECK

Check for leakage, cracks or loose supports.

CLUTCH (FOR MANUAL TRANSMISSION)

Check for the following.

• Clutch is completely released when depressing clutch pedal,

• No slipping clutch occurs when releasing pedal and accelerating.

• Clutch itself is free from any abnormal condition.

GEARSHIFT OR SELECT LEVER (TRANSMISSION)

Check gear shift or select lever for smooth shifting to all positions and for good performance of transmission in
any position.
With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to
which position select lever is shifted to.
With automatic transmission equipped vehicle, make sure that vehicle is at complete stop when shifting select
lever to “P” range position and release all brakes.

0B-22 MAINTENANCE AND LUBRICATION

FOOT BRAKE

Check the followings:

• that brake pedal has proper travel,

• that brake works properly,

• that it is free from noise,

• that vehicle does not pull to one side when brake is applied.

• and that brake do not drag.

PARKING BRAKE

Check that lever has proper travel.

WARNING:

With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any per­sonal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should
start to move.

Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.

STEERING

• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling.

• Check that the vehicle does not wander or pull to one side.

ENGINE

• Check that engine responds readily at all speeds.

• Check that engine is free from abnormal noise and abnormal vibration.

BODY, WHEELS AND POWER TRANSMITTING SYSTEM

Check that body, wheels and power transmitting system are free from abnormal noise and abnormal vibration or
any other abnormal condition.

METERS AND GAUGE

Check that speedometer, odometer, fuel meter, temperature gauge, etc. are operating accurately.

LIGHTS

Check that all lights operate properly.

WINDSHIELD DEFROSTER

Periodically check that air comes out from defroster outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan switch lever to “HI” position for this check.

MAINTENANCE AND LUBRICATION 0B-23

Recommended Fluids and Lubricants

Engine oil

Engine coolant
(Ethylene glycol base coolant)

SG, SH, SJ or SL grade (Refer to “Engine Oil and Oil Filter Replace­ment” in this section for engine oil viscosity.)

“Antifreeze / Anticorrosion coolant”

Brake fluid DOT 4 or SAE J1704
Manual transmission oil Refer to “Manual transaxle Oil Change” in Section 7A or 7A2.
Automatic transmission fluid An equivalent of DEXRON

®

-III
Transfer oil (4WD) Refer to “Transfer Oil Change” in Section 7D.
Differential oil (4WD) Refer to “Rear Differential Oil Change” in Section 7F.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant

0B-24 MAINTENANCE AND LUBRICATION

AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

AIR CONDITIONING (OPTIONAL)

WARNING:

For vehicles equipped with Supplemental Restraint (Air Bag) System:

• 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 Section 10B in order to confirm whether you are performing service on or
near the air bag system components or wiring. Please observe all WARNINGs and “Service Precau­tions” under “On-Vehicle Service” in Section 10B before performing service on or around the air
bag system components or wiring. Failure to follow WARNINGs could result in unintentional activa­tion of the system or could render the system inoperative. Either of these two conditions may result
in severe injury.

• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

CAUTION:

The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte­nance. For identification between these two types, refer to the description in page 1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

1B

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

CONTENTS

Diagnosis........................................................ 1B-2

Wiring Circuit (M13 Engine Model)............... 1B-2

A/C System Inspection of ECM and Its

circuits (M13 Engine Model)......................... 1B-3

Compressor Drive Belt

(M13 Engine Model)..................................... 1B-5

On-Vehicle Service ........................................ 1B-6

Dual Pressure Switch................................... 1B-6

A/C Compressor Relay ................................ 1B-6

Compressor (M13 Engine Model) ................ 1B-7

1B-2 AIR CONDITIONING (OPTIONAL)

Wiring Circuit (M13 Engine Model)

Diagnosis

1. Main fuse box 7. A/C switch 13. A/C evaporator thermistor

2. Main relay 8. Dual pressure switch 14. ECT sensor

3. Radiator (and condenser) cooling fan motor relay 9. Blower fan motor relay 15. Compressor relay

4. Radiator (and condenser) cooling fan motor 10. Blower fan motor 16. Compressor

5. Ignition switch 11. Blower fan motor resistor 17. Connector

6. Circuit fuse box 12. Blower fan switch 18. ECM

AIR CONDITIONING (OPTIONAL) 1B-3

A/C System Inspection of ECM and Its cir­cuits (M13 Engine Model)

ECM and its circuits can be checked at ECM wiring couplers by
measuring voltage.

CAUTION:

ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
disconnected from it.

Inspection

1) Remove ECM (1) from vehicle.

2) Connect ECM (1) couplers to ECM.

[A]: Fig. A

[B]: Fig. B

2. E22-01

3) Check voltage at each terminal of couplers connected. Refer
to next page and “Inspection of ECM and Its Circuits” in Sec­tion 6–2.

NOTE:

As each terminal voltage is affected by the battery volt­age, confirm that it is 11 V or more when ignition switch
is ON.

a. To “A/C” fuse (10A) in circuit fuse box 1. A/C switch 6. Blower fan switch 11. Main relay

1B-4 AIR CONDITIONING (OPTIONAL)

b. To “HEATER” fuse (25A) in circuit fuse box 2. Dual pressure switch 7. A/C evaporator thermistor 12. Radiator (and condenser) cooling

c. To “IG COIL” fuse (15A) in circuit fuse box 3. Blower fan motor relay 8. ECT sensor 13. Radiator (and condenser) cooling

d. To “FI” fuse (20A) in main fuse box 4. Blower fan motor 9. Compressor relay 14. ECM

e. To “RDTR” fuse (30A) in main fuse box 5. Blower fan motor resistor 10. Compressor

fan motor relay

fan motor

Terminal Arrangement of ECM Coupler (viewed from Harness Side)

ECM Voltage Values Table for Relation of A/C Control (M13 Engine Model)

Termi -

nal

E22-01 BLK Main ground

E21-05 BLK/

Wire Circuit Measurement

ground

Ground to

RED

for ECM
Power supply
for engine con-

body (Fig A)
Ground to
engine (Fig B)

Normal value Condition

–0.3 – 0.3 V Ignition switch ON

10 – 14 V Ignition switch ON

trol

E23-01 BLK/

YEL

ECM ground
for power cir-

Ground to
body (Fig A)

–0.3 – 0.3 V Ignition switch ON

cuit

E21-06 BLK/

RED

Power supply
for engine con-

Ground to
engine (Fig B)

10 – 14 V Ignition switch ON

trol

E21-4 BLU Radiator

(condenser)
cooling fan
relay output

Ground to
engine (Fig B)

0 – 1 V A/C switch ON or engine coolant

temp. sensor more than 96 ºC

(205

ºF) with engine running

10 – 14 V Except the above-mentioned with

engine running

E23-15 BLU/

BLK

E23-11 ORN Compressor

E23-02 BLK/

YEL

Main relay Ground to

engine (Fig B)
Ground to

magnet clutch

engine (Fig B)
relay output
ECM ground
for power cir-

Ground to

body (Fig A)

0 – 1 V Ignition switch ON

10 – 14 V Ignition switch OFF

0 – 1 V A/C switch ON with engine running

10 – 14 V Except the above-mentioned with

engine running

–0.3 – 0.3 V Ignition switch ON

cuit

E21-15 GRN/

RED

Evaporator
thermistor
temp.
input

Ground to

engine (Fig B)

2.0 – 2.3 V

(1800 – 2200

3.5 – 3.6 V

(6300 – 7000

Evaporator thermistor temp. at

)

Ω

Approx. 25 ºC (77 ºF) with

switch ON

Evaporator thermistor temp. at

)

Ω

Approx. 0 ºC (32 ºF) with ignition

ignition

switch ON

AIR CONDITIONING (OPTIONAL) 1B-5

Termi -

Wire Circuit Measurement

nal

E21-30 LT

GRN/

RED

E22-16 YEL/

GRN

E22-28 BRN/

WHT

E21-13 PNK/

BLU

ground

A/C switch
input

Engine coolant
temperature

Ground to
engine (Fig B)

Ground to
engine (Fig B)

sensor input

Sensor ground Ground to

body (Fig A)
Blower fan
speed input

Ground to

engine (Fig B)

Normal value Condition

0 – 1 V A/C switch ON with ignition switch

ON

10 – 14 V A/C switch OFF with ignition switch

ON

0.71 – 0.76 V

(290 – 320

Engine coolant temperature at

)

Ω

Approx. 80 ºC (176 ºF) with ignition
ON

0.35 – 0.37 V

(136 – 144

Engine coolant temperature at

)

Ω

Approx. 110 ºC (230 ºF) with ignition
ON

–0.3 – 0.3 V Ignition switch ON

0 – 2 V Blower switch 2nd, 3rd or 4th position

with ignition switch ON

3 – 5 V • Blower switch 1st position with igni-

tion switch ON

• A/C switch ON and blower switch
off with ignition ON

10 – 14 V Blower switch OFF position with igni-

tion switch ON

Compressor Drive Belt (M13 Engine Model)

Inspection

• Check compressor drive belt (6) for wear and cracks, and
replace as required.

• Check compressor drive belt (6) tension by measuring how
much it deflects when pushed at intermediate point between
compressor pulley (1) and tension pulley (2) with about 100
N (10 kg, 22 lbs) force after crankshaft pulley 1 rotating. If
belt tension is without specification, adjust belt tension refer­ring to below procedures.

Compressor drive belt tension
“a”: 3 – 5 mm (0.12 – 0.20 in.)
New compressor drive belt tension
“a”: 2 – 4 mm (0.08 – 0.16 in.)

Adjustment

1) Loosen tension pulley nut (3).

2) Adjust belt tension by tighten or loosen tension pulley adjust­ing bolt (4).

3) Tighten tension pulley nut (3).

4) Turn the crank pulley (5) 1 revolution, then check belt ten­sion.

Replacement

1) Loosen tension pulley nut (3).

2) Loosen belt tension by loosen tension pulley adjusting bolt
(4).

3) Remove compressor drive belt (6).

1B-6 AIR CONDITIONING (OPTIONAL)

4) Install new compressor drive belt.

5) Adjust belt tension referring to above procedure.

On-Vehicle Service

Dual Pressure Switch

Inspection

1)

Check dual pressure switch (1) for continuity at normal tempera­ture (approx. 25
charge of refrigerant and when A/C system (compressor) is
under operation. In each of these cases, switch should show
proper continuity.

2) Check switch for continuity at specified pressure as shown.

ºC (77 ºF)) when A/C system has a proper

Continuity

No continuity

A: Approx 200 KPa (2.0 kg/cm2)

CD

AB

Pressure

B: Approx 3200 KPa (32 kg/cm
C: Approx 260 KPa (2.6 kg/cm
D: Approx 2600 KPa (26 kg/cm

A/C Compressor Relay

Inspection

1) Disconnect negative cable at battery.

2) Remove A/C compressor relay (1) from relay box (2).

2

)

2

)

2

)

3) Check resistance between each two terminals as in table
below. If check results are as specified, proceed to next
operation check. If not, replace.

Terminals Resistance

Between A and B

Between C and D

(infinity)

∞

Approx. 170

Ω

AIR CONDITIONING (OPTIONAL) 1B-7

4) Check that there is continuity between terminals “A” and “B”
when battery is connected to terminals “C” and “D”. If found
defective, replace.

Compressor (M13 Engine Model)

Removal

1) Run engine at idle speed with air conditioning ON for 10 min­utes. After that, stop the engine.

2) Disconnect negative (–) cable at battery.

3) Recover refrigerant from refrigeration system by using recov­ery and recycling equipment.

4) Remove front bumper.

5) Remove engine front cover.

6) Disconnect magnet clutch lead wire and disengage lead wire
clamp.

7) Remove compressor drive belt by loosening tension pulley
bolt (1) and adjust bolt (2).

8) Disconnect suction and discharge hoses from compressor.

NOTE:

Cap open fittings immediately to keep moisture out of
system.

9) Remove compressor with magnet clutch assembly (1) from
its mount by loosening mounting bolts (2).

10) Drain oil from compressor, and measure its amount.

1B-8 AIR CONDITIONING (OPTIONAL)

FRONT WHEEL ALIGNMENT 3A-1

SECTION 3A

FRONT WHEEL ALIGNMENT

WARNING:

Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by
the wheel bolts.
Leave a bolt at least not to drop the wheel.
Support the wheel and/or tire and then remove the bolt(s) left with the wheel.

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

3A

General Description........................................3A-2

Front Wheel Alignment Specifications .......... 3A-2

3A-2 FRONT WHEEL ALIGNMENT

General Description

Front Wheel Alignment Specifications

Item Front Wheel

Toe (total)
Camber
Caster
Side Slip Limit mm/m
Steering Angle
(Turning angle)

NOTE:

Toe value in the specifications table was measured by using a toe-in gauge.

Inside
Outside (Reference)

0 ± 1 mm

–0 ° 20’ ± 1 °

3 ° 40’ ± 1 °

0 – IN 3 mm/m

35 ° ± 3 °
31 ° ± 3 °

Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts
and the ground. Generally, the only adjustment required for front alignment is toe setting.
Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to the
damage caused by hazardous road conditions or collision, whether the damage is in body or in suspension
should be determined. If the body is damaged, it should be repaired and if suspension is damaged, it should be
replaced.

MANUAL RACK AND PINION 3B-1

SECTION 3B

MANUAL RACK AND PINION

WARNING:

For vehicles equipped with Supplemental Restraint (Air Bag) System:

• Service on and around the air bag system components or wiring must be performed only by an
autho-rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“Gener-al Description” in air bag system section in order to confirm whether you are performing
service on or near the air bag system components or wiring. Please observe all WARNINGS and
“Service Precau-tions” under “On-Vehicle Service” in air bag system section before performing ser-
vice on or around the air bag system components or wiring. Failure to follow WARNINGS could
result in unintentional activation of the system or could render the system inoperative. Either of
these two conditions may result in severe injury.

• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

• Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by
the wheel bolts.
Leave a bolt at least not to drop the wheel.
Support the wheel and/or tire and then remove the bolt(s) left with the wheel.

3B

NOTE:

• All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/ or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci­fied during reassembly to assure proper retention of these parts.

• For discriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in “FOREWORD” of this manual.

CONTENTS

On-Vehicle Service..........................................3B-2

Tie Rod End ..................................................3B-2

Manual Rack and Pinion Assembly

(Steering Gear Case) ....................................3B-3

Tightening Torque Specifications................. 3B-4

3B-2 MANUAL RACK AND PINION

On-Vehicle Service

Tie Rod End

Installation

1) Install tie rod end lock nut (1) and tie rod end (2) to tie rod
(3). Align lock nut with mark (4) on tie rod thread.

2) Connect tie rod end to knuckle. Tighten new tie rod end nut
(1) to specified torque.

Tightening torque
Tie rod end nut (a): 40 N·m (4.0 kg-m, 29.0 lb-ft)

3) Inspect for proper toe (Refer to “Front Wheel Alignment”).

4) After confirming proper toe, tighten tie rod end lock nut to
specified torque.

Tightening torque
Tie rod end lock nut (a): 45 N·m (4.5 kg-m, 32.5 lb-ft)

5) Tighten wheel to specified torque and lower hoist.

Tightening torque
Wheel bolt: 95 N·m (9.5 kg-m, 69.0 lb-ft)

MANUAL RACK AND PINION 3B-3

Manual Rack and Pinion Assembly

(Steering Gear Case)

Installation

1) Apply grease to inside of pinion packing and install pinion
packing onto pinion. Mount steering gear case (1) to body
and tighten gear case mount bolts (2) and nuts (3) to speci­fied torque.

Tightening torque
Steering gear case mounting bolt and nut
(a): 25 N·m (2.5 kg-m, 18.0 lb-ft)

2) Install engine rear mounting bolt (1). Tighten bolts to speci­fied torque.

Tightening torque
Engine rear mounting bolt (a): 55 N·m (5.5 kg-m, 40 lb-ft)

3) Remove transmission jack.

4) Install tie rod ends to knuckles (right & left). Tighten each
new tie rod end nut (1) to specified torque.

Tightening torque
Tie rod end nut (a): 40 N·m (4.0 kg-m, 29.0 lb-ft)

5) Be sure that steering wheel and brake discs (right & left) are
all straight-ahead position and then insert steering lower joint
into steering pinion shaft.

6) Tighten steering shaft joint bolts (1) and (2) to specified
torque (Lower side first and then upper side).

Tightening torque
Steering shaft joint bolt (a): 28 N·m (2.8 kg-m, 20.5 lb-ft)

[A]: Power steering

[B]: Manual steering

3B-4 MANUAL RACK AND PINION

7) Reinstall cover (1) removed previously to steering shaft joint.

8) Put back floor mat as it was.

9) Install both wheels and tighten wheel bolts to specified
torque.

Tightening torque
Wheel bolt: 95 N·m (9.5 kg-m, 69.0 lb-ft)

10) Lower hoist.

11) Check toe setting. Adjust as required (refer to “Front Wheel
Alignment” in Section 3A).

12) Tighten both tie rod end lock nuts to specified torque.

Tightening torque
Tie rod end lock nut (a): 45 N·m (4.5 kg-m, 32.5 lb-ft)

Tightening Torque Specifications

Fastening part

Engine rear mounting bolt 55 5.5 40.0
Steering gear case mounting bolt and nut 25 2.5 18.0
Steering shaft joint bolt 28 2.8 20.5
Tie rod end lock nut 45 4.5 32.5
Tie rod end nut 40 4.0 29.0
Wheel bolt 95 9.5 69.0

N•m kg-m lb-ft

Tightening torque

ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-1

SECTION 3B1

ELECTRICAL POWER STEERING (EPS) SYSTEM

(IF EQUIPPED)

WARNING:

For vehicles equipped with the Supplemental Restraint (Air Bag) System:

• 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 Section 10B in order to confirm whether you are performing service on or
near the air bag system components or wiring. Please observe all WARNINGs and “Service Precau­tions” under “On-Vehicle Service” in Section 10B performing service on or around the air bag sys­tem components or wiring. Failure to follow WARNINGs could result in unintentional activation of
the system or could render the system inoperative. Either of these two conditions may result in
severe injury.

• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

3B1

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

CONTENTS

General Description......................................3B1-2

Wiring Diagram ...........................................3B1-2

Diagnosis.......................................................3B1-3

“EPS” Warning Lamp Circuit Check

Flow Table for M13 Engine Model .............. 3B1-3

Table-B “EPS” Warning Lamp

Remains ON ............................................... 3B1-4

3B1-2 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED)

General Description

Wiring Diagram

1. Main fuse box 8. Speedometer 15. Motor assembly (with clutch incorporated)

2. “EPS” fuse (30 A) 9. “EPS” warning lamp 16. Torque sensor

3. Ignition switch 10. To vehicle speed sensor (VSS) for G10 engine model,

4. Circuit fuse box 11. Noise suppressor for G10 engine model 18. Connector “G14”

5. “IG COIL” fuse (15A) 12. ECM/PCM 19. Connector “B”

6. “METER” fuse (10A) 13. To data link connector (DLC) 20. Connector “C”

7. Combination meter 14. P/S control module

To ECM/PCM for M13 engine model

17. P/S control module body ground

ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-3

Diagnosis

“EPS” Warning Lamp Circuit Check Flow Table for M13 Engine Model

CAUTION:

Be sure to perform “System Check Flow Table” before starting diagnosis according to flow table.

Step Action Yes No

1 1) Make sure that battery voltage is about 11 V

or higher.

2) Note “EPS” warning lamp as ignition switch
is turned to ON position.

Does “EPS” warning lamp come ON when igni­tion switch is turned to ON position?

2Check that “EPS” warning lamp lights for 2 sec.

and then goes OFF.

Go to Step 2. Proceed to “Ta b l e - A

“EPS” Warning Lamp
Does Not Light”.

“EPS” warning lamp is in
good condition.

Check for any DTC refer­ring to “Diagnostic Trouble
Code (DTC) Check” in
Section 6-1 for G10
engine model or in Sec­tion 6-2 for M13 engine
model. If there is any,
troubleshoot the prob­lem(s). If not, proceed to
“Ta bl e - B “EPS” War ni ng
Lamp Remains ON”.

3B1-4 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED)

Table- B “EPS” Warning Lamp Remains ON

Step Action Yes No

1Was “System Check Flow Table” performed? Go to Step 2. Go to “System Check

Flow Table” in this section.

2 1) With ignition switch OFF, disconnect 8 pin

(“A”) connector from P/S control module.

2) Measure resistance between “G14-5” termi-
nal of “A” connector and body ground.

Is resistance 1

or less?

Ω

3 1) Disconnect “G25” connector from Combina-

tion meter.

2) Turn ignition switch to ON position.

3) Check voltage between “G25-9” and body
ground.

Is it 10 – 14 V?

[A]: Fig. for Step 2

Go to step 3. Substitute a known-good

P/S control module and
recheck.

Replace bulb in combina­tion meter, and then

Repair short to ground in
“G14-5” wire circuit.

recheck.

FRONT SUSPENSION 3D-1

SECTION 3D

FRONT SUSPENSION

WARNING:

Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by
the wheel bolts.
Leave a bolt at least not to drop the wheel.
Support the wheel and/or tire and then remove the bolt(s) left with the wheel.

NOTE:

• All front suspension fasteners are an important attaching part in that it could affect the perfor­mance of vital parts and systems, and/or could result in major repair expense. They must be
replaced with one of the same part number or with an equivalent part if replacement becomes nec­essary. Do not use a replacement part of lesser quality or substitute design. Torque values must be
used as specified during reassembly to assure proper retention of this part.

• Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or
damage to the part may result.

• For descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

CONTENTS

General Description........................................3D-2

Diagnosis.........................................................3D-3

Wheel Disc, Bolt & Bearing Check................3D-3

On-Vehicle Service..........................................3D-4

Stabilizer Bar and/or Bushings......................3D-4

Strut Assembly ..............................................3D-5

Steering Knuckle / Bearing ........................... 3D-6

Suspension Control Arm / Bushing.............3D-12

Tightening Torque Specifications...............3D-14

Required Service Material............................3D-15

Special Tool...................................................3D-15

3D

3D-2 FRONT SUSPENSION

General Description

The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehi­cle body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also
installed a little lower to the rubber mount.
The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is
attached to the stud of a ball joint which is incorporated in a unit with a suspension control arm. And connected
to this steering knuckle is the tie-rod end.
Thus, movement of the steering wheel is transmitted to the tie-rod end and then to the knuckle, eventually caus­ing the wheel-and-tire to move. In this operation, with the movement of the knuckle, the strut also rotates by
means of the strut bearing and lower ball joint.

1. Strut assembly 3. Suspension control arm 5. Wheel bearing 7. Wheel Tightening torque

2. Steering knuckle 4. Ball stud 6. Front wheel hub 8. Wheel bolt

FRONT SUSPENSION 3D-3

Diagnosis

Wheel Disc, Bolt & Bearing Check

1) Inspect each wheel disc for dents, distortion and cracks. A
disc in badly damaged condition must be replaced.

2) Check wheel bolts for tightness and retighten them to specifi­cation as necessary.

Tightening torque

Wheel bolt (a): 95 N·m (9.5 kg-m, 69.0 lb-ft)

3) By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If defective, replace bearing.

4) Check wheel bearing for wear. When measuring thrust play,

a) Remove wheel.
b) Fix brake disc tightening wheel bolts.
c) Set a dial gauge.
d) Check wheel bearing for thrust play.

When measurement exceeds limit, replace bearing.

Thrust play limit “a”: 0.1 mm (0.004 in.)

3D-4 FRONT SUSPENSION

Stabilizer Bar and/or Bushings

Components

On-Vehicle Service

1. Split pin 4. Stabilizer bar bushing 7. Mount bushing 10. Paint mark Tightening torque

2. Castle nut 5. Suspension control arm 8. Mount bush bracket 11. Paint mark (RH side) Do not reuse.

3. Stabilizer bar washer 6. Stabilizer bar 9. Mount bracket bolt

Installation

For installation, reverse removal procedure, observing the follow­ing instructions.

• Install stabilizer bar (1) so that paint mark (2) on it comes to
the right side of vehicle.

• Align the outside edge (1) of mount bushing with the inside
edge (2) of paint as shown in figure.

FRONT SUSPENSION 3D-5

• Install mounting bracket (1) so that its oblong hole side (2)
comes to the rear.

• Tighten stabilizer bar bracket bolts to specified torque.

Tightening torque

Stabilizer bar bracket bolt: 45 N·m (4.5 kg-m, 32.5 lb-ft)

• After tightening castle nut (1) to specified torque, install new
split pin (2) as shown.

Tightening torque

Castle nut
(a): 50 – 150 N

m (5.0 – 15.0 kg-m, 36.5 – 108.5 lb-ft)

·

• Install wheels and tighten wheel bolts to specified torque.

Tightening torque

Wheel bolt (a): 95 N·m (9.5 kg-m, 69.0 lb-ft)

Strut Assembly

Installation

• Install strut assembly by reversing removal procedure.

CAUTION:

• Don’t twist brake hose when installing it.

• Install E-ring as far as it fits to bracket.

• Torque all fasteners to specification.

Tightening torque
Strut support nut: 23 N·m (2.3 kg-m, 17.0 lb-ft)
Strut bracket bolt:

115 N·m (11.5 kg-m, 83.5 lb-ft)

3D-6 FRONT SUSPENSION

Steering Knuckle / Bearing

Components

• Install wheel and tighten wheel bolts to specified torque.

Tightening torque

Wheel bolt (a) 95 N·m (9.5 kg-m, 69.0 lb-ft)

• Confirm front end (wheel) alignment, referring to Section 3A.

1. Wheel hub 5. Dust cover 9. Tie-rod end nut 13. Brake disk screw

2. Circlip 6. Tie-rod end 10. Control arm ball stud bolt 14. Brake disc

3. Wheel bearing:
Face grooved rubber seal side to
wheel hub.

4. Steering knuckle 8. Drive shaft nut:

7. Wheel speed sensor (if equipped) 11. Strut bracket bolt:

Calk, after tightening.

Insert from the direction as
shown.

12. Brake caliper carrier bolt Do not reuse.

Tightening torque

FRONT SUSPENSION 3D-7

Removal

1) Hoist vehicle and remove wheel.

2) Uncaulk drive shaft nut (1).

3) Depress foot brake pedal and hold it there. Remove drive
shaft nut.

4) Remove caliper carrier bolts.

5) Remove caliper with carrier.

NOTE:

Hang removed caliper with a wire hook of the like so as
to prevent brake hose from bending and twisting exces­sively or being pulled.
Don’t operate brake pedal with pads removed.

6) Remove brake disk screws.

7) Pull brake disc (1) off by using two 8 mm bolts (2).

8) Pull out wheel hub (1) with special tools.

Special tool
(A): 09943-17912
(B): 09942-15511

3D-8 FRONT SUSPENSION

9) Remove tie-rod end nut and disconnect tie-rod end (2) from
knuckle (1) with puller.

CAUTION:

• Never reuse tie-rod end nut.

• Reused nut will not be locked securely.

10) Remove wheel speed sensor (1) from knuckle (if equipped).

11) Remove strut bracket bolts (1) from strut bracket and then
control arm ball stud bolt (2).

12) Remove knuckle (3).

Disassembly

1) Uncaulk and remove dust cover (1).

FRONT SUSPENSION 3D-9

2) Remove circlip (1).

Special tool
(A): 09900-06108

3) Remove wheel bearing using special tool and hydraulic
press.

Special tool
(A): 09913-75810 (for gasoline engine model)
(A): 09913-85210 (for diesel engine model)

CAUTION:

• Never reuse wheel bearing.

• When replacing bearing, inner races or outer race, be

sure to replace them with new ones as a set.

4) Remove wheel bearing outside inner race (1) as shown by
hammering lightly at 3 locations around it so as not to cause
damage to seating part (2) of wheel hub.

Special tool
(C): 09913-61110
(D): 09925-88210

Assembly

1) Face grooved rubber seal side (1) of new wheel bearing
upward as shown and press-fit new wheel bearing into
knuckle using special tools.

Special tool
(A): 09913-75520 (for gasoline engine model)
(A): 09913-75510 (for diesel engine model)
(B): 09951-18210

3D-10 FRONT SUSPENSION

2) Install circlip (1).

Special tool
(A): 09900-06108

3) Drive in dust cover (1) so that dimensions “a” and “b”
become equal as shown.

CAUTION:

When drive in dust cover, be careful not to deform it.

4) Caulk with a punch.

Installation

1) Using special tools and hydraulic press (1), drive wheel hub
(2) into wheel bearing (3) as shown.

Special tool
(A): 09913-75810

FRONT SUSPENSION 3D-11

• Apply grease lightly to contact part (1) of wheel bearing and
drive shaft.

“A”: Grease 99000-25050

2) Install knuckle (2) to ball stud (3) on suspension control arm
(4) and strut bracket (1). Installing direction of each bolt is as
shown.
Align knuckle bolt hole with ball stud groove and install con­trol arm ball stud bolt (5). Tighten each bolt and nuts to spec­ified torque.

Tightening torque

Strut bracket bolt (a): 115 N·m (11.5 kg-m, 83.5 lb-ft)
Control arm ball stud bolt (b): 60 N

m (6.0 kg-m, 43.5 lb-ft)

·

F. F o r w a r d

3) Install wheel speed sensor (if equipped).

4) Connect tie-rod end (1) to knuckle (2) and install new tie-rod
end nut.
Tighten tie-rod end nut (3) to specified torque.

Tightening torque

Tie-rod end nut (c): 40 N·m (4.0 kg-m, 29.0 lb-ft)

5) Tighten new drive shaft nut temporarily.

3D-12 FRONT SUSPENSION

6) Install brake disc.

7) Tighten brake disc screws.

Tightening torque
Brake disc screw (a): 9 Nm (0.9

kg-m, 6.5 lb-ft)

8) Install brake caliper/caliper carrier.

9) Tighten caliper carrier bolts to specified torque.

Tightening torque

Brake caliper carrier bolt (b): 95 N·m (9.5 kg-m, 69.0 lb-ft)

10) Depress foot brake pedal and hold it there.
Tighten new drive shaft nut (1) to specified torque.

Tightening torque

Drive shaft nut (c): 175 N·m (17.5 kg-m, 127.0 lb-ft)

11) Calk drive shaft nut as shown.

CAUTION:

Be careful while caulking nut so that no crack will occur
in caulked part of nut. Cracked nut must be replaced with
new one.

12) Install wheel and tighten wheel bolts to specified torque.

Tightening torque

Wheel bolt: 95 N·m (9.5 kg-m, 69.0 lb-ft)

Suspension Control Arm / Bushing

Removal

1) Hoist vehicle and remove wheel referring to “Wheel
Removal” in Section 3F.

2) Remove split pin (12), stabilizer bar nut (10), washer (9) and
bushing (8).

3) Remove stabilizer bar mount bracket (right & left) bolts (5).

4) Remove ball stud bolt (2).

5) Remove suspension Control arm mounting bolt (6) and
washer.

6) Remove suspension control arm (7).

1. Stabilizer bar 8. Stabilizer bar bushing

2. Control ar m ball stud bolt 9. Washer

3. Knuckle 10. Stabilizer bar nut

4. Ball stud 11. Suspension control arm bushing:

5. Stabilizer bar bracket bolt 12. Split pin

6. Control ar m mounting bolt Tightening torque

Before installing, apply soap water.

7. Suspension control arm Do not reuse.

FRONT SUSPENSION 3D-13

7) Remove bushing.
Place suspension control arm onto flat surface side of spe­cial tool and push out bushing with special tool and oil
hydraulic press as shown.

Special tool
(A): 09943-77910

Installation

1) Place suspension control arm onto flat surface side of spe­cial tool and install new bushing with special tool and oil
hydraulic press as shown.

Special tool
(A): 09943-77910

NOTE:

• Before installing bushing, apply soap water on its cir­cumference to facilitate installation.

• When installed, bush should be equal on the right and
left of arm as shown.

2) Install suspension control arm to vehicle body and tighten
suspension Control arm mounting bolt (1) and washer tem­porarily.

3D-14 FRONT SUSPENSION

3) Install ball stud (2) to knuckle (1). Align ball stud groove with
knuckle bolt hole as shown.
Then install ball stud bolt from the direction as shown.
Tighten control arm ball stud bolt to specified torque.

Tightening torque

Control arm ball stud bolt
(a): 60 N

m (6.0 kg-m, 43.5 lb-ft)

·

4) Install wheel and tighten wheel bolts to specified torque.

Tightening torque

Wheel bolt (a): 95 N·m (9.5 kg-m, 69.0 lb-ft)

5) Lower hoist and vehicle in non-loaded condition, tighten con­trol arm mounting bolt (1) to specified torque.

Tightening torque

Control arm mounting bolt (a): 60 N·m (6.0 kg-m, 43.5 lb-ft)

• Install stabilizer bar, referring to “Stabilizer Bar Installation” in
this section.

Tightening Torque Specifications

Fastening part

N•m kg-m lb-ft

Brake caliper carrier bolt 95 9.5 69.0
Brake disk screw 9 0.9 6.5
Castle nut 50

– 150

Control arm ball stud bolt 60 6.0 43.5
Control arm mounting bolt 60 6.0 43.5
Drive shaft nut 175 17.5 127.0
Stabilizer bar bracket bolt 45 4.5 32.5
Strut bracket bolt 115 11.5 83.5
Strut support nut 23 2.3 17.0
Tie-rod end nut 40 4.0 29.0
Wheel bolt 95 9.5 69.0

Tightening torque

5.0 – 15.0 36.5 – 108.5

Required Service Material

FRONT SUSPENSION 3D-15

Material

Lithium Grease
(Should be applicable for –40 C° – 130 °C or –40
°F – 266 °F)

Recommended SUZUKI product

(Part Number)

SUZUKI SUPER GREASE (E)
(99000-25050)

• Wheel bearing

Special Tool

09943-17912 09942-15511 09900-06108 09913-75810
Front wheel hub remover Sliding hammer Snap ring pliers

(closing type)

Bearing installer
(for gasoline engine
model)

Use

09913-85210 09913-61110 09925-88210 09913-75510
(for diesel engine
model)

09951-18210 09943-77910 09913-75520
Remover booster body oil
No.2

Bearing puller Bearing puller attachment Bearing installer

(for diesel engine
model)

Suspension lower arm
bush remover

Bearing installer
(for gasoline engine
model)

3D-16 FRONT SUSPENSION

REAR SUSPENSION 3E-1

SECTION 3E

REAR SUSPENSION

WARNING:

Do not removal all of the wheel bolts at once, because all the wheels of this vehicle are mounted by
the wheel bolts.
Leave a bolt at least not to drop the wheel.
Support the wheel and/or tire and then remove the bolt(s) left with the wheel.

NOTE:

• All suspension fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci­fied during reassembly to assure proper retention of this part.

•

Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage
to the part may result.

• For descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

CONTENTS

3E
3F

4

4B

5
5A
5B
5C

General Description........................................3E-2

Diagnosis......................................................... 3E-4

Wheel Disc, Bolt and Bearing Check ............3E-4

On-Vehicle Service..........................................3E-5

Lateral Rod.................................................... 3E-7

Coil Spring..................................................... 3E-8

Bump Stopper ............................................... 3E-9

Trailing Arm...................................................3E-9

Rear Axle (for 2WD Model)......................... 3E-11

Wheel Bearing (for 2WD Model) ................. 3E-13

Rear Axle Shaft and Wheel Bearing (for 4WD

Model)......................................................... 3E-15

Rear Axle Housing (for 4WD Model)........... 3E-19

Tightening Torque Specifications............... 3E-24

Required Service Material............................ 3E-25

Special Tool................................................... 3E-26

6-2

6A2

6B2

3E-2 REAR SUSPENSION

2WD model

General Description

3

63 N·m(6.3 kg-m)

4

1

1

175 N·m
(17.5 kg-m)

95 N·m(9.5 kg-m)

10

8

9

3

6

4

2

7

63 N·m(6.3 kg-m)

2

100 N·m
(10.0 kg-m)

5

7

50 N·m(5.0 kg-m)

80 N·m(8.0 kg-m)

80 N·m(8.0 kg-m)

1. Rear coil spring 4. Rear shock absorber 7. Rear axle 10. Circlip

2. Rear bump stopper 5. Lateral rod 8. Wheel bearing Tightening torque

3. Rear spring upper seat 6. Trailing arm 9. Brake drum

6

90 N·m(9.0 kg-m)

4WD model

REAR SUSPENSION 3E-3

A: With ABS 4. Rear shock absorber 9. Brake drum 14. Wheel bearing retainer ring or rear wheel sensor ring (if

B: Without ABS 5. Lateral rod 10. Rear axle shaft 15. Spacer

1. Rear coil spring 6. Trailing arm 11. Breather cap Tightening torque

2. Rear bump stopper 7. Rear axle housing 12. Oil seal protector

3. Rear spring upper seat 8. Wheel bear ing 13. Oil seal

equipped with ABS)

3E-4 REAR SUSPENSION

Diagnosis

Wheel Disc, Bolt and Bearing Check

• Inspect each wheel disc for dents, distortion and cracks.
A disc in badly damaged condition must be replaced.

• Check wheel bolts for tightness and, as necessary, retighten
to specification.

Tightening torque

Wheel bolt (a): 95 N·m (9.5 kg-m, 69.0 lb-ft)

• Check wheel bearings for wear. When measuring thrust play,
apply a dial gauge to spindle cap center.

When measurement exceeds limit, replace bearing.

Thrust play limit “a”: 0.1 mm (0.004 in.)

• By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If it is defective, replace bearing.

2WD model

REAR SUSPENSION 3E-5

On-Vehicle Service

“A”: Body outside 7. Lateral rod outer washer 14. LSPV bracket

1. Rear coil spring 8. Rear axle 15. Brake back plate:

2. Rear bump stopper:
Apply soap water, when
installing.

3. Rear spring upper seat 10. Brake drum 17. Lateral rod body side

4. Rear shock absorber 11. Circlip 18. Shock absorber upper

5. Lateral rod 12. Spindle nut:

6. Trailing arm 13. Spindle cap 20. Trailing arm front bolt:

9. Bearing:
Seal side of bearing
comes brake back plate
side.

Caulk, after tightening.

(only vehicle with LSPV)

Apply water tight sealant
99000-31090 to joint of
plate and axle.

16. Lateral rod axle side nut Tightening torque

bolt:
Insert from the direction
as shown.

bolt:
Insert from vehicle out­side.

19. Shock absorber lower
bolt

Insert from vehicle inside.

21. Trailing arm rear bolt:
Insert from vehicle inside.

22. Brake back plate bolt

Do not reuse.

3E-6 REAR SUSPENSION

4WD model

28

27

25

5

26

"A"

“A”: Body outside 11. Oil seal 22. Brake back plate bolt

1. Rear coil spring 12. Spacer:

2. Rear bump stopper:
Apply soap water, when installing.

3. Rear spring upper seat 14. LSPV bracket (only vehicle with LSPV) 25. Lateral rod dumper

4. Rear shock absorber 15. Brake back plate 26. Lateral rod dumper nut

5. Lateral rod 16. Lateral rod axle housing side nut 27. Lateral rod dumper

6. Trailing arm 17. Lateral rod body side bolt:

7. Rear axle shaft 18. Shock absorber upper bolt:

8. Rear axle housing:
Apply water tight sealant 99000-31090 to
joint of plate and axle housing.

9. Bearing 20. Trailing arm front bolt:

10. Brake drum 21. Trailing arm rear bolt:

The tapered side of spacer inner diameter
directed toward outside (brake drum side).

13. Oil seal protector 24. Bearing retainer ring (with ABS)

Insert from the direction as shown.

Insert from vehicle outside.

19. Shock absorber lower bolt Do not reuse.

Insert from vehicle inside.

Insert from vehicle inside.

23. Bearing retainer ring (without ABS)

28. Lateral rod dumper bolt

Tightening torque

REAR SUSPENSION 3E-7

Lateral Rod

Installation

1) Install lateral rod (1) or (2) to rear axle (or axle housing) (3)
and vehicle body (4) referring to figure for proper installing
direction of bolt (5) and washer (6).
Tighten nuts (7) temporarily at this step.

NOTE:

• When installing Rod (1) for 2WD, identify rod end by
smaller diameter “a” and install that end to vehicle
body side.

• When installing rod (2) for 4WD, identify rod end by
damper (8) and install that end to vehicle body side.
Also make sure that both dampers are directed rear­ward of vehicle.

[A]: 2WD model

[B]: 4WD model

2) Lower hoist.

3) Tighten lateral rod nuts (1) to specified torque. It is the most
desirable to have vehicle off hoist and in non-loaded condi­tion when tightening them.

Tightening torque

Lateral rod nut (axle side) (a): 50 N·m (5.0 kg-m, 36.5 lb-ft)
Lateral rod nut (body side) (b): 100 N

[A]: 2WD model

[B]: 4WD model

m (10.0 kg-m, 72.5 lb-ft)

·

3E-8 REAR SUSPENSION

Coil Spring

Installation

1) Install coil springs (1) (right & left) on spring seat (2) of rear
axle as shown in figure and then raise rear axle.

NOTE:

When seating coil spring (1), mate spring end with
stepped part (3) of rear axle spring seat as shown.

A. Upper side

“a”:Small

“b”: Large

2) Install shock absorber (1) lower side to rear axle (or axle
housing).
Tighten shock absorber lower bolt (2) temporarily by hand at
this step.

3) Install lateral rod (1) to vehicle body, referring to the figure for
proper installing direction of bolt (2).
Tighten nut (3) temporarily by hand at this step.

4) Remove floor jack from rear axle (or axle housing).

[A]: 2WD model

[B]: 4WD model

F: Forward

5) Install brake flexible hose E-ring.

6) Install LSPV spring to rear axle. Tighten LSPV adjust nut
temporarily at this step (if equipped with LSPV).

7) Install wheel (1) and tighten wheel bolts (2) to specified
torque.

Tightening torque
Wheel bolt (a): 95 N·m (9.5 kg-m, 69.0 lb-ft)

REAR SUSPENSION 3E-9

8) Lower hoist and vehicle in non-loaded condition, tighten
absorber lower bolt (1) and lateral rod body side nut (2) to
specified torque.

Tightening torque
Rear shock absorber lower bolt
(a): 63 N·m (6.3 kg-m, 45.5 lb-ft)
Lateral rod nut (body side)
(b): 100 N·m (10.0 kg-m, 72.5 lb-ft)

9) If equipped with LSPV, check and adjust LSPV spring refer­ring to “LSPV (Load Sensing Proportioning Valve) Inspection
and Adjustment” in Section 5A and “Brake Fluid Pressure
Test (if equipped with LSPV)” in Section 5.

Bump Stopper

Installation

1) Install bumper stopper.

NOTE:

Before installing bump stopper apply soap water on it.

2) Install wheel and tighten wheel bolts to specified torque.

Tightening torque
Wheel bolt: 95 N·m (9.5 kg-m, 69.0 lb-ft)

Trailing Arm

Installation

1) Install trailing arm (1) to vehicle body and rear axle, referring
to figure for proper installing direction of bolts (2) and then
tighten

A. Vehicle center side

B. Vehicle outside

nuts (3) temporarily by hand.